Republic of the Philippines

MARINDUQUE STATE COLLEGE

SCHOOL OF ENGINEERING
Tanza, Boac, Marinduque
Bachelor of Science in Mechanical Engineering
Level I Accredited by the Accrediting Agency for Chartered Colleges Universities in the Philippines (AACCUP), Inc.

ME Laboratory 2

Activity no.: 4

Test of an Air Compressor

Date : September 21, 2021

Student name : Ahl Francis Rey

Engr. Jayruel Rodil

Instructor
Objectives:
After the performance of the experiment, the student should be able:

1. To explain how to evaluate the performance of an air compressor.

2. To measure the data needed in the performance evaluation of an air compressor.

3. To find out the Actual Free Air Delivery (FAD) of the compressor

4. To find out Isothermal power required

5. To find out Volumetric efficiency

6. To find out Specific power requirement

7. To develop professional work ethics, including precision, neatness, safety, and

ability to follow instructions.

Apparatus:
• Portable air compressor with pressure gage and thermometer or
Reciprocating air compressor test rig.
• Thermometer
• Steel Tape
• Stop Watch
• Thermometer

Brief Background:

Years ago, it was common for shops to have a central power source that drove all
the tools through a system of belts, wheels and driveshafts. The power was routed
around the work space by mechanical means. Many shops still use a mechanical system
to move power around the shop, even though belts and shafts are no longer used. It is
based on the energy stored in compressed air, and the air compressor is at the heart of the
system.
 Air compressors are utilized in a variety of settings, from corner gas stations to
large manufacturing operations. Air compressors are increasingly being found in home
workshops, basements, and garages. Models that can perform any duty, from inflating to
deflating

Research Activities

A. What is air compressor?

Compressors provide reliable operation for a wide variety of applications,

including starting and purging air, cooling turbines and reactor cores, nitrous
oxide treatment, fuel gas boosting, desulphurization and soot blowing. Air
compressors are machines that provide power to machinery. These are used
in many places, from the refueling stations to water purification units and
everything in between you will come across a lot of these devices being used.
The basic purpose of these devices is to provide power and hence its output is
measured at the crankshaft, just like with automobile engines.
Air compressors are machines that provide power to machinery. These are
used in many places, from the refueling stations to water purification units
and everything in between you will come across a lot of these devices being
used. The basic purpose of these devices is to provide power and hence its
output is measured at the crankshaft, just like with automobile engines.
Power plants need air compressors, in large part for the purpose of
producing high-quality and reliable instrument. Instrument air is highly
 purified air that has no moisture, particulates or other contaminants. Its
purpose of the is to allow throttling of the Air Operated Valves the system
uses for flow and level control. Without the clean, compressed air that air
compressors provide, the Air Operated Valves, as well as the ports of the
instruments, could suffer from clogs as a result of debris, oil or moisture that
commonly develop in non-purified air. Power Plants use air compressors to
produce Service Air, as the name indicates it used for cleaning, purging and
other basic purpose. There are four most common types of air compressors
you will see in a powerplant.

B. How does it work?

Since we know that air is compressible and we only need some mechanical
device to do that and for that we have air compressor. It takes air form one end
and than squeeze this air to high pressure and deliver it to the other end for
various application.
In the case of an air compressor, the compressing mechanism is compressing the
atmospheric air. The air compressor works in the following way:
 Air enters the piston or vane, and it is compressed by increasing its pressure and
at the same time decreasing its volume. As soon as the pressure reaches a
maximum set by the operator or the manufacturer, a switch mechanism prevents
any further air intake in the compressor. The compressed air is used and pressure
levels decrease. As soon as the pressure reaches a minimum, also set by the
operator or the manufacturer, the switch allows air to enter the compressor. This
procedure is repeated as long as the compressor is being used.
  By one of several methods, an air compressor forces more and more air into a
storage tank, increasing the pressure. When tank pressure reaches its upper limit
the air compressor shuts off. The compressed air, then, is held in the tank until
called into use. The energy contained in the compressed air can be used for a
variety of applications, utilizing the kinetic energy of the air as it is released and
the tank depressurizes. When tank pressure reaches its lower limit, the air
compressor turns on again and re-pressurizes the tank.

C. Main parts of air compressor?

The basic components of the air compressor are the electric motor, pump, and
receiver. The receivers can be vertical or horizontal and have different size and
capacity. An electric Motor powers the compressor pump. The motor then drives
a pulley via two belts, which help in transferring power from motors to the pump
pistons through a flywheel and crankshaft the flywheel fan helps cool the
compressor pump.

Compressor Pump: The pump compresses the

air and discharges it into the receiver. Two-stage air
compressors have a minimum of two pump
cylinders. By compressing the air twice, first in a
larger, low pressure cylinder, then in a smaller,
high pressure cylinder, two-stage compressors can
produce pressures.

The Piston: As the piston in the

pump cylinder moves downward, air
enters the large cylinder through the
filter and air Intake valves at
atmospheric pressure. On the
upstroke, the piston in the large
cylinder compresses the air to
approximately 50 psi, and discharges
it to the smaller cylinder through the
intercooler tube.
 The Receiver: The air is cooled using a flywheel fan
this passes through the intercooler and into the smaller
cylinder. In the smaller cylinder, high pressure is used to
compress further to a final state. As the piston moves
upward, it compresses the air and discharges it into the
receiver through a check valve.

D. System component of air compressor

Compressed air systems usually consist of the following components:

 compressor
 air cooler
 air receiver tank
 filter
 dryer
 condensate trap
 distribution system
 The compressor produces compressed air at the required pressure.
The air receiver tank acts as a reservoir to store and cool the compressed air
and helps make sure the system can cope with variations in demand.
The air cooler, filter and dryer all treat the air at different points in the
system. They remove impurities such as water, dirt and oil from the air taken
in by the compressor, as well as those added by the compressor.
Compressed air may be fed to various uses on a site via a distribution
system. These distribution systems can be relatively straightforward or very
complex. Some businesses use portable units, which consist of all of these
components in a compact package. Portable units are usually used for small-
scale applications, or when a mobile source of compressed air is needed.

E. Classification of compressor and its application

There are two methods of achieving air compression: positive and
dynamic displacement. Each method has several sub-categories which we
cover below. The outcomes are relatively similar, but the processes to achieve
them vary.
POSITIVE DISPLACEMENT
Positive displacement air compressors force air in a chamber where the
volume is decreased to compress the air.
Positive displacement is an umbrella term that describes different air
compressors that are power through positive air displacement. Although the
internal systems vary among different machines, the method of providing the
power is the same.
Some types of positive displacement compressors are better equipped for
industrial workloads while others are better for hobbyists or private projects.
Here are the three main types of air compressors that use positive
displacement:
1. Rotary Screw - screws turn, screw motion creates vacuum, air trapped in spaces
compress, air is forced through. Rotary screw
compressors have two internal “screws” that rotate in
opposite directions, trapping and compressing air
between them. The two screws also generate constant
movement as they rotate around. This is a common
type of air compressor and is one of the easiest to take
care of. The engines are typically industrial-sized and
are great for continuous use.
2. Rotary Vane - spinning rotor is off center, arms with self-adjusting length, air fills
the cavity and travels around, air
pressure goes up, air is forced through
output. Rotary vane compressors are like
rotary screw compressors, but instead of
screws, vanes are mounted on a rotor
and rotated inside the cavity. The air
compresses between the vane and its
casing and is then pushed out at a
different exhaust port. Rotary vane
compressors are very easy to use, making them very popular for private projects.

3. Reciprocating/Piston Type - A piston (reciprocating) compressor uses pistons

controlled by a crankshaft to deliver the gas at
high pressure. These are typically found at
smaller worksites and aren’t designed for
continuous use.

There are two types of piston compressors: single stage and two stage.
1. Single Stage - rotor spins, forcing a piston to move up and down, when the piston
moves down, the valve opens and air is pulled into the chamber, when the piston
moves up, air is forced into the chamber, air is forced through output. In the single
stage compressors, the air is compressed on one
side of the piston, while the other side deals
with the functionality of it: as the piston moves
down, the air is drawn in, and when it moves
up, the air is compressed .Single stage
compressors are relatively affordable compared
to the other compressors and are typically easy
to acquire; they can be found in almost any
mechanic shop.
2. Two Stage - rotor spins, large piston pulls in air, intercooler uses water to cool the
air, small piston pulls large volume of air into a small
space, pressurizing it, small piston forces the pressurized
air through the output. Two stage compressors have two
compression chambers on either side of a piston. Double-
acting compressors are typically water-cooled by a
continuous stream of water through the engine. This
provides a better cooling system than other compressors.Due to their high cost, two
stage compressors are better for factories and workshops versus private projects.

Dynamic Displacement - Dynamic displacement compressors utilize a rotating blade

powered by an engine to generate airflow. The
air is then restricted to create pressure, and the
kinetic energy is stored within the compressor.
These are mainly designed for
large projects, like at chemical plants or steel
manufacturers, so it’s unlikely you’ll be able to
find one at your local mechanic.
Just like with positive
displacement compressors, there are two
distinct types of dynamic displacement: axial
and centrifugal.

1. Axial Compressors - large fans pull in air at high velocity, stationary fan blades are
places to guide the air to the next fan, as the
space between fans gets smaller, the high
kinetic energy of the air causes it to
pressurize, and pressurized air is forced
through the outlet. Axial compressors use a
series of turbine blades to generate air,
forcing it through a small area. Although
similar to other bladed compressors, axial
compressors operate with stationary blades
which slow airflow, increasing pressure. These types of air compressors aren’t very
common and have limited functionality. They’re used mainly in aircraft engines and
in large air separation plants.

2. Centrifugal Compressors - high speed rotating fan pulls air, when air hits the fan,
centrifugal force expels it radically
outward, air travels around the casing, as
air passes through a diffuser it slows and
increases in pressure, pressurized air is
forced through the outlet pipe.
Centrifugal, or radial compressors, work
by bringing air into the center through a
rotating impeller, which is then pushed
forward through centrifugal, or outward, force. By slowing the flow of air through a
diffuser, more kinetic energy is generated. Electric high-speed motors are typically
used for these kinds of compressors. One of the more common uses of centrifugal
compressors is through HVAC systems.

F. Setup of Typical compress air system.

A compressed air system operates on pressure. Compressors are a motor-
driven mechanical device used to pressurize the air. The motor can be variable speed
or shut on and off. The compressed air then passes through a dryer to reduce
humidity and is distributed through pipes out to the plant.

Typical Compress Air System

Source: Improving Compressed Air System Performance: A Sourcebook for Industry, USDOE 2003
G. Test arrangement for measurement of compound air flow
Air Balancing Hood Measurement
If you’re lucky, and air exhaust fan airflow is being pulled from the room
through a grille that is flat against a ceiling or wall, and the volume of airflow
is between 30 and 2000 CFM, use a calibrated air balancing hood. Set you the
balancing hood to read in exhaust mode, securely place the hood over the
grille to capture all of the fan airflow coming through the grille. Then read
and record airflow.
Airflow specifications are plus or minus 10% of design airflow. With most
smaller fans this spec is adequate. If you’re all caught up in exactness, forget
about it. If you’re concerned about the determining the precise amount of
duct leakage, your effort is better spent in installing the duct so that is doesn’t
leak.When airflow cannot be measured directly with a balancing hood,
airflow can be measured in the exhaust duct by performing an airflow
traverse.
Traverse the Airflow in the Exhaust Duct
An airflow traverse requires at least 5 lengths of straight exhaust duct. Two or
more 3/8-in. test holes are then drilled into the duct. An anemometer, a test
instrument that measures air velocity is used to determine the average air
speed in the duct. Then the average feet per minute is multiplied by the area
of the duct in square feet to determine the airflow moving through the duct.
Plot Fan Airflow
Each fan manufacturer publishes fan performance tables for each fan.
Normally, these fan tables are shipped with the fan, or the information can be
easily found online at the manufacturer’s website. In order to interpret
exhaust fan airflow, you must measure the fan operating static pressure and
the fan speed or Revolutions Per Minute. This field data is then used to plot
fan airflow. Smaller fans are often constant or single-speed. With these fans,
you are not required to measure fan RPM. Larger fans require that you
measure the fan RPM. This is normally done using a non-contact tachometer
that reads RPM from reflective tape affixed to the fan.

Exhaust fan performance chart

 Fan static pressure is measured using a manometer (a pressure gauge) and a
hose or tube and a static pressure tip.
Since many fans are located at either end of the duct, the operating fan static
pressure is measured as air enters or exits the exhaust fan. Drill a test hole in
the duct and read and record the fan static pressure.
Exhaust fan test

Armed with the fan operating static pressure and the fan speed, go to the
manufacturer’s fan table matching the fan being measured and plot fan
airflow.

H. Formula for amount of air compressed

I. Formula for work compression