Materials Used For Construction: 1. Reciprocating Compressor
Materials Used For Construction: 1. Reciprocating Compressor
Materials Used For Construction: 1. Reciprocating Compressor
1. Reciprocating Compressor
2. Screw Compressor
1. Reciprocating Compressor
Reciprocating compressors are characterized with higher pressures and reduced mass flow rate.
They are mainly used in high pressure applications since it can deliver air at about 30 – 40 bar.
1) For diesel engine starting, where electric motor starting becomes costly and impractical.
2) Refrigeration compressors are normally reciprocating type (Single Stage) with a discharge pressure
around 10 bar.
3) Air conditioning systems also uses reciprocating compressors (Nowadays trend is changed to
screw compressors).
2. Screw Compressors
Screw type compressors provide air at increased mass flow rate but with reduced discharge
pressure around 8 bar. Hence applications are also in low pressure systems, such as,
2) Air conditioning systems nowadays employ screw compressors. (which have low power consumption
and increased mass flow rate as advantages)
3) For low pressure air required for running pneumatic tools, pneumatic-hydraulic equipment, etc.
Cycle of operation
(3) – (4) – As piston travels from BDC to TDC air trapped inside the cylinder is compressed.
(4) – (1) – As piston approaches TDC discharge valve opens and compressed air is delivered.
(1) – (2) – Undelivered air trapped in the clearance space is expanded as piston moves down.
(2) – (3) – When trapped air in the clearance space is expanded to atmospheric pressure, further
downward movement of the piston creates a vacuum inside the cylinder and thereby atmospheric
air enters through suction valve.
In fig. ‘Va’ indicates the volume corresponding to actual stroke of the piston from TDC to BDC (also
called stroke volume). Similarly ‘Ve’ indicates the volume corresponding to the effective stroke of piston,
when atmospheric air enters the cylinder.
The ratio of effective stroke volume to the swept volume is known as the volumetric efficiency of the
compressor,
Graph of Pressure against volume in a reciprocating compressor
For greater efficiency air compression should be isothermal as this requires the minimum work input. In
practice Isothermal compression is not possible, an ideal Isothermal cycle requires sufficient time to allow
all the required heat to be transferred out of the cylinder, practicality dictates that the piston must have a
relatively high speed to give a reasonable output,
In other words, no clearance volume exists. This is practically impossible, because some clearance space
is required otherwise piston hits on the cylinder head as it travels. Also expansion of piston occurs as it
travels and very little clearance may cause the same problem. Also increased clearance space reduces
compressor efficiency and increase its running hours. So clearance volume must be kept around a
reasonable value as instructed by the manufacturer.
It is important that the compressor clearance volume is kept small as possible in order to improve
overall volumetric efficiency as the air trapped in this space must expand to below suction
pressure before new air can enter, this is an effective loss of stroke.
A clearance is required in order to prevent the piston striking the cylinder cover when starting or
stopping off load. The clearance volume is sometimes referred to as the 'Bump Clearance'.
In water cooled compressors, freshwater is circulated through jackets that are built into the walls of the
cylinders and cylinder heads.
Above cycle compresses gas from atmospheric pressure to 8 bar in a single stage. The area
enclosed by the points 12341 represents the work of compression in a single stage compressor.
Also see the cycle or Pressure-Volume diagram (P-V) below which compresses gas from
atmospheric pressure to 8 bar in two stages.
1. The work done in compressing the air is reduced, thus power can be saved
2. Prevents mechanical problems as the air temperature is controlled
3. The suction and delivery valves remain in cleaner condition as the temperature and vaporization
of lubricating oil is less
4. The machine is smaller and better balanced
5. Effects from moisture can be handled better, by draining at each stage
6. Compression approaches near isothermal
7. Compression ratio at each stage is lower when compared to a single-stage machine
8. Light moving parts usually made of aluminum, thus less cost and better maintenance
Plain Tube-
o -easy to clean
o -very effective due to large surface area of large number small diameter tubes
o -plugging of failed tube allows cooler to continue in service with little loss in efficiency
o -must allow for thermal expansion by having one tube plate floating
'U' tube-
o -suitable for higher pressures than plain tube
o -self compensating for thermal expansion
o -efficient due to large number of small diameter tubes
o -failed tubes may be plugged
o -more expensive than plain tube and difficult to clean
Coil tube
o -self compensating for expansion
o -suitable for high pressures
o -difficult to clean
o -inefficient due to large tube diameter
o - not easy to plug
o -expensive
SAFETY FEATURES OF MARINE COMPRESSORS
Marine compressors have various safety features and cutouts installed so that they will trip when
running in an unsafe mode. The compressors are reliable machines, but have to be maintained
properly and in the proper intervals. There have been cases of the cylinder heads bursting and
often resulting in fatalities. The various safety devices put in a marine compressor are as follows:
1. Lubricating oil low pressure trip
2. Cooling water high temperature trip
3. Motor overload trip and Motor overheating trip
1. Relief valve, Set 10% exceed maximum working pressure, fitted at Stage outlet. Protect
overpressure on airside.
2. Bursting disc (or relief valve fitted on coolers), fitted at Waterside. Protect against over pressure
due to rupture of cooling air pipe. Relief at about 3 bars and sufficient flow area. Copper disc.
3. Drain valve. To remove condensed water and oil
4. Fusible plug. May be fitted instead of relief valve on compressor outlets immediately after
discharge valve. Melt at 120 deg C
Control of output
For compressors designed for starting air requirements a water jacket relief valve is fitted