ME 323: FLUID MACHINERY

Compressors
3.1 Definition
3.2 Types of Compressors
3.3 Reciprocating Compressors
3.4 Compressor Fundamentals
3.1 Definition
COMPRESSORS
Compressors are machines that
are used to transfer another gases
from one location to another at a
higher differential pressure ranges.
There are various types of
compressors and they are classified in
two major categories: (1) dynamic or
also known as continuous flow or
turbo compressor, (2) positive
displacement or intermittent
compressor, and (3) jet compressor

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3.2 Types of Compressors
1. Dynamic or Continuous Flow- are types of compressor in
which the flow of gas is accelerated thru high speed rotating
element, converting velocity head into pressure head. Continuous
flow includes centrifugal and axial flow compressors.

Centrifugal Compressors
These are compressors built
in capacities of 500 to 100,000
ft3/min. and deliver pressures as
high as 150 psi where 10 to 15
stages would be required.

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3.2 Types of Compressors

Axial Flow Compressors

Are compressors which
extended the field of axial flow
fans by the use of multistaging
so that pressures of 75 psi can
be developed with a 20 or 25
stage unit. Capacities range
from 2000 to 100,000 ft3/min.

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3.2 Types of Compressors
2. Positive Displacement or Intermittent Flow- are those units
that confine gas in a closed space, reducing its volume and
discharging it at a higher pressure. Intermittent flow includes
reciprocating, screw, and rotary vane types of compressors.
Reciprocating Compressors
Are compressors built in sizes
as large as 5000 to 10,000 ft3/min.
piston displacement and are
capable of delivering air from a
pressure of 35 psig up to 250 psig.
They are widely used in industrial
applications because of their over-
all efficiency, wide range of
capacity, simplicity of use and
compactness.
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3.2 Types of Compressors
Screw Type Compressors
Are compressors that have
two internal “screws” that rotate
in opposite directions, trapping
and compressing air between
them. The two screws also
generate constant movement as
they rotate around. This is a
common type of air compressor
and is one of the easiest to take
care of. The engines are
typically industrial-sized and are
great for continuous use.

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3.2 Types of Compressors
Rotary Vane Compressors
Are like screw type
compressors, but instead of
screws, vanes are mounted on
a rotor and rotated inside the
cavity. The air compresses
between the vane and its casing
and is then pushed out at a
different exhaust port. Rotary
vane compressors are very
easy to use, making them very
popular for private projects.

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3.2 Types of Compressors
Some other ways of classifying compressors includes the following:
a)Number of Stages: Single, Two, Three-stages or Multi-stage
b)Reciprocating Compressor Element: Single Acting or Double Acting
c)Cylinder Arrangement: Vertical, Horizontal, V-type
d)Cooling System: Water-cooled, Air-cooled
e)Mounting Condition: Portable, Stationary

Compressor Applications:
1.)For high pressure, low-capacity applications, use Reciprocating
Compressors.
2.)For moderate or medium pressure, low-capacity applications, use
Rotary Compressors.
3.)For low pressure, high-capacity applications, use Centrifugal
Compressors.

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3.3 Reciprocating Compressors
A reciprocating compressor uses pistons controlled by a crankshaft to
deliver the gas at high pressure. These are typically found at smaller
worksites and aren’t designed for continuous use.
Some of the disadvantages of reciprocating compressors are the
excessive vibrations due to the forces exhibited by the reciprocating
movement of the piston. This requires strong machine foundation and higher
maintenance cost compared with other types of compressor. Figure below
shows a typical reciprocating compressor with its parts.

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3.3 Reciprocating Compressors
A reciprocating compressor resembles automotive engines and
can be air-cooled or liquid-cooled. Generally, low capacity compressor
are air-cooled and they have air fins cast around the cylinder to
dissipate heat. On the other hand, liquid-cooled compressors have
cooling fins and water jackets cast around the cylinder to circulate
water.
Reciprocating compressors needs lubrication to reduce wear,
provide cooling and to act as a sealant between moving parts.
Lubricant is distributed thru a splash system crank and connecting
rods with oil in the crankcase.
Non-lubricating reciprocating compressors use special design
piston and non-metallic piston rings without oil in the crankcase. They
have higher maintenance cost because valves and piston rings wear
faster than in lubricated reciprocating compressor.
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3.3 Reciprocating Compressors
Single-acting Reciprocating
Compressor

The cylinders of reciprocating

compressors can be classified as
single-acting and double –acting.

Single-acting compressors as
shown in the figure, compresses
gas in one side of the piston only.
They are commonly air cooled
and widely used for small capacity
applications.

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3.3 Reciprocating Compressors
Compression stroke starts at point 1. As the
compressor compress the air from point 1 to 2,
the suction valves immediately closed, shutting
off the suction line of the cylinder. At point 2, the
discharge valves opens and compressed air is
pushed out of the cylinder into the discharge line
of the cylinder.
The discharge stroke is completed at point 3.
At this point, the piston returns to point 4, where
the pressure drops and closing the discharge
valve. The clearance between the end of the
cylinder and the top dead center (TDC) is known
as the “clearance volume”.
The piston expands from point 3 to 4. And the
intake stroke occurs from point 4 to 1, which is
also known as the “compressor capacity”. The
complete cycle is shown in the P-v diagram.
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3.3 Reciprocating Compressors
Reciprocating Air Compressor Without Clearance

Note:
2s – Isentropic Compression
2p – Polytropic Compression
2t – Isothermal Compression

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3.3 Reciprocating Compressors
Compressor Work Without Clearance:
1. For Isothermal Compression (𝑃𝑉 = 𝐶) 3. For Polytropic Compression (𝑃𝑉 𝑛 = 𝐶)
𝑽𝟐 𝑷𝟏 𝒏−𝟏
𝑾 = 𝑷𝟏 𝑽𝟏 𝐥𝐧 = 𝑷𝟏 𝑽𝟏 𝐥𝐧 𝒏𝑷𝟏 𝑽𝟏 𝑷𝟐 𝒏
𝑽𝟏 𝑷𝟐 𝑾= −𝟏
𝒏−𝟏 𝑷𝟏
𝑽𝟐 𝑷𝟏
𝑾 = 𝒎𝑹𝑻𝟏 𝐥𝐧 = 𝒎𝑹𝑻𝟏 𝐥𝐧 𝒏−𝟏
𝑽𝟏 𝑷𝟐 𝒏𝒎𝑹𝑻𝟏 𝑷𝟐 𝒏
𝑾= −𝟏
2. For Isentropic Compression (𝑃𝑉 𝑘 = 𝐶) 𝒏−𝟏 𝑷𝟏
𝒌−𝟏
𝒌𝑷𝟏 𝑽𝟏 𝑷𝟐 𝒌
Where:
𝑾= −𝟏
𝒌−𝟏 𝑷𝟏 isentropic constant, k = 1.4
𝒌−𝟏
polytropic constant, 0<n<1.4
𝒌𝒎𝑹𝑻𝟏 𝑷𝟐 𝒌
𝑾= −𝟏
𝒌−𝟏 𝑷𝟏
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3.3 Reciprocating Compressors
Reciprocating Air Compressor With Clearance

Note:
𝑉𝑐
𝑐 = 𝑐𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 =
𝑉𝐷

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3.3 Reciprocating Compressors
Compressor Work With Clearance:
1. For Isothermal Compression (𝑃𝑉 = 𝐶) 3. For Polytropic Compression (𝑃𝑉 𝑛 = 𝐶)
𝑽𝟐 𝑷𝟏 𝒏−𝟏
𝑾 = 𝑷𝟏 𝑽𝟏 ′ 𝐥𝐧 = 𝑷𝟏 𝑽𝟏 ′ 𝐥𝐧 𝒏𝑷𝟏 𝑽𝟏 ′ 𝑷𝟐 𝒏
𝑽𝟏 ′ 𝑷𝟐 𝑾= −𝟏
𝒏−𝟏 𝑷𝟏
𝑽𝟐 𝑷𝟏
𝑾 = 𝒎′𝑹𝑻𝟏 𝐥𝐧 = 𝒎′𝑹𝑻𝟏 𝐥𝐧 𝒏−𝟏
𝑽𝟏 ′ 𝑷𝟐 𝒏𝒎′𝑹𝑻𝟏 𝑷𝟐 𝒏
𝑾= −𝟏
2. For Isentropic Compression (𝑃𝑉 𝑘 = 𝐶) 𝒏−𝟏 𝑷𝟏
𝒌−𝟏
𝒌𝑷𝟏 𝑽𝟏 ′ 𝑷𝟐 𝒌
Where:
𝑾= −𝟏
𝒌−𝟏 𝑷𝟏 𝑃1 𝑉1′ = 𝑚′ 𝑅𝑇1
𝒌−𝟏
𝑚′ =amount of air inside cylinder
𝒌𝒎′𝑹𝑻𝟏 𝑷𝟐 𝒌 𝑉1 ′=compressor capacity
𝑾= −𝟏
𝒌−𝟏 𝑷𝟏
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Sample Problem:
1. An ideal single stage air compressor without clearance takes in air at 100
kPa with a temperature of 16°C and delivered it at 413 kPa after isentropic
compression. What is the discharge work done by the compressor in kJ/kg?
Solution:
𝑘−1
𝑘𝑚𝑅𝑇1 𝑃2 𝑘
𝑊= −1
𝑘−1 𝑃1

𝑘−1 1.4−1
𝑊 𝑘𝑅𝑇1 𝑃2 𝑘 (1.4)(0.287)(16 + 273) 413 1.4
= −1 = −1
𝑚 𝑘−1 𝑃1 1.4 − 1 100

𝑾 𝒌𝑱
= −𝟏𝟒𝟓
𝒎 𝒌𝒈

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3.3 Reciprocating Compressors
Sample Problem:
2. An air compressor receives 8 m3/min of a gas (R=0.410 kJ/kg-K, Cp=1.03
kJ/kg-K) at 108 kPa, 27°C and delivers it at 650kPa. Find the work if compression
is polytropic with 𝑃𝑉 1.3 = 𝐶.
Solution:
𝑛−1
𝑛𝑃1 𝑉1 𝑃2 𝑛
𝑊= −1
𝑛−1 𝑃1
1.3−1
1.3 108 (8) 650 1.3
= −1
1.3 − 1 108
𝒌𝑱
𝑾 = −𝟏𝟗𝟐𝟏. 𝟐𝟒 = −𝟑𝟐. 𝟎𝟐 𝒌𝑾
𝒎𝒊𝒏

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3.4 Compressor Fundamentals
SINGLE STAGE COMPRESSOR 2. Piston Displacement
Piston Displacement- is the volume
1. P, V, and T Relations: displaced by the piston as it moves from
top dead center to bottom dead center.
𝑷𝟏 𝑽𝟏 𝒏 = 𝑷𝟐 𝑽𝟐 𝒏 𝝅𝑫𝟐
𝒏−𝟏 𝑽𝑫 = 𝑳𝑵 × 𝑵𝒐. 𝒐𝒇 𝑪𝒚𝒍𝒊𝒏𝒅𝒆𝒓 × 𝑵𝒐. 𝒐𝒇 𝑷𝒊𝒔𝒕𝒐𝒏 𝑨𝒄𝒕𝒊𝒐𝒏
𝟒
𝑻𝟐 𝑷𝟐 𝒏
= Where:
𝑻𝟏 𝑷𝟏 VD = volume displacement
D = bore, m
𝒏−𝟏 L = stroke, m
𝑻𝟐 𝑽𝟏
= N = speed, rev/s
𝑻𝟏 𝑽𝟐 Note: for FREE AIR (air at normal atmospheric condition
in a particular geographical location)
Where:
n is a polytropic exponent
n = 1.4, if isentropic compression
𝑷𝒂 𝑽𝒂 𝑷𝟏 𝑽𝟏 Where:
= P1,V1,T1 = actual or given conditions
n = 1, if isothermal compression 𝑻𝒂 𝑻𝟏 Pa,Va,Ta = standard conditions

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3.4 Compressor Fundamentals
3. Volumetric Efficiency: 5. Actual Volumetric Efficiency:
Volumetric Efficiency- is the ratio of the actual The actual volumetric efficiency is usually less
gas drawn-in at intake condition to the than the clearance volumetric efficiency because
displacement volume (piston displacement). of the number of factors such as pressure drop
𝟏 at the valves, heat transfer between surrounding
′
𝑽𝟏 𝑷 𝟐
𝒏 and device, and the presence of residual gas in
𝒆𝒗 = OR 𝒆 = 𝟏 + 𝒄 − 𝒄 the cylinder at the end of the delivery stroke.
𝑽𝑫 𝒗
𝑷𝟏 𝟏
Where:
′
𝑷𝟐 𝒏 𝑷𝟏 𝑻𝒂𝒕𝒎
𝑉
c = clearance = 𝐶 𝒆𝒗 = 𝟏+𝒄−𝒄 × ×
𝑉𝐷 𝑷𝟏 𝑷𝒂𝒕𝒎 𝑻𝟏
4. Capacity of Compressor:
6. Compressor Efficiency, ec:
Capacity of Compressor is the actual volume Compressor efficiency is the ration of the
of gas delivered as measured at intake compressor power to the brake power
pressure and temperature
𝒎′𝑹𝑻𝟏 Where: 𝑪𝒐𝒎𝒑𝒓𝒆𝒔𝒔𝒐𝒓 𝑷𝒐𝒘𝒆𝒓
𝑽𝟏 ′ = 𝑚1 𝑒𝑣 𝑉1 𝑒𝑣 𝒆𝒄 =
𝑚′ = 1+𝑐 and 𝑉1 ′ = 1+𝑐 𝑩𝒓𝒂𝒌𝒆 𝑷𝒐𝒘𝒆𝒓
𝑷𝟏
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3.4 Compressor Fundamentals
7. Piston Speed, V: 9. Adiabatic Compressor Efficiency:
Piston Speed is the total distance a piston Adiabatic Compressor Efficiency is the ratio of
travels in a given time. It depends on the the isentropic work to the actual fluid work.
length of stroke and the angular speed. 𝑰𝒔𝒆𝒏𝒕𝒓𝒐𝒑𝒊𝒄 𝑾𝒐𝒓𝒌
𝒆𝒄(𝒂𝒅𝒊𝒂𝒃𝒂𝒕𝒊𝒄) =
𝑨𝒄𝒕𝒖𝒂𝒍 𝑭𝒍𝒖𝒊𝒅 𝑾𝒐𝒓𝒌
𝑽 = 𝟐𝑳𝑵
Piston Displacement of a Double-Acting,
Where:
V = piston speed, m/s Single Stage Compressor:
L = length of stroke, m a.)If piston rod is neglected
N = angular speed, rev/s 𝝅𝑫𝟐 𝝅𝑫𝟐 𝑳𝑵
𝑽𝑫 = 𝑳𝑵 × 𝟐 =
𝟒 𝟐
8. Ideal Indicated Power, Pi: a.)If piston rod is considered
Ideal Indicated Power is the product of the
indicated mean effective pressure and 𝝅𝑫𝟐 𝝅 𝟐
𝑽𝑫 = 𝑳𝑵 + 𝑫 − 𝒅𝟐 𝑳𝑵
displacement volume. 𝟒 𝟒

𝑷𝒊 = 𝑷𝒎𝒊 𝑽𝑫 𝝅𝑫𝟐 𝝅𝒅𝟐

𝑽𝑫 = 𝑳𝑵 − 𝑳𝑵
𝟐 𝟒

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3.4 Compressor Fundamentals
TWO STAGE COMPRESSOR 1. Compressor Work:
𝒏−𝟏
′ 𝒏
𝟐𝒏𝑷𝟏 𝑽𝟏 𝑷𝒙
𝑾= −𝟏
𝒏−𝟏 𝑷𝟏
Note: For Ideal Condition: WLP=WHP
2. Intercooler Pressure:
𝑷𝒙 = 𝑷𝟏 𝑷𝟒
3. Heat Rejected in 4. Heat Absorbed
Intercooler: by Cooling Water
𝑸 = 𝒎𝑪𝒑 (𝑻𝒙 − 𝑻𝟏 ) 𝑸 = 𝒎𝒘 𝑪𝒑𝒘 ∆𝑻𝒘
Where:
𝑛−1
𝑃𝑥 𝑛 𝑘𝐽
𝑇𝑥 = 𝑇1 ; 𝐶𝑝 = 1.0
𝑃1 𝑘𝑔 − 𝐾

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3.4 Compressor Fundamentals
THREE STAGE COMPRESSOR
1. Compressor Work:
𝒏−𝟏
′
𝟑𝒏𝑷𝟏 𝑽𝟏 𝑷𝒙 𝒏
𝑾= −𝟏
𝒏−𝟏 𝑷𝟏
2. Intercooler Pressure:
𝟑 𝟑 𝟐
𝑷𝒙 = 𝑷𝟏 𝟐 𝑷𝟔 𝑷𝒚 = 𝑷𝟏 𝑷𝟔
For Ideal Conditions:
𝑃𝑥 𝑃𝑦 𝑃6
= =
𝑃1 𝑃𝑥 𝑃𝑦

3. Heat Rejected in Intercoolers:

𝑸 = 𝟐𝒎𝑪𝒑 (𝑻𝒙 − 𝑻𝟏 )

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3.4 Compressor Fundamentals
MULTI-STAGE COMPRESSOR
GENERAL FORMULA
1. Compressor Work:
for “s” no. of stages:
𝒏−𝟏
′ 𝒏
𝒔𝒏𝑷𝟏 𝑽𝟏 𝑷𝒙
𝑾= −𝟏
𝒏−𝟏 𝑷𝟏
2. Intercooler Pressure:
𝒔
𝑷𝒙 = 𝑷𝒊 𝒔−𝟏 𝑷
𝒇

Where:
𝑃𝑖 = 𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝑠𝑢𝑐𝑡𝑖𝑜𝑛 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒
𝑃𝑓 = 𝑓𝑖𝑛𝑎𝑙 𝑜𝑟 𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒

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3.4 Compressor Fundamentals
Sample Problem:
3. A single-acting reciprocating air compressor with a clearance of 5% receives air at
100 kPa and 30°C and is delivered at 450 kPa. The bore and stroke are 350 mm and 390
mm respectively when operating at 1000 rpm. Determine:
a.) Volume Displacement, m3/s
b.) Volumetric Efficiency, %
c.) Compressor Capacity, m3/s
d.) Compressor Work, kW
e.) Compressor Efficiency, in percent if the brake power input to the
compressor is 120 kW.
f.) Temperature of air at the discharge, °C.
Assume no pressure drop in the intake and discharge port of compressor and take the
compression and expansion process to be 𝑃𝑉 1.3 = 𝐶 .

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Solution:

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3.4 Compressor Fundamentals
Sample Problem:
4. A double acting compressor with a volume displacement of 0.432 m3/s, delivers air at
725 kPa at a rate of 0.188 m3/s. The inlet condition of air 100 kPa and 30°C and the angular
speed of the compressor is 200 rpm. For a compression and expansion process given by
.
𝑃𝑉1 3 = 𝐶, determine:
a) The percent clearance of the compressor
b) The bore and stroke, in meters, assuming that the stroke is equal with the bore and
the volume displacement of the crank end and head end are the same.
Solution:

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3.4 Compressor Fundamentals

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3.4 Compressor Fundamentals
Sample Problem:
5. A single acting reciprocating compressor receives air at 100 kPa and 30°C and
delivered at 700 kPa. The clearance volume is taken to be 10% and the compression and
expansion process to have a polytropic exponent of 1.3. The compressor piston
displacement is 450 cm3 and operating at a speed of 850 rpm. Determine the mass of air
compressed, in kg/hr and the required compressor power, in kilowatts when the pressure
drop at the suction and discharge port are 10 kPa and 15 kPa, respectively.
Solution:

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′ −3
𝑚3 3600 𝑠
𝑉1 = 3.8732 × 10
𝑠 1 ℎ𝑟
′ 𝑚3
𝑉1 = 13.9434
ℎ𝑟

𝑇ℎ𝑒𝑟𝑒𝑓𝑜𝑟𝑒, 𝑓𝑜𝑟 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑎𝑖𝑟:

𝑚3
90 𝑘𝑃𝑎 13.9434
ℎ𝑟 𝒌𝒈
𝑚𝑎 = = 𝟏𝟒. 𝟒𝟑𝟎𝟕
𝑘𝐽 𝒉𝒓
0.287 (303 𝐾)
𝑘𝑔 − 𝐾

ME33Fluid
: Fluid Flow
Machinery 31 Chapter 2: Properties
Chapter of Fluids
3: Compressors
3.4 Compressor Fundamentals
Sample Problem:
6. A reciprocating compressor receives air at 100 kPa and 0.20 m3 of air per second
and delivered at 1000 kPa. Assuming conditions are ideal, and the compression and
expansion has a polytropic exponent of 1.3, determine the savings in compressor work kW,
due to (a) two staging and (b) three staging.
Solution:

ME33Fluid
: Fluid Flow
Machinery 32 Chapter 2: Properties
Chapter of Fluids
3: Compressors
3.4 Compressor Fundamentals

ME33Fluid
: Fluid Flow
Machinery 33 Chapter 2: Properties
Chapter of Fluids
3: Compressors