DESIGN AND FABRICATION OF A SINGLE STAGE DOUBLE­

ACTING RECIPROCATING AIR COlVtPRESSOH

BY

OLATUNJI SAMSON ADEOLA

(2004/19002EM)

DEPARTMENT OF MECHANICAL ENGINEERING

SCHOOL OF ENGINEERING AND ENGINEERING TECHNOLOGY

FEDERAL UNIVERSITY OF TECHNOLOGY, MINNA, NIGERIA.

JANUARY, 2010

DESIGN AND FABRICATION OF A SINGLE STAGE DOUBLE­

ACTING RECIPROCATING AIR COMPRESSOR

BY

... OLATUNJI SAMSON ADEOLA

(2004/19002EM)

A Project Report Submitted in Partial Fulfillment of the Requirements

for the Award of Bachelor of Engineering (B. Eng) Degree in Mechanical

Engineering, Federal University of Technology, Minna, Nigeria.

JANUARY, 2010

1\

DECLARATION

I do hereby declare that this thesis presented in partial fulfillment for the requirement for

the award of Bachelor of Engineering ( B. Eng) Degree has not been presented before either

wholly or partially for any other degree elsewhere. Information hereby obtai ned from

published and unpublished works of others have been acknowledged accordingly.

~ .rr/'f/"-D/o STUDENT'S NAME SIGNATURE/DATE

III

CERTIFICATION

This is to certify that this project titled "Design and fabrication of a single stage doublc-

acting reciprocating air compressor" was carried out by Olatunj i Samson ./\. with

Registration Number 2004119002EM, under the supervi sion of Mr. J. Folaranmi and

subm itted to the Mechanical engineering department of the rederal University of technology.

Minna in partial fulfillment of the requirement for the a\vard of Bachelor of Engineering

(B . Eng) Degree in the department of Me ehanica I engineering.

1 .' , . .J __ - ~.'Vr

"'- - I • • • • •• ., ~ • ~ • • ( ~: ., • • 1 .- • • ~ ' !.j

PROJECT SUPERVISOR. SIG /\TURE/D/\TF

I lEAD OF DEPARTM ENT. SIGN/\TUREID/\TE

EXTERNAL EXAMINER SIGNA TURE/DATE

IV

DEDICATION

This project is dedicated to the Almighty God, our ever-loving, caring and wonderful

Being. He who gives knowledge and forgives in his great grace and infinite mercy. which

had made me a stronger person in hand ling life and its problems to the best of my knowledge

and understanding.

v

ACKNOWLEDGEMENT

I hereby seize this 0ppol1unity to express my profound and sincere gratitude to the

King of glory, Lord of Lords, for the peace, good health and promise he bestowed on me and

my entire family mem bel's for the period of my academ ic programme.

Special thanks to my supervisor Mr. J. Folaranmi for his unflinching support and

assistance he gave to me towards the completion of this project. I am also very grateful to the

entire mechanical engineering lecturers, as they have affected my life positively. Again, to

the entire staff of Federal University of Technology, Minna, I recognize and acknowledge

their contributions in making this project a successful one.

Futhermore, lowe a lot of profound and sincere gratitude to my fam i Iy members. To

my parents Mr. and Mrs. Olatunji, my lovely sister Mis~ Olatunji Felicia and my ever caring

brothers Mr. Olatunji Gbenga, Mr. Olatunji Solomon, Mr. Olatunji Micheal for their love,

financial and moral support.

Once again, I want to appreciate God for his love and mercies towards us all. To you

all, I am indeed grateful.

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ABSTRACT

The design and fabrication of a sing le stage double-acting reciprocating air

compressor is presented in this project report. The project work has helped to minimile the

problems associated with industrial complex ways of' designing and how to filbricate the air

com pressor. A II the materia Is used for the fabricat ion were loca II y sourced . The air

compressor can be used for spraying of paints and powering of diflercnt types of pneumatic

tools. The air compressor is powered by a 5hp motor and delivers air of O.665kg/min \\ ith F.

A. D ofO.16 lkg/min into the storage tank ofO.977m\'0Iullle. The air compressor·s dcliyers

compressed air with a volumetric efficiency of 66%

VII

TAI3LE OF CONTENT

Covcr page

Title page II

Dcclaration III

Ccrt i tication 1\

Dcd icat ion

A cknow ledgclllc nt \ I

Abstract \ II

Table of content \ III

List of Figurcs

List ofTablc .\\

Notation .\\1

CHAPTER ONE

1.0 INTRODUCTIO

1.1 Uscs of Air COll1prcssor ...,

1. 2 Mcthod ofColl1prcssion ...,

1.3 Objcctivcs or thc Projcct

1.4 Limitation of project

1.5 Justification of Project -I

1.6 Layollt oftllc Projcc t -I

CHAPTER TWO

2.0 LITERATURE REVIEW

2.1 Typcs orColllprcssors

2. 1.1 Positivc Displaccmcnt Compressors

VIII

2. 1.1 a Reciprocating Compressors

2.1 .1 b Reciprocating Air compressor accessorie c; and paris

2.1. 1c Detailed descriptiun of double-acting reciprl1catin g air comprc",,\lr

2. 1.2 Dynam ic C(lll1 prcs"llrs

2.1.2a Ccntrifugal Cl1l11pre s~urs

2.1 .2b /\ .\ial-Ilo\\' CUlllprcssllr~

2.2 A.C l'dotors or Elcctric 1\ lotor

2.3 Pressure Gauge Operating Principle

2.4 Gas Cy linder or Tank and Pressure S\\'itch

2.5 Salet: Standard

CHA PTER THREE

3.0 THEORETICA l. DFSIGN ANALYSIS or AIR co lPR LSSOR

3.1 The lherll1odyn<lll1ic principle of Com pressi un

3.1. 1 Determination o r S\\'Cpt Vo lume

3. 1.2 Determinati on or C) lillder Volume

3.1.3 Determination or Mass Flo\\' Rate of Air Delivered

3.1.4 Determination or Delivery Temperature

3.1 .5 Determination of Volullle of Air per Cycle

3. 1.6 DetcrIllination or Volumetric Efficienc),

3. 1.6a Determination of the Abso lute Volullletri c Efficiency

3.1.6b Determination orOvera l1 Volumetric Eflic ienc),

3. 1.7 Determination or ;\ir Flow Rate in the Compressor

3.1.7a Determination or F.A .D of the Compressor

1,\

l)

I ()

I h

17

IX

IX

Il)

21

21

1 ' - .'

1 ' - .'

l' - .'

1 ' - .'

2-1

3.1.7b Determination of Area of the Orifice of the Compressor

3.1.7c Determination of the Atmospheric Pressure

3.1.7d Determination of Volume of air per Kilogram

3.1.8 Mechanical Efficiency and Actual Indicator diagram

3.1.9 Workdone by Compressor and Effect of Clearance

3. 1.9a Determination of Workdone when Compression Inw is PVn = C

3.1 .9b Determination of Workdone when Compression is Abiabatic. PV' = C

3.1.9c Determination of Workdone when Compression is Isothermal. PV = C

3.1.9d Determination of the Power Requirement

3.2 Determination of Transm itted Torque by the Electric Motor

3.3 Determination of the Mass per unit Length of Belt

3.4 Determination of Peripheral Speed of Belt (i .e for no belt slipping)

3.5 Determination of Centrifugal Tension on Belt

3.6 Determination of Speed of Rotating Shafis

3.7 Determination of Angle of Laps or Wraps

3.7.1 Determination of the Angle of Lap of the Electric Motor Pulley

3.7.2 Determination of Angle of Lap of the Compressor Pulley

3.8 De:termination of Belt Tensions

3.9 Determination of the Belt Number

3.10 Determination of Belt Length

3.11 Determination of Stresses in the Air Receiver

3.11.1 Determination of Stresses in the Cylindrical part of the Tank

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3.ll.la Determination of Circumferential Stress in the Cylindrical part of the Tank 35

3.11.1 b Detennination of Longitudinal Stress in the Cylindrical part of the Tank 35

x

3.11.2 Determination of Stresses in the Hemispherical part of the Tank 36

3.12 Determination of the Volume of the Storage Tank

3.13 Determination of Time required to fill the Tank 37

3.13.1 Determination of Mass of air in the full tank 37

CHAPTER FOUR

4.0 DESIGN CALCULATION, MATERIAL SELECTION, CONSTRUCTION 38

DETAILS, TESTING AND COST ANALYSIS

4.1 Design Calculations 38

4.1.1 Calculation of the Area of the Compressor Orifice 38

4.1.2 Calculation of the Absolute Atmospheric Pressure 38

4.1.3 Calculation of the Volume of Air per Kilogram 38

4.1.4 Calculation of the Free Air Delivery (F. A. D) 39

4.1.5 Calculation of Compressor Speed 39

4.1.6 Calculation of the Volume Delivered per Stroke 39

4.1.7 Calculation of the Swept Volume 40

4.1.8 Calculation of the Cylinder Volume 40

4.1.9 Calculation of Mass of Air Delivered 40

4.1.10 Calculation of the Delivery Temperature 41

4.1.11 Calculation of Compression Ratio 41

4.1.12 Calculation of Volumetric Efficiency 42

4.1.13 Calculation of Workdone by c{)mpressor 42

4.1.14 Calculatiori of the Power Requirement 42

4.1.15 Calculation of the Transmitted Torque by the Electric Motor 43

4.1.16 Calculation of the Mass per unit Length of Belt 43

XI

4.1.1 7 Calculatio n of the Peripherall3elt Speed -l-l

4. 1.1 8 Ca lculat ion of Cent rifuga l Tension on rklt 4-l

4. 1.19 Ca lcul ati on of Anglc of La p of the Elec tric 1\ lntm !lui k~ -l-l

-l. 1.20 Ca lcu lati on nl' lkl llcns ions -l-l

4.1 .2 1 Ca lculation of the Belt Number -l'

4. 1.22 Ca lcul ati on oC th e CircumtCrential Stress of tile Cy lind rica l ra rt llf the tanl-. -l(l

4.1 .23 Ca lculation of the Longitudinal Stress orthe Cylindrical part of the tank -l()

4. 1.24 Ca lcul ati on of the Il oop Stress of the Cy lindrica l part o f the tank -l 6

4. 1.25 Ca lcul ati on for Tank Sa fety 47

4.1.26 Calc ul ati on of tile Storage Tank Voluille -l7

4. 1.27 Calculation of Time required to {ill up the Tank -l7

4.2 tvlaterial Selec ti on -lX

4.3 Des ign Desc ript ion -lS

4.3 .1 The Rec iprocat in g I\i r Compressor Machinc i:sscnti ail inih -lX

4.3. 1 a The Power Transmiss ion Unit -l<}

4.3. 1 b The Process ing Unit -l9

4.3. lcTheStorageU nit -l9

4.3. ld The Cont ro l lJ nit of tile System 50

4.3.2 Machines and Too ls Used in the Construction 50

4.3.2a Machines U. cd 50

4.3.2b Tools Used 50

4.4 Construction Dctail s 50

4.5 Operation :111(\ lain te n<l nce

4.6 Testing

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51

4.7 Costing and Costing Analysis 52

4.7.1 Material Cost 53

4.7.2 Labour Cost 53

4.7.3 Overhead Cost 5-l

4.7.4 Total Cost 5-l

CHAPTER FIVE

5.0 RESULTS AND DISCUSSION OF RESULTS 55

5.1 Results 55

5.2 Discussion of Results 56

CHAPTER SIX

6.0 CONCLUSION AND RECOMMENDATION 57

6.1 Observation 57

6.2 Conclusion 57

6.3 Recommendation 58

References 59 ','

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