EJERS, European Journal of Engineering Research and Science
Vol. 4, No. 4, April 2019
Performance Assessment of a Two-Stage Reciprocating
Air Compressor
Ikpobari Amuele Nwakpang, Barinaadaa Thaddeus Lebele-Alawa, and Barinyima Nkoi
 and the painter’s spray gun. Usually, a compressor is driven
Abstract—This paper presents the performance assessment
of a two-stage reciprocating air compressor operating at an Oil
and Gas Terminal in Rivers State, Nigeria. The main focus was
to investigate the effects of control parameters and clogging on
the performance of the compressor. Data were obtained from
the manufacturer’s manual, field reports and the field
operator’s log sheets. Relevant thermodynamic equations were
used to determine and analyse appropriate control parameters
of the compressor. Data were also analysed using various
appropriate compressor equations and a thermodynamic
analysis of the compressor was done to evaluate its
performance. The outcome of all the analyses showed that the
compressor experienced 26% loss or reduction in the
volumetric efficiency, 8% loss in the isothermal efficiency,
11.1% loss in volume flow rate and 21% decrease or reduction
in the mass flow rate due to clogging when compared with the
design specifications. The analysis also showed that the
performance of the compressor was affected by several other
factors including the climatic and environmental conditions
such as the high operating ambient temperature of the inlet air
to the compressor. It revealed that the effects of clogging
caused a continuous rise in temperature which reduced the
discharge pressure, mass and volume flow rates, isothermal
and volumetric efficiencies; thereby reducing its performance
in comparison with the design specifications. The results
further revealed that clogging was a major factor that affected
the performance effectiveness of the reciprocating compressor.
Index Terms—Isothermal Efficiency, Compressor Clogging,
Discharge Temperature, Two-Stage Compression,
Compression, Discharge Pressure, Volumetric Efficiency,
Intercooler Pressure.
I. INTRODUCTION
Compressors are of vital importance in modern-day
industries. They play tremendous roles in ensuring that
industrial processes and works are done [1]. Compressors
are mechanical devices that can compress a substance in
gaseous state [2]. When air is used as the working fluid in a
compressor, it is called an air compressor. This means that
an air compressor is a machine that increases the pressure
and temperature of air [3]. During the process of air
compression, the inlet/intake pressure of the air is usually
raised to a higher exhaust pressure [4].
Air compressors have earned a fair amount of popularity
in several industries as a result of the various uses of
compressed air. Some of such uses and applications of
compressors and compressed air are in the industries and in
equipment such as refrigerator, air conditioner, trucks and
for the filling of apparatus used for breathing, bicycle pump
Published on April 19, 2019.
Authors are with River State University, Nigeria.
nwakpangikpobari@yahoo.com)
DOI: http://dx.doi.org/10.24018/ejers.2019.4.4.1130
by a prime mover such as a diesel engine or electric motor
[5].
In general, air compressors are sometimes classified
according to their working principles or principle of
operations, according to their actions and according to their
number of stages. Furthermore, based on the principle of
operation, compressors are classified into positive
displacement compressors and non-positive displacement or
dynamic compressors [6]. Positive displacement
compressors are also grouped into reciprocating and rotary
compressors. They are also called piston compressors [7].
Reciprocating compressors operate on the same principle as
the old, familiar bicycle pump which is by means of a piston
in a cylinder [8].
A reciprocating air compressor increases the pressure of
air via the use of piston by ensuring that the volume is
reduced in such a way that it takes in successive volumes of
air, confines the air within a space called the cylinder and
elevates the air to a higher pressure [9]. The piston
compressor is considered one of the most widely used
equipment for air and gas services and it embraces the use of
piston – cylinder arrangement such that the piston is driven
by a crankshaft and that causes a displacement of the piston
in the cylinder thereby resulting in a rise in pressure [10].
Some of the key components or parts of a reciprocating
air compressor are cylinder, crankshaft, piston, suction/inlet
and outlet/delivery valves and connecting rod [11].
Reciprocating air compressors may be single or double
acting, single stage or multi-stage [11], [12]. In a single
stage reciprocating air compressor, compression takes place
in one stage while the multi-stage type involves more than
one compression stage for achieving the required high
pressure and low temperature by using intercooler [13]. An
example of the multi-stage compressor is the double or two-
stage compressor under consideration in this work.
Apart from the segmentation of the compression stages
into different stages to help increase the pressure and reduce
the temperature during the compression process for the
improvement of the performance of the compressor, one
major concern is the problem of compressor clogging which
it experiences - especially in a humid environment. The air
compressor under study is located at an Oil and Gas
Terminal in Rivers State, Nigeria. The said compressor had
suffered breakdown in the past due to clogging thereby
reducing production because of the period used in
maintenance. The aim of this study, therefore, is to assess
the performance of the compressor with regard to the
problem of clogging. The objectives of this research are to
investigate the effects of the control parameters (pressure,
(e-mail: temperature, mass and volume flow rates) on the
74
 EJERS, European Journal of Engineering Research and Science
Vol. 4, No. 4, April 2019

performance of the compressor, to investigate the effects of method for analyzing the compressor under consideration.
clogging on the performance of the compressor and to do a There are three types of compression processes which are
thermodynamic analysis of the said compressor to assess or possible in the reciprocating air compressor. They are
evaluate its performance. polytropic, isothermal and adiabatic compression processes.
In a bid to improving the efficiency of two-stage
reciprocating air compressor due to high temperature, an
experimental investigation was performed involving the use
of different intercoolants such as air, water, cooling source,
radiator coolant and ethylene glycol. Consequently, it was
concluded that the isothermal work required to compress the
air and the power required to drive the reciprocating
compressor reduced with respect to the intercooling [13].
Reference [14] carried out a thermodynamic analysis of a
reciprocating air compressor. During the thermodynamic
analysis, they found out that the clearance volume is one of
the parameters on which the performance and efficiency of
the compressor depend.
Fig. 1. Graph showing different compression processes.
Reference [15] presented a paper on improving the
performance and development of two stage reciprocating air The area under Fig. 1 shows the workdone in
compressor with particular focus on the case study of a compressing the air to P2 from P1 and the line with the least
reciprocating air compressor of a locomotive with the slope (isothermal compression) produces minimum or
associate problems, diagnosis and solutions highlighted. It lowest work. As seen from the graph, isothermal
involved a simulation model which they did. The simulation compression produces minimum work and it is the condition
model can predict volumetric efficiency, free air delivered, under which minimum work can be achieved in a
indicated power, shaft power, cylinder air pressure, cylinder compressor.
air temperature, resultant torque and the mass of air drawn
in or discharged out per cycle, by varying any operating 2) Polytropic Compression
parameter like speed, discharge pressure, etc. and physical This process lies between the isothermal and adiabatic
parameters like clearance volume, crank radius, connecting processes. In Fig. 1, 1-2p is a polytropic process and the
rod length and cylinder diameter. Also, compressed air was relationship between pressure (P) and volume (V) is given
produced without the use of electricity. That was done with as;
the use of speed breaker setup in roadways. Instead of using PVn = C (1)
electric drive, mechanical drive was used to generate the Also, workdone during a polytropic process is given as;
compressed air. This method of using speed breakers for the  n1 
generating of electricity is of great value especially because 2n  P2  2 n  (2)
W  
P1V1  
  1
of the over reliance on electricity for the production of n 1  1 
P 
 
compressed air which has been the norm for many years
now [16]. where

P 
II. MATERIALS AND METHODS r p =  2  (3)
 P1 
A. Materials
The manufacturer’s manual, operational data and field P1 = Inlet Pressure (N/m2), P2 = Discharge Pressure (N/m2),
reports for the air compressor under investigation were used V1 = Inlet Volume (m3), n = Index of Compression and
for this study. From these data, values were computed and r p = Pressure Ratio
used for the assessment of the performance of the
compressor. Also, relevant operating parameters such as the
inlet and outlet temperatures and pressures of the 3) Isothermal Compression
compressor were obtained for its thermodynamic analysis. Isothermal compression takes place at constant
temperature [14]. Workdone during an isothermal
B. Methods compression is evaluated as:
Wi = P1V1 ln rp (4)
The analysis and assessment of the compressor were done
to achieve the aim and objectives of this research with the where P1 = Inlet pressure (N/m2), P2 = Discharge
use of relevant fundamental equations that govern a two-
stage reciprocating air compressor, relevant models and pressure(N/m2) and rp = Pressure Ratio
thermodynamic analysis.
4) Adiabatic Compression
1) Analytical Model This type of air compression takes place in the absence of
A thermodynamic analysis was chosen as a suitable heat transfer [8]. The workdone during adiabatic

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Vol. 4, No. 4, April 2019

compression process is calculated using: 2n  n1 

WT  P1V 1rp 2 n  1 (8)
n 1  
2   1 
Wa = P1V1 rp 2  1 (5)
 1  
9) Overall Pressure Ratio (rp)
where  = Index of compression for air The overall pressure ratio of the compressor is given as
the ratio of the discharge pressure of the air to its inlet
pressure.
5) Volumetric Efficiency (ηv)
This is the ratio of the actual volume of air taken into the
P2
cylinder during suction stroke to the pistol displacement rp  (9)
volume (PDV) or swept volume. P1

ηv = 1+C-C r 
p
1
n
(6)
Where P1 = Inlet Pressure (N/m2) and P2 = Discharge
Pressure (N/m2)
where C = Clearance ratio
10) Intercooler Pressure
For minimum work condition with perfect intercooling to
6) Isothermal Efficiency (  i ) be obtained, the intercooler pressure is evaluated as:
Isothermal efficiency is given as the ratio of the
isothermal work to the actual work. Px = P1 P2 (10)

Wi
i  (7) 11) Intercooler Temperature
W
For complete or perfect intercooling in a two-stage
reciprocating air compressor, the intercooler temperature
7) Multistage Compressor (also known as the intermediate temperature) is given as;
Multistage compression involves more than one stage of
 
compression and it is done when high pressures are required n 1

 Px  n
 (11)
[17]. It has the two-stage (low and high pressure stages)
Tx  T1 
P 
 
compression as its typical example where compression of
the air is done in two stages with an intercooler incorporated  1
  

between the two stages [18]. The essence is basically to Where Tx = Intercooler Temperature, K
reduce the discharge temperature and increase the discharge Px = Intercooler Pressure, N/m2
pressure to the required pressure {19]. Achieving lower P1 = Inlet Pressure, N/m2
work, better capacity and efficiency while maintaining T1 = Inlet Temperature, K
isothermal condition is very difficult since increasing
pressure ratio, rp, causes a decrease in volumetric efficiency 12) Heat rejected in the intercooler
and an increase in delivery temperature, T 2 [20]. This The rate of heat rejected in the intercooler in kg/s is given
therefore requires a multistage compressor (a two-stage type as
in this case) to solve the problem as shown in Fig. 2.
Qx = Cp (Tx-T1) (12)

Where m = Mass flow rate, kg/s
Tx = Intercooler Temperature, K
T1 = Inlet Temperature, K
Cp = Specific heat at constant pressure, KJ/kgk

III. RESULTS AND DISCUSSION

Fig. 2. P-V diagram showing 2-stage compressor with intercooler
8) Total Work Done (WT)
For a 2-stage reciprocating compressor with complete or
perfect intercooling, WT is given as
A. Thermodynamic Performance Assessment of the two-
stage Reciprocating Air Compressor
A thermodynamic analysis of the compressor under study
was done to evaluate its performance behaviour with regard
to the problem of clogging with the use of the equations
already deduced, collected data and the operating
parameters of the compressor.

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Vol. 4, No. 4, April 2019

B. Reciprocating Compressor Analysis

With the aid of equations deduced and substitution of the
appropriate values of the operating parameters, some
parameters were evaluated and tabulated as shown in Table
I.

TABLE I: CALCULATED VALUES OF CONTROL PARAMETERS

Inlet Pressure Discharge Volumetric Suction Isothermal Work Isothermal Efficiency
P1 (bar) Pressure Efficiency Temperature Wi (KJ/Kg) ηi (%)
P2 (bar) ηv (%) T1 (K)
0.92 6.3 66.07287 298 186.2798 89.25721
1 6.847826 68.80188 298.2 186.4048 89.31712
1.05 7.190217 70.31943 298.4 186.5298 89.37702
1.1 7.532609 71.71428 298.6 186.6549 89.43692
1.15 7.875 73.00128 298.8 186.7799 89.49683
1.2 8.217391 74.19294 299 186.9049 89.55673
1.25 8.559783 75.29986 299.2 187.0299 89.61664
1.3 8.902174 76.33112 299.4 187.1549 89.67654
1.35 9.244565 77.29451 299.6 187.28 89.73644
1.4 9.586956 78.19677 299.8 187.405 89.79635
1.45 9.929348 79.04377 300 187.53 89.85625
1.5 10.27174 79.84061 300.2 187.655 89.91616
1.55 10.61413 80.59181 300.4 187.78 89.97606
1.6 10.95652 81.30132 300.6 187.9051 90.03597
1.65 11.29891 81.97265 300.8 188.0301 90.09587
1.7 11.6413 82.60893 301 188.1551 90.15577
1.75 11.9837 83.21294 301.2 188.2801 90.21568
1.8 12.32609 83.78717 301.4 188.4051 90.27558
1.85 12.66848 84.33386 301.6 188.5302 90.33549
1.9 13.01087 84.85501 301.8 188.6552 90.39539
1.95 13.35326 85.35245 302 188.7802 90.45529
2 13.69565 85.82782 302.2 188.9052 90.5152
2.05 14.03804 86.28262 302.4 189.0302 90.5751
2.1 14.38043 86.71821 302.6 189.1553 90.63501
2.15 14.72283 87.13583 302.8 189.2803 90.69491
2.2 15.06522 87.53661 303 189.4053 90.75482
2.25 15.40761 87.92159 303.2 189.5303 90.81472
2.3 15.75 88.29173 303.4 189.6553 90.87462

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TABLE II: AVERAGE COMPRESSOR OPERATING DATA PER DAY (CLOGGING)

Volumetric flow Mass flow rate
 
Discharge Temperature Discharge Pressure
Days T2 (K) P2 (bar) rate v (m3/s) m (kg/s)
1 416 6.3 0.4 0.38
2 416.3 6.2 0.398 0.379
3 416.5 6.1 0.396 0.377
4 417.1 5.96 0.394 0.374
5 418 5.89 0.392 0.372
6 418.2 5.7 0.39 0.37
7 418.4 5.52 0.388 0.369
8 418.7 5.4 0.386 0.367
9 418.8 5.35 0.384 0.365
10 419.1 5.22 0.38 0.363
11 419.3 5.1 0.376 0.361
12 419.5 5 0.372 0.36
13 419.9 4.81 0.37 0.358
14 420.2 4.72 0.366 0.356
15 420.5 4.61 0.362 0.353
16 421 4.59 0.357 0.352
17 421.6 4.46 0.354 0.35
18 421.9 4.34 0.351 0.346
19 422.3 4.21 0.346 0.342
20 422.8 4.13 0.342 0.34
21 423.4 4 0.338 0.339
22 424 3.9 0.334 0.335
23 424.4 3.84 0.33 0.331
24 425.1 3.74 0.32 0.33
25 425.7 3.67 0.315 0.325
26 426.2 3.54 0.31 0.321
27 426.6 3.41 0.305 0.31
28 427.3 3.3 0.3 0.28
29 428.1 3.21 0.28 0.25
30 428.8 3.1 0.27 0.23

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Vol. 4, No. 4, April 2019

TABLE III: AVERAGE COMPRESSOR OPERATING DATA PER DAY (NORMAL)

Volumetric flow Mass flow rate
 
Discharge Temperature Discharge Pressure
Days T2 (K) P2 (bar) rate v (m3/s) m (kg/s)
1 416 6.3 0.4 0.38
2 416.3 6.30445 0.40028 0.38027
3 416.9 6.31353 0.40086 0.38082
4 415.8 6.29688 0.3998 0.37981
5 416.105 6.30149 0.40009 0.38009
6 415.91 6.29854 0.39991 0.37991
7 416.6 6.30899 0.40057 0.38054
8 415.99 6.29975 0.39998 0.37998
9 415.98 6.2996 0.39997 0.37998
10 416.2 6.30293 0.40019 0.38018
11 416.4 6.30596 0.40038 0.38036
12 416.1 6.30142 0.40009 0.38009
13 416.07 6.30096 0.40006 0.38006
14 415.7 6.29536 0.39971 0.37972
15 416.21 6.30308 0.4002 0.38019
16 415.7 6.29536 0.39971 0.37972
17 416 6.2999 0.39999 0.37999
18 416.31 6.3046 0.40029 0.38028
19 416.2 6.30293 0.40019 0.38018
20 416 6.2999 0.39999 0.37999
21 416.1 6.30142 0.40009 0.38009
22 416.1 6.30142 0.40009 0.38009
23 416.3 6.30445 0.40028 0.38027
24 416.1 6.30142 0.40009 0.38009
25 415.91 6.29854 0.39991 0.37991
26 416.5 6.30748 0.40047 0.38045
27 416.1 6.30142 0.40009 0.38009
28 415.8 6.29688 0.3998 0.37981
29 416.1 6.30142 0.40009 0.38009
30 416 6.2999 0.39999 0.37999
Average 416.1162 6.30167 0.40011 0.3801

Tables II and III represent clogging and normal periods the changes in the operating conditions of the
respectively, show the various daily average operating thermodynamic parameters of the compressor. The clarity of
values over a 30-day period when the compressor under the effects of these parameters on the performance
investigation was operating under the influence of clogging assessment of the compressor is therefore simplified via
and when it was operating almost normally. In Table II, the graphical representations as shown in Figures 3-12.
values are for a period when the compressor experienced the
problem of clogging which negatively affected the
performance of the compressor and thereby caused an
increase in discharge temperature and decrease in discharge
pressure, mass and volume flow rates respectively as the
days went by. As observed in Table III, the mean values of
the control parameters (discharge temperature, discharge
pressure, mass and volume flow rates) over another 30-day
period referred to as “normal” did not change or fluctuate
significantly; they only varied around their daily mean
values thereby making the average values per day over the
afore-mentioned period almost constant.
C. Off-design Behaviour of the Compressor
Fig. 3. Effect of Ambient Temperature on Discharge Pressure.
The Tables I and II clearly illustrate the trend in terms of

DOI: http://dx.doi.org/10.24018/ejers.2019.4.4.1130 79

From Fig. 3, it is observed that the discharge pressure is a
function of the operating ambient temperature of the intake
air such that as the operating ambient temperature of the
intake air increases the discharge pressure also increased
correspondingly. Also, a decrease in the operating ambient
temperature also led to a drop or decrease in the discharge
pressure.
Fig. 4. Effect of Ambient Temperature on Isothermal Work.
Fig. 4 illustrates a direct proportionality which shows that
the isothermal work increased with an increase in the
ambient temperature. This means that a reduction in the
ambient temperature also caused a corresponding reduction
in the isothermal work of the compressor.
Fig. 5. Effect of Discharge Pressure on Volumetric Efficiency.
Fig. 5 clearly illustrates the fact that, as the ambient
temperature increased, the volumetric efficiency of the
compressor also increased and verse versa.
Fig. 6. Effect of Isothermal Work on Isothermal Efficiency.
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EJERS, European Journal of Engineering Research and Science
Vol. 4, No. 4, April 2019
The trend in Fig. 6 shows that the change in isothermal
work of the compressor affected the isothermal efficiency
such that an increase in the isothermal work brought about
an increase in isothermal efficiency. The reverse is the case
when the isothermal work decreased as the isothermal
efficiency also decreased.
Fig. 7. Effect of Clogging on discharge temperature over a period of time.
Fig. 7 shows what happened to the discharge temperature
during clogging and normal periods. During the clogging
period, the effect of clogging caused a gradual increase in
the discharge temperature of the compressor over time as the
days went by and this is a disturbing trend considering the
danger of continuous rise in temperature on mechanical
systems which can cause wear and tear, damage and
consequently lead to a complete breakdown of the
compressor if clogging is not minimized. During the normal
period, the discharge temperature did not experience any
significant change as the days went by but only the daily
average temperature experienced small changes in their
values around their mean values per day.
Fig. 8. Effect of Clogging on discharge Pressure over a period of time.
Fig. 8 shows that the discharge pressure continued to drop
every day during the clogging period but this was not the
case when the compressor discharge pressure operated under
normal condition as the discharge pressure did not
experience any significant change as the days went by;
rather it only experienced small changes in its values around
the mean values per day.
80

Fig. 9. Effect of Clogging on Volume flow rate over a period of time.
Fig. 9 shows that the volumetric flow rate of the air kept
decreasing as the number of days increased thereby
negatively affecting the flow capacity of the air compressor
and lowering its performance. The case was different and
better when the compressor operated under normal
condition.
Fig. 10. Effect of Clogging on Mass flow rate over a period of time
Fig. 10 also illustrates the fact that as the days went by,
the mass flow rate reduced continuously. This gradual
decrease in the mass flow rate continued until after the 26th
day when a sharp decrease began.
Fig. 11. Effect of Temperature during clogging on Volume flow and Mass
flow rates
Fig. 11 shows that during the clogging period, every
increase in temperature caused decrease in the mass and
volume flow rates. The negative effect of clogging on the
performance of the compressor was such that, as the
temperature increased daily, the volume flow rate and the
mass flow rate of the discharged air decreased.
DOI: http://dx.doi.org/10.24018/ejers.2019.4.4.1130
EJERS, European Journal of Engineering Research and Science
Vol. 4, No. 4, April 2019
Fig. 12. Effect of Temperature during clogging on discharge pressure over
a period of time
Fig. 12 shows that the effect of clogging (during the
clogging period) caused a gradual temperature increase that
resulted in a gradual decrease in the discharge pressure over
time as the days went by.
IV. CONCLUSION
The performance of the two-stage reciprocating air
compressor located and operating at an Oil and Gas
Terminal in Rivers State, Nigeria was assessed and analysed
via the application of some relevant thermodynamic
equations. From the analysis of the performance of the
compressor, it was evident that the performance of the
reciprocating air compressor depended significantly on the
effects of clogging on the compressor.
From the thermodynamic analysis done, it was evident
that the compressor experienced 26% loss in the volumetric
efficiency of the compressor, 8% reduction or decrease in
the isothermal efficiency, 11.1% loss in the volume of air
discharged every second and 21% loss or reduction in the
mass flow rate when compared with the design
specifications. These low efficiencies could be as a result of
clogging which may have taken place to cause the reduction
in the performance of the compressor to such a level.
Table II and Figures 7 to 12 show that clogging had
negative effects on the performance of the compressor
which caused increase in discharge temperature, decrease in
discharge pressure, mass and volume flow rates. Therefore,
it may be justifiable to say that minimising clogging in the
compressor would likely cause improved performance that
may meet the required design performance. This work
therefore shows an effective thermodynamic performance
evaluation of the compressor at an Oil and Gas Terminal in
Rivers State, Nigeria; hence, the objectives of this research
work have been achieved. This study also contributes to the
understanding that thermodynamic analysis is a veritable
tool that can be used in analysing and accessing the effects
of clogging in two-stage reciprocating air compressors.
In order to solve or minimize the menacing problem of
clogging for an improved performance of the air
compressor, the double-filter installation method should be
applied to limit the degree and amount of unwanted
elements gaining entrance into the compressor. Periodic and
timely change of the desiccants inside the compressor’s air
dryer is also recommended to minimise clogging and to
prevent moist air from being discharged; thereby ensuring
81

that discharged air are always dry. Periodic cleaning of the
cylinders of the reciprocating air compressor helps to
minimize clogging caused by accumulation of deposits and
unwanted build-ups due to corrosive effects on the internal
surface of the cylinders. Further research could be carried
out to detect the presence of clogging and the exact quantity
of clog in reciprocating compressors without opening the
compressor during maintenance.
ACKNOWLEDGMENT
The authors would like to profoundly appreciate the
department of Mechanical Engineering, Rivers State
University, Port Harcourt, Nigeria for the technical supports
given during the process of this research work.
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