Thermal Sciences Laboratory

2-Stage Reciprocating Air Compressor

1. Objectives
The experiment aims at studying the performance of a 2-stage reciprocating air compressor and
determining some or all of the following:
Isothermal and volumetric efficiencies, energy balance, effect of intermediate pressure, effect of
intercooling.
2. Test Rig
As shown in the accompanying figure, the test rig consists of two separate units: a low pressure
(LP), and a high pressure (HP) stage, each having twin cylinders. The LP stage is driven by a
constant speed AC motor, while the HP stage is driven by a variable speed DC motor. This
feature allows variation of the intermediate pressure. Each stage is provided with its own
dynamometer.
At compressor's inlet there is an airbox with a sharp-edged orifice for flow measurement. An
intercooler is provided between the two stages, and an intercooler between the second stage and
the pressure vessel. Connected to the pressure vessel is an exhaust pipe with a throttling valve
and a calibrated flow nozzle for additional flow measurement. If testing of the LP stage only is
required the HP stage can be shut down completely. The test rig is fully equipped with measuring
instruments like thermometers, pressure gauges, inclined U-tube manometers, tachometers, etc.
The technical data of the test rig are as follows:
Item
Number of cylinders
Bore D (mm)
Stroke s [mm]
Stroke volume VS [cm3]
Clearance volume Vc [cm3]
Maximum pressure Pmax [kPa]
Speed ratio motor/compressor
Ind. spring const. ki [kPa/mm]= 20 "LP", HP= 30.77
Orifice diameter d0 = 32 mm, Orifice coeff. K0 = 0.6
Nozzle diameter dN = 32 mm, Nozzle coeff. KN = 0.994

LP
2
101.6
101.6
1647
20
1000
3:1

HP
2
66.7
63.5
444
13
1500
3:1

3. Test Procedure
Close the throttle valve on the exhaust line, then start the motors and adjust the IHP stage speed.
When the pressure in the vessel reaches the desired level manipulate the throttle valve such that the
pressure in the vessel remains constant. This means that mass of air in the vessel does not
change (mass flow rate in = mass flow rate cut). Record all readings. Repeat if further
runs are needed, e.g. change HP stage speed, or interrupt cooling water supply to
intercooler, etc.

Observations .4
TA

T1

T2

T3

T4

T5

T6

T7

T8

T9

pA

p1

p2

p3

ho

hN

V.ic

V.ac

NM1

NM2

F1

F2

Ai1

Ai2

Li1

Li2

Calculations .5
m.o= 0.001232 do2 (pAh0/TA)1/2
m.N= 0.002012 dN2 (pAhN/T7)1/2
m.= (m.o+ m.N)/2
m . i d e a l = ( P A / RT A ) ( V s N c y c l e s ) L P
vol = m. / m.ideal
(ip) = (imep)

VsNcycles

w h e r e (imep)=(Ai/Li) ki
(bp) = F r (2Nm/60)
mech = (ip)/(bp)
(w.)isoth = m. R T1 In (p3/p1) , and

isoth

= ( w . ) i s o t h /(ip)

6. Requirements
c a l c u l a t e t h e p o l yt r o p i c i n d e x ( n ) f o r e a c h s t a g e calculate all quantities under item #5 above for constant p3 investigate the, effect of p2 on (ip) -

T10