IC Engine Test Rig LAB MANUAL

LABORATORY
MANUAL
I.C. ENGINE TEST RIG.
AIM: To conduct a load test on a single cylinder, 4-stroke Diesel engine and study
its performance under various Loads.
EQUIPMENT REQUIRED:
1. Single cylinder Diesel engine with electrical loading.

2. Stop watch
SPECIFICATIONS:
Stroke, L : 66.7mm
Bore, D : 80mm
Swept volume, V : 256 cm3
Rated R.P.M : 3000rpm
Out put : 2.2KW
Compression ratio, CR : 4.67:1
Orifice Diameter : 15mm
Fuel : Diesel
Sp. Gr. Of Diesel : 0.88
Calorific Value of Diesel : 45100 KJ/Kg
Loading : Electrical, Air heater connected to
AC Generator
Cooling : Air cooling
INTRODUCTION:
Internal combustion engines develop varying brake power depending on the
compression ratio, while the other parameters held constant. For compression
ignition engines, the compression ratio is brought to be above certain value for
ignition to take place, but the spark ignition engines can be operated at lower
compression ratios. The ignition being controlled by spark strength and advance.
The effect of compression ratio, which of present concern is studied in the present
test rig.
DESCRIPTION:
The Test Rig consists of Four-Stroke Diesel Engine (Air Cooled) to be tested
for performance is coupled to AC Generator .To facilitate the change in compression
ratio, an auxiliary head-piston assembly above the main head has been provided. The
auxiliary piston is operated up-down by hand wheel-screw rod assembly to fix the
required compression ratio. When the piston is in the bottom most position, the
compression ratio is at its maximum value, and in the top most position it is at
minimum value of 2s. The minimum clearance volume is 35 cc when the piston it is
at bottom most position. The charge from this initial volume of clearance is
determined by the displacement of the piston and thus used for calculation of the
compression ratio.
Compression Ratio = SweptVolume + ClearenceVolume

ClearenceVolume
Swept Volume : 250 cc (fixed)
Clearance Volume : Initial clearance volume + Additional clearance
volume
due to
auxiliarypiston
movement
Clearance Volume :Π x d
35cc + 2
x
l
4
cc
Where, d is the diameter of auxiliary piston = 70 mm, l is the axial movement of
piston. The hand wheel which operates the screw holding the auxiliary piston is
provided with holes circumferentially along the locking plate. The bolts used for
locking the movement of screw are loosened and the hand wheel is operated. A
scale with the compression ratio directly marked is provided for indicating this. After
adjusting to the required compression ratio, all the bolts are tightened well before
conducting experiment. The rate of fuel Consumption is measured by using
Volumetric Pipette. Air Flow is measured by Manometer, connected to air box.
The different electrical loading are achieved by loading the Electrical generator in
steps which is connected to the Air Heaters (Resistance Load)The engine speed &
AC Alternator speed are measured by electronic digital counter. Temperatures at
air inlet and engine exhaust gas are measured by electronic digital temperature
indicator with thermocouple The whole instrumentation is mounted on a self-
contained unit ready for operation.
.
PROCEDURE:
1. Open the 3-way cock. So that fuel flows into the engine.
2. Start the engine and allow it to run on no load condition for few minutes.
3. Apply the load on the engine by switching ON the heater switch which is
provided on the control panel loading the AC generator by switching
4. Allow the engine to run at this load for few minutes.
5. Note the following readings.
a) Engine Speed
b) Energy meter
c) Manometer
d) Time for 10cc of fuel consumption
6. Repeat the procedures two different loads.
7. Stop the engine after removing load on the engine.
OBSERVATIONS:
For Single heater load
Energy
Time for
meter
10 cc fuel
reading for mf
Loading Speed consump T.F.C, B.P ηthermal
S.NO ‘n’ number Kg/mi H.I B.P
Switches rpm tion, Kg/hr (eng),
of n KW (elec)
Sec KW
revolutions KW
, Sec
For double heater Load
Energy
Time for
meter
10 cc fuel
reading for mf
Loading Speed consump T.F.C, B.P ηthermal
S.NO ‘n’ number Kg/mi H.I B.P
Switches rpm tion, Kg/hr (eng),
of n KW (elec)
Sec KW
revolutions KW
, Sec
SAMPLE CALCULATIONS:
Engine output (Brake Power):
Engine out put, B.P

n x 60 x 60
(elec) = ……. KW
Em x t
BPelec
……. KW
B
. y tran
P
(e
Where
ng
) n = No. of revolution of energy meter
= Em = Energy meter constant = rev / Kw – hr
t= time for ‘ n’ revolutions of energy meter in sec
y trans = transmission efficiency = 0.7
Indicated Power
Time for 10cc of fuel consumption, t = …19.66…. Sec,

10 Sp.Gravity.of. Diesel
Mass of fuel consumption per min, mf = x
x 60
tx 1000
……. Kg / min.
Total Fuel Consumption, TFC = mf x 60….kg / hr.
TFC x
Heat Input, HI =
CV
60 x …….Kw
60
=
Where CV is calorific value of given fuel =

47100 KJ/ kg
Brake thermal efficiency, ƞB th = BP/HI
x100
PRECAUTIONS:
1. Before stating the engine check all the

systems such as cooling , lubrication and
fuel system
2. Ensure oil level is maintained in the

engine upto recommended level always.
Never run the engine with insufficient oil.
3. Never run the engine with insufficient

engine cooling water and exhaust gas
calorimeter cooling water.
4. For stopping the engine, load on the
engine should be removed
5. Don’t increase the compression ratio
beyond 8.0

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LABORATORY

1. Single cylinder Diesel engine with electrical loading.

Compression Ratio = SweptVolume + ClearenceVolume

Engine output (Brake Power):

Engine out put, B.P

Time for 10cc of fuel consumption, t = …19.66…. Sec,

Where CV is calorific value of given fuel =

1. Before stating the engine check all the

2. Ensure oil level is maintained in the

3. Never run the engine with insufficient

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