PolyLab Engineering Equipment, Miraj

INSTRUCTION MANUAL
TWO STAGE AIR COMPRESSOR TEST RIG
Compressed air has found many applications in now-a-days life, right from inflating automobile tyres to driving pneumatic circuits and tools. Generally, compression process found in single stage compressors in polytropic process, in which pv n = c. For air, value of n is between 1 to 1.4 . For n = 1, compression is isothermal, which is desired, but practically it is not possible, Isothermal compression gives lesser work requirement and cool working of the compressor. Several means are adopted for the compression process to become as near as possible to isothermal, like cooling of cylinder, cold water spray in cylinder or multistage compression. In two stage compression, air is partially compressed in low pressure cylinder. This air is passed through cooler between first stage and second stage so that air at inlet of second temperature completed in than first stage stage. outlet. stage is at lower is

Final

compression are

second

Additionally,

cylinders

also

provided with fins for cooling. This system helps to lower the value of Polytropic index n. Also, as the compressors are provided with clearance volume, two stage compressors can achieve higher volumetric efficiency than single

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stage compressors, because of lower compression ratio per stage. This effect is more pronounced at higher delivery pressures.

THE APPARATUS : The apparatus consists of a two stage air compressor with

intercooler driven by an induction motor. It sucks air from inlet air tank through an orifice and air filter. Compressed air from first stage goes to finned intercooler, where its temperature is lowered and it enters the second stage cylinder. Final compression is completed here and air is then send to the air receiver. For forcing the air over the fins, a fan is mounted over the compressor pulley. SPECIFICATIONS : 1] Compressor -Two cylinder, two stage compressor with finned intercooler, mounted over air receiver, variable speed, L. P. cylinder bore 50 mm, stroke length 70 mm. Max. working pressure 7 Kg/cm 2. Air receiver capacity 145 liters., provided with pressure relief valve, pressure switch and receiver drain cock. 2] Motor - 2 HP, 3-Phase, 1440 rpm induction motor with DOL starter. 3] Measurements Provideda) Air inlet tank with air filter and orifice with water manometer for inlet air volume measurement. Orifice diameter -16 mm.

PolyLab Engineering Equipment, Miraj

b) Multichannel digital temperature indicator for indicating temperatures at various points. c) Energymeter for measurement of input to motor. d) Pressure gauges for intercooler and delivery pressure.

EXPERIMENTAL PROCEDURE : 1) Ensure the presence of sufficient oil in the crankcase of compressor. ( Up to red mark of oil indicator glass ). 2) Fill up water in the manometer upto about half of the height of manometer. 3) Close delivery valve of the compressor and start the compressor. 4) Let the receiver pressure rise upto around 2.5 Kg / cm 2. Now open the delivery valve so that constant delivery pressure of 2 Kg / cm 2 is achieved. 5) Wait for some time and see that delivery pressure remains constant. Note down the observations and complete the observation table. 6) Now close the delivery valve and let pressure rise to about 4.5 Kg/cm
2.

Open the delivery valve and adjust delivery pressure to 4

Kg/cm2 7) Note down all the observations. 8) Repeat the same procedure for different delivery pressures.

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OBSERVATIONS Sr. No Speed (Comp.) (rpm ) Intercooler Pressure Kg/cm 2 Delivery Pressure Kg/cm 2 Atmospheric Temp. T1 Temp. after first stage before intercooler T2' Temp. after intercooler T3' Temp. after second stage 'T4' Manometer difference mm. Time for 10 Amps of energymeter t Sec.

CALCULATIONS : 1] Air Flow Manometer difference, mw = m of water

PolyLab Engineering Equipment, Miraj

1.293 X 273 Density , a = -------------------( 273 + T1 0C) ( Density of air is 1.293 Kg / m
3

Kg / m

at 0 0C, i.e. 273 0 K )

Air volume flow rate ( i.e. free air delivered ) :V 1 = Cd x a x 2 x g x [(mw x (1000 / a) ] x 3600 m Where, Cd = Coefficient of discharge of orifice = 0.64 a = Area of orifice = 2.04 x 10
-4 3

/ hr.

(Orifice 16 mm) m / sec

2

g = Gravitational acceleration = 9.81

2) Swept volume of compressor = /4 x d2 x L x N x 60 d = bore dia., - 50 mm. L = Stroke length, - 70 mm N= Speed of Compressor. (rpm) Volumetric efficiency of the compressor Free air delivered m 3 /hr. = -------------------------------------------------Swept volume of compressor m 3 /hr. m
3

/hr

3) Absolute delivery pressure a ) First stage P 2 = ( Intercooler pressure x 0.981 ) + 1.014 Bar b) Second stage -

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P3 = ( Delivery pressure x 0.981 ) + 1.014 Bar. P 1 , suction pressure is atmospheric , i.e. 1.014 Bar. First stage compression ratio, P2 r 1 = ------P1

P3 And, second stage compression ratio, r 2 = ------P2 Overall Compression ratio , ( Total compression ratio ) P3 r = ------P1 4) Isothermal work done wISO = Pl V1 loge r where, Pl = Suction pressure, = 1.014 x 105 N / m2 V1 = Inlet Volume, m3/Sec 5) Work input to Motor (win ) Let , time required for 10 revolutions of energymeter be t sec & taking motor efficiency as 75 % , N/m2 Joules / Sec ( or watts )

Then motor input , 10 x 3600 win = ---------------- x 1000 x 0.75 watts t x EMC Where, EMC = Energymeter constant = 1600 imp / kw.hr

6) Isothermal efficiency -

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Isothermal work done wiso iso = -------------------------------- = --------- x 100 % work input win

7) Mass Flow rate of air ma = V1 x a Kg/Sec.

Heat rejected to intercooler, hic = ma x cP x ( T2 - T3 ) where, cP = 1 x 103 J/kg . k 8) Polytropic index For Polytropic compression, first stage,
n-1

watts

------n T1 P1 ------ = -----T2 P2 where, P1 & T1 are absolute inlet pressure & temperature and P2 & T2 are absolute outlet pressure & temperature respectively. T1 ----- = T2 n-1 ----n P1 ---P2

log

log

1 ---- = n

log ( T1 / T2) log ( P1/ P2)

similarly, for second stage, 1 ---- = n 1 log ( T3 / T4) log ( P2 / P3)

RESULTS TABLE : Sr. No. Delivery Pressure

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Kg/cm2 r1 r2 r V % iso % Plot the graph compression ratio vs Isothermal efficiency & Volumetric efficiency.

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PRECAUTIONS1. Always check for proper water level in manometer and oil level in compressor before starting the compressor. 2. Proper earthing is necessary for the equipment. 3. Do not temper with settings of pressure relief valve and pressure switch. 4. Run the compressor at least 5 minutes a week. 5. Replace compressor oil every 100 hrs. of operation. 6. Never obstruct the orifice while compressor is working as it will suck the manometer water. 7. Drain the water collected in receiver every 10 hrs. of operation.