CHAPTER 1: FLUID

COMPRESSORS MACHINERIES

COMPRESSORS
Compressor is a fluid machine used to increase the pressure of a gas by decreasing its volume.

TYPES OF COMPRESSORS
Reciprocating compressors – are compressors built in sizes as large as 5, 000 to 10, 000 ft3/min. piston
displacement with pressure range up to 1, 000 atm and vacuum down to 0.50 in. Hg abs.

Rotary Compressors without liquid seals – are compressors built in sizes as large as 50, 000 ft3/min.
and are suitable for moderate vacua not less than 15 in. Hg abs for moderate pressures of 5 to 20 psi.

Rotary Compressors with liquid seals – are compressors built in sizes up to 5000 ft3/min. and are
suitable for ratios of compression reflected in vacuum pump service to 28 in. hg and positive pressure
service to 75 psig.

Centrifugal Compressors – 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.

Axial Flow Compressors – are compressors which extended the field of the 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

Hydraulic Jet Compressors – are primarily employed for vacuum pump service requiring 1 to 4 in Hg
abs pressure and capacities of 1000 ft3/min at suction conditions.

Vapor Jet Compressors – are used for both exhauster and blower service with steam as the usual
actuating fluid.

1. Positive displacement compressors draw fluid into a cavity, or displace the fluid, and then
force the fluid out of the cavity through suction.
2. Centrifugal, or aerodynamic compressors, pumps have a spinning impeller that draws the
fluid into the pump and forces it out of the outlet point at an increased velocity.

PREPARED BY: JOHN PAUL JACALAN

AIR COMPRESSORS
Industrial plants with its various processes requires gases at pressure above or below atmospheric
condition. The most widely used of the gases is the compressed air in operating air engines, drive
pneumatic tools such as pneumatic hammers and drills, cleaning by air blast in operating air hoists,
spraying paints, pumping water by air lift, manufacture of plastics and other industrial products and
host of other jobs.

PERFORMANCE ANALYSIS OF RECIPROCATING AIR COMPRESSOR

1. P, V and T Relations:

𝑃𝑃1 𝑉𝑉1 𝑛𝑛 =𝑃𝑃2 𝑉𝑉2 𝑛𝑛 𝑇𝑇2 𝑃𝑃2 𝑛𝑛−1 𝑇𝑇2 𝑉𝑉1

= ( ) 𝑛𝑛 = ( )𝑛𝑛−1
𝑇𝑇1 𝑃𝑃1 𝑇𝑇1 𝑉𝑉2

Where: n is a polytropic index.

n = 1.4, if isentropic compression, n = 1, if isothermal compression
2. Compressor Work

a. Work for Polytropic Process

𝑛𝑛−1
𝑛𝑛𝑚𝑚𝑚𝑚𝑚𝑚1 𝑃𝑃 𝑛𝑛
𝑊𝑊𝑊𝑊 = (𝑛𝑛𝑛𝑛1𝑉𝑉1′/1−𝑛𝑛)(𝑃𝑃2𝑃𝑃1)𝑛𝑛−1𝑛𝑛−1 𝑊𝑊𝐶𝐶 = � � ��𝑃𝑃2 � − 1� 𝑜𝑜𝑜𝑜 𝑊𝑊𝐶𝐶 =
1−𝑛𝑛 1
𝑛𝑛−1
𝑛𝑛𝑃𝑃1 𝑉𝑉1 ′ 𝑃𝑃
( 1−𝑛𝑛
) �(𝑃𝑃2 ) 𝑛𝑛 − 1�
1

b. Work for Isentropic Process

𝑘𝑘−1
𝑘𝑘−1
𝑘𝑘𝑚𝑚𝑚𝑚𝑚𝑚1 𝑃𝑃 𝑘𝑘 𝑘𝑘𝑃𝑃1 𝑉𝑉1 ′ 𝑃𝑃
𝑊𝑊𝐶𝐶 = � � ��𝑃𝑃2 � − 1� 𝑜𝑜𝑜𝑜 𝑊𝑊𝐶𝐶 = ( ) �(𝑃𝑃2 ) 𝑘𝑘 − 1�
1−𝑘𝑘 1 1−𝑘𝑘 1

c. Work for Isothermal Process

𝑃𝑃2 𝑃𝑃2
𝑊𝑊 = 𝑃𝑃1 𝑉𝑉1′ ln � � 𝑜𝑜𝑜𝑜 𝑊𝑊 = 𝑚𝑚𝑚𝑚𝑚𝑚1 ln � �
𝑃𝑃1 𝑃𝑃1

𝑉𝑉1 𝑉𝑉1
𝑊𝑊 = 𝑃𝑃1 𝑉𝑉1′ ln � � 𝑜𝑜𝑜𝑜 𝑊𝑊 = 𝑚𝑚𝑚𝑚𝑚𝑚1 ln � �
𝑉𝑉2 𝑉𝑉2

3. Piston Displacement – is the volume displaced by the piston as it moves from top dead
center to bottom dead center.

𝜋𝜋
𝑉𝑉𝐷𝐷 = 𝐿𝐿𝐿𝐿𝐿𝐿𝑛𝑛𝑐𝑐 𝑛𝑛𝑝𝑝 = ( 𝐷𝐷2 )𝐿𝐿𝐿𝐿𝑛𝑛𝑐𝑐 𝑛𝑛𝑝𝑝
4
4. Volumetric Efficiency – is the ratio of the actual gas drawn – in at intake condition to
the displacement volume (piston displacement).

𝑉𝑉 ′ 1
𝑃𝑃 𝑉𝑉
𝑒𝑒𝑉𝑉 = 𝑉𝑉1 or 𝜂𝜂𝑉𝑉𝑉𝑉 = 1 + 𝑐𝑐 − 𝑐𝑐(𝑃𝑃2)𝑛𝑛 or 𝜂𝜂𝑉𝑉𝑉𝑉 = 1 + 𝑐𝑐 − 𝑐𝑐(𝑉𝑉1)
𝐷𝐷 1 2

𝑉𝑉
Where: 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐, 𝑐𝑐 = 𝑉𝑉𝐶𝐶
𝐷𝐷

5. Actual Volumetric Efficiency – is the usually less than the clearance volumetric
efficiency because of the number of factors such as pressure drop at the valves, heat
transfer between surrounding and device, and the presence of residual gas in the
cylinder at the end of the delivery stroke.
 𝑉𝑉1 𝑃𝑃1 𝑇𝑇𝑎𝑎𝑎𝑎𝑎𝑎
𝜂𝜂𝑉𝑉𝑉𝑉 ′ = �1 + 𝑐𝑐 − 𝑐𝑐 � �� 𝑥𝑥 𝑥𝑥
𝑉𝑉2 𝑃𝑃𝑎𝑎𝑎𝑎𝑎𝑎 𝑇𝑇1

6. Compressor Efficiency, ec – is the ratio of the compressor power to the brake power.

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝
𝑒𝑒𝑐𝑐 =
𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝

7. Piston Speed, V – is the total distance a piston travels in a given time. It is dependent on
the length of stroke and the angular speed.

𝑉𝑉 = 2𝐿𝐿𝐿𝐿

8. Ideal Indicated Power, Pi – is the product of the indicated mean effective pressure and
the displacement volume.

𝑃𝑃𝑖𝑖 = 𝑃𝑃𝑚𝑚𝑚𝑚 𝑥𝑥 𝑉𝑉𝐷𝐷

9. Adiabatic Compressor Efficiency – is the ratio of the isentropic work to the actual fluid
work.

𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤
𝑒𝑒𝑐𝑐(𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎) =
𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤

10. Piston displacement of a double acting, single stage compressor:

a. If piston rods is neglected:

𝜋𝜋𝐷𝐷2 𝜋𝜋𝐷𝐷2
𝑉𝑉𝐷𝐷 = 𝐿𝐿𝐿𝐿 𝑥𝑥 2 = 𝐿𝐿𝐿𝐿
4 2

b. If piston rod is considered:

𝜋𝜋𝐷𝐷2 𝜋𝜋(𝐷𝐷2 − 𝑑𝑑2 )

𝑉𝑉𝐷𝐷 = 𝐿𝐿𝐿𝐿 + 𝐿𝐿𝐿𝐿
4 4

𝜋𝜋𝐷𝐷2 𝜋𝜋𝑑𝑑 2
𝑉𝑉𝐷𝐷 = 𝐿𝐿𝐿𝐿 − 𝐿𝐿𝐿𝐿
2 4
11. Multi – Stage Compressor (General Formula)

Uses of Multi – Stage Compressor

 Save on compressor power input

 Limit the gas discharge temperature
 Limit the pressure differential per cylinder
 Prevent the vaporization of the lubricating oil to prevent its ignition should the
temperature becomes too high. Which could easily happen in single – stage
compression to a high pressure.

Compressor Work

𝑛𝑛−1
𝑛𝑛𝑃𝑃1 𝑉𝑉1 ′ 𝑃𝑃𝑋𝑋 𝑆𝑆
𝑊𝑊𝐶𝐶 = 𝑆𝑆( 1−𝑛𝑛
) �( ) 𝑛𝑛 − 1� where: 𝑃𝑃𝑋𝑋 = �(𝑃𝑃𝑖𝑖 )𝑠𝑠−1 (𝑃𝑃𝑓𝑓 )
𝑃𝑃1

Heat Rejected in Intercooler:

𝑄𝑄 = 𝑚𝑚𝐶𝐶𝑝𝑝 (𝑇𝑇𝑥𝑥 − 𝑇𝑇1 )

SAMPLE PROBLEMS:
1. An ideal single stage air compressor without clearance takes in air at 100 kPa
with a temperature of 16ºC and delivered it at 413 kPa after isentropic
compression. What is the discharge work done by the compressor in kJ/kg.

Answer: -145 kJ/kg

2. An air compressor is to compress 8.5 m3/min from 98.56 kPa to 985.6 kPa.
Assuming ideal conditions and with n = 1.3, what will be the saving in work due
to two staging?

Answer: 5.60 kW

3. Air taken from the atmosphere at 100 kPa and 21ºC is delivered to the air
receiver at 690 kPa and 150ºC by means of a water jacketed reciprocating
compressor. The compressor has rated capacity of 0.15 m3/s free air. Determine
the power required to compress the air.

Answer: 34.94 kW

4. A rotary compressor receives 6 m3/min of gas (R = 410 J/kg-K, cp = 103 J/kg-

K, and k = 1.67) at 105 kPaa, 27 ºC and delivers it at 630 kPaa. Changes of
potential and kinetic energies are negligible. Find the compressor work if the
process is a) isentropic, b) polytropic with n = 1.4; and c) isothermal.

Answer: -1642.07 kJ/min, -1,474.07 kJ/min, -1128.81 kJ/min

5. A 355.6 x 381 mm, double acting, air compressor, whose clearance is 4%, runs
at 150 rpm. At state 1, the air is at 97 kPaa and 27ºC; discharge is at 386 kPaa;
compression and re-expansion are isentropic. The state of the surrounding air is
at a pressure of 101.325 kPaa and a temperature of 21ºC. a) Estimate the amount
of free air using the conventional volumetric efficiency, b) compute the
compressor power for an efficiency of 75% based on shaft work.

Answer: 9.93 m3/min, -38.65 kW

6. The mean effective pressure of an air compressor is 500 kPa. If the compressor
work is 150 kW, what is the volume displacement in m3/min.

Answer: 18 m3/min
7. A two stage air compressor has a suction pressure of 101.325 kPa and a
discharge pressure of 1,140 kPa. What is the intercooler pressure in kPa?

Answer: 339.37 kPa

8. Air is compressed in a two – stage, double acting compressor that is

electrically driven at 165 rpm. The low – pressure cylinder (30.5 x 35.5 cm)
receives 6.85 m3/min of air at 96.53 kPaa, 43.3ºC, and the high pressure
cylinder (20.5 x 35.5 cm) discharges the air at 717.06 kPaa. Piston rods are 5.1
cm in diameter and the isentropic overall efficiency is 74%. Find the a)
volumetric efficiency; and b) power of the driving motor.

Answer: 81.2%, 35 kW

9. A three -stage compressor delivers 23 kg/s of air. The suction pressure and
temperature are 100 kPaa and 27ºC, respectively. The discharge pressure is
1,380 kPaa. An intercooler is installed after each stage. Determine the a)
pressure in each intercooler; and b) compressor work.

Answer: 239.86 kPaa, 573.34 kPaa, 1380 kPaa, -5 906.59 kW

10. Liquified Petroleum Gas (LPG) is manufactured by compressing propane

(C3H8) gas to high pressures. A multi-stage centrifugal compressor driven by
electric motor is installed to handle the job. The compressor draws 500 liters
per second of the gas at 140 kPa and -35ºC. The gas is delivered into a spherical
tank elevated 7 m from the centerline of the compressor. Discharge pressure
and temperature are 4.25 MPa and 45ºC respectively. Suction diameter is 50
cm while the discharge is 30 cm. Rise in temperature of water for cooling the
compressor is 6ºC. Take cp for propane as 1.65 kJ/kg-C and M = 44 kg/kg mol,
SG = 0.55. Determine the number of stages are in the compressor, if each stage
can develop a head of 160 m.

Answer: 5 stages.