Two Stage Compressor

P.A.
HILTON LTD
EXPERIMENTAL
OPERATING
AND
MAINTENANCE MANUAL
TWO STAGE COMPRESSOR TEST UNIT
F865
F865M/E/2/004
JUL11
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(i)
POLICY STATEMENT
After Sales Service
We, P.A. Hilton Ltd., attach considerable importance in being able to retain the confidence and goodwill
of our clients in offering an effective after sales service. Every effort is made to answer clients
correspondence promptly and to provide a rapid follow up of spares and replacement parts by maintaining
comprehensive stocks of components usually available ex-stock.
Should our clients encounter any difficulty in operating or maintaining a Hilton product we would ask that
as a first step they contact the Hilton representative in their country or, in the absence of a local
representative, write direct to P.A. Hilton Ltd.
In the extreme case a problem may arise in the operation of equipment which could seriously disrupt a
teaching or research schedule. In such circumstances rapid advice from the manufacturers is desirable and
we wish our clients to know that Hiltons' will accept from them a transfer charge telephone call from
anywhere in the world.
We ask our clients to treat this service as an emergency service only and to use it sparingly and wisely.
Please do be aware of the time differences that may exist and, before making a telephone call, make notes
of the problem you wish to describe. English is a preferred language. Our telephone number is "Romsey
(01794) 388382" and the telephone is normally manned between 0800 and 1700 hrs GMT every day.
Advance notice of an impending telephone call by fax would be appreciated.
Each product manufactured by P.A. Hilton Ltd., is tested under operating conditions in our permanent
installations before despatch. Visitors to Horsebridge Mill are encouraged to operate and evaluate our
equipment with initial guidance from a Hilton engineer.
2
(ii)
EDUCATION AND TRAINING EQUIPMENT
Declaration of Conformity:
Directives (where applicable) 89/392/CEE as amended by 91/368/EEC
89/336/CEE
72/23/CEE
We declare that the following unit complies with the above EEC directives:
F865 Two Stage Compressor Test Unit
The use of the apparatus outside the classroom, laboratory, study area or similar such place invalidates
conformity with the protection requirements of the Electromagnetic Compatibility Directive (89/336/EEC)
and could lead to local prosecution.
For and on behalf of

P.A. HILTON LIMITED
Technical Director
P.A. HILTON LIMITED

Horsebridge Mill, King's Somborne,
Stockbridge, Hampshire, SO20 6PX,
England.
Tel No. National Romsey (01794) 388382

International +44 1794 388382
Fax No. +44 1794 388129
E-mail: sales@p-a-hilton.co.uk
3
(iii)
INDEX
SCHEMATIC DIAGRAMS 1
INTRODUCTION 6
SCHEMATIC DIAGRAM NOTATION 6
INSTALLATION 6
Water and Drain Connection 12
Test Running After Installation. 12
DESCRIPTION 14
The compressor module. 14
The Control Console 16
PRECAUTIONS AND WARNINGS 17
OPERATING PROCEDURES 18
Starting and Maintaining Stable Conditions as a Two Stage Compressor 18
Adjustment or Removal of Intercooling Effect 18
MAXIMUM OPERATING PRESSURE 19
Starting and Maintaining Stable Conditions as a Single Stage Compressor 19
Stopping and Shutting Down 20
MAINTENANCE 21
Compressor Module 21
Control Console 21
USEFUL DATA 22
Compressor Dimensions 22
Air Flow Measurement 22
1. INVESTIGATION OF VARIATION IN AIR FLOW RATE, WITH COMPRESSOR
PRESSURE RATIO:- With and Without Intercooling 24
2. INVESTIGATION OF VARIATION IN VOLUMETRIC EFFICIENCY WITH
COMPRESSOR PRESSURE RATIO:- With and Without Intercooling 31
3. INVESTIGATION OF VARIATION OF ISOTHERMAL EFFICIENCY WITH
COMPRESSOR PRESSURE RATIO:- With and Without Intercooling 35
4. INVESTIGATION OF THE COMPRESSOR PERFORMANCE RELATIVE TO
ELECTRICAL POWER, SHAFT POWER, AND HEAT LOSS:- With and Without
Intercooling 43
BLANK OBSERVATION TABLE 52

Control Console Front Panel
1. Main Switch 8. Temperature Selector Switch

2. Tachometer lead 9. Thermocouple Sockets
3. Motor Tachometer
4. Orifice Plate Manometer
5. Compressor Ammeter
6. Compressor Voltmeter
7. Temperature Indicator
1
Control Console Rear Panel
10. Main Power Inlet

11. Port for Optional Data Logger Upgrade
12. 2.5A MAX power outlet for optional Data Logger
13. Power outlet for Compressor
2
3
Compressor Module
14. Compressor 23. Intercooler

15. Motor 24. Valve “A”
16. Cooling Water Flowmeter 25. Valve “B”
17. 1st Stage Pressure 26. Water Purge Valve
18. 1St Stage Receiver 27. 2nd Stage Receiver
19. 1St Stage Safety Valve 28. 1st Stage Intake Pipe.
(4Bar) 29. 1st Stage Discharge
20. 2nd Stage Pressure 30. 2nd Stage Intake
21. 2nd Stage Safety Valve 31. 2nd Stage Discharge
(11Bar)
22. Intake Orifice / Damping
Vessel
4
Compressor Module (Detail)
20. 2nd Stage Pressure Gauge

21. 2nd Stage Safety Valve (11Bar)
22. Intake Orifice / Damping vessel
32. Receiver Discharge / Vent Valve.
33. Compressor ON SWITCH (Green)
34. Compressor OFF / STOP SWITCH (RED)
35. Pressure Switch
5
UNITS
Symbol Designation
Unit
f Dynamometer balance load kg
g Acceleration due to gravity m/s2
h Orifice plate pressure differential mmWg
I Electric motor current Amps
m& Air Air mass flow rate kg/s
N Rotational speed 1/second
p Gauge pressure kN/m2
P Absolute pressure kN/m2
qv Air volume flow rate Litres/second
Q& Heat transfer Watts
r Motor dynamometer torque arm radius m
R Gas constant for air kJ/kgK
t Temperature °C
T Absolute temperature K
v Volume m3
Vs Swept volume Litres/second
V Motor supply voltage Volts
W Work or high grade energy(electrical) Watts
γ Ratio of specific heats -
η Efficiency %
ω Rotational speed radians/second
Suffix Description
Ambient
Ambient condition
c Compressor
Em Electric Motor
i Inlet Condition
o Outlet condition
6
INTRODUCTION
The reciprocating air compressor is a fundamental subject for thermodynamic analysis and study. The
process of induction and compression is a cyclic one. However by the use of a large reservoir on intake
and discharge the system can be examined as a steady flow process.
The Hilton Single Stage Compressor Test Unit F860 allows the compression process to be analysed in
detail. However for larger volume compressors the compression process is divided into multiple stages
with cooling of the compressed air after each stage being used to reduce the energy required to drive the
compressor.
The Hilton Two Stage Compressor Test Unit F865 allows students to investigate two stage
compression, both with and without the use of an intercooler and to operate the unit as a single stage
compressor.
A small bench mounted control console provides instrumentation and control for the compressor module
which is a belt driven unit with intake, intermediate and discharge reservoirs to smooth out the pressure
pulsations. An orifice plate flow measuring device is included in the air inlet and this connects to a
manometer mounted on the control console.
Pressure gauges on the reservoirs allow the first and second stage pressures to be measured. An ammeter
and voltmeter connected to the motor power supply allow the motor load to be monitored as the
compressor pressure ratio is increased. A tachometer sensor on the motor drive connects to the control
console mounted display..
A water cooled intercooler reduces the air temperature between stages and a water flowmeter allows
flow measurement and control.
Thermocouples on the compressor inlet and outlet at each stage and on the intercooler water flows
allow all relevant temperatures to be measured.
All of the instruments supplied allow the unit performance to be examined in detail.
An optional Computerised Data Acquisition system FC865A is available complete with its own
Installation, Operating and Maintenance Manual. The unit has been designed so that the upgrade
components can be fitted at any time during the life of the unit. In addition, the unit and upgrade have
been designed to allow installation by any competent technician.
SCHEMATIC DIAGRAM NOTATION

To assist in identifying all of the components there are three annotated schematic diagrams on pages 1,
2 and 3 . Each relevant component has a number identifier. In order to simplify component
identification in the text the relevant number is placed alongside the component name which is also in
bold text. For example on page 1 the main switch would be identified in text as main switch(1).
This convention is used throughout the manual.
INSTALLATION
Remove the unit from its packing case and visually inspect. Any damage found should be reported to
the insurers immediately.
Assuming that no damage is found, proceed as follows:

Note that the unit requires a 3 phase (+ Neutral for 380- 415V supplies), power supply (with
earth/ground)within reasonable distance to its ultimate location
1. Place the compressor module on the floor near to a suitable bench on which to rest the control
console. As the unit can generate high velocity air flows at ground level it is recommended that
the local area is cleaned of dust and loose debris, particularly on the floor.
2. The compressor module may have been shipped with the receiver discharge/vent (32) pipe
removed and packed separately. Connect the pipe to the receiver discharge/vent (32 and
7
tighten. Note that the end of the pipe can be directed under the 2nd stage receiver(27). It is
MOST IMPORTANT that the air discharge pipe or a suitable alternative is connected to
the receiver discharge/vent (32). The vent valve MUST NOT be allowed to vent openly
with nothing connected to it. Refer to the safety precautions on page 17.
3. If the unit is supplied with the optional computerised data acquisition upgrade FC865A
factory fitted there will be additional leads and cables to connect to the data logger module
that is part of the upgrade. This is dealt with in the computerised data acquisition manual
that is supplied as part of this manual.
4. Assuming the unit is not supplied with the optional computerised data acquisition system
FC865A then proceed as follows.
Locate the air intake vessel adjacent to the unit.
The pressure tapping shown at A is connected using the small diameter hose supplied to the
suction tapping on the orifice plate manometer(4) .This measures the pressure drop across the
orifice plate shown at C. The large diameter hose is used to connect the 1st stage air intake
pipe(28) on the compressor to the suction coupling B on the air intake vessel as shown above.
Tighten both hose clamps to ensure an air tight seal.
8
The manometer will normally require filling using the red fluid supplied. Fill to the zero (0mm)
mark on the adjustable scale. Connect the hose to the low pressure coupling on the orifice plate
manometer(4) as shown below.
5. Connect the motor tachometer sensor lead to the socket below the motor tachometer(3) display
on the control console as shown below.
6. Connect the numbered thermocouple plugs to the corresponding thermocouple sockets(9) .

Note that socket No 1 is on the left hand side.
9
7. The compressor uses a 3 phase power supply and local regulations MUST be observed
concerning installation of electrical equipment. If in any doubt, a qualified electrician should
be employed to complete the electrical installation.
8. The compressor has a pre-fitted power inlet cable. This MUST be connected to the control
console through the cable gland , power outlet for compressor(13) on the rear of the console
as shown below.
The cable must be connected internally and to do this the top cover must be removed from the
console. Remove the two top screws and 4 (larger) side screws. To make access to the rear panel
easier the central (bottom face) screw can be removed and the rear panel folded downwards.
9. The cable from the compressor is brought through the cable gland as shown below.
The transducer shown above right is only fitted if the data logging has been purchased and
factory fitted.
NOTE that of the 4 cables in the compressor wire, ONE is Green and Yellow. This is the
EARTH cable (Shown as A above) and MUST be connected to one of the Green and Yellow
terminals also shown as A above.
The remaining three wires are the three phase conductors (Shown B above) and these must be
connected to the three BROWN terminals also shown as B above. Normally the cables and
terminals will have been numbered by the Hilton factory engineer before shipment but in
extreme cases these can be lost in transit. Refer to the paper wiring diagram supplied in the
brown envelope containing all other documentation.
10
10. The local power supply must also be connected to the control console through cable gland main
power inlet (10) in the rear panel.
The local power supply must be capable of supplying the current ( Amps per phase) that is
indicated on the compressor motor plate. Note that in accordance with local regulations the
power supply must also have suitably rated fuses or overload cut out devices and it must also
have a low resistance Earth or Grounding point. It is recommended that the supply also has an
isolator switch.
The cables from the local supply to the unit must comply with local regulations and be suitably
protected (conduit or a bundled conductor) .
The compressor operates on a 3 phase balanced supply and depending upon the local supply
voltage, the instrumentation console operates on a single phase supply with neutral (or other
arrangement as specified below).
Connect the local supply cables to the unit.

The 3 phase (LINE) supply cables are connected to the 3 terminals shown at F above. The
NEUTRAL cable is connected to terminal G. The local Earth or Ground conductor is
connected to the terminal shown as H above.
11
Note that the device shown as E is the RCCB or earth leakage circuit breaker. This constantly
monitors the incoming and outgoing current in the circuit and in the event of a leakage to
ground above 30mA it will disconnect the power. The test button is shown adjacent to E
above and the reset button is below. Note that ON is UP .
The switch on the right above shown as D is the main overload cut out. This will disconnect
the power in the event of an overload or short circuit. To reset the cut out the switches under
D are lifter UP.
When all cables are correctly secured re-assemble and close the instrument console.
12
Water and Drain Connection

11. The unit requires a water supply for the intercooler and a drain to receive the heated water.
The water is connected at the rear of the cooling water flowmeter(16) on the compressor
module.
Note that if the optional data logging system has been purchased and factory fitted the water
inlet hose will already be connected at this point. The reinforced inlet hose supplied has a push
fit nozzle to match the coupling at the bottom of the flowmeter.
A similar hose connects to the outlet coupling adjacent to the T6 themocouple point as shown
below.
WARNING
The hose should be firmly secured in a drain that is capable of receiving the water. Note that
the drain must be secured as it is used to vent water from the heat exchanger when not in use.
The compressed air supply is used to flush the water from the heat exchanger.
Test Running After Installation.
Ensure that the motor belt cover is fully secure.

Ensure that the compressor has oil in its sump by viewing through the window in the side of
the compressor.
Before turning on the local supply ensure that the RED compressor OFF/STOP switch(34)
on the compressor module is pressed DOWN. This will stop the compressor starting suddenly.
Turn on the local power supply at its local isolator.

Firstly turn on the main switch(1) on the control console and ensure that the digital
instruments show figures.
It is ESSENTIAL that the compressor rotates in the correct direction as indicated by the
arrows on the large end of the belt guard. When the compressor ON Switch(33) is
pressed the compressor will start. Monitor the compressor pulley wheel and immediately press
the RED compressor OFF/STOP switch(34). Check the compressor rotation direction.
If the rotation direction is not correct isolate the local electrical supply and swap the location
of ANY TWO of the local 3 phase (LINE) POWER conductors to the unit at the local power
outlet. This will reverse the rotation direction of the motor.
13
DO NOT move the EARTH/ground conductor or NUETRAL conductor. These MUST stay in
their correct location.
Ensure valve A (24) is open (Turned Anti-clockwise), valve B (25) is closed and the water
purge valve(26) is closed. Also close the receiver discharge/vent valve(32).
Check that the water drain valve shown below the receiver(27) is closed.
Finally press the green compressor ON switch(33) on the pressure switch(35) body and the
compressor will start.
Air may be heard venting from the high pressure switch(35) area. This is normal. The high
pressure switch(35) also activates a compressor unloading device to aid starting when the main
air receiver(27) is at high pressure.
Ensure that the motor tachometer(3) indicates the motor speed and that the orifice plate
manometer(4) shows a positive differential pressure. If the pressure is negative reverse the
plastic pipe location on the manometer.
Open the valve on the cooling water flowmeter(16) and ensure the water flows through the
meter and leaves via the drain hose.
Monitor the 1st stage pressure(17) gauge and the 2nd stage pressure gauge(20). Ensure both
are increasing.
To turn off the compressor press the red compressor Off/stop switch(34) . NOTE that the
main switch(1) on the instrument console ONLY turns off power to the instruments. It
does NOT turn off the compressor..
14
DESCRIPTION
Please refer to the Schematic Diagrams on page 1, 2, 3and 4.
The standard unit includes a compressor module and a control console. An optional computerised data
acquisition option is also available and this is dealt with in a separate section of the manual.
The compressor module.
The compressor(14) is mounted together with its drive motor(15) on top of the 2nd stage air
receiver(27) .
Air is drawn into the unit through the intake orifice/damping vessel(22) attached to the 1st stage
intake pipe(28) on the compressor
The orifice plate is connected to the orifice plate manometer(4) mounted on the front panel of the
separate control console.
The compressor is a twin cylinder device (two cylinders in parallel) with one cylinder taking air in at
the intake(28) and compressing to an intermediate pressure and . Air then leaves the 1st stage
discharge(29) to the 1st stage receiver(18) and passes through the water cooled intercooler(23). The
air passes to the 2nd stage intake(30) for the final stage compression. The air leaves the 2nd stage
discharge(31) at high pressure and passes to the 2nd stage receiver(27).
The intermediate pressure is shown by the 1st stage pressure gauge(17) and the 2nd stage pressure is
shown by the 2nd stage pressure gauge(20) on the receiver(27). The final stage pressure can be
controlled by adjusting the receiver discharge/vent valve(32) on the end of the receiver.
The intercooler water flow rate is monitored and controlled by the flowmeter(16). The valve A (24)
15
can be closed and valve B(25) opened to operate the unit as a single stage compressor.
The motor speed is monitored by a sensor which connects directly to the motor tachometer(3) display
which is mounted on the front panel of the separate control console.
As the compressed air is likely to contain moisture which will condense in the 2nd stage air
receiver(27) a drain valve is located under one end of the receiver.
The relevant temperatures of air and water are recorded by 6 insulated thermocouples located as
required on the unit. All six thermocouples are duplex ready for the optional FC865A computerised
data acquisition option that can be added at any time.
All thermocouples plug into sockets on the separate control console.
The 1st stage receiver(18) is fitted with a safety valve(19) set to operate at 4 Bar gauge. This is
primarily to prevent overloading of the motor due to the large diameter of the low pressure cylinder.
The compressor is fitted with a high pressure switch(35) . This is factory set to operate at 10Bar gauge
and is connected to the 2nd stage air receiver(27) . The 2nd stage outlet air receiver(27) has a safe
working pressure of 11 Bar gauge and a safety valve(21) is also fitted to the receiver set to vent at 11
bar gauge.
The inlet to the 2nd stage air receiver(27) is fitted with a non-return valve and an unloading valve.
The combined high pressure switch(35) also has an unloading device that allows the compressor to
start under zero pressure conditions even when the 2nd stage air receiver(27) is at high pressure. This
prevents overloading of the compressor motor and ensures a long operating life.
The compressor Green on switch(33) and Red stop switch(34) are both located on top of the high
pressure switch(35). These are the main compressor controls.
16
The Control Console.
The control console is used as the main electrical supply to the compressor module and to carry all of
the instrumentation except for the pressure gauges.
The power from the local supply enters the rear panel main power inlet(10) . An internal RCCB or
earth leakage circuit breaker constantly monitors incoming and outgoing current and in the event of an
imbalance of 30mA or more (as in a leakage to earth situation) the RCCB will disconnect the power.
This is for operator protection in the event of a local earthing failure combining with an internal fault.
The console also contains the main overload cut out device which will disconnect the unit from the
supply in the event of an overload or short circuit. Both RCCB and overload are internally mounted
and the case will need to be opened to reset the devices.
The main switch(1) is a double pole switch and overload cut out. This supplies power to the
instrumentation only. NOTE that the main switch(1) does not turn off the compressor. The main
switch will disconnect the instrumentation from the supply in the event of a fault with the small current
loads of the instruments.
The motor tachometer(3) displays the motor speed in revolutions per minute(rpm) . The ammeter(5)
and voltmeter(6) indicate the electrical power supplied via the rear power outlet(13) to the
compressor..
The digital temperature indicator(7) will indicate the temperature of the thermocouples connected to
the thermocouple sockets(9). The temperature selector switch(9) selects the temperature to be
displayed on the indicator.
The orifice plate manometer(4) displays the pressure drop across the intake orifice plate allowing the
air flow rate to be calculated.
17
PRECAUTIONS AND WARNINGS

IMPORTANT
If used carelessly compressed air can be highly dangerous and potentially lethal. Debris
projected by compressed air can be as deadly as a conventional rifle bullet.
Compressed air alone if directed at the human body can be deadly resulting in loss of eyes,
embolism(bubbles in the bloodstream), loss of hearing and death in several recorded cases.
It is important that locally applicable safety precautions are fully explained to students before
operating the F865 Two Stage Compressor Test Unit.
The following are a list of general safety comments. There will be others that are covered by local
regulations.
1. A discharge pipe is supplied to be fitted to the receiver discharge/vent valve(32). This is

designed to direct the high pressure air under the 2nd stage air receiver(27) at floor level.
2. The unit MUST NOT be operated with nothing connected to the outlet receiver
discharge/vent valve(32). Venting compressed air at this level can be highly dangerous.
3. It is not recommended by P.A.Hilton Ltd but it is possible of course for the user to connect
other suitably pressure rated air tools to the outlet control valve(32) . However the operation
and safety aspects of such devices are entirely the responsibility of the user.
4. It is recommended that safety goggles are used by persons operating the compressor,
particularly if the local area is dusty or there is loose debris on the floor that may get blown
into eyes.
5. The compressor can generate pressures up to 10 Bar gauge. The high pressure switch is
designed to turn off the compressor at 10 bar gauge. Do not tamper with the high pressure
switch. If the compressor does not turn off at 10 bar gauge or the safety valve(21) vents at 11
bar gauge for ANY reason press the red compressor ON/OFF switch(34) immediately and
vent the receiver by opening the receiver discharge/vent valve(32). The unit should then be
investigated by a qualified engineer.
6. Do not tamper with the 2nd stage safety valve(21) or 1st stage safety valve(19) or allow
students to tamper with the safety valves.
7. The motor and compressor pulleys and belt are covered with a safety cover. The unit MUST
NOT be operated with this removed. Prevent students from attempting to insert anything into
air vent grilles or apertures adjacent to pulleys and the motor cooling fan.
8. If the RCCB or overload cut outs inside the control console operate for any reason the unit
should be investigated by a qualified electrician.
It is recommended that the internal RCCB press to test is pressed periodically or at intervals
specified by local regulations. As this must be tested with the control console cover removed
and the electrical power on this should only be undertaken by a qualified electrician. If the
device does not trip when tested the unit should be investigated by a qualified electrician.
9. Depending upon local regulations the outlet air vessel may require inspection by a competent
authority.
An access point is available on the receiver for internal access and a metal plate carries the vessel
details.
18
OPERATING PROCEDURES
Please refer to the Schematic Diagrams on page 1, 2, 3 and 4
It is assumed that the Installation procedures detailed on page 6 onwards have been carried out and that
the compressor module is connected to the control console and its instrumentation. If the optional
computerised data acquisition upgrade FC865A has been purchased operation of this is dealt with in a
separate section. The operation of the F865 unit however remains the same.
Ensure that the Precautions and Warnings detailed on page 17 have been read, understood and
explained to the students/operators.
Starting and Maintaining Stable Conditions as a Two Stage Compressor

1. Ensure that the and receiver discharge /vent valve (32) is fully open. Check that the drain
valve at the base of the outlet air receiver(27) is closed.
2. Fully open valve A(24) (turn anti-clockwise) and fully close valve B(25) (turn clockwise).
3. If intercooling is to be used turn on the local water supply and open the valve on the cooling
water flowmeter(16). If Intercooling is not required close the cooling water flowmeter(16)
valve fully.
4. Adjust the orifice plate manometer(4) scale to zero. Turn on the main switch(1) on the
control console and the instruments will illuminate.
5. Ensure that the motor belt cover is fully secure.Ensure that the compressor has oil in its
sump.
6. Finally press the green compressor ON switch(33) on the high pressure switch(34) on
the compressor module and the compressor will start.
Air should be heard venting from the receiver discharge/vent valve(32) AND from
the high pressure switch area. This is normal. The high pressure switch also activates
a compressor unloading device to aid starting when the outlet air receiver(27) is at
high pressure. Ensure that the motor tachometer(3) indicates the motor speed and that the
orifice plate manometer(4) shows a positive differential pressure.
7. Most tests involve adjusting the discharge pressure to a set value and maintaining this
until all readings (including temperatures) are stable and recording the data. To increase
the discharge pressure close the outlet receiver discharge/vent valve(32) fully and air will
be heard venting from the high pressure cut out and the non-return valve on the 2nd stage
air receiver(27). The 2nd stage pressure gauge(20) will show a slowly rising pressure
until at approximately 100kN/m2 the automatic vent closes and the pressure will start to
rise faster.
8. When the pressure has reached the desired level slowly open the receiver discharge/vent
valve(32) until the pressure is stable. This may take several attempts. There is a delay of
several seconds after each adjustment has an effect on the discharge pressure.
Adjustment or Removal of Intercooling Effect

9. The amount of intercooling on the F865 is controlled by the cooling water flowmeter(16).
This increases or decreases the cooling water flow to the air/water heat exchanger and this
in turn increases or decreases the cooling of the air depending upon the local water supply
temperature. If the intrecooling is to be removed the cooling water flowmeter valve(16) is
first closed.
For the next part of the procedure some positive pressure has to exist in the 2nd stage air
receiver(27) e.g approximately 200-500 kN/m2.
Ensure the water drain valve is secure in the drain (Refer to the WARNING on page 12)
and then carefully open the water purge valve(26). This will blow the water from the
intercooler and reduce the time taken for stability to be achieved.
10. To return to use of the intercooler simply open the cooling water flowmeter(16) valve.
19
MAXIMUM OPERATING PRESSURE

The maximum pressure that can be sustained is approximately 10 bar gauge as this is the set
pressure of the high pressure cut out. The actual value can only be determined by experiment
as the setting will vary slightly from machine to machine.
If the unit cuts out on the high pressure cut out then the pressure in the outlet air
receiver(27). will have to be allowed to fall until the compressor re-starts automatically.
Starting and Maintaining Stable Conditions as a Single Stage Compressor

1. Ensure that the and receiver discharge /vent valve (32) is fully open. Check that the drain
valve at the base of the outlet air receiver(27) is closed.
2. Fully close valve A(24) (turn clockwise) and fully open valve B(25) (turn anti-clockwise).
3. There is no intercooling function in single stage operation
4. Adjust the orifice plate manometer(4) scale to zero. Turn on the main switch(1) on the
control console and the instruments will illuminate.
5. Ensure that the motor belt cover is fully secure. Ensure that the compressor has oil in its
sump.
6. Finally press the green compressor ON switch(33) on the high pressure switch(34) on
the compressor module and the compressor will start.
Air should be heard venting from the receiver discharge/vent valve(32) AND from the
high pressure switch area. This is normal. The high pressure switch also activates a
compressor unloading device to aid starting when the outlet air receiver(27) is at high
pressure.
1. Ensure that the motor tachometer(3) indicates the motor speed and that the orifice plate
manometer(4) shows a positive differential pressure.
7. Most tests involve adjusting the discharge pressure to a set value and maintaining this
until all readings (including temperatures) are stable and recording the data. To increase
the discharge pressure close the outlet receiver discharge/vent valve(32) fully and air will
be heard venting from the high pressure cut out and the non-return valve on the 2nd stage
air receiver(27). The 2nd stage pressure gauge(20) will show a slowly rising pressure
until at approximately 100kN/m2 the automatic vent closes and the pressure will start to
rise faster.
8. NOTE that the MAXIMUM operating pressure in single stage mode is approximately
350kN/m2 as the large diameter 1st stage cylinder is not designed for high pressure
operation. The 1st stage safetyvalve(19) will vent at approximately 4000kN/m2. Do not
attempt to exceed this pressure or damage to the compressor may result.
9. When the pressure has reached the desired level slowly open the 2nd stage discharge/vent
valve(32) until the pressure is stable. This may take several attempts. There is a delay of
several seconds after each adjustment has an effect on the discharge pressure.
20
Stopping and Shutting Down

1. In the event that the compressor has to be stopped in an emergency press the red
compressor OFF/Stop switch(34) on the high pressure switch(35)
2. To shut down the compressor normally slowly open the receiver discharge/vent
valve(32) and allow the outlet air receiver to vent. While the receiver is still under pressure
also open the drain valve located under the receiver. This will allow any condensate in the
receiver to vent and reduce the possibility of corrosion.
3. When the unit is back to atmospheric pressure, press the red press the red compressor
OFF/Stop switch(34) on the high pressure switch(35) and then turn off the main
switch(1) on the control console.
4. Finally it is recommended that the unit is isolated from the local electrical supply and
water supply to prevent inadvertent operation.
21
MAINTENANCE
Compressor Module
- After each use open the drain valve on the outlet receiver to vent any condensate.
- Ensure the oil level shows in the compressor sight glass.
The sight glass and filler are visible in the above picture.
- If the level is low add SAE 40 mineral oil only by unscrewing the filler plug.
- If it is ever necessary to drain the compressor the drain plug is below the sight glass.
- Ensure that the cylinder head bolts are tight. The maximum torque is 25Nm.
- The belt tension must not allow the belt to slip. The belt should have a flex of
approximately 10mm (0.5 inch) . To adjust the belt it is necessary to remove the belt
guard and then loosen the bolts securing the plate holding the motor support bearings.
- Always replace and secure the belt cover after adjusting the belt. Do not run the unit
with the belt cover removed.
Control Console
- Periodically check the operation of the internal RCCB at the rear of the control
console or at intervals specified by local safety regulations. As this must be
undertaken with the cover removed and the power on it should be carried out by a
qualified person. Press the press to test button and the unit should turn off the power.
If it does not then the unit should be checked by a competent electrician.
22
USEFUL DATA
Compressor Dimensions
Cylinders 2
Low Pressure Cylinder
Bore 95mm
Stroke 50mm
High Pressure Cylinder
Bore 50mm
Stroke 50mm
Swept Volume per revolution 0.3544 x 10-3 m3
Specific Heat of Water Cp = 4.18 × 10 J/kgK

3
Air Flow Measurement

qv = 5.670 × 10−5 h × ( t1 + 273.15)
Where qv = Air flow volume m3/second

h = Orifice plate manometer pressure mmWg
Temperature Measuring points

t1 Air into 1st stage cylinder (ambient temperature)
t2 Air leaving 1st stage Cylinder (before intercooler)
t3 Air entering 2nd stage cylinder (after intercooler)
t4 Air leaving 2nd stage cylinder
t5 Water into intercooler
t6 Water leaving intercooler
23
EXPERIMENTAL PROCEDURES
The following detail suggested experimental procedures for the Two Stage e Compressor Test unit F865
If the optional Computerised Data Acquisition Upgrade FC865A has been purchased the operating
procedures for the F865 are identical except that data may be recorded continuously or at discrete
intervals using the software. The procedures for software operation are detailed elsewhere in this manual.
1. Investigation of Variation in Air Flow Rate With Compressor Pressure Ratio:-

With and without intercooling
2. Investigation of Variation in Volumetric Efficiency with Compressor Pressure Ratio. With and
without intercooling.
3 Investigation Of Variation Of Isothermal Efficiency With Compressor Pressure Ratio. With
and without intercooling.
4 Investigation Of The Compressor Performance Relative To Electrical Power, Shaft Power,
And Heat Loss. With and without intercooling.
24
1. INVESTIGATION OF VARIATION IN AIR FLOW RATE, WITH COMPRESSOR

PRESSURE RATIO:- With and Without Intercooling
Experimental Procedure
It is assumed that the unit has been installed and configured following the procedures detailed on pages 6
onwards. Start the unit following the procedures shown on page 18 onwards. Initially set the intercooler
cooling water flow rate at a suitable value, such as 20 grammes/second, or any convenient value.
The compressor will be operated at a range of discharge pressures up to the high pressure cut out point
(approximately 10 bar gauge) and the specified operating parameters recorded.
First record the local ambient air pressure PAmbient using a barometer or obtain this from meteorological
sources.
1. Ensure that the receiver discharge/vent valve(32) is also fully open. Record the data shown on
page 25.
A blank table that may be used for data collection is shown on page 52.
2. Increase the outlet pressure to approximately 100-150kN/m2 by closing the receiver

discharge/vent valve(32) following the procedure shown on page 18 onwards. Note that the
actual pressure is not important and that the minimum operating pressure will depend upon the
individual machine characteristics. The pressure at which the vent valve closes will vary from
machine to machine.
3. Increase the outlet pressure by convenient amounts (e.g. 50 or 100kN/m2 ) and repeat the
observations. Note that at approximately 10 bar gauge the high pressure cut out will limit the
maximum operating pressure. As with the minimum pressure the exact maximum operating
pressure will vary slightly from machine to machine.
Typical observations are shown on page 25.
Sample Calculations.
Air flow rate
From Useful Data on page 22

qv = 5.670 × 10−5 h × ( t1 + 273.15)
From the sample data on page 25, for observation No 4
qv = 5.670 × 10−5 h × ( t1 + 273.15)
= 5.670 × 10−5 61 × ( 24.3 + 273.15)
= 0.00716 m 3 / s
= 7.16 l/s
25
Observations
WITH INTERCOOLING
Ambient Pressure 1.01 Bar (1.010 x 105 N/m2)
Sample No.
1 2 3 4 5 6 7 8 9 10 11 12
Inlet Temperature
t1 /°C 22.5 23.2 23.8 24.3 24.2 24.3 24.3 24.4 24.5 24.6 24.6
st
Air out of 1 stage
t2 /°C 136.3 147.2 151.6 154.8 155.7 157.9 159.2 160.8 162.7 163.6 162
nd
Air into 2 stage
t3 /°C 37.6 41.1 42.6 43.7 43.8 44.1 44.1 44.3 44.5 44.6 38.1
Air out of 2nd stage
t4 /°C 68.6 83.6 94.8 109.1 115.4 125 131.7 138.9 145.1 146.9 144.1
Water Inlet
t5 /°C 13.1 14 14 14.4 14.3 14.5 14.4 14.4 14.6 14.5 13.1
Water Outlet
t6 /°C 20.8 22.1 22.4 22.9 23.1 23.3 23.3 23.3 23.2 23.6 17.4
st
1 stage Pressure
p1 / kN/m2 220 250 260 260 270 280 280 280 300 300 300
nd
2 stage Pressure
p2 / kN/m2 100 200 280 440 500 600 680 800 900 960 900
Manometer Height
f / kg 69.6 66.4 64.8 60.9 60.1 60.1 59.3 58.5 58.5 57.7 58.5
Motor Volts
V / Volts 420 420 420 418 410 410 410 410 410 410 415
Compressor Speed
Nc / rpm 1380 1370 1360 1360 1350 1360 1360 1350 1340 1350 1340
Cooling Water Flow
m& w /g/s 20 20 20 20 20 20 20 20 20 20 20
Compressor Current
I / Amps 5.5 5.7 6 6.2 6.5 6.6 6.8 6.9 7 7 7
26
Inlet Absolute Pressure Pi

Pi = pi + PAmbient
= 0 + 1.01×105
= 101×103 N/m 2
Similarly 1st stage Outlet Pressure
P1 = p1 + PAmbient
= 260 × 103 + 1.01×105
= 361× 103 N/m 2
Similarly 2nd stage Outlet Pressure
P 2 = p 2 + PAmbient
= 440 × 103 + 1.01× 105
= 541× 103 N/m 2
1st stage Pressure ratio
P1 361× 103
=
Pi 101× 103
= 3.57
2nd stage Pressure ratio
P 2 541× 103
=
P1 361× 103
= 1.49
Overall Pressure Ratio
P 2 541× 103
=
Pi 101×103
= 5.37
By repeating the calculations on the remaining data the parameters may be presented graphically. A typical
graph is shown on the following page
If the procedure is repeated with the intercooling disabled then a different set of results may be obtained.
The procedure for removing the intercooling effect is described on page 18.
Repeat the test procedure without intercooling and repeat the data collection procedure.
Note that in high ambient temperatures the motor current may get excessively high (7.5-8Amps) if this
should happen it is recommended that the test procedure is stopped as the motor may overheat.
A set of sample results are shown on the following pages.

27
Two Stage Compression

With Intercooling
Volume Flow L/s
Overall Pressure
Ratio
Second
Stage First Stage
Pressure Pressure
Ratio
28
Observations
WITHOUT INTERCOOLING
Sample No.
1 2 3 4 5 6 7 8 9 10 11 12
Inlet Temperature
t1 /°C 25 25.1 25.4 25.3 26 26.4 26.4 26.6
st
Air out of 1 stage
t2 /°C 154.2 158.2 164.1 167.2 170.4 171.4 176.3 177.2
nd
Air into 2 stage
t3 /°C 137.1 143.8 148.5 151.2 154.6 155.9 160 161
t4 /°C 103.9 114.7 126 139.1 149.8 158.6 174.4 176.9
Water Inlet
t5 /°C - - - - - - - -
Water Outlet
t6 /°C - - - - - - - -
st
1 stage Pressure
p1 / kN/m2 250 280 300 320 320 320 330 340
nd
2 stage Pressure
p2 / kN/m2 100 200 280 400 510 600 740 800
Manometer Height
f / mm 61.7 60.1 58.5 56.9 56.1 55.7 54.5 53.7
Motor Volts
V / Volts 420 420 420 420 420 420 420 420
Compressor Speed
Nc / rpm 1370 1370 1360 1360 1360 1360 1350 1350
Cooling Water Flow
m& w /g/s 0 0 0 0 0 0 0 0
Compressor Current
I / Amps 5.7 5.8 6 6.3 6.5 6.7 7 7.1
29
Two Stage Compression

WITHOUT Intercooling
Volume Flow L/s
Overall
Pressure Ratio
First Sstage
Second Stage
Pressure Ratio
Pressure Ratio
30
It can be seen from the graph on page 27 that, as the overall pressure ratio increases the volume flow
decreases.
The reduction in air flow rate is partially due to the clearance volume that must be left at the top of both the
low pressure and high pressure cylinder to allow room for the inlet valves to operate.
For economy and simplicity of operation these valves are usually spring steel and so require some pressure
differential in order to open. Similarly the discharge valves are also spring steel and require a differential
pressure across them to remain open.
For the above reasons a significant amount of air at or above the discharge pressure is left in the cylinder at
the end of each discharge stroke.
Hence as the discharge pressure (or pressure ratio) is increased the volume flow rate of the air through the
compressor decreases.
The effect of the intercooling is to reduce the volume (increase the density) of the air between the low
pressure and high pressure cylinder. The effectiveness of the intercooling is illustrated by the graph on page
29 showing a similar test but without intercooling . This shows similar test conditions to the results on
page 27 but the volume flow is substantially reduced at similar pressure ratios due to the air between stages
being at very high temperatures and hence a low density.
The significant difference between the single stage and two stage compressor is not only the effective air
volume flow arte but also the effect of the intercooling on the power required to drive the compressor. This
is demonstrated in later experiments.
31
2 INVESTIGATION OF VARIATION IN VOLUMETRIC EFFICIENCY WITH

COMPRESSOR PRESSURE RATIO:- With and Without Intercooling
.
The experimental procedure for this experiment is identical to that used for experiment No1 on page 24.
The data collected is identical to experiment No 1 and therefore the data from this may be used in this
procedure.
Typical observations are shown on page 25
The data shown on page 25 was collected with the intercooler operating. It is recommended that the
procedure is repeated with the intercooler disabled following the procedure on page 18.
Typical data with the intercooler inoperative is given on page 28.
Air flow rate

qv = 5.67 × 10−5 h × ( t1 + 273.15)
For observation No 4 on page 25

qv = 5.67 × 10−5 h × ( t1 + 273.15)
= 5.67 × 10−5 60.9 × ( 24.3 + 273.15)
= 0.00763 m3 / s
= 7.63 l/s
Pi = pi + PAmbient
= 0 + 1.01×105
= 101×103 N/m 2
P1 = p1 + PAmbient
= 260 × 103 + 1.01×105
= 361× 103 N/m 2
= 440 × 103 + 1.01× 105
= 541× 103 N/m 2
32
P1 361× 103
=
Pi 101× 103
= 3.57
P 2 541× 103
=
P1 361× 103
= 1.49
P 2 541 × 103
=
Pi 101 × 103
= 5.35
From Useful Data on page 22 the compressor swept volume per revolution 0.3544 x 10-3 m3 or
0.3544 litre
From the sample data on page 25 , observation No 4
The measured compressor speed Nc = 1360rpm
Hence the volume swept by the compressor at this speed is.
0.3544 × 1360
Swept Volume Vs =
60
= 8.033 Litres/second
For a perfect compressor , with no clearance volume at the top of the cylinder and no throttling at the inlet
or discharge valves this would be the maximum air flow rate through the compressor. However as
demonstrated in experiment No 1 the volume decreases with increasing pressure ratio.
Therefore comparing the swept volume with the actual volume is a method of describing the efficiency of
the compressor. As a non-dimensional parameter this can be used to compare similar compressors.
Volumetric Efficiency
ActualVolume Swept Per cycle
ηVol =
Swept Volume
qv
=
Vs
7.63
= × 100%
8.033
= 94.9%
By repeating the calculations on the remaining data the parameters may be presented graphically. A typical
graph is shown on page 33.
33
WITH
INTERCOOLING
WITHOUT
INTERCOOLING
34
The reduction in volumetric efficiency is caused by the same parameters detailed at the completion of
experiment No. 1. However as the parameters are non-dimensional the data may be used to compare
compressors in order to assess their performance.
It can also be seen from the graphical data that the intercooler increases the volumetric efficiency under all
conditions. This is also due to the increase in air density between stages due to the cooling of the air.
35
3 INVESTIGATION OF VARIATION OF ISOTHERMAL EFFICIENCY WITH

COMPRESSOR PRESSURE RATIO:- With and Without Intercooling
procedure.
THEORY
The pressure – volume diagram for the air in the cylinder of an ideal compressor is shown below.
v
The constant pressure line a-b represents the induction, inlet, or suction stroke. The air is then compressed
adiabatically pv = Constant as shown by the curve b-c and the air is forced out of the cylinder at
1.4
constant pressure shown by the line c-d. As the piston moves downward any air remaining in the clearance
volume of the cylinder expands along the line d-a.
The work done on the air is the area is represented by the area abcd.
If the gas is compressed isothermally (at constant temperature) pv = Constant then the compression
1
will follow the line b-e. If during the expansion process the air also expands isothermally the process will
follow the line d-a’
Considering the work done on the gas is represented by the area abed, in the isothermal case it can be seen
that the area is less than the adiabatic compression. Hence the work required is a minimum for isothermal
compression.
In order for the compressor to even approach isothermal compression it would have to run extremely
slowly and this is obviously not practical.
36
It can be shown that the work required for adiabatic compression is
Where i = inlet condition, o= outlet condition

γ −1
⎛ ⎞
γ ⎜ ⎡ Po ⎤ γ
WAdiabatic = m& airPivi − 1⎟
γ − 1 ⎜ ⎢⎣ Pi ⎥⎦ ⎟
⎝ ⎠
Or, as Pivi = RTi
γ −1
⎛ ⎞
γ ⎜ ⎡ Po ⎤ γ
= m& airRTi − 1⎟
γ − 1 ⎜ ⎢⎣ Pi ⎥⎦ ⎟
⎝ ⎠
Similarly for adiabatic compression
γ −1
⎛ Po ⎞ γ
To = T i ⎜ ⎟
⎝ Pi ⎠
In the case of isothermal compression To = Ti
For the ideal case of isothermal compression pv = Constant it can also be shown that:
1
⎛ Po ⎞
WIsothermal = m& airPivi ln ⎜ ⎟
⎝ Pi ⎠
or
⎛ Po ⎞
= m& airRTi ln ⎜ ⎟
⎝ Pi ⎠
In order to reduce the work required to a minimum various methods have been used to try and make the
compression process approach the isothermal line. These include water injection to cool the air, water
cooling of the cylinder or air cooling of the cylinder. In addition it is possible to approach isothermal
compression by dividing the compression into two or more stages and cooling the air between stages using
a heat exchanger. This is the procedure adopted in the Hilton F865 Tow Stage Compressor Test Unit
The first stage compression is taken from b to c’ in the first stage (or low pressure) cylinder. The air is
cooled at constant volume from c’ to f and then the compression is completed from f to e (isothermal) or e’
adiabatic.
In practice the compression process will be somewhere between isothermal pv = Constant and
1
γ
adiabatic pv = Constant
In practice the compression will be polytropic and the index γ of the compression
γ
process Pv = Constant will be between 1.1 and 1.4
37
Note that the expansion of the clearance volume in the two cylinders will also be separated but this has not
been shown for simplicity.
To give a measure of the thermodynamic efficiency of a compressor a useful term is the isothermal
efficiency.
This is the ratio

Isothermal Work
η Isothermal =
Actual Work
WIsothermal
=
WActual
⎛ Po ⎞
m& airRTi ln ⎜ ⎟
= ⎝ Pi ⎠
WActual
For a compressor with Intercooling
Air flow rate

qv = 5.67 × 10−5 h × ( t1 + 273.15)
Where qv = Air flow volume litres/second
t1 = Air inlet temperature °C
From the test data on page 25, for observation No 5

qv = 5.67 × 10−5 h × ( t1 + 273.15)
= 5.67 × 10−5 60 × ( 24.2 + 273.15)
= 0.0075m3 / s
= 7.5 Litre/s
The air density ρ Air can be determined using the perfect gas law
Pi
ρ Air =
RTi
Where Pi = Inlet Air Pressure, Ti = Intake Temperature T1
Due to the design of the orifice plate the inlet pressure Pi is very close to ambient pressure P
Pi = pi + PAmbient
= 0 + 1.01×105
= 101×103 N/m 2
P1 = p1 + PAmbient
= 270 ×103 + 1.01×105
= 371×103 N/m 2
38

= 500 ×103 + 1.01×105
= 601×103 N/m 2
P1 371×103
=
Pi 101×103
= 3.67
P 2 601×103
=
P1 371×103
= 1.62
P 2 601×103
=
Pi 101×103
= 5.95
From sample data on page 25, for observation No 5 t1 = 24.2°C
Hence
Pi
ρ Air =
RTi
1.01 × 105
=
287 × ( 24.2 + 273.15)
= 1.18 kg/m3
= 1.18 × 10−3 kg/Litre
Hence the mass flow of air
m& Air = qv × ρ Air
= 7.5 × 1.18 × 10−3
= 8.87 × 10−3 kg/s
39
If it is assumed that the first stage compression is adiabatic then
For adiabatic compression
γ −1
⎛ Po ⎞ γ
To = T i ⎜ ⎟
⎝ Pi ⎠
or
γ −1
⎛ P1 ⎞ γ
T 2 = T 1⎜ ⎟
⎝ Pi ⎠
P1
For the first stage compression (sample No 5 page 25) the pressure ratio = 3.67 , T 1 = 24.2°C, γ=1.4
Pi
γ −1
⎛ P1 ⎞ γ
T 2 = T1⎜ ⎟
⎝ Pi ⎠
1.4 −1
= (24.2 + 273.15) ( 3.67 ) 1.4
= 431.2 K
= 431.2 − 273.15 o C
= 158.0o C
Referring to sample No 5 page 25, the recorded T2 = 155.7 °C

Therefore the first stage compression may be assumed to be adiabatic.
The adiabatic work required for compression
γ −1
⎛ ⎞
γ ⎜ ⎡ Po ⎤ γ
WAdiabatic = m& airRTi − 1⎟
γ − 1 ⎜ ⎢⎣ Pi ⎥⎦ ⎟
⎝ ⎠
γ −1
⎛ ⎞
γ ⎜ ⎡ P1 ⎤ γ
= m& airRT 1 − 1⎟
γ − 1 ⎜ ⎢⎣ Pi ⎥⎦ ⎟
⎝ ⎠
Substituting for known values
γ −1
⎛ ⎞
γ ⎜ ⎡ Po ⎤ γ
WAdiabatic = m& airRTi − 1⎟
γ − 1 ⎜ ⎣⎢ Pi ⎦⎥ ⎟
⎝ ⎠
1.4 ⎛ 1.4 −1
⎞
= 8.87 × 10−3 × 287 × ( 24.2 + 273.15) ⎜ [ 3.67] 1.4 − 1⎟
1.4 − 1 ⎝ ⎠
= 1195.8Watts
40
Before the air enters the second stage it passes through the intercooler where heat is removed and it is
cooled from T2= 155.7°C to T3 = 43.8 °C
The heat is absorbed by the cooling water and the heat lost can be determined from
Q& water = m& waterCpwater (T 6 − T 5 )

Substituting for known values from sample No 5 page 25
And from Useful Data on page 22
Q& water = m& waterCpwater (T 6 − T 5 )
= 20 × 10−3 × 4.18 ×103 ( 23.1 − 14.3)
= 735.6Watts
Examining the second stage compression. IF the compression is adiabatic then,
γ −1
⎛ P2 ⎞ γ
T 4 = T 3⎜ ⎟
⎝ P1 ⎠
γ −1
⎛ P2 ⎞ γ
T 4 = T 3⎜ ⎟
⎝ P1 ⎠
1.4 −1
= ( 43.8 + 273.15 )(1.62 ) 1.4
= 363.7 K
= 363.7 − 273.15o C
= 90.6o C
Referring to sample No 5 page 25, the recorded T4 = 115.4 °C
Therefore it is reasonable to assume the compression process is close to adiabatic. However as the final
temperature T4 is HIGHER than the expected adiabatic value it is likely that heat is being transferred to
the air from the adjacent parallel cylinder and due to friction heating in the compressor.
However without the use of the intercooler T3 would have been at a higher temperature and the calculated
second stage work requirement would have been higher. This is investigated at a later stage.
41
γ −1
⎛ ⎞
γ ⎜ ⎡ P2 ⎤ γ
WAdiabatic = m& airRT 3 − 1⎟
γ − 1 ⎜ ⎢⎣ Pi ⎥⎦ ⎟
⎝ ⎠
1.4 ⎛ 1.4 −1
⎞
= 8.87 × 10−3 × 287 × ( 43.8 + 273.15) ⎜ [1.62 ] 1.4 − 1
⎟
1.4 − 1 ⎝ ⎠
= 418Watts
The sum of the work required for both stages is therefore
WTotal = 1195.8 + 418

= 1613.8Watts
The isothermal work required for compression in the two stages.
⎛ P1 ⎞ ⎛ P2 ⎞
WIsothermal = m& airRT 1 ln ⎜ ⎟ + m& airRT 3 ln ⎜ ⎟
⎝ Pi ⎠ ⎝ P1 ⎠
WIsothermal = 8.87 × 10−3 × 287 ( 24.3 + 273.15) ln ( 3.67 ) + 8.87 × 10−3 × 287 ( 43.8 + 273.15) ln (1.62 )
= 987 + 389
= 1376Watts
A measure of the efficiency of the compression process
Isothermal Work
η Isothermal =
Actual Work
WIsothermal
=
WActual
1376
= × 100%
1613
= 85.3%
The effect of the intercooling can be seen more readily if the calculations are repeated for tests undertaken
WITHOUT the intercooler operating.
Examining the test data on page 28 sample No 5 which was recorded at a similar second stage pressure
(510kN/m2).
The equivalent calculations give the following results.

γ −1 γ −1
⎛ ⎞ ⎛ ⎞
γ ⎜ ⎡ P1 ⎤ γ
⎟ + m& airRT 3 γ ⎜ ⎡ P 2⎤ γ
⎟
WAdiabatic = m& airRT 1 − 1 − 1
γ − 1 ⎜ ⎣⎢ Pi ⎦⎥ ⎟ γ − 1 ⎜ ⎣⎢ P1 ⎦⎥ ⎟
⎝ ⎠ ⎝ ⎠
1.4 ⎛ 1.4 −1
⎞
= 8.86 × 10−3 × 287 × ( 26.0 + 273.15) ⎜ [ 4.17 ] 1.4 − 1 +
⎟
1.4 − 1 ⎝ ⎠
1.4 ⎛ 1.4 −1
⎞
8.86 × 10−3 × 287 × (154 + 273.15) ⎜ [1.45] 1.4 − 1⎟
1.4 − 1 ⎝ ⎠
= 1341 + 427
= 1768Watts
42
The above figure compares with 1613 Watts for the unit with the intercooling in operation. The
intercooling does reduce the overall power requirement slightly but its major effect is the increase in
volumetric efficiency.
It can be shown that for a two stage compressor the optimimum condition is where the total work
requirement is shared equally between the two stages. From the equations this condition will exist when
⎛ P1 ⎞ ⎛ P 2 ⎞
⎜ ⎟=⎜ ⎟
⎝ Pi ⎠ ⎝ P1 ⎠
For this compressor this condition does not exist as in the above sample result from page 28 sample No 5
⎡ P1 ⎤
⎢⎣ Pi ⎥⎦ = 4.17,WLP = 1341Watts
⎡ P2 ⎤
⎢⎣ P1 ⎥⎦ = 1.45,WHP = 427Watts
It is evident that the pressure ratio could be changed in this case to reduce the overall work input but of
course this would be a design change to the compressor.
43
4 INVESTIGATION OF THE COMPRESSOR PERFORMANCE RELATIVE TO

ELECTRICAL POWER:- With and without Intercooling
.
procedure.
Air flow rate
qv = 5.67 × 10−5 h × ( t1 + 273.15)
Where qv = Air flow volume litres/second
t1 = Air inlet temperature °C
From the test data on page 25, for observation No 5

qv = 5.67 × 10−5 h × ( t1 + 273.15)
= 5.67 × 10−5 60.1 × ( 24.2 + 273.15)
= 0.00757 m 3 / s
= 7.58 Litre/s
Due to the design of the orifice plate the inlet pressure Pi is very close to ambient pressure P
Pi = pi + PAmbient
= 0 + 1.01×105
= 101×103 N/m 2
P1 = p1 + PAmbient
= 270 × 103 + 1.01×105
= 371× 103 N/m 2
= 500 ×103 + 1.01× 105
= 601× 103 N/m 2
44

P 2 601× 103
=
Pi 101× 103
= 5.95
0.3544 litre
0.3544 × 1350
Swept Volume Vs =
60
ηVol =
Swept Volume
qv
=
Vs
7.56
= × 100%
7.97
= 94.8%
The electric motor on the compressor is a 3 phase device.
In some instances the motor plate will refer to the typical power factor Cosθ ( θ is the phase angle
between active and reactive current) of the motor. In the event that the motor does not carry this
information a typical value is Cosθ = 0.9
The active power of a 3 phase motor can be determined from
WElectrical = 3 ×V × I × Cosθ
The derivation of the above equation is beyond the scope of this manual but should be found in most
electrical engineering text books.
45

V=410 Volts I = 6.5 Amps.
Hence
WElectrical = 3 × 418 × 6.2 × 0.9
= 3815Watts
This value may be compared with the calculated work from the previous experiment at the same test
conditions. The calculated work input based upon the compressor pressure ratios , temperatures and air
flow rate was
WTotal = 1168.9 + 409
= 1577.9Watts
This is approximately 40% of the electrical power input and indicates the magnitude of frictional losses
in the belt drive and compressor and electrical losses in the motor.
Repeating the above calculations for all of the test data on page 25 where the intercooler is in use and for
the test data on page 28where the intercooler is not used results in a graph as shown on the following
page .
It can be seen that with the intercooler the volumetric efficiency is higher for the same pressure ratio and
the electrical power input is lower, particularly at high pressure ratios.
Considering that most air compressors of this type are used on a continuous basis the saving in electrical
power can be considerable.
46
47
5 OPERATION OF THE COMPERSSOR AS A SINGLE STAGE DEVICE
.
It is assumed that the unit has been installed and configured following the procedures detailed on pages
6 onwards. The unit will be operated as a single stage machine and in order to do this it must be started
following the procedure on page 19, Starting and Maintaining Stable Conditions as a Single Stage
Compressor
In single stage use only the larger low pressure cylinder passes air and the high pressure cylinder and
intercooler are bypassed. Due to the valve arrangement there is no air flow at all through the high pressure
cylinder and hence the overall work input to the high pressure stage will be friction effects, assuming that
any air trapped in the high pressure cylinder compresses and expands adiabatically and reversibly.
Due to the pressure limitations of the low pressure stage the range of operation must be restricted to an
upper 4 Bar limit.
First record the local ambient air pressure PAmbient using a barometer or obtain this from meteorological
sources.
1. Ensure that the receiver discharge/vent valve(32) is also fully open. Record the data shown on
page51.
2. Increase the outlet pressure to approximately 100-150kN/m2 by closing the receiver
discharge/vent valve(32) following the procedure shown on page 18 onwards. Note that the
actual pressure is not important and that the minimum operating pressure will depend upon the
individual machine characteristics. The pressure at which the vent valve closes will vary from
machine to machine.
3. Repeat the above readings.
4. Increase the outlet pressure by convenient amounts (e.g. 50 or 100kN/m2 ) and repeat the
observations. Note that the maximum operating pressure in single stage operation will be limited
by the low pressure safety valve which is set at 4 Bar gauge pressure. If the relief valve vents then
reduce the pressure by opening the receiver discharge/vent valve(32) .
5. As with the minimum pressure the exact maximum operating pressure will vary slightly from
machine to machine
Typical test results are shown on page 51.
Air flow rate

qv = 5.67 × 10−5 h × ( t1 + 273.15)
From the sample data on page51, for observation No 5
qv = 5.67 × 10−5 h × ( t1 + 273.15)
= 5.67 × 10−5 54.5 × ( 22.6 + 273.15)
= 0.0071m3 / s
= 7.1 l/s
48
0.3544 litre
0.3544 ×1370
Swept Volume Vs =
60
ηVol =
Swept Volume
qv
=
Vs
7.1
= × 100%
8.092
= 87.7%

Pi = pi + PAmbient
= 0 + 1.01×105
= 101×103 N/m 2
P1 = p1 + PAmbient
= 400 ×103 + 1.01×105
= 501× 103 N/m 2
st
1 stage Pressure ratio
P1 361×103
=
Pi 101×103
= 3.57
The electric motor on the compressor is a 3 phase device.
In some instances the motor plate will refer to the typical power factor Cosθ ( θ is the phase angle
between active and reactive current) of the motor. In the event that the motor does not carry this
information a typical value is Cosθ = 0.9
49
The active power of a 3 phase motor can be determined from
WElectrical = 3 ×V × I × Cosθ
The derivation of the above equation is beyond the scope of this manual but should be found in most
electrical engineering text books.

V=420 Volts I = 5.8 Amps.
Hence
WElectrical = 3 × 420 × 5.8 × 0.9
= 4019Watts
Repeating the above calculations the data may be plotted on a graph as shown on page 50. The data from a
similar overall pressure ratio range has been added to the graph and it can be seen that the addition of the
second stage with intercooling greatly increases the volumetric efficiency and reduces the power
consumption.
However it should be noted that the two stage compression is only beneficial providing the second stage
compression pressure is higher than tne first stage. This will normally be the case if the compressor is
correctly sized for the duty(air consumption) and is operating in an industrial situation where the receiver is
operating at or near maximum pressure.
50
51
Observations
SINGLE STAGE
Sample No.
1 2 3 4 5 6 7 8 9 10 11 12
Inlet Temperature
t1 /°C 20.6 21.3 21.9 22.2 22.6
st
Air out of 1 stage
t2 /°C 107.9 130.3 143.6 150.3 160
nd
Air into 2 stage
t3 /°C 38.6 41.2 42 42.2 4203
t4 /°C 35.5 44.3 51.8 55.6 50.6
Water Inlet
t5 /°C - - - - -
Water Outlet
t6 /°C - - - - -
st
1 stage Pressure
p1 / kN/m2 120 220 300 380 400
nd
2 stage Pressure
p2 / kN/m2 100 200 300 380 400
Manometer Height
f / kg 71.1 66.4 60.1 55.3 54.5
Motor Volts
V / Volts 420 420 420 420 420
Compressor Speed
Nc / rpm 1390 1380 1380 1370 1370
Cooling Water Flow
m& w /g/s 0 0 0 0 0
Compressor Current
I / Amps 5 5.4 5.6 5.7 5.8
52
Observation Sheet F865 Two Stage Compressor Test Unit

Operating Condition (delete as appropriate)*
SINGLE STAGE TWO STAGE WITH INTERCOOLING TWO STAGE WITHOUT INTERCOOLING
Ambient Pressure
Sample No.
1 2 3 4 5 6 7 8 9 10 11 12
Inlet Temperature
t1 /°C
st
Air out of 1 stage
t2 /°C
Air into 2nd stage
t3 /°C
t4 /°C
Water Inlet
t5 /°C
Water Outlet
t6 /°C
st
1 stage Pressure
p1 / kN/m2
2nd stage Pressure
p2 / kN/m2
Manometer Height
f / kg
Motor Volts
V / Volts
Compressor Speed
Nc / rpm
Cooling Water Flow
m& w /g/s
Compressor Current
I / Amps

Two Stage Compressor

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P.A.

TWO STAGE COMPRESSOR TEST UNIT

EDUCATION AND TRAINING EQUIPMENT

F865 Two Stage Compressor Test Unit

For and on behalf of

P.A. HILTON LIMITED

Tel No. National Romsey (01794) 388382

Fax No. +44 1794 388129

BLANK OBSERVATION TABLE 52

1. Main Switch 8. Temperature Selector Switch

10. Main Power Inlet

14. Compressor 23. Intercooler

Compressor Module (Detail)

20. 2nd Stage Pressure Gauge

SCHEMATIC DIAGRAM NOTATION

Assuming that no damage is found, proceed as follows:

6. Connect the numbered thermocouple plugs to the corresponding thermocouple sockets(9) .

Connect the local supply cables to the unit.

Water and Drain Connection

Test Running After Installation.

Ensure that the motor belt cover is fully secure.

Turn on the local power supply at its local isolator.

The compressor module.

The Control Console.

PRECAUTIONS AND WARNINGS

1. A discharge pipe is supplied to be fitted to the receiver discharge/vent valve(32). This is

Starting and Maintaining Stable Conditions as a Two Stage Compressor

Adjustment or Removal of Intercooling Effect

MAXIMUM OPERATING PRESSURE

Starting and Maintaining Stable Conditions as a Single Stage Compressor

Stopping and Shutting Down

Swept Volume per revolution 0.3544 x 10-3 m3

Specific Heat of Water Cp = 4.18 × 10 J/kgK

Air Flow Measurement

Where qv = Air flow volume m3/second

Temperature Measuring points

1. Investigation of Variation in Air Flow Rate With Compressor Pressure Ratio:-

1. INVESTIGATION OF VARIATION IN AIR FLOW RATE, WITH COMPRESSOR

2. Increase the outlet pressure to approximately 100-150kN/m2 by closing the receiver

Typical observations are shown on page 25.

Air flow rate

From Useful Data on page 22

Inlet Absolute Pressure Pi

1st stage Pressure ratio

A set of sample results are shown on the following pages.

Two Stage Compression

Two Stage Compression

2 INVESTIGATION OF VARIATION IN VOLUMETRIC EFFICIENCY WITH

Typical observations are shown on page 25

Air flow rate

For observation No 4 on page 25

1st stage Pressure ratio

Hence the volume swept by the compressor at this speed is.

3 INVESTIGATION OF VARIATION OF ISOTHERMAL EFFICIENCY WITH

Typical observations are shown on page 25

It can be shown that the work required for adiabatic compression is

Where i = inlet condition, o= outlet condition

This is the ratio

Air flow rate

From Useful Data on page 22

From the test data on page 25, for observation No 5

Similarly 2nd stage Outlet Pressure

1st stage Pressure ratio