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De La Salle University

Mechanical Engineering Department

MECHANICAL ENGINEERING PRINCIPLES AND PRACTICES 3


(LBYME17 Laboratory Manual)

Archie B. Maglaya
Gerardo L. Augusto
Neil Stephen A. Lopez
Arvin H. Fernando
Laurence A. Gan Lim

Revised Edition
April 2016

1
TABLE OF CONTENTS

PREFACE................................................................................................................................................................. II
MECHANICAL ENGINEERING DEPARTMENT LABORATORY POLICIES ....................................................................... III
EXPERIMENT NO. 1................................................................................................................................................. 1

PERFORMANCE TEST OF A CENTRIFUGAL PUMP ..................................................................................................... 1


EXPERIMENT NO. 2................................................................................................................................................. 9
PERFORMANCE TEST OF A AXIAL FLOW PUMP ........................................................................................................ 9
EXPERIMENT NO. 3............................................................................................................................................... 17
PERFORMANCE TEST OF SERIES AND PARALLEL CENTRIFUGAL PUMPS .................................................................. 17
EXPERIMENT NO. 4............................................................................................................................................... 26
PERFORMANCE TEST OF A GEAR PUMP ................................................................................................................ 26
EXPERIMENT NO. 5............................................................................................................................................... 33
PERFORMANCE TEST OF A PELTON WHEEL TURBINE............................................................................................. 33
EXPERIMENT NO. 6............................................................................................................................................... 41

PERFORMANCE TEST OF A FRANCIS TURBINE........................................................................................................ 41


EXPERIMENT NO. 7............................................................................................................................................... 48
PERFORMANCE TEST OF AN AXIAL FLOW TURBINE ............................................................................................... 48

EXPERIMENT NO. 8............................................................................................................................................... 55


PERFORMANCE TEST OF A SINGLE STAGE SINGLE ACTING RECIPROCATING AIR COMPRESSORS ............................ 55

EXPERIMENT NO. 9............................................................................................................................................... 77


PERFORMANCE TEST OF A MULTI-STAGE RECIPROCATING AIR COMPRESSOR (TWO STAGE-SINGLE ACTING AIR
COMPRESSOR) ..................................................................................................................................................... 77
EXPERIMENT NO. 10 ........................................................................................................................................... 100
PERFORMANCE TEST OF AN AXIAL FLOW FAN..................................................................................................... 100
REFERENCES ....................................................................................................................................................... 107

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PREFACE
Mechanical Engineering Laboratory3 (LBYME17) Manual is the third in a series of four Mechanical
Engineering laboratory courses. The prerequisite of LBYME17 is Mechanical Engineering Laboratory 2
(LBYME16) and Fluid Machineries (FLUIMAC).
LBYME17 deals with the analysis and evaluation of performance and characteristic of fluid machines such as
pumps, hydraulic turbines, air compressors and fans. It also deals with the performance test of axial flow
pump, centrifugal pump, pumps connected in series and parallel, and gear pumps. Axial flow, Pelton Wheel
and Francis turbine fall under hydraulic turbines. Air compressors and fans are also discussed.
The set-up of experiments is based on LBYME15. Structural formulas have been included to assist the
students in understanding, identifying and solving problems.
Sincere acknowledgment and warm appreciation is hereby expressed to Dr. Jonathan Dungca, Dean of the
Gokongwei College of Engineering, Mr. John Philip L. Espiloy, Vice President of BlitzPro and former DLSU
Mechanical Engineering student, and the authors and colleagues in the Mechanical Engineering Department
who contributed valuable suggestions.
The Authors would like to express their sincere gratitude to the students of LBYME17, the faculty and
technicians, Mr. Melvin Favila, Mr. Raymond De Ocampo and Mr. Romeo Cruz, who have assisted them in the
revision of this manual.
Sincerest thanks are extended to De La Salle University through the College Research Committee and the
University Research Coordination Office for the funding of this endeavour.
Since this manual is part of continuing technological advancement, the authors would like to encourage both
faculty, technicians, industry practitioners, researchers, graduates and students utilizing this manual to
suggest improvements and recommend further development of this revised edition.

ARCHIE B. MAGLAYA
Graduate Program Coordinator
Mechanical Engineering Department
De La Salle University

GERARDO L. AUGUSTO
Research Coordinator
Mechanical Engineering Department
De La Salle University

NEIL STEPHEN A. LOPEZ


Vice Chair
Mechanical Engineering Department
De La Salle University

ARVIN H. FERNANDO
Power and Thermodynamics Laboratory Coordinator
Mechanical Engineering Department
De La Salle University

LAURENCE A. GAN LIM


Chair
Mechanical Engineering Department
De La Salle University

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MECHANICAL ENGINEERING DEPARTMENT
LABORATORY POLICIES
1. Safety measures in the laboratories must be strictly observed by everyone at all times.
Appropriate personal protective equipment must be worn by the laboratory personnel,
instructors, and students throughout the experiment or shop work. For instance, safety
goggles must always be worn whenever operating machines in the shop and laboratory
gowns must likewise be worn when performing experiments.
2. Only students who are officially enrolled in laboratory courses are allowed to use the
laboratory facilities designated for such courses. Students who intend to use a laboratory
facility for purposes like thesis projects should secure permit from the Coordinator of the
laboratory concerned.
3. Instructors are requested to inform the laboratory Coordinator about any change in the
schedule of a laboratory class at least a day in advance.
4. Laboratory technicians are assigned to assist the instructors in the preparation of
materials and operation of equipment for the duration of the laboratory class.
5. No equipment will be issued nor operated for a laboratory class even during its scheduled
period if the instructor is not present. Conduct of make-up classes which requires
securing a permit from the Coordinator of the laboratory concerned is also covered by
this rule.
6. For students intending to do a make-up work, a permit from the laboratory instructor and
approved by the laboratory coordinator must be secured at least one day before the
performance of the experiment. The student must be duly supervised by the concerned
instructor.
7. All laboratory requisition slips must be accompanied with the borrower’s identification
card. Transfer of equipment to another borrower is not allowed. The person whose name
appears in the requisition slip should be the one to return all borrowed items.
8. All damages and/or losses of items like tools, instruments, and equipment will be
charged to the borrower. If the experiment is performed by a group, replacement cost of a
damaged and/or lost item shall be equally divided among the group members. As much
as possible, damaged and/or lost items shall be replaced with a new one instead of
payment of such item which must be settled at the accounting office.
9. All damages and/or losses of items must be promptly reported either verbally or in
writing to the technician or laboratory Coordinator by the concerned instructor or student.
10. No item like tool or equipment may be taken out of the laboratory premises without the
proper authorization of the concerned laboratory Coordinator. If such item is to be used
outside the campus, a permit must be secured from the Physical Facilities Office properly
endorsed by the concerned instructor and approved by the concerned laboratory
Coordinator and Department Chair.

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11. No modification, repair, or alteration of any equipment in the laboratory is allowed
without a written authorization from the concerned laboratory Coordinator and
Department Chair.
12. Instructors are required to fill-up the Laboratory Status Report at the end of each
laboratory class to report the status of the instruments, equipment, and materials used in
the experiment or shop work and to make recommendations on how to improve
laboratory procedures and/or facilities. This report is submitted to the concerned
laboratory Coordinator for proper action.
Operating manuals of laboratory instruments and equipment are available to borrowers at the
Power and Thermodynamics Laboratory Office.

iv
De La Salle University
Mechanical Engineering Department

Experiment No. 1
Performance Test of a Centrifugal Pump

NAME : ______________________________________

SUBJECT & SECTION : ______________________________________

INSTRUCTOR : ______________________________________

DATE PERFORMED : ______________________________________

DATE DUE : ______________________________________

DATE SUBMITTED : ______________________________________ RATING: _________

REMARKS: ________________________________________________________________________

________________________________________________________________________

________________________________________________________________________
1
Objectives
• To determine the total dynamic head, water power, brake power and efficiency of a
centrifugal pump at different speed and capacities.
• To plot and identify the performance characteristic curve of a centrifugal pump.

Materials and Equipment


• Centrifugal pump – electric motor unit
• Tachometer
• Spring scale
• Venturi meter
• Meter stick
• U-tube manometer
• Set of weights

Experiment Set-up
Figure 1.1 shows the materials and equipment set-up for the performance test of centrifugal pump.

FIGURE 1.1Centrifugal Pump TestSet-up

Theory
The pump industry is one of the biggest in the world. In the United States alone there are over 1,000
manufacturers of pumps producing over a million different models. Next to electric motors, pumps
are the most common equipment found in all types of industrial and power plants including in
heavy machinery. The most highly developed form of pumping machine is the centrifugal pump.
This type of pump is widely used in residential, industrial, institutional, or even in city water
supply. The centrifugal pumps are used for irrigation and drainage works, for fire and house
services, including in large power plants where boiler feed and condenser circulating pumps are
present.

2
Centrifugal pumps are manufactured in a very wide range of sizes and materials. For general
industrial applications typical standard pipe sizes are ranging from 50 mm to 300 mm suction line
and 32 mm to 300 mm discharge line with impeller sizes ranging from 125 to 500 mm. Typical
materials used are either cast iron or bronze for the casing and impeller with stainless steel being
widely preferred for the shaft.
Figure 1.2 shows a cross-section of a volute casing of single suction centrifugal pump. Water passed
through the centre of a rotating impeller with radial channels. Rotation of the impeller imparts
kinetic energy to the water driving it outward with centrifugal force. For the pump to develop a
pressure head, it is necessary that this kinetic energy be converted into pressure energy by means
of a diffuser.

FIGURE 1.2 Typical Cross-section of a Volute Casing Single-Suction Centrifugal Pump

The performance of a centrifugal pump may be expressed in terms of


WP
ηp = BP
(1.1)

where: 𝜂𝜂𝑝𝑝 = pump efficiency

𝑊𝑊𝑊𝑊 = water power or work power


𝐵𝐵𝐵𝐵 = brake power
The amount of power transmitted to the water by the pump is commonly known as the water
power or work power. It can be expressed in the form of
𝑊𝑊𝑊𝑊 = 𝑄𝑄𝑄𝑄ℎ (1.2)

where: 𝑄𝑄 = pump capacity or discharge

𝛾𝛾 = specific weight or weight density of water

ℎ = pump head or total dynamic head

A common method of measuring the discharge flow rate is to restrict the flow by means of a Venturi
tube as shown in Figure 1.3. The pressure tends to decrease as it approaches the throat section of
the Venturi. The velocity at the throat is greater than at the inlet side. If we let the reference line

3
coincides the centreline of Venturi then, the elevation head can be eliminated. The volume flow rate
can be determined by applying continuity, Bernoulli’s and manometer equations simultaneously.

FIGURE 1.3 Venturi tube in a pipe

Using mass conservation and considering the fluid mass density is constant then, the volume flow
rate of Venturi meter can be expressed as
𝑄𝑄 = 𝐴𝐴1 𝑉𝑉1 = 𝐴𝐴2 𝑉𝑉2 (1.3)

where, 𝐴𝐴 and 𝑉𝑉 represent the cross-sectional area and mean velocity, respectively. Calculating the
fluid velocities at desired sections of Venturi yield
4𝑄𝑄 4𝑄𝑄
𝑉𝑉1 = 𝜋𝜋 𝐷𝐷 2 and 𝑉𝑉2 = 𝜋𝜋 𝐷𝐷 2 (1.4)
1 2

Assuming ideal flow condition in Venturi meter then, the Bernoulli’s equation denoted as 𝐻𝐻𝑖𝑖 can be
expressed in the form of pressure head, elevation head and velocity head.
𝐻𝐻1 = 𝐻𝐻2

𝑝𝑝 1 𝑉𝑉12 𝑝𝑝 2 𝑉𝑉22
+ 𝑧𝑧1 + = + 𝑧𝑧2 +
𝛾𝛾 2𝑔𝑔 𝛾𝛾 2𝑔𝑔

Neglecting the elevation heads, the above equation reduced to


𝑝𝑝 1 𝑉𝑉12 𝑝𝑝 2 𝑉𝑉22
+ = + (1.5)
𝛾𝛾 2𝑔𝑔 𝛾𝛾 2𝑔𝑔

However, the manometer equation in a Venturi meter can be determined using fluid static concept
given as
𝑝𝑝1 + 𝛾𝛾(𝑦𝑦 + ℎ𝑚𝑚 ) − 𝛾𝛾𝑚𝑚 ℎ𝑚𝑚 − 𝛾𝛾𝛾𝛾 = 𝑝𝑝2
𝑝𝑝 1 −𝑝𝑝 2 𝛾𝛾𝑚𝑚
𝛾𝛾
= �−1 + 𝛾𝛾
� ℎ𝑚𝑚 (1.6)

where, 𝛾𝛾𝑚𝑚 and ℎ𝑚𝑚 represent the weight density and height of manometer fluid. Combining
equations (1.5), (1.6) and (1.7), eliminating the pressure head difference and velocity components
reduced the equation to
𝑉𝑉22 −𝑉𝑉12 𝛾𝛾
2𝑔𝑔
= � 𝛾𝛾𝑚𝑚 − 1� ℎ𝑚𝑚

4
8𝑄𝑄 2 1 1 𝛾𝛾

𝑔𝑔𝜋𝜋 2 𝜙𝜙 24
− 𝜙𝜙 4 � = � 𝛾𝛾𝑚𝑚 − 1� ℎ𝑚𝑚
1

𝑔𝑔𝜋𝜋 2 ℎ 𝑚𝑚 𝛾𝛾𝑚𝑚 1 1
𝑄𝑄 = � �� − 1���𝐷𝐷 4 − 𝐷𝐷 4 �� (1.7)
8 𝛾𝛾 2 1

However, in an experimental set-up where the U-tube manometer is connected to an orifice meter
and the data reading provides values of volumetric flow rate in L/min then, the use of equation
(1.7) is no longer required.
Now applying Bernoulli’s theorem to a pump, we find that the total dynamic head ℎ is the sum of
the difference in pressure head, velocity head and elevation head which can be rewritten as
𝑝𝑝 𝑑𝑑 −𝑝𝑝 𝑠𝑠 𝑉𝑉𝑑𝑑2 −𝑉𝑉𝑠𝑠2
ℎ=� � + (𝑧𝑧𝑑𝑑 − 𝑧𝑧𝑠𝑠 ) + � �
𝛾𝛾 2𝑔𝑔

where,the subscripts 𝑠𝑠 and𝑑𝑑refer to the suction and discharge sides of the pump, respectively.
The brake power is the power exerted by the electric motor coupled to a pump in delivering a
certain amount of water. We may define brake power as
𝐵𝐵𝐵𝐵 = 2𝜋𝜋𝜋𝜋𝜋𝜋𝜋𝜋 (1.8)

where: 𝐹𝐹 = net brake force

𝑅𝑅 = brake arm or torque arm, and

𝑛𝑛 = shaft rotative speed in rpm

Take note that 𝐹𝐹 can be measured either by force gage or set of weights, R is measured from the
centre of motor shaft to the point where the brake force is applied, and n is determined using
tachometer.

Procedure
1. Make at least 3 set of runs at different speeds of 1,500, 2,000, and 2,500 rpm.
2. For each speed, start with the control valve at discharge fully closed.
3. Have at least six sets of data, which means that there will be six opening of the valve, the last
one with the valve fully open.
4. For every set, the following data are to be gathered: suction pressure, discharge pressure,
pressure difference in the Venturi meter indicated by the manometer, and the brake force.
Remember to keep the rotative speed constant.
5. Plot the pump performance characteristic curve at different speeds mentioned. Plot the pump
performance curves such as total-dynamic head, water power, brake power, and efficiency as
ordinates against the discharge capacity on the same Cartesian coordinate system using
Microsoft Excel.
6. Find the equation of pump head as a function of volume flow rate with maximum exponential
index of three (3).

5
Experimental Data

Diameter of suction pipe =


Diameter of discharge pipe =
Venturi meter size =
Length of brake arm =

TABLE 1.1 Centrifugal Pump Performance Test Data


n T, 𝐵𝐵𝐵𝐵, Q, 𝑝𝑝𝑑𝑑 , 𝑝𝑝𝑠𝑠 , ℎ, 𝑊𝑊𝑊𝑊,
m, kg F, N 𝜂𝜂𝑝𝑝 , %
rpm N-m kW m3/s m of H2O m of H2O m kW

1500

2000

2500

6
Sample Computations

Results and Analysis

Interpret the experimental data statistically as required by the laboratory instructor.

Observations and Recommendations


Present briefly your individual observations and recommendations

Conclusion

7
Questions and Answers (NOTE: Use separate sheet for the answers.)

1. Explain why priming is necessary in centrifugal pumps.


2. What is a foot value? Where is it used and why?
3. What is the importance of having multi-stage pumps?
4. What is the purpose of installing stationary vanes in a centrifugal pump?
5. What are the advantages and disadvantages of a centrifugal pump from a reciprocating pump?
6. A centrifugal pump is constructed so that the suction pressure is read by a gage 2 m below the
pump centre line while the discharge pressure is read by a gage 1.5 above its centre line. The
pipe diameters of suction and discharge lines are 127 mm and 102mm respectively. If the
suction gage reading and discharge gage reading are 203 mm Hg and 207 kPa respectively
when water is pumped at a rate of 0.25 m3/s then, find the power delivered to the fluid.
7. A centrifugal pump discharged 0.025 m3/s against a head of 15 m at 1,400 rpm with an impeller
diameter of 0.45 m. A geometrically similar pump of 30 cm diameter is run at 2,800 rpm.
Calculate the head, discharge and horse power ratio required assuming equal efficiencies
between two pumps.
8. Determine the specific speed of a centrifugal pump running at 1450 rpm which delivers 15 L/s
of water with a head of 12.8 m.
9. A centrifugal pump delivers 20 L/s with a head of 22 m when the impeller speed is 960 rpm.
Determine the corresponding discharge and head, if the impeller speed is increased to 1,450
rpm.
10. Determine a suitable pump for a specific application with a head of 50m, discharge volume flow
rate of 25 L/s, and a shaft speed of 1,450 rpm.

8
De La Salle University
Mechanical Engineering Department

Experiment No. 2
Performance Test of a Axial Flow Pump

NAME : ______________________________________

SUBJECT & SECTION : ______________________________________

INSTRUCTOR : ______________________________________

DATE PERFORMED : ______________________________________

DATE DUE : ______________________________________

DATE SUBMITTED : ______________________________________ RATING: ____________

REMARKS: ________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

9
Objectives
• To determine the water power, brake power and efficiency of an axial flow pump.
• To plot the performance characteristic curve of an axial flow pump.

Materials and Equipment

• Axial Flow Pump-Turbine set with 4-inch impeller diameter


• Venturi meter
• U-tube manometer
• Tachometer
• Spring Scale
• Meter stick

Experiment Set-up
Figure 2.1 shows the materials and equipment set-up for the performance test of axial flow pump.

FIGURE 2.1Axial Flow Pump Test Set-up

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Theory
Axial flow pumps are used to convey or transfer large capacity of fluid at a relatively low head. The
impeller configuration is in fact a propeller type. These pumps develop most of its head by the
lifting action of the blades or vanes on the water. The simplest arrangement for this is shown in
Figure 2.2. It is designed such that the suction and discharge lines of water are along the propeller
axis. The conversion of mechanical energy to pressure energy takes place with little intermediate
production of kinetic energy.

Figure 2.2: Axial flow pump

The efficiency of an axial flow pump is given by


𝑊𝑊𝑊𝑊
𝜂𝜂𝑝𝑝 = (2.1)
𝐵𝐵𝐵𝐵

where: 𝜂𝜂𝑝𝑝 = pump efficiency

𝑊𝑊𝑊𝑊 = water power or work power

𝐵𝐵𝐵𝐵 = brake power

Water power is the amount of energy transmitted to fluid by the pump as a function of time. It can
be expressed in terms of the product of weight density, discharged capacity, and pumped head
given as
𝑊𝑊𝑊𝑊 = 𝑄𝑄𝑄𝑄ℎ (2.2)

where: 𝑄𝑄 = pump capacity or discharge

𝛾𝛾 = specific weight or weight density of water

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ℎ = pump head or total dynamic head.

Brake power is the power input to the pump which can be expressed in the form of

𝐵𝐵𝐵𝐵 = 2𝜋𝜋𝜋𝜋𝜋𝜋𝜋𝜋 (2.3)

where: 𝐹𝐹 = net brake force

𝑅𝑅 = brake arm or torque arm

𝑛𝑛 = shaft rotative speed in rpm

Please take note that the brake force increases as the capacity increases because more power is
required to pump a larger quantity of water.

Procedure
1. Operate the test set as a pump by selecting the “MOTOR” function on the motor generator
switch.
2. Open the valve in the bypass loop and ensure that all manometers are free of air.
3. Open the main valve. Set the runner blades to approximately 15 degrees.
4. Slowly increase the speed of the motor. Perform the experiment at three different shaft speeds
of 1,000, 1,500 and 2,000 rpm.
5. Make at least five sets of reading for every speed. For each speed, determine the brake force,
and the reading on the manometer. Use approximately equal increments in the capacity.
6. Interpret the experimental data statistically as required by the laboratory instructor.
7. Plot the pump performance characteristic curves at different speeds mentioned. Plot the
performance curve such as total dynamic head, water power, brake power and efficiency as
ordinates against volumetric capacity on the same Cartesian coordinate system using Microsoft
Excel.
8. Find the equation of pump head as a function of volume flow rate with maximum exponential
index of three (3).

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Experimental Data

Diameter of suction pipe =


Diameter of discharge pipe =
Venturi meter dimensions =
Brake arm length =

TABLE 2.1a Axial Flow Pump Performance Test Data


Suction and
Discharge Valve Rotative Speed, Venturi Meter
Force, N Discharge ΔP,
Opening rpm Reading, mm Hg
mm Hg

TRENT 1,000

TRENT 1,500

TRENT 2,000

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TABLE 2.1b Axial Flow Pump Performance Test Data
Volume Total
Rotative Speed, Brake Water 𝜂𝜂𝑝𝑝 , %
Torque, N-m Flowrate, Dynamic
rpm Power, kW Power, kW
m3/s Head, m

1,000

1,500

2,000

Sample Computations

14
Results and Analysis
Interpret the experimental data statistically as required by the laboratory instructor.

Observations and Recommendations


Present briefly your individual observations and recommendations

Conclusion

15
Questions and Answers (NOTE: Use separate sheet for the answers.)

1. Differentiate a positive displacement pump from a non-positive displacement or rotor dynamic


pump.
2. Classify a positive displacement pump.
3. Briefly discuss the following design parameters of axial flow pump which are not included in
the preceding theoretical discussions but which directly affect the performance of axial flow-
type impeller
a. Hub ratio c. Chord-spacing ratio
b. Number of vanes d. Vane thickness
4. An axial flow pump delivers 300 L/s at a head of 6 meters when rotating at 2,000 rpm. If the
efficiency is 80% then, how much driving torque is needed by the pump? If the same pump is
used operating at 2,400 rpm then, what would be the head, capacity and power delivered by the
shaft?
5. Explain why an axial flow pump could achieve maximum efficiency with large, slow rotating
impellers rather than small and fast moving ones.
6. What is a mixed flow pump?
7. What is the difference between divergent cone type and volute type mixed-flow pumps?
8. What is the appropriate specific speed of an axial flow pump?
9. With the aid of diagram, discuss the principle of operation of an axial flow pump.
10. Determine the most suitable pump for each of the following applications:

Head, Discharge, Shaft speed,


m L/s rpm
8 15 1450
20 12 1450
2 20 1450

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De La Salle University
Mechanical Engineering Department

Experiment No. 3
Performance Test of Series and Parallel Centrifugal Pumps

NAME : ______________________________________

SUBJECT & SECTION : ______________________________________

INSTRUCTOR : ______________________________________

DATE PERFORMED : ______________________________________

DATE DUE : ______________________________________

DATE SUBMITTED : ______________________________________ RATING: ____________

REMARKS: ________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

17
Objectives
• To determine the water power, brake power and efficiency of centrifugal pumps connected in
series and in parallel.
• To plot the performance characteristic curves of centrifugal pumps connected in series and in
parallel.

Materials and Equipment

• 2 nos. of centrifugal pump-motor sets


• Venturi meter
• Spring scale
• U-tube manometer
• Tachometer
• Meter stick
• Set of weights

Experiment Set-up

Figure 3.1 shows the materials and equipment set-up for the performance test of series and parallel
centrifugal pumps.

FIGURE 3.1Series and Parallel Centrifugal Pumps Test Set-up

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Theory

If a pump is providing too little discharge with the right head then, a second pump may be
connected in parallel to the first will remedy the situation. The parallel arrangement is also used
where there is a variation in the flow demand. For low flow requirements, one pump is closed and
for higher flow demands, the second pump is started. However, care should be taken to avoid
backflow when one of the pumps is shutoff. This can be remedied by having check valves installed
at the pump discharge line.

Two pumps in parallel need not be identical. If the two pumps are not identical, the second pump
should not be started if the operating point is above its shutoff head. If the conditions are
favourable such that they can now run in parallel, their flow will sum up to the same head. The
combined efficiency of pumps connected in parallel yields
𝑊𝑊𝑊𝑊 ∑ 𝑄𝑄𝛾𝛾ℎ
𝜂𝜂𝑝𝑝 = 𝐵𝐵𝐵𝐵
= ∑ 𝐵𝐵𝐵𝐵
(3.1)

where: 𝑊𝑊𝑊𝑊 = total power of pump connected in parallel

∑ 𝐵𝐵𝐵𝐵 = total brake power of pumps connected in parallel

∑ 𝑄𝑄 = total water volumetric flow rate

𝛾𝛾 = weight density of water

ℎ = average total dynamic head of pumps connected


in parallel

If a pump provides the right discharge with too little head then, a similar pump connected in series
is needed so that the output of the first pump is fed directly into the suction side of the second
pump. Combining two pumps in series provides a total dynamic head equivalent to the sum of
heads of two pumps. However, they must have the same volumetric flow rate. The two pumps need
to be identical but they must be able to handle the same discharge. Although, the pumps may also
run at different speeds but, the usual set-up is to pump at the same shaft speed. The combined
efficiency of pumps connected in series is given by
𝑊𝑊𝑊𝑊 𝑄𝑄𝑄𝑄 ∑ ℎ
𝜂𝜂𝑝𝑝 = 𝐵𝐵𝐵𝐵
= ∑ 𝐵𝐵𝐵𝐵
(3.2)

where: 𝑊𝑊𝑊𝑊 = total power of pump connected in series

∑ 𝐵𝐵𝐵𝐵 = total brake power of pumps connected in series

∑ℎ = total dynamic head

𝛾𝛾 = weight density of water

𝑄𝑄 = water volumetric flow rate

19
Procedure
1. Connect the two pumps in series.
2. The pumps are to be tested under two shaft speeds, preferably 1500 and 2000 rpm.
3. Start gathering data with the discharge valve fully closed.
4. Must have at least six sets of data for every speed.The suction and discharged pressures of each
pump, the dynamometer force of each pump, the difference in height of the mercury in the
monometer connected of either Venturi or orifice must be recorded. Make sure that the speed is
constant in all six sets of data.
5. After the test operation, measure the Venturi size, brake or torque arm, static heads of each
pump, and the diameter of the suction and discharge pipes.
6. Repeat procedure 2 to 4 for pumps connected in parallel.
7. Plot the pump performance characteristic curves connected in series and parallel for the speeds
mentioned. Plot the pump performance curves such as total dynamic head, water power, brake
power and efficiency as ordinates against the discharge capacity on the same Cartesian
coordinate system using Microsoft Excel.
8. Find the equation of pump heads as a function of volume flow rate with maximum exponential
index of three (3).

20
Experimental Data

Brake arm =
Venturi meter size =
Discharge pipe diameter =
Suction pipe diameter =

TABLE 3.1a Data of Pumps in Series Connection


Total Total Brake Suctions Pressure in Discharge Pressure in
Shaft Speed Net Brake Force, 𝐹𝐹𝑛𝑛𝑛𝑛𝑛𝑛 in N
Torque,T in Power, BP in m H 2O m H 2O
rpm
Pump 1 Pump 2 N-m KW Pump 1 Pump 2 Pump 1 Pump 2

1500

2000

21
TABLE 3.1b Data of Pumps in Series Connection
Total Dynamic Head, h in m of H2O Venturi meter Total Water
Shaft Speed Discharge, Q, in Pump Efficiency,
reading in mm Power, WP in
rpm h1 h2 ht L/min 𝜂𝜂𝑝𝑝
Hg KW

1500

2000

TABLE 3.2a Data of Pumps in Parallel Connection


Total Brake Suctions Pressure in Discharge Pressure in
Shaft Speed Net Brake Force, 𝐹𝐹𝑛𝑛𝑛𝑛𝑛𝑛 in N Total Torque,
Power, BP in m H 2O m H 2O
rpm T in N-m
Pump 1 Pump 2 KW Pump 1 Pump 2 Pump 1 Pump 2

1500

2000

22
TABLE 3.2b Data of Pumps in Parallel Connection
Total Dynamic Head, h in m of H2O Venturi meter Total Water
Shaft Speed Discharge, Q, in Pump Efficiency,
reading in mm Power, WP in
rpm h1 h2 ht L/min 𝜂𝜂𝑝𝑝
Hg KW

1500

2000

23
Sample Computations

Results and Analysis

Interpret the experimental data statistically as required by the laboratory instructor.

Observations and Recommendations


Present briefly your individual observations and recommendations.

Conclusion

24
Questions and Answers (NOTE: Use separate sheet for the answers.)

1. What is the main difference between pumps connected in series and pumps connected in
parallel?
2. Select the specific speed of pump or pumps required to lift 0.3m3/s of water at 114 m through a
pipe length of 3,000m with 900mm diameter pipe and friction factor of 0.22. The pump
rotational speed is 1,750 rpm. Consider the following cases: Single pump, two pumps in series,
three pumps in series, two pumps in parallel, and three pumps in parallel.
3. A pump is to be installed from a reservoir whose surface elevation is zero to another elevation
of 100m. The 1,500mm diameter suction pipe with friction factor of 0.024 is 300m long and the
300mm discharge pipe with friction factor of 0.02 is 305m long. The pump characteristic curve
at 1000 rpm is defined by h=375 – 20Q2 where h is the pump total dynamic head in feet and Q is
the pump discharge in cubic feet per second. Compute the rate at which this pump will deliver
water under these conditions, assuming the setting is low enough to avoid cavitation.
4. Repeat problem 3 for determining the volumetric flow rate if two pumps are connected in
series.
5. Repeat problem 3 for determining the volumetric flow rate if two pumps are connected in
parallel.

25
De La Salle University
Mechanical Engineering Department

Experiment No. 4
Performance Test of a Gear Pump

NAME : ______________________________________

SUBJECT & SECTION : ______________________________________

INSTRUCTOR : ______________________________________

DATE PERFORMED : ______________________________________

DATE DUE : ______________________________________

DATE SUBMITTED : ______________________________________ RATING: ____________

REMARKS: ________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

26
Objectives
• To study the principle of operation of a gear pump
• To determine the power rating of a gear pump
• To evaluate the efficiency of a gear pump

Materials and Equipment


• Gear pump- motor set
• Set of weights
• Tachometer
• Graduated Cylinder
• Stop watch

Experiment Set-up
Figure 4.1 shows the materials and equipment set-up for the performance test of gear pump.

FIGURE 4.1Gear Pump Test Set-up

Theory
Gear pump is classified as a positive displacement pump. It is used for conveying or transferring of
lubricating oil. The pump has moving boundaries which confined the oil and force it by volume
changes. Figure 4.2 shows oil is admitted through one opening, fills the spaces between the gears,
carries around and squeeze in another outlet by pulsating or periodic flow.

27
FIGURE 4.2 Schematic diagram of gear pump

The total dynamic head of gear pump is given by

𝑝𝑝 𝑑𝑑 −𝑝𝑝 𝑠𝑠 𝑉𝑉𝑑𝑑2 −𝑣𝑣𝑠𝑠2


ℎ= 𝛾𝛾
+
2𝑔𝑔
+ 𝑧𝑧𝑑𝑑 − 𝑧𝑧𝑠𝑠 (4.1)

where: 𝑝𝑝,𝑉𝑉 and 𝑧𝑧 = pressure, velocity and elevation head of gear


pump, respectively
= weight density of oil

The subscripts 𝑑𝑑 and 𝑠𝑠 represent the respective discharge and suction sides of gear pump.

The power output of gear pump can be expressed as

Po = γQh (4.2)

And the power input of gear pump is brake power given by

𝑃𝑃𝐼𝐼 = 𝐵𝐵𝐵𝐵 = 2𝜋𝜋𝜋𝜋𝜋𝜋𝜋𝜋 (4.3)

where: 𝐹𝐹 = net brake load or force due to gravity net

𝑄𝑄 = volumetric flow rate

𝑅𝑅 = length of brake arm

𝑛𝑛 = shaft rotative speed in rpm

28
The gear pump efficiency can be expressed as
Po
ηp = × 100% (4.4)
PI

Procedure
1. Pertinent data should be taken before operating the pump such as specific gravity of oil to be
used in the testing machine, the brake arm length and barometric pressure reading.
2. The gear pump is first set at low speed to start the cycle of oil in the system.
3. Then, the discharge pressure is varied from 80 psi to 180 psi with an increment of 20 psi.
Record the rotative speed of the pump, volume of oil discharge at a given period of time in
second and the net load.
4. Set the pump to high speed and perform the same procedure as described in item no. 3 except
that the discharge pressure is set starting at 100 psi. to 180 psi with an increment of 20 psi.
5. Plot the head developed by the pump and efficiency as ordinates for both speeds as a function
of volume flow rate on the Cartesian coordinate system using Microsoft Excel.
6. Find the equation of pump heads as a function of volume flow rate with maximum exponential
index of three (3).

Experimental Data

Specific gravity of oil =


Length of brake arm =
Height of reservoir =
Height of discharge =

TABLE 4.1a Gear Pump Test data (Low Speed: ______rpm)


Volume
Discharge Input Volume Output
Torque, Time, flow
Pressure, Force, N Power, Discharge, Head, m Power, 𝜂𝜂𝑝𝑝
N-m sec rate,
psi kW ml kW
m3/s
90

100

110

120

130

140

29
TABLE 4.1b Gear Pump Test data (High Speed: ______rpm)
Volume
Discharge Input Volume Output
Torque, Time, flow
Pressure, Force, N Power, Discharge, Head, m Power, 𝜂𝜂𝑝𝑝
N-m sec rate,
psi kW ml kW
m3/s

100

120

140

160

180

Sample Computations

Results and Analysis

Interpret the experimental data statistically as required by the laboratory instructor.

30
Observations and Recommendations
Present briefly your individual observations and recommendations.

Conclusion

31
Questions and Answers (NOTE: Use separate sheet for the answers.)

1. What are the different types of rotary pumps?


2. What are the advantages and disadvantages of using gear pumps?
3. Discuss the principle of operation of a herringbone gear pump and vane pump.
4. What are the advantages of using two-stage adjustable discharge gear pump?
5. Draw a combination of gear and lobe pumps. Discuss its operation and applications.

32
De La Salle University
Mechanical Engineering Department

Experiment No. 5
Performance Test of a Pelton Wheel Turbine

NAME : ______________________________________

SUBJECT & SECTION : ______________________________________

INSTRUCTOR : ______________________________________

DATE PERFORMED : ______________________________________

DATE DUE : ______________________________________

DATE SUBMITTED : ______________________________________ RATING: ____________

REMARKS: ________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

33
Objectives
• To study the principle of operation of a Pelton wheel turbine.
• To determine the water power, brake power, and efficiency of a Pelton turbine.
• To plot the performance characteristic curve of a Pelton wheel turbine.

Materials and Equipment


• Pelton Wheel Turbine Demonstration Unit
• Prony brake
• Stroboscope
• 2 nos. of Force gages
• Flow meter
• Tachometer

Experiment Set-up

Figure 5.1 shows the materials and equipment set-up for the performance test of Pelton wheel
turbine.

FIGURE 5.1Pelton Wheel Turbine Test Set-up

34
Theory
The most successful design of impulse turbine is the Pelton water wheel shown in Fig 5.2. In an
impulse turbine, the total drop in pressure of water takes place in one or more stationary nozzles
and there is no change in pressure of water as it flows through the rotating buckets. If there is only
one nozzle then, only a portion of the bucket is acted on by the water at any one instance. Its
principal feature is a splitter at the middle of the buckets, instead of more cups. Most modern forms
have ellipsoidal buckets which is an improvement over the original design. However, the Pelton
wheel is still the basis of these modern forms. The ellipsoidal buckets also have notches on their
ends in order for the jets to strike more bucket at one time.

FIGURE 5.2Overview of Pelton Wheel

Impulse turbines are usually installed with horizontal shafts and one jet on the wheel. Turbines
with horizontal shaft are of two types, namely the single overhung unit and the double overhung
unit. A single overhung unit has one wheel driving a generator mounted horizontally between two
bearings. If the generator is driven by two wheels, then it is called a double overhung unit.

Turbines may also be installed on vertical shafts. For vertical shaft turbines, two or more jets may
be employed on one wheel to increase the power. The power input to the turbine is known as
waterpower which can be expressed as

𝑊𝑊𝑊𝑊 = 𝑄𝑄𝑄𝑄ℎ (5.1)

where: 𝑄𝑄 = volumetric flow rate

𝛾𝛾 = specific weight of water

ℎ = net head or effective turbine head

The power available at turbine’s shaft is known as brake power in which the torque can be
measured by the prony brake. It is the output power of the rotating turbine which may be utilized
to drive a generator, a pump, or any driven machine. The brake power can be expressed as

35
𝐵𝐵𝑃𝑃 = 2𝜋𝜋𝜋𝜋𝜋𝜋𝜋𝜋 (5.2)

where: 𝐹𝐹 = net brake force

𝑅𝑅 = length of brake arm or torque arm

𝑛𝑛 = turbine shaft speed in rpm

The turbine efficiency is the ratio of power at turbine’s shaft to the power available at turbine’s
inlet which is given by
𝐵𝐵𝐵𝐵
𝜂𝜂𝑡𝑡 = 𝑊𝑊𝑊𝑊 × 100% (5.3)

Procedure
1. Make a series of six constant head test with five loads at each head.
2. Vary the load by increasing the force at the prony brake.
3. Make sure that initial readings are recorded before doing the experiment.
4. Record the shaft’s speed and water volumetric flow rate in each load.
5. With the above measurements, power input, power output, and efficiency are computed.
6. Plot the turbine performance characteristic curve as a function of volume flow rate. Plot the
water power, brake power, and efficiency as ordinates against water volumetric flow rate on
the Cartesian coordinate system using Microsoft Excel.
7. Find the equation of turbine head as a function of volume of flow rate with maximum
exponential index of three (3).

36
Experimental Data

TABLE 5.1aPelton Wheel Turbine Performance Test data


Head, Flow, Force,𝐹𝐹 Speed,
ℎ in psig 𝑄𝑄in m3/s in N 𝑛𝑛in rpm

7.5

L
O
W
12.5
H
E
A
D

17.5

25.0

H
I
G
H

H 30.0
E
A
D

35.5

37
TABLE 5.1bPelton Wheel Turbine Performance Test data
Head, Flow, Force, 𝐹𝐹 Speed,
ℎ in psig 𝑄𝑄 in m3/s in N 𝑛𝑛in rpm

7.5

L
O
W
12.5
H
E
A
D

17.5

25.0

H
I
G
H
30.0
H
E
A
D

35.0

38
Sample Computations

Results and Analysis

Interpret the experimental data statistically as required by the laboratory instructor.

Observations and Recommendations


Present briefly your individual observations and recommendations.

Conclusion

39
Questions and Answers (NOTE: Use separate sheet for the answers.)

1. A Pelton wheel is required to generate 3,750 KW under an effective head of 400m. Find the total
volumetric flow rate and diameter of jet, if the generator and turbine mechanical efficiencies are
95% and 80%, respectively. Let the coefficient of velocity be 0.97 and speed ratio of 0.46. If the
jet ratio is 10 then, determine the synchronous speed at 60 Hz.
2. Why is the Pelton wheel the best suited turbine for high heads above 1500 ft.?
3. The pressure of water at the base of a nozzle of an impulse turbine is 5,000 psi with the velocity
of 25ft/s and jet diameter of 10 in. The velocity coefficient of the nozzle is 0.98. If the efficiency
of turbine wheel is 86% then, find the brake horsepower.
4. A multi-nozzle Pelton wheel is to develop 60,000 hp at 400 rpm under a head of 1,400 ft. How
many nozzles should this turbine have? Specify the wheel diameter using a velocity coefficient
of 0.96.
5. An impulse wheel runs at 500 rpm under a head of 5,330 ft. and produces 25,000 hp. At this
condition, it has a specific speed of 1.74. Investigate the possibility of using a reaction turbine
with a specific speed of 30 for this condition. Is this reasonable?

40
De La Salle University
Mechanical Engineering Department

Experiment No. 6
Performance Test of a Francis Turbine

NAME : ______________________________________

SUBJECT & SECTION : ______________________________________

INSTRUCTOR : ______________________________________

DATE PERFORMED : ______________________________________

DATE DUE : ______________________________________

DATE SUBMITTED : ______________________________________ RATING: ____________

REMARKS: ________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

41
Objectives
• To determine the power input, power output, and efficiency of a reaction turbine.
• To plot the performance characteristic curve of a reaction turbine.

Materials and Equipment


• Reaction turbine demonstration unit
• Stroboscope
• Computer with data acquisition system
• Flow meter
• Pressure sensor
• Force gage sensor
• Rotative speed sensor

Experiment Set-up
Figure 6.1 shows the materials and equipment set-up for the performance test of Francis turbine.

FIGURE 6.1Francis Turbine Test Set-up

42
Theory
Another type of hydraulic turbine is the reaction turbine. A reaction turbine is one in which the
pressure drop takes place in the vanes. The water fills all the runner passages completely and the
velocity varies from inlet to outlet. The entire circumference of a reaction turbine filled with water
and spins due to reaction force rather than a push or impulse. It is smaller than an impulse wheel
for the same power. Reaction turbines are further classified into the Francis type and the Kaplan
type. Francis turbines have vanes which are of the mixed type, while Kaplan turbines are of the
propeller type.

The original design of Francis turbine consists of a radial flow runner where the flow is directed
radially inward by guided vanes. The inner diameter of the runner is almost as large as the outer
diameter so that both entrance and discharge edges of the runner vanes are parallel to the axis of
rotation. The pure radial turbine is no longer built and the modern reaction turbines are of the
mixed flow and axial-flow types. Since the modern types are the outgrowth of the radial unit, they
are generally known as Francis turbines.

However, in this experiment a reaction turbine demonstration unit was used. In a reaction turbine
the fluid is subject to a pressure drop as it flows through the rotor. It allows the pressure energy to
convert into useful work with considerable amount of kinetic energy. In this study, water enters the
rotor via a face seal and discharged tangentially through two (2) nozzles at the periphery of the
rotor. The power supplied to the turbine is the waterpower which can be expressed in the form of

𝑊𝑊𝑊𝑊 = 𝑄𝑄𝑄𝑄ℎ (6.1)

where: 𝛾𝛾 = weight density of water

𝑄𝑄 = volumetric flow rate

𝑃𝑃𝐵𝐵 𝑉𝑉𝐵𝐵2 𝑉𝑉𝐶𝐶2


ℎ = net head given byℎ = � + + 𝑧𝑧𝐵𝐵 � −
𝛾𝛾 2𝑔𝑔 2𝑔𝑔

𝑝𝑝𝐵𝐵 = gage pressure upstream of reaction turbine at point B

𝑉𝑉𝐵𝐵 = absolute velocity upstream of reaction turbine at


point B

𝑧𝑧𝐵𝐵 = elevation head between centre line of reaction


turbine and tailpipe discharge

𝑉𝑉𝐶𝐶 = absolute velocity at tailpipe discharge or downstream


of draft tube

43
The brake power generated at turbine shaft yields

𝐵𝐵𝐵𝐵 = 2𝜋𝜋𝜋𝜋𝜋𝜋𝜋𝜋 (6.2)

where: 𝑅𝑅 = brake arm length equal to 0.405 m

𝐹𝐹 = brake force

𝑛𝑛 = rotational speed of turbine shaft

The efficiency of reaction turbine may be computed using the equation given by
𝐵𝐵𝐵𝐵
𝜂𝜂𝑡𝑡 = 𝑊𝑊𝑊𝑊 × 100% (6.3)

Procedure
1. Use the reaction turbine demonstration unit from ARMFIELD with model no. FM61.
2. Load the FM6X software and select FM61 as the option.
3. Click the pump on button on the software with pump setting of 100%.
4. In each run, introduce a brake control ranging from 10% to 30% with an increment of 5%.
5. Record the rotative speed, force, pressure and volume flow rate in each run.
6. After completing the 1st set, adjust the pump setting to 80% and repeat the process by following
the instructions mentioned in item nos. 4 and 5.
7. Compute the net turbine head, water power, brake power, pump and turbine efficiencies in
each reading.
8. Plot the performance characteristic curve of reaction turbine. Let the water power, brake power
and turbine efficiency as ordinates and should be plotted against water volumetric flow rate on
the Cartesian coordinate system using Microsoft Excel.

44
Experimental Data

Length of brake arm = __________________

TABLE 6.1a Francis Turbine Performance Test (with pump setting of 100%)
Water
Brake Turbine Pressure, Water Brake Turbine
Force, F Power,
Control, Speed, n p Flowrate, Power, BP Efficiency,
N WP
% rpm kPa L/min kW ηt
kW
10
15
20
25
30

TABLE 6.1b Francis Turbine Performance Test (with pump setting of 80%)
Water
Brake Turbine Pressure, Water Brake Turbine
Force, F Power,
Control, Speed, n p Flowrate, Power, BP Efficiency,
N WP
% rpm kPa L/min kW ηt
kW
10
15
20
25
30

Sample Computations

45
Results and Analysis

Interpret the experimental data statistically as required by the laboratory instructor.

Observations and Recommendations


Present briefly your individual observations and recommendations.

Conclusion

46
Questions and Answers (NOTE: Use separate sheet for the answers.)

1. What are the so-called guide vanes in a Francis turbine?


2. A reaction turbine operates under a head of 10 m with a speed of 60 rpm and develops 7460
kW. Investigate the possibility of using an impulse wheel with a specific speed of 3 for this
installation. Is it practical?
3. A 3m diameter reaction turbine is to be operated at 75 rpm under a head of 30m. A 1:5 turbine
model is built and tested in the laboratory. If the model is operated at 460 rpm, under what
head should it be tested to simulate normal operating conditions?
4. The model in problem 3 is operated at 460 rpm under a head of 16 m. It was observed that the
water volumetric flow rate and power of the model were 2 m3/s and 240 kW, respectively.
Calculate the efficiency and shaft torque of the model.
5. A hydraulic turbine runner operates at 160 rpm at a head of 60 m and delivers 18650 kW.
Assuming similar flow conditions and the same specific speed, estimate the power and speed of
this turbine if operated under a head of 67 m.

47
De La Salle University
Mechanical Engineering Department

Experiment No. 7
Performance Test of an Axial Flow Turbine

NAME : ______________________________________

SUBJECT & SECTION : ______________________________________

INSTRUCTOR : ______________________________________

DATE PERFORMED : ______________________________________

DATE DUE : ______________________________________

DATE SUBMITTED : ______________________________________ RATING: ____________

REMARKS: ________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

48
Objectives
• To determine the water power, brake power, and efficiency of an axial flow turbine.
• To plot the performance characteristic curve of an axial flow turbine.

Materials and Equipment


• Axial flow turbine-electric generator unit
• Prony brake and force gage
• Tachometer
• 3 numbers of manometer tubes
• Voltmeter
• Ammeter

Experiment Set-up
Figure 7.1 shows the materials and equipment set-up for the performance test of axial flow turbine.

FIGURE 7.1Axial Flow Turbine TestSet-up

Theory
An axial flow turbine is a type of hydraulic turbine used for low heads which has design turbine
specific speeds in English unit ranging from 100 to 250. An axial flow runner may have adjustable
blades in order to vary the area in proportion to the load. The adjustable axial runner is sometimes
called the Kaplan type. It has a much higher efficiency at part load than the fixed-blade runners. The
water power supplied to axial flow turbine yields

𝑊𝑊𝑊𝑊 = 𝑄𝑄𝑄𝑄ℎ (7.1)

where: 𝛾𝛾 = weight density of water

𝑄𝑄 = volumetric flow rate

49
ℎ = net or effective head

The brake power or shaft power output of axial flow turbine is given by

𝐵𝐵𝐵𝐵 = 2𝜋𝜋𝜋𝜋𝜋𝜋𝜋𝜋 (7-2)

where: 𝐹𝐹 = force applied on the prony brake

𝑅𝑅 = brake arm or torque arm

𝑛𝑛 = shaft rotative speed of the turbine

The electrical power output of generator gives

𝐸𝐸𝐸𝐸 = 𝑉𝑉 × 𝐼𝐼 (7-3)

where, V and I denote the voltage and current produced by electric generator. The axial flow
turbine efficiency is given by
𝐵𝐵𝐵𝐵
𝜂𝜂𝑡𝑡 = 𝑊𝑊𝑊𝑊 × 100% (7-4)

However, the generator efficiency is the ratio of electrical power and brake power.
𝐸𝐸𝐸𝐸
𝜂𝜂𝑡𝑡 = 𝐵𝐵𝐵𝐵 × 100% (7-5)

Procedure
1. Set the rheostat control at “0”.
2. Record the force speed, voltage and current output including the difference in height readings
on the Venturi and axial flow turbine.
3. Compute the water volume flow rate using the combined equation of continuity and Bernoulli’s
equations.
4. Then calculate the effective head of the axial flow turbine by taking the sum of axial flow
differential reading and elevation head.
5. Increase the rheostat setting by 10 until about 8 readings are obtained.
6. Adjust the flow valve to increase the flow and repeat the same procedure.
7. Make another adjustment in the valve to obtain another set of readings.
8. From the gathered data, compute the water power, turbine shaft power, electrical power as
well as turbine and generator efficiencies.
9. Plot the performance characteristic curve of axial flow turbine with water power, brake power,
electrical power and turbine efficiency as ordinates against water volume flow rate on the
Cartesian coordinate system using Microsoft Excel.

50
Experimental Data

Length of torque arm =


Venturi size =

TABLE 7.1a Axial Flow Turbine Performance Test data


Venturi Turbine Voltage Current
Rheostat Force, Speed, Flow,
Diff. Diff. Output, Output,
Setting N rpm m3/s
mm, Hg mm, Hg Volts Amperes
0
10
20
30
40
50
60
70
80
0
10
20
30
40
50
60
70
80
0
10
20
30
40
50
60
70
80

51
TABLE 7.1b Axial Flow Turbine Performance Test data
Generator Turbine Generator
Rheostat Flow, Effective Water Brake
Output, Efficiency Efficiency
Setting m3/s Head, m Power, kW Power, kW
kW Nt, % Ng, %
0
10
20
30
40
50
60
70
80
0
10
20
30
40
50
60
70
80
0
10
20
30
40
50
60
70
80

52
Sample Computations

Results and Analysis

Interpret the experimental data statistically as required by the laboratory instructor.

Observations and Recommendations


Present briefly your individual observations and recommendations.

Conclusion

53
Questions and Answers (NOTE: Use separate sheet for the answers.)

1. What is the purpose of draft tube in a reaction type hydraulic turbine?


2. Why are the blades of axial Kaplan turbine constructed in such a way that its blades angle
setting could be adjusted?
3. An axial flow turbine develops 12 MW under a head of 12.5 m with rotational speed of 95 rpm,
and an efficiency of 90 %. However, a turbine model of 1/10 size operates under a head of 6.5
m. Find the new rotational speed, brake horsepower, efficiency, specific speed and discharge of
the model.
4. It is desired to develop 30,000 HP under a head of 20 m for runners operating at 360 rpm. If
Kaplan turbines with a specific speed of 190 are to be used, how many units are required?
5. A 4 m diameter reaction turbine is to be operated at 75 rpm under a head of 30 m. A model ratio
of 1:5 of this turbine is built and tested in the laboratory. If the model is operated at 460 rpm,
under what head should it be tested to simulate normal operating conditions?

54
De La Salle University
Mechanical Engineering Department

Experiment No. 8
Performance Test of a Single Stage Single Acting Reciprocating
Air Compressors

NAME : ______________________________________

SUBJECT & SECTION : ______________________________________

INSTRUCTOR : ______________________________________

DATE PERFORMED : ______________________________________

DATE DUE : ______________________________________

DATE SUBMITTED : ______________________________________ RATING: ____________

REMARKS: ________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

55
Objectives

• To study the principle of operation for a single-stage reciprocating compressor


• To determine the compressor volumetric capacity, power output and input, volumetric
efficiency, compression efficiency, mechanical efficiency and overall compression efficiency
• To determine the heat transfer on the compressor and aftercoolers

Materials and Equipment


• Air compressor fitted with aftercooler. Use high pressure stage compressor for this
experiment.
• Dynamometer
• Tachometer
• Engine Indicator
• Air Flow meter
• Water flow meter
• Voltmeter
• Ammeter
• Barometer
• Stopwatch
• Air receiver

Experiment Set-up
Figure 8.1 shows the materials and equipment set-up for the performance test of single stage single
acting reciprocating air compressor.

FIGURE 8.1Single Stage Single Acting Reciprocating Air


Compressor Test Set-up

56
Theory
An air compressor is a high pressure power absorbing machine which adds energy to the air. It
operates at a pressure above 50 psi. Air compression is an important process which is applied in
many fields of engineering. Some of its industrial applications are as follows: (a) to drive pneumatic
tools and automatic control devices; (b) to convey solid and powdered materials in pipe line; (c) to
operate reciprocating tools such as riveting hammers, chipping hammers paving breakers and
diggers; (d) to spray paints, oils and insecticides; (e) to operate piston for presses, opening doors
for lifting and clamping; (f) to aerate and agitate liquids; (g) to inflate tires and casing of all types;
(h) also to charge shock absorbers to start large diesel engines and inject fuel in Diesel engine
cylinders; etc. Air compressors can be classified into reciprocating and rotary compressors as
shown in Figure 8.2. Each group can be further classified as follows:

FIGURE 8.2Classifications of Air Compressors

Figure 8.3 represents the major parts of a single-stage single-acting compressor. The construction
of air compressor is similar to a simple steam engine. It consists of a cylinder, piston connecting
rod, crank, crankshaft and a cylinder head. The cylinder head has an intake and discharge valves.
The corresponding PV diagram is also included to describe its cycle of operation.
Referring to Compressor with clearance,

Process 4-1 is defined as suction stroke. In this process, the piston is moving down the cylinder
causing the intake valve to open and a volume of air is admitted into the cylinder.

Process 1-2 is commonly known as compression stroke. The piston starts to move upward and the
pressure begins to rise. In this process, both valves are closed and air is being
compressed and sealed within the cylinder.

Process 2-3 is called the delivery or discharge stroke. In this process, further movement of the
piston along the cylinder is observed. As a result, the pressure of the compressed air
increases reaching the delivery pressure. The pressure of the compressed air forces
the discharge valve to open allowing the compressed air out of the cylinder into a
compressed air receiver.

57
(a)

(b)

(c)

FIGURE 8.3 (a) Reciprocating Air Compressor


(b)Aftercooler
(c) PV and TS Diagrams of Single-Stage Single Acting Air Compressor

58
Process 3-4 is the expansion stroke. This process is an expansion of the compressed air left in the
cylinder clearance space.

Compression process could be done isentropically, isothermally and polytropically. The amount of
power on the air depends on the compression curve. If compression is done rapidly and assured to
be no heat is being transferred then, it will be practically isentropic. If compression occurs slowly at
constant temperature then, it will approach isothermal condition. However, polytropic process is
usually considered in actual practice. Neither the isentropic and isothermal compression conditions
can be achieved. Actual compression lies between isentropic and isothermal.

A. Theoretical or Ideal Power for a Single-Stage Reciprocating Air Compressor

(a) Polytropic compression (i.e., 𝑝𝑝𝑉𝑉 𝑛𝑛 = 𝑐𝑐) for water jacketed air compressor
(𝑛𝑛−1)⁄𝑛𝑛
𝑛𝑛𝑚𝑚 ′ 𝑅𝑅𝑅𝑅 𝑝𝑝
Power of polytropic compressor = (𝑛𝑛−1)
�� 2 � − 1�
𝑝𝑝 1

(𝑛𝑛−1)⁄𝑛𝑛
𝑛𝑛𝑝𝑝 𝑉𝑉 ′
1 1 𝑝𝑝
= (𝑛𝑛−1) �� 2 � − 1� (8.1)
𝑝𝑝 1

(b) Isentropic compression (i.e., 𝑝𝑝𝑉𝑉 𝑘𝑘 = 𝑐𝑐) for perfectly insulated air compressor
(𝑘𝑘−1)⁄𝑘𝑘
𝑘𝑘𝑚𝑚 ′ 𝑅𝑅𝑅𝑅 𝑝𝑝
Power of isentropic compressor = (𝑘𝑘−1)
�� 2 � − 1�
𝑝𝑝 1

(𝑘𝑘−1)⁄𝑘𝑘
𝑘𝑘𝑝𝑝 𝑉𝑉 ′
1 1 𝑝𝑝
= (𝑘𝑘−1) �� 2 � − 1� (8.2)
𝑝𝑝 1

(c) Isothermal compression (i.e., 𝑝𝑝𝑝𝑝 = 𝑐𝑐) for perfectly cooled air compressor
𝑝𝑝 1 𝑝𝑝 1
Power of isothermal compressor = 𝑚𝑚 ′ 𝑅𝑅𝑇𝑇1 ln = 𝑝𝑝1 𝑉𝑉1 ln (8.3)
𝑝𝑝 2 𝑝𝑝 2

where: 𝑝𝑝1 = absolute pressure of air at start of compression

𝑉𝑉1′ = volume of air drawn in corresponding to mass m, air


capacity of compressor or theoretical piston
displacement

𝑉𝑉1 = total volume of air at the end of suction

T1 = absolute temperature of air at start of compression

p2 = absolute pressure of air at the end of compression

V2 = volume of air at the end of compression

T2 = absolute temperature of air at the end of


Compression

m′ = mass of air drawn from compressor cylinder

59
mc = mass of residual air or mass of air in the clearance
volume

Cpa = specific heat of air at constant pressure

Cva = specific heat of air at constant volume

n = Polytropic index

k = isentropic gas constant = 𝐶𝐶𝑝𝑝𝑝𝑝 ⁄𝐶𝐶𝑣𝑣𝑣𝑣

𝑚𝑚1 = 𝑚𝑚 ′ + 𝑚𝑚𝑐𝑐 = total mass of air after suction

B. Efficiency of a Reciprocating Compressor

1. Mechanical Efficiency denoted as (𝜂𝜂𝑚𝑚 ) takes into account the effect of bearing friction and
other losses during the operation of air compressor.

(a) Engine Driven Air Compressor


Indicated power of compressor
ηm = Indicated power of driving engine
(8.4)

(b) Motor Driven Air Compressor


Indicated power of compressor
ηm = Brake power input to compress or
(8.5)

where: Indicated Power of Air Compressor = pmi LANn (8.6)


𝑎𝑎×𝑠𝑠
Indicated mean effective pressure = 𝑙𝑙
(8.7)

𝑝𝑝𝑚𝑚𝑚𝑚 = indicated mean effective pressure

L = length of piston stroke or stroke

A = Cross-sectional area of the cylinder or cross-sectional


area of piston

𝑁𝑁 = compressor rotative speed

𝑛𝑛 = number of compressor cylinder

𝑎𝑎 = area of indicator card

𝑠𝑠 = spring scale

𝑙𝑙 = length or height of indicator card

60
2. Compression Efficiency is the ratio of theoretical compressor power required to compress
all the air delivered by the compressor to the power developed in the air compressor
cylinder.

(a) Polytropic Compression Efficiency


𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝
𝜂𝜂𝑝𝑝 = 𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 𝑜𝑜𝑜𝑜 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐
(8.8)

(b) Isentropic Compression Efficiency


𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝
𝜂𝜂𝑐𝑐 = 𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 𝑜𝑜𝑜𝑜 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐
(8.9)

(c) Isothermal Compression Efficiency


𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼 ℎ𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝
𝜂𝜂𝑡𝑡 = 𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 𝑜𝑜𝑜𝑜 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐
(8.10)

3. Overall Efficiency is the product of mechanical and compression efficiencies.

Mechanical Compression
Overall Efficiency = × (8.11)
Efficiency Efficiency

(a) Polytropic Overall Efficiency

Mechanical Polytropic Compression


ηop = ×
Efficiency Efficiency

Indicated power of compressor Polytropic compressor power


ηop = Brake power input to compressor
× Indica ted power of compressor

Polytropic compressor power


ηop = Brake power input to compressor
(8.12)

(b) Isentropic Overall Efficiency

Mechanical Isentropic Compression


ηoc = ×
Efficiency Efficiency
Indicated power of compressor Isentropic compressor power
ηoc = Brake power input to compressor
× Indicated power of compressor

Isentropic compressor power


ηoc = Brake power input to compressor
(8.13)

61
(c) Isothermal Overall Efficiency

Mechanical Isothermal Compression


ηot = ×
Efficiency Efficiency

Indicated power of compressor Isothermal compressor power


ηot = Brake power input to compressor
× Indicated power of compressor

Isothermal compressor power


ηot = Brake power input to compressor
(8.14)

4. Volumetric Efficiency is the ratio of volume of fresh air at atmospheric condition taken in
during the suction stroke to the full piston displacement.
𝑉𝑉 ′ 𝑝𝑝 1⁄𝑛𝑛
𝜂𝜂𝑣𝑣 = 𝑉𝑉1 = 1 + 𝑐𝑐 − 𝑐𝑐 �𝑝𝑝 2 � (8.15)
𝐷𝐷 1

where:

V1′ = Volume of fresh air at atmospheric condition corresponding to mass m’ or theoretical


piston displacement

m ′ RT 1
V1′ = (8.16)
p1

𝑉𝑉𝐷𝐷 = Piston displacement or actual piston displacement

𝑉𝑉𝐷𝐷 = 𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿 (8.17)

𝑅𝑅 = specific gas constant of air

𝑐𝑐 = percent clearance

C. Heat transfer in a Reciprocating Compressor

1. Heat transfer from the air during compression

(a) Polytropic Compression

𝑄𝑄𝑝𝑝 = 𝑚𝑚𝑎𝑎 𝑐𝑐𝑛𝑛 (𝑇𝑇1 − 𝑇𝑇2 ) (8.18)

where: ma = mass flow rate of compressed air

𝑐𝑐𝑛𝑛 = polytropic specific heat of air

𝑐𝑐𝑣𝑣𝑣𝑣 = specific heat of air at constant volume


𝑘𝑘−𝑛𝑛
cn = cva � 1−𝑛𝑛 � (8.19)

62
(b) Isentropic Compression
𝑄𝑄𝑐𝑐 = 0 (8.20)

(c) Isothermal Compression

𝑄𝑄𝑡𝑡 denotes isothermal compressor power which is given by


𝑝𝑝1
𝑄𝑄𝑡𝑡 = 𝑚𝑚 ′ 𝑅𝑅𝑇𝑇1 ln
𝑝𝑝2
p
Qt = p1 V1′ ln p 1 (8.21)
2

2. Heat transfer to cylinder jacket cooling water during compression

𝑄𝑄𝑗𝑗𝑗𝑗 = 𝑚𝑚𝑗𝑗𝑗𝑗 𝑐𝑐𝑝𝑝𝑝𝑝𝑝𝑝 (𝑇𝑇𝑎𝑎 − 𝑇𝑇𝑏𝑏 ) (8.22)

where: mjw = Cylinder jacket cooling water mass flow rate

𝑐𝑐𝑝𝑝𝑝𝑝𝑝𝑝 = specific heat of cylinder jacket cooling water at


constant pressure

𝑇𝑇𝑏𝑏 = absolute temperature of cylinder jacket cooling water


leaving air compressor

𝑇𝑇𝑎𝑎 = absolute temperature of cylinder jacket cooling water


entering air compressor

D. Heat transfer in the aftercooler. Air Compressors are usually supplied with jacket cooling
water and sometimes it is fitted with an aftercooler. An aftercooler is used to cool the
compressed air. The heat transfer in the aftercooler is of sensible type.

1. Heat rejected by the compressed air

𝑄𝑄𝑎𝑎 = 𝑚𝑚𝑎𝑎 𝑐𝑐𝑝𝑝𝑝𝑝 (𝑇𝑇1 − 𝑇𝑇0 ) (8.23)

where: ma = mass flow rate of compressed air

𝑐𝑐𝑝𝑝𝑝𝑝 = specific heat of air at constant pressure

𝑇𝑇0 = absolute temperature of air leaving the aftercooler

𝑇𝑇1 = absolute temperature of air entering the aftercooler

63
2. Heat absorbed by the cooling water

𝑄𝑄𝑤𝑤 = 𝑚𝑚𝑤𝑤 𝑐𝑐𝑝𝑝𝑝𝑝 (𝑇𝑇𝑐𝑐 − 𝑇𝑇𝑑𝑑 ) (8.24)

where: mw = mass flow rate of cooling water

𝑐𝑐𝑝𝑝𝑝𝑝 = specific heat of cooling water at constant pressure

𝑇𝑇𝑑𝑑 = absolute temperature of water leaving aftercooler

𝑇𝑇𝑐𝑐 = absolute temperature of water entering aftercooler

Note:

(a) Air flow meter to be used consists of 1.256 in. sharp edges orifice.

(b) The water flow meter is a Reynolds column type. The water volumetric flow rate
equations are given below.
(1) Jacket cooling water volumetric flow rate for high pressure stage compressor

𝑉𝑉𝑗𝑗𝑗𝑗 = 0.675ℎ 0.54 , gal/hour (8.25)

(2) Jacket cooling water volumetric flow rate in the after cooler where, h indicates head
of water in inches.

𝑉𝑉𝑗𝑗𝑗𝑗 = 0.704ℎ 0.54 , gal/hour (8.26)

(c) Air volumetric flow rate

𝑉𝑉𝑎𝑎 = 𝐶𝐶𝑑𝑑 𝐴𝐴0 𝑉𝑉0 (8.27)

𝑉𝑉0 = �2𝑔𝑔ℎ𝑎𝑎 (8.28)


𝜌𝜌 𝑤𝑤 ℎ 𝑤𝑤
ℎ𝑎𝑎 = 𝜌𝜌 𝑎𝑎
(8.29)

𝑝𝑝 𝑎𝑎
𝜌𝜌𝑎𝑎 = (8.30)
𝑅𝑅𝑇𝑇𝑎𝑎

where: Cd = coefficient of discharge

A0 = cross-sectional area of orifice

𝑉𝑉0 = velocity of air passing through the orifice

ha = head of air

ρw = density of water

64
hw = head of water

ρa = density of air

pa = absolute pressure of surrounding air

𝑇𝑇𝑎𝑎 = absolute temperature of surrounding air

(d) Brake power of driving motor shaft


FN
BPm = 5000 , hp (8.31)

where: F = dynamometer load, lb.

N = motor rotational speed, rpm

(e) Brake power input to air compressor where, 𝜂𝜂𝐵𝐵 means efficiency of belt drive.

BPi = ηB BPm (8.32)

Procedure
1. Set the three valves such that the operation is a single stage compression with after cooling.
2. Adjust cooling water flow to give readings between 4 and 10 in (10 and 25 cm) on the flow
meters.
3. Operate the compressor lever in the compressor.
4. Set speed control to “resistance in”.
5. Start up the compressor by slowly operating the starters.
6. As air receiver pressure approaches desired value, gradually open throttling valve to give
constant air receiver pressure. The correct setting of the throttling valve to give constant air
receiver pressure will give approximately the same pressure drop across the British Standard
nozzle as across the inlet orifice.
7. Have at least three or more different pressure readings at the air receiver tank and take
necessary data for every five minutes intervals for the duration of twenty minutes for each set.
8. Set speed of the machine and air receiver pressure to desired values and run for at least ten
minutes to attain stable conditions before taking results.
9. Throttle valve should be manned, making periodical small adjustments to ensure constant air
receiver pressure.

65
Experimental Data

A. Technical Data

HIGH PRESSURE STAGE COMPRESSOR (2nd stage)

No. of cylinder =
Bore diameter = mm
Length of stroke = mm
Swept volume = m3
Speed range =
Maximum Delivery pressure = kPag
Speed ratio, motor/compressor
=
Efficiency of belt drive = %
Maximum power consumption
= kW
Maximum cooling water flow = m3/s
Maximum free air delivery = m3/s
Volume of air receiver = m3

B. Performance Data

Barometric pressure = kPa


Room temperature = ᵒC
Engine Indicator (spring scale) = kPa/mm

66
I. RUN NO. 1: Discharge Pressure (Air Receiver Pressure) = 345 kPa gage
Air Receiver Temperature = _______________⁰C

TABLE 8.1a Single Acting Single Stage Reciprocating Air Compressor Performance Test data
Driving Motor Indicator Card
Time, Supply Supply Dynamometer
Area, Length,
min Voltage, Current, load, N Pmi, kPa
mm2 mm
Volts Amperes

10

15

20

Average

TABLE 8.1b Single Acting Single Stage Reciprocating Air Compressor Performance Test data

AIR COMPRESSOR
Time,
min AIR CYLINDER JACKET COOLING WATER
Flow, Temperature Temperature Flow, Temperature Temperature
mm H2O in, ⁰C out, ⁰C mm H2O in, ⁰C out, ⁰C

10

15

20

Average

67
TABLE 8.1c Single Acting Single Stage Reciprocating Air Compressor Performance Test data

AFTERCOOLER
Time,
min AIR COOLING WATER
Flow, Temperature Temperature Flow, Temperature Temperature
mm H2O in, ⁰C out, ⁰C mm H2O in, ⁰C out, ⁰C

10

15

20

Average

II. RUN NO. 2: Discharge Pressure (Air Receiver Pressure) = 515 kPa gage
Air Receiver Temperature = _______________ ⁰C

TABLE 8.2a Single Acting Single Stage Reciprocating Air Compressor Performance Test data
Driving Motor Indicator Card
Time, Supply Supply Dynamometer
Area, Length,
Min Voltage, Current, load, N Pmi, kPa
mm2 mm
Volts Amperes

10

15

20

Average

68
TABLE 8.2b Single Acting Single Stage Reciprocating Air Compressor Performance Test data

AIR COMPRESSOR
Time,
min AIR CYLINDER JACKET COOLING WATER
Flow, Temperature Temperature Flow, Temperature Temperature
mm H2O in, ⁰C out, ⁰C mm H2O in, ⁰C out, ⁰C

10

15

20

Average

TABLE 8.2c Single Acting Single Stage Reciprocating Air Compressor Performance Test data

AFTERCOOLER
Time,
min AIR COOLING WATER
Flow, Temperature Temperature Flow, Temperature Temperature
mm H2O in, ⁰C out, ⁰C mm H2O in, ⁰C out, ⁰C

10

15

20

Average

69
III. RUN NO. 3: Discharge Pressure (Air Receiver Pressure) = 690 kPa gage
Air Receiver Temperature = _______________ ⁰C

TABLE 8.3a Single Acting Single Stage Reciprocating Air Compressor Performance Test data
Driving Motor Indicator Card
Time, Supply Supply Dynamometer
Area, Length,
min Voltage, Current, load, N Pmi, kPa
mm2 mm
Volts Amperes

10

15

20

Average

TABLE 8.3b Single Acting Single Stage Reciprocating Air Compressor Performance Test data

AIR COMPRESSOR
Time,
min AIR CYLINDER JACKET COOLING WATER
Flow, Temperature Temperature Flow, Temperature Temperature
mm H2O in, ⁰C out, ⁰C mm H2O in, ⁰C out, ⁰C

10

15

20

Average

70
TABLE 8.3c Single Acting Single Stage Reciprocating Air Compressor Performance Test data

AFTERCOOLER
Time,
min AIR COOLING WATER
Flow, Temperature Temperature Flow, Temperature Temperature
mm H2O in, ⁰C out, ⁰C mm H2O in, ⁰C out, ⁰C

10

15

20

Average

71
AVERAGE RESULTS

A. RUN No: 1 345 kPa gage discharge pressure

Air capacity = m3
Theoretical piston displacement
= m3
Power input to driving motor = kW
Electric motor brake power = kW
Indicated power of air
compressor = kW
Polytropic compressor power = kW
Isentropic compressor power = kW
Isothermal compressor power = kW
Compressor mechanical
efficiency = %
Electric motor efficiency = %
Volumetric efficiency = %

Compression efficiency

a. Polytropic = %
b. Isentropic = %
c. Isothermal = %

Overall efficiency
a. Polytropic = %
b. Isentropic = %
c. Isothermal = %

72
AVERAGE RESULTS

B. Run No: 2 515 kPa gage discharge pressure

Air capacity = m3
Theoretical piston displacement
= m3
Power input to driving motor = kW
Electric motor brake power = kW
Indicated power of air
compressor = kW
Polytropic compressor power = kW
Isentropic compressor power = kW
Isothermal compressor power = kW
Compressor mechanical
efficiency = %
Electric motor efficiency = %
Volumetric efficiency = %

Compression efficiency

a. Polytropic = %
b. Isentropic = %
c. Isothermal = %

Overall efficiency
a. Polytropic = %
b. Isentropic = %
c. Isothermal = %

73
AVERAGE RESULTS

C. Run No: 3 690 kPa gage discharge pressure

Air capacity = m3
Theoretical piston displacement
= m3
Power input to driving motor = kW
Electric motor brake power = kW
Indicated power of air
compressor = kW
Polytropic compressor power = kW
Isentropic compressor power = kW
Isothermal compressor power = kW
Compressor mechanical
efficiency = %
Electric motor efficiency = %
Volumetric efficiency = %

Compression efficiency

a. Polytropic = %
b. Isentropic = %
c. Isothermal = %

Overall efficiency
a. Polytropic = %
b. Isentropic = %
c. Isothermal = %

74
TABLE 8.4 Heat Balances Performance data
Discharge
Heat from the air, kW Heat to cooling water
Pressure,
kPa gage
Compressor After cooler Compressor After cooler

345

515

690

Sample Computations

Results and Analysis

Interpret the experimental data statistically as required by the laboratory instructor.

Observations and Recommendations


Present briefly your individual observations and recommendations.

75
Conclusion

Questions and Answers(NOTE: Use separate sheet for the answers.)

1. Why does air from a reciprocating air compressor contain a certain amount of oil?
2. A single-acting air compressor has a volumetric efficiency of 87 percent and operates at 500
rpm. It takes in air at 100 kPa and 30⁰C. However, air is discharge at 600 kPa. The air handled is
6 m3/min measured at the discharge condition. If the compression is isentropic, find:
a) Piston displacement per stroke in m3
b) Mean effective pressure in kPa
3. A single-stage, single-cylinder air compressor is rated at 425.08 m3/min of free air. The intake
air is 101.325 kPa and 27 ⁰C. It is compressed to 1,033.93 kPa. The compression constant is
1.35
equal to 𝑃𝑃𝑉𝑉 .
a) Find the horsepower required to compress the air.
b) If the overall efficiency of the prime power and air compressor is 83%, what is the horsepower
of the diesel engine required to drive it?
4. Find the dimensions of a single cylinder, double-acing air compressor handling 28 liters per
revolution of air from 100 kPa to 742 kPa. Compression and re-expansion are in accordance
with 𝑝𝑝𝑉𝑉1.35 = C . Use the conventional volumetric efficiency, c = 5% and L/D= 1.
5. There is a required 1900 kW of compressor power to handle air adiabatically from one
atmosphere to 26.7⁰C and 304 kPa. The initial air velocity is 20 m/s and the final velocity is 85
m/s. Find the volumetric flow rate of air handled at inlet conditions per minute.

76
De La Salle University
Mechanical Engineering Department

Experiment No. 9
Performance Test of a Multi-Stage Reciprocating Air
Compressor (Two Stage-Single Acting Air Compressor)

NAME : ______________________________________

SUBJECT & SECTION : ______________________________________

INSTRUCTOR : ______________________________________

DATE PERFORMED : ______________________________________

DATE DUE : ______________________________________

DATE SUBMITTED : ______________________________________ RATING: ____________

REMARKS: ________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

77
Objectives

• To study the principles of operation of a two-stage reciprocating air compressor


• To determine the compressor volumetric capacity, power input and output, volumetric
efficiency, mechanical efficiency, compression efficiency and overall compression efficiency
• To draw up a heat balance analysis on the air compressors and coolers

Materials and Equipment


• Air compressor-motor unit
• Dynamometer set: spring balance and tachometer
• Electrical instruments: voltmeter and ammeter
• Engine indicator
• Barometer
• Stop watches
• Air receiver tank

Experiment Set-up
Figure 9.1 shows the materials and equipment set-up for the performance test of Multi-Stage
Reciprocating Air Compressor (Two Stage-Single Acting Air Compressor).

FIGURE 9.1Multi-Stage Reciprocating Air Compressor (Two Stage-Single


Acting Air Compressor) Test Set-up

78
Theory
Multi-stage air compressors use two or more stages in separate cylinders to compress the air.
These employ intercoolers between stages. The inter-cooling of air may be perfect or imperfect.
This reduces the air temperature which results in a proportionate saving of work, and a
corresponding increase in the isothermal efficiency.
The advantages of multi-stage compression are as follows: a) better mechanical balance and
uniform torque, b) reduced leakage losses, c) lighter cylinders, d) reduced power consumption, e)
increased volumetric efficiency of the compressor, and f) less difficulty in lubrication due to the
lower working temperature.

Figure below (Figure 9.2) shows the PV and TS diagrams of a two-stage reciprocating air
compressor with the high pressure stage superposed on the low pressure stage.

FIGURE 9.2PV and TS diagrams of a Two-Stage Reciprocating Air Compressor

Suction process in the low pressure stage cylinder starts at 8 allowing a volume of air to enter the
cylinder. It is then compressed from 1-2 and discharges along 2-7. This discharged air passes
through an intercooler being cooled by circulating water. Immediately, the cooled air enters the
high pressure stage cylinder and it is compressed to the final pressure along 3-4. It is discharged
from 4-5, after which the clearance air re-expands from 5-6. If leakage is neglected, the mass of
discharged air in both cylinders are the same. Thus,

𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝑜𝑜𝑜𝑜 𝐿𝐿𝐿𝐿𝐿𝐿 𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝑜𝑜𝑜𝑜 𝐻𝐻𝐻𝐻𝐻𝐻ℎ


𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼 𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 = +
𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶

NOTE:

1. For ideal compressor power equations for polytropic, isentropic and isothermal
processes, refer to Experiment no. 8.
2. In this experiment, computations for the displacement volume, high pressure stage
jacket cooling water volumetric flow rate, volume of air drawn in the cylinder,
volumetric efficiency, compressor mechanical efficiency, cooling water volumetric flow
rate in the after cooler compression efficiency and overall compression efficiency are
required. The formula is given in Experiment no. 8.

79
3. Additional Formulas:
a) Volumetric flow rate of jacket water in the low pressure stage cylinder

𝑉𝑉𝑗𝑗𝑗𝑗 = 0.724ℎ 0.522 , gal/hour

b) Volumetric flow rate of cooling water in the intercooler

𝑉𝑉𝑗𝑗𝑗𝑗 = 0.697ℎ 0.532 , gal/hour

4. Air flow rate to be used consist of 1.256 in sharp edge orifice where, h is defined as head
of water in inches.

Procedure
1. Set the three valves such that the operation is a two stage compression with inter-cooling and
after cooling.
2. Adjust water flow to give readings between 4 and 10 in (10 and 25 cm) on the flow meters.
3. Operate the compressor levers on each compressor.
4. Set speed control to “resistance”.
5. Start up the compressor by slowly operating the starters.
6. As air receiver pressure approaches desired value, gradually open throttling valve to give
constant air receiver pressure. The correct setting of the throttling valve to give constant air
receiver pressure will give approximately the same pressure drop across the British Standard
nozzles across the inlet orifice.
7. Have at least three or more different pressure readings at the air receiver tank and take
necessary data at every five minutes interval for the duration of twenty minutes for each set.
8. Set speed of the machine and air receiver pressure to desired values and run for at least ten
minutes to attain stable conditions before taking results. Remember to keep the pressure in the
air receiver tank constant.

80
Experimental Data

A. Low Pressure Stage Cylinder

No. of cylinder =
Bore diameter = mm
Length of stroke = mm
Swept volume = m3
Speed range =
Maximum Delivery pressure = kPag

Speed ratio, motor/compressor =


Efficiency of belt drive = %
Engine Indicator Spring Scale = kPa/mm

B. High Pressure Stage Cylinder

No. of cylinder =
Bore diameter = mm
Length of stroke = mm
Swept volume = m3
Speed range =
Maximum Delivery pressure = kPag

Speed ratio, motor/compressor =


Efficiency of belt drive = %
Engine Indicator Spring Scale = kPa/mm

Barometric pressure = kPa


Room temperature = ᵒC

RUN NO. 1: Air Receiver Pressure = 345 kPa gage

Air Receiver Temperature = _______________⁰C

81
LOW PRESSURE STAGE CYLINDER

Discharge Pressure = _______________kPa gage

TABLE 9.1aMulti-Stage Reciprocating Air Compressor (Two Stage-Single Acting Air Compressor)
Performance Test data
Driving Motor Indicator Card
Time, Supply Supply Dynamometer
Area, Length,
min Voltage, Current, load, N Pmi, kPa
mm2 mm
Volts Amperes

10

15

20

Average

TABLE 9.1bMulti-Stage Reciprocating Air Compressor (Two Stage-Single Acting Air Compressor)
Performance Test data

AIR COMPRESSOR
Time,
min AIR CYLINDER JACKET COOLING WATER
Flow, Temperature Temperature Flow, Temperature Temperature
mm H2O in, ⁰C out, ⁰C mm H2O in, ⁰C out, ⁰C

10

15

20

Average

82
HIGH PRESSURE STAGE CYLINDER

Discharge Pressure = _______________kPa gage

TABLE 9.2aMulti-Stage Reciprocating Air Compressor (Two Stage-Single Acting Air Compressor)
Performance Test data
Driving Motor Indicator Card
Time, Supply Supply Dynamometer
Area, Length,
min Voltage, Current, load, N Pmi, kPa
mm2 mm
Volts Amperes

10

15

20

Average

TABLE 9.2bMulti-Stage Reciprocating Air Compressor (Two Stage-Single Acting Air Compressor)
Performance Test data

AIR COMPRESSOR
Time,
min AIR CYLINDER JACKET COOLING WATER
Flow, Temperature Temperature Flow, Temperature Temperature
mm H2O in, ⁰C out, ⁰C mm H2O in, ⁰C out, ⁰C

10

15

20

Average

83
TABLE 9.3IntercoolerPerformance Test data

INTERCOOLER
Time,
min AIR COOLING WATER
Flow, Temperature Temperature Flow, Temperature Temperature
mm H2O in, ⁰C out, ⁰C mm H2O in, ⁰C out, ⁰C

10

15

20

Average

TABLE 9.4AftercoolerPerformance Test data

AFTERCOOLER
Time,
min AIR COOLING WATER
Flow, Temperature Temperature Flow, Temperature Temperature
mm H2O in, ⁰C out, ⁰C mm H2O in, ⁰C out, ⁰C

10

15

20

84
AVERAGE RESULTS

LOW PRESSURE STAGE CYLINDER

(RUN NO. 1)

A. Discharge Pressure = kPag


Air capacity = m3
Theoretical piston displacement
= m3
Power input to driving motor = kW
Electric motor brake power = kW
Indicated power of air
compressor = kW
Polytropic compressor power = kW
Isentropic compressor power = kW
Isothermal compressor power = kW
Compressor mechanical
efficiency = %
Electric motor efficiency = %
Volumetric efficiency = %

Compression efficiency

a. Polytropic = %
b. Isentropic = %
c. Isothermal = %

Overall efficiency
a. Polytropic = %
b. Isentropic = %
c. Isothermal = %

85
AVERAGE RESULTS

HIGH PRESSURE STAGE CYLINDER

(RUN NO. 1)

A. Discharge Pressure = kPag


Air capacity = m3
Theoretical piston displacement
= m3
Power input to driving motor = kW
Electric motor brake power = kW
Indicated power of air
compressor = kW
Polytropic compressor power = kW
Isentropic compressor power = kW
Isothermal compressor power = kW
Compressor mechanical
efficiency = %
Electric motor efficiency = %
Volumetric efficiency = %

Compression efficiency

a. Polytropic = %
b. Isentropic = %
c. Isothermal = %

Overall efficiency
a. Polytropic = %
b. Isentropic = %
c. Isothermal = %

86
RUN NO. 2: Air Receiver Pressure = 515 kPa gage

Air Receiver Temperature = _______________⁰C

LOW PRESSURE STAGE CYLINDER

Discharge Pressure = _______________kPa gage

TABLE 9.5aMulti-Stage Reciprocating Air Compressor (Two Stage-Single Acting Air Compressor)
Performance Test data
Driving Motor Indicator Card
Time, Supply Supply Dynamometer
Area, Length,
min Voltage, Current, load, N Pmi, kPa
mm2 mm
Volts Amperes

10

15

20

Average

TABLE 9.5bMulti-Stage Reciprocating Air Compressor (Two Stage-Single Acting Air Compressor)
Performance Test data
AIR COMPRESSOR
Time, AIR CYLINDER JACKET COOLING WATER
min Flow, Temperature Temperature Flow, Temperature Temperature out,
mm H2O in, ⁰C out, ⁰C mm H2O in, ⁰C ⁰C

10

15

20

Average

87
HIGH PRESSURE STAGE CYLINDER

Discharge Pressure = _______________kPa gage

TABLE 9.6aMulti-Stage Reciprocating Air Compressor (Two Stage-Single Acting Air Compressor)
Performance Test data
Driving Motor Indicator Card
Time, Supply Supply Dynamometer
Area, Length,
min Voltage, Current, load, N Pmi, kPa
mm2 mm
Volts Amperes

10

15

20

Average

TABLE 9.6bMulti-Stage Reciprocating Air Compressor (Two Stage-Single Acting Air Compressor)
Performance Test data

AIR COMPRESSOR
Time,
min AIR CYLINDER JACKET COOLING WATER
Flow, Temperature Temperature Flow, Temperature Temperature out,
mm H2O in, ⁰C out, ⁰C mm H2O in, ⁰C ⁰C

10

15

20

Average

88
TABLE 9.7IntercoolerPerformance Test data

INTERCOOLER
Time,
min AIR COOLING WATER
Flow, Temperature Temperature Flow, Temperature Temperature out,
mm H2O in, ⁰C out, ⁰C mm H2O in, ⁰C ⁰C

10

15

20

Average

TABLE 9.8AftercoolerPerformance Test data

AFTERCOOLER
Time,
min AIR COOLING WATER
Flow, Temperature Temperature Flow, Temperature Temperature out,
mm H2O in, ⁰C out, ⁰C mm H2O in, ⁰C ⁰C

10

15

20

Average

89
AVERAGE RESULTS

LOW PRESSURE STAGE CYLINDER

(RUN NO. 2)

A. Discharge Pressure = kPag


Air capacity = m3
Theoretical piston displacement = m3
Power input to driving motor = kW
Electric motor brake power = kW
Indicated power of air compressor = kW
Polytropic compressor power = kW
Isentropic compressor power = kW
Isothermal compressor power = kW
Compressor mechanical efficiency = %
Electric motor efficiency = %
Volumetric efficiency = %

Compression efficiency

a. Polytropic = %
b. Isentropic = %
c. Isothermal = %

Overall efficiency
a. Polytropic = %
b. Isentropic = %
c. Isothermal = %

90
AVERAGE RESULTS

HIGH PRESSURE STAGE CYLINDER

(RUN NO. 2)

A. Discharge Pressure = kPag


Air capacity = m3
Theoretical piston displacement = m3
Power input to driving motor = kW
Electric motor brake power = kW
Indicated power of air compressor = kW
Polytropic compressor power = kW
Isentropic compressor power = kW
Isothermal compressor power = kW
Compressor mechanical efficiency = %
Electric motor efficiency = %
Volumetric efficiency = %

Compression efficiency

a. Polytropic = %
b. Isentropic = %
c. Isothermal = %

Overall efficiency
a. Polytropic = %
b. Isentropic = %
c. Isothermal = %

91
RUN NO. 3: Air Receiver Pressure = 690 kPa gage

Air Receiver Temperature = _______________⁰C

LOW PRESSURE STAGE CYLINDER

Discharge Pressure = _______________kPa gage

TABLE 9.9aMulti-Stage Reciprocating Air Compressor (Two Stage-Single Acting Air Compressor)
Performance Test data
Driving Motor Indicator Card
Time, Supply Supply Dynamometer
Area, Length,
min Voltage, Current, load, N Pmi, kPa
mm2 mm
Volts Amperes
5

10

15

20

Average

TABLE 9.6bMulti-Stage Reciprocating Air Compressor (Two Stage-Single Acting Air Compressor)
Performance Test data

AIR COMPRESSOR
Time,
min AIR CYLINDER JACKET COOLING WATER
Flow, Temperature Temperature Flow, Temperature Temperature out,
mm H2O in, ⁰C out, ⁰C mm H2O in, ⁰C ⁰C
5

10

15

20

Average

92
HIGH PRESSURE STAGE CYLINDER

Discharge Pressure = _______________kPa gage

TABLE 9.10aMulti-Stage Reciprocating Air Compressor (Two Stage-Single Acting Air Compressor)
Performance Test data
Driving Motor Indicator Card
Time, Supply Supply Dynamometer
Area, Length,
min Voltage, Current, load, N Pmi, kPa
mm2 mm
Volts Amperes

10

15

20

Average

TABLE 9.10bMulti-Stage Reciprocating Air Compressor (Two Stage-Single Acting Air Compressor)
Performance Test data

AIR COMPRESSOR
Time,
min AIR CYLINDER JACKET COOLING WATER
Flow, Temperature Temperature Flow, Temperature Temperature out,
mm H2O in, ⁰C out, ⁰C mm H2O in, ⁰C ⁰C

10

15

20

Average

93
TABLE 9.11IntercoolerPerformance Test data

INTERCOOLER
Time,
min AIR COOLING WATER
Flow, Temperature Temperature Flow, Temperature Temperature out,
mm H2O in, ⁰C out, ⁰C mm H2O in, ⁰C ⁰C

10

15

20

Average

TABLE 9.12AftercoolerPerformance Test data

AFTERCOOLER
Time,
min AIR COOLING WATER
Flow, Temperature Temperature Flow, Temperature Temperature out,
mm H2O in, ⁰C out, ⁰C mm H2O in, ⁰C ⁰C

10

15

20

Average

94
AVERAGE RESULTS

LOW PRESSURE STAGE CYLINDER

(RUN NO. 3)

A. Discharge Pressure = kPag


Air capacity = m3
Theoretical piston displacement = m3
Power input to driving motor = kW
Electric motor brake power = kW
Indicated power of air compressor = kW
Polytropic compressor power = kW
Isentropic compressor power = kW
Isothermal compressor power = kW
Compressor mechanical efficiency = %
Electric motor efficiency = %
Volumetric efficiency = %

Compression efficiency

a. Polytropic = %
b. Isentropic = %
c. Isothermal = %

Overall efficiency
a. Polytropic = %
b. Isentropic = %
c. Isothermal = %

95
AVERAGE RESULTS

HIGH PRESSURE STAGE CYLINDER

(RUN NO. 3)

A. Discharge Pressure = kPag


Air capacity = m3
Theoretical piston displacement = m3
Power input to driving motor = kW
Electric motor brake power = kW
Indicated power of air compressor = kW
Polytropic compressor power = kW
Isentropic compressor power = kW
Isothermal compressor power = kW
Compressor mechanical efficiency = %
Electric motor efficiency = %
Volumetric efficiency = %

Compression efficiency

a. Polytropic = %
b. Isentropic = %
c. Isothermal = %

Overall efficiency
a. Polytropic = %
b. Isentropic = %
c. Isothermal = %

96
TABLE 9.13a Heat Balances Performance data (Heat from the air kW)
LOW HIGH
RUN PRESSURE PRESSURE
NO. STAGE INTERCOOLER STAGE AFTERCOOLER
CYLINDER CYLINDER

Average

TABLE 9.13b Heat Balances Performance data (Heat to cooling water kW)
LOW HIGH
RUN PRESSURE PRESSURE
NO. STAGE INTERCOOLER STAGE AFTERCOOLER
CYLINDER CYLINDER

Average

Sample Computations

97
Results and Analysis

Interpret the experimental data statistically as required by the laboratory instructor.

Observations and Recommendations


Present briefly your individual observations and recommendations.

Conclusion

98
Questions and Answers (NOTE: Use separate sheet for the answers.)

1. A two stage air compressor takes air at atmospheric pressure and 27 ⁰C. The flash point of the
oil in the air cylinder is 260⁰C. Safety precautions limit the temperature of the air in the high
pressure cylinder to be 28⁰C below the flash point of the oil. Assuming perfect intercooling and
no pressure drop through the intercooler, what would be the allowable working pressure of
this air compressor if the compression curve follows the equation PV 1.34 = c?
2. A 200 m3/min air compressor with 101.325 kPa, 30 ⁰C intake air is made to run two stage at
optimum intercooler pressure with perfect intercooling. What will be the horsepower of the
diesel engine required to drive this air compressor if the overall efficiency of the prime over and
air compressor is 80%? The compressed air is delivered at 1000 kPa and the compression
constant C = PV 1.35.
3. An air compressor delivers 2200kg/hr of air at a pressure of 103.5 kPa, with air entering at
15.55⁰C. Neglecting frictional losses, find the power required to operate a two-stage air
compressor with air entering the second stage at 331 kPa and 18 ⁰C. Also find the temperature
of air going to the receiver. Use a polytropic index of 1.36.
4. A two stage double-acting air compressor operating at 150 rpm takes in air at 100 kPa and
27⁰C. The low pressure cylinder is 35 x 38 cm. The stroke of the high pressure cylinder is 38 cm
and the clearance of both cylinders is 4%. Air is discharged at 385 kPa from the low pressure
cylinder, passes through the intercooler and enters the high pressure cylinder at 370 kPa and
27⁰C. It leaves the high pressure cylinder at 1480 kPa. The polytropic experiment is 1.3 for both
cylinders. Atmospheric conditions are 101.325 kPa and 21⁰C. Dete rmine the volume of free air
compressed, diameter of high pressure cylinder and total compressor power.
5. What would be the displacement of a similar air compressor to handle the same of air as in
problem 4 when operated at 1800 m elevation?

99
De La Salle University
Mechanical Engineering Department

Experiment No. 10
Performance Test of an Axial Flow Fan

NAME : ______________________________________

SUBJECT & SECTION : ______________________________________

INSTRUCTOR : ______________________________________

DATE PERFORMED : ______________________________________

DATE DUE : ______________________________________

DATE SUBMITTED : ______________________________________ RATING: ____________

REMARKS: ________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

100
Objectives

• To determine the fan volumetric capacity, power rating and efficiency


• To plot and study the performance characteristic curve of an axial flow fan

Materials and Equipment


• Air flow demonstration unit
• Inclined manometer
• Barometer
• Pitot tube
• Venturi meter
• Orifice meter
• Sling psychrometer

Experiment Set-up
Figure 10.1 shows the materials and equipment for the performance test of axial flow fan.

FIGURE 10.1Axial Flow Fan TestSet-up

Theory
Fans are classified as axial flow low pressure compressor. They operate at a pressure equal to or
below 7 kPa. One of the functions of fan is to circulate air through the ducts of an air conditioning
unit. It is also used for handling fuel gases, light materials and furnace gases.
Axial flow fans are divided into three groups namely, the propeller fan, the tube axial fan and the
vane axial fan as shown in Figure 10.2. A propeller fan could be either of the propeller type or disk
type. It is designed so that it could be mounted on a ring or plate. In the case of a tube axial fan, it is
used usually mounted on a cylinder or duct. Like the propeller fan, it is also either propeller type or

101
disk type in construction. Vane axial fan consists of an air foil blade wheel. It is supported by a
stationary guide to obtain stability during operation.

FIGURE 10.2Classifications of Fans

In the design of fans, the terms often used for power output and power input are total air power
and brake power, respectively. The total air power is calculated with the use of the equation below.

𝑃𝑃𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂 = 𝑄𝑄𝑄𝑄ℎ𝐴𝐴𝐴𝐴 (10.1)

where: 𝑄𝑄 = volumetric flow rate

𝛾𝛾 = weight density of air

ℎ𝐴𝐴𝐴𝐴 = total fan head

FIGURE 10.3 Energy Diagram of Fan System

To determine the total fan head, let us consider the fan suction and discharge sides denoted with
subscripts s and d, respectively. Considering ℎ𝐴𝐴𝐴𝐴 be the total fan head, then the energy equation
between suction and discharge can be expressed as

𝑝𝑝 𝑠𝑠 𝑉𝑉 2 𝑝𝑝 𝑑𝑑 𝑉𝑉 2
𝛾𝛾𝑎𝑎
+ 𝑧𝑧𝑠𝑠 + 2𝑔𝑔𝑠𝑠 + ℎ𝐴𝐴𝐴𝐴 = 𝛾𝛾𝑎𝑎
+ 𝑧𝑧𝑑𝑑 + 2𝑔𝑔𝑑𝑑 + ℎ𝐿𝐿𝑠𝑠−𝑑𝑑 (10.2)

𝑝𝑝
where, 𝛾𝛾
= pressure head

𝑉𝑉 2
2𝑔𝑔
= velocity head

102
𝑧𝑧 = elevation head

ℎ𝐿𝐿𝑠𝑠−𝑑𝑑 = head loss from s to d

As axial flow fan is our point of interest then, calculating the total fan head and neglecting head loss
component yields

𝑝𝑝 𝑑𝑑 −𝑝𝑝 𝑠𝑠 𝑉𝑉𝑑𝑑2 −𝑉𝑉𝑠𝑠2


ℎ𝐴𝐴𝐴𝐴 = � � + [𝑧𝑧𝑑𝑑 − 𝑧𝑧𝑠𝑠 ] + � � (10.3)
𝛾𝛾𝑎𝑎 2𝑔𝑔

The power input or brake power is obtained with the use of the formula given as

𝑃𝑃𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼 = 2𝜋𝜋𝜋𝜋𝜋𝜋 (10.4)

where: 𝑇𝑇 = torque in N-m

𝑛𝑛 = fan rotative speed

The total fan efficiency however, is given by the equation in the form of
𝑃𝑃𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂
𝜂𝜂𝐹𝐹𝐹𝐹𝐹𝐹 = 𝑃𝑃𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼
× 100% (10.5)

Procedure
1. Study the set-up of the Air Flow Apparatus and locate the point in which the air velocity could
be measured.
2. Connect the Pitot tube and insert in a pipe outlet pointing upstream.
3. Place the Pitot tube at the centre of the pipe and clamp firmly in position.
4. Set the inclined manometer and torque meter at zero position prior to air flow measurement.
5. Record fluid manometer temperature as well as dry and wet bulb air temperatures.
6. Close the variable discharge opening of Air Flow Apparatus and run the fan with a rotative
speed of 3,450 rpm.
7. Allow ample time to attain flow stability and measure the static pressures of Pitot tube, Venturi
and orifice meters.
8. Record the difference of static heads for Venturi meter to determine the volume flow rate.
9. Take readings of torque, barometer as well as dry and wet bulb temperatures.
10. Turn outlet valve three times and allow again ample time to secure good average readings.
Measure the size of the orifice and record.
11. Adjust the discharge valve opening by increments of three turns until it reaches the 18th turns.
Again in each position, record the readings of static pressure for Pitot tube, Venturi and orifice
meters including torque. Also, measure each opening of the orifice.
12. Plot the following curve on the Cartesian coordinate system using Microsoft Excel.
a. Total fan head against air volumetric flow rate
b. Static fan head against air volumetric flow rate
c. Fan brake power against air volumetric flow rate
d. Total and static fan efficiencies against air volumetric flow rate

103
Experimental Data

Orifice diameter: 108 mm Discharge diameter: 140 mm


Venturi upstream diameter: 140 mm Venturi throat section: 91 mm
Manometer inclination angle: 10° Conversion: 0.1 kPa = 13 mm
Wet Bulb Temperature: __________ °C __________ °C __________ °C __________ °C
Dry Bulb Temperature: __________ °C __________ °C __________ °C __________ °C
Manometer Fluid Temperature: __________ °C __________ °C __________ °C __________ °C

TABLE 10.1a Axial Flow Fan Performance Test data


Pitot-tube Inclined Venturi Inclined Orifice Inclined
Manometer Reading Manometer Reading Manometer Reading
Valve
No. of Torque, Pressure
Clearance, Total Static Upstream Throat Upstream
Turns N-m after
mm Pressure, Pressure, Pressure, Pressure, Pressure,
orifice,
mm mm mm mm mm
mm
0
3
6
9

12
15
18

TABLE 10.1b Axial Flow Fan Performance Test data


Discharge Total Fan Static Fan Total Air Static Air
Brake Total Fan Static Fan
No. of Flow Head, Head, Power, Power,
Power, Efficiency, Efficiency,
Turn rate, Q in ℎ𝑇𝑇𝑇𝑇𝑇𝑇 in m ℎ𝑆𝑆𝑆𝑆𝑆𝑆 in m 𝑃𝑃𝑇𝑇𝑇𝑇𝑇𝑇 in 𝑃𝑃𝑆𝑆𝑆𝑆𝑆𝑆 in
𝐵𝐵𝐵𝐵 in kW 𝜂𝜂𝑇𝑇𝑇𝑇𝑇𝑇 in % 𝜂𝜂𝑆𝑆𝑆𝑆𝑆𝑆 in %
m3/s of H2O of H2O kW kW

12

15

18

104
Sample Computations

Results and Analysis

Interpret the experimental data statistically as required by the laboratory instructor.

Observations and Recommendations


Present briefly your individual observations and recommendations.

105
Conclusion

Questions and Answers (NOTE: Use separate sheet for the answers.)

1. Why do fans or blowers have higher heads than a pump under the same operating speed and
capacity?
2. Find the air horsepower of an industrial fan that delivers 25.98 m3/s of air through a 0.915 m
by 1.22 m duct. Pressure is 127 mmHg of water; air temperature is 21 ⁰C and the barometer
pressure is 760 mm of mercury.
3. A fan discharges 265 m3/min of air through a duct of 92 cm in diameter against a static pressure
of 22 m of water. The gage fluid density is 995 kg/m3, the air temperature is 29⁰C and the
barometer pressure is 730 mmHg. If the power input to the fan is measured as 3.5 HP, what is
the overall mechanical efficiency and static efficiency of the fan?
4. A manufacturer rates his fan at 11.25 cm of water, air static pressure of 170 m3/min at 21⁰C, fan
speed of 1,500 rpm, and 760 mmHg barometric pressure with 71% static efficiency. What will
be the flow, static pressure and shaft power at 1,800 rpm, air temperature of 93⁰C, and 660
mmHg barometer pressure?
5. A large forced draft fan is handling air at 1 atmosphere and 43⁰C under a total head of 266 mm
water gage at 43 ⁰C. The power input to the fan is 224 kW and the fan is 75% efficient.
Determine the volume of air handled each minute. Local acceleration is 9.71 m/s2.

106
References

[1] Faires, V.M. and C.M. Simmang, 1978. Thermodynamics, 6thed. New York: MacMillan.

[2] Maglaya, A.B., 1986. Mechanical Engineering Principles and Practices II. De La Salle University
Press, Manila, Philippines.

[3] Lamorena, S.R. and Maglaya, A.B. 1985. Fluid Mechanics and Machineries, De La Salle
University Research Center, Manila, Philippines.

[4] Morse, F.T. 1953. Power Plant Engineering, 3rded. New York: D. Van Nostrand.

[5] Moyer, J.A. 1972. Power Plant Testing, 4thed. New York: McGraw Hill.

[6] Tuve, G.L. 1961. Mechanical Engineering Experimentation. New York: McGraw Hill.

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