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INSTRUCTION MANUAL

FOR

TWIN LOBE COMPRESSOR


TEST RIG

INTRODUCTON:
Compressed air is a source of storing mechanical energy. It is a reversible
procedure where work can be returned with small loss of energy in the form of
heat. A compressor is machine which takes air from atmosphere, compressor it
with aid of some mechanical energy & delivers it to storage vessel. The pressure of
air is increased by reducing volume compressed air then can be taken by pipe
wherever it is required.

APPLICATION:
a. In blast furnace, boiler furnace.
b. Pneumatic tools spray painting, sand blasting.
c. Pneumatic conveying of cement & grains.
d. In construction of large projects, highway & tunnels.
e. Supercharging in IC Engines & gas turbines.
f. Pneumatic brakes & clutches.
g. In air conditioning drying & ventilators

CLASSIFICATION:
A. RECIPROCATING TYPE:
In this type, successive volumes of air or gas are confirmed within closed space
where pressure is increased by reducing the volume characterized for volumetric
capacity & large delivery pressure. For larger pressure ratio, the compression is
carried out in multistaging with intercooler so that the compression process can be
made near to isothermal so as to minimize the work to supplied.
B. ROTATING TYPE:
In this type, air is trapped in the space formed by two manually emerging
surface.Due to which the volume in between surfaces reduces & Pressure
increases.The rotary type compressor are characterized by large volumetric
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capacity & relative low pressure .They are high running compressor. ROOTS,
BLOWERS, SLIDING, CENTRIFUGAL & AXIAL FLOW COMPRESSORS are
rotary compressor.

WORKING OF TWIN LOBE COMPRESSOR:


Figure 1(a) shows Twin lobe compressor. There are two rotors, each having two
lobes, one rotor sets the drive from the motor & the other rotor is driven by the first
by gears external to the casing. The lobes rotor in opposite direction pressurizing
the gas .The lobes have well designed cyclical profiles to give perfect meshing &
leak proof seating between the high pressure space & the low pressure space at all
regular positions. A slight clearance between the meeting lobes avoids wear at
sealing surface.

THEORY:
A volume Vs of the gas at the suction pressure p 1 is trapped between the left hand
rotor & the casing, of shown in figure. This trapped volume of the gas does not
change its stage until this space is opened to the high pressure side. Instantly, some
high pressure gas from the receiver rushes back & mixes irreversibly with the gas
in the blower until the pressure is equalized. The gas is then displaced in to the
receiver.
Figure 1(b) shows p-v diagram for roots blower. The flow gas in to the receiver is
not continuous despite the rotors at uniform speed.
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Work required to drive:

Vap KJ /Cycle
1

There are 4 cycles per revolution in a Twin lobe compressor


Work required to drive,
W= 4Vs (p2-p1) n

KJ/min

4 Vs( p 2 p 1) n
60

KW

Where,
4vs n is the volume of air delivered per minute & n is the speed of rotor in
rev/min.
4vs is the volume of air delivered per revolution.
As the ideal compression process is isentropic, work required for isentropic
compression is,

Wi = 1

p 1 4 Vsn
60

( pp 21 )

-1] KW

Roots Efficiency =

Isentropic work required


ActualWork required

ADVANTAGES OF ROTORY POSITVE DESPLACEMENT TWIN


LOBE COMPRESSOR:
1. Rotary Twin lobe air compressor is a positive displacement, constant volume
machine to operate against varying pressure. With each revolution, the compressor
delivers a metered amount of air measured at inlet conditions. Operating at
constant speed against a constant pressure increases the volume by amount equal to
displacement of the compressor times the increased number of revolutions.
2. Should on the job pressure requirements be less than originally calculated, rotary
positive displacement compressor automatically adjusts to the opening job
pressure. There is no horsepower sacrificed because of overestimated pressure
needs. A rotary positive displacement compressor need not be ported for specific
pressure. It adapts itself immediately to changes in operating conditions avoiding
costly generation of unnecessarily high pressure.
3. Rotary positive Twin lobe compressor are built to the closest tolerance by highly
skilled personnel operating the finest of modern machine tools at our Sinepat
works. Since rotary positive compressor requires no internal lubrication or seal, the
volumetric efficiency is a direct function of good catings, highly accurate
machining & the best in machine tools at our Sinepat Works.
4. Rotary Positive Compressors are available in a complete range of sizes & types
to give the customer the most compact & economical unit possible. The drive shaft
is extended for direct connection to the motor, or to accommodate a multiple VDrive. Units may be assembled with either right or left hand shaft extension.
Vertical units with the shafts parallel in a vertical plane are also available to
facilitate piping & drive lay-out.
5. One of the principal advantages of the rotary positive compressor& gas pump is
that the absence of friction in the impeller chamber makes internal lubrication unnecessary. This permits the delivery of gas or air free from contaminating
lubricants. It is an especially valuable feature in chemical processing & material
agitation application that require minimum contamination.

6. Rotary Positive displacement compressors are engineered & manufactured by


capable & experienced personnel in a modem plant with the latest imported &
H.M.T Machines & also with latest toolings. Production is controlled by close
Inspection, tests & attention to the smallest detail. Reliable field service is
maintained by factory trained personnel. Compressor range in capacity up to
50,000 M3/hr. You are invited to request information on sizes not covered in this
bulletin.
Rotary Positive displacement has two figures eight impellers rotating in opposite
direction. As each lobe of an impeller passes the compressor inlet, it traps a quality
of air equal to exactly one-fourth the displacement of the compressor. This
entrapment occurs four times per revolution, moving the entrained air around the
case to the compressor outlet Ground helical timing gears accurately position the
impellers in relation to each other, maintaining the minute clearances so vital to the
high volumetric efficiency of the rotary positive compressor. Because the
compressor operates with very close internal tolerances, a slight amount of air
escapes past the opening clearances back to the suction side of the compressor.
This leakage, defined as 'slip' is predictable constant volume for any given
compressor at any given pressure. For ease in calculation, this leakage is expressed
in compressor rpm. A standard slip, based on handling air at standard condition,
has been established for each compressor size. For gases having a specific gravity
other than
1.0 the slip will vary & this must be taken into consideration when calculating total
operating speed unit. Compressor is built with the closest possible tolerances to
give highest volumetric efficiency.
7. SPECIAL FEATURES OF ROTARY POSITIVE DISPLACEMENT
COMPRESSOR.
a. Manufactured on imported machines with latest technology.
b. All rotating parts dynamically balanced.
c. Computerized profile of the Impeller for higher efficiency.
d. Helical ground gears for silent operation & longer compressor life.
e. Heavy-duty roller bearing ensure 24 hour continuous trouble free operation.
f. Tested as per British Standard 1571 Part-II
g. Very low maintenance cost.
h.100% oil free air.
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8. CASING: Newly designed one piece style, including extra deep rib section for greater
rigidity under vaccum or pressure since. Every casing is hydraulically tested. In many
of internal inspection & clearance checks
IMPELLERS:
Are accurately machined for close tolerance operation, dynamically balanced for
smooth running & lower bearing loads. I.S. Grade 25 is used in standard model; however,
in higher speeds of compressors, forged/So G. Iron material is used with integral shaft
arrangement.
TIMING GEARS:
Alloy steel, Heat Treated, Helical Ground cut for greater strength & quieter
operation. Helical Gears Fitted with adjustable hub (called locking device) are mounted on
shaft for easy timing setting & easy in dismantling. No hydraulic jack or any Hammering
required ensuring longer life for Bearings.
STEELSHAFT;
Are carefully machined & ground from Chrome Alloy Steel. The ground shafts are
fitted in impellers through interference fit which eliminates torsional deflections & permits
increased ratings & Greater efficiency.
BEARINGS:
Are Heavy duty Roller Spherical, double row, for maximum loading Bearings are
held in machined bearing cartridges Gear & Bearings are fixed axially against shaft
shoulder to control thrust loads & maintain end clearances.
LUBRICATION:
The basic units in the series' features trouble free splash lubrication of a Timing
Gears, Generous size sumps are located in the Gear Case. The oil is poured in the gear
case & high temperature grease is poured in driver & driven cover. To prevent undedutcted
losses of lubricant, the series has been designed with visual indicator at oil end cover.

SPECIFICATIONS:
The technical specifications of the test rig are as follows:
Compressor Unit:
Model

TH - 42

Fabrication Number

220169

Manufacturing Year:

2000

Tested on

14/05/2000.

Free Air Delivery

254.99 m3/hr

Working Pressure

0-3000 mm of WC

RPM

1440

MOTOR:
Power

5 HP

RPM

1440

Volts

440V, 3 PH, 50 Hz,

Type

TEFC

COMPRESSOR TEST RIG:


The Test' Rig Consists of Air Compressor with air suction tank, is fitted with an
orifice to determine the volume flow rate at the inlet side & pitot tube at outlet side
to measure pressure of compressed air. The exit side of the compressor is
connected to reservoir. Energy meter is used to record the power input to motor &
in turn the work required for compression. The control panel houses starter for
motor, main switch, Temperature Indicator.
PRECAUTIONS:
1. The reservoir cum air tank should be emptied before stating the compressor.
2. Orifice should not be blocked otherwise rubber sheet of Air tank will cut
drastically.

Aim: To Determine Roots Efficiency


APPARATUS:
Stop Watch, Tachometer.
SPECIFICATIONS
Max Delivery Pressure

3000 mm of WC

Dia. of Orifice

40 mm.

Coefficient discharge (cd) of surface

0.62

PROCEDURE:
1. Note down barometric pressure in mm of Hg & room temperature in c.
2. Start the compressor.
3. After reaching stable pressure note down manometer reading in mm of water to
obtain intake air pressure.
4. Note down the pressure gauge manometer reading in mm of Hg to determine
outlet air pressure
5. Note the time in sec required for 10 revolutions of energy meter.
7. Repeat the same procedure 3 - 7 for other desired pressure

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OBSERVATION TABLE:
Sr.

Delivery

Manometer

Compressor

Inlet Air

Inlet Air

Time t (sec)

Head Ha in

No

pressure

Reading

speed 1440

Temp

Pressure

for 10 Rev of

metrs. of

(c)

(Bar)

Energy meter

air

(mm)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

WORK REQUIRED FOR ISENTROPIC COMPRESSION.

Wi = 1

Roots Efficiency =

p 1 4 Vsn
60

( pp 21 )

-1]

KW

Isentropic work required


ActualWork required

Calculations of V1
Actual volume of air compressed/sec at room temp & pressure is given by
V1= CdA

2 gHa

Where,
Cd= Coefficient discharge of Orifice
A= area of cross section of Orifice
d2
Dd = 4
2

Where, (D=0.040m)

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g= 9.81 m/sec2
Ha= Equivalent manometer head of air in meters.
Ha is calculated as:

w Hw=a Ha
w= Density of water
Hw=Manometer head of water in mtrs.

a = Density of air
a is calculated by using relation:
PaVa = mRTa

a =

Pa
RTa

Pressure from height of mercury is calculated as


P= Hmmg

m = Density of mercury
Hm = Barometer height of mercury in m
R = Characteristic air constant
Ta = Temperature of intake air k
The atmospheric pressure is calculated as
Pa=

0.760 13600 9.81


103

=101.4 Kpa
Similarly Pd= 117.3 Kpa
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Density of air is now given as


RTa
Pa

101.4 10 3
287 297

= 1.1896 Kg/m3

The Height of Air is given as


Ha =

w Hw
a
10 123 103
1.1896

Calculation:
a) Actual work of compression
Wa=V (P2-P1)
Where,
V=Volume of air handled in cubic m/sec.
P1= Atmospheric pressure in bar.
P2 = Discharge pressure in bar.
b) Isentropic work of compression

Wi = 1

c) Roots Efficiency =

Wa=

p1 V

( pp 21 )

-1]

KJ/S

Isentropic work required


ActualWork required

4 Vs n
(P2-P1)
60
13

4 0.06721404
60

(1.3-1)

= 1.88 KW

Wi= 1

p1 V

1.4
1.41

( pp 21 )

11020.0672

-1]

( 1.31 )

-1]

= 1.83 KW
Roots Efficiency =

Wi
Wa

1.83
1.88

= 97.49 %

Vs =Discharge
= CdA

2 gh

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