INSTRUCTION MANNUAL

OF

RECIPROCATING AIR COMPRESSOR TEST RIG

RECIPROCATING AIR COMPRESSOR TEST RIG

CONTENTS: 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 Theory Specifications Objectives Measurements Suggested Experimental work Results and Discussions Sample Data Sheet Appendix-l: Critical data of Experimental set-up Page No. 03 04 04 05 05 05 07 07

RECIPROCATING AIR COMPRESSOR TEST RIG

1.0 THE ORY: The function of a compressor is to take a definite quantity of fluid (usually a gas, and most often air) and deliver it at a required pressure. The most efficient machine is one, which will accomplish with the minimum input of mechanical work. Both reciprocating and rotary positive displacement machines are used for a variety of purposes. However, here we are concerned only with reciprocating machines. Terminology: 1. Single acting compressors are those compressors in which suction, compression and delivery of a gas take place on one side of the piston and we have one cycle per revolution of the crankshaft. 2. Double acting compressors are those compressors in which suction, compression and delivery of air take place on both the sides of the piston and we have two cycles per revolution of the crankshaft. 3. Single stage compressors are those compressors in which the compression of air from the initial pressure to the final delivery pressure is carried out in one cylinder only. 4. Multi stage compressors ire those in which the compression of air from the initial pressure to the final pressure is carried out in more than one cylinder. The air after compression in one cylinder is further compressed in the second cylinder and so on. Multistage, reciprocating air compressors are used for compressing air for very high pressures up to 1000 bar. But they have low rate of flow, limited up to 5m3/s. In a multistage air compressor, air compressed in low-pressure cylinder is further compressed in high-pressure cylinder. For minimum power, isothermal compressor is aimed at, i n which case compressed air of low-pressure stage is cooled in the intercooler to initial temperature (in perfect cooling) before it goes to highpressure stage. The advantages of multistage compression are Better volumetric efficiency. Working temperature is much lower therefore, lubrication is better and wear and tear is less. Cooling is more efficient with intercoolers and cylinder wall cooling. The cylinders are higher, only the high-pressure cylinder need be robust. They have better mechanical balance requiring smaller flywheel due to uniform torque. 5. Ratio of compression is defined as the ratio of absolute discharge pressure to absolute intake pressure. 6. Free Air is the volume delivered by the compressor measured at the pressure and temperature of the atmosphere in which the machine is situated. 7. Displacement of compressor is the volume swept through by the first stage piston. In double acting compressors it is the volume swept through by the both sides of the pistons. 8. Actual capacity of a compressor is the quantity of gas actually delivered. It is expressed in cubic meter of free gas per minute. The actual capacity of a compressor is always less than its displacement. 9. The volumetric eff iciency is defined as the ratio of mass of air delivered to the mass of air, which would fill the swept volume at the free air conditions of pressure and temperature. Or it may also be defined as the volume of air delivered measured at the free air pressure and temperature divided by the swept volume of the cylinder.

2 . 0 S PE C I FI C A T I O N S : Following are the specifications of the compressor ELGI make: Compression Stage : Double stage Cylinders : Two Power : 3 H.P. Piston Displacement : 10.69 CFM Receiver Capacity : 220 litre Working pressure : 12.0 kgf/C.2 Lubrication : Splash Lubrication Diameter of LP cylinder : 70 (mm) Diameter of H.P. cylinder SO (mm) Stroke length 85 (mm) Motor Speed, N 1420 (rpm) Compressor speed 925 (rpm) 3.0 OBJECTIVE: To determine: (i) (ii) The free air delivered by the compressor The volumetric efficiency of the compressor

4.0 MEASUREMENTS: (i) To find free air delivered by the compressor: Free air delivered is measured with the help of a orificemeter (flow meter) Let M = Mass flow rate, kg/sec Cd = Coefficient of discharge of Orificemeter do = the diameter of smallest cross section of the flow meter, m Ao = the area of smallest cross section of the flow meter, m2 g = acceleration due to gravity H = difference in the fluid level in the manometer limb = density of manometric fluid Water Pair = density of air at the entrance to the flow meter M = air corresponds to the pressure and temperature of air in the tank. Free air delivered is given by M = PV RT Where P&T are the atmospheric pressure and temperature and R is the gas constant. (ii) To find volumetric efficiency of the compressor: Volumetric efficiency = Free air delivered Swept Volume 5.0 SUGGESTED EXPERIMENTAL WORK: Step I: Start the compressor and allow it to run for a period of 15-20 minutes to adjust itself to the load. Note that the delivery valve is kept open. Step2: Record temperature T2 and pressure P2 of air after compression in the low- pressure cylinder and temperature, T3 of air after it passes through the intercooler. Step3: Vary the opening of 'the valve, that will vary the pressure P2 and temperature T2

6.0 RESULTS & DISCUSSIONS: 1. Collect the data carefully and till up the data sheet. 2. Calculate, (i) free air delivered and (ii) volumetric efficiency at noted speed. 3. Compute the index of compressor from the equation

Where, P1 = Atmospheric pressure T1 = Atmospheric temperature at the entry of the compressor 4. The temperature deference (T 2-T3) indicates the cooling in the intercooler. Ideally T 3 should be equal to T1, but because of non-perfect cooling temperature would be higher than T3. Comment on the temperature difference (Tg2-T3) as the flow rate decreases.

7.0 SAMPLE DATA SHEET: Name of Experiment: "To determine free air delivered by the compressor and volumetric efficiency of the compressor." Name of the student:Semester Batch Session Cd of venturi meter = Diameter of throat, do, m = Throat area, A o m 2 = g, m/Sec2 = 3 Density of manometeric fluid, w, kg/m = Density of air entering the compressor at To C, kg/m3 = o Atmospheric temperature T1, C = Atmospheric pressure, P1, kg/cm2 = Air temp Sr. after LP No. cylinder T2 Pressure after LP cylinder P2 Air Temp. after inter cooler T3 Mass flow rata M Free air delivered Volumetric efficiency

8.0 APPENDIX-1: Critical data of experiment Cd of orifice meter Diameter of orifice, d0, m Throat area, A0 m2 g, m/Sec2 Density of manometeric fluid w kg/m3 Density of air entering the compressor at 27o C, kg/m3 = 0.62 = 0.015 = 1.767 = 9.81 = 995-1000 = 1.20