Thermodynamics II Laboratory Instructions

Compressor
Exercise No 11

Introduction
Objective of the exercise is to investigate thermodynamic processes occurring in a reciprocating
compressor, determine key components of its energy balance and compare obtained results with
theoretical description.
In an ideal reciprocating compressor the compression process is isothermal. In such a process the
work needed to compress gas would be minimal. Real compressors however do not work that way;
compression process is polytropic, almost adiabatic. This results with increased energy consumption
and increased outlet gas temperature, which may cause some problems. This is one of the reasons of
utilising multi-stage compressors with intercooling. Intercooling allows to decrease final gas
temperature (and also its final volume), decrease dimensions of further stages and lower work
needed for entire compression process. Figure below shows theoretical single-stage compression in
a reciprocating compressor.

1-2 is the actual compression process, 3-2 is gas removal from the cylinder, 3-4 is decompression of
remaining gas (there is always some gas remaining after the outlet valve is closed) and 4-1 is supply
of another batch of low pressure gas.
Area inside the curve reflects the work theoretically needed to complete entire compression cycle.

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Thermodynamics II Laboratory Instructions

The figure above shows real-life chart. The differences include:

Processes 2-3 and 4-1 are not isobaric, there are visible pressure variations near points 2 and
4 related to valve opening
Compression/expansion processes are not adiabatic.

Due to those facts the actual work (indicated work) is higher than theoretical value for the same
pressure difference and volume.

Investigated machinery
The investigated piece of equipment is a low-speed two-stage reciprocating compressor with both
pistons installed on common connecting rod, driven by a three-phase AC electric motor via belt
transmission system. The ambient air is sucked into the 1st stage, compressed there, then cooled in
an intercooler and further compressed with the 2nd stage, which has additional jacket cooling. From
the 2nd stage the air is directed to an equalising tank and then to a system of pipelines with flow
measurement devices installed.
The main dimensions of the compressor are:

Stroke s = 0.15 m

1st stage bore D1 = 0.30 m

2nd stage bore D2 = 0.24 m.

Both intercooler and 2nd stage jacket are cooled with water (parallel connection on the water side).
There are following measurements:

Motor voltage
Motor current
Motor power (currently unserviceable, use power factor value from the motors plate)

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Thermodynamics II Laboratory Instructions

Speed
Air pressure after 1st stage
Air pressure after 2nd stage
Inlet water temperature
Intercooler outlet water temperature
Jacket outlet water temperature
Intercooler water flow
Jacket water flow.

The compressor is also equipped with an indicator a mechanical device which draws p-V diagrams
for both stages.

Measurements and calculations

For all formulas use values in main SI units, unless otherwise indicated.

Flow measurement
Flow measurement may be calculated according to the displacement volume and number of cycles in
a unit of time (speed):

D1 n s
V
s
4
2

1st stage bore

Stroke

Speed

where : D1

s V
m
0
The air density shall be calculated for measured ambient conditions, using ideal gas law and
gas constant of R = 287 J/(kg K).
Flow in the pipeline downstream from the compressed air tank may be measured with measurement
nozzle:

K d2
m
where: d
p

p
v

nozzle diameter ( d = 0.031 m)

nozzle pressure drop [Pa]

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Thermodynamics II Laboratory Instructions

v

air specific volume for conditions inside pipeline

empirical coefficient.
K = 1.15292967

While both values should be identical (in a steady state and with valves at the pipeline open, i.e.
when the flows into the tank and from the tank are equal), but there will be a noticeable difference.
This is primarily caused by:

Fact that the piston never actually reaches cylinder head, so some of the compressed air is
not pushed out of the cylinder, but gets expanded instead (see Vs on charts above)

Possible leaks in the system.

Indicated power measurement

The indicated power shall be determined from indicator diagrams crated during operation. Using
these you may obtain average indicated pressure pi. This is the highest pressure which would occur in
a rectangular cycle with an area equal to that of the real one, and the same base length. As the
length of the diagram l is equal to the piston stroke, the average indicated pressure may be
calculated as:

pi

where: F

la

measured area of the indicator diagram

[ mm2 ] ;

diagram length along horizontal axis [ mm ] ;

indicators spring coefficient [mm/Pa], different for each stage:

a1 = 12 10-5 mm/Pa,
a2 = 3 10-5 mm/Pa.

After average indicated pressure is determined for each stage, indicated power Ni may be calculated
as:

2012 Division of Thermodynamics, Institute of Heat Engineering

Thermodynamics II Laboratory Instructions

NI

n s
2
2
D1 pi1 pi2 D2 pi2
4

1st stage bore

D2

2nd stage bore

stroke

speed

pi1

1st stage average indicated pressure

pi2

2nd stage average indicated pressure.

where: D1

Other components of the energy balance

Electric power may be calculated from measured voltage U and current I for the three-phase motor:

Nel U I 3 cos
where cos = 0.86.
Compressor shaft power is therefore:

N s Ne m t
where: m

electric motor efficiency m = 0. 86

transmission efficiency

t = 0. 97

Thus mechanical efficiency of the system is:

Ni
Ns

Thermal power of the water cooling QW is calculated as:

m
w 1 c w (t w 2 t w 1 ) m
w 2 c w (t w 3 t w 1 )
Q
w
where:

w1
m

intercooler water flow

w2
m

jacket water flow

2012 Division of Thermodynamics, Institute of Heat Engineering

Thermodynamics II Laboratory Instructions

t w1

water inlet temperature

t w2

intercooler water outlet temperature

t w3

jacket outlet water temperature

cw

water specific heat capacity

c w = 4.19 kJ/(kg K)

Report
The report should contain measurement results, calculation of individual energy balance components
and conclusions. Detailed information will be provided by the instructor.

2012 Division of Thermodynamics, Institute of Heat Engineering