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IS 5456 (2006): Testing of Positive Displacement Type AirCompressors and Exhausters - Code of Practice [MED 22:Compressor, Blowers and Exhausters]

IS 5456:2006

Indian Standard

TESTING OF POSITIVE DISPLACEMENT TYPEAIR COMPRESSORS AND EXHAUSTERS

CODE OF PRACTICE

(Second Revision)

1CS23.140

0 BIS 2006

B.UREAU OF INDIAN STANDARDSMANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG

NEW DELHI 110002

November 2006 Price Group 7

Compressors, Blowers and Exhausters Sectional Committee, ME 22

FOREWORD

This Indian Standard (Second Revision) was adopted by the Bureau of .Indian Standards, after the draft finalizedby the Compressors, EUowersand Exhausters Sectional Committee had been approved by the Mechanical EngineeringDivision Council.

This standard was first published in 1969 and subsequently revised in 1985. This second revision incorporatesAmendments No. 1 to 4 and other changes which were felt necessa~ as a result of experience gained in testing ofpositive displacement type compressors and exhausters.

For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observedor calculated, expressing the result of a test or analyses shall be rounded off in accordance with IS 2: 1960 Rules forrounding off numerical values (revise o.The number of significant places retained in the rounded off value should besame as that of the specified value in this standard,

IS 5456:2006

Indian Standard

TESTING OF POSITIVE DISPLACEMENT TYPEAIR COMPRESSORS AND EXHAUSTERS

CODE OF PRACTICE

(Second Revision )

1 SCOPEThis standard prescribes type tests and routine tests forboth reciprocating and rotary type positive displacementair compressors and exhausters.

1.1 This standard does not deal with:a) centrifugal and axial flow compressors, andb) machines giving a pressure rise of less than

0.01 MPa and greater than 6 MPa.

2 REFERENCESThe following standards contain provisions which throughreference in this text, constitute provision of this standard.At the time of publication, the editions indicated werevalid. All standards are subject to revision and parties toagreements based on this standard are encouraged toinvestigate the possibility of applying the most recenteditions of the standards indicated below:

IS No. Title

325:1996 Three phase induction motors Specification (fifth revision)

5727:1981 Giossary of terms relating tocompressors and exhausters ~ir.strevision)

10431:1994 Measurement of air flow ofcompressors and exhausters(@t revision)

3 TERMINOLOGYFor the purpose of.this standard the following definitions,in addition to those given in IS 5727 shall apply.

3.1 Supplier The party supplying the machines. Thesupplier may or may not be the actuai manufacturer of themachines. The term supplier shall also cover any partywith whom the supplier places an order for partialcompliance.

3.2 Purchaser The party purchasing the machines.The term purchaser shall also cover person or persons

1

authorized in writing by the purchaser to act on his behalffor inspection of the machines.

3.3 Manufacturer The party manufacturing themachine. The manufacturer may or may not be thesupplier.

3.4 New Design A design which will give analtogether rrew-setof performance as regards pressure andoutput capacity shall be considered as a new design of thecompressor. New design implies distinctly different valuesof design parameters, for example, input power, theoreticalwork done during compression, important dimensions likebore and stroke (in case of reciprocating compressor),material of construction as against those of the old design.Change in the performance parameters and designparameters should be substantial and appreciable and notmarginal to give rise to the new design.

3.5 Major Modification Any modification whichsubstantially alters the performance of the compressor, canbe termed as major modification, whereas a modificationwhich does not in any way affect the performance of thecompressor can be termed as minor modification. Majormodification implies marginal change in the performancecaused due to alterations/replacement of the maincomponentslsub-assemblies of the.compressor.

4 TESTS

4.1 The object of the tests is to veritj the performanceguaranteed by the supplier as covered in 4.2.

4.2 The following two tests shall be conducted.

4.2.1 ~pe Tests Whenever anew design of compressorsis manufactured or major design changes affected in theexisting model, one unit from the series shall be selectedand subjected to a series of tests as given in 6, to establishits mechanical reliability and performance characteristics.In case of minor changes made by manufacturer,subsequent to type test, such changes shall be indicated.The proforma for type test report shall be as given inAnnex A. Tyye test report shali be given to the purchaserif requested.

IS 5456:2006

4.2.2 Routine TestsRoutine tests asgivenin8 shall becarried out on all compressors before acceptance by thepurchaser.

5 GENERAL CONDITIONS FOR CONDUCTINGTESTS

5.1 If the site of tests is not specified in the contract, thesetests shall be carried out at the suppliers or manufacturerspremises.

5.2 When routine tests are conducted at the premises ofthe supplier, he shall be responsible for providing all thematerial, measuring instruments and the requiredpersonnel.

5.3 If routine tests are to be conducted at the premises ofthe purchaser; the purchaser shall provide necessary helpand equipment for installing the apparatus for testing atmutually agreed terms.

5.3.1 During type tests, if any major modification isnecessary, the complete test shall be repeated.

5.3.2 When the routine tests are conducted at the premisesof the purchaser, the supplier shall always have the rightto conduct, prior to these tests, an examination of thecompressor or the complete unit to ensure that thecompressor or the complete unit is in perfect workingcondition. If any major modification to the installation iseffected by the supplier which does not form part of thegeneral maintenance work, the examination of thecompressor of the complete unit shall be conducted again.

5.4 If the test, as conducted by the supplier, is notacceptable to the purchaser, by mutual agreement, thepurchaser and the supplier may appoint a competent personor body for conducting the final tests. The report ofthetests shall be supplied to the supplier and the purchaserwithin four weeks of the test.

5.4.1 The expenses of the competent person or body shallbe borne by the purchaser, if the equipment is found tocomply with the specification; and the expenses shall beborne by the supplier, if the equipment does not complywith the specification.

5.5 If the results obtained during the tests do not conformto the contract values, the supplier shall have the right toeffect minor modifications to enable the machine to satisfjthe guarantee requirements, at his own cost, within aspecified period to be agreed mutually between thepurchaser and the supplier.

6 PRECUATIONS TO BE TAKEN WHILECONDUCTING TESTS

6.1 There shall be no leakage of air between the compressoroutlet and the location at which the pressure is measured.

6.2 The tests shall be carried out when the complete unithas reached a steady condition, as shown by the constancyof.temperature and pressure.

6.3 If different tests are to be conducted under differentworking conditions, they shall be done oneafter the other.But, it is essential to provide between two successive tests,a period long enough generally half an hour, for the newworking conditions to stabilize.

6.4 Care shall be exercised to maintain the driving unit ofthe compressor throughout the period of the test at aconstant speed, within the limits as specified in D-1.2and E-1.2.

6,4.1 Throughout the test, the right flow of cooling watershall be maintained in the case of water-cooledcompressors and exhausters.

6.4.2 While conducting the tests, the operating personnelshall not alter any of the controlling devices except withthe specific instructions of the person in-charge of the test.

6.4.3 During the tests arrangementshall be made to takereadings of all measuring devices, as far as possible,simultaneously. The time of each set of reading shall alsobe recorded. All accepted readings from any test run shallbe consecutive.

6.4.4 It is recommended that four sets of readings,spaced at an interval of 15 rein, may be obtained duringeach test.

7 TYPE TESTS

7.1 These tests may be carried out in the premises of themanufacturer or a well recognized inspecting authority orby any of the natural research laboratories or a well-equipped technological institution.

7.2 Type test shall constitute the following tests andmeasurements:

a)b)c)

d)e)i)g)

Mechanical tests;Capacity (free air delivery);Specific power consumption at various pressuresfrom minimum to maximum working pressureunder fi,dlflow conditions;Maximum operating speed;Volumetric and overall efficiency of machine;Lubricating oil consumption;Testing of loading and unloading mechanism; and

2

h) Flow of cooling water, if applicable, with rise intemperature.

NOTE The procedure for calculating the overall efficiency ofthe compressor is given in Annex B.

7.3 The mechanical tests are intended to ascertain thereliability of the machine and its accessories. Prior to thestarting of this test, essential working parts of compressorand its accessories shall be checked for accuracy with themanufacturers drawings. Allmechanical parts shall alsobe checked for proper fi,mctioning when assembled and inoperation.

7.3.-1 At the end of these tests, as shown in Table 1, thecompressor shall be opened and the parts checked again.

7.4 The duration of the separate stages of type tests shallbe as given in Tables 1 and 2 for reciprocating and rotarycompressors respectively.

8 -ROUTINE TESTS

8.-1 The routine tests shall constitute the following:a) Capacity (free air delivery),b) Speed, andc) Specific power consumption in the case of

electrically driven compressors and specific fuelconsumption with other drives at full load.

8.2 The various stages of the routine tests shall beconducted for the duration shown in Table 3.

9 TEST LAYOUTThe recommended arrangements of test layout for thecompressors and the exhausters shall be as shownin IS 10431.

10 MEASUREMENT OF PRESSURE

10.1 For pressure above 2 MPa, calibrated bourdongauges, dead weight gauges, mercury manometers or theirequivalent shall be employed. Diaphragm gauges shallnot be used.

10.1.1 For type tests, the gauges selected shall be of suchsize that one percent pressure difference or 0.01 barwhichever is greater, shall easily be read and the pressureto be read shall lie between one-fourth and three-fourthsof the total scale reading.

10.1.2 For type tests, the bourdon gauges shall becalibrated against standard dead weight test gauges beforeand after the tests. The difference between the twocalibrations shall not exceed one percent for the test to betaken into consideration.

IS 5456:2006

10.1.3 For type tests, the bourdon gauges shall becalibrated by means of a standard dead weight gauge inwhich the pressure is transmitted through the medium ofoil. The piston of the dead weight gauge shall haveminimum working clearance. Before making a test, allmoving parts of the dead weight gauge shall be given aslight rotary motion to reduce the frictional effects. Theweights used for the dead weight loading shall be comparedwith standard dead weights, The diameter of the piston ofthe dead weight gauge shall be measured and the forcerelated to the weights. The calibration of the bourdongauges shall be carried to the nearest 1/100 MPa.

10.1.4 For r-outine tests, the bourdon gauges shall becalibrated against a master gauge once in every threemonths. The difference between the two calibrations shallnot exceed five percent, allowing one percent error incalibration of master gauge when checked against deadweight gauge.

10.2 For measurement of pressures below 2 MPa,manometer or vacuum gauges shall be employed. Closedmercury columns known as absolute vacuum gauges shallnot be used. This condition is applicable only for thosepressure readings which are required for calibrationpurposes and is not applicable for the readings which arerequired for checking purposes only, for example,intermediate stage pressure.

10.2.1 Manometers or coiumns for low pressuremeasurement shall comprise of glass tubing of not lessthan 10 mm bore for single limb and not less than 6 mmbore for double limb U-type and with a ~cale clearlygraduated to allow the column to be read within 1 mm.

10.2.2 The manometer glass tube shall be degreased,dried and filled with stable liquids of known mass density.

10.2.3 Where pressure difference is evaluated from thedifference of levels of the mercury in the two branches ofthe manometer, the effective pressure expressed in kgf/cm2is given by the product of difference in mercury levelsin the two branches expressed in mm, and the specificweight of mercury expressed in kg/dm~ corresponding tothe temperature of the mercury in the manometer.

10.2.4 Due account shall be taken of the variation in thespecific weight of the mercury with temperature as shownbelow:Temperature, C O 10 20 30 40 50Specific mass ofmercury, kg/cm3 13.60 13.67 13.55 13.52 13.5013.47

10.2.5 The connecting piping shall not be less than 6 mmin bore for pressure gauges anti not less than 10 mm borefor vacuum gauges to eliminate the capillary effect.

3

IS 5456:2006

Tablel Stages of~pe Tests for Reciprocating Compressors(Clauses 7.3.1 and 7.4)

sl Stage Tests Duration of theNo. No. Working ofthe

Compressor

(1) (2) (3) (!)

1 Mechanical Tests:

2

b) Endurance Tests

a) Running of thecompressor on lowdischarge pressure: i) At20percent ofrated pressure

ii) At40percent ofrated pressureiii) At 60 percent ofrated pressureiv) At 80percent ofrated pressure

Running of compressors on load at the rated discharge pressureThe compressors shall be run at full load for a minimum of 8 h atastretch, Atleast forhalfan hourinthe 8hnarnin~-thec oppressorshall be loaded and unloaded at frequent intervals to check theperformance of the unloading mechanism. In addition, thecompressor with diesel engine asprime motor shall be run at 110percent ofrated pressure (gauge) foronehour in every 12hdistributed over the entire run of endurance test

3

5

7

10

400

In case electric motor is the prime motor the compressor shall berun at 10 percent overload for 10 percent of the time distributedover the entire run ofendurance test

Determination of other characteristics as given in 7.2 Time requiredfor the actual

test

Table 2 -Stages of Type Tests for Rotary Compressors(Cfause 7.4)

SI Stage Tests Duration of theNo. No. Working of the

Compressor

(1) (2) (3) (!)

1 Mechanical Tests:

a) Running of thecompressor on lowdischarge pressure: i) At minimum discharge pressure specified by the manufacturers

ii) At pressure in between the above minimum discharge pressureand rated discharge pressure

b) Endurance Tests Running of compressors on load at the rated discharge pressure,The compressors shall be run at full load for a minimum of 8 h running,thecompressorshali be loaded and unloaded at frequent interwalstocheck the perfomrance of the unloading mechanism. In addition, thecompressor withdiesel engine asprimemotorshall berunat llOpercentofrated pressure (gauge) forl hinevery 12hdistributed overtheentirerun of endurance test

lncmeelectric motor istbeprime motor thecompressor shall be run at10 percent overload for 10 percent of the time distributed over the entirerun of endurance test

12

12

400

2 Determination of other characteristics as given in 7.2 Time requiredfor the actual test

4

Table 3 Stages of Routine Tests(Clause 8.2)

Stage Description of Duration of TestsNo. Stages in the Manufacturers

Factory or PurchasersPremises for All

Compressorsh

(1) (2) (3)

1 Running of the compressor on load 1at rated discharge pressure

2 Preparation of the stage requirement 2for getting the final characteristic ofthe compressor at the rated dischargepressure

3 Determination of the characteristics Time required foras given in 7.1 the actualtests

10.2.6 The connecting piping to pressure gauges andmanometers shall be as short as possible. [t shall beensured that there is no water, grease or oil in theconnecting pipes. A leakage test of all pipe connectionsshall be made with soap solution and leaks rectified.

10.3 Delivery Pressure The delivery pressure shallbe measured by a bourdon gauge placed on the mainreceiver which is nearest to the compressor.

10.3.1 The receiver shall have sufficient capacity suchthat the pressure gauge readings are not affected to anymarked degreeby pulsatory discharge of the compressor.The minimum receiver capacity shall be as specifiedin IS 10431.

10.3.2 The connection between the compressor and themain receiver, in which the pressure measurements aremade, shall be so designed that the loss of head producedat entry shall be neglected in calculation.

10.3.3 Where the main receiver is located at a considerabledistance away from the compressor, the effective deliverypressure shall be determined by adding to the pressurereading on the main receiver, the loss of head evaluatedfor the connecting piping as given in Annex B. As far aspossible, the layout of the test arrangement shall be suchas to avoid the use of this correction.

10.4 If the intermediate stage pressure has to be measuredaccording to the contractual clause; the calibrated bourdontype pressure gauges shall be mounted on the inter-coolerbetween the various stages of the compressor to obtainthe inter-stage gauge pressure.

10.5 Suction Pressure The intake pressure shallnormally be measured with the manufacturers standardintake filter.

IS 5456:2006

10.5.1 If the intake pipe is short and introduces a fi-ictionpressure below 20 mm of water gauge, the absolutepressure at suction shall be taken as the atmosphericpressure.

10,5.2 If the intake piping is long and it is notpossible todisconnect the same; the absolute intake pressure shall becalculated by deducting fi-om the atmospheric pressure,the loss of head in the piping as shown in Annex B. Ifspecial filter is used, correction shall be made as agreedto between the supplier and the purchaser. The effectiveintake pressure shall be measured by means of a mercurymanometer or water manometer.

10.6 Atmospheric Pressure The atmospheric pressureshall be determined by means of a mercury in-glassbarometer which shall be read up to 0.5 mm.

10.6.1 The barometer shall be located in theneighbourhood of the compressor and the pressure readingshall be taken at the time of the test. The pressure readingshall be corrected for the expansion of the mercury andthe scales carrying the graduations.

10.6.2 Aneroid barometers of sound construction,calibrated against a mercury barometer, may also be used.

10.6.3 The atmospheric pressure data, as furnished bythe meteorological station located in the neighbourhoodwhere the tests are conducted, may also be used, providedproper corrections are applied.

10.7 The variation in pressure measurement shall notexceed the values shown in Table 4.

11 MEASUREMENT OF TEMPERATURE

11.1 The temperature shall be measured by any of thefollowing

a) Calibrated mercury in-glass thermometer,b) Thermocouple,c) Resistance thermometer, andd) Thermistors.

Table 4 Allowable Variations in PressureMeasurement During Test

(Clause 10.7)Variable Maximum Allowable Variatkma

from Average During Any Setof Readings in Percent

/ \Type Test Routine Test

(1) (2) (3)

Absolute intake pressure lI *1.5

Pressure ratio l1 +1.5

Fall in pressure due to other auxiliaries 1.5

5

IS 5456:2006

Commercial or industrial metal-encased thermometer shallnot be used.

11.2 The thermometer shall be calibrated against astandard thermometer by immersion in a liquid bathmaintained at a uniform temperature.

11.3 Mercury in-glass thermometers shall have anetched stem.

11.3.1 The thermometer shall .be inserted directly into theair stream, where possible. When this is not possible, thethermometer wells shall be of thin steel or brass tube whichmay be welded or brazed to a hole pierced in the pipe.The internal diameter of the wells shall be as small aspracticable with their outside surface substantially freetlom corrosion or oxide. The wells shall be partially filledwith a suitable fluid of sufficient quantity to cover thethermometer bulb.

11.3.2 The thermometer well shall extend into the pipe adistance of 100 mm, or one-third of diameter of the pipe,whichever is less.

11.3.3 When taking readings the thermometer shall notbe Iitled out of the well.

11.3.4 The thermometer reading shall be corrected forthe emergent stem according to the following formula

where

t=

t,=

n=

y=

-tav=

t = t, + ny (tr-tav)

true temperature,

actual reading,

length of the emerging fluid column in degrees,

apparent expansion coefficient of thethermometer fluid for mercury in-glass &, and

average temperature of the emergent fluidcolumn.

11.4 The average air velocity shall not exceed 30 tis atthe point of measurement. The average velocity shall becomputed from the capacity of the machine and the areaof the pipe.

11.4.1 The immediate vicinity of the thermometer welland the projecting parts of the connection shall be wellinsulated so that the well is sensibly at the same temperatureas the medium being observed.

11.4.2 The sensitive part of any temperature measuringdevice or well shall be swept by the air under measurement.

11.5 The thermocouples shall have a welded jot junctionand shall be calibrated together with their wires for the

anticipated operating range. They shall be made ofmaterials suitable for air and the temperature beingmeasured. The electromotive force of the thermocoupleshall be established by a potentiometer-type instrument.The cold junction shall be established by an ice-bath orby a compensating circuit built into the potentiometer.

11.5.1 If thermocouples are used with thermometerwells,the hot junction of the thermocouple shall, where possible,be welded to the bottom of the well.

11.6 The variation in temperature measurement shall notexceed the values shown in Table 5.

Table 5 Allowable Vacations in TemperatureMeasurement During Test

Description of Maximum Allowxble VariationsMeasurement from Average During Any Set

of Readings in Cc A \

Type Test Routine Test(1) (2) (3)

Temperature of air at intake *2 l2

Temperature of cooling water at inlet +1 Q

Temperature of oil (for rotary compressors) +2 i2

11.6.1 For outdoor tests with portable compressors,the allowable inlet temperature fluctuation shall be takenas *3C.

11.7 Cooling Water Flow Rate and Temperature

11.7.1 No correction is necessary for the rate of flow ofcooling water, provided the deviation from contract valueis not more than +1Opercent.

11.7.2 Tests shall be conducted to ascertain that theminimum flow rate, as mentioned in the contract, isachieved. The coolant flow may be determined with theaid of a vessel of known volume and a stop watch or acalibrated flow meter, or with a nozzle as specifiedin IS 10431.

11.7.3 If no minimum flow rate is mentioned in thecontract, the flow rate of cooling water shall be such thatthe rise in temperature does not exceed 15C.

11.7.4 The inlet water temperature shall not differmore than +8C from the contractual temperature.

11.7.5 If the inlet temperature differs from that givenin 11.7.4, the power consumption of multi-stagecompressors, and capacity of single and multi-stagecompressors shall be corrected. The correction factor shallbe obtained by running the compressor at two different

6

temperatures and the required value obtained byinterpolating or extrapolating the specified conditions witha straight line through the two test points.

12 MEASUREMENT OF HUMIDITY

=12.1 The humidity conditions (hydrometric state) of theair drawn in shall be determined on the basis of the readingsobtained by means of a psychrometer.

12.2 The psychomotor consists of a wet and dry bulbthermometer arrangement capable of reading correctly to0.5C. The thermometer maybe placed at the mouth ofthe intake pipe to obtain correct results.

1-3MEASUREMENT OF SPEED

13.1 The speed shall be measured by any of the following

a) Tachometer,b) Speed counter,c) Tachoscope, andd) Stroboscope.

13.1.1 The use of a separate revolution counter and astop watch is not recommended for the measurement ofthe compressor speed.

13.2 All instruments mentioned in 13.1 shall be testedand calibrated periodically.

13.3 The error of the speed measuring instruments shalllie within %2percent.

14 MEASUREMENT OF AIR FLOW

14.1 The air flow measurement shall be carried out inaccordance with IS 10431. In particular cases, themeasurement may be carried out as shown in Annex C.

14.2 Corrections for air flow measurementdue to variationin speed during tests from the value specified in thecontract, variations in polytropic exponent and pressureratios, from the contractual values, shall be applied asshown-in Annex D.

15 MEASUREMENT OF OIL CONSUMPTION

15.1 The oil consumption shall be measured over aperiod of at least 50 h.

15.2 Prior to the commencement of the test, thecompressor shall be run and warmed up to its operatingtemperature. The compressor shall then be stopped andthe oil drained from the bearing frame or the oil sump fora period of at least 30 min.

IS 5456:2006

15.2.1 The oil shall then be weighed and poured backinto the oil sump of the compressor.

15.2.2 At the end of the test, the oil shall once again beweighed in accordance with the procedure laid downin 15.2, observing that the oil is at the same operatingtemperature.

15.2.3 The difference in weight of oil plus the weight ofany oil filled in during the test shall be taken as theconsumption of lubricating oil.

16 MEASUREMENT OF POWER

16.1 Shaft Power

16.1.1 The shatl power shall be measured by any of thefollowing:

a)

b)

c)

Torsion meter, mounted on the compressor shaft,with an accuracy of +1 percent;

Calibrated electric motor whose efllciency has beendetermined in accordance with IS 325 and not olderthan 3 years; and

Prime mover other than an electrical drive, whichhas previously been tested in accordance with therelevant Indian Standard.

16.1.2 When any intermediate form of power transmission,such as belt drive or gear box is interposed between theprime mover and the machine, its power consumption shallbe taken into account.

16.1.3 As a basis for the efficiency of the transmission,the following figures shall be used unless reliableinformation is available:

For properly lubricated 98 percent forprecision gear drive each step

For flat belt drive 97 percent

For V-belt drive 95 percent

16.1.4 When an electric motor is used as the primemover, the fluctuations of voltage and frequency shall notbe more than +6 percent and +3 percent of the rated valuefor that machine res~ectively.

16.1.5 When an electric motor is used as the prime mover,the fluctuations of voltage and frequency during any testshall not be more than +2 percent and +0.5 percent ofrated value respectively.

16.2 Total PowerWhen the power consumption of the compressor isguaranteed jointly with its prime mover, the power

7

IS 5456:2006

consumption recorded on tests shall be corrected for anydeviation of the test conditions from the guaranteedconditions of the prime mover.

16.3 Power ConsumptionPower consumption shall be corrected for variation in shaftspeed during tests from the value specified in the contract,variations in polytropic exponent and pressure ratio tlomthe contractual values, as shown in Annex E.

17 ALLOWABLE DIFFERENCE BETWEENMEASURED AND CONTRACT VALUES

17.1 The maximum allowable difference betweencorrected test value and contract value shall be as shownbelow:

Variable Maximum Limit

Inlet pressure, pa *8 percentPressure ratio, r %5percentShaft speed, n *4 percentInlet water temperature *5cDifference between the *IO percent

coolant and air temperatureCoolant flow rate +1OpercentVoltage +5 percentFrequency * 1 percent

17.2 If the -deviation from test conditions, after duecorrections as specified in this standard, results in adeviation in specific power consumption above 7 percentof the contractual-value for machines less than 10kW andabove 4 percent for machines of 10 kW and above, thetest shall not be considered.

17.3 Test at a shaft speed other than the specified valueshall not be permitted, if reasonant pressure pulsationsoccur at the test speed.

17.4 If the deviation exceeds the values specified in 17.1,the method mentioned in 17.4.1 shall be adopted with the

agreement of the purchaser and the manufacturer.

17,4.1 When the specified operating conditions cannotbe met, the influence of the operating conditions on theperformance of the actual compressor shall be determinedby a method of variation, so that the amount of eachcorrection to the specified operating conditions, may bedetermined by interpolation or, in extreme cases, byextrapolation.

18 TOLERANCES

18.1 Tolerances on flow rate and specific powerconsumption shall be as shown below:

Compressor At 100 Percent At 50 Percent No LoadShaft Inputs Flow Rate Flow Rate Power

~~

Flow Specific Flow Specificrate power rate power

consump- consump-tion tion

Below 10 kW +6 *7 *2O

10 to 100kW *5 +6 *7 +7 *2O

Above 100 kW +4 +5 +5 +6 &20

18.2 If the specific power consumption.is guaranteed foronly one flow rate, and the specific power consumption,according to the test, meets the guarantee at a flow ratethat does not deviate more than +5 percent from the flowrate for which the guarantee is valid, the specific powerconsumption shall be considered as acceptable.

18.2.1 If the specific power consumption values areguaranteed for more than one flow rate or pressure, thenweighted averages shall be used both for the test resultsand for the guarantees. If no agreement has been made,the weight of every point may be taken as 1.

19 T-EST REPORT

The recommended form of test report is given in Annex F.

8

IS 5456:2006

ANNEX A(Clause 4.2. 1)

PROFORMA FCIR TYPE TEST REPORT (As per 1S 5456)

1. Date of test ........................................................................................

2. Location of test ........................................................................................

3. Name of the Agency who carried on type test ........................................................................................

4. Manufacturers Model No. & S1No. for ........................................................................................the type tested compressor

5. Duration of test ........................................................................................

6. Remarks from Test Agency ........................................................................................

1. Dimensional Measurement of Wear Parts

Name of the Part (A) Prior to test (to be (B) Atler the testgiven from drawingwith tolerances)

NOTE The manufacturer shall specifi the expected life between overhaul and the expected wear during first 500 h,

Running Test

1) Mechanical Test

i) Compressor working pressure (rated pressure) .....................................................................................ii) Compressor Maximum overload pressure .....................................................................................iii) Compressor Speed at working pressure at .....................................................................................

unload condition

iv) Type of coupling and details ..........................................................................................................................................................................

v)

Pressure (MPa)r 3

Stages of compressor Suction Discharge

First stage compressor ..............

Second stage compressor ..............

Third stage compressor ..............

vi) Intercooling Temperatures above ambient(A) After first stage (B) After intercooling(A) After second stage (B) Afier intercooling(A) After third stage (B) Final

vii) Medium of intercooling and details of intercooling

..............

..............

..............

Accc

................

Temperature ~C)( \

Suction Discharge

.............. ..............

.............. ..............

.............. ..............

Bccc

.......... ...!. .

viii) Leakage through the systems

9

...........!... .

IS 5456:2006

2)

3)

4)

5)

6)

7)

8)

9)

10)

ix) Engine detailsManufacturers name .....................................................................................Type and Model No. .....................................................!...............................BHPcomected at RPM .. ...ataltitmde . . . . ..m .....................................................................................Fuel consumption 1/h. . .. . . . . ..at RPM .....................................................................................Lubricating oil pressure . . . . . . . . ..at RPM .....................................................................................Type of governing .....................................................................................

x) Motor detailsManufacturers name .....................................................................................Type and Model No. .....................................................................................Rating of the motor .....................................................................................

Free Ah DeliveryFree air delivery at rated pressure i) .....................................................................................

ii) .....................................................................................iii) .....................................................................................iv) .....................................................................................

Free air delivery is corrected for:a) Altitude .....................................................................................b) RPM .....................................................................................c) Humidity .....................................................................................

Specific Power ConsumptionlSpecitic Fuel Consumption at:

i) 40 percent rated pressure .....................................................................................ii) 80 percent rated pressure .....................................................................................iii) Full rated pressure .....................................................................................iv) 110 percent rated pressure .....................................................................................

Volumetric and Overall Efficiency of the Machine

Lubricating Oil Consumption:Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. in50hours .....................................................................................Engine . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . ..in50 hours .....................................................................................

Lubricating Pump Type and Specification .....................................................................................

Safety Valve Setting Make and .~pe .....................................................................................

Total Weight of Compressor .....................................................................................

Portability Test .....................................................................................Running Trials and Brake Trials .....................................................................................

Overall Dimensions of the Compressor .....................................................................................

Remarksi) Major breakdownldefects during type .....................................................................................

test to be indicatedii) Major tests/adjustrnents carried out during .....................................................................................

tests with running periods specified

10

IS 5456:2006

ANNEX B[Clauses 7.2 (Nate), 10.3.3 and 10.5.2]

OV-ERALL EFFICIENCY AND CORRECTION FOR LOSS OF HEAD IN CONNECTING PIPES,

-B-1 Overall efficiency is the ratio of theoretical powerrequired to compress the amount of air actually deliveredto input power to the compressor. To determine the overallet%ciencyof the compressor, the following procedure maybe followed:

a) Measure the output of the compressor (FAD),b) Measure the suction and delivery pressure and input

power to the compressor,

c) Find out swept and clearance volume from the bore,stroke and total volume of the cylinder, and

d) By drawing the PV diagram work done per sweptvolume of air shall be found out. Multiply it by theratio of output capacity to swept volume. This shallgive -theoretical power required to compress theamount of air actually delivered.

Ratio of this to the input power to compressor shallgive overall efficiency of the compressor.

B-2 Loss Qfhead Ah in the piping connecting compressor

and receiver and from the inlet end to the compressor isgiven by:

PLAh=k

2g D

where

Ah = loss of head in meters,Z = dimensionless quantity known as friction factor,V = mean velocity of fluid =

( Volume of flowCross-sectional area ) in mls,g= acceleration due to gravity in rn/s2,L = length of pipe in meters, andD = diameter of the pipe in meters.

The friction factor shall be assessed in accordance withIS 10431. For installations in which the length ofconnecting pipes is kept short, this correction may beneglected.

ANNEX C(clause 14.1)

CALCULATION OF FLOW RATE WITHOUT THE USE OF NOZZLE

C-1 FLOW RATE MEASUREMENT

C-1.l When the compressor fimctions under wide pressurevariation as in-the case of compressors filling air bottlesand those used for starting large engines, the flow ratemeasurement shall be made by charging a receiver ofknown capacity.

C-2 CALCULATION OF FLOW RATE

C-2.1 The charging flow rate of cubic metres per minute

v, v,(m3/min) =

Time of charging in minutes

where

V~ = volume of air in receiver atreduced to intake conditions =

the end of test

11

P, (t,+ 273)v,

P, (t, + 273)

V~ = volume of air in receiver at the start of-testreduced to intake conditions =

P, (t,+ 273)v,

P. (t, + 273)

V, = calibrated volume of receiver,

PP = pressure at receiver at the end of test (absolute),ta = intake temperatur.e,

P, = intake pressure (absolute),tF = temperature at receiver at the end of test afier

stabilization,

IS 5456:2006

P~ =pressure at receiverat start of test (absolute), C-2.2 Thereceiver used formeasurement of flow rateand shall be well insulated against heat losses.

tE = temperature at receiver at start of test. C-2.3 Thereceiver temperature attheend oftestshallbemeasured after the temperature has stabilized.

ANNEX D(Clause 14.2)

CORRECTION OF FLOW RATE

D-1 CORRECTION FOR VARIATION IN SPEED

D-1. 1 If the speed during the tests is different fromcontractual value, correction shall be applied to the flowrate for deviations in values within the limits specifiedin 17.

nFlow correction factor, KI = ~

n{nwhere

n = contractual speed, andcn = measured shaft speed during test.In

D-1.2 The fluctuation in speed during any test shall bewithin + 1 percent from the average value during the test.

D-2 CORRECTION FOR VARIATION IN THEVALUES OF POLYTROPIC EXPONENT ANDPRESSURE RATIO

D-2.1 When the intake and delivery pressures during testdiffer slightly from the contractual value, the flow rateshall be assumed constant. For larger variations,corrections shall be applied to the flow rate of singlestage reciprocating compressors only. However, it isrecommended that the compressor on test shall be run asnear the specified pressure ratio as possible.

D-2.2 A change in the ratio of specific heats and in the

pressure ratio shall influence the capacity as the expansionsof the gas trapped in the clearance volume is affected.For deviations in values within the limits specified in 17,correction for flow rate shall be as given below:

iy

Flow correction factor, K, =lc(r, 1)

1

wherec .

r=c

u=c

r=m

u=m

1

~

l-c(r~-l)

relative clearance volume,specified pressure ratio,polytropic exponent (as stated in contract),measured pressure ratio, andpolytropic exponent (= 0.9 X-ratio of specificheats).

D-3 CORRECTED FLOW RATE

D-3.1 Corrected flow rate is then given by:

q,= KLx KzXqlm

where

9, = corrected flow rate, and

ql,m= measured flow rate reduced to intake conditions.

12

IS 5456:2006

ANNEX E(Clause 16.3)

CORRECTION OF POWER CONSUMPTION

E-1 CORRECTION FOR VARIATION IN SPEED

E-1.1 If the speed is different from the contractual valueduring tests, correction shall be applied to powerconsumption for deviations in values within the limitsspecified in 17.

Power correction factor Ky = ~m

wheren

c= contractual speed, and

n = measured shaft speed during test.m

E-1.2 The fluctuation in speed during any test shall bewithin + 1 percent from the average value during the test.

E-2 CORRECTION FOR VARIATION INPOLYTROPIC EXPONENT AND PRESSURERATIO

E-2. 1 When the intake and delivety pressures during atest differ from the contractual values within the limitsspecified in 17, confection shall be applied to the powerconsumption evaluated during the tests on the basis oftheoretical isentropic work in the case of multi-stagecompressors.

E-2.1.1 Theoretical isentropic work is given-by:

p, ~, k (( ))fl . k KW36.7 k-l rl

whereP, = absolute intake pressure, kgflcmz;

9, = tlee air delivered, m3/h;k = ratio of specific heats; andr = pressure ratio.

For single-stage machines, cooled or uncooled, powercorrection factor Kd is given by:

P,cK,=

P-lm

where subscript c refers to contractual values and subscriptm to measured values.

E-2.1.2 Theoretical isothermal work is given by:

PI 9, log~r kW

3.67

For multi-stage machines with intercooling,correction factor KJ is given by:

P,C log. rCK, =

P,~ logC r~

power

E-2.2 During the test, if the pressure ratio is maintainedwithin *0.2 percent of the contract value, the powercorrection factor ki for al1displacement compressors maybe simplified to:

P,,K,=

D lm

E-3 CORRECTED POWER CONSUMPTION

E-3. 1 Corrected power consumption is then given by:

N=K3x K,x Nm

whereN = corrected power consumption, andN. = measured value of power consumption.

13

IS 5456:2006

ANNEX F(ClauL~e 19)

TEST REPORT

F-1 REPORT

F-1.1 It is recommended that the following type ofreport may be adopted:

F-1.1.1 Ontiial of a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .at ............................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .made at the request of . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .under the direction of . . . ..... ...... ... . . . . . . . . . . . . . . . . . . ....and in the presence of .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..on .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

Signature of the EngineerDirecting the Test

F-2 GENERAL INFORMATION

F-2.1 The test report shall include the followinginformation:

a)b)c)d)

e)

0

Suppliers name;Number and year of manufacture;Type of prime mover;Name of manufacturer of prime mover and itsnumber;Type of speed increasing or reducing gear, iffitted; andName of manufacturer of speed gear.

F-3.2 Test Observations Only those measurementsnecessary to verify any guarantee given by the suppliertothe purchaser shall be taken, together with any otherobservations called for when placing the contract or asmay be subsequently ?greed to between the purchaser andthe supplier.

F-4 SIZE OF NOZZLE

F-4.1 Where the diameters and lengths of upstream anddownstream pipes do not conform to IS 10431, the factsshall be recorded in addition to the details shown below:

Speed .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . ..rev/minBarometric pressure . .. . .. . . . . . . ......... . . mm of mercuryPressure atintake . .. . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..MPaPressure drop across nozzle . .. . . . .. . . . . . . . . . ..mmofwaterPressure on downstream side of nozzle .. . ...mm of waterPressure at delivery .. . . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..MPaTemperature ofairatintake . . .. . . . . . . . . . . . . . . . . . . . . . . . . . ..K

Temperature ofairat nozzle .. . . . . . . . . . . . . . . . . . . . . . . . . . . ..KPower consumption .. . . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..kW

F-4. 1.1 Any other observations that are required to verifia guarantee, for example, quantity of cooling water, inletand outlet temperature of cooling water, etc, may also berecorded.

F-3 GUARANTEED PERFORMANCE ON TEST

F-3.1

a)b)c)d)e)f)

Guaranteed performance test shall include:Specified intake pressure and temperature;Free air delivered;Delivery pressure;Power consumption;Speed; andAny other requirement of this standard.

F-5 RESULTS DERIVED FROM THEOBSERVATIONS

The following results shall be derived from theobservations:

a)b)

FAD, andCorrected power consumption. (This is the powerconsumption corrected for any deviation of the testcondition from the guaranteed conditions of theprime mover).

14

IS 5456:2006

ANNEX G(Foreword)

COMMITTEE COMPOS-ITION

Compressors, Blowers and Exhausters Sectional Committee, CHD 22

Orgunizalion

Bharat Heavy Electrical Ltd, Hyderabad

Acc Machinery Company Ltd, Butibori

Atlas Copco (India) Ltd, Pune

Bharat Pumps and Compressors Ltd, Allahabad

Central Mine Planning and Design Institute Ltd, Kolkata

Directorate of Quality Assurance, New Delhi

Dresser-Rand (1) Pvt Limited, Ahemdabad

Elgi Equipments Limited, Cnimbatore

Engineers India Limited, New Delhi

Indian Register of~hipping, Mumbai

Kirloskar Pneumatic Co Ltd, Pune

Ministry of Defence, New Delhi

Ministry of Defence (R&D), Pune

National Physical Laboratory, New Delhi

Newman and Essar Engineers India Pvt Ltd, Pune

Reliance India Ltd, Mumbai

Reliance Industries Ltd, Na~i Mumbai

Research Design Development Organization, Lucknow

Revati Chicago Pneumatic India Ltd, Nasik

Representative(s)

SIIRI AVINASH Grmml~ (Chairman)St!rclP. NAGESWARARAO (A)ter-nate)

StIRI JAYANTIKLJMARSHW K. R, BALAWBItANIANI(A [(ernate)

SURIJ. M. KAULSHRI K. N. SIOHWi+NI(Alternate)

SHRI V. K. SHRIVASTAVASHRI S~JRAJSINCH (Alternate)

Smu R. DASGUPTA

SHRINACXNDRAPALLT COL P. K. SAUNIRA (Alternate)

SHRI I? S. GVANISHRI SORESI{KAUL (Alfernafe)

Smu T. V. N. KRISHNANSHRI D. SLrNDERRAJAN(4fernate)

SIIRI RAVINnEI{KUMARSHRIA. K. NIJHAWAN(A//ernafe)

SHRI U. S. KAI.CHKIGISHRI R. K. KALRA (Alfernate)

SI+RISHRIDIIARV. NAIKSHRI S. K. DESMUKH(A)fernafe)

SNRI H. C. SAHNISHRI P. K. GOVARDHAN(A1/ernafe)

SHRI V. B. WARI{~HRl M. K, [ArNAK (Aherndte)

SIWUJ. C. StIARMASNRI H. M. P. PO~OAR(Alternate)

SHICISHANKARCHATTOPADHYAYStwo VIRAF B. DEOOO(Alternate)

SIIIUS. K. GARYALIFIJSIIRI RANJII S. MI INORA(Aherna/e)

SIIICIS, K. GARYALISHRI RANJITS. MUNORA (Alternate)

NOMtNATION AWAITED

SHIUANIL K. LALSIHG V. S. MATHUR (A//erna/e)

15

IS 5456:2006

Organization

Steel Authurhy of lndia Ltd, New Delhi

BIS Directorate General

Representative(s)

SHRI B. P. SINGHSHRI S. K. JHA (Ahernate)

SHRI C. K. VEDA, Scientist F and Head (MED)[Representing Director General (Er-oflcio)]

Member SecretarySI{RI S. CIiOwDHtJRY

Scientist E (WED), BIS

16

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Amend No. Date of Issue Text Affected

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