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TECHNOLOGY
RECIPROCATING COMPRESSORS
Active Learning Assignment
Subject: 2151903 – FLUID POWER ENGINEERING
5th Semester, Academic Year 2017-18
By :
Godhaviya Prayag -150110119033
Gohil Parth - 150110119034
Hadavani Jeet - 150110119035
Hirani Hiral -150110119036
Hrishikesh Shah - 150110119037
Air Compressors
COMPRESSOR – A device which takes a definite quantity of fluid ( usually gas, and
Reciprocating Rotary
Centrifugal
2. Principle of Operation
Fig. shows single-acting piston actions in the
cylinder of a reciprocating compressor.
The piston is driven by a crank shaft via a
connecting rod.
At the top of the cylinder are a suction valve
and a discharge valve.
A reciprocating compressor usually has two,
three, four, or six cylinders in it.
Reciprocating Compressor - Working
Reciprocating Compressor – Equation for Work
3 2’ 2 2”
P2 PV C
(Isothermal)
PV C
(Adiabatic)
Pressure
PV n C
4 1 (Polytropic)
P1
V2 V1
Volume
Operations : 4 – 1 : Volume V1 of air aspirated into Compressor, at P1 and T1.
1 – 2 : Air compressed according to PVn = Const. from P1 to P2.
→ Temp increase from T1 to T2.
2 – 3 : Compressed air at P2 and V2 with temperature T2 is delivered.
Reciprocating Compressor – Equation for Work
During Compression, due to the excess temperature above surrounding, the air will
exchange the heat to the surrounding.
Compression Index, n is always less than γ, the adiabatic index.
As Compressor is a work consuming device, every effort is desired to reduce the work.
n
P2 P1
1/ n
Wiso P1V1 1
n 1 P1 P2
Reciprocating Compressor – Equation for Work
n P P 1/ n
Wiso P1V1 1 2 1
n 1 P1 P2
n P P 1/ n
3 2’ 2 2” P1V1 1 2 2
P2 PV C
(Isothermal)
n 1 P1 P1
PV C n 1
(Adiabatic) n P2 n
PV n C Wiso P1V1 1
4 1 (Polytropic) n 1 P1
P1
n 1
V2 V1 n P n
Delivery Temperature, Wiso mRT1 1 2
n 1 n 1 P1
P2 n
T2 T1
P
The solution of this equation is always negative.
1 This shows that Work is done ON the Compressor.
Reciprocating Compressor – Equation for Work
Clearance Volume :
PV n C
5 4 1
P1
V3 V4 V1
Total Volume, V1
Reciprocating Compressor – Volumetric Efficiency
Volumetric Efficiency :
↓ Volumetric Efficiency
V1 V4
vol
5 4 1 V1 V3
P1
V1 V3 V3 V4 1
V3
V4
V1 V3 V1 V3 V1 V3
V3 V4 V1
Effective Swept Volume,
V1-V4 V3 V4 V
Clearance Volume, 1 3
V3=Vc Swept Volume, V1-V3=Vs V1 V3 V1 V3 V3
Total Volume, V1 V3 V3 V
1 4
V1 V3 V1 V3 V3
Reciprocating Compressor – Volumetric Efficiency
6 3 2
P2
V3 V3
vol 1 1
V1 V3 V4
V3 V3
vol 1 1
V1 V3 V4
V3 P3
1/ n
vol 1 1
V1 V3 P4
P 1 / n
5 4 1 vol 1 3 1
P4
P1
V3 V4 V1
Effective Swept Volume,
V1-V4
Clearance Volume,
V3=Vc Swept Volume, V1-V3=Vs
Total Volume, V1
Reciprocating Compressor – Actual P-V Diagram
Receiver Pressure 1-2-3-4-1 : Theoretical P-V Diagram.
Pressure rise, followed by valve bounce and then pressure settles at a level higher than
the delivery pressure level.
Pt 101.325KN / m 2
Tt 15 C 288K
0
Reciprocating Compressor – Multistage
Intercooler
Air Intake
Reciprocating Compressor – Multistage
Delivery Pr. 6 9 3 5 Overall Pr. Range : P1 – P3
Perfect Intercooling
P3 or Pd
Single – stage cycle : 8-1-5-6
Without Intercooling
H.P. Without Intercooling :
PV n C L.P. : 8-1-4-7
Intermediate Pr. 7 4
P2 H.P. : 7-4-5-6
2 PV C
L.P. With Intercooling :
Intake Pr. 8 1 L.P. : 8-1-4-7
P1 or Ps
H.P. : 7-2-3-6
Volume
Perfect Intercooling : After initial compression in L.P. cylinder, air is cooled in the
Intercooler to its original temperature, before entering H.P. cylinder
i.e. T2 = T1 OR
Points 1 and 2 are on SAME Isothermal line.
Reciprocating Compressor – Multistage
Ideal Conditions for Multi – Stage Compressors :
n
n P5
n 1
H.P. W P1 V1 1
n 1 P1
7 PV n C
4
2 PV C Delivery Temperature,
L.P. n 1
8 1 P5 n
T5 T1
P
1
Reciprocating Compressor – Multistage
B. Two – Stage Compressor (Without Intercooling) :
Without Intercooling :
6 9 3 5 L.P. : 8-1-4-7
H.P. : 7-4-5-6
H.P. n 1
n P4
n
PV n C W P1 V1 1
7 4 n 1 P1
2 PV C
L.P. n 1
n P5 n
8 1 P4 V4 1
n 1 P4
7 PV n C Now, T2 = T1
4
P2V2 = P1V1
2 PV C
L.P.
8 Also P4 = P 2
1
n 1 n 1
n P2 n P3 n
W P1 V1 2
n 1 P1 P2
Shaded Area 2-4-5-3-2 : Work Saving due to Intercooler…!!
Reciprocating Compressor – Multistage
Condition for Min. Work :
Intermediate Pr. P2 → P1 : Area 2-4-5-3-2 → 0
7 PV n C
n 1
n 1
P1 V1 2 2 3
4 n P n P n
W
2 PV C n 1 P1 P2
L.P.
For min. Work,
8 1
n 1 n 1
P P
d 2
n n
3
P1 P2
dW
0
dP2 dP2
Reciprocating Compressor – Multistage
Condition for Min. Work : n 1 n 1
d 2 3
P n P n
P1 P2
dW
0
n 1 n 1 n 1 n 1 n 1
dP2 dP2
P2 n P3 n P2 n 0
1 1 1
n 1
P1 n n n
6 9 3 5
P2 1/ n P1 P
n 1
n
2 n 1 3
H.P. P2 n
PV n C
P2 2 P1 P3
7 4
2 PV C
L.P.
P2 P
8 1 P2 P1 P3 OR 3
P1 P2
Reciprocating Compressor – Multistage
P2 obtained with this condition (Pr. Ratio per stage is equal) is the Ideal Intermediate
Pr. Which, with Perfect Intercooling, gives Minimum Work, Wmin.
Equal Work per cylinder…!!
1/ 2
n 1
n
2n P P
W P1 V1 1 1 3
n 1
P1
n 1
P1 V1 1 2
2n P n
W
n 1 P1
n 1
P1 V1 1 3
2n P 2 n
W
n 1 P1
Reciprocating Compressor – Efficiency
Indicated Power : Power obtained from the actual indicator card taken during a
test on the compressor.
1
P1 V1 1 2
P
1 P1
adiabatic
Brake Power required to drive the Compressor
A. Spray Injection : Assimilation of water into the compressor cylinder towards the
compression stroke.
Object is to cool the air for next operation.
B. Water Jacketing : Circulating water around the cylinder to help for cooling the
air during compression.
Reciprocating Compressor – Efficiency
How to Increase Isothermal Efficiency ?
C. Inter – Cooling : For high speed and high Pr. Ratio compressors.
Compressed air from earlier stage is cooled to its original
temperature before passing it to the next stage.
D. External Fins : For small capacity compressors, fins on external surfaces are useful.
E. Cylinder Proportions : Short stroke and large bore provides much greater surface
for cooling.
Cylinder head surface is far more effective than barrel surface.
Reciprocating Compressor – Efficiency
Clearance Volume : Consists of two spaces.
1. Space between cylinder end & the piston to allow for wear.
2. Space for reception of valves.
High – class H.P. compressors : Clearance Vol. = 3 % of Swept Vol.
: Lead (Pb) fuse wire used to measure the gap between
cylinder end and piston.
P3 = P 2 and P4 = P1
n 1
5 4 1 n P2 n
P1 W P1 (V1 V4 ) 1
n 1 P1
V3 V4 V1
Effective Swept Volume,
V1-V4 n 1
P
P1 Va 1 2
Clearance Volume, n n
V3=Vc
P1
Swept Volume, V1-V4=Vs
n 1
Total Volume, V1
Reciprocating Compressor – Work Done
n 1
n P2
n
W m1 R T1 1
P2
6 3 2
n 1 P1
m1 is the actual mass of air delivered.
Total Volume, V1