Materials used for construction

1. Reciprocating Compressor

Crankcase and body – Cast Iron

Crankshaft – Spheroidal graphite cast iron or stainless steel

Connecting rod – Forged Steel

Piston – Aluminium Alloy or Cast / Ductile Iron

Piston Rings – Cast Iron

Valve Seats – Steel

Valve Plates – Vanadium Steel

2. Screw Compressor

Casing – Cast or Ductile Iron

Screw – Steel or Stainless Steel or Nickel Alloy

Where they are used?

1. Reciprocating Compressor

Reciprocating compressors are characterized with higher pressures and reduced mass flow rate.
They are mainly used in high pressure applications since it can deliver air at about 30 – 40 bar.

1) For diesel engine starting, where electric motor starting becomes costly and impractical.

2) Refrigeration compressors are normally reciprocating type (Single Stage) with a discharge pressure
around 10 bar.

3) Air conditioning systems also uses reciprocating compressors (Nowadays trend is changed to
screw compressors).

2. Screw Compressors

Screw type compressors provide air at increased mass flow rate but with reduced discharge
pressure around 8 bar. Hence applications are also in low pressure systems, such as,

1) Service air compressors used in industry (For cleaning air, etc.)

2) Air conditioning systems nowadays employ screw compressors. (which have low power consumption
and increased mass flow rate as advantages)
3) For low pressure air required for running pneumatic tools, pneumatic-hydraulic equipment, etc.

Cycle of operation

Consider one cycle of operation in a reciprocating compressor.

ONE COMPLETE CYCLE OF OPERATION

The process that occurs in a cycle 1-2-3-4-1 are explained below

The process that occurs in a cycle 1-2-3-4-1 are explained below

 (3) – (4) – As piston travels from BDC to TDC air trapped inside the cylinder is compressed.

 (4) – (1) – As piston approaches TDC discharge valve opens and compressed air is delivered.

 (1) – (2) – Undelivered air trapped in the clearance space is expanded as piston moves down.

 (2) – (3) – When trapped air in the clearance space is expanded to atmospheric pressure, further
downward movement of the piston creates a vacuum inside the cylinder and thereby atmospheric
air enters through suction valve.

Again cycle repeats.

In fig. ‘Va’ indicates the volume corresponding to actual stroke of the piston from TDC to BDC (also
called stroke volume). Similarly ‘Ve’ indicates the volume corresponding to the effective stroke of piston,
when atmospheric air enters the cylinder.

The ratio of effective stroke volume to the swept volume is known as the volumetric efficiency of the
compressor,
Graph of Pressure against volume in a reciprocating compressor

Volumetric efficiency Vh = Actual suction volume Vx/

Theoretical suction volume Vs

For greater efficiency air compression should be isothermal as this requires the minimum work input. In
practice Isothermal compression is not possible, an ideal Isothermal cycle requires sufficient time to allow
all the required heat to be transferred out of the cylinder, practicality dictates that the piston must have a
relatively high speed to give a reasonable output,

Then why clearance space?

It was already seen from the above equation that volumetric efficiency is 100% when

Effective stroke = Actual stroke

In other words, no clearance volume exists. This is practically impossible, because some clearance space
is required otherwise piston hits on the cylinder head as it travels. Also expansion of piston occurs as it
travels and very little clearance may cause the same problem. Also increased clearance space reduces
compressor efficiency and increase its running hours. So clearance volume must be kept around a
reasonable value as instructed by the manufacturer.

It is important that the compressor clearance volume is kept small as possible in order to improve
overall volumetric efficiency as the air trapped in this space must expand to below suction
pressure before new air can enter, this is an effective loss of stroke.

A clearance is required in order to prevent the piston striking the cylinder cover when starting or
stopping off load. The clearance volume is sometimes referred to as the 'Bump Clearance'.

Why cooling is required?

Reciprocating compressors are generally cooled with air or water. The cylinders in air cooled
compressors often include large external fins that increase the surface area available for heat transfer.

In water cooled compressors, freshwater is circulated through jackets that are built into the walls of the
cylinders and cylinder heads.

The compression cycle is illustrated graphically down below.

 Single Stage Compression

Above cycle compresses gas from atmospheric pressure to 8 bar in a single stage. The area
enclosed by the points 12341 represents the work of compression in a single stage compressor.
Also see the cycle or Pressure-Volume diagram (P-V) below which compresses gas from
atmospheric pressure to 8 bar in two stages.

Two stage compression is shown below.

Cylinder cooling on a single stage compressor gives better efficiency but there is a limitation in
the surface area to cylinder volume that can be used for cooling effect, but multistage
compressors with an efficient extended surface interstage cooler gives cycle improved
compression efficiency better approaching that of the isothermal. In theory the greater the
number of stages the closer the curve will approach the ideal isothermal compression curve,
however there is an increase in cost, complexity, and the law of diminishing returns limit the
number.

Compression in stages has the following advantages;

1. The work done in compressing the air is reduced, thus power can be saved
2. Prevents mechanical problems as the air temperature is controlled
3. The suction and delivery valves remain in cleaner condition as the temperature and vaporization
of lubricating oil is less
4. The machine is smaller and better balanced
5. Effects from moisture can be handled better, by draining at each stage
6. Compression approaches near isothermal
7. Compression ratio at each stage is lower when compared to a single-stage machine
8. Light moving parts usually made of aluminum, thus less cost and better maintenance

AIR COMPRESSOR COOLERS

 Plain Tube-
o -easy to clean
o -very effective due to large surface area of large number small diameter tubes
o -plugging of failed tube allows cooler to continue in service with little loss in efficiency
o -must allow for thermal expansion by having one tube plate floating
 'U' tube-
o -suitable for higher pressures than plain tube
o -self compensating for thermal expansion
o -efficient due to large number of small diameter tubes
o -failed tubes may be plugged
o -more expensive than plain tube and difficult to clean
 Coil tube
o -self compensating for expansion
o -suitable for high pressures
o -difficult to clean
o -inefficient due to large tube diameter
o - not easy to plug
o -expensive
 SAFETY FEATURES OF MARINE COMPRESSORS
Marine compressors have various safety features and cutouts installed so that they will trip when
running in an unsafe mode. The compressors are reliable machines, but have to be maintained
properly and in the proper intervals. There have been cases of the cylinder heads bursting and
often resulting in fatalities. The various safety devices put in a marine compressor are as follows:
1. Lubricating oil low pressure trip
2. Cooling water high temperature trip
3. Motor overload trip and Motor overheating trip

Safety fittings on air compressor

1. Relief valve, Set 10% exceed maximum working pressure, fitted at Stage outlet. Protect
overpressure on airside.
2. Bursting disc (or relief valve fitted on coolers), fitted at Waterside. Protect against over pressure
due to rupture of cooling air pipe. Relief at about 3 bars and sufficient flow area. Copper disc.
3. Drain valve. To remove condensed water and oil
4. Fusible plug. May be fitted instead of relief valve on compressor outlets immediately after
discharge valve. Melt at 120 deg C

Control of output

1. Unloading of suction valve

2. Plugging of suction passage
3. Bypass, discharge to suction

For compressors designed for starting air requirements a water jacket relief valve is fitted