‫جامعـــة البلقــاء التطبيقيـــة‬

‫كليــــــة الهندســــة التكنولوجيــــة‬

AL-BALQA APPLIED UNIVERSITY
FACULTY OF ENGINEERING
TECHNOLOGY 1997 ‫تأسسـت عام‬

Experiment number (1)

Experiment title
)Reciprocating Air Compressors Double Stages(

Course title (Thermodynamic lab)

Instructor’s Name
Dr. Abdullah N. Olimat
:Student Names
Rita khader Emran al-dawawseh
:Experiment Contacted on 15/4/2025
Report Submitted on 29/5/2025
.Dept. of Mech Eng

Faculty of Engineering and Technology

AL- Balqa Applied University

Objectives
 To study the performance of a two-stage air compressor without
intercooling.
 To calculate mechanical and electrical power for each stage.
 To analyze the relation between power/speed and intermediate pressure.
  To determine and compare volumetric, mechanical, and isothermal
efficiencies.
 To present trends using graphical representation.

Introduction and Theoretical Background

Two-stage air compressors are used to achieve higher pressure ratios more
efficiently by compressing the air in two steps. In this experiment, the focus is
on a system without intercooling, which increases the thermal load on the
second stage. Each compression stage behaves approximately like a polytropic
process:
The polytropic index can be calculated using measured pressure and
temperature values. Also, the system efficiency can be characterized by:
 Volumetric Efficiency: Ratio of actual intake air volume to swept volume.
 Mechanical Efficiency: Ratio of mechanical power output to indicated
power.
 Isothermal Efficiency: Ratio of isothermal work to actual work input.

Without intercooling, the compression work and temperature rise in the second
stage increase significantly, which is reflected in performance measurements.

Experimental Setup and Procedure

Setup Includes:
 Two-stage reciprocating air compressor.
  Pressure gauges before and after each stage.
 Thermocouples for temperature measurement.
 Electrical power meter.
 Speed measurement system for the second stage.
 Data acquisition unit.

Procedure:
1. Confirm system readiness and safety.
2. Start the compressor and allow it to stabilize.
3. Measure inlet/outlet pressures and temperatures for both stages.
4. Record electrical readings (voltage and current) to compute electrical power.
5. Measure mechanical power (via torque/speed or other device).
6. Record the speed of stage 2.
7. Repeat measurements at various operating conditions.
8. Stop the system and analyze data.

Experimental Observations

 In the two-stage compressor, a noticeable rise in air temperature was

recorded between the first and second stages due to the absence of
intercooling.
 Intermediate pressure readings were essential to track system performance,
and their variation clearly affected both stages' power consumption.
 The second stage operated at a visibly higher speed and temperature
compared to the first.
 Mechanical vibration and noise increased slightly in the second stage,
possibly due to higher compression ratios.
 Observation of the gauges and power meter showed that total electrical and
mechanical power increased with intermediate pressure.
 Before entering the compressor there is a throttle area.
 At the entrance there are two thermometers, one for dry and the other for
wet.
 At the end of the suction line there is a filter to draw in air without
impurities.
 The compressor began operation smoothly, and pressure readings increased
steadily as expected.
 Heat generation was noticeable around the cylinder, emphasizing the need
for cooling mechanisms.
  A delay in pressure buildup was observed, possibly due to clearance volume
or minor leaks in the system.
 The collected condensate indicated the presence of moisture in the
compressed air, which varied with operating conditions.
 Differences in intake and discharge pressures suggested potential losses in
volumetric efficiency.
 The sound was considered a little loud, maybe there are mechanical
problems.
 Ventilation process to stabilize pressure.

Experimental measured data

Table 1 Data collected from the experiment
Local atmospheric pressure :1.012 bar
Compressor 1 N1 speed : 720 RPM
Intercooler : No
N2 P1 Tq1 V1 A1 P2 Tq2 V2 A2 T1 T3 T5 ΔP
Rev/min bar N.m volt amperes bar N.m volt amperes ℃ ℃ ℃ mm H 2 O
250 2.7 4.9 100 10 2.5 2.6 40 7 16 81 19 116

350 1.9 4.3 100 8.5 1.7 5.3 50 7.2 16 87 22 120

450 1.7 3.9 100 7.5 1.6 5.5 60 8 16 87 25 124

550 1 3.5 100 7 0.9 5.6 75 8 16 86 31 125

650 0.7 3.1 100 6 0.6 5.3 90 7.5 16 83 37 127

750 0.6 3 100 5.5 0.5 5.1 100 7 16 80 41 130

850 0.5 2.7 100 5 0.4 5.4 110 8 15 77 44 131

Results tables

For compressor 1
Table 2. the result obtained from stage number 1
N= 720 RPM P° =1.012 ¯¿

( )
P1 bar p1 T1 T3 T5 Ti n cal Air Manometer Actual air
abs p° K K K K density ΔP mass flow
ρ kg/m3 m ṁ kg/s
abs
3.712 3.66798419 289 354 1.22011
292 323 1.18497 5 0.116 0.003987
2.912 2.877470356 289 360 1.26238 1.22011
295 327.5 5 5 0.12 0.004055
2.712 2.679841897 289 360 1.28675 1.22011
298 329 5 5 0.124 0.004122
2.012 1.988142292 289 359 1.46118 1.22011
304 331.5 1 5 0.125 0.004139
1.712 1.691699605 289 356 1.65726 1.22011
310 333 5 5 0.127 0.004172
1.612 1.592885375 289 353 1.75343 1.22011
314 333.5 5 5 0.13 0.004221
1.512 1.494071146 288 350 1.94403 1.22435
317 333.5 1 2 0.131 0.004244
Ideal air Actual η Theory Tq1 Ẇ elec Ẇ i Ẇ mech Ẇ iso
A1 V1
mass flow vol,a η vol
ṁ kg/s
0.00563 70.7573 1.33083 537.89 886.68
5 5% 2 4.9 10 100 1000 78 31 429.7769
0.00563 71.9669 0.98259 426.14 778.10
5 6% 2 4.3 8.5 100 850 74 97 355.4836
0.00563 73.1565 0.89074 398.99 705.72
5 8% 2 3.9 7.5 100 750 71 74 337.0321
0.00563 73.4509 0.54949 265.10 633.34
5 7% 8 3.5 7 100 700 28 51 235.9005
0.00563 74.0362 0.39136 198.82 560.96
5 5% 7 3.1 6 100 600 12 28 181.9106
0.00563 74.9055 0.33664 176.30 542.86
5 9% 4 3 5.5 100 550 07 72 162.9767
0.00565 75.0629 0.28077 150.71 488.58
4 3% 7 2.7 5 100 500 11 05 140.8523

**we don’t have values of T6 here**

Figures and Data Discussion

Fig. 1 illustrates the variation of mechanical work (stage 1) and speed (stage 2) with respect to the
intermediate pressure.

Fig. 2 illustrates the variation of electrical work (stage 1) and speed (stage 2) with respect to the
intermediate pressure.
For fig 1

The intersection point on the graph, where the mechanical work of the first stage
and the speed of the second stage are plotted against the intermediate pressure,
represents the optimal intermediate pressure for the two-stage air compressor.
This point indicates the intermediate pressure at which the compressor operates
with maximum efficiency, achieving a balance between the mechanical work
.required in the first stage and the performance (speed) of the second stage
:Relationship Explanation
Mechanical Work of the First Stage: As the intermediate pressure 
increases, the mechanical work required in the first stage decreases. This is
because the pressure differential between the inlet and the intermediate
pressure is reduced, requiring less energy to compress the air to the
.intermediate stage
Speed of the Second Stage: The speed of the second stage is also 
influenced by the intermediate pressure. At lower intermediate pressures, the
second stage must compress the air from a lower pressure to the final desired
pressure, necessitating higher speed or energy. As the intermediate pressure
increases, the second stage requires less speed since the air is already
.partially compressed in the first stage
Intersection Point: The intersection point represents the intermediate 
pressure that minimizes the total energy consumption of the two-stage
compressor while maintaining optimal system performance. At this pressure,
the workload is evenly distributed between the two stages, resulting in
.reduced overall power requirements and enhanced operational efficiency
Practical Significance: Selecting the intermediate pressure at the intersection
point ensures the two-stage air compressor operates at peak efficiency. This
optimal pressure reduces operational costs, minimizes energy consumption, and
extends the lifespan of the compressor by preventing excessive mechanical stress
.on either stage

Fig 2
Building on the previous analysis, a second graph was plotted, replacing the
mechanical work of the first stage with the electrical work consumed by the motor
driving the first stage, while keeping the speed of the second stage and
intermediate pressure as variables. The intersection point of the curves still
represents the optimal intermediate pressure, where the two-stage air compressor
achieves maximum efficiency by balancing the electrical energy consumption of
.the first stage with the performance (speed) of the second stage
Key Difference Due to Electrical Work: Unlike mechanical work, which directly
reflects the energy required for compression, electrical work accounts for the
energy consumed by the motor, including electrical losses (e.g., heat or motor
inefficiency). As the intermediate pressure increases, the electrical work required
in the first stage decreases due to a reduced pressure differential, similar to the
mechanical work trend. However, the inclusion of electrical work introduces
additional considerations, such as motor efficiency and power conversion losses,
which may slightly alter the energy consumption profile compared to the
mechanical work analysis. Despite this, the intersection point remains the optimal
intermediate pressure, minimizing total electrical energy usage while ensuring
.efficient compressor operation
Practical Implications: Using electrical work in the analysis provides a more
comprehensive view of the compressor’s energy efficiency, as it reflects the actual
power drawn from the electrical supply. Operating at the optimal intermediate
pressure identified by the intersection point reduces electricity costs and enhances
the system’s overall sustainability, making it a critical parameter for designing and
.operating energy-efficient two-stage air compressors

Error Analysis

 Instrument Calibration Errors: Inaccuracies in pressure gauges, power

meters, or flow sensors due to improper calibration may lead to erroneous
.measurements of intermediate pressure, electrical work, or other parameters
 Environmental Variations: Fluctuations in ambient temperature, humidity, or
inlet air conditions could affect compressor performance, impacting variables like
.second-stage speed and energy consumption
 Manual Data Recording Errors: Human errors during data collection, such as
inconsistent logging or misreading instrument outputs, may introduce random
.inaccuracies in the recorded values
 Operational Inconsistencies: Slight variations in the compressor’s operating
conditions (e.g., load changes or stage synchronization) across trials could cause
.deviations in measured parameters
 Sensor Precision Limitations: Limited resolution or sensitivity of
measurement devices may result in small errors, particularly for critical variables
.like intermediate pressure or electrical work
Recommendations

 Use High-Precision Instruments: Employ advanced sensors with higher

resolution and accuracy for measuring parameters such as intermediate
pressure, electrical work, and second-stage speed to reduce systematic
errors.
 Automate Data Collection: Implement an automated data acquisition
system to minimize human errors in recording measurements and ensure
consistent data logging across trials.
 Control Environmental Conditions: Conduct the experiment in a
controlled environment with stable temperature, humidity, and inlet air
conditions to reduce the impact of external variations on compressor
performance.
 Perform Regular Calibration: Calibrate all measurement devices (e.g.,
pressure gauges, power meters, and flow sensors) before each trial to ensure
reliable and accurate data.
 Increase Trial Repetitions: Conduct additional experimental trials to
improve data repeatability and allow for statistical analysis to better identify
the optimal intermediate pressure.
 Incorporate Real-Time Monitoring: Use real-time monitoring tools to
track compressor performance during operation, enabling immediate
detection and correction of inconsistencies.
 Analyze Additional Parameters: Measure and analyze supplementary
variables, such as temperature at each stage or air flow rate, to gain deeper
insights into the compressor’s efficiency and performance.

Conclusion
The two-stage air compressor experiment showed that the optimal intermediate
pressure, identified by the intersection of electrical work and second-stage speed
curves, minimizes energy consumption while maintaining efficient operation.
Despite minor errors from instruments and environmental factors, the results
highlight the importance of this pressure for energy efficiency. Future
improvements, such as precise sensors and automated data collection, can enhance
.accuracy, supporting better compressor design and cost savings