Reciprocating Compressor

5 Course Contents
RECIPROCATING 5.1 Introduction

COMPRESSOR 5.2 Classification of Compressors
5.3 Applications of Compressed air, Gases and Vapours
5.4 Working principle of Reciprocating Compressor
5.5 Work Done for Operating Single Stage
Reciprocating Compressor Neglecting Clearance
Volume
5.6 Necessity of Clearance Volume and Work Done
Equation for Operating Single Stage Reciprocating
Compressor Considering Clearance Volume
5.7 Volumetric Efficiency
5.8 Need of Multi Stage Compression
5.9 Advantages of Multi Stage Compressors
5.10 Work Done in Two Stage Reciprocating Compressor
with Intercooler Neglecting Clearance
5.11 Condition for Minimum work or maximum
efficiency for Two Stage Reciprocating Compressor
5.12 Work Done in Two Stage Reciprocating Compressor
Considering Clearance volume
5.13 Optimum Intermediate Pressure required in a Two
Stage Compression but with Incomplete
Intercooling
5.14 Methods of Controlling the Output of Reciprocating
Compressor (Capacity Control of Compressors)
5.15 Solved Numerical
Department of Mechanical Engineering Page 5.1

5. Reciprocating Compressor Fluid Power Engineering
5.1 Introduction
− A compressor is a power absorbing machine used to increase the pressure of fluid
(air, gas or vapour) above that at which it is available.
− Compressor may be of the reciprocating piston-cylinder type or of the rotary type.

Since the process of compressing fluid requires that the work should be done on it, a
compressor has to be driven by a prime mover, such as electric motor or engine.
− “A machine which takes in air during suction stroke at low pressure and compresses
it to high pressure in a piston cylinder arrangement and then delivers it to some
storage vessel (receiver) is known as reciprocating air compressor”. The high
pressure air from the receiver may be supplied by a pipe line to wherever it is
required.
5.2 Classification of Compressors

− Compressors are classified on the basis of:
(1) According to design and principle of operation:

(i) Positive Displacement type compressor (ii) Roto Dynamic type compressors
(i) Positive displacement type:
− “In positive displacement type compressors, the pressure of air is increased by
decreasing its volume.”
− They further divided in two types as below:

a) In positive displacement reciprocating compressors the air is compressed due to the
action of reciprocating piston moving axially in the cylinders.
b) In positive displacement rotary compressors the air is trapped in between two sets of
engaging surfaces and the pressure rise is either by the back flow of air (roots
blower) or by both squeezing action and back flow of air (vane blower).
(ii) Dynamic compressors:
− “In dynamic compressors the air is not trapped in specified boundaries but it flows
continuously and steadily through the machine and the kinetic energy imparted to
the air by the rotor is changed into pressure energy partly in the rotor and the rest in
the diffuser” i.e. the rise in pressure is carried by the dynamic action of air (due to
change in angular momentum of air passing through the rotor).
− They further divided in two types as below:

a) In centrifugal compressors, the flow of air is more or less radial. The kinetic energy
imparted to the air is partly changed into pressure energy due to centrifugal and
diffusion action in the rotor and the rest in diffuser due to diffusion action.

▪ In axial flow compressors the flow is axial and there is no centrifugal action. Dynamic
compressors are characterized by large volumetric capacity and relatively low
pressures.
(2) According to the delivery pressure limit:

(i) Low pressure compressors: delivery pressure up to 10 bar
(ii) Medium pressure compressors: delivery pressure 10 to 80 bar
(iii) High pressure compressors: delivery pressure 80 to 100 bar
(iv) Super high pressure compressors: delivery pressure above 100 bar
(3) According to pressure limit:

(i) Fan: pressure ratio 1 to 1.1 (ii) Blower: pressure ratio 1.1 to 2.5 (iii) Compressors:
pressure ratio above 2.5.
(4) According to the number of stages:

(i) Single Stage: delivery pressure up to 10 bar (ii) Multistage: delivery pressure above 10 bar
(5) According to the capacity:

(i) Low capacity: volume of air delivered 9 m3/min or less
(ii) Medium capacity: volume of air delivered from 9 to 300 m3/min
(iii) High capacity: volume of air delivered above 300 m3/min
(6) According to the action of piston:

(i) Single acting compressor (ii) Double acting compressor
(7) According to the method of cooling:

(i) Air cooled compressor (ii) Water cooled compressor
(8) According to the method of drive:

(i) Electric motor driven (ii) I. C Engine driven (iii) Turbine driven
(9) According to the arrangement of cylinders

(i) Vertical (ii) Horizontal (iii) Radial (iv) V type (v) W type
5.3 Applications of Compressed air, Gases and Vapours

− Some typical uses of compressed air and gases are discussed below.
(1) In mining
− In mines due to danger of explosion-fire, no electrical or fuel motors can be used and
the of the machinery such as air motors, drills, haulage, coal cutters, mine
locomotives are driven by compressed air.
− Air lift pumps to pump water are very common with mines. Leakage improves
ventilation.

(2) In I. C. Engines
− Compressed air is used for starting I.C engines, fuel injection in diesel engines,
supercharging scavenging purposes.
(3) In Automobiles
− ln automobile industry compressed, air is used for spray painting, servicing cars, car
lifts, filling air in tyres, pneumatic brakes, pneumatic steering in heavy vehicles.
(4) In Civil engineering

− In constructional works compressed air is used for pneumatic drilling of hard rocks
for blasting, tunnelling, driving vibrators for even mixing of cement, concrete and
water.
(5) Pneumatic appliances

− Compressed air is used for operating pneumatic appliances such as hammers, hoists,
drills, sand blasters, chuck pile drivers.
(6) In workshops
− Compressed air is used to operate blast furnace, forged hammers, presses,
pneumatic riveting and cleaning purposes.
(7) Acid and Chemical Industries

− Compressed air plays an important role in the manufacture of soda, in
hydrogenation of coal with pressure up to 300 bar, in manufacture of synthetic
ammonia using pressure up to 1000 bar and polymerization of ethylene with
pressure 2500 bar.
(8) Refrigeration and Air conditioning

− Compressed air and vapours are used in refrigeration plants, such as freezers, cold
storage and air conditioners.
(9) Conveying Purpose

− Compressed air is used for conveying solid and powder materials in pipe lines or
though ducts.
(10) Operation of Gas turbines

− Compressed air is used for gas turbine system, where rotary compressor is a vital
component.
(11) Agriculture
− Compressed air is used in processing of food farm maintenance by spraying of
insecticides.
(12) Ammunition Depots

− The safety of compressed air as well as its versatility makes it a desirable form of
powder for many operations in ammunition deposits and self locating plants. Air
operated ammunition hoists are spark free and quick acting.
5.4 Working Principle of Single Stage Single Acting Reciprocating

Compressor
− A single stage, single acting reciprocating air compressor is shown in Fig. 5.1. It
consists of a piston cylinder assembly fitted with inlet and delivery valves.
− The piston reciprocates in a cylinder and derives its motion through a connecting rod
and crank mounted in a crank case, the inlet and delivery valves are provided are
mostly of thin steel plates provided with light springs because of pressure difference
across them.
a) Forward Stroke (or Suction Stroke)
− As shown in Fig. 5.1 (a) the piston is moving down the cylinder and any residual
compressed air left in the cylinder after the previous compression will expand. The
pressure of this air will drop below the atmospheric pressure.
− The inlet valve will open due to difference of pressure and fresh air will enter into
the cylinder. Admission of air goes on until the piston reaches the end of the
downward stroke.
− During admission of air the delivery valve remains closed because the receiver
pressure on the outside of this valve is much higher than the suction pressure.
(a) (b)
Fig. 5.1 Single stage single acting reciprocating compressor

b) Reversed Stroke (or Compression & delivery stroke)

− As shown in Fig. 5.1 (b), the piston is now moving upwards. At the beginning of this
upward stroke, a slight increase in cylinder pressure will close the inlet valve.
− Since both the inlet and delivery valves are closed, the pressure of air will rapidly rise
at the expense of its volume.
− Eventually a pressure will be reached which is slightly of the compressed air pressure
on the outside of the delivery valve and hence the delivery valve will open. The
compressed air is now delivered from the cylinder to the receiver until the piston
reaches the end of its upward stroke.
− At the end of compression stroke piston once again begin to move down the
cylinder, the delivery valve closes, the inlet valve eventually opens and the cycle is
repeated.
− “In double acting compressor the same action takes place on each side of the piston.
The delivery from the compressor is intermittent. To smooth out pulsation the
compressed air is stored in a receiver from where continuous flow of compressed air
can be supplied.”
5.5 Work Done for Operating Single Stage Reciprocating

Compressor Neglecting Clearance Volume
− Fig. 5.2 shows a theoretical P-V and T-S diagrams for a reciprocating air compressor
neglecting clearance volume.
− The sequences of operations as represented on the diagrams are as follows:
Suction Process 4-1:
− In suction process, the volume in the cylinder increases from zero at 4 to that
required to fill the cylinder at 1 and volume of air V1, inducted into the compressor
at constant pressure P1, and temperature T1.
Compression Process 1-2:

− In compression process, air is compressed according to the law PVn = constant from
pressure P1 to pressure P2, volume decreases from V1 to V2 and temperature
increases from T1 to T2.
− The compression process 1-2 may take place isentropically, polytropically or

isothermally. In the absence of heat transfer, the compression process: 1-2" will be
isentropic with its equation pvϒ = constant, where ϒ is the ratio of specific heats.
− If the heat transfer during compression is controlled in such a way that temperature
during compression process remains constant. The process 1 -2' will be isothermal
represented by, PV = constant.

− “ln practice the compression process 1-2 is neither isentropic nor isothermal. It lies
between isentropic and isothermal processes and may be regarded as polytropic
process with equation PVn = constant.”
Fig. 5.2 P-V and T-S diagrams for a reciprocating air compressor neglecting clearance volume
Delivery Process 2-3:

− In delivery process, compressed air at volume V2, at pressure P2, and temperature T2,
is delivered from the compressor to the receiver.
Case: (A) Work Done During Polytropic Compression (PVn = Constant)

− The net work done in the cycle is given by the area of the P-V diagram and is the
work done on the air as shown in Fig. 5.2.
Let, P1 = Pressure of the air at the beginning of the compression, N/m2
V1 = Volume of the air at the beginning of the compression, m3
T1 = Absolute temperature of the air at the beginning of the compression, K
P2, V2, T2 = Corresponding value at the end of the compression
Indicated work done on the air per cycle,
W = area 1-2-3-4-1
= area 2-3-5-6-2 + area 1-2-6-7-1 – area 1-4-5-7-1
= area under 2-3 + area under 1-2 – area under 1-4
2 2 − PV
PV
= PV2 2 +
1 1
− PV
n −1
1 1
2 2 − PV
PV
= ( PV
2 2 − PV1 1)+
1 1
n −1
 1 
= ( PV
2 2 − PV1 1 ) 1 + 
 n −1 
n
= ( PV
2 2 − PV 1 1)
n −1
n  PV 
= PV1 1
2 2
− 1
n −1  PV
1 1 
Now for polytropic process 1-2,
1 1 = PV
n n
PV 2 2
1/ n −1/ n
V P P 
 2 = 1  = 2 
V1  P2   P1 
V
Substituting the value of 2 in equation, we get
V1
n  P  P −1/ n 
W= 1 1   2  − 1
2
PV
n −1  1  P1 
P 
 n −1

  P2  n
− 1 J/cycle
n
1 1 
 P1 
W = PV (5.1)
n −1 
 
n −1
P  n
T2
Also, for polytropic process,  2  = 1 1 = mRT1 in above equation
and substitute PV
 P1  T1
(5.1),
n  T  
W= mRT1  2  − 1
n −1  T1  
n
W= mR (T2 − T1 ) J/cycle
n −1
Where ‘m’ is the mass of air inducted and delivered per cycle.
Work input per kg of air is,
 n −1

 
RT1   − 1 J/kg

n P2 n
W= (5.2)
n −1  P1  
 
Case: (B) Work Done During Isentropic Compression (PVϒ = Constant)

The work required per cycle when the air is compressed isentropically is obtained by
substituting ϒ in place of n in above equations.
 −1
 
   
PV   − 1
 P
W= 2
(5.3)
 − 1 1 1  P1  
 
 −1
 
   
mRT1   − 1
 P
W= 2
 −1  P1  
 

W= mR (T2 − T1 ) J/cycle
 −1
CP
But the ratio of specific heats,  = and CP − CV = R
CV
Substitute these values in above equation we get,

CP
CV
W= m ( CP − CV )(T2 − T1 )
CP
−1
CV
W = mCP (T2 − T1 ) J/cycle (5.4)
Case: (C) Work Done During Isothermal Compression (PV = Constant)

− Isothermal compression follows the law of PV= constant.
− In isothermal compression, P1V1= P2V2 and the temperature remains constant, thus
by the law of conservation of energy the entire work of compression is discharged to
the cooling media, thus no energy is wasted in heating the air or increasing the
internal energy.
− Thus less energy will be required to be done per kg of air to raise its pressure from P1
to P2.
Work done on air per cycle,
W = area 1-2-3-4-1
= area 2-3-0-V2-2 + area 1-2-V2-V1-1 – area 1-4-0-V1-1
= area under 2-3 + area under 1-2 – area under 4-1
V1
= PV
2 2 + PV
2 2 ln − PV
1 1
V2
V1 P2
1 1 = PV
But for isothermal process, PV 2 2 and =
V2 P1
V1 V1 P2
W = PV
2 2 ln = PV
1 1 ln = PV
1 1 ln
V2 V2 P1
P2
W = mRT1 ln J/cycle
P1
P2
W = RT1 ln J/kg (5.5)
P1
Condition for Minimum Work

− The work done on the air is given by the area of the indicator diagram and the work
done will be minimum when the area of the diagram is minimum.
− For a given compressor, height of the P-V diagram is fixed by the required pressure
ratio P2/P1 when P1 is fixed and the length of line 4-1 is fixed by the cylinder volume
i.e. stroke length. The only process which can influence the area of the diagram is
the compression process 1-2. The position taken by this curve decided by the value
of the compression index n.

Fig. 5.3 Possible compression processes on P-V diagram
− The work done on air is least when the compression is isothermal (n = 1) and
maximum when it is adiabatic (n = ϒ), because the isothermal compression curve has
least slope than an adiabatic compression.
− Work required for isothermal compression = area 4-1-2’-3-4
o Work required for adiabatic compression = area 4-1-2”-3-4
o Hence work saved if air is compressed isothermally = area 1-2”-2’-1.
− Thus least desirable form of compression in reciprocating compressor is isentropic
compression process.
Methods to Achieve Approximation of Isothermal Compression
− Isothermal compression is achieved by the following methods even running at higher
speed.
(1) Cold water spray (Injection):
− In this method, the increasing temperature of the air is reduced by spraying cold
water while air being compressed.
Fig. 5.4 Approximation to isothermal compression

− Without the cold water spray the compression will be adiabatic 1-2”. With cold
water spray the compression curve 1-2 will be approximately of the form of PV1.2,
this bring the compression near the isothermal and saving in work shown by shaded
area. (Refer Fig. 5.4)
(2) Suitable cylinder dimension:

− The cooling can be done more effectively if the surface area is increased by using a
cylinder of large diameter and shorter stroke length. However this increases
clearance volume which is not desirable.
(3) Water jacketing:

− The cooling water is circulating around the cylinder through the water jacket which
helps to cool air during compression.
(4) External fins:

− Effective cooling can be achieved with the use of fins on the external surface of the
cylinder.
(5) Multistage compression:

Compression process can be approximated to that of isothermal compression by using
multistage with Intercooling between two stages.
5.6 Necessity of Clearance Volume and Work Done Equation for

Operating Single Stage Reciprocating Compressor Considering
(with) Clearance Volume
Fig. 5.5 P-V diagram of single stage reciprocating compressor considering clearance volume
Work Done Equation:
Net work required per cycle,

W = area 1-2-3-4-1
W = work required on air for compression without clearance volume
–
work done by clearance air in expanding from volume V3 to V4
= area 1-2-6-5-1 – area 4-3-6-5-4
Assuming polytropic index n to be same for both compression and expansion, then
 n −1
  n −1

n   P2  n
 n   
P3 n 
W= 1 1 
PV  − 1 − 4 4 
PV  − 1
n −1  n −1 
 1   4 
P P
 
But P4 = P1 and P3 = P2
 n −1

 P2  n
P1 (V1 − V4 )   − 1

n
W= (5.6)
n −1  P1  
 
 n −1

  
− 1 J/cycle
n
n P
W= 1 as 
 P1 
2
PV
n −1 
 
Where, Vas = V1 − V4 = actual or effective swept volume
Now substitute PV
1 as = ma RT1 in above equation,
 n −1

 
ma RT1   − 1

n
n P
W= 2
n −1  P1  
 
n −1
n T  P  n
T2
W= ma RT1  2 − 1 but  2  =
n −1  T1   P1  T1
n
W= ma R T2 − T1  J/cycle
n −1
n
W= R T2 − T1  J/kg (5.7)
n −1
[Note FYI: This equation independent of clearance volume. Thus clearance volume does not
affect the theoretical work required to compress and deliver the air, this is because work
required to compress the mass air held in clearance space is returned when the same mass
of air expands during the expansion 3-4.]

5.7 Volumetric Efficiency

5.7.1 Volumetric Efficiency Referred to Suction Conditions
− “It is defined as the ratio of actual volume sucked by per cycle OR it is the ratio of
effective swept volume to the swept volume.”
Effective swept volume
V =
Swept volume
V −V
V = 1 4 but V1 = VC + VS
VS
V =
(VC + VS ) − V4
VS
VC V4
V = 1 + − (5.8)
VS VS
For polytropic expansion process 3-4 we can write,
3 3 = PV
n n
PV 4 4
1/ n
P 
V4 = V3  3  But P4 = P1 and P3 = P2 and V3 = VC
 P4 
1/ n
P 
V4 = VC  2 
 P1 
Substitute the value of V4 in the above equation (5.8),
1/ n
V V P 
V = 1 + C − C  2 
VS VS  P1 
 P 1/ n 
V = 1 − C  2  − 1 (5.9)
 P1  
V P
Where C = clearance ratio = C and r = 2 = pressure ratio
VS P1
5.7.2 Volumetric Efficiency Referred to Ambient Conditions

− “Volumetric efficiency referred to ambient or free conditions is the ratio of effective
swept volume reduced to ambient condition to the swept volume.”
Effective swept volume reduced to ambient condition
V ( amb ) =
Swept volume
Va
V ( amb ) = (5.10)
VS
Let,

Pa = Pressure of ambient air

Ta = Temperature of ambient air
Va = Effective swept volume reduced to ambient condition
P1 = Intake pressure of air
T1 = Intake temperature of air
PaVa P1 (V1 − V4 )
=
Ta T1
P1 Ta
Va =   (V1 − V4 )
Pa T1
Substitute the value of Va in equation (5.10)
P1 Ta V1 − V4
V ( amb ) =  
Pa T1 VS
But from volumetric efficiency referred to suction condition is given by,
V1 − V4   

1/ n
 P2 
= 1 − C   − 1
VS   1 
 P



Thus,
P1 Ta   

1/ n
 P2 
V ( amb ) =  1 − C   − 1 (5.11)
Pa T1   P1  
  
5.7.3 Factor Affecting the Volumetric Efficiency

Following are the factors affecting the volumetric efficiency:
(1) Increase in delivery pressure

− By increasing the delivery pressure, the actual volume of air inducted during the
suction stroke is decreased where as the swept volume of the piston remains the
same, thus the volumetric efficiency decreases. (Refer Fig. 5.6 and 5.7 and Eq. 5.9)
(2) Very high speed

− It is because at very high speeds, the air does not get enough time to fill the cylinder
fully during suction stroke, thus the volumetric efficiency of a given compressor
decreases.

Fig. 5.6 Volumetric efficiency variation

(3) Leakage past the piston
− During compression and delivery, some air leaks past the piston, thus decreasing the
amount of air delivered, thus the volumetric efficiency decreases. This tendency
increases with the increase of delivery pressure.
(4) Too large clearance volume

− The volumetric efficiency of the compressor is decreased with the increase of its
clearance volume. (Refer Eq. 5.9)
(5) Over heating of the air

When air enters in to the compressor during the suction stroke, it is heated and expanded
due to the temperature of the cylinder walls and thus the expanded clearance air is higher
than that of incoming air. So the volume of air taken in during the suction stroke is
decreased considerably. This lowers the volumetric efficiency of the compressor.
(6) Turbulence in air passage

The pressure inside the cylinder during the suction stroke is decreased due to the frictional
effects in the air itself and turbulence in air passages. This decreases the actual quantity of
air taken in during the induction. Thus, the volumetric efficiency is decreased.
5.8 Need of the Multi Stage Compression

 P 1/ n 
(Refer Fig. 5.7) As the Volumetric efficiency is given by, V = 1 − C  2  − 1 . This
 P1  
equation shows that the volumetric efficiency of a reciprocating compressor with fixed
clearance volume is decreases with the increase in pressure ratio as shown in Fig. 5.7.
▪ For compression ratio from P1 to P2, the cycle is 1 -2-3-4- 1 and the effective swept
volume per cycle is (V1 – V4). For compression ratio P1 to P2’ the cycle is 1 - 2' - 3' - 4'- 1
and the effective swept volume is (V1 – V4') which is less than (V1 – V4).

Fig. 5.7 The effect on the volumetric efficiency of increasing the delivery pressure
▪ In the limit, if the compression ratio is increased from P1 to P2", the compression
Iine intersects the line of clearance volume at point 2" and the re-expansion-follows
the same path as compression, the effective swept volume is zero and there is no
delivery of air. The attempt made to deliver the air at a higher pressure of P2" would
result in compression and re-expansion of the same air again and again without any
delivery of high pressure air. Therefore, the maximum pressure ratio attainable with
a single stage compressor is limited by the clearance volume.
▪ An intercooler is used between two stages, so that the compressed air from the first
stage cools down before it enters second stage with low temperature. Air cooling
between stages provides the means of an appreciable reduction in the compressor
work and maintaining air temperature within safe operating limits. By cooling the air
between stages the compression is made to approach isothermal.
5.9 Advantages of Multi Stage Compressors

(1) Less Power: less power is required to run a multistage compressor as compared to a
single stage compression for the same delivery pressure and the same quantity of free air
due to intercooler. For a high pressure range the saving may be about 20%.
(2) Better Mechanical Balance: when the air is being compressed in one cylinder, there is
suction in the other cylinder. Thus due to phasing of operation more uniform torque and
hence better mechanical balance for the machine is attained. This require smaller flywheel
due to uniform torque.
(3) Increased Volumetric Efficiency: volumetric efficiency increases due to the reduction of
pressure and hence the temperatures range in each cylinder.
(4) Better Lubrication: due to lower temperature encountered better lubrication is possible.

(5) Less Leakage: due to better lubrication and reduced pressure difference across the two
sides of the piston and valve, there is less leakage loss past the piston.
(6) Size of cylinders: Size and strength of cylinders can be adjusted to suit volume and
pressure of air.
(7) Lighter Cylinders-Lighter Construction: due to lower pressure range in low pressure
stages Iight6r cylinders are used where as in high pressure stages robust but less
voluminous are used. This makes the construction lighter.
(8) Disadvantages: a multistage compressor needs more than one cylinder, intercoolers with
water pipes and a continuous supply of water. The multistage unit becomes more
complicated and expansive in initial cost.
5.10 Work Done in Two Stage Reciprocating Air Compressor with Intercooler
Fig. 5.8 shows the schematic diagram of a two stage reciprocating compressor and P-V and
T-S diagrams of the compression cycle.
First Stage Compression (L.P Stage)
▪ In the two stage compressor with intercooler, the air is first drawn into the low
pressure (L.P) cylinder at point 1 with pressure P1, and volume V1. The air is
compressed polytropically to some intermediate pressure P2, as shown by process 1-
2'.
▪ The compressed air at pressure P2 and temperature T2 is then cooled at constant
pressure P2, by passing the air through intercooler. This is represented by a constant
pressure process 2’-2.
Second Stage Compression (H.P Stage)
▪ The air then enters the high pressure (H.P) cylinder, where it is further compressed
polytropically along 2 - 3. Pressure of air increases from P2 to P3, and finally
discharged to the receiver at pressure P3. Thus in each stage pressure of the air is
successively increased and the initial temperature is maintained at the end. During
the whole process the compression is approximated isothermal process.

Fig. 5.8 Schematic of two stage compressor with intercooler and P-V & T-S diagram
▪ If the compression had taken place in a single stage, the compression curve would
have followed the polytropic curve 1 - 3". The saving in work input by the use of
multi stage compression with intercooling is shown by shaded area 2 - 2' -3" -3 - 2.
Both the LP and H.P cylinders are mounted on the same crank shaft and are driven by an
electric motor or prime mover.
Assumptions:
1. The effect of clearance is neglected.
2. The index 'n' in the polytropic compression law PVn = C is same for each cylinder.
3. The intercooling in each stage is at constant pressure and there is no pressure drop
between two stages i.e. delivery pressure of one stage equals the suction pressure of
the next stage.
4. The mass of air handled by the L.P and H.P cylinders is the same.
5. Suction and delivery pressures remain constant during each stage.
Consider a two stage reciprocating air compressor with intercooler. Then,
Let P1 = pressure of air entering the L.P cylinder
V1 = volume of L.P cylinder = stroke volume of L.P cylinder
P2 = Pressure of air leaving the L.P cylinder or entering the H.P cylinder
V2 = Volume of the H.P cylinder = stroke volume of the H.P cylinder.
P3 = Pressure of air leaving the H.P cylinder

Case-I When the Intercooling is Imperfect or Incomplete:
Fig. 5.9 Incomplete intercooling of air

If the temperature of air leaving the intercooler, T2 is greater than the original atmospheric
air temperature T1 the intercooling is called imperfect or incomplete cooling. In this case
point 2 lies on the right side of isothermal curve as shown in Fig. 5.9.
Work done required per cycle in the L.P cylinder,
 n −1

  
− 1
n
n P
WLP = 1 1 
 P1 
2
PV
n −1 
 
Work done required per cycle in the H.P cylinder,
 n −1

n   P  n

WHP = 2 2 
PV 3
 − 1
n −1   P2 
 
Total work done required per cycle in both the cylinders is,
W = WLP + WHP
 n −1
  n −1

n   P2  n
 n   P3  n 
W= 1 1 
PV  − 1 + 2 2 
PV  − 1 (5.12)
n −1  n −1 
 1   2 
P P
 
Case-II When the Intercooling is Perfect or Complete:

If the temperature of air leaving the intercooler T2, is equal to the original atmospheric air
temperature T1, the intercooling is called complete or perfect In this case point 2 lies on
isothermal curves shown in Fig. 5.10. The work saved due to intercooling is shown by the
shaded area 2'-3'-3-2-2' in both the cases. The amount of work saved with incomplete
intercooling is less than that in case of complete intercooling.

Fig. 5.10 Complete intercooling of air

 n −1
  n −1

      
− 1
n P n
n P n
W= 1 1  −1 +
 P1   n − 1 2 2  P2 
2 3
PV PV
n −1 
   
1 1 = PV
But for perfect intercooling, PV 2 2
1 1 = PV
Substituting PV 2 2 in above equation,
 n −1 n −1

n   P  n  P  n

W= 1 1 
PV 2
 +   − 2
3
(5.13)
n −1   P1   P2 
 
5.11 Condition for Minimum Work or Maximum Efficiency for a Two Stage
Reciprocating Compressor
The total work required per cycle by two stage reciprocating compressor with complete
Intercooling is given by,
 n −1 n −1

    
+   − 2
n P n P n
W= 1 1 
 P1 
2 3
PV
n −1  P4  
 
n
Let, =y
n −1
 P  y  P  y 
W = Constant  2  +  3  − 2 
 P1   P4  
 1 
= Constant  P2 y  y + P3 y  P2 − y − 2 
 P1 
For minimum work,

dW  yP y −1 
= Constant  2 y − yP3 y  P2 − y −1 − 0  = 0
dP2  P1 
yP2 y −1 yP3 y
 = y +1
P1 y P2
P2 y −1  P2 y +1 = P1 y P3 y
P2 2 y = ( P1 P3 )
y
P2 P3
P2 = PP
1 3 or = (5.14)
P1 P2
Above equation shows that for minimum work required, the intercooler pressure is
geometric mean of the initial and final pressures or pressure ratio in each stage is the same.
P P
Substitute the 2 for 3 in equation of work done,
P1 P2
Total minimum work required per cycle,
 n −1 n −1

n   P2  n  
P2 n 
W= 1 1 
PV  +   − 2 (5.15)
n −1 
 1   P1 
P

 n −1

2n   P2  n 
W= 1 1 
PV  − 1
n −1 
 1 
P

2 1
P P P  P P P P P  2
Since 2 = 3 , then  2  = 2  3 = 3 , thus 2 =  3 
P1 P2  P1  P1 P2 P1 P1  P1 
1
P2  P3  2
Substitute the =   in above equation of work done,
P1  P1 
 n −1

  
− 1
2n P 2n
Wmin = 1 1 
 P1 
3
PV
n −1 
 
For x number of stages, the pressure ratio is,
1 1
P2 P3 P4 Px Px +1  Px +1  x  Final pressure  No. of stages
= = = = =  = 
P1 P2 P3 Px −1 Px  P1   Initial pressure 
Minimum work for X number of stages with perfect intercooling at all stages is given by,
 n −1

  
− 1
xn P xn
W= 1 1 
x +1
 P1 
PV (5.16)
n −1 
 
Where Px +1 = final delivery pressure and P1 = initial or suction pressure
The following conclusions are drawn for the minimum work required to compress and
deliver air in a multistage compressor:
(1) The air is cooled to the initial temperature after each stage of compression.
(2) The pressure ratio in each stage is the same.

(3) Work done in all stages is equal.
(4) The temperature ratios and maximum temperature are same in each stage.
5.12 Work Done in a Two Stage Reciprocating Compressor Considering

Clearance
Consider a two stage reciprocating compressor with clearance. The P-V diagram of a two
stage compressor with clearance is shown in Fig. 5.11. It is assumed that the intercooling is
perfect. Areas 1-2-3-4-1 and 5-6-7-8-5 represent respectively the P-V diagram of L.P stage
and H.P stage.
Let, V3 = clearance volume of L.P stage
V7 = clearance volume of H.P stage
Fig. 5.11 P-V diagram for two stage compressor with clearance
W = WLP + WHP
 n −1
  n −1

     
P2 (V5 − V8 )   − 1

n P n
n P n
W= P1 (V1 − V4 )   − 1 +
2 3
n −1   P1   n −1  P2  
   
For perfect intercooling, T1 = T5 therefore, P1 (V1 − V4 ) = P2 (V5 − V8 )
 n −1 n −1

   
P1 (V1 − V4 )   +   − 2 

n P n P n
W= 2 3
(5.17)
n −1  P1   P2  
 
5.13 Optimum Intermediate Pressure Required in a Two Stage Compression

with Incomplete Intercooling

Irrespective of the temperature T2’ attained in the first stage, T2 is the temperature to which
the air at the intermediate pressure P2, can be cooled is fixed. Here T2 > T1 as shown in Fig.
5.12.
Work done required per cycle in the L.P cylinder,
 n −1

  
− 1
n
n P
= 1 1 
 P1 
2
WLP PV
n −1 
 
Fig. 5.12 Two stage compressor with incomplete intercooling

Work done required per cycle in the H.P cylinder,
 n −1

n   
P3 n 
WLP = 2 2 
PV  − 1
n −1 
 2 
P

W = WLP + WHP
 n −1
  n −1

n   P  n
 n   P  n

W= 1 1 
PV 2
 − 1 + 2 2 
PV 3
 − 1
n −1   P1  n −1   P2 
   
 n −1
  n −1

     
mRT2   − 1

n P n
n P n
W= mRT1   − 1 +
2 3
n −1   P1   n −1  P2  
   
n n
Let, mR = A and = B and substitute in above equation,
n −1 n −1
 P  B   P  B 
W = AT1   − 1 + AT2  3  − 1
2
 P1    P2  
W = AT1  P2 B P1− B − 1 + AT2  P3 B P2 − B − 1
For minimum work input,

dW
= 0 = AT1 BP2 B −1 − AT2 P3 B BP2 − B −1
dP2
AT1 BP2 B −1 AT2 BP3 B
=
P1B P2 B +1
T2 B B
P2 B −1  P2 B +1 = P1 P3
T1
T2
( P1P3 )
B
P2 2 B =
T1
1 n
T  B
T  n −1
P2 =  2 
2
 ( P1 P3 ) =  2   ( P1 P3 )
 T1   T1 
1
n
 n
 2
 T2  n −1
P2  P3  T2  n −1 
P2 = PP
1 3   or =   (5.18)
 T1  P1  P1  T1  
 
The minimum work required for a two stage compressor with incomplete intercooling is
obtained by substituting the value of P2 in equation of work done then,
 
 
 n −1
  
 n
 2n
  − 
n  T2  n −1  1 n 
n 1
1
Wmin = 
mRT1  P1 P3      
−1 + mRT2 P3 
n
− 1
n −1   1 
T n − 1  n − 1  n −1

  P1
   n
 2n 
 n    T2  
n −1
  P1 P3     
   1 
T 
   
 n −1
  n −1

     
mR T1T2   − T2 

n P3 2 n
n P3 2 n
= mR T1T2   − T1 +
n −1   P1   n −1   P1  
   
 n −1

 
mR 2 T1T2   − (T1 + T2 ) 

n P 2n
Wmin = 3
(5.19)
n −1   P1  
 
5.13 Optimum Intermediate Pressure required in a Two Stage Compression

with Pressure Drop between Stages but Incomplete Intercooling
Let P2' = CP2 = intake pressure to the H.P cylinder
P2 = discharge pressure from L.P cylinder
Total work done,
W = WLP + WHP
 n −1
  n −1

     
P2 V2   − 1
' ' 
n P n
n P n
W= 1 1 
PV 2
 − 1 +
3
n −1   P1  n −1  P2  
   

Fig. 5.13 Two stage compressor with perfect intercooling pressure drop in the intercooler
For perfect intercooling P2'V2' = PV
1 1 and P2 = CP2
'
W = WLP + WHP
 n −1
  n −1

      
− 1
n P n
n P n
W= 1 1  −1 + ' '
 P1   n − 1 2 2  P2 
2 3
PV PV
n −1 
   
 n −1 n −1

n   P  n  P  n

W= 1 1  +  − 2
 P1 
2 3
PV
n −1  2
CP
 
n n
Let, mR = A and = B and substitute in above equation, then
n −1 n −1
 P  A  P  B 
W = A  2  +  3  − 2 
 P1   CP2  
= A  P1− B P2 B + P3 B C − B P2 − B − 2 
For minimum work required,
dW
= 0 = A  P1− B BP2 B −1 − P3 B C − B P2 − B −1 
dP2
P2 B −1 P3 B P2 − B −1 P3 B
= = B B +1
P1B CB C P2
B
 PP 
P2 =  1 3 
2B
 C 
PP
P2 2 = 1 3
C
P2 P P
= 3 = 3' (5.20)
P1 CP2 P2
If C = 1, the pressure ratio reduces to the same pressure ratio in both the stages. The work
done will be larger compared to the condition of zero pressure drop. Though work done in

each case will be equal, it will be larger than when there is no pressure drop. This is a
practical situation as some pressure drop will occur in flow through the heat exchanger.
5.14 Actual Indicator Diagram

In Fig. 5.14 shows an actual indicator diagram for a single stage reciprocating compressor. 1-
2-3-4-1 is the theoretical P-V diagram.
▪ At point 4, when the clearance air has reached to atmospheric pressure, the inlet
valve in practice will not open. There are two main reasons for this (i) There must be
finite pressure difference between the atmosphere and the cylinder interior so that
the spring may be pushed down to open the inlet valve, (ii) The valves are spring
loaded and they do not open instantaneously because of the inertia effect. Thus, the
pressure drops away until the valve is forced off its seat and some valve bounce will
then set in, as shown by wavy line and eventually intake will become near enough
steady at some pressure below atmospheric pressure. The negative pressure
difference, called the intake depression settles naturally. The atmospheric air forces
its way into the cylinder against a reduced pressure.
Fig. 5.14 Actual compressor P-V diagram

▪ Similar situation occurs at 2, at the beginning of compressed delivery. The delivery
valve opens only when the pressure in the cylinder becomes higher than that of
receiver pressure. Thus there is a pressure rise, followed by valve bounce and the
pressure then settles at some pressure above receiver pressure. Other small effects
at inlet and delivery would be air inertia and turbulence.
▪ The practical effects discussed above are responsible for the addition of the two
small shaded negative work areas shown in Fig. 5.14. These are in addition to the
theoretical area 1-2-3-4-1.
Actual P-V Diagram for Two Stage Compressor
The actual indicator diagram for a two stage compressor is shown in Fig. 5.15.

▪ The wavy curves during suction and delivery strokes are due to valve flutter,
resulting in fluctuation in intake and delivery pressure. The H.P and L.P diagrams
overlap due to pressure drop in intercooler.
▪ The inertia and friction effects result in valve flutter increase the area of the diagram
slightly. The overall effect of this is to increase the total work of compression.
Fig. 5.15 Actual indicator diagram for a two stage compressor

5.14 Methods of Controlling the Output of Reciprocating Compressor
(Capacity Control of Compressors)
− Generally the compressors are not required to run continuously at their maximum rated
capacity but also required to supply at a fraction of their rated or maximum capacity
according to requirement. As the requirements may continuously vary it is necessary to
incorporate some methods to control the amount of air delivered.
− Capacity control comprises the adjustment for the quantity of air to be supplied by
reciprocating compressor to meet the fluctuating demand, so that the discharge
pressure varies within acceptable limits.
There are two main methods of control: (1) Variable speed and (2) Constant speed
(1) Variable speed
Capacity control by speed variation is the simplest method of controlling the amount of air
delivered. It is best suited for compressors that are driven by steam engine or internal
combustion engines or electric, commutator motor. But these are rarely used due to their
high price and sensitivity.
(2) Capacity control at constant speed
Where the drive is by means of electric synchronous motor, capacity control by speed
variation is not possible. The different methods used to control the capacity at constant
speed are:
1. Throttling the suction line
2. Increasing the clearance volume by clearance pocket

3. Blowing off to waste

4. By passing air from delivery to suction inlet
5. Temporary unloading of suction valve
6. Automatic stop-start control
1. Throttling the suction line
(Refer Fig. 5.16) When the demand is less, the pressure in the receiver increases and the
high pressure air from the receiver is led to piston cylinder at point A. The movement of the
piston is resisted by spring.
Fig. 5.16 Throttling the suction line

With excessive pressure the piston depresses the spring, thus closing partly the suction
valve B, till the supply and demands are balanced. The reversed action takes place when the
pressure in the receiver falls due to increased demand.
2. Clearance control
(Refer Fig. 5.17) shows typical arrangement for increasing or reducing clearance by
providing clearance pockets. The volumetric efficiency is reduced in proper proportion to
control the output. When the receiver pressure exceeds the desired amount, a dead weight
is raised by the diaphragm releases air to pressure chamber A. Thus the spring 1 lifts the
valve 2 and clearance space is put in communication with the cylinder.
If the pressure still continues to rise, a second valve B puts another pocket of clearance
space in communication till the supply and demand are balanced. The use of clearance
pockets results in a reduction of power in proportion to load reduction because the work is
recovered by re-expansion.

Fig. 5.17 Clearance control

3. Cylinder ports
The stroke of the compressor decreases by the use of ports in the cylinder. The ports are
connected back to the compressor intake and the air is allowed to escape from the cylinder
at the beginning of the compression stroke. There is loss of power by the use of ports. The
ports may be controlled manually or automatically.
4. By passing air from delivery to suction line
Fig. 5.18 By passing control

The output is controlled by passing the air from delivery line to suction line as shown in Fig.
5.18. The stop valve on the bypass line is actuated by an automatic air governor which is
connected to the receiver. In some cases the delivery line is connected by a throttle valve to
the suction line.
5. Blowing off to waste
Fig. 5.19 shows the device in which there is a bypass valve from the high pressure cylinder
delivering air direct to atmosphere when the receiver pressure exceeds a predetermined
value due to decrease in demand. The high pressure air forces the relay piston upwards
against the resistance of a dead weight until the port through which B is connected is
uncovered. Thus the high pressure air forces the piston downward and the air is released to
atmosphere. The check valve prevents the receiver air escaping to atmosphere. When the
pressure in the receiver falls, the relay piston moves down by the dead weight and closes
the communication between relay cylinder and cylinder B.

Fig. 5.19 Blowing off to waste

5.15 Solved Numerical

Example 5.1 A single stage, single acting reciprocating air compressor takes in air 5 m 3/min
at 1 bar and 27°C and compresses to a delivery pressure of 7 bar. Determine each of the
below neglecting clearance with the help of P-V and T-S diagram, when compression takes
place (a) polytropically (PV1.3 = constant), (b) adiabatically (PV1.4 = constant), and (c)
isothermally (PV = constant). Take ambient conditions 1.013 bar and 15°C.
(a) Temperature and volume of air at the end of compression
(b) Work done by air during suction, work done on air during compression, work
done on air during delivery and net work done on air (I.P)
(c) Heat transfer during compression
(d) Brake power of compressor if the mechanical efficiency is 80%.
Solution:
Given data: Find:
V1 = 5 m3 / min T2
P1 = 1 bar = 100 Kpa Ws ,Wc ,Wd ,Wnet
T1 = 27 + 273 = 300 K Q
P2 = 7 bar B.P
Case − (a) Polytropic compression,n = 1.3
Temperature of air at the end of compression
n −1 1.3−1
P  n
7 1.3
T2 = T1  2  = 300   = 470 K
 P1  1
100  5
Work done by air during suction = P1V1 = = 8.333 kW
60
P1 V1
Mass of air, m = = 5.807 kg/min
RT1
P2 V2 − P1 V1 mR ( T2 − T1 )
Work done by air during compression = =
n−1 n−1
5.807  0.287  ( 470 − 300 )
=
1.3 − 1
= 15.74 kW
Work done by air during delivery = P2V2 = mRT2
5.807  0.287  470
=
60
= 13.055 kW

Net work done on air

 n−1

 
P1 V1   − 1

n P n
W= 2
n−1  P1  
 
 0.3

1.3 5  7  1.3
=  100    − 1
0.3 60  1  
 
= 20.468 kW
Heat transfer during compression
 −n
Q=  Work done during compression
 −1
1.4 − 1.3
=  15.74
1.4 − 1
= 3.935 kW
Brake power
I.P 20.468
B.P = = = 20.585 kW
m 0.8
Case − (b) Adiabatic compression, = 1.4
−1 1.4 −1
P  
7 1.4
T2 = T1  2  = 300   = 523.1 K
 P1  1
100  5
Work done by air during suction = P1V1 = = 8.333 kW
60
P V − P V mR ( T2 − T1 )
Work done by air during compression = 2 2 1 1 =
 −1  −1
5.807  0.287  ( 523.1 − 300 )
=
1.4 − 1
= 15.492 kW
5.807  0.287  523.1
Work done by air during delivery = P2 V2 = mRT2 = = 14.53 kW
60
 
−1

  P  
W= P1 V1  2  − 1
 −1  P1  
 
 
1.4−1
1.4
1.3 5  7  
=  100    − 1
0.3 60  1 
 
= 21.69 kW

Heat transfer during compression

Since the process is adibatic,the heat transfer is zero
Brake power
I.P 21.69
B.P = = = 27.11 kW
m 0.8
Case − (c) Isothermal compression,n = 1
T2 = T1 = 300 K
100  5
Work done by air during suction = P1 V1 = = 8.333 kW
60
P
Work done by air during compression = P1V1 ln 2
P1
5 7
= 1  105   ln
60 1
= 16.215 kW
Work done by air during delivery = P2 V2 = P1V1 = 8.333 kW
P2
Wnet = P1V1 ln
P1
5 7
= 1  105   ln
60 1
= 16.215 kW
During Isothermal compression, temperature remains constant. Therefore heat transfer
is equal to work done during the compression
Q 1-2 = 16.215 kW
Brake power
I.P 16.215
B.P = = = 20.268 kW
m 0.8
Example 5.2 The diameter of reciprocating air compressor cylinder is 140 mm and stroke
length of the piston is 180 mm and the clearance volume is 77 cm3. The pressure and
temperature at the end of suction and at beginning of compression is 0.97 bar and 13°C. The
delivery pressure is constant at 4 bar. Taking the law of compression and expansion as PV 1.3
= constant. Calculate,
1. For what length of stroke air is delivered
2. The volume of air delivered per stroke in liters
3. The temperature of the compressed air
Solution:

Data given: Find:

Vc = V3 = 77  10 −6 m3 Stroke lenght when air is delivered
d = 140 mm = 0.140 m V1 − V4
L = 180 mm = 0.18 m T2
P1 = 0.97 bar = P4
T1 = 13 + 273 = 286 K
P2 = P3 = 4 bar
n = 1.3
 
Swept volume Vs = d2L = 0.142  0.14 = 2.77  10 −3 m3
4 4
Cylinder volume V1 = Vc + Vs = 2.847  10 −3 m3
From polytropic compression 1 - 2,
P1 V1n = P2 V2n
1
 P n
V2 = V1  1  = 9.574  10 −4 m3
 P2 
Volume of air delivered at delivery pressure
V2 − V3 = 8.804  10 −4 m3 = 0.8804 m3
(1) For what length of stroke air is delivered

V2 − V3 9.574  10 −4  77  10−6
= = 0.0572 m
Area of piston  2
0.14
4
(2) The volume of air delivered per stroke in liters
1 1
 P n  4  1.3
V4 = V3  3  = 77  10 −6    = 2.2897  10 m
−4 3
 P4   0.97 
V1 − V4 = 2.847  10 −3 − 2.2897  10−4 = 2.618  10 −3 m3
(3) The temperature of the compressed air
n−1 0.3
P  n
 4  1.3
T2 = T1  2  = 286    = 396.6 K
 P1   0.97 
Example 5.3 In a two stage single acting reciprocating compressor, intake pressure and
temperature are 1 bar and 20°C respectively. Air is taken into the compressor at the rate of
6 m3/min and compressed to a final pressure of 9 bar. The law of compression in both the
cylinders is PV1.3 = C. If the intermediate pressure is ideal and intercooling is perfect and
the compressor runs at 600 rpm. Neglecting the clearance and determine,
(1) Intermediate pressure
(2) Volume of L.P. and H.P cylinder
(3) Power required to drive the compressor if mechanical efficiency is 80%.
(4) The rate of heat rejected in the intercooler

(5) Rise in temperature of cooling water if the mass flow rate of water through the
intercooler is 8 kg/min. Take Cpa = 1 kJ/kg k for air and Cpw = 4.2 kJ/kg k for
water.
Solution:
Data given: Find:
V1 = 6 m3 / min P2
P1 = 1 bar = 100 Kpa VLP ,VHP
T1 = 20 + 273 = 293 K B.P
P3 = 9 bar Q IC
N = 600 rpm dTw
Cpa = 1 kJ / kg K Cpw = 4.187 kJ / kg K
m = 0.8
mw = 8 kg / min
(1) For perfect intercooling, the intermediate pressure,
P2 = P1P3 = 1  9 = 3 bar
(2) Volume of L.P and H.P cylinder
Volume of L.P cylinder / cycle is,
V1 6
V LP = = = 0.01 m3 / cycle
N 600
For perfect intercooling,
P1 VLP = P2 VHP
P1 VLP 1  0.01
VHP = = = 0.0033m3 / cycle
P2 3
(3) For perfect intercooling work required to compressed air in two stage is,
 n−1

 
P1 V1   − 1

2n P 2n
W= 3
n−1  P1  
 
 1.3−1

2  1.3 6  9  21.3 
=  100    − 1
1.3 − 1 
60  1  
 
= 25 kW
Brake power required to drieve the compressor,
I.P 25
B.P = = = 31.25 kW
m 0.8
(4) The rate of heat rejected in the intercooler
Mass flow rate of air per minute,
P1 V1 100  6
m= = = 7.135 kg / min
RT1 0.287  293
Now, temperature of air entering the intercooler

n−1 1.3−1
P  n  3  0.3
T2' = T1  2  = 293    = 377.55 K
 P1  1
Heat rejected by the air in the intercooler,
mCpa ( T2' − T2 ) = mCpa ( T2' − T1 )
7.135  1  ( 377.55 − 293 ) = 603.26 kJ / min
(4) Rise in temperature of cooling water in intercooler
Heat gained by intercooler water = Heat lost by air = Heat rejected by the air
mw Cpw dTw = maCpa ( T2' − T1 )
4  4.2  dTw = 603.26
dTw = 17.954 0 C
Example 5.4 A single acting, two stage reciprocating air compressor has to deals with 3
m3/min of air under atmospheric conditions 1 bar, 25°C at 220 rpm and delivers it at 80 bar,
assuming perfect intercooling between stages. Find out,
(1) Minimum power to drive the compressor
(2) Diameter of L.P and H.P cylinder and common stroke length
(3) % saving in minimum power if compression is assumed as three stage
Take piston speed is 154 m/min, mechanical efficiency of compressor is 80%, volumetric
efficiency is 85% same for each stage, law of compression in both the cylinders is PV 1.3 = C.
Solution:
Data given: Find:
V1 − V4 = V a = 3 m3 / min B.Pmin
N = 220 rpm dLP ,dHP
Px +1 = 80 bar % saving in power
P1 = 1 bar
T1 = 250 C + 273 = 298 K
Vp = 2LN = 150 m / min
m = 0.8,n = 1.3
For two stage compression, with perfect intercooling the minimum I.P
 n−1

 
P1 ( V1 − V4 )   − 1 

2n P 2n
N
I.P = 3
n−1  P1   60
 
 0.3

2  1.3 3  80  21.3  220
=  100    − 1 
0.3 220  1   60
 
= 28.513 kw
I.P 28.513
B.P = = = 35.64 kW
m 0.8

154 154
Piston speed = 2LN = 154 L = = = 0.35 m
2N 2  220
Volumetric effciency of LP cylinder,
V1 − V4
vL = = 0.85
VSLP
V1 − V4 3 1
Swept volume of LP cylinder = VSLP = =  = 0.016 m3 / stroke
0.85 220 0.85
But swept volume,

VSLP = dLP2  L = 0.016
4
dLP = 0.24 m
3 3
Actual volume of air inducted by L.P cylinder / cycle,V1 − V4 = m
220
For perfect intercooling,
P1 ( V1 − V4 ) P2 ( V5 − V8 )
= and since T5 = T1
T1 T5
P1 ( V1 − V4 ) 3 1
V5 − V8 = = 1  = 1.525  10 −3 m3
P2 220 8.94
Swept volume of HP cylinder =

( V5 − V8 )
v
−3
1.525  10
VSHP = = 1.794  10-3 m3
0.85

But VSHP = dHP2  L = 0.016 dHP = 0.08 m
4
For three stage compression, minimum power is given by,
 n−1

  
− 1
xn P xn
I.P = P1 Va  x +1
n−1  P1  
 
 0.3

3  1.3 3  80  31.3  220
=  100    −1 
0.3 220  1   60
 
= 26.5 kW
28.513 − 26.5
% saving in power =  100 = 8.638%
28.513

Reciprocating Compressor

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Reciprocating Compressor

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5 Course Contents

RECIPROCATING 5.1 Introduction

Department of Mechanical Engineering Page 5.1

− Compressor may be of the reciprocating piston-cylinder type or of the rotary type.

5.2 Classification of Compressors

(1) According to design and principle of operation:

− They further divided in two types as below:

− They further divided in two types as below:

Department of Mechanical Engineering Page 5.2

(2) According to the delivery pressure limit:

(3) According to pressure limit:

(4) According to the number of stages:

(5) According to the capacity:

(6) According to the action of piston:

(7) According to the method of cooling:

(8) According to the method of drive:

(9) According to the arrangement of cylinders

5.3 Applications of Compressed air, Gases and Vapours

Department of Mechanical Engineering Page 5.3

(4) In Civil engineering

(5) Pneumatic appliances

(7) Acid and Chemical Industries

(8) Refrigeration and Air conditioning

(9) Conveying Purpose

(10) Operation of Gas turbines

(12) Ammunition Depots

Department of Mechanical Engineering Page 5.4

5.4 Working Principle of Single Stage Single Acting Reciprocating

Department of Mechanical Engineering Page 5.5

b) Reversed Stroke (or Compression & delivery stroke)

5.5 Work Done for Operating Single Stage Reciprocating

Compression Process 1-2:

− The compression process 1-2 may take place isentropically, polytropically or

Department of Mechanical Engineering Page 5.6

Delivery Process 2-3:

Case: (A) Work Done During Polytropic Compression (PVn = Constant)

Case: (B) Work Done During Isentropic Compression (PVϒ = Constant)

Department of Mechanical Engineering Page 5.8

Case: (C) Work Done During Isothermal Compression (PV = Constant)

Condition for Minimum Work

Department of Mechanical Engineering Page 5.9

Fig. 5.3 Possible compression processes on P-V diagram

Fig. 5.4 Approximation to isothermal compression

Department of Mechanical Engineering Page 5.10

(2) Suitable cylinder dimension:

(3) Water jacketing:

(4) External fins:

(5) Multistage compression:

5.6 Necessity of Clearance Volume and Work Done Equation for

Net work required per cycle,

Department of Mechanical Engineering Page 5.12

5.7 Volumetric Efficiency

5.7.2 Volumetric Efficiency Referred to Ambient Conditions

Department of Mechanical Engineering Page 5.13

Pa = Pressure of ambient air

5.7.3 Factor Affecting the Volumetric Efficiency

(1) Increase in delivery pressure

(2) Very high speed

Department of Mechanical Engineering Page 5.14

Fig. 5.6 Volumetric efficiency variation

(4) Too large clearance volume

(5) Over heating of the air