2nd Semester EME

Air Compressor

Prepare by
Prof. Kartik Mandavia
Mechanical Engineering Department
DDU

Lectures 1-4
Lecture 01
 Introduction

A compressor is a mechanical device that increases the pressure of a gas by reducing

its volume. An air compressor is a specific type of gas compressor.
Compressors are similar to pumps: both increase the pressure on a fluid and both can
transport the fluid through a pipe. As gases are compressible, the compressor also
reduces the volume of a gas. Liquids are relatively incompressible; while some can
be compressed, the main action of a pump is to pressurize and transport liquids.

They can also be classified according to the design and principle of operation:
Single-stage reciprocating compressor
1. Two-stage reciprocating compressor
2. Compound compressor
3. Rotary-screw compressor
4. Rotary vane pump
5. Scroll compressor
6. Turbo compressor
7. Centrifugal compressor
A reciprocating compressor is a positive-displacement machine that uses
a piston to compress a gas and deliver it at high pressure. They are often some of the
most critical and expensive systems at a production facility, and deserve special
attention.The reciprocating compressor consists of a piston moving back and forth in
the cylinder with suction and discharge valve arranged to allow pumping to take
place. The rotary and centrifugal compressors have rotating members but the rotary
compressor has a positive displacement where as a centrifugal compressors draws the
vapour and discharges it at high pressure by centrifugal force.
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Construction and working of reciprocation air
compressor
Explain construction and working of single stage reciprocating air compressor
with neat sketch. Also represent it on P-V diagram.

In single stage reciprocating air compressor, the entire

compression is carried out in a single cylinder. The opening &
closing of a simple check valve (plate or spring valve)
depends upon the difference in pressure, if mechanically
operated valves are used for suction & discharge then their
functioning is controlled by cams. The weight of air in the
cylinder will be zero when the piston is at top dead center. At
this position, you have to neglect clearance volume. When
piston starts moving downwards, the pressure inside the
cylinder falls below atmospheric pressure& suction
valve/inlet valve opens. The air is drawn into the cylinder
through a suction filter element. This operation is known as
suction stroke. When the piston moves upwards, compresses
the air in cylinder & inlet valve closes when the pressure
reaches atmospheric pressure. Further compression follows as
the piston moves towards the top of its stroke. Until when the
pressure in the cylinder exceeds that in the receiver. This is
compression stroke of a compressor. At the end of this stroke
discharge/delivery valve opens & air is delivered to a receiver
 Air Compressors

COMPRESSOR – A device which takes a definite quantity of fluid ( usually gas, and

most often air ) and deliver it at a required pressure.

Air Compressor – 1) Takes in atmospheric air,

2) Compresses it, and

3) Delivers it to a storage vessel ( i.e. Reservoir ).

Compression requires Work to be done on the gas,

 Compressor must be driven by some sort of Prime Mover ( i.e. Engine )
 Classification
Air Compressors

Reciprocating Rotary

Centrifugal

No. of Stages No. of Sides of Piston

for Compression in operation
Single – stage Single – acting
Multi - stage Double - Acting
 Reciprocating Compressor - Working

2. Principle of Operation
Fig. shows single-acting piston actions in
the cylinder of a reciprocating compressor.
The piston is driven by a crank shaft via a
connecting rod.
At the top of the cylinder are a suction
valve and a discharge valve.
A reciprocating compressor usually has
two, three, four, or six cylinders in it.
Reciprocating Compressor - Working
Lecture 02
Reciprocating Compressor – Equation for Work
without Clearance
Reciprocating Compressor – Equation for Work
with Clearance
 Factors Affecting the Volumetric Efficiency of
Reciprocating Compressor
a) Clearance volume
The volume of the cylinder between the top of the piston and the delivery valve plate
when the piston is at top dead center is known as clearance volume. Clearance
volume is necessary, though it should be minimum, to prevent damage to the valves.
The refrigerant gas present in the clearance volume will expands on the down ward
movement of the piston. There will not be any intake of suction gas until the pressure
of the cylinder gas drops below the suction pressure of the refrigeration system. The
clearance volume is expressed as % of the total volume. It is about 2-4 % of the
cylinder volume. Higher cylinder volume reduces the volumetric efficiency of the
reciprocating compressor.

b) Compressor ratio
Higher compression ratio reduces the volumetric efficiency of the compressor.
Higher compression ratio either due to higher discharge pressure or lower suction
pressure. This requires more piston displacement in order to expand the refrigerant
gas present in the clearance volume for the intake of suction gas. Therefore, lower
compression ratio during operation of the refrigeration system is desirable to achieve
higher volumetric efficiency of the compressor.
 Factors Affecting the Volumetric Efficiency of
Reciprocating Compressor
c) Leakage through valves
Any leakage of gas through suction valve or delivery valve will reduce the volumetric
efficiency of the compressor. It is obvious that the gas filled in the cylinder leaks
back either on suction side or from delivery side to the cylinder will reduce the
volumetric efficiency of the compressor.

d) Cylinder heating effect

Higher temperature of cylinder wall increases the volume of the gas which intern
reduces the intake of suction gas. Therefore, effective head cooling of the compressor
is important to avoid reduction in volumetric efficiency of the compressor due to
cylinder heating effect.
Lecture 03
 Roots blower
Construction: It consists of two lobed rotors placed in separate parallel axis of a
casing as shown in fig:. The two rotors are driven by a pair of gears (which are driven
by the prime mover) and they revolve in opposite directions. The lobes of the rotor
are of cycloid shape to ensure correct mating. A small clearance of 0.1 mm to 0.2 mm
is provided between the lobe and casing. This reduces the wear of moving parts.
Working: When the rotor is driven by the gear, air is trapped between the lobes and
the casing. the trapped air moves along the casing and discharged into the receiver.
There is no increase in pressure since the flow area from entry to exit remains
constant. But, when the outlet is opened, there is a
back flow of high pressure air in the receiver. This creates the rise in pressure of the
air delivered. These types of blowers are used in automobiles for supercharging.
Construction: A vane blower consists of (1) a rotor, (2) vanes mounted on the rotor,
(3) inlet and outlet ports and (4) casing. The rotor is placed eccentrically in the outer
casing. Concentric vanes (usually 6 to 8 nos.) are mounted on the rotor. The vanes are
made of fiber or carbon. Inlet suction area is greater than outlet delivery area.
 Vane blower
Working: When the rotor is rotated by the prime mover, air is entrapped between two
consecutive vanes. This air is gradually compressed due to decreasing volume
between the rotor and the outer casing. This air is delivered to the receiver. This
partly compressed air is further increased in pressure due to the back flow of high
pressure air from the receiver.
Advantages: 1. Very simple and compact, 2. High efficiency 3. Higher speeds are
possible
 Centrifugal compressor
Construction: It consists of an impeller, a casing and a
diffuser. The impeller consists of a number of blades or
vanes, is mounted on the compressor shaft inside the casing.
The impeller is surrounded by the casing.
Working: In this compressor air enters axially and leaves
radially. When the impeller rotates, air enters axially through
the eye of the impeller with a low velocity. This air moves
over the impeller vanes. Then, it flows radially outwards
from the impeller. The velocity and pressure increases in the
impeller. The air then enters the diverging passage known as
diffuser. In the diffuser, kinetic energy is converted into
pressure energy and the pressure of the air further increases.
It is shown in fig:. Finally, high pressure air is delivered to
the receiver. Generally half of the total pressure rise takes
place in the impeller and the other half in the diffuser.
Applications: Centrifugal compressors are used for low
pressure units such as for refrigeration, supercharging of
internal combustion engines, etc.
 Axial flow compressor
In this air compressor, air enters and leaves axially.
Construction: It consists of two sets of blades: Rotor blades and stator blades. The
blades are so arranged that the unit consists of adjacent rows of rotor blades and
stator blades as shown in fig:4.15. The stator blades are fixed to the casing. The rotor
blades are fixed on the rotating drum. The drum is rotated by a prime mover through
a driving shaft. Single stage compressor consists of a row of rotor blades followed by
a row of stator blades. Compression of air takes place in each pair of blades (one
rotor blade and one stator blade). Hence there are many stages of compression in this
type of compressor.
Working: When the switch is switched on, the prime mover rotates the drum. Air
enters through the compressor inlet and passes through the rotor and stator blades.
While passing
Applications:
1. They are widely used in high pressure units such as industrial and marine gas
turbine plants,
2. They are most suitable for aircraft work (Jet propulsion) since they require less
frontal area.
Example
Question Bank
Question Bank
MCQ
 MCQ
1. The ratio of work-done per cycle to the stroke volume of the compressor is known
as.......

A.Compressor capacity
B.Compression ratio
C.Compressor efficiency
D.Mean effective pressure

Answer D.Mean effective pressure

2. The capacity of a compression is 10 m3/minute.10 m 3/minute refers to.......

A.Standard air
B.Free air
C.Compressed air
D.Compressed air at delivery pressure

Answer B.Free air

3. Aeroplanes employe following type of compressor.........

A.Radial flow
B.Axial flow
C.Centrifugal
C.Combination of above

Answer B.Axial flow

4. The multi stage compression as compared to single stage compression......

A.Improves volumetric efficiency for the given pressure ratio

B.Reduces work done per kg of air
C.Reduces cost of compressor
D.Gives more uniform torque
E.All of the above

Answer E.All of the above

5. Compression efficiency is compared against.......

A.Ideal compression
B.adiabatic compression
C.both isothermal and adiabatic compression
D.Isentropic compression
E.Isothermal compression

Answer E.Isothermal compression

6. The volume of air delivered by the compressor is called.......

A.Free air delivery

B.Compressor capacity
C.Swept volume
D.None of the above

B.Compressor capacity
7. The most efficient method of compressing air is to compress it.......

A.Isothermal
B.Adiabatically
C.Isentropically
D.Isochronically

Answer A.Isothermal

8. Ratio of indicated HP and break HP is known as.........

A.Mechanical efficiency
B.Volumetric efficiency
C.Isothermal efficiency
C.Adiabatic efficiency

Answer A.Mechanical efficiency

9. Maximum work is done in compressing air when the compression is......

A.Improves volumetric efficiency for the given pressure ratio

B.Isothermal
C.Adiabatic
D.Polytropic
E.Any of the above

Answer B.Adiabatic

10. The value of air sucked by the compressor during its suction stroke is called.......

A.Free air delivery

B.Compressor capacity
C.Swept volume
D.none of the above
Answer C.Swept volume
11. The ratio of indicated HP to shaft HP is known as.......

A.Compressor efficiency
B.Isothermal efficiency
C.Volumetric efficiency
D.Mechanical efficiency

Answer D.Mechanical efficiency

12 Volumetric efficiency is.......

A.The ratio of stroke volume to clearance volume

B.The ratio of the air actually delivered to the amount of piston displacement
C.Reciprocal of compression ratio
D.Index of compressor performance

Answer D.70 to 90%

14. The pressure of air at the beginning of the compression stroke is......atmospheric
pressure

A.Equal to
B.Less than
C.More than
D.None of the above

Answer B.Less than

15 The intercooling in multistage compressors is done.......

A.To cool the air during compression

B.To cool the air at delivery
C.To enable compression in two stages
D.To minimise the work of compression
Answer D.To minimise the work of compression
16. Ratio of compression is the ratio of.......

A.Gauge discharge pressure to the gauge intake pressure

B.Absolute discharge pressure to the absolute intake pressure
C.Stroke Volume and clearance volume
D.None of the above
Answer B.Absolute discharge pressure to the absolute intake pressure

18. Cylinder clearance in a compression should be .........

A.As large as possible

B.As small as possible
C.about 50% of sweet volume
C.About 100% of swept volume

Answer B.As small as possible

19. Volumetric efficiency of a compressor with clearance volume.......

A.Volumetric efficiency of a compressor with clearance volume

B.Decreases with increase in compression ratio Compressed air
C.In not dependent upon compression ratio
D.May increase or decrease depending on compressor capacity
Answer B.Decreases with increase in compression ratio
20. Volumetric efficiency of a compressor without clearance volume.......

A.Increases with increase in compression ratio

B.Decreases with increase in compression ratio
C.In not dependent upon compression ratio
D.May increase or decrease depending on compressor capacity

Answer C.In not dependent upon compression ratio

21. The clearance volume of the air compressor is kept minimum because .........

A.It allows maximum compression to be achieved

B.It greatly affects volumetric efficiency
C.It results in minimum work
C.It permits isothermal compression
Answer B.It greatly affects volumetric efficiency
Short question and answers
1. List out the applications of compressed air.
The compressed air is mostly used in pneumatic brakes, pneumatic drills, pneumatic jacks,
pneumatic lifts, spray painting, shop cleaning, injecting fuel in diesel engines, supercharging internal combustion engines,
refrigeration and air conditioning systems.
2 Classify the various types of air compressor.
(a) According to the design and principles of operation

(a) Reciprocating compressor

(b) Rotary compressor

(b) According to the action

(a) Single acting compressor

(b) Double acting compressor

(c) According to the number of stages

(a) Single stage compressor (for compression ratio up to 5)

(b) Multistage compressor (for compression ration than 5)

(d) According to the pressure limit

(a) Low pressure compressor (having maximum pressure up to 1 bar)

(b) Medium pressure compressor (having maximum pressure from 1 bar to 8 bar)
(c) High pressure compressor (having maximum pressure of 8 bar and more)

(e) According to the capacity

(a) Low capacity compressor (Volume delivered 0.15m3/s or less)

(b) Medium capacity compressor (Volume delivered 0.15m3/s to 5 m3/s)
(c) High capacity compressor (Volume delivered is above 5m3/s)
3. Give the classification of compressor based on the movement of piston
 Single acting compressor
 Double acting compressor
4. What is meant by single acting compressor?
In a single acting compressor, the suction, compression and delivery of air take place on one
side of the piston.

5. What is meant by double acting compressor?

In a double acting reciprocating compressor, the suction, compression and delivery of air take place
on both sides of the piston.

6. What is meant by single stage compressor?

In a single stage compressor, the compression of air from the initial pressure to the final pressure is
carried out in one cylinder only.
7. Define the term isothermal compression efficiency

Isothermal efficiency is defined as the ratio between isothermal work to the actual work of the
compressor. Isothermal efficiency. iso = Isothermal work/Actual Work

8. Define the mechanical efficiency of a reciprocating air compressor

Mechanical efficiency of the reciprocating air compressor is defined as the ratio between

theoretical or indicated power required to the driving power required or actual power supplied to the compressor.

Mechanical efficiency. max =Theoretical power or Indicated power/Driving power required or actual power supplied
9. Define volumetric efficiency of an air compressor
volumetric efficiency of air compressor is the ratio (or as a percentage) between the volume of air drawn in to the cylinder and sweft volume.

Volumetric efficiency is defined as the ratio of volume of free air sucked into the compressor per

cycle to the stroke volume of the cylinder.

vol = Volume of free air taken per cycle/Stroke volume of the cylinder
10. State the conditions which lower the volumetric efficiency of an air compressor.

Increase in clearance volume ,Increased pressure and temperature of suction.

11. Define clearance ratio

Clearance ratio is defined as the ration of clearance volume (Vc) to swept volume (or) stroke
volume (Vs). C = Vc/Vs

12. Define isentropic efficiency

Isentropic efficiency is the ratio of the isentropic power to the brake power required to drive the
compressor.
Isentropic efficiency = Isentropic power/Actual brake power
13. Define mean effective pressure. How it is related to indicated power of an IC engine?
Mean effective pressure is defined as hypothetical pressure which is considered to be acting on the
piston throughout the stroke.
Indicated power of an IC engine is given by the relation.
IP = Pm x L x A x K x n Where Pm = Mean effective
pressure
L = Stroke length m
A = Area m2
n = number of working stroke per second [N/2 for 4 stroke]& [N for 2 stroke] K = number of cylinders.
14. Define FAD or free air delivered [
The free air delivered is the actual volume delivered at the stated pressure with reduced intake
pressure and temperature and expressed in m3/min
15. Explain how flow of air is controlled in a reciprocating compressor.
The flow of air is controlled by a centrifugal governor or maintaining the speed of motor constant or
providing the air pocket advancement to the cylinder.
16. What factors limit the delivery pressure in a reciprocating compressor? [

Size of the cylinder., Stroke length, Pressure and temperature of intake air.

19. Name the compression process in which work done is minimum in a reciprocating air
compressor.
Isothermal compression
20. What is compression ratio?
Compression ratio is defined as the ratio between total volume and clearance volume.
Compression ratio = Total volume/Clearance volume

17. Why clearance is necessary and what is its effect on the performance of reciprocating
compressor?
When the piston reaches top dead center in the cylinder, there is a dead space between piston top
and cylinder head. This space is known as clearance space and the volume occupied by this space is
known as clearance volume. Some minimum clearance volume is necessary to prevent piston/head contact. The clearance is necessary in
reciprocating compressors to trap the gas after each stroke.
The clearance volume limits the stroke of the piston. Hence, it reduces the capacity of the compressor as well as its volumetric efficiency.
18. Which type of compression is the best in reciprocating compressor?
Isothermal compression
21. What is meant by multistage compressor?
In a multistage compressor, the compression of the air from the initial pressure to the final

pressure is carried out in more than one cylinder.

22. What is meant by intercooler? Or How is the intercooler used to reduce the power

consumption of compressor?
An intercooler is a simple heat exchanger. It exchanges the heat of compressed air from the low-

pressure compressor to the circulating water before the air enters the high pressure compressor. The
purpose of intercooler is to minimize the work of compression. As the intercooler reduces the intake temperature of air HP cylinder, the amount of work required is
reduced.
23. What do you mean by perfect intercooling?
When the temperature of air leaving the intercooler (T2’) is equal to the original atmospheric air
temperature (T1), then intercooling is known as perfect intercooling.
24. Draw p-V diagram of a two stage reciprocating air compressor [

25. Indicate the application of reciprocating compressors in industry.

 Pneumatic brakes
 Pneumatic drills
 Pneumatic jacks
 Pneumatic lifts
 Spray painting
 Injecting fuel in diesel engines
 Supercharging internal combustion engines
 Refrigeration and air conditioning systems.
26. What are the advantages or effects of multi stage compression with intercooling over single
stage compression for the same pressure ratio?

 The work done per kg of air is reduced in multistage compression with intercooler as
compared with single stage compression for the same delivery pressure.
 It improves the volumetric efficiency for the given pressure ratio.
 The size of the cylinder (i.e. high pressure and low pressure) may be adjusted to suit the volumetric and the pressure of the
air.

 It reduces thee leakage loss considerably.

 It gives more uniform torque and hence, a smaller flywheel is required. It provides effective
lubrication because of lower operating temperature.

 It reduces the cost of the compressor.

27. What are the factors that affect the volumetric efficiency of a reciprocating compressor?

Provided in previous slides

30. Why clearance is necessary in reciprocating compressors?

The clearance is necessary in reciprocating compressors to trap the gas after each stroke.
31. What is the effect of clearance volume on the power required and work done in a
reciprocating air compressor?
Both power required and work done in a reciprocating compressor will decrease due to clearance
volume.
32. Discuss the effect of clearance upon the performance of an air compressor [
i) The volumetric efficiency of air compressor increases with decrease in clearance of the

compressor.
ii) The free air delivered by the compressor is increased by reducing the clearance volume.
33. If C is the clearance ratio for a reciprocating air compressor, what will be the volumetric efficiency?

Provided in previous slides

34. What is the main advantage of intercooling in multi-stage reciprocating compressors? [

The work done per kg of air is reduced in multistage compression with intercooler as compared with

a single stage compression for the same delivery pressure.

35. Give two merits of rotary compressor over reciprocating compressor.
 A rotary compressor gives uniform delivery of air when compared to a reciprocating
compressor.
 Rotary compressors are small in size for the same discharge as compared with reciprocating compressors.
 Lubricating system is more complicated in a reciprocating compressor where as it is very simple in rotary compressor.
37. Under what conditions the reciprocating compressors or rotary compressors are selected.

Reciprocating compressors are selected when the high pressure ratio is required whereas the rotary

compressors are selected when the continuous flow of air with low pressure required.

38. What are a slip factor and a pressure coefficient?

Slip factor:

Slip factor is the ratio of whirl velocity of static pressure to tip velocity.

Pressure coefficient:

Pressure coefficient is the ratio of isentropic work of the compressor to the Euler work (u.Vw).
39. What is rotary compressor?

A rotary screw compressor is a type of gas compressor which uses a rotary type positive

displacement mechanism. The mechanism for gas compression utilizes either a single screw element or two counter rotating intermeshed helical screw elements housed within a

specially shaped chamber.

40. Differentiate rotary and reciprocating compressors.

S.No Rotary compressor Reciprocating compressor
1 It is simple in construction. Construction is complicated.
2 Speed is high. Speed is low.
3 It is suitable for large rate of flow at low It is suitable for low rate of flow at very

discharge pressure. high discharge pressure.

4 Maintenance cost is less. Maintenance cost is high.
5 There is no balancing problem Balancing is major problem.
41. Differentiate centrifugal compressor and axial flow compressor
S.No Centrifugal compressor Axial compressor
1. Starting torque is low. Starting torque is high
2. Isentropic efficiency is around 70% Isentropic efficiency is around 85%
3. It is not suitable for multistage compression. It is suitable for multistage compression.
4. More frontal area is required. Less frontal area is required.
5. Manufacturing cost is low. Manufacturing cost is high.
6. Running cost is low. Running cost is high.
42. What is meant by single stage compressor?
In this types of compressor, the compression of the air takes place in two stages i.e. the air is first

compressed to some extent in one cylinder and then it is transferred to the second cylinder for further compression. Finally the compressed air is stored in a tank.
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