2024

Practical 1: Reciprocating
Compressors (Double-stage)

Ditaba Kashe
Thermodynamics II
8/23/2024
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 RESULT%

Student number(s): 2 1 5 1 2 5 0 2 9

Surname and initials: Kashe DJ

Diploma in Engineering Technology

Programme:
(Mechanical Engineering)

Module name: THERMODYNAMICS II

Graduate None 1 2 3 4 5 6 7 8 9 10
Attribute (GA)
assessment: X x

Practical/Assignment
1
number:

Group number: 2

Lecturer: OY Odofuwa

DECLARATION OF OWN WORK:

I,_Ditaba Kashe Joseph________, student number___215125029_________________________, hereby
declare that the content of this assignment/project is my own work, as defined and constituted in
the Rules and Regulations of the Central University of Technology, Free State (Please consult the
Programme Guide of the Department).

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Table of Contents
INTRODUCTION ................................................................................................. 4
AIM .................................................................................................................. 4
SUMMARY OF THEORY ................................................................................. 4
APPARATUS.................................................................................................... 6
EXPERIMENTAL PROCEDURE ....................................................................... 6
CALCULATION ................................................................................................... 7
ANALYTICAL CALCULATIONS ........................................................................ 8
RESULTS AND DISCUSSION ........................................................................... 11
CONCLUSION .................................................................................................. 11

LIST OF FIGURES
Figure 1: Air-flow and intercooling

Figure 2: P-V diagram for double-stage compressor

Figure 3: Apparatus

LIST OF TABLES

Table 1: Technical data

Table 2: Calculated results

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INTRODUCTION
AIM
The aim of the experiment was to determine the volumetric efficiency, input power and
discharge of the intercooler and compare them with the standard values.

The objectives were to familiarize the students with practical operation of the air
compressors.

SUMMARY OF THEORY

Double-Stage Air Compressor Operation

A double-stage air compressor has two compression stages, with an intercooler
between the stages. The key steps are (A, 1993):
1. First-stage compression:
Air is drawn into the first-stage compressor cylinder and compressed.
The air temperature rises due to the compression work.
2. Intercooling:
The hot compressed air from the first stage passes through an intercooler, which
removes some of the heat.
This reduces the air temperature before entering the second stage.
3. Second-stage compression:
The cooled air from the intercooler enters the second-stage compressor cylinder and is
further compressed.
The air temperature again rises due to the second-stage compression work.
4. Final compression:
The doubly compressed air exits the second stage at the final desired pressure.
The intercooling between stages is key, as it reduces the work required per stage and
overall, leading to a more efficient compression process.

Advantages on multistage compression

• Saving of work input as compared to single stage compressor.
• It reduces cost of compressor.
• There is reduction in maximum temperature.
• It reduces leakage loss considerably.

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Disadvantages of multistage compression
• The construction is more complicated.
• Initial cost is more.
Application of high-pressure compressors
• To start heavy diesel engines.
• To cool large buildings.
• To supercharge internal combustion engines.
• To clean workshops, generators and automobile vehicles.
• To inject or spray fuel into the cylinder of a diesel engine.
• To operate drills, hammers etc.

Figure 1: The above figure shows the double-stage air compressor sketch and
illustrates the air flow with inteercooling between the two stages.

Figure 2: The above figure is that of p-V diagram for a double-stage reciprocating
compressor. It also ashows the effects of cooling ( both perfect and imperfect), which
results in less input work.

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RELEVANT FORMULAS
𝑛−1
𝑃
• 𝑇2 = 𝑇1 (𝑃2 ) 𝑛
1
𝑛−1
𝑛 𝑃
• 𝑃𝑜𝑤𝑒𝑟 = 𝑛−1 𝑃1 𝑉̇ [(𝑃2 ) 𝑛 − 1]
1
𝑧𝑛
𝑧𝑛 𝑃2 𝑛−1
• 𝐼𝑃 = 𝑃 𝑉̇ {(𝑃 ) − 1}
𝑛−1 1 1
2𝜋𝑁
• 𝑣= ∗𝑟
60
• 𝑄̇ = 𝑚𝐶𝑝 (𝑇2𝑥 −𝑇2 )
1
𝑉𝑐 𝑃 𝑛
• դ𝑣 = 1 − [(𝑃2 ) − 1]
𝑉𝑠 1

• 𝑚̇ = 𝑃1 𝑣𝐴

The above are applicable formulas for this practical and they will be used later in
the calculations. (Joel, 1996)

APPARATUS

Figure 3: A set-up for a double-stage reciprocating air compressor.

In the figure above, there is a two-stage reciprocating air-compressor with inlet and
outlet air tanks on top. An intermediate air tank is positioned at the bottom of the
stand, and inter-cooling tubes are situated behind the compressor within the flow
path of the cooling fan air. Pressure gauges and thermocouples are linked to
different inlet and outlet ports of both compressor stages. The compressor is belt-
driven by an external electric motor. All electronically measured pressure and
temperature values are transmitted to an external computer through a computer
interface cable (computer not included).

EXPERIMENTAL PROCEDURE
• All relevant data acquisition apparatus was connected via the computer
interface cable before switching on the mains power supply.

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 • The exact positions of the electronic pressure, temperature, and mass flow
sensors as well as the flow path of air through the 2 compressor stages were
familiarized.
• The electric motor was started with the On-Off-switch on the control panel.
The pressure rise on the manual pressure gauges was observed until
reaching the point where the safety pressure relief valve on the 2nd stage
opened. Approximately 2 minutes were allowed for system equilibrium before
acquiring relevant measured data via the connected computer.
• The computer program was allowed to gather data from the compressor for
about 1.5 minutes. The program automatically calculated average values for
each measured data-point. Once satisfied with the data, a data report sheet
was printed out and then, finally, compressor motor was switched off via
control panel. (Odofuwa, 2024)

CALCULATION
TECHNICAL DATA

Table 1 Technical data for the air compressor apparatus

Stage 1 Stage 2

Cylinder Diameter (mm) 76.0 32.0

Stroke Length (mm) 70.0 70.0

Stroke Volume (cm³) 317.6 56.3

% Clearance: Stroke Volume 1.2% 4.7%

Units

Dry Air Density (100kPa @ 25°C) 1.169 kg/m³

Air Gas Constant (R) 287.0 J/kg.K

Dry Air Density (100kPa @ 25°C) 1.169 kg/m³

Air Gas Constant (R) 287.0 J/kg.K

Electric Motor Voltage (Volt) 220.0 Volt

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 Power Factor - (Electric Motor 80% %
Efficiency)

Electric Motor Revolutions 1440.0 RPM

Electric Motor: Compressor - Drive 2.0 1

Ratio

Air Flow - Pipe Diameter (mm) 9.0 mm

EXPERIMENTAL DATA

ANALYTICAL CALCULATIONS
1. Polytropic indexes
𝑛−1
𝑃
𝑇2 = 𝑇1 (𝑃2 ) 𝑛
1

498 𝑛−1
360 = 294( 87 ) 𝑛

𝑛 = 1.29

𝑛−1
𝑃
𝑇2 = 𝑇1 (𝑃2 ) 𝑛
1

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 𝑛−1
𝑃
𝑇2 = 𝑇1 (𝑃2 ) 𝑛
1

𝑚 = 1.087

𝑉𝐼𝑛𝑑 = 𝑉1 − 𝑉7

𝑉𝐼𝑛𝑑 = 321.41 − 17.88

𝑉𝐼𝑛𝑑 = 303.53 𝑐𝑚3

𝑉𝐼𝑛𝑑 = 𝑉2 − 𝑉5

𝑉𝐼𝑛𝑑 = 68.5 − 4.45

𝑉𝐼𝑛𝑑 = 64.05 𝑐𝑚3

𝑛−1
𝑛 𝑃
𝑃𝑜𝑤𝑒𝑟 = 𝑛−1 𝑃1 𝑉̇ [(𝑃2 ) 𝑛 − 1]
1

1.29−1
1.29 498
𝑃𝑜𝑤𝑒𝑟 = 1.29−1 87(303 ∗ ̇ 10−3 )[( 87 ) 1.29 − 1]

𝑃𝑜𝑤𝑒𝑟 = 675.79 𝑊

𝑚−1
𝑚 𝑃
𝑃𝑜𝑤𝑒𝑟 = 𝑚−1 𝑃5 𝑉̇ [(𝑃3 ) 𝑚 − 1]
2

1.087 912 1.087−1

𝑃𝑜𝑤𝑒𝑟 = 1.087−1 498(64.05 ∗ ̇ 10−3 )[(498) 1.087 − 1]

𝑃𝑜𝑤𝑒𝑟 = 237.29 W

Total power = 675.79 + 237.29 = 913.08 W

Average n= 1.18
𝑧𝑛
𝑧𝑛 𝑃 𝑛−1
𝐼𝑃 = 𝑛−1 𝑃1 𝑉̇ {(𝑃2 ) − 1}
1

1.18−1
2∗1.18 −3 498 2∗1.18
𝐼𝑃 = 87(303.53 ∗ 10 ) {( 87 ) − 1}
1.18−1

𝐼𝑃 = 591.34 W

𝜋𝑑2
𝐴= 4

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 𝜋(76∗10−6 )2
𝐴= 4

𝐴 = 4.54*10−9 𝑚2

2𝜋𝑁
𝑣= ∗𝑟
60

2𝜋1440
𝑣= ∗ (38 ∗ 10−6 )
60

𝑣 = 5.73 *10−3 𝑚⁄𝑠

𝑚̇ = 𝑃1 𝑣𝐴

𝑚̇ = (87)(5.73 ∗ 10−3 )(4.54 ∗ 10−9 )

𝑚̇ = 2.26 * 10−9 kg/s

𝑄̇ = 𝑚𝐶𝑝 (𝑇2𝑥 −𝑇2 )

𝑄̇ = ( 2.26 ∗ 10−9 )(1.006)(360 − 300)

𝑄̇ = 136.41 * 10−9 kW

1
𝑉𝑐 𝑃 𝑛
դ𝑣 = 1 − [(𝑃2 ) − 1]
𝑉𝑠 1

1
3.81∗10−3498 1.29
դ𝑣 = 1 − [( 87 ) − 1]
317.6∗10−3

դ𝑣 = 0.99
1
𝑉𝑐 𝑃 𝑚
դ𝑣 = 1 − [(𝑃3 ) − 1]
𝑉𝑠 2

1
2.65∗10−3 498 1.087
դ𝑣 = 1 − [( 87 ) − 1]
56.3∗10−3

դ𝑣 = 0.9649

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RESULTS AND DISCUSSION
Table 2: Tabulated results for above calculations

Units
Index n 1.29
Index m 1.087

Mass flow rate 2.26 * 10−9 Kg/s

Stage 1 IP 675.79 W
Stage 2 IP 237.29 W
Total IP 591.34 W

Stage 1 Volumetric efficiency 99.2 %

Stage 2 Volumetric efficiency 96.49 %
Total compression efficiency 97.85 %

We were able to determine all the thermodynamics parameters for the two-stage
reciprocating air compressor and determine the efficiency needed and the results are
tabulated in table 2. From the table we can see that the efficiency of the first stage is
higher than that of the second stage and the input power for the first stage is also
higher, this may be due to because in the first stage the compressor does majority of
the work. The volume induced in the second stage is also less than that of the first
stage.

CONCLUSION
There is a difference between the polytropic indexes (n = 1.29 and m = 1.083). This
is because the index is a measure of departure from ideal gas behavior and is
affected by multiple factors which are different between the two stages. These
factors include temperature changes, pressure ratios, clearance volume and
intercooling.
The difference between theoretical and summative power of the compressor may be
due to interstage pressure losses, clearance volume and re-expansion, heat transfer
and cooling and compressor efficiency. To improve the reliability of the results
obtained, the experiment can be performed in duplicates (i.e multiple times)

In general, the experiment was a success as we were able to obtain valid results and
familiarize ourselves with the practical applications of compressors. This, despite
some components not being available (e.g computer for collecting data).

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Bibliography
A, E. T. &. M., 1993. Applied thermodynamics for engineering technologists. 5th ed.
s.l.:Pearson Education limited.

Joel, R., 1996. Basic engineering thermodynamics. 5th ed. s.l.:Addison Wesley Longman
Limited.

Odofuwa, O., 2024. Lab Guide Thermodynamics II, Bloemfontein: Central University Of
Technology.

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