SINGLE STAGE AIR

COMPRESSOR
Instruction Manual

CREATIVE LAB
AN ISO 9001 – 2008 CERTIFIED CO.
MANUFACTURES & SUPPLIERS OF ENGG LAB EQUIPMENT
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OBJECT: To study the operation of a double stage air compressor.

AIM:
To find out the volumetric efficiency
To find out isothermal efficiency
To calculate the compression ratio

INTRODUCTION:
Air Compressor is a device, which sucks the air from atmosphere and compresses
it and delivers in reservoir tank. It compresses the air by means of a reciprocating
piston, which reciprocates in a stationary cylinder. It can be single stage or multi
stage. It can be single acting or double acting.

THEORY:
In two-stage compression, air is partially compressed in low-pressure cylinder.
This air is passed through cooler between first stage and second stage so that air at
inlet of second stage is at lower temperature than the first stage outlet. This is
done to reduce the work of compression in second stage. Final compression is
completed in second stage i.e. in high-pressure cylinder. Also, the compressors are
provided with clearance volume, two stage compressors can achieve higher
volumetric efficiency than single stage compressors, because of lower
compression per stage. As the compressed air is used in a wide range in industrial,
domestic, aeronautics fields etc. so compressors are applied in wide range.
Compressors are used where the air is required at high pressure.
DESCRIPTION:

Double stage air compressor test rig consists of two cylinders and pistons, a
reservoir tank. Driven by A.C. motor. Temperature sensors are provided at inlet
and outlet. To find out the inlet volume of air, an orifice meter is provided. To
stream line the intake, a diaphragm base manifold is provided. Pressure Gauge is
provided at reservoir tank. Safety valve and auto power out switch is provide for
the safety factor.

UTILITIES REQUIRED:
Electricity Supply: Single Phase, 220 VAC, 50 Hz, 5-15 amp socket with earth
connection.
Floor Area Required: 1.5m x 0.75 m

EXPERIMENTAL PROCEDURE:

1. Close the outlet valve of tank and start the compressor.

2. Let the receiver pressure rise up to around 2 kg /cm2. Now open the
delivery valve so that constant delivery pressure is achieved.
3. Wait for some time and see that delivery pressure remain constant. Now
note down the pressure.
4. Record the time for 10 pulses of energy meter.
5. Record the manometer reading.
6. Record the temperature of air at inlet, before second stage and after second
stage.
7. Find out the RPM of compressor with the help of RPM indicator.
8. Repeat the same procedure for different delivery pressure.
STANDARD DATA

 Bore Diameter, d of cylinder = _____ mm

 Length of stroke, L = ______ mm
 Diameter of orifice, do = ______ mm
 Cross- sectional area of orifice, ao = _____ m2
 Diameter of pipe, dp = 25
 Cross- sectional area of pipe, = 4.91×10-4 m2
 Density of water, m = 1000 kg/m3
 Density of air at 0o C i.e. 273o K a = 1.293 kg/m3
 Co-efficient of discharge Cd = 0.64
 Energy meter constant, E.M.C = 3200 Pulses/KW-hr
 Atmospheric pressure, Pa = 1.013 x 105 N/m2
 Conversion Factor 1 HP = 746 Watt
 Radius of swinging Field Dynamometer = 0.16 m

OBSERVATION TABLE

Manometer No. of
Gauge Time Taken
Reading Weight Pulses of
N Pressure for P Pulses
S.N. Energy
(RPM) Reading tp (sec)
W, kg Meter
h1 h2 (kg / cm2)
(P)
FORMULAE

h1  h2
h ,m
100
 
H   w  1  h , m of air
 a 

 2
ao  d o , m2
4
 2
a P  d P , m2
4

ao a p
Qa  C d 2 gH , m3/sec
a 2p  ao2

 d2 L N
Qt  , m3/sec
60  4

Qa
v   100%
Qt
P  3600
Ei 
t p  EMC , KW

w  
 Air Head Causing Flow, H = h x   1 m of air.
 a 

Where, ρw is density of Water =1000 kg/m3

ρa is density of Air =1.205 kg/m3
h is differential manometer reading
ao a p
 Actual Volume of air, Qactual = Cd 2* g * H m3 /sec
a 2p  ao2

Where,
Cd = Discharge Coefficient of Orifice
ao = Cross Sectional Area of Orifice
 ap = Cross Sectional Area of Pipe
g = Acceleration due to Gravity =9.81 m/sec2
H = Air Head Causing Flow
 N
 Swept Volume of Compressor, Qt = 4
x d2 x L x 60
m3 / sec.

Where,
L = Length of Compressor Cylinder (Stroke)
d = Diameter of Compressor Cylinder (Bore)
N = RPM
Q
 Volumetric efficiency,  vol %  Q  100
act

Guage Pr essure  Atmospheric Pr essure

 Compression Ratio, r = Atmospheric Pr essure

 Isothermal Power = Qact  log e r  Pact Watt.

P  3600  1000
 Electrical Input = t p  EMC Watt.

Where P = Pulses of Energy Meter

tp = Time taken for P Puleses
EMC = Energy Meter Constant

IsothermalPower
 Isothermal Efficiency ηiso % = ElectricalInput
 100

746 Watt = 1 HP

CALCULATION TABLE

S. N Head Q act Qt Electrical Volum. Comp. Isothermal Isothermal

N. (RPM) H(m) m 3/sec m 3/sec Input Eff. Ratio Power Effi.
(Watt) η vol (%) r (Watt) η iso (%)
NOMENCLATURE

T1 : Inlet Temp. of Air.

T2 : Outlet Temp. of Air
N : RPM (Rated Speed)of Compressor.
EMC : Energy Meter Constant =3200 Pulses/KW-hr.
Cd : Discharge Coefficient of Orifice =0.64
ao : Cross Sectional Area of Orifice, m2
ap : Cross Sectional Area of Pipe, m2
g : Acceleration due to Gravity = 9.81 m/s2
H : Air Head Causing Flow
ρw : Density of Water =1000 kg/m3
ρa : Density of Air =1.205 kg/m3
h : Differential Manometer Reading.
Qact : Actual Discharge,m3/sec .
Qt : Swept Volume per second,m3/sec .
r : Compression Ratio.
ηvol: Volumetric Efficiency.
ηiso : Isothermal Efficiency.
P : Pulses of Energy Meter.
tp : Time for pulses, sec.
L : Length of Compressor Cylinder (Stroke)
d : Diameter of Compressor Cylinder (Bore)
 Pact : Actual Pressure of Discharge

PRECAUTIONS AND MAINTENANCE INSTRUCTIONS

1. Check the Oil before starting the Air Compressor
2. Check the proper voltage while conducting experiments.
3. Be Careful while measuring the RPM
4. Close the delivery valve of Tank before starting the experiments.

TROUBLESHOOTING
1. If Control Panel does not show input, check fuse and main supply.
2. If Pressure gauge is not showing the pressure , there may be a
leakage of air. Check the suction line and valves provided on delivery
line.
3. If Manometer is not showing the pressure difference, check the orifice
plate and suction line.