Bataan Heroes College

Module 4: Gas Compressors

Learning Objectives:

After studying this module, students should be able to:

1. Understand the general concept of gas compressor.

2. Analyze the fundamental principles of gas compressor.

3. Apply the knowledge target in the field of engineering.

4.1 Gas Compressor

Gas Compressor

Are machines in which mechanical work is done on a flowing fluid, raising its pressure.

Two general types of gas compressors

1. Reciprocating compressor – for high pressure and low volume flow rates.

2. Rotative compressor – for low pressure and high volume flow rates (centrifugal and
rotary compressors)

These types are further specified by:

 The number of compression stages

 Cooling method (air, water, oil)

 Drive method (motor, engine,

steam and others)

 Lubrication (oil and oil-free –

means no lubricating oil contacts
the compressed air) Figure 1 High Pressure Gas Compressor

 Packaged or custom-built

Module 4: Gas Compressors Page | 1

Engr. Ruel B. Cabahug
 Bataan Heroes College
Reciprocating air compressors

Reciprocating air compressors are positive displacement machines, meaning that they
increase the pressure of the air by reducing its volume. This means they are taking in successive
volumes of air which is confined within a closed space and elevating this air to a higher pressure.
The reciprocating air compressor accomplishes this by a piston within a cylinder as the
compressing and displacing element.

 Single-stage reciprocating compressors are generally used for pressures in the range of 70
psig to 100 psig.

 Two-stage reciprocating compressors are generally used for higher pressures in the range
of 100psig to 250 psig.

Note:

 1 hp ~ 4 cfm at 100 psi

 1 ~ 5 hp are typically for reciprocating units. Compressors 100 hp and above are
typically rotary screw or centrifugal compressors.

Reciprocating air compressor is single acting when the compressing is accomplished

using only one side of the piston. A compressor using both sides of the piston is considered
double acting.

Load reduction is achieved by unloading individual cylinders. Typically this is

accomplished by throttling the suction pressure to the cylinder or bypassing air either within or
outside the compressor. Capacity control is achieved by varying speed in engine-driven units
through fuel flow control.

Reciprocating air compressors are available either as air-cooled or water-cooled in

lubricated and non-lubricated configurations and provide a wide range of pressure and capacity
selections.

Module 4: Gas Compressors Page | 2

Engr. Ruel B. Cabahug
 Bataan Heroes College
Rotary screw compressors

Rotary air compressors are positive displacement compressors. The most common rotary
air compressor is the single stage helical or spiral lobe oil flooded screw air compressor. These
compressors consist of two rotors within a casing where the rotors compress the air internally.
There are no valves. These units are basically oil cooled (with air cooled or water cooled oil
coolers) where the oils seals the internal clearances.

Since the cooling takes place right inside the compressor, the working parts never
experience extreme operating temperatures. The rotary compressor, therefore, is a continuous
duty, air cooled or water cooled compressor package.

Centrifugal compressors

Centrifugal air compressor is a dynamic compressor which depends on transfer of energy

from a rotating impeller to the air.

Centrifugal compressors produce high-pressure discharge by converting angular

momentum imparted by the rotating impeller (dynamic displacement). In order to do this
efficiently, centrifugal compressors rotate at higher speeds than the other types of compressors.
These types of compressors are also designed for higher capacity because flow through the
compressor is continuous.

Adjusting the inlet guide vanes is the most common method to control capacity of a
centrifugal compressor. By closing the guide vanes, volumetric flows and capacity are reduced.

The centrifugal air compressor is an oil free compressor by design. The oil lubricated
running gear is separated from the air by shaft seals and atmospheric vents.

Uses of compressed air

1. Driving and starting air engines (diesel and gas turbines)

2. Driving pneumatic tools (hammer and drills)

3. Spraying paint

Module 4: Gas Compressors Page | 3

Engr. Ruel B. Cabahug
 Bataan Heroes College
4. Cleaning by air blast

5. Operating air hoist

6. Pump water by air lift

7. Air supply for mine tunnel

8. Food processing

9. Liquefying gases

10. Conveying materials

Illustration: Flow diagram:

Figure 3 Single-stage single-acting single cylinder reciprocating

compressor

Figure 2 Single-stage reciprocating compressor

Air compressor – is a device that converts electrical or mechanical power (usually from an
electrical motor, a diesel engine or a gasoline engine) into kinetic energy by
compressing and pressurizing air.

Module 4: Gas Compressors Page | 4

Engr. Ruel B. Cabahug
 Bataan Heroes College

Figure 4 Electric Motor driven air compressor and its part

Types of air compressor

1. Positive-displacement air compressors work by forcing air into a chamber whose

volume is decreased to compress the air. Piston-type air compressors use this principle by
pumping air into an air chamber through the use of the constant motion of pistons. They
use one-way valves to guide air into a chamber, where the air is compressed. Rotary
screw compressors also use positive-displacement compression by matching two helical
screws that, when turned, guide air into a chamber, whose volume is decreased as the
screws turn. Vane compressors use a slotted rotor with varied blade placement to guide
air into a chamber and compress the volume. A type of compressor that delivers a fixed
volume of air at high pressures.

2. Negative-displacement air compressors include centrifugal compressors. These use

centrifugal force generated by a spinning impeller to accelerate and then decelerate
captured air, which pressurizes it.

COMPRESSOR (Definition of terms)

Air receiver A component that stores compressed gas and helps

stockpile a constant supply of pressurized gas.

Module 4: Gas Compressors Page | 5

Engr. Ruel B. Cabahug
 Bataan Heroes College
Axial compressor A type of dynamic compressor in which gas flows parallel
to the rotation of the axis.

Blower The rotors of a lobe compressor. Common blowers have

either 2 or 3 lobes.

Centrifugal compressor A type of dynamic compressor that compresses air and

expels it with a centrifugal force from a rotating wheel with
radial vanes. Centrifugal compressors are often used for
fans and cooling units.

Centrifugal force A force directed outward and away from the center of a
rotating object.

Compressor A component that pressurizes ambient air and directs it into

a pneumatic system.

Crankshaft A rod that spins and drives a piston in a piston compressor.

The crankshaft is powered by a prime mover.

Diesel motor A type of internal combustion engine, controlled by a

throttle, that is often used as a prime mover for mobile
pneumatic applications.

Diffuser A part of a centrifugal compressor that transforms the high-

speed low-pressure gas into higher pressure.

Double-acting compressor A pneumatic actuator that directs energy in both directions.

Dry rotary screw compressor A type of rotary screw compressor that delivers air without
the use of lubrication.

Dynamic compressor A type of compressor that delivers larger volumes of air at

lower pressures. Common types of dynamic compressors
include centrifugal and axial compressors.

Module 4: Gas Compressors Page | 6

Engr. Ruel B. Cabahug
 Bataan Heroes College
Electric motor A machine that converts electricity into mechanical energy
or motion. An electric motor is a type of prime mover for a
pneumatic system.

Flow rate a specification of a compressor that indicates how much air

compressor can move in a certain amount of time. Flow
rate for pneumatic pumps is measured in cubic feet per
minute.

Fluid power Power derived from the motion and pressure of a fluid,
such as water, oil, or air. Hydraulics and pneumatics are
sources of fluid power.

Gas turbine engine A type of rotary engine driven by high-speed gases that
convert the chemical energy into mechanical energy by
internal combustion.

Impeller The rotors of a lobe compressor. Common impellers have

either 2 or 3 lobes.

Intercooler A component that cools air inside a compressor. An

intercooler is a type of heat exchanger that also removes
moisture.

Internal combustion engine A type of engine in which heat energy and mechanical
energy is produced inside the engine. Internal combustion
engines include gas turbines and types of diesel motors.

Liquid ring compressor A type of vane compressor that expels liquid with a
centrifugal force to create a liquid ring that forms a seal.
Liquid ring compressors are dust and oil free but not very
efficient compared to other compressors.

Lobe The portion of a lobe compressor’s impeller that interlocks

and provides the ability to compress air.

Module 4: Gas Compressors Page | 7

Engr. Ruel B. Cabahug
 Bataan Heroes College
Lobe compressor A compressor that derives its pressurizing ability from two
interlocking gear-type rotors called impellers or blowers.

Multi-stage compressor A type of compressor that compresses air to the required

pressure in multiple stages with cooling in between stages.
Multi-stage compressors are often used for higher
pressures.

NTP An abbreviation for normal temperature and pressure.

Operating pressure The pressure at the actual operating point used to specify
the valves, actuators, and other devices.

Piston A rod inside cylinder that is moved by pneumatic pressure.

Piston compressor A pneumatic compressor that uses a piston driven by a

rotating crankshaft to pressurize air in a pneumatic system.

Pneumatic power Power derived from the motion and pressure of a gas, such
as air.

Positive displacement compressor A type of compressor that delivers a fixed volume of air at
high pressures. Common types of positive displacement
compressors include piston compressors and rotary screw
compressors.

Prime mover The component of a pneumatic system that powers the

compressor.

Reciprocating compressor A compressor that derives its pressurizing ability from a

component, usually a piston, that moves back-and-forth.

Revolutions per minute The number of times a component rotates 360°, or in a

complete circle, in one minute. Revolutions per minute
(rpm) is a measurement of speed.

Module 4: Gas Compressors Page | 8

Engr. Ruel B. Cabahug
 Bataan Heroes College
Rotary screw compressor A compressor that derives its pressurizing ability from two
interlocking threaded cylinders. The male-female thread
interaction traps and compresses air.

Rotor The main spinning portion of a rotary compressor.

Single-acting compressor A pneumatic actuator that directs energy in one direction.

Single-stage compressor A type of compressor that compresses air to the required

pressure in a single operation. Single-stage compressors are
often used for lower pressures.

Staging A method that handles the various pressure requirements in

a compressor. Compressors come in single and multiple
stages.

Stator A stationary component used together with a rotating part

in an axial compressor.

STP An abbreviation for standard temperature and pressure.

STP must be specified in a compressor before determining
volume of flow.

Vane A retractable spring-loaded mechanism that extends

radially from the center of a compressor rotor. Vanes strap
and move fluid to an outlet port.

Vane compressor A pneumatic compressor that consists of a rotor mounted

off-center in a circular cavity. As the rotor spins, vanes trap
and compress air.

Water trap A part of an air receiver that traps and drains away the
condensation formed due to reducing the air temperature in
the receiver.

Module 4: Gas Compressors Page | 9

Engr. Ruel B. Cabahug
 Bataan Heroes College
Wet rotary screw compressor A type of rotary screw compressor that delivers air with the
use of oil to lubricate the screws.

Working pressure The maximum pressure used to specify the compressor at

the outlet.

Illustration:

Lobe

Screw

Rotary Liquid ring

Scroll
Positive
displacement Vane

Diaphragm
Compressor types
Reciprocating Double acting

Centrifugal Single acting

Dynamic
Axial

Theoretical work or power needed by a single-stage compressor involving different

compression processes

At the initial state (beginning of compression) of the compressor

𝑃1 𝑉1 ′ = ṁ𝑎 𝑅𝑎 𝑇1

Without pressure drop or valve resistance (ΔPS = 0 and ΔPd = 0)

𝑃1 = 𝑃𝑠 and 𝑃2 = 𝑃𝑑

Without temperature change (ΔTS = 0)

𝑇1 = 𝑇𝑠

Module 4: Gas Compressors Page | 10

Engr. Ruel B. Cabahug
 Bataan Heroes College
and,

𝑃𝑠 𝑉𝑠 𝑃1 𝑉1 ′
= 𝑃𝑉′
𝑇𝑠 𝑇1 1 1

𝑉𝑠 = 𝑉1 ′

1. Isothermal compression (T = C) – ideal process

𝑃2 𝑃2
𝑊𝑐 = −𝑃1 𝑉1 ′ 𝑙𝑛 = −ṁ𝑎 𝑅𝑎 𝑇1 𝑙𝑛
𝑃1 𝑃1

2. Isentropic compression (S = C) – theoretical process

𝑘−1 𝑘−1
𝑘𝑃1 𝑉1 ′ 𝑃2 𝑘 𝑘ṁ𝑎 𝑅𝑎 𝑇1 𝑃2 𝑘
𝑊𝑐 = [( ) − 1] = [( ) − 1]
(1 − 𝑘) 𝑃1 (1 − 𝑘) 𝑃1

3. Polytropic compression (PVn = C) – the process which could be attained in actual

practice

A. Water cooled (n = 1.34 or higher) B. air cooled (n = 1.33 – 1.35)

𝑛−1 𝑛−1
𝑛𝑃1 𝑉1 ′ 𝑃2 𝑛 𝑛ṁ𝑎 𝑅𝑎 𝑇1 𝑃2 𝑛
𝑊𝑐 = [( ) − 1] = [( ) − 1]
(1 − 𝑛) 𝑃1 (1 − 𝑛) 𝑃1

Where:

WC = Theoretical work or power needed by the compressor

V1’ = compressor capacity

P4 = P1 = PS = Absolute suction pressure

P3 = P2 = Pd = Absolute discharge pressure

T3 = T2 = Td = Absolute discharge temperature

Module 4: Gas Compressors Page | 11

Engr. Ruel B. Cabahug
 Bataan Heroes College
T4 = T1 = TS = Absolute suction temperature

ṁa = mass flow rate of air

Ra = gas constant of air

Questions commonly asked in compressor problems:

1. Motor efficiency

𝐵𝑟𝑎𝑘𝑒 𝑃𝑜𝑤𝑒𝑟
Ƞ𝑀 = × 100%
𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑎𝑙 𝑃𝑜𝑤𝑒𝑟

𝐵𝑃
Ƞ𝑀 = × 100%
𝐸𝑃

2. Mechanical efficiency

𝐼𝑛𝑑𝑖𝑐𝑎𝑡𝑒𝑑 𝑃𝑜𝑤𝑒𝑟
Ƞ𝑚 = × 100%
𝐵𝑟𝑎𝑘𝑒 𝑃𝑜𝑤𝑒𝑟

𝐼𝑃
Ƞ𝑚 = × 100%
𝐵𝑃

If the brake power is not directly given, then:

𝐵𝑃 = 𝐼𝑃 + 𝐹𝑃

Since:

Friction Power (FP) = power used to overcome friction in the compressor.

𝐹𝑃 = 0.105(𝑉𝐷 , 𝑓𝑡 3 ⁄𝑚𝑖𝑛)3⁄4 , ℎ𝑝

Where: VD = actual volumetric or piston displacement, ft3 /min

If the compressor is driven by a steam or internal combustion engine the mechanical

efficiency of the system,

𝐼𝑛𝑑𝑖𝑐𝑎𝑡𝑒𝑑 𝑃𝑜𝑤𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑜𝑟

Ƞ𝑚𝑠 = × 100%
𝐼𝑛𝑑𝑖𝑐𝑎𝑡𝑒𝑑 𝑃𝑜𝑤𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑑𝑟𝑖𝑣𝑖𝑛𝑔

Module 4: Gas Compressors Page | 12

Engr. Ruel B. Cabahug
 Bataan Heroes College

𝐼𝑃𝑐
Ƞ𝑚𝑠 = × 100%
𝐼𝑃𝐸

3. Compression efficiency

𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑜𝑟 𝑝𝑜𝑤𝑒𝑟 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑎𝑠 𝑜𝑏𝑡𝑎𝑖𝑛𝑒𝑑 𝑓𝑟𝑜𝑚 𝑎 𝑐𝑜𝑛𝑣𝑒𝑛𝑡𝑖𝑜𝑛𝑎𝑙 𝑑𝑖𝑎𝑔𝑟𝑎𝑚

Ƞ𝑐𝑛 = × 100%
𝐼𝑛𝑑𝑖𝑐𝑎𝑡𝑒𝑑 𝑃𝑜𝑤𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑜𝑟

a. Isothermal compression efficiency

𝑊𝐶 𝑇=𝐶
Ƞ𝑐𝑛 𝑇=𝐶 = × 100%
𝐼𝑃

b. Isentropic compression efficiency

𝑊𝐶 𝑆=𝐶
Ƞ𝑐𝑛 𝑆=𝐶 = × 100%
𝐼𝑃
c. Polytropic compression efficiency,
𝑊𝐶 𝑃𝑉 𝑛 =𝐶
Ƞ𝑐𝑛 𝑃𝑉 𝑛 =𝐶 = × 100%
𝐼𝑃

4. Over-all efficiency or compressor efficiency,

Ƞ𝑐 = Ƞ𝑐𝑛 × Ƞ𝑚 × 100%

𝑊𝑐 𝐼𝑃
Ƞ𝑐 = × × 100%
𝐼𝑃 𝐵𝑃

𝑊𝑐
Ƞ𝑐 = × 100%
𝐵𝑃

5. Actual volumetric efficiency (usual range: 50% – 85%)

𝐴𝑐𝑡𝑢𝑎𝑙 𝑞𝑢𝑎𝑛𝑡𝑖𝑡𝑦 𝑜𝑓 𝑔𝑎𝑠 𝑑𝑒𝑙𝑖𝑣𝑒𝑟𝑒𝑑 𝑜𝑟 𝑠𝑢𝑐𝑘𝑒𝑑 𝑖𝑛

Ƞ𝑉𝐴 = × 100%
𝐼𝑛𝑑𝑖𝑐𝑎𝑡𝑒𝑑 𝑃𝑜𝑤𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑑𝑟𝑖𝑣𝑖𝑛𝑔

𝑉𝐹
Ƞ𝑉𝐴 = × 100%
𝑉𝐷

Where:

VF = volumetric flow rate of free air

Module 4: Gas Compressors Page | 13

Engr. Ruel B. Cabahug
 Bataan Heroes College
Since the actual volumetric or piston displacement (VD) could be determined if the
compressor acting is known,

a. For single acting compressor (suction at the head end of the piston)

Where:

AHE = area of the bore at the head end

π
A HE = ( ) D2
4

L = length of stroke

n
no.of cylinders × no.of acting × 60 × 2 power cycles
NS = ( ),
no.of stroke second

Note:

Reciprocating compressors are always operating at 2-stroke.

n power cycles
NS = (no. of cylinders × no. of acting × ),
60 second

VD = A HELNs

π n
VD = ( D2 ) (L) (no. of cylinders × no. of acting × )
4 60

b. For double acting compressor (suction on both ends of the piston)

Module 4: Gas Compressors Page | 14

Engr. Ruel B. Cabahug
 Bataan Heroes College

If the rod diameter (d) is given:

𝑉𝐷𝑇 = 𝑉𝐷𝐻𝐸 + 𝑉𝐷𝐶𝐸

𝑉𝐷𝑇 = 𝐴𝐻𝐸 𝐿𝑁𝑆 + 𝐴𝐶𝐸 𝐿𝑁𝑆

π π n
𝑉𝐷𝑇 = {( D2 ) + [ (D2 − d2 )]} L (no. of cylinders × no. of acting × )
4 4 60

π 2 n
𝑉𝐷𝑇 = [D + (D2 − d2 )]L (no. of cylinders × 1 × )
4 60

If the rod diameter (d = 0) is not given:

π n
𝑉𝐷𝑇 = (D2 + D2 )L (no. of cylinders × no. of acting × )
4 60

n
𝑉𝐷𝑇 = 2(AHE)L (no. of cylinders × 1 × )
60

n
𝑉𝐷𝑇 = (AHE)L (no. of cylinders × 2 × )
60

Where:

n = rotative speed in rpm

6. Conventional volumetric efficiency

Volume of gas measured at the intake of the conventional card

Ƞ𝑉𝐶 = × 100%
Theoretical Volumetric or Piston displacement

V1 ′
Ƞ𝑉𝐶 = × 100%
VD

Module 4: Gas Compressors Page | 15

Engr. Ruel B. Cabahug
 Bataan Heroes College

1
P n
cVD + VD − cVD ( 2 )
P1
Ƞ𝑉𝐶 = × 100%
VD

1
P2 n
Ƞ𝑉𝐶 = [1 + c − c ( ) ] × 100%
P1

Where:

Clearance

Percent clearance , c = 6% – 12% (usual range)

Clearance ratio

7. Free air – is air at normal atmospheric condition in a given particular geographical location.

If the free air conditions are not given, then let it be at standard condition:

PF = 1 atm (14.7 psia) (101.325 kPa) ; tF = 70 °F (21.11 °C)

The volume of the free air could be determined by using the General Gas Law equation,

𝑃𝐹 𝑉𝐹 𝑃1 𝑉1 ′
=
𝑇𝐹 𝑇1

𝑃1 𝑇𝐹
𝑉𝐹 = 𝑉1 ′ ( ) ( )
𝑃𝐹 𝑇1

The actual volumetric efficiency could also be expressed,

𝑉𝐹
Ƞ𝑉𝐴 = × 100%
𝑉𝐷

𝑉1 ′ 𝑃1 𝑇𝐹
Ƞ𝑉𝐴 = ( ) ( ) ( ) × 100%
𝑉𝐷 𝑃𝐹 𝑇1

Ƞ𝑉𝐴 = Ƞ𝑉𝐶 × Ƞ𝑉𝐹 × Ƞ𝑉𝑇 × 100%

Where:

ȠVC = volumetric efficiency due to clearance

Module 4: Gas Compressors Page | 16

Engr. Ruel B. Cabahug
 Bataan Heroes College
ȠVF = volumetric efficiency due to friction

ȠVT = volumetric efficiency due to thermal change

8. Piston speed, Vp

𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒
𝑆𝑝𝑒𝑒𝑑 =
𝑡𝑖𝑚𝑒

2(𝐿, 𝑚) 𝑚 2(𝐿, 𝑚)(𝑛, 𝑟𝑒𝑣/𝑚𝑖𝑛)

𝑉𝑝 = = 2(𝐿, 𝑚)(𝑛, 𝑟𝑒𝑣/𝑚𝑖𝑛), = , 𝑚/𝑠
1 𝑚𝑖𝑛 60𝑠/𝑚𝑖𝑛
( )
𝑛, 𝑟𝑒𝑣/𝑚𝑖𝑛

Where:

L = length of stroke

n = rotative speed

Stage reciprocating compressor [usually used for pressures 115 psia (780 kPa) up]

– Intercooling between stages can save compressor work or power needed.

A. Two-stage reciprocating compressor

For ideal case:

a. No pressure drop between stages: P2 = Px = P3

b. Perfect intercooling: T 1 = T3

c. WC 1st stage = WC 2nd stage

d. Total theoretical work or power needed by the compressor

WC = WC 1st stage + WC 2nd stage

WC = 2(WC 1st stage) = 2(WC 2nd stage)

Module 4: Gas Compressors Page | 17

Engr. Ruel B. Cabahug
 Bataan Heroes College
Flow diagram:

𝑊𝑐 1𝑠𝑡 𝑠𝑡𝑎𝑔𝑒 = 𝑊𝑐 2𝑛𝑑 𝑠𝑡𝑎𝑔𝑒

𝑃𝑥 = (𝑃𝑠 × 𝑃𝑑 )1⁄2 Intermediate pressure between LP and HP stages

The total theoretical work or power needed by the two-stage reciprocating compressor.

𝑘−1
2𝑘𝑃1 𝑉1 ′ 𝑃𝑑 2𝑘
𝑊𝑐 = [( ) − 1]
(1 − 𝑘) 𝑃𝑠

The percent savings in compressor work or power,

𝑆𝑎𝑣𝑖𝑛𝑔𝑠 𝑖𝑛 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑜𝑟 𝑤𝑜𝑟𝑘 𝑜𝑟 𝑝𝑜𝑤𝑒𝑟

% 𝑆𝑎𝑣𝑖𝑛𝑔𝑠 = × 100%
𝑊𝑠 1 𝑠𝑡𝑎𝑔𝑒

𝑊𝑐 1 𝑠𝑡𝑎𝑔𝑒 − 𝑊𝑐 2 𝑠𝑡𝑎𝑔𝑒
% 𝑆𝑎𝑣𝑖𝑛𝑔𝑠 = × 100%
𝑊𝑐 1 𝑠𝑡𝑎𝑔𝑒

Solving for the amount of cooling water,

𝐻𝑒𝑎𝑡 𝑎𝑏𝑠𝑜𝑟𝑏𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑤𝑎𝑡𝑒𝑟 (𝑄𝑤 ) = 𝐻𝑒𝑎𝑡 𝑔𝑖𝑣𝑒𝑛 𝑜𝑓𝑓 𝑏𝑦 𝑡ℎ𝑒 𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑤𝑎𝑡𝑒𝑟 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑒𝑑 𝑎𝑖𝑟(𝑄𝑎 )

ṁ𝑤 𝐶𝑝𝑤 (𝑡𝑤2 − 𝑡𝑤1 ) = ṁ𝑎 𝐶𝑝𝑎 (𝑇2 − 𝑇3 )

ṁ𝑎 𝐶𝑝𝑎 (𝑇2 − 𝑇3 )
ṁ𝑤 =
𝐶𝑝𝑤 (𝑡𝑤2 − 𝑡𝑤1 )

Module 4: Gas Compressors Page | 18

Engr. Ruel B. Cabahug
 Bataan Heroes College
Where:

T3 = T1

From process 1-2: (S = C)

𝑘−1
𝑇2 𝑃2 𝑘 𝑉1 𝑘−1
=( ) =( )
𝑇1 𝑃1 𝑉2

Two-stage reciprocating compressor with pressure drop in the intercooler

The theoretical work or power needed by the two-stage reciprocating compressor with
pressure drop,

𝑊𝑐 = 𝑊𝑐 1𝑠𝑡 𝑠𝑡𝑎𝑔𝑒 + 𝑊𝑐 2𝑛𝑑 𝑠𝑡𝑎𝑔𝑒

𝑘−1 𝑘−1
𝑘𝑃1 𝑉1 ′ 𝑃2 𝑘 𝑘𝑃3 𝑉3 ′ 𝑃4 𝑘
𝑊𝑐 = [( ) − 1] + [( ) − 1]
(1 − 𝑘) 𝑃1 (1 − 𝑘) 𝑃3

B. Three-stage reciprocating compressor

For ideal case:

a. No pressure drop between stages: P2 = Px = P3; P4 = Py = P5

b. Perfect intercooling: T 1 = T3 = T5

c. WC 1st stage = WC 2nd stage = WC 3rd stage

d. Total theoretical work or power needed by the compressor

WC = WC 1st stage + WC 2nd stage + WC 3rd stage

WC = 3(WC 1st stage)

Module 4: Gas Compressors Page | 19

Engr. Ruel B. Cabahug
 Bataan Heroes College

𝑊𝑐 1𝑠𝑡 𝑠𝑡𝑎𝑔𝑒 = 𝑊𝑐 2𝑛𝑑 𝑠𝑡𝑎𝑔𝑒 = 𝑊𝑐 3𝑟𝑑 𝑠𝑡𝑎𝑔𝑒

𝑘−1 𝑘−1 𝑘−1

𝑘ṁ𝑎 𝑅𝑎 𝑇1 𝑃2 𝑘 𝑘ṁ𝑎 𝑅𝑎 𝑇3 𝑃4 𝑘 𝑘ṁ𝑎 𝑅𝑎 𝑇5 𝑃6 𝑘
[( ) − 1] = [( ) − 1] = [( ) − 1]
(1 − 𝑘) 𝑃1 (1 − 𝑘) 𝑃3 (1 − 𝑘) 𝑃5

𝑃𝑥 𝑃𝑦 𝑃𝑑
= =
𝑃𝑠 𝑃𝑥 𝑃𝑦

The intermediate pressure between LP and IP stage,

1⁄3
𝑃𝑥 = (𝑃𝑠 2 × 𝑃𝑑 )

The intermediate pressure between IP and HP stage,

1⁄3
𝑃𝑦 = (𝑃𝑠 × 𝑃𝑑 2 )

The total theoretical work or power needed by the three-stage reciprocating compressor,

𝑘−1
3𝑘𝑃1 𝑉1 ′ 𝑃2 3𝑘
𝑊𝑐 = [( ) − 1]
(1 − 𝑘) 𝑃1

The percent savings in compressor work or power,

𝑆𝑎𝑣𝑖𝑛𝑔𝑠 𝑖𝑛 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑜𝑟 𝑤𝑜𝑟𝑘 𝑜𝑟 𝑝𝑜𝑤𝑒𝑟

% 𝑆𝑎𝑣𝑖𝑛𝑔𝑠 = × 100%
𝑊𝑐 1 𝑠𝑡𝑎𝑔𝑒

𝑊𝑐 1 𝑠𝑡𝑎𝑔𝑒 − 𝑊𝑐 3 𝑠𝑡𝑎𝑔𝑒𝑠
% 𝑆𝑎𝑣𝑖𝑛𝑔𝑠 = × 100%
𝑊𝑐 1 𝑠𝑡𝑎𝑔𝑒

Three-stage reciprocating compressor with pressure drops in the intercoolers

The total theoretical work or power needed by the three-stage reciprocating compressor
with pressure drops,

𝑊𝑐 = 𝑊𝑐 1𝑠𝑡 𝑠𝑡𝑎𝑔𝑒 + 𝑊𝑐 2𝑛𝑑 𝑠𝑡𝑎𝑔𝑒 + 𝑊𝑐 3𝑟𝑑 𝑠𝑡𝑎𝑔𝑒

Module 4: Gas Compressors Page | 20

Engr. Ruel B. Cabahug
 Bataan Heroes College

𝑘−1 𝑘−1 𝑘−1

𝑘𝑃1 𝑉1 ′ 𝑃2 𝑘 𝑘𝑃3 𝑉3 ′ 𝑃4 𝑘 𝑘𝑃5 𝑉5 ′ 𝑃6 𝑘
𝑊𝑐 = [( ) − 1] + [( ) − 1] + [( ) − 1]
(1 − 𝑘) 𝑃1 (1 − 𝑘) 𝑃3 (1 − 𝑘) 𝑃5

General formula for ideal case

No. of stages Compressor work or power Intermediate pressure

(between 1st and 2nd stage
only)
𝑘−1
𝑘𝑃1 𝑉1 ′ 𝑃𝑑 𝑘
1 𝑊𝑐 = [( ) − 1] _______________
(1 − 𝑘) 𝑃𝑠

𝑘−1
2𝑘𝑃1 𝑉1 ′ 𝑃𝑑 2𝑘
2 𝑊𝑐 = [( ) − 1] 𝑃𝑥 = (𝑃𝑠 × 𝑃𝑑 )1⁄2
(1 − 𝑘) 𝑃𝑠

𝑘−1
3𝑘𝑃1 𝑉1 ′ 𝑃𝑑 3𝑘 1⁄3
3 𝑊𝑐 = [( )
(1 − 𝑘) 𝑃𝑠
− 1] 𝑃𝑥 = (𝑃𝑠 2 × 𝑃𝑑 )

𝑘−1
𝑆𝑘𝑃1 𝑉1 ′ 𝑃𝑑 𝑆𝑘 1⁄𝑠
s 𝑊𝑐 = [( ) − 1] 𝑃𝑥 = (𝑃𝑠 𝑠−1 × 𝑃𝑑 )
(1 − 𝑘) 𝑃𝑠

Where:

P1 V1’ = ṁaRaT1

and,

S = for any number of stages

Module 4: Gas Compressors Page | 21

Engr. Ruel B. Cabahug
 Bataan Heroes College

Sample Problems
1. A single acting air compressor has a volumetric efficiency of 87%, operates at 500 rpm. It
takes in air at 100 kPa and 30 °C and discharges it at 600 kPa. The air handled is 6 m 3 /min
measured at discharge condition. If compression is isentropic, find the mean effective
pressure in kPa.

Given:

Single-acting air compressor

𝜂𝑣𝑐 = 87% ← 𝑎𝑠𝑠𝑢𝑚𝑒 𝑎𝑠 𝑐𝑜𝑛𝑣𝑒𝑛𝑡𝑖𝑜𝑛𝑎𝑙 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦

𝑛 = 500𝑟𝑝𝑚
No pressure drop
𝑃𝑠 = 100𝑘𝑃𝑎
𝑃1 = 𝑃𝑠
𝑡𝑠 = 30°𝐶
𝑃2 = 𝑃𝑑
𝑃𝑑 = 600𝑘𝑃𝑎
𝑘 = 1.4 ← 𝑐𝑜𝑙𝑑 𝑎𝑖𝑟 𝑠𝑡𝑎𝑛𝑑𝑎𝑟𝑑
𝑚3
𝑉2 ′ = 6
𝑚𝑖𝑛

𝑃𝑉 𝑘 = 𝐶 ← 𝑖𝑠𝑒𝑛𝑡𝑟𝑜𝑝𝑖𝑐 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛

Solution:

𝑊𝐶
𝑃𝑚 =
𝑉𝐷

* Solve for WC:

𝑘−1
𝑘𝑃1 𝑉1 ′ 𝑃2 𝑘
𝑊𝑐 = [( ) − 1]
(1 − 𝑘) 𝑃1

* Solve for V1’:

𝑃1 𝑉1 ′𝑘 = 𝑃2 𝑉2 ′𝑘 ← 𝑖𝑠𝑒𝑛𝑡𝑟𝑜𝑝𝑖𝑐 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛

𝑃1 (𝑉1 ′ )1.4 = 𝑃2 (𝑉2 ′ )1.4

Module 4: Gas Compressors Page | 22

Engr. Ruel B. Cabahug
 Bataan Heroes College
𝑃2 (𝑉2 ′ )1.4
(𝑉1 ′ )1.4 =
𝑃1

𝑃2 (𝑉2 ′ )1.4
(𝑉1 ′ )1.4 =
𝑃1

1
𝑃2 (𝑉2 ′ )1.4 1.4
′
𝑉1 = [ ]
𝑃1

1
1.4 1.4
𝑚3
600𝑘𝑃𝑎 (6
𝑚𝑖𝑛 )
𝑉1 ′ =
100𝑘𝑃𝑎
[ ]

𝑚3
𝑉1 ′ = 21.5761
𝑚𝑖𝑛

𝑚3 1.4−1
1.4(100𝑘𝑃𝑎) (21.5761
𝑚𝑖𝑛 ) 600𝑘𝑃𝑎 1.4 1𝑚𝑖𝑛
𝑊𝑐 = [( ) − 1] ×
(1 − 1.4) 100𝑘𝑃𝑎 60𝑠

𝑊𝑐 = 84.1391𝑘𝑊

* Solve for VD:

𝑉1 ′
𝜂𝑣𝑐 = × 100%
𝑉𝐷

𝑉1 ′
𝑉𝐷 =
𝜂𝑣𝑐

𝑚3
21.5761
𝑉𝐷 = 𝑚𝑖𝑛
0.87

𝑚3
𝑉𝐷 = 24.8
𝑚𝑖𝑛

For Mean Effective Pressure:

Module 4: Gas Compressors Page | 23

Engr. Ruel B. Cabahug
 Bataan Heroes College
𝑊𝐶
𝑃𝑚 =
𝑉𝐷

𝑘𝐽 60𝑠
84.1391𝑘𝑊 84.1391 ×
𝑃𝑚 = = 𝑠 1𝑚𝑖𝑛
𝑚3 𝑚3
24.8 24.8
𝑚𝑖𝑛 𝑚𝑖𝑛

𝑃𝑚 = 203.56𝑘𝑃𝑎

2. A single acting reciprocating air compressor has a clearance volume of 10%. Air is received
at 90 kPa and 29.3 °C and is discharged at 600 kPa. The compression and expansion are
polytropic with n = 1.28. the pressure drop is 5 kPa at the suction port and 10 kPa at the
discharge port. The compression piston displacement is 500 cm3 when operating at 900 rpm.
Determine the mass of air compressed in kg per hour.

Given:

Single-acting air compressor

𝑐 = 0.1

𝑃𝑠 = 90𝑘𝑃𝑎

∆𝑃𝑠 = 5𝑘𝑃𝑎

𝑡𝑠 = 𝑡1 = 29.3°𝐶

𝑃𝑑 = 600𝑘𝑃𝑎

∆𝑃𝑑 = 10𝑘𝑃𝑎

𝑃𝑉 𝑛 = 𝐶 ; 𝑛 = 1.28 ← 𝑝𝑜𝑙𝑦𝑡𝑟𝑜𝑝𝑖𝑐 𝑎𝑖𝑟 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛

𝐴𝐻𝐸 (𝐿 ) = 500𝑐𝑚 3

𝑛 = 900𝑟𝑝𝑚

𝑘𝑔
ṁ𝑎 =? ,
ℎ𝑟

Module 4: Gas Compressors Page | 24

Engr. Ruel B. Cabahug
 Bataan Heroes College
Solution:

𝑃1 𝑉1 ′ = ṁ𝑎 𝑅𝑎 𝑇1

𝑃1 𝑉1 ′
ṁ𝑎 =
𝑅𝑎 𝑇1

* Solve for PC:

With pressure drop

𝑃1 = 𝑃𝑠 − ∆𝑃𝑠 ; 𝑃1 ≠ 𝑃𝑠

𝑃1 = 90𝑘𝑃𝑎 − 5𝑘𝑃𝑎

𝑃1 = 85𝑘𝑃𝑎

𝑃2 = 𝑃𝑑 + ∆𝑃𝑑

𝑃2 = 600𝑘𝑃𝑎 + 10𝑘𝑃𝑎

𝑃2 = 610𝑘𝑃𝑎

* Solve for V1’:

𝑉1 ′
𝜂𝑣𝑐 = × 100%
𝑉𝐷

𝑉1 ′ = 𝜂𝑣𝑐 𝑉𝐷

* Solve for 𝜂𝑣𝑐 :

1
P2 n
Ƞ𝑉𝐶 = [1 + c − c ( ) ] × 100%
P1

1
610kPa 1.28
Ƞ𝑉𝐶 = [1 + 0.1 − 0.1 ( ) ] × 100%
85kPa

Ƞ𝑉𝐶 = 0.6337

Module 4: Gas Compressors Page | 25

Engr. Ruel B. Cabahug
 Bataan Heroes College
* Solve for VD:

VD = A HELNs

π n
VD = ( D2 ) (L) (no. of cylinders × no. of acting × )
4 60

1𝑚 3 900𝑟𝑝𝑚
VD = (500𝑐𝑚 3 × ) (1 × 1 × )
(100𝑐𝑚 ) 3 60

𝑚3
VD = 7.5 × 10−3
s

𝑚3
𝑉1 ′ = 0.6337 × 7.5 × 10−3
s

𝑚3
𝑉1 ′ = 4.75275 × 10−3
s

𝑚3
85𝑘𝑃𝑎 (4.75275 × 10−3
s ) 3600𝑠
ṁ𝑎 = ×
𝑘𝐽 1ℎ𝑟
0.287 (29.3°𝐶 + 273)𝐾
𝑘𝑔𝑚 ∙ 𝐾

𝑘𝑔𝑚
ṁ𝑎 = 16.76
ℎ𝑟

3. A single acting reciprocating air compressor has a clearance volume of 10%. Air is received
at 90 kPa and 29.3 °C and is discharged at 600 kPa. The compression and expansion are
polytropic with n = 1.28. the pressure drop is 5 kPa at the suction port and 10 kPa at the
discharge port. The compression piston displacement is 500 cm3 when operating at 900 rpm.
Determine the required compressor power.

* Solve for WC:

𝑛−1
𝑛𝑃1 𝑉1 ′ 𝑃2 𝑛
𝑊𝑐 = [( ) − 1]
(1 − 𝑛) 𝑃1

Module 4: Gas Compressors Page | 26

Engr. Ruel B. Cabahug
 Bataan Heroes College
𝑚3
1.28(85𝑘𝑃𝑎) (4.75275 × 10−3
1.28−1
s ) 610𝑘𝑃𝑎 1.28
𝑊𝑐 = [( ) − 1]
(1 − 1.28) 85𝑘𝑃𝑎

𝑊𝑐 = 0.9954𝑘𝑊

4. A single acting air compressor operates at 150 rpm with an initial condition of air at 97.9 kPa
and 27 °C and discharges the air at 379 kPa to a cylindrical tank. The bore and stroke are 355
mm and 381 mm, respectively, with a 5% clearance. If the surrounding air is at 100 kPa and
20 °C while the compression and expansion processes are PV1.3 = C. Determine the free air
capacity in m3/s.

Given:

Single-acting air compressor

𝑛 = 150𝑟𝑝𝑚

𝑃𝑠 = 𝑃1 = 97.9𝑘𝑃𝑎

𝑡𝑠 = 𝑡1 = 27°𝐶

𝑃𝑑 = 𝑃2 = 379𝑘𝑃𝑎

𝐷 = 355𝑚𝑚 = 0.355𝑚

𝐿 = 381𝑚𝑚 = 0.381𝑚

𝑐 = 5%

𝑃𝐹 = 100𝑘𝑃𝑎

𝑡𝐹 = 20°𝐶

𝑃𝑉 1.3 = 𝐶 ; 𝑛 = 1.3 ← 𝑝𝑜𝑙𝑦𝑡𝑟𝑜𝑝𝑖𝑐 𝑎𝑖𝑟 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛

𝑚3
𝑉𝐹 =? ,
𝑠

Solution:

Module 4: Gas Compressors Page | 27

Engr. Ruel B. Cabahug
 Bataan Heroes College
𝑃1 𝑇𝐹
𝑉𝐹 = 𝑉1 ′ ( ) ( )
𝑃𝐹 𝑇1

* Solve for V1’:

𝑉1 ′
𝜂𝑣𝑐 = × 100%
𝑉𝐷

𝑉1 ′ = 𝜂𝑣𝑐 𝑉𝐷

* Solve for Ƞ𝑉𝐶 :

1
P2 n
Ƞ𝑉𝐶 = [1 + c − c ( ) ] × 100%
P1

1
379kPa 1.3
Ƞ𝑉𝐶 = [1 + 0.05 − 0.05 ( ) ]×1
97.9kPa

Ƞ𝑉𝐶 = 0.9084

* Solve for VD:

VD = A HELNs

π n
VD = ( D2 ) (L) (no. of cylinders × no. of acting × )
4 60

π 150𝑟𝑝𝑚
VD = [ (0.355m) 2 ] (0.381𝑚 ) (1 × 1 × )
4 60

𝑚3
VD = 0.0943
s

𝑚3
𝑉1 ′ = 0.9084 × 0.0943
s

𝑚3
𝑉1 ′ = 0.0857
s

Module 4: Gas Compressors Page | 28

Engr. Ruel B. Cabahug
 Bataan Heroes College
𝑚3 97.9𝑘𝑃𝑎 (20°𝐶 + 273) 𝐾
𝑉𝐹 = 0.0857 ( )[ ]
s 100𝑘𝑃𝑎 (27°𝐶 + 273) 𝐾

𝑚3
𝑉𝐹 = 0.0819
s

5. A single acting air compressor operates at 150 rpm with an initial condition of air at 97.9 kPa and 27
°C and discharges the air at 379 kPa to a cylindrical tank. The bore and stroke are 355 mm and 381
mm, respectively, with a 5% clearance. If the surrounding air is at 100 kPa and 20 °C while the
compression and expansion processes are PV1.3 = C. Determine the power of compressor.

* Solve for WC:

𝑛−1
𝑛𝑃1 𝑉1 ′ 𝑃2 𝑛
𝑊𝑐 = [( ) − 1]
(1 − 𝑛) 𝑃1

𝑚3 1.3−1
1.3(97.9𝑘𝑃𝑎) (0.0857
s ) 379𝑘𝑃𝑎 1.3
𝑊𝑐 = [( ) − 1]
(1 − 1.3) 97.9𝑘𝑃𝑎

𝑊𝑐 = 13.3304𝑘𝑊

6. A 2-stage, double acting, L-type air compressor 16” x 10” x 7”, 600 rpm, has a free air
unloader at each end for capacity control. It is driven through V-belts by a 150 hp electric
motor, 460 V; 3 phase; 60 Hz; 1,200 rpm. Barometric pressure is 125 psi gage. Calculate the
piston displacement in m3 /h.

Given:

2 stage double acting air compressor

𝐷1 = 6𝑖𝑛

𝐷2 = 10𝑖𝑛

𝐿 = 7𝑖𝑛

𝑛 = 600𝑟𝑝𝑚

Module 4: Gas Compressors Page | 29

Engr. Ruel B. Cabahug
 Bataan Heroes College
𝐵𝑃 = 150ℎ𝑝

𝑃𝐹 = 125𝑝𝑠𝑖𝑔

460𝑉

3𝑝ℎ𝑎𝑠𝑒
Motor Specifications
60𝐻𝑧

1200𝑟𝑝𝑚

𝑚3
𝑉𝐷 =? ,
ℎ𝑟

Solution:

* Solve for VD @ first stage:

VD = A HELNs

π n
VD = ( D2 ) (L) (no. of cylinders × no. of acting × )
4 60

rev
π 1ft 2 1ft 600
min 1m3 3600s
VD = (6in × ) (7in × ) (1 × 2 × s ) × ×
4 12in 12in 60 (3.28ft)3 1hr
min

m3
VD = 233.6994
hr

* Solve for VD @ second stage:

VD = A HELNs

π n
VD = ( D2 ) (L) (no. of cylinders × no. of acting × )
4 60

π 1ft 2 1ft 600rpm 1m3 3600s

VD = (10in × ) (7in × ) (1 × 2 × )× 3
×
4 12in 12in 60 (3.28ft) 1hr

Module 4: Gas Compressors Page | 30

Engr. Ruel B. Cabahug
 Bataan Heroes College

m3
VD = 649.1651
hr

Module 4: Gas Compressors Page | 31

Engr. Ruel B. Cabahug
 Bataan Heroes College

Practice Problems

1. The piston displacement of a double acting compressor is 0.358 m3/s, delivers gas from
101.325 kPa and 300 K to 675 kPa at the rate of 0.166 m 3/s at 150 rpm. Value of n for
compression and expansion is 1.33. Find the compressor percent clearance.

2. The piston displacement of a double acting compressor is 0.358 m 3/s, delivers gas from
101.325 kPa and 300 K to 675 kPa at the rate of 0.166 m 3/s at 150 rpm. Value of n for
compression and expansion is 1.33. Find the bore and stroke assuming bore = stroke.

Module 4: Gas Compressors Page | 32

Engr. Ruel B. Cabahug