IMPROVING PERFORMANCE AND DEVELOPMENT OF TWO-STAGE

RECIPROCATING COMPRESSORS

 ABSTRACT

The most troublesome part in the development of a compressor technology

depends strongly on improvement of its performance. For this purpose, a
performance characteristic evaluation of a two stage reciprocating
compressor is carried out in this paper. The aims were to improve
compressor performance by illustrating the effects of various parameters:
primary air tank, compressor running time, background working condition,
and air leakage. The effect of each parameter was compared with the normal
performance condition and, in turn, it was demonstrated the most/least
important parameters on the performance.

Keywords: Reciprocating compressor, Two-stage, Performance,

Development and Experimental.

 INTRODUCTION

Currently, compressors are multipurpose tools used widely in industry for a

variety of purposes. Compressors are used to operate various machines, tools
and hydraulic devices; and, in many cases, compressors are so vital that the
facility cannot operate without them. Most industrial plants, from a small
workshop machine to an enormous power plant, pulp, and paper mill, have
some type of compressed air system wherein the energy generated from
these compressors is essential to operate the mechanical equipment and
power tools. In view of that, plant air compressor can vary in size from a
small unit of 5 horsepower (HP) to huge systems with more than 50,000 HP.
 BACKGROUND

A compressor is a mechanical device that takes an ambient air and increases

its pressure [1]. In the early time, the compressor was bellow that used by
blacksmiths to intensify the heat in their furnaces. The first industrial
compressor was simple, a reciprocating piston-driven machine powered by a
water wheel. In the early 1960s, modern engineering was first applied to air
compressor, and hereafter its design was enhanced significantly.

 RESEARCH

Generally, the sub-systems and equipment of compressed air systems are

organized as air compressor followed by coolers, separator, air dryers, and
air storage tank. Such organization is common for both single stage and
multistage compressors. In a multiple stage compressor, the final discharge
pressure is generated over several individual steps/stages. The individual
stages are mounted in tandem with the second stage driven directly from the
rear of the first stage. Alternatively, the stages may be mounted side by side
either in separate stators or within a common, multi bore housing stator.
Multistage compressors save energy by cooling the air between stages,
reducing the volume and work required to compress the air. After final
stage, same as in a single stage compressor, compressed air passes though
coolers, separator, air dryers, and air storage tank. Storage tank has many
functions; it represents the available air that can be released or replenished at
any time as required. It can be used to control demand events (peak demand
periods) in a compressed air system by reducing both the amounts of
pressure drop and the rate of decay. Storage can be used to protect critical
pressure applications from other events in the system. Storage can also be
used to control the rate of pressure drop to end uses.

 LITERATURE REVIEW

Axial-flow compressors are dynamic rotating compressors types that use

arrays of fanlike airfoils to progressively compress the air or gas. The arrays
of airfoils are set in rows, usually as pairs: rotating and stationary. The
 rotating airfoils, also known as blades or rotors, accelerate the air/gas. The
stationary airfoils, also known as stators or vanes, decelerate and redirect the
flow direction of the air/gas, preparing it for the rotor blades of the next
stage. Axial compressors are usually multistage, with the cross-sectional
area of the air/gas passage diminishing along the compressor to maintain
optimum axial Mach number. Axial-flow compressors are used where there
is a need for a high flow rate or compact design. Such compressor types are
relatively expensive, requiring a large number of components, tight
tolerances and high quality materials. Mainly, they can be found in medium
to large gas turbine engines, in natural gas pumping stations, and within
certain chemical plants. Dynamic air compressors (in both their main types,
centrifugal and axial) are very useful and widely used in many applications,
but not as common as the positive displacement compressors. The positive
displacement compressors are the most universally used compressors; not
only are they common in the industry but also they are popular at home and
they are widely used by the mechanics and woodworkers.

 METHADOLOGY

The experiment was carried out in a two-stage reciprocating air/gas

compressor mounted in a V-shape with two separated cylinders.

 APPARATUS

Reciprocating compressor, Two-stage, Performance, Development and

Experimental.

 PRECAUTIONS

To achieve a steady operating state, the compressed air is blown off via a
bleeder valve with sound absorbing. Safety and pressure regulator valves,
which are compulsory components in any compressor, are installed for
safety and control.
 MATHEMATICAL FORMULA

 RESULTS & OBSERVATIONS

All measured parameters (pressures and temperatures) have no changes with

time since stabilizing of the background conditions. The inlet temperature
(T1) and inlet pressure (P1) are about 20 co. and 0.9 bar, respectively. The
pressure after first and second stages (P2 and P4, respectively) is identical to
P1 (0.9 bar) and, in turn, all curves come over each other in the figure. The
temperature after the intercooler (T3) gets slightly higher (about 22 co.);
however, the temperatures after first and second stages (T2 and T4,
respectively) get in a much higher level (38 co. for both); that may be
 attributed to the accumulated heat in the compressor material, which leads to
the higher temperature of T2, T3 and T4 than background condition (T1).

 TABLE
 CONCLUSIONS

A two-stage reciprocating compressor was investigated experimentally in

this work in order to develop and improve the compressor performance.
Several process parameters were carried out to investigate the performance
and efficiency: effect of the primary air tank, compressor background
working condition, compressor running time, and air leakage. The
parameters were measured using a digital display unit, instruments fixed on
system layout, and a PC-data acquisition system. The results show that the
primary tank could be eliminated from the compressed air system without
influencing on the performance. Although early researchers recommend
using the primary tank for stabilization of pressure input, the current study
shows an insignificant effect and, in turn, primary tank can be eliminated in
the coming designs. Consequently, the new design will be less cost and
space investigating of air leakage on performance shows dominate effect
where it is one of the most significant energy losses and, in addition, it
causes to reduce the output pressure. Air leakage causes the compressor to
work for a longer period of time to overcome the leakage and, in turn,
compressor may work continuously in case of a large leakage. Therefore,
failure may occur in some system controllers and components. As a
recommendation, fixing the leaks has often been relatively cheap and that
have immediate results compared with great impact on energy use and
failure of the system

 REFERENCES

i) https://www.slideshare.net/
ii) www.google.com
iii) Lab manual thermodynamics