AIR OR GAS COMPRESSORS

By: Engr. Yuri G. Melliza

Compressor is a machine used to compressed air or gas to a final pressure exceeding 241.25 KPa gage (342.6 KPaa).

TYPES OF COMPRESSORS
 Centrifugal Compressors - For low pressure and high capacity application
 Rotary Compressors - For medium pressure and low capacity application
 Reciprocating Compressors - For high pressure and low capacity application

USES OF COMPRESSED AIR

 Operation of small engines
 Pneumatic tools
 Air hoists
 Industrial cleaning by air blast
 Tire inflation
 Paint Spraying
 Air lifting of liquids
 Manufacture of plastics and other industrial products
 To supply air in mine tunnels
 Other specialized industrial applications

ANALYSIS OF CENTRIFUGAL AND ROTARY TYPE

W
2
m
1
m

Q = h + KE + PE + W (Steady state - steady flow equation)

W  Q  Δh  ΔKE  ΔPE


W   VdP  ΔKE  ΔPE


Q  Δh   VdP

For a compressor work is done on the system, therefore

the work is (-W)
 W  Δh - Q  ΔKE  ΔPE


 W  VdP  ΔKE  ΔPE

let - W  Wc
Wc  Δh - Q  ΔKE  ΔPE


Wc  VdP  ΔKE  ΔPE
A) Isentropic Compression (PVk = C)
P

2
W    VdP

PV k  C

V
For Isentropic Compressio n
k 1
T2  P2  k
 
T1  P1 
Q0
Wc  Δh  ΔKE  ΔPE


Wc  VdP  ΔKE  ΔPE

Δh  mC p (T2  T1 )
 k 1 
k(P2 V2 - P1V1 ) kmR(T2 - T1 ) kmRT1  P2  k 
 VdP 
k 1

k 1
  
 
k  1  P1 

 1

 
if ΔKE  0 and ΔPE  0
Wc  Δh  mC p (T2  T1 )
 k 1 
k(P2 V2 - P1V1 ) kmR(T2 - T1 ) kmRT1  P2  k 
Wc       1
k 1 k 1 k  1  P1 
 
 

where
m - mass flow rate of the gas in kg/sec
W - work in KW
P - pressure in KPa
T - temperature in K
R - gas constant in KJ/kg-K
V - volume flow rate in m3/sec
B) Polytropic Compression (PVn = C)
P

2
W    VdP

PV n  C

For Polytropic compression, Q  0

n 1
n 1
T2  P2  n V 
     1 
T1  P1   V2 
Wc  Δh  Q  ΔKE  ΔPE


Wc  VdP  ΔKE  ΔPE

Δh  mC p (T2  T1 )
 n 1 
n (P2 V2  P1V1 ) nmR (T2  T1 ) nmRT1  P2  n 
VdP 
n 1

n 1
  
n  1  P1 

 1

 
Q  mC n (T2  T1 )
kn 
Cn  Cv  
 1 n 
If ΔKE  0 and ΔPE  0
Wc  Δh  Q
 n 1 
n (P2 V2  P1V1 ) nmR (T2  T1 ) nmRT1  P2  n 

Wc  VdP 
n 1

n 1
  
n  1  P1 

 1

 
 n 1 
nmRT1  P2  n 
W    1
n  1  P1  
 
 
C) Isothermal Compression (PV = C)

2
W    VdP

PV  C

P1V1  P2 V2
T1  T2
Wc  Δh  Q  ΔKE  ΔPE
Δh  0


Wc  VdP  ΔKE  ΔPE

 VdP  P V ln P
P2
1 1
1
if ΔKE  0 and ΔPE  0
Wc  Q
P2
Wc  P1V1 ln
P1
P1V1  mRT1
ANALYSIS OF RECIPROCATING TYPE COMPRESSOR

Cylinder
Piston
Valve Piston
HE CE Rod

d D

P
P2 2' 2

P1 1' 1
V1'

cVD VD V

HE - Head end
CE - Crank end
L - length of stroke, m
VD - Displacement volume, m3/sec
D - diameter of bore, m
d - diameter of piston rod, m
V1’ – Volume flow rate measured at intake in m3/sec

PERCENT CLEARANCE
Clearance Volume
C
Displaceme nt Volume
V
C  2' x 100%
VD

For compressor design, values of percent clearance C ranges from 3 to 10 %.

V2'  CVD

where:
V2’ - clearance volume

VOLUMETRIC EFFICIENCY
Volume flow rate at intake
ηv  x 100%
Displaceme nt Volume
V
ηv  1' x 100%
VD
 A) For Isentropic Compression (PVk= C)
 1
  P2  k 
ηv  1  C  C   x 100%
  P1  
 

B) For Polytropic Compression (PVn = C)

 1
  P2  n 
ηv  1  C  C   x 100%
  P1  
 

C) For Isothermal Compression (PV = C)

  P 
ηv  1  C  C 2  x 100 %
  P1 

ACTUAL VOLUMETRIC EFFICIENCY

Va
ηva  x 100%
VD

Va - actual volume of air or gas drawn in

DISPLACEMENT VOLUME
A) For single acting
πLD 2 Nn' m3
VD 
4(60) sec

B) For Double acting without considering the volume of piston rod

2πLD 2 Nn' m3
VD 
4(60) sec

C) For Double acting considering volume of piston rod

VD 
πLNn'
4(60)

2D 2  d 2 
m3
sec
where:
L - length of stroke, m
D - diameter of bore, m
d - diameter of piston rod, m
n' - no. of cylinders
N = no. of RPM
 A) For Isentropic Compression and RE-expansion process (PVK = C),no heat is removed from the gas.

k 1
T2  P2  k
 
T1  P1 
Q0
Wc  Δh  ΔKE  ΔPE


Wc  VdP  ΔKE  ΔPE

Δh  mC p (T2  T1 )
 k 1   k 1 
kmRT1  P2  k  kP1V1'  P2  k 
VdP  

 
 
k  1  P1 
 1 

 

k  1  P1 

  1

   
P1V1'  mRT1
m - mass flow rate measured at intake, kg/sec
V1'  volume flow rate at intake, m3/sec
if ΔKE  0 and ΔPE  0
Wc  Δh  mC p (T2  T1 )
 k 1   k 1 
kmRT1  P2  k  kP1V1'  P2  k 
Wc     1     1
k  1  P1   k  1  P1  
   
   

B) For Polytropic Compression and Re-expansion process (PVn = C), some amount of heat is removed from the gas.

n 1
n 1
T2  P2  n V 
     1 
T1  P1   V2 
Wc  Δh  Q  ΔKE  ΔPE


Wc  VdP  ΔKE  ΔPE

Δh  mC p (T2  T1 )
 n 1   n 1 
nmRT1  P2  n  nP V  P2  n 

VdP 

 
n  1  P1 
 1  1 1'

n 1  P 
 1 
 1

   
Q  mC n (T2  T1 )
 kn 
Cn  C v  
 1 n 
If ΔKE  0 and ΔPE  0
Wc  Δh  Q
 n 1   n 1 
nmRT1  P2  n  nP1V1'  P2  n 

Wc  VdP   
n  1  P1 

 1 

 
n  1  P1 

 1

   
 n 1   n 1 
nmRT1  P2  n  nP1V1'  P2  n 
Wc     1  n 1  1
n  1  P1   P  
   1  
   
C) For Isothermal compression and re-expansion process (PV = C), an amount of heat equivalent to the
compression work is removed from the gas.

P1V1  P2 V2
T1  T2
Wc  Δh  Q  ΔKE  ΔPE
Δh  0


Wc  VdP  ΔKE  ΔPE

 VdP  P V ln P
P2
1 1'
1
if ΔKE  0 and ΔPE  0
Wc  Q
P2
Wc  P1V1' ln
P1
P1V1'  mRT1

MEAN EFFECTIVE PRESSURE

W
Pm  KPa
VD

W in KJ, KJ/kg, KW
VD in m3, m3/kg, m3/sec

PISTON SPEED

2LN m
PS 
60 sec

EFFICIENCY

a. COMPRESSION EFFICIENCY
Ideal Work
ecn  x100%
Indicated Work

b. MECHANICAL EFFICIENCY
Indicated Work
em  x100%
Brake or Shaft Work

c. COMPRESSOR EFFICIENCY

Ideal Work
ec  ecnem  x100%
Brake or Shaft Work
MOTOR EFFICIENCY

BP
emotor  x100%
MP
BP  Brake or Shaft Power
MP - Motor Power
MOTOR POWER

A. For Single Phase Motor

EI (Power Factor)
MP  KW
1000

B. For 3 – Phase Motor

3 EI (Power Factor)
MP  KW
1000

Where:
E – Volts
I – Current in Amperes
PF – Power Factor

MULTISTAGE COMPRESSION
Multi staging is simply the compression of air or gas in two or more cylinders in place of a single cylinder compressor. It is used in
reciprocating compressors when pressure of 300 KPa and above are desired, in order to:
 Save power
 Limit the gas discharge temperature
 Limit the pressure differential per cylinder
 Prevent vaporization of lubricating oil and to prevent its ignition if the temperature becomes too high.
It is common practice for multi-staging to cool the air or gas between stages of compression in an intercooler, and it is this cooling
that affects considerable saving in power.

A) 2 - Stage Compression without pressure drop in the intercooler

For an ideal multistage compression, with perfect inter-cooling and minimum work, the cylinder were properly designed so that:
 the work at each stage are equal
 the air in the intercooler is cooled back to the initial temperature
 no pressure drop occurs in the intercooler
 the pressure at each stage are equal
W1 = W2 ; T1 = T3 ; P2 = P3 = Px
where:
W1 - work of the LP cylinder (1st stage)
W2 - work of the HP cylinder (2nd stage)
Px = ideal intercooler pressure, optimum pressure
 Assuming polytropic compression and expansion processes:

W1  W2 Work for LP cylinder (W1 )

T1  T3
 n 1 
n 1 nP V  P2 

n 
T2  P2  n W1  1 1'  P  1
  n 1
 1  
T1  P1   
n 1 P1V1'  mRT1
T4  P4  n
 
T3  P3 
Work for HP cylinder (W2 )

T2  T4  n 1 
nP V  P4 

n 
W2  3 3'  P   1
P2 P4 n 1
  3  
P1 P3  
P1V1'  P3V3' P3 V3'  mRT3

Total Work (W) for Ideal 2 - stage

W  W1  W2 Pressure Ratio
W  2 W1 P2 P4

P1 P3
 n 1 
2nP1V1'  P 
 2  n  Px  P2  P3
W1   P   1
n 1
 1   PX P4

 
1
P1 PX
1 1 1 1
P2 Px P1P4 P 2P 2 P 2 P 2  P 2 Px  P1P4  Ideal intercoole r pressure
   1 4  4 1  4 1   4 
P1 2  1 
P1 P1 P1 P1 P
P1P1 2
 n 1 
2nP1V1'  P4  2 n 
W1   P   1
n 1
 1  
 
By Energy Balance in the Intercoole r
Q x  m(h 2 - h1 )  mC p (T2 - T1 )

Heat produced during compressio n (PV n  C)

Q1  mC n (T2 - T1 )
Q 2  mC n (T4 - T3 )
 k-n 
Cn  Cv  
 1- n 

B) 2 stage compressor with pressure drop in the intercooler For 2 stage compression with
pressure drop in the intercooler,
P2  P3
The air in the intercooler may or may not be cooled to the initial temperature, and the work at each stage may or may not be equal,
thus the work W = W1 + W2

For 2 - stage ompression with pressure drop

P2  P3
W1  W2 or W1  W2
T1  T3 or T1  T3
P2 P4 P P
 or 2  4
P1 P3 P1 P3
T2 T4 T T
 or 2  4
T1 T3 T1 T3
W  W1  W2
where
Work for LP cylinder (W1 )
 n 1 
nP V  P2 

n 
W1  1 1'  P  1
n 1
 1  
 
P1V1'  mRT1
Work for HP cylinder (W2 )
 n 1 
nP V  P4 

n 
W2  3 3'  P   1
n 1
 3  
 
P3 V3'  mRT3
By Energy Balance in the Intercoole r
Q x  m(h 2 - h1 )  mC p (T2 - T1 )

Heat produced during compressio n (PV n  C)

Q1  mC n (T2 - T1 )
Q 2  mC n (T4 - T3 )
 k-n 
Cn  Cv  
 1- n 

C. Three-Stage compressor without pressure drop in the intercooler

Considering Polytropic compression and expansion processes and with perfect inter-cooling and minimum work
For 3 - stage ompression without pressure drop
P2  P3  Px
P4  P5  Py
W1  W2  W3
T1  T3  T5
P2 P4 P
  6
P1 P3 P5
Px Py P
  6
P1 Px Py

Px  3 P12 P6  LP Intercoole r pressure

Py  3 P1P6 2  HP Intercoole r pressure

T2 T4 T
  6
T1 T3 T5
W  W1  W2  W3
where
Work for 1st Stage cylinder (W1 )
 n 1 
nP V  P2 

n 
W1  1 1'  P  1
n 1
 1  
 
P1V1'  mRT1
Work for 2nd Stage cylinder (W2 )
 n 1 
nP V  P4 

n 
W2  3 3'  P   1
n 1
 3  
 
P3 V3'  mRT3
Work for 3rd Stage cylinder (W3 )
 n 1 
nP V  P6 

n 
W3  5 5'  P   1
n 1
 5  
 
P5 V5'  mRT5
  n 1 
3nP1V1'  P2  n 
W  P   1
n 1
Total W  1  
 
W  W1  W2  W3
1
but  P2   P6  3
    
W1  W2  W3  P1   P1 
W  3W1  n 1 
3nP1V1'  P6  3n 
W  P   1
n 1
 1  
 
For multistage compression with minimum work and perfect inter-cooling and no pressure drop in the inter-coolers between stages,
the following conditions apply:
1. the work at each stage are equal
2. the pressure ratio between stages are equal
3. the air temperature in the inter-coolers are cooled to the
original temperature T1
4. the total work W is equal to
 n 1 
SnP1V1'  P2S  Sn 
WS     1
n  1  P1  
 
 
where S - number of stages

INTERCOOLER PRESSURES

1
Pa Pb Pc Pd Pe P2S  P2S  S
      
P1 Pa Pb Pc Pd Pe  P1 
1
Pa  P2S  S
 
P1  P1 
1
 P S
Pa  P1  2S 
 P1 
1 1 1
 P S  P S  P S
Pb  Pa  2S   P1  2S   2S 
 P1   P1   P1 
2
 P S
Pb  P1  2S 
 P1 
1 1 1
 P S  P S  P S
Pc  Pb  2S   P1  2S   2S 
 P1   P1   P1 
3
 P S
Pc  P1  2S 
 P1 
4
 P S
Pd  P1  2S 
 P1 
5
 P S
Pe  P1  2S 
 P1 
Sample Problems
1. A 2-stage, double acting air compressor 41cm and 25cm bore x 18 cm running 600 RPM has a free air un-loader at
each end for capacity control. It is driven by a 150 HP motor, 460V,3 phase, 60 hertz, 1175 RPM thru super-high
capacity V-belts at sea level installation.P1 = 101 KPa and P4= 984 KPa, calculate the power assuming the LP cylinder
discharges the air to the ideal pressure and intercooler cools the air to the initial temperature of 21C.
2. A single acting compressor has a volumetric efficiency of 87% operates at 500 RPM. It takes in air at 100 KPa and
30C and discharges it to 600 KPa. The air handled is 6 m3/min measured at discharge condition. If compression and
expansion processes are isentropic, find the piston displacement per stroke.
3. A two-stage reciprocating air compressor is required to deliver 0.70 kg/sec of air from 98.6 Kpa and 305K to 1276
KPa. The compressor operates at 205 RPM, compression and re-expansion processes are PV1.25 = C, and both
cylinders have 3.5% clearance. There is a 20 KPa pressure drop in the intercooler. The LP cylinder discharges at the
optimum pressure into the intercooler. The air enters the HP cylinder at 310K. the intercooler is water cooled with the
water entering at 295K and leaving at 305K. Determine the motor power required if m= 85%.( 260 KW)
4. A 36 cm x 36 cm , horizontal double acting air compressor w/ 5% clearance operates at 120 RPM and draws air at 100
KPa and 31C and discharges it to 397 KPa. Compression and expansion processes follows PV1.3 = C. Determine
compressor power required in KW.(22 KW)
5. An ideal 3-stage air compressor with intercoolers handles air at the rate of 2 kg/min. The suction pressure is 101 Kpa,
suction temperature is 21C, delivery pressure is 5000 KPa. Assuming perfect inter-cooling and minimum work,
calculate total power required if compressor efficiency is 60% and both compression and expansion processes are
PVn=C, where n = 1.2. (21 KW)
6. A two stage compressor with 5% clearance delivers 40 kg/min of air to 965 Kpa. At intake the pressure is 98.6 KPa and
the temperature is 16C. the compression is polytropic with n = 1.31 and the intercooler cools the air to 16C. Determine
the mean effective pressure in KPa.
7. A double acting, 2 stage air compressor running at 150 RPM has a suction pressure and temperature of 100 KPa and
27C, respectively. The low pressure cylinder is 36 cm x 38 cm and connected in tandem to the high pressure cylinder.
The LP cylinder discharges the air at 386 KPa. The intercooler cools back the air to its initial temperature and the air
enters the HP cylinder at 370 KPa and leaves at 1 480 KPa. Both LP and HP cylinders have 4% clearance and
compression follows PV1.3 = C. Neglect effect of piston rods. Standard air is at 101 KPa and 16C. Determine:
a) the volume of free air based on apparent volumetric efficiency
b) the heat removed by cooling water in the intercooler ( 24 KW)
c) the diameter of the HP cylinder in cm (19 cm)
d) the power required to drive the compressor if the aggregate losses is 20% of the power of the conventional diagram. (72 KW)
8. A turbine driven compressor handles 10 kg/sec of air from 100 KPa to 600 KPa with an inlet temperature of 300K and
a discharge temperature of 530K. The inlet tubing has a 0.5 m inside diameter and the discharge piping a 0.20 m
diameter. The compression is adiabatic. Determine:
a) the air inlet and exit velocities in m/sec
b) the isentropic compression efficiency
c) the power required in KW

9. A large centrifugal compressor handles 9 kg/sec of air, compresses it from 100 KPa and 15C and with an initial
velocity of 110 m/sec to discharge pressure. The velocity of the high pressure air stream is 90 m/sec. The pressure
ratio is 4:1 the compressor has an isentropic compression efficiency of 80%. Determine
a) the exit pressure in KPa
b) the exit temperature in K
c) the power required
10.A centrifugal compressor handling air draws 6 m 3/sec of air at a pressure of 96.5 KPa and a temperature of 15.6C.
The air delivered from the compressor at a pressure 482.5 KPa and a temperature of 73C. The area of the suction
pipe is 0.2 m2, the area of the of the discharge pipe is 0.4 m2, the discharge pipe is located 6 m above the suction
pipe. The weight of the jacket water that enters at 16C and leaves at 43C is 3.45 kg/sec. Find the power required
to drive this compressor assuming no loss from radiation.

11.A low pressure water jacketed air compressor, compresses 6.8 kg/min of air from 101.325 KPa and 21C to 136 Kpa
and 43C.
 a) let the process to be polytropic, neglecting KE and PE find W and the mass flow rate of cooling water circulating if
tw = 4C.
b) considering the process to be irreversible adiabatic with a final temperature of 54C, find the value of m in
PVm = C and W.
ANSWER: a) 3 KW; 1.7 kg/sec; b) W = 4 KW; m = 1.6
12.There are required 1903 KW of compressor power to handle air adiabatically from 1001 KPa, 27C to 305 KPa. The
initial air velocity is 21 m/sec and the final velocity is 85 m/sec.
a) if the process is isentropic, find the volume of air handled in m3/min measured at inlet conditions.
b) If the compression is an irreversible adiabatic to a final temperature of 158C,with the capacity found in (a)
find the power input.

13.A 36 cm x 30 cm, single cylinder, double acting air compressor with 5.5% clearance operates at 125 RPM. The
suction pressure and temperature are 96 KPa and 38C, respectively. The discharge pressure is 290 KPa.
Compression and re-expansion processes are PVn=C with n = 1.3. /neglecting piston rod effects, determine:
a) the volumetric efficiency ( 93%)
b) the volume flow rate at suction conditions (7.07 m3/min)
c) the work in KW (15 KW)
d) the heat rejected during compression (3 KW)
e) the indicated power in KW in the compression efficiency is 75%. (20 KW)
14.An industrial plant operates an air compressor system for cooling. The air entering the compressor has a temperature
of 16 C at 345 KPa and is compressed to 1206 KPa. The compressed air is then cooled by circulating water to a
temperature of 38C and then allowed to expand to the original pressure. Assume adiabatic compression and dry air.
Find:
a) temperature of the compressed air
b) final temperature of air after expansion
c) diameter of the pipe necessary to conduct 0.02 m3/sec if the piping system has a 12- 90 elbow long radius
elbow , 2-globe valves, 3 tees on run, and 61 m of straight pipe. Friction drop in the pipeline is limited to 14
KPa. Assume specific weight and velocity remains constant along the pipe
15.Air is compressed from 103.4 KPa and 21 C to 4132 KPa by a three-stage compressor with a value of n =
1.32.Determine the theoretical work of the compressor and the heat absorbed by the intercoolers.
16.A single acting compressor with a clearance of 6% takes in air at atmospheric pressure and at a temperature of 29C
and discharges it at a pressure of 586 KPa. The air handled is 0.0071 m3/cycle measured at the discharge pressure. If
the compression is isentropic,find:
a) Piston displacement per cycle (0.03 m3/cycle)
b) Compressor power if n = 750 RPM ( 72 KW)
17.A single cylinder, double acting air compressor running at 200 RPM has a piston speed of 183 m/min. It compresses
27 kg/min of air from 97 KPa and 16C to 654 KPa. Clearance is 5.5%. For isentropic compression,
Find:
a) the volumetric efficiency (84%)
b) the piston displacement in m3/min (28 cu.m./min)
c) the work in KW (96 KW)
d) the mean effective pressure in KPa (207 Kpa)
e) the bore and stroke of the compressor in cm. (D=44 cm;L=46 cm)
18.An air compressor with a clearance of of 6% is to compress 0.43 m3/sec of free air where the atmospheric pressure is
101 KPa and the atmospheric temperature is 24C. At the end of the suction stroke, the pressure and temperature of
the air in the cylinder are 97 KPa and 32C. For a discharge pressure of 520 KPa, Determine the conventional
volumetric efficiency and displacement of the compressor when the compression process is:
a) Isothermal (74%; 0.6 cu.m./sec)
b) Isentropic (86%; 0.5 cu.m./sec)
c) polytropic with n = 1.33 (84.8%; 0.51 cu.m./sec)
19.A single stage reciprocating air compressor has two double acting cylinders each 46 cm diameter and 36 cm stroke
and the piston rods are 50 mm in diameter. The intake and discharge pressure are 101 KPa and 445 KPa, respectively
and the speed is 257 RPM. If the volumetric efficiency is 78%, mechanical efficiency is 94% and the isothermal
compression efficiency is 66%, Find:
a) the metered flow per second (0.795 cu.m./sec)
b) the indicated power in KW (181 KW)
c) the power required to drive this compressor in KW ( 193 KW)
d) the adiabatic compression efficiency ( 82%)
20. An air pollution control device requires 0.23 cu.m./sec of free air. To provide this demand a double acting, single stage
reciprocating air compressor having a clearance of 3% was bought. Suction conditions are 101 KPa and 21C and a
discharge pressure of 724 KPa is desired. When tested under these conditions, performance was within the terms of
guarantee.
a) what is the piston displacement in cu.m./sec of the compressor if n =1.34
b) if the compression ratio is held constant and the unit is operated at an altitude of 1800 m, what will be its
capacity and discharge pressure
d) what would be the displacement of a similar compressor to handle the same mass of air as in (a) when operated at 1800
m elevation.

21. A 2-stage, double acting air compressor, 410mm x 250 mm bore x 180 mm
stroke, running at 600 RPM, has a free air unloader at each end for
capacity control. It is driven by a 150 HP electric motor, 460 volts,
3 phase, 60 Hz, 1175 RPM thru superhigh capacity V-belts at sea level
installation. Suction pressure is 1.034 kg/ cm2 absolute and discharge
pressure is 9 kg/cm2 gage. Calculate:
a) piston displacement in m3/hr ( 1711; 636)
b) piston speed in m/sec ( 3.6)
c) ideal pressure gage reading in kg.cm2 ( 2.2)
22. A reciprocating 2-stage air compressor takes in air at atmospheric
pressure and 27C.The flash point of the oil used in the cylinder is
260C. Safety precautions limit the temperature of the air in the HP
cylinder to be 28 C below the flash point of the oil. Assuming perfect
intercoooling, what would be the allowable working pressure of this
compressor if the compression curve follows PV1.34 = C.
(P4 = 6144.3 KPa)
23. The following data were obtained from a performance test of a 10 cm x
4 cm x 9 cm single acting, water jacketed two stage air compressor;
Pressures:
Atmospheric – 102 KPa
Leaving 1st stage – 634 KPa
Entering 2nd stage – 634 KPa
Leaving 2nd stage – 4200 KPa
Temperature:
Atmospheric – 24C
Leaving 1st stage – 108C
Entering 2nd stage –25C
Leaving 2nd stage – 127C
Compressor speed – 648 RPM
Power input to motor – 5.65 KW
Motor and belt efficiency – 81.5%
The following are calculated from test data:
Air flow rate – 0.387 kg/min
Compression exponents: 1st stage, 1.15: 2nd stage, 1.2
Calculate:
a) approximate indicated power (2.4 KW)
b) power for isothermal compression ( 2.04 KW)
c) Shaft power ( 4.6 KW)
d) 1st stage piston displacement ( 0.458 m3/min)
e) actual volumetric efficiency ( 70.52%)
f) isothermal compression efficiency ( 86.61%)
g) mechanical efficiency based on the approximate indicated
power ( 51.3%)
h) overall efficiency of the compressor ( 44.49%)
24. An industrial plant requires 127.5 m3 of free air per hour for its
processes. Two steam engine driven three stage air compressor has to
compress the under the following conditions:
Intercooler pressure between 1st and 2nd stage – 353 KPa
Barometer reading – 792.5 mm Hg
Exponent n = 1.3
 Mechanical efficiency of compressor – 80%
Thermal efficiency of the steam engine – 14%
Boiler, Furnace, An piping efficiency – 70%
Heating value of Malangas coal – 32 103 KJ/kg
Assuming the intermediate pressure between stages is that required
for minimum work , find the amount of Malangas coal to produced
enough steam to operate two compressors ( 3 stage) of the same
diameter to compresses the required capacity. ( 45 kg/hr)
25. Determine the percent clearance of a single cylinder, double acting
air compressor with bore and stroke of 45 cm x 45 cm x 180 RPM. The
compressor is tested and it delivers air from 101.3 KPa and 300 K to
675 KPa at a rate of 0.3 m3/sec. The exponent n = 1.33 for compression
and expansion processes. There is a 5% pressure drop through the inlet
and discharge valves. The air is warmed to 38 C during the intake
stroke. (c = 6.78%)
26. A two stage, reciprocating air compressor is required to deliver 0.70
kg/sec of air from 986 KPa and 32 C to 1276 KPa. The compressor
operates at 205 RPM , compression and expansion processes follow PV1.25
= C, and both cylinders have 3.5% clearance. There is a 20 KPa
pressure drop in the intercooler. The LP cylinder discharges at the
optimum pressure into the intercooler. The air enters the HP cylinder
at 37 C. The intercooler is water cooled, with the water entering at
22 C and leaving at 32 C. Determine:
a) the free air capacity in m3/sec 0.583)
b) the LP and HP discharge temperature ( 121 ; 405)
c) the optimum interstage pressure (354.7 KPa)
d) the cooling water required for the intercooler in
kg/sec ( 1.41)
e) the theoretical power required in KW (185)
f) the LP cylinder dimensions if L/D = 0.70 (706.5 mm x
494.6 mm)
g) the motor requirements in KW, if the adiabatic
compression efficiency is 83% and mechanical efficiency
is 85%. (278.14 KW)
27. A single acting, 2-stage air compressor with 3% clearance is required
to compressor has a mean piston speed of 140 m/min, and that each
piston has the same stroke. Take free air conditions to be the same as
suction conditions and for perfect intercooling, Calculate:
a) piston areas for minimum power (0.0435 m2; 0.0251 m2)
b) total power required in KW (6 KW)
c) heat loss in the intercooler in KW ( 3 KW)
28. Find the indicated power of a compressor delivering NH3 at 2.3 kg/min.
The gas enters the compressor at 207 KPa and –7C and is compressed
to 1103 KPa at 121C. Five kilograms of cooling water enters the
compressor jacket at 27C and leaves at 30C.(12 KW)
29. A 2 cylinder, single acting air compressor is directly coupled to an
electric motor running at 1000 RPM. Other data are as follows:
Size of each cylinder – 15 cm x 20 cm
Clearance volume - 10% of displacement
Exponent n for PVn = C - 1.6
Calculate the following:
a) the volume rate of air delivery in terms of standard air
for a delivery pressure of 8 times ambient pressure under ambient air
conditions of 100 KPa and 300 K.
b) Shaft power required if mechanical efficiency is 81%.
30. A single acting air compressor operates at 300 RPM with an initial
conditions of air at 98 KPa and 27 C, and discharges the air at 380
KPa to a cylindrical tank. The bore and stroke are 355 mm and 381 mm,
respectively, with a percent clearance of 5%. If the surrounding air
is at 100 KPa and 20 C while the compression and expansion processes
are PV1.3= C. Determine:
a) the free air capacity in m3/sec (0.164)
 b) power of compressor in KW ( 27 KW)
31. A closed metal tank is designed to be safe when subjected to an
internal pressure of 689 KPa. It is used to hold compressed air and is
filled with this material at a temperature of 16C and a pressure of
551 KPa. The tank stands in the sun and its contents may obtained a
temperature of 52 C.
a) Assuming the tank does not expand with temperature and
pressure changes will the design pressure be exceeded
b) what temperature will have to be attained to raise the
pressure of the air to the value for which the tank was designed.
32. An air compressor receives air from the surroundings at 100 KPa and
21C. There is a 2 KPa drop through the intake valves, and the
temperature at the end intake stroke is 38 C. The discharge pressure
is 480 KPa and there is a 20 KPa pressure drop through the discharge
valves. Determine
a) the ideal volumetric efficiency (80%)
b) the actual volumetric efficiency (74.1%)
c) the power if the piston displacement is 14 Liters and
the ideal intake volume is 11.2 Liters. The compressor is operating
at 200 RPM and n = 1.35 ( 7 KW)
33. Required an air compressor to supply 36 kg of air per minute at a
pressure of 1034 KPa; Temperature of air entering the compressor is 16
C, atmospheric. Not counting frictional losses , Find:
a) the power require to operate the compressor if;
1. Single stage with n = 1.35 (160 KW)
2. 2-stage with air entering 2nd stage cylinder at 339
KPa and 18 C. ( 137 KW)
b) the temperature of the air going to the receiver in each
case.( 255 C ; 119 C)
34. An air compressor is direct connected to a heat engine. The compressor
handles 28.5 m3/min of free air and delivers it to 1203 KPa.
Atmospheric pressure and temperature being 97 KPa and 16 C,
respectively and the overall isothermal efficiency of the compressor
is 70%. The brake thermal efficiency of the heat engine is 25% and all
the engine comes from an oil, the combustion of each liter of which
liberates 41 000 KJFind:
a) The liters of oil per day required by the engine if run
continuously at the given load (1386.5 L/day)
b) The combined thermal efficiency based on the indicated
power of the compressor if the compression efficiency is 77%. ( 23%)
35. Determine the percent clearance of a single cylinder, double acting
air compressor with bore and stroke of 45 cm x 45 cm by 3 RPS. The
compressor is tested and it delivers air from 101.3 KPa and 300 K
to 675 KPa at a rate of 0.3 m3/sec. The exponent n = 1.33 for
compression and expansion processes. There is a 5% pressure drop
through the inlet and
discharge valve. The air is warmed to 311 K during the intake stroke.
(7%)
36. A reciprocating compressor with 3 % clearance receives air at 100 KPa
and 27 C and discharges it at 1000 KPa. The compression and expansion
are polytropic with n = 1.25. There is a 5% pressure drop through the
inlet and discharge valves. The air is warmed to 38 C by the cylinder
walls by the end of the intake stroke. Determine:
a) the theoretical and actual volumetric efficiency (82.5%; 75.6%)
b) the percentage of the work needed to overcome the throttling
process.
37. A single acting compressor has a volumetric efficiency of 87% and
operates at 500 RPM. It takes in air at 100 KPa and 30 C and
discharges it at 600 KPa. the air handled is0.10 m3/sec measured at
discharge condition. If the compression is PVk = C, find the mean
effective pressure in KPa. (204 KPa)
38. A reciprocating, 2-stage, single acting air compressor has a rated
capacity of 0.02 m3/sec of free air at 101 KPa and 27 C when running
at 600RPM. The discharge pressure is 30 kg/cm2 and the air is
discharge into an air receiver of 1250 Liters capacity. The compressor
has two LP cylinders each 13 cm diameter and one HP cylinder 7 cm in
diameter; piston stroke is 10 cm. the intercooler is of the finned
tube type with the cooling fan mounted on the compressor shaft. The
compressor is driven by a 1750 RPM,3-phase,60 Hz, 460 V motor thru V-
belts with transmission efficiency of 95%. Calculate:
a) Optimum intercooler pressure for equal work in the LP and HP
cylinders
b) Volumetric efficiency of compressor
c) Brake power at compressor shaft if compressor efficiency is 85%
d) KW of the driving motor in KW
e) Time in minutes to fill air receiver from empty condition.
39. A two stage air compressor receives 0.20 m3/sec of air at 103 KPa and
27 C and discharges it at 828.5 KPa. All clearances are 3.5%. The
compression and expansion processes on both cylinders is polytropic
with n = 1.35. Determine:
a)the ideal intercooler pressure in KPa b) the minimum power required in
KW
c) the displacement volume of each cylinder in m3/min
d) the LP and HP cylinder dimensions if the compressor operates at 205 RPM and L/D = 1.2 for both cylinder
e) the cooling water required in the intercooler for perfect inter- cooling assuming 10 C temperature rise in cooling water.
f) the percentage of the work saved for single stage compression to
the same pressure.
40. A natural pipeline distributes gas through the country, pumped by a
large gas-turbine driven centrifugal compressors. Assume that the
natural gas is methane, the pipe diameter is0.2m and the gas enters
the compressor at 300 K and 105 KPa. the velocity of the methane
entering the compressor is 4 m/sec. The compression process is
isentropic and the discharge pressure is 700 KPa. Determine:
a) the discharge temperature (475.7 K)
b) the mass flow rate in kg/sec ( .085 kg/sec)
c) the power required in KW (32 KW)
For Methane: R = 0.5183 KJ/kg-K ; k = 1.321
41. A 2 stage, double acting air compressor, operates at 150 RPM. The
conditions of the air at the beginning of compression are P1 = 97.9
KPa and t1 = 27 C. The LP cylinder with a bore and stroke of 35.5 cm x
38.1 cm discharges the air at 379 KPa into the intercooler. The air in
the intercooler suffers a 17.2 KPa pressure drop and enters the HP
cylinder at 29 C. the discharge pressure from the compressor is
2000 KPa. Compression and expansion process in both cyclinders are
PV1.3 = C. The surrounding are at
100 KPa and 20 C. The percent clearance of each cylinder is 5%.
Determine:
a) the free air capacity in m3/sec ( 0.164)
b) the heat loss in the intercooler in KJ/min (1270)
c) the total power required in KW (62 KW)
d) the optimum interstage pressure in KPa. ( 442.5)
e) the diameter of the HP piston if the stroke is the
same as the LP piston (19 cm)
f) the heat loss in the LP and the high pressure
compression processes.(Q1 = 308 KW; Q2 408 KW)
42. There are compress 0.2 m3/sec 0f air from 103 KPa, 27 C to 828 KPa.
All clearances are 8%.
a) Find the isentropic power and piston displacement required for a
single stage compression
b) Using the same data, find the minimum ideal power for 2-stage
compression when the intercooler cools the air to the initial
temperature.
c) Find the displacement of each cylinder for the conditions of
 part (b).
d) How mush heat is exchanged in the intercooler.
e) For a compressor efficiency of 78%, what driving motor output is
required for 2-stage compression.
43. A single cylinder, double acting air compressor running at 200 RPM
has a piston speed of 183 m/min. It compresses 27 kg/min of air from
97 KPa and 16 C to 654 KPa. Clearance is 5.5%. For isentropic
compression, Find:
a) the volumetric efficiency (84%)
b) the piston displacement in m3/min ( 28 cu.m./min)
c) the work in KW ( 96 KW)
d) the mean effective pressure in KPa (207 Kpa)
e) the bore and stroke of the compressor in cm. (D=44
cm;L=46 cm)