IC Engines and Reciprocating Machine (MEng4202) Dilla University

Chapter 14

RECIPROCATING COMPRESSOR

INTRODUCTION TO COMPRESSOR:

 Compressors are work absorbing devices which are used for increasing pressure of fluid
at the expense of work done on fluid.
 The compressors used for compressing air are called air compressors. Compressors are
invariably used for all applications requiring high pressure air.
 Some of popular applications of compressor are, for driving pneumatic tools and air
operated equipments, spray painting, compressed air engine, supercharging in internal
combustion engines, material handling (for transfer of material), surface cleaning,
refrigeration and air conditioning, chemical industry etc.

 Compressors are supplied with low pressure air (or any fluid) at inlet which comes out as
high pressure air (or any fluid) at outlet. Work required for increasing pressure of air is
available from the prime mover driving the compressor. Generally, electric motor,
internal combustion engine or steam engine, turbine etc. are used as prime movers.
 Compressors are similar to fans and blowers but differ in terms of pressure ratios. Fan is
said to have pressure ratio up to 1.1 and blowers have pressure ratio between 1.1 and 4
while compressors have pressure ratios more than 4.

Prepared by: Dr. Shiva Prasad KV., Assistant Professor, Dept. of Automotive Engineering 1
IC Engines and Reciprocating Machine (MEng4202) Dilla University

CLASSIFICATION OF COMPRESSORS:

Compressors can be classified in the following different ways.

1. Based on principle of operation: 2 types

 Positive displacement compressors
 Non-positive displacement compressors

Prepared by: Dr. Shiva Prasad KV., Assistant Professor, Dept. of Automotive Engineering 2
IC Engines and Reciprocating Machine (MEng4202) Dilla University

Positive displacement compressors:

 In positive displacement compressors the compression is realized by displacement of

solid boundary and preventing fluid by solid boundary from flowing back in the direction
of pressure gradient.
 Due to solid wall displacement these are capable of providing quite large pressure ratios.
 Positive displacement compressors can be further classified based on the type of
mechanism used for compression. They are :

Reciprocating Compressor:

Reciprocating compressors generally, employ piston-cylinder arrangement where

displacement of piston in cylinder causes rise in pressure. Reciprocating compressors are
capable of giving large pressure ratios but the mass handling capacity is limited or small.
Reciprocating compressors may also be single acting compressor or double acting
compressor. Single acting compressor has one delivery stroke per revolution while in double
acting there are two delivery strokes per revolution of crank shaft.

Rotary compressors:

The types are (i) Roots blower (ii) Vaned type compressors

Rotary compressors of above type are capable of running at higher speed and can handle
large mass flow rate than reciprocating compressors of positive displacement type.

Non-positive displacement compressors:

It is also called as steady flow compressors use dynamic action of solid boundary for
realizing pressure rise. Here fluid is not contained in definite volume and subsequent volume
reduction does not occur as in case of positive displacement compressors. Non-positive
displacement compressor may be of axial or centrifugal type depending upon type of flow in
compressor.

2. Based on number of stages:

 Compressors may also be classified on the basis of number of stages.

Prepared by: Dr. Shiva Prasad KV., Assistant Professor, Dept. of Automotive Engineering 3
IC Engines and Reciprocating Machine (MEng4202) Dilla University

 Generally, the number of stages depends upon the maximum delivery pressure.
Compressors can be single stage or multistage.
 Normally maximum compression ratio of 5 is realized in single stage compressors.
 For compression ratio more than 5 the multi-stage Compressors are used. Typical values
of maximum delivery pressures generally available from different types of compressor
are,

(i) Single stage compressor, for delivery pressure up to 5 bar

(ii) Two stage compressor, for delivery pressure between 5 and 35 bar
(iii) Three stage compressor, for delivery pressure between 35 and 85 bar
(iv) Four stage compressor, for delivery pressure more than 85 bar

2 stage reciprocating compressor

3. Based on capacity of compressors:

Compressors can also be classified depending upon the capacity of compressor or air delivered
per unit time. Typical values of capacity for different compressors are given as;

(i) Low capacity compressors, having air delivery capacity of 0.15 m3 /s or less

(ii) Medium capacity, having air delivery capacity between 0.15 and 5 m3 /s.

(iii) High capacity compressors, having air delivery capacity more than 5 m 3 /s.

4. Based on highest pressure developed:

Depending upon the maximum pressure available from compressor they can be classified
as low pressure, medium pressure, high pressure and super high pressure compressors.

Prepared by: Dr. Shiva Prasad KV., Assistant Professor, Dept. of Automotive Engineering 4
IC Engines and Reciprocating Machine (MEng4202) Dilla University

Typical values of maximum pressure developed for different compressors are as under;

(i) Low pressure compressor, having maximum pressure up to 1 bar

(ii) Medium pressure compressor, having maximum pressure from 1 to 8 bar
(iii) High pressure compressor, having maximum pressure from 8 to 10 bar
(iv) Super high pressure compressor, having maximum pressure more than 10 bar.

COMPONENTS OF RECIPROCATING AIR COMPRESSOR:

Prepared by: Dr. Shiva Prasad KV., Assistant Professor, Dept. of Automotive Engineering 5
IC Engines and Reciprocating Machine (MEng4202) Dilla University

Frame:

 The frame is a heavy, rugged housing containing all the rotating parts and on which the
cylinder and crosshead guide is mounted.
 Compressor manufacturers rate frames for a maximum continuous horsepower and frame
load.

Cylinder:

 The cylinder is a pressure vessel that contains the gas in the compression cycle.
 Single-acting cylinders compress gas in only one direction of piston travel. They can be
either head end or crank end.
 Double-acting cylinders compress gas in both directions of piston travel. Most
reciprocating compressors use double-acting cylinders.

Crankshaft:

The crankshaft rotates around the frame axis and drives the connecting rod, piston rod,
and piston.

 Connecting rod connects the crankshaft to the crosshead pin

 Crosshead converts the rotating motion of the connecting rod to a linear, oscillating
motion that drives the piston
 Piston rod connects the crosshead to the piston.

Piston:

 The piston is located at the end of the piston rod and acts as the movable barrier in the
compressor cylinder.
 Selection of material is based on strength, weight, and compatibility with the gas being
compressed.

Prepared by: Dr. Shiva Prasad KV., Assistant Professor, Dept. of Automotive Engineering 6
IC Engines and Reciprocating Machine (MEng4202) Dilla University

 The piston is usually made of a lightweight material such as aluminum or from cast iron
or steel with a hollow center for weight reduction.

Bearings:

 Bearings located throughout the compressor frame assure proper radial and axial
positioning of compressor components.
 Main bearings are fitted in the frame to properly position the crankshaft.
 Crank pin bearings are located between the crankshaft and each connecting rod.
 Wrist pin bearings are located between each connecting rod and crosshead pin.
 Crosshead bearings are located at the top and bottom of each crosshead.

Compressor valves:

 The essential function of compressor valves is to permit gas flow in the desired direction
and to block all flow in the opposite (undesired) direction.
 Each operating end of a compressor cylinder must have two sets of valves. The set of
inlet (suction) valves admits gas into the cylinder.
 The set of discharge valves is used to evacuate compressed gas from the cylinder.

Performance Terms of Air compressor:

 Actual capacity:

Actual capacity is a term that is sometimes applied to the capacity of a compressor at intake
conditions. It is commonly expressed by either the term ICFM (intake cubic feet per minute), or
ACFM (actual cubic feet per minute).

 Volumetric efficiency

Volumetric efficiency is the ratio of the actual capacity of the compressor to displacement and is
expressed as a percentage.

Prepared by: Dr. Shiva Prasad KV., Assistant Professor, Dept. of Automotive Engineering 7
IC Engines and Reciprocating Machine (MEng4202) Dilla University

 Mechanical efficiency

Mechanical efficiency is the ratio of the indicated horsepower in the compressing cylinders to the
brake horsepower delivered to the shaft. It is expressed as a percentage.

 Overall efficiency

Overall efficiency is the product of the compression efficiency and the mechanical efficiency.

 Compression efficiency

Compression efficiency is the ratio of the theoretical horsepower to the actual indicated
horsepower required to compress a definite amount of gas.

 Compression ratio

Compression ratio is the ratio of the absolute discharge pressure (psia) and the absolute inlet
pressure (14.696). Thus, a compressor operating at sea level on plant air service with a 100 psi
discharge pressure would have a compression ratio of 7.8.
(100psi + 14.7) ÷ 14.7 = 7.8

(1 pound force square inch (1 psi) = 0.069 bar)

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Prepared by: Dr. Shiva Prasad KV., Assistant Professor, Dept. of Automotive Engineering 8