Jay Kamath (216059461) MECH 3504 Group 3ii Experiment Performed: 2023-02-13. Report Submitted: 2023-03-19. MECH 3504 Thermofluids Laboratory Air Compressors Page 1 of 16 Jay Kamath (216059461) MECH 3504 Group 3ii Experiment Performed: 2023-02-13. Report Submitted: 2023-03-19. Contents Abstract ........................................................................................................................................... 3 Introduction, Background & Objectives ......................................................................................... 4 Experimental Apparatus & Method ................................................................................................ 5 2.1 Experimental Apparatus ........................................................................................................ 5 2.2 Experimental Method ............................................................................................................ 5 2.3 Experimental Uncertainties ................................................................................................... 6 Results & Discussion ...................................................................................................................... 7 4. Summary & Conclusions ......................................................................................................... 10 References ..................................................................................................................................... 11 Appendix ....................................................................................................................................... 12 Results Tables ........................................................................................................................... 12 Results for Rotary Vane Compressor at n=1500 RPM ......................................................... 12 Results for Rotary Vane Compressor at n=2300 RPM ......................................................... 12 Results for Piston Compressor at 1000 RPM ........................................................................ 13 Results for Piston Compressor at 1500 RPM ........................................................................ 13 Sample Calculations .................................................................................................................. 14 Uncertainty Calculations: .......................................................................................................... 15 Page 2 of 16 Jay Kamath (216059461) MECH 3504 Group 3ii Experiment Performed: 2023-02-13. Report Submitted: 2023-03-19. Abstract Air compressors provide a useful conversion of low-pressure air to high pressure. They can be used in many industrial uses, such as pneumatic machinery, or industrial air systems. This report analyzes the characteristics of two types of positive displacement air compressors: The Piston and the Rotary Vane compressor, at various speeds, and flow rates. We found that efficiency tends to be higher in both compressors at higher pressure differentials across the pumps, whilst piston compressors will always be more efficient than vane compressors. Additionally, we found that for higher flow rates the Vane compressor is much more useful and performs far better. This helps in determining use cases for both compressor types as we can determine that vane compressors are more applicable in high flow rate applications such as industrial air ventilation. Piston compressors are more applicable in high pressure differential uses such as pneumatic machinery. We can use finding from this report to justify specific use cases for compressors, as well as identifying ideal use conditions for required efficiency or flow rate. Page 3 of 16 Jay Kamath (216059461) MECH 3504 Group 3ii Experiment Performed: 2023-02-13. Report Submitted: 2023-03-19. Introduction, Background & Objectives Air compressors are devices used in various industries: Automotive, manufacturing, construction, agriculture etc. Due to their varied use cases, there are many different types of compressors. To make identification easier, air compressors are usually placed into 2 categories. Positive Displacement (working with a constant flow) and Dynamic (working with constant pressure). For the purposes of this report, we will be discussing 2 positive displacement air compressors: A Piston compressor and a Rotary Vane Compressor. Piston compressors can be used in the automotive industry for spraying paint or powering pneumatic tools. Rotary vane compressors can be used in vacuum pumps allowing manufacturers to vacuum seal and vacuum dry food. Positive displacements work by moving a piston up and down in a cylinder, compressing air as it moves. By reducing the cylinder volume, then exhausting the compressed air. A rotary Vane compressor works much in the same way, but instead of a piston moving up and down a cylinder, the compression is done by moving a rotor with small gaps past a stator to compress air in the tiny gaps, then discharge it through an outlet port. Both variations provide power at differing rates and can be used for different results. Thus understanding peak efficiencies, best practices and the characteristics of Positive Displacement air compressors is key to ensuring we can effectively operate compressors. The efficiency of a pump is calculated by finding the hydraulic power output of the compressed air and dividing it by the electrical power input to the compressor. The objectives for this experiment are: 1. To compare the performance of rotary vane and piston compressors in terms of efficiency, pressure ratio, and airflow rate. 2. To investigate the effect of different operating parameters, such as speed, and pressure, on the performance of rotary vane and piston compressors. 3. To analyze the advantages and disadvantages of rotary vane and piston compressors and their suitability for different applications. We can analyze the efficiencies of air compressors by finding the Hydraulic power output of each compressor at various flow rates and speeds. The governing equations we used are: π πβπ¦ππππ’πππ = ππ ππ ln ππ π Where: ο§ Phyd = Hydraulic power in Watts ο§ Ps = Suction-side pressure in N/m2 or P3 from measurements ο§ Pd = Pressure-side pressure in N/m2 or P4 from measurements. ο§ Vs= Suction flow in m3/s π And: π = πβπ¦π β 100% ππ Page 4 of 16 Jay Kamath (216059461) MECH 3504 Group 3ii Experiment Performed: 2023-02-13. Report Submitted: 2023-03-19. Experimental Apparatus & Method 2.1 Experimental Apparatus The Experimental apparatus consists of either a Rotary vane, or piston compressor (16), attached to a mounting rail (1). A drive motor (2) is also attached to the mounting rails along side 2 centrifugal pumps (4,5). There were also 2 control valves (6, 12) to control flow input from the compressed air tank (11) and the measuring tank (7). The control cabinet (8) was connected to all sensors in the apparatus, allowing us to record and see live properties in the pipes, particularly pressures, temperatures, and motor speed and output. A stabilization tank (9) and compressed air tank(11) are also used to allow for somewhere to store compressed air and to regulate pressure throughout the experiment. A venturi nozzle (10) is also used to measure the flow rate through the pumps/compressors. Compressors were connected to the drive motor with controllable input. Figure 1- Image of experimental setup and apparatus with all parts numbered for reference, courtesy of MECH 3504 at Lassonde School of Engineering, York University (Harris) 2.2 Experimental Method We first installed the piston compressor and connected it to the drive motor. After connecting all appropriate valves, we first fully closed control valve V22(12) to prevent air flowing through the compressor, we then started the drive motor, setting its speed to 1000 RPM as our first testing group. Next, we slowly opened the valve a few turns at a time and took measurements at steady state. The measurements taken were for the pressure side pressure(P4), and the pressure for the Page 5 of 16 Jay Kamath (216059461) MECH 3504 Group 3ii Experiment Performed: 2023-02-13. Report Submitted: 2023-03-19. suction side (P3), as well as values for dP(P4-P3) , Temperature, and RPM of the motor. After collecting data at this point the team then opened the valve again, and repeated procedure, each time ensuring to compensate for any changes in RPM due to the valve changes. The procedure was continued until the control valve had been turned from fully closed position to a fully open position. Then the setup was powered down and reset by closing the control valve. For piston compressors the experiment was completed at n=1000 RPM and n= 1500 RPM. The exact same procedure was used for the Rotary Vane compressor however the rpm values were set to be n=1500 RPM and n= 2300 RPM as the two compressors have different rpm tolerances. 2.3 Experimental Uncertainties Systematic Errors for this experiment included: ο§ Measuring at incorrect times when data was not steady state. ο§ Instruments being difficult to precisely stick to correct RPM requirements. ο§ Fluctuation in readings, leading to some ballpark measurements. Random errors for this experiment included: ο§ Vibrations in the experimental setup ο§ Hydraulic Energy lost as sound/heat energy. As manufacturer specifications were not available at time of reporting. The estimation is that of 95% confidence rate. Every measured value will therefore be considered to have uncertainty level of ±5%. Next, we found aggregate uncertainties for all major calculated values using the Root Sum Square Method: π ππ π ]2 ππ₯π π ππ§ = √∑[ π=1 Worked examples for an uncertainty calculation for Hydraulic Power will be shown in the appendices. But note that for all measured properties, we take a 5% uncertainty level. Page 6 of 16 Jay Kamath (216059461) MECH 3504 Group 3ii Experiment Performed: 2023-02-13. Report Submitted: 2023-03-19. Results & Discussion We collected 4 sets of results, 2 each for both types of compressors. For the Piston compressor values were taken at drive train rpms of n=1000 RPM and n=1500 RPM. For the Rotary Vane compressors, values were measured at n=1500 RPM and n= 2300 RPM. 0,0014 Volumetric Flow Rate (m3/s) 0,0012 0,001 0,0008 0,0006 0,0004 0,0002 0 42000 37000 17000 14000 12000 6000 10 860 790 Pressure Difference (Pa) Vane n1500 Vane n2300 Rotary n1000 Rotary n1500 Figure 2: Volumetric Flow Rate vs P4-P3, demonstrating change in volumetric flow rate as the difference between Suction Side and Pressure-Side pressures. Results are shown for both compressors at both RPM’s. First looking at Figure 2 we can see a plot of the performance of each compressor at various speeds in terms of comparing the Volumetric flow rate and the pressure difference on both sides of the compressors. Generally, we can see that as the pressure difference for each compressor gets lower the volumetric flow rate is slowly increasing. This effect is seen most clearly when considering the Vane compressor at 2300 RPM, we can see that at lower pressure differences of 860 Pa the volumetric flow rate is closer to 0.0012 m3/s but at higher pressure differentials of 42000 Pa, the volumetric flow rate is less than 0.0008m3/s. We can also see that as a general trend the Vane compressors have higher flow rates at higher pressure differentials, but the Piston compressors have negligible change to flow rate as the pressure differential is altered. This indicates that as the pressure difference across the rotary vane compressor is decreased. The vane compressor can put in less work to compress the air as the internal flow of the Rotary Vane compressor is much more stable. Hence their will be lower friction and turbulence in the compressor, meaning it will be able to compressor larger volumes of air much easier as the pressure differential is lowered. We might say that we can see from this graph that Rotary Vane compressors are more effective at lower pressure differentials, which helps us determine industrial uses for Rotary Vane Page 7 of 16 Jay Kamath (216059461) MECH 3504 Group 3ii Experiment Performed: 2023-02-13. Report Submitted: 2023-03-19. compressors. Particularly in areas that require high efficiency such as air systems or automotive engines. We can also see that for both types of compressors, greater RPM leads to a higher flow rate processed at all pressure differentials. Which tells us that for both compressors we can operate them at higher RPM, all within operating limits of the compressor. 60 50 Efficiency (%) 40 30 20 10 0 7,39 7,06 Rotary Vane n=1500 6,77 5,67 5,03 3,98 Pressure Difference (bar) Rotary Vane n=2300 3,16 Piston n=1000 1,92 1,18 Piston n=1500 Figure 3: Graph of Compressor efficiency against difference of suction-side and pressure-side pressures. Next looking at Figure 3, we can see a distribution of each piston’s performance and how efficiently they perform at various flow rates, the efficiency can be calculated by comparing the initial input electrical power (shown on the control module for the experimental setup), against the Hydraulic power output (calculated in appendix). We can see that the clear trend is that as we decrease pressure difference across each of the compressors The efficiency for each compressor also drops. Both compressors clearly trend downwards as the pressure difference is decreased. Particularly, Piston compressors can be seen to have generally higher efficiencies at all RPMs, and at all pressure differences than rotary vane compressors. This can be attributed to Air leakage in the rotary vane compressors, as the design of the compressor allows air to escape from the compression area, contrasted to piston compressors where the air canoe escape or leak in any way. In addition, due to the adjustable stroke length in a piston compressor, the piston compressor can effectively process higher pressure ratios, this is not possible with rotary vane compressors, hence the efficiency of rotary vane compressors at any pressure ratio is much lower than that of piston compressors. Page 8 of 16 Jay Kamath (216059461) MECH 3504 Group 3ii Experiment Performed: 2023-02-13. Report Submitted: 2023-03-19. We can also look at the achievable pressure differences for the compressors. Note that in both figure 2 and 3, graphs for both compressors achieve lower pressure difference with higher motor RPM than at lower RPM. Telling us that in both piston and vane compressors, we can achieve lower pressure differences by increasing RPM. This corroborates with previous theory, since it is generally accepted that due to the increase in temperature during the compression process air will expand and lower the pressure in the compressor. Since this pressure increases, the pressure drop through the compressor is decreased, and this effect can get significant as the RPM is increased even more. Hence higher RPM leads to allowable, lower pressure differences. Generally, there were some forms of uncertainty, primarily, in that there was a lot of noise from the setup at higher RPM’s for both compressors, meaning a certain amount of energy was lost this way, just as well, guiding rails were not the most stable so the setup vibrated during the experiment. Finally, the controllability of inputs was very difficult so managing the speed to be exact values was not always possible. Whilst results are not completely accurate, with some level of uncertainty they allow us to characterize each pump type reasonable in terms of its usability in industry. We can clearly see from Figure 2, that in general for higher flow rate applications the Rotary vane compressor is more useful as it outperforms the piston compressor in every scenario. We also know that if we want the highest volumetric flow rate we must encourage a smaller pressure drop across the compressor. We can also determine that working at higher RPM’s is better when we need to work with smaller pressure drops. Figure 3 tells us that for processes requiring high efficiency from the compressor, the best choice is always a piston compressor, as they outperformed the rotary vane compressor at all pressure drops and RPM’s. We also learn that for all compressors the way to increase efficiency is to have a higher pressure drop across the compressor. Page 9 of 16 Jay Kamath (216059461) MECH 3504 Group 3ii Experiment Performed: 2023-02-13. Report Submitted: 2023-03-19. 4. Summary & Conclusions Air compressors are devices used in various industries, and are divided into two categories: Positive Displacement (working with a constant flow) and Dynamic (working with constant pressure). This report compares the performance of rotary vane and piston compressors in terms of efficiency, pressure ratio, and airflow rate. It also investigates the effect of different operating parameters, such as speed, and pressure, on the performance. Finally, it analyzes the efficiencies of air compressors by finding the hydraulic power output of each compressor at various flow rates and speeds. This experiment used two control valves to control flow input from the compressed air tank and the measuring tank. A control cabinet was connected to all sensors in the apparatus, allowing us to record and see live properties in the pipes. Compressors were connected to the drive motor with controllable input, and the experiment was completed at n=1000 RPM and n= 1500 RPM. Systematic errors included measuring at incorrect times when data was not steady state, instruments being difficult to precisely stick to correct RPM requirements, and random errors such as vibrations in the experimental setup. We collected 4 sets of results for both types of compressors, with values taken at drive train rpms of n=1000 RPM and n=1500 RPM. Figure 2 shows the performance of each compressor at various speeds in terms of comparing the Volumetric flow rate and the pressure difference on both sides of the compressors. The Vane compressors have higher flow rates at higher pressure differentials, but the Piston compressors have negligible change to flow rate as the pressure differential is altered. This indicates that the vane compressor can put in less work to compress the air as the internal flow of the Rotary Vane compressor is much more stable, meaning it will be able to compress larger volumes of air much easier. Piston compressors have higher efficiencies at all RPMs and at all pressure differences than rotary vane compressors, due to air leakage and adjustable stroke length. Both compressors can achieve lower pressure differences with higher motor RPM than at lower RPM. The most important details are that the rotary vane compressor outperforms the piston compressor for higher flow rate applications, and that working at higher RPM's is better when working with smaller pressure drops. The best choice is always a piston compressor for processes requiring high efficiency, and the way to increase efficiency is to have a higher pressure drop across the compressor. Page 10 of 16 Jay Kamath (216059461) MECH 3504 Group 3ii Experiment Performed: 2023-02-13. Report Submitted: 2023-03-19. References [1] Harris, Jeffrey. “York University - MECH-3504-Air Compressors.” Eclass.yorku.ca, eclass.yorku.ca/course/view.php?id=63964§ion=17#tab9. Accessed 19 Mar. 2023. Page 11 of 16 Jay Kamath (216059461) MECH 3504 Group 3ii Experiment Performed: 2023-02-13. Report Submitted: 2023-03-19. Appendix Results Tables Results for Rotary Vane Compressor at n=1500 RPM Tem p (C) (n1) RPM P3 (bar ) 21.7 1500 0.97 21.9 1500 0.97 22.1 1500 0.97 22.5 1500 0.97 22.4 1500 0.97 22.4 1500 0.97 22.4 1500 0.97 P3 (Pa) 970 00 970 00 970 00 970 00 970 00 970 00 970 00 P4 (bar ) 0.97 1.39 1.34 1.14 1.11 1.09 1.03 P4 (Pa) 970 00 139 000 134 000 114 000 111 000 109 000 103 000 P4P3(ba r) P4-P3 (Pa) dp (mBar ) dp (Pa) 0 0 3.4 340 1.197698 0.42 42000 1.3 130 1.196886 0.37 37000 1.9 190 1.196075 0.17 17000 2.5 250 1.194456 0.14 14000 2.7 270 1.19486 0.12 12000 3 300 1.19486 0.06 6000 3.2 320 1.19486 density (kg/m^3) Flow rate (m^3/s) 0.0007906 01 0.0004890 31 0.0005914 1 0.0006788 54 0.0007053 66 0.0007435 21 0.0007679 06 P_el (W) 120 148 145 130 127 126 125 P_hyd (W) η_total (%) 0 17.065 72894 18.536 87158 10.633 76153 9.2244 03381 8.4120 37393 4.4705 52133 0 11.530 89793 12.784 04937 8.1798 16561 7.2633 09748 6.6762 20153 3.5764 41706 P_hyd (W) 1.20727 167 45.7732 3676 44.3847 6254 41.0710 9599 37.9059 3047 32.9845 0036 24.6132 1179 19.2667 1279 12.1635 2716 η_total (%) 0.74985 818 17.7415 6464 17.8252 0584 18.3353 1071 17.7962 1149 16.7434 012 13.3767 4554 11.0728 2344 7.28354 9196 Results for Rotary Vane Compressor at n=2300 RPM Temp (C) (n1) RPM 22.1 2300 22.3 2300 22.5 2300 22.1 2300 22.1 2300 22.1 2300 22.2 2300 22 2300 22.2 2300 P3 0. 96 0. 97 0. 97 0. 97 0. 97 0. 97 0. 97 0. 97 0. 97 Page 12 of 16 P3( Pa) 960 00 970 00 970 00 970 00 970 00 970 00 970 00 970 00 970 00 P4 0. 97 1. 83 1. 76 1. 57 1. 47 1. 36 1. 23 1. 16 1. 08 P4(P a) 9700 0 1830 00 1760 00 1570 00 1470 00 1360 00 1230 00 1160 00 1080 00 P4P3 0.0 1 0.8 6 0.7 9 P4P3(Pa) dp (mBar ) 10 8 800 1.196075 860 3 300 1.195265 790 3.2 320 1.194456 0.6 600 4.2 420 1.196075 0.5 0.3 9 0.2 6 0.1 9 0.1 1 500 4.8 480 1.196075 390 5.5 550 1.196075 260 6.2 620 1.19567 190 6.7 670 1.19648 110 7.4 740 1.19567 dp (Pa) density (kg/m^3) Flow rate (m^3/s) 0.00121354 9 0.00074339 6 0.00076803 6 0.0008793 0.00094001 1 0.00100622 1 0.00106851 7 0.00111039 1 0.00116735 1 P_el (W) 161 258 249 224 213 197 184 174 167 Jay Kamath (216059461) MECH 3504 Group 3ii Experiment Performed: 2023-02-13. Report Submitted: 2023-03-19. Results for Piston Compressor at 1000 RPM Tem p (C) (n1) RPM P3 (bar) 21.7 1000 0.97 21.7 1000 0.97 22 1000 0.97 21.4 1000 0.97 21.4 1000 0.97 21.4 1000 0.97 21.3 1000 0.97 P3( Pa) 970 00 970 00 970 00 970 00 970 00 970 00 970 00 P4( bar) 0.97 8.7 5.08 4.92 1.86 2.48 1.87 P4( Pa) 970 00 870 000 508 000 492 000 186 000 248 000 187 000 P4-P3 (bar) 0 7.73 4.11 3.95 3.54 1.51 0.9 P4P3(Pa ) dp (mBar ) dp (Pa) 0 7730 00 4110 00 3950 00 3540 00 1510 00 9000 0 1.5 150 1.197698 1.5 150 1.197698 1.6 160 1.19648 1.1 110 1.198919 1.4 140 1.198919 1.6 160 1.198919 1.6 160 1.199326 P4P3(Pa ) dp (mBar ) dp (Pa) 1000 7390 00 7060 00 6770 00 5670 00 5030 00 3980 00 3160 00 1920 00 1180 00 2.6 260 1.192438 2.1 210 1.194456 2.1 210 1.194456 2.2 220 1.194052 2.2 220 1.193648 2.2 220 1.192922 2.3 230 1.192841 2.4 240 1.192841 2.5 250 1.192438 2.5 250 1.192841 density (kg/m^3) Flow rate (m^3/s) 0.0005251 26 0.0005251 26 0.0005426 24 0.0004494 62 0.0005070 61 0.0005420 71 0.0005419 79 P_el (W) Flow rate (m^3/s) 0.0006928 83 0.0006221 8 0.0006221 8 0.0006369 29 0.0006370 37 0.0006372 31 0.0006515 74 0.0006655 88 0.0006794 28 0.0006793 13 P_el (W) 97 225 187 185 165 141 126 P_hyd (W) η_total (%) 0 111.74 51163 87.150 61806 70.792 70274 32.021 16003 49.358 64987 34.508 13367 0 49.664 49613 46.604 60859 38.266 3258 19.406 76365 35.006 13466 27.387 40768 P_hyd (W) 0.6893 3616 129.99 20586 127.56 14703 128.31 28951 118.86 24292 112.63 38628 103.01 07431 93.533 43397 71.948 99949 52.446 3285 η_total (%) 0.4657 67676 41.136 7274 40.885 08662 41.795 73129 40.292 34888 39.659 81084 38.580 80265 37.264 31632 32.409 45923 26.223 16425 Results for Piston Compressor at 1500 RPM Tem p (C) (n1) RPM P3 (bar) 23 1500 0.97 22.5 1500 0.97 22.5 1500 0.97 22.6 1500 0.97 22.7 1500 0.97 22.88 1500 0.97 22.9 1500 0.97 22.9 1500 0.97 23 1500 0.97 22.9 1500 0.97 Page 13 of 16 P3( Pa) 970 00 970 00 970 00 970 00 970 00 970 00 970 00 970 00 970 00 970 00 P4( bar) 0.98 8.36 8.03 7.74 6.64 6 4.95 4.13 2.89 2.15 P4( Pa) 980 00 836 000 803 000 774 000 664 000 600 000 495 000 413 000 289 000 215 000 P4-P3 (bar) 0.01 7.39 7.06 6.77 5.67 5.03 3.98 3.16 1.92 1.18 density (kg/m^3) 148 316 312 307 295 284 267 251 222 200 Jay Kamath (216059461) MECH 3504 Group 3ii Experiment Performed: 2023-02-13. Report Submitted: 2023-03-19. Sample Calculations Density example calculation: π= 100 β π0 100(1013) = = 1.192438 ππ/π3 π π β (π + 273) 287 β (23 + 273) Flow rate example calculation: πΜ = π΄π β √ 2 β ππ 2 β (260) = (3.318 × 10−5 ) β √ = 0.000692883(π3 /π ) π 1.192438 Hydraulic Power example calculation: π 98000 πβπ¦ππππ’πππ = ππ ππ ln ππ = 97000 β 0.000692883 β ln (97000) = 0.68933616(π) π Efficiency example calculation: π= Page 14 of 16 πβπ¦π 129.992W β 100% = ( ) β 100% = 41.1367274 πππ 316 Jay Kamath (216059461) MECH 3504 Group 3ii Experiment Performed: 2023-02-13. Report Submitted: 2023-03-19. Uncertainty Calculations: Page 15 of 16 Jay Kamath (216059461) MECH 3504 Group 3ii Experiment Performed: 2023-02-13. Report Submitted: 2023-03-19. Summarizing Uncertainties: πΌπ = ±π. ππππ ππ/ππ \ πΌπ½Μ = ±π. π × ππ−π ππ /π πΌπ·πππ ππππππ = ±π. ππ πΎ πΌπΌ = ±π% Uncertainty Values are shown directly on graphs: Fig.2 and Fig.3 Page 16 of 16