IC Engine Lab

FOUR STROKE SINGLE CYLINDER DIESEL

ENGINE WITH ELECRICAL LOAD

User Manual
Version 1.0
MODEL NO : MMIICE –021

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CONTENTS

1. INTRODUCTION 03

2. SPECIFICATION 04

i) Engine
ii) Ac Alternator
iii) Rheostat Load Bank
iv) Control Panel

3. CONSTANT VALUES 06

4. FORMULAS 07

5. EXPERIMENTAL SECTION 10

6. HEAT BALANCE TEST 21

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1. INTRODUCTION

WELCOME to MICRO MECH INSTRUMENTS, the leader in manufacturing and designing

of Mechanical, Automobile, Civil, and Instrumentation for Technical Institutions, Polytechnics,
Industrial Training Institute, Aeronautical Marine Training Centers & Engineering Colleges.
Founded in 2011 Micro Mech Instruments are providersof Automation Training Systems and
Industrial Control Solutions. We proudly announce that we have almost all Mechanical and
Automobile Lab. Our Product are cost effective without compromising the quality & Built-on
latest technology.

These are manufactured under strict supervision for good quality, workmanship and
our products enjoy the patronage of many leading technical educational institutions.

Internal combustion engines are those heat engines that burn their fuel inside the
engine cylinder. On the other side, external combustion engines are those heat engines that
burn their fuel outside the engine cylinder. These are steam engines. The energy developed
during the combustion of fuel is transmitted to steam which acts on the piston inside the
cylinder. In internal combustion engines, the chemical energy stored intheir operation. The
heat energy is converted into mechanical energy by the expansion of gases against the piston
attached to crankshaft that can rotate. The engines that burn petrol are known as petrol
engines. Other types of internal combustion engines burn heavier oils, of these types the
diesel engine has come into the widest use.

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2. SPECIFICATION

i) ENGINE
Make : Kirloskar
Type : AV1
Cylinder Type : Single cylinder, Vertical, Water cooled, Diesel
No. of Cylinder : 1
Power : 5 bhp (3.7 kW), 1500 rpm
Bore Size : 80 mm
Stroke : 110 mm
Compression ratio : 16.5

ii) A.C. GENERATOR

Make : Kirloskar
Rpm : 1500
Volt : 230
Power : 5.0 (kva)
Amps : 21.7

iii) RHEOSTAT LOAD BANK

Watts : 4kw (Each Selector Switch 500W – 8 Nos)
Phase : singe phase
Volt : 230V

iv) CONTROL PANEL

a. TEMPERATURE MESUREMENT
Thermocouples
Type :K
Temperature Range : 0-1200 Deg.C

Temperature Indicator
Channel 8
Operating Voltage : 230V AC
Thermocouple type :K
Range : 0-1200 deg.C
Size : 92X184
b. FUEL MASUREMENT

Measurement type : Burette

Volume : 33ml

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c. SPEED MEASUREMENT
Proximity sensor
Proximity sensor : M12
Transistor : PNP
Amps : 300 mA
Input Volts : 5 to 30 V DC
Output Voltage : 12 V DC

Speed indicator
Channel 1
Operating Voltage : 230 V AC
Size : 92X92
Input Signal Voltage : 12 Vdc

d. AIR INTAKE MEASUREMENT

Reservoir of size : 300 x 300 x 500 mm
orifice Plate : 16mm
U Tube Manometer Height : 300 mm

3. CONSTANT VALUES

D = Density of water = 1000 Kg / m3

Cd = Co-efficient of discharge = 0.64
Sg = Specific gravity of diesel = 0.84
CVd = Calorific value of diesel = 43,000 Kj /Kg
g = Acceleration due to gravity = 9.81m/s2
ηg Generator efficiency = 0.85
=
TP = Friction power = 1.2
PF = Power factor = 1
d = Density of air assume = 1.225 kg/m3

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4. FORMULAES
i) Brake Power (BP)

V x I x PF
BP =-------------------- KW
1000 x ηg

Where,
V :Volt meter reading in volts
I : Ammeter reading in Amps
PF : Power factor = 1
ηg : Generator Efficiency – 0.85

ii) Total fuel Consumption (TFC)

x 3600
TFC = ----- x ------ x Sg kg/ hr
t 1000
Where,
x - Fuel consumption in cc
t - Time for 10cc of fuel consumption in sec
Sg - Specific Gravity of Diesel
iii) Specific fuel consumption (SFC)
TFC
SFC = -------------- kg/KW - hr
BP
Where,
TFC - Total fuel consumption in Kg/ hr
BP - Brake power in K

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iv) Brake thermal efficiency (bth)
BP x 3600
bth = --------------- x 100 %
TFC x CV
Where,
C.V = Calorific value of fuel in KJ/kg (43,000)
TFC = Total fuel consumption in Kg/ hr

Dxh
v) Pressure head H =--------------------- (m)
d x 1000
Where,
D = Density Of Water 1000 (kg/m3)
h = Manometer reading (mm) (h1-h2)
d = density of air ( assume 1.225 kg/m3

vi) Mechanical efficiency (m)

BP
m = ----------- x 100 %
IP
Where,

IP = BP + FP
IP = Indicated power in KW
BP= Brake power in KW
FP= Frictional power in KW (from graph BP vs TFC)

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vii) Volumetric Efficiency (v)
AA
v = ---------- x 100 %
TA

Actual air consumption AA= Co-efficient of discharge X

orifice gas section area X (2gH)0.5 (M3/SEC)

Theatrical air consumption TA = 𝜋 𝗑(bore 𝑑2) x (stock length) X 𝑁 x

4 𝑛 60
Where,
N = Speed in rpm
n = Number of cylinder

viii) Area

𝐴 = 𝜋 𝑋 𝑑2
4

Where,

d = orifice gas section area

ix) Indicator power (IP)

I P = BP +FP
Where,
BP = Break power
FP = Friction power

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5. EXPRIMENTAL SECTION
Expt No :
Date :

Expt Name : FOUR STROKE SINGLE CYLINDER DIESEL ENGINE

WITH ELECTRICAL LOAD TEST RIG

AIM
To study the FOUR STROKE SINGLE CYLINDER DIESEL ENGINE WITH
ELECTRICAL LOAD TEST RIG and to draw the characteristic curves.

APPARATUS REQUIRED

➢ Engine Set-up
➢ Control Panel
➢ Diesel (As per Require)
➢ Stop Watch
➢ Load Bank

PROCEDURE
1. The maximum load for which the engine can be loaded is found.
2. The engine is provided with the lubricating oil and cooling water and the
required amount of fuel.
3. Start the engine
4. First for the no load condition the time taken for 10 cc of fuel consumption isnoted
using stop clock
5. The engine is loaded in regular interval by adding ON the Rheostat switchload.
6. The speed is maintained for each reading to constant 1500 rpm.
7. Time taken for 10cc of fuel consumption is calculated for each load.
8. Find the values of SFC, TFC, b, m and B.P using the above values.
9. Plot the different curves for the various parameter obtained with respect to the
Brake power
10. Get Friction power from fuel consumption vs Brake power linear plot x-intercept

1.4
fuel consumption, kg/hr

1.2
1.0
0.8
0.6
0.4
0.2
0.0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
Brake Power, kW

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I- READING MEASUREMENT

U-Tube Rota meter

S.N Load RPM V A T1 T2 T3 T4 T5 T6 Time
Manometer (LPH)
in in Sec (v) (a) (c) (c) (c) (c) (c) (c) for
Watts (Kg/hr) 10-
(w) CC h1 h2 Engine Colori
(SEC) (mm) (mm) meter

01 4000 1425 230 17.5 29 42 29 32 288 105 25 45 -45 250 250

Temperature Details

➢ T1 : Water inlet temp of Engine

➢ T2 : Water outlet temp of Engine
➢ T3 : Exhaust temp of calorimeter inlet
➢ T4 : Exhaust temp of calorimeter outlet
➢ T5 : Water inlet temp of calorimeter
➢ T6 : Water outlet temp of calorimeter

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II -RESULT TABULATION

S.N WATTS B.P T.F.C S.F.C Brake Mechanical Volumetric

(W) (KW) (Kg/hr) (Kg/Kw- thermal efficiency Efficiency
hr) efficiency (m) (v)
(bth) %) (%) (%)
01 4000 4.735 1.180 0.249 33.59 79.78 69.76

Sample CALCULATION

i) BP = V x I x PF/ (1000 x ηg) KW

( 230 x 17.5 x 1)
= -------------------- KW BP = 4.735 KW
( 1000 x 0.85 )

ii) TFC = X/t *3600/1000 x sg kg/ hr

10 3600
TFC = ------ x --------- x 0.82
25 1000
TFC = 0.4 x 3.6x 0.82 = 1.180 kg/ hr

iii) SFC =TFC/BP kg/KW - hr

1.180
SFC = --------- = 0.249 kg/KW - hr
4.735

iv) bth = BP x 3600/ (TFC x CV ) x 100

( 4.735 x 3600)
bth = ----------------------- x 100 = 33.59 %
(1.180 x 43000 )

v) m = BP/IP x 100 %

4.735
= ------------ x 100 = 79.78 %
(4.735+1.2)

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vi) Volumetric Efficiency (v)

i) Actual air consumption AA= Co-efficient of discharge X

orifice gas section area X (2gH)0.5 (m3/sec)

• Pressure head H = D x h/ (d x 1000) ---------- (m)

1000 X (45-(-45))
• Pressure head H = --------------------------- = 73.469(m)
(1.225x 1000)

AA = 0.64 x ( 𝜋/4 x 0.0162) x ( 2 x 9.81 x73.469)0.5 = 4.580 x10-3

ii) Theatrical air consumption TA = 𝜋/4 𝗑(bore 𝑑2) x (stock length) X N/2 x rpm/60

TA = 𝜋 𝗑(0. 08^2) x (0.11) X 1425 x 1

4 2 60

(v) = AA/TA x 100 %

4.580 x 10-03v
v = -------------------x 100 %
6.565 x 10-03
v = 69.76%

RESULT

Thus the FOUR STROKE SINGLE CYLINDER DIESEL ENGINE WITH ELECTRICAL LOAD TEST RIG
has been studied and characteristic curve weredrawn.

Brake thermal efficiency = 33.59%

Mechanical efficiency = 79.78%
Volumetric Efficiency = 69.76%

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HEAT BALANCE TEST

AIM
To conduct Heat balance test to find the heat supplied and heat lost to cooling
water,brake power, exhaust gas & unaccounted loss.

FORMULAE USED
1. Heat supplied Qs = (TFC x CV)/3600 J/s ,
Where TFC=Total fuel consumption in kg/hr
CV= calorific value of Diesel =43000 kJ/kg

2. Heat equivalent to useful work = BP in kW

3. Heat carried by engine cooling water, Qw = mwCpw(T2-T1) kW

Where,
T1 = Inlet temperature of engine cooling water (K)
T2 = Outlet temperature of engine cooling water (K)
Cpw = Specific heat of water = 4.187 kJ/kgK
mw = Mass flow rate of engine cooling water kg/sec

4. Heat carried by calorimeter cooling water, Qc = mcCpw(T6-T5) kW

Where, T3 = Inlet temperature of calorimeter cooling water (K)
T4 = Outlet temperature of calorimeter cooling water (K)
mc = mass flow rate of calorimeter cooling water kg/sec

5. Heat carried by exhaust gas, Qg = mgCpg(T4-T3) kW

Where, T5 = Exhaust gas temperature from engine (K)
T6 = Exhaust gas temperature from calorimeter (K)
Cpg = Specific heat of exhaust gas = 1.1 kJ/kgK
mg = Mass flow rate of exhaust gas = TFC(in sec) + ma
ma = Mass flow rate of air = CdA √(2gHa)×ρa (kg/sec)
Cd = Co-efficient of discharge of orifice meter = 0.64
A = Area of orifice =π/4 d2
d = Diameter of orifice = 16 mm

Ha = Head of air column = (Hw×ρw/ρa) (m)

Hw = Head of water column (m) (h1  h2)
ρw = Density of water = 1000 kg/m3
ρa = Density of air = Pa/RTa kg/m3 (or) 1.225 kg/m3
Pa = Atmospheric pressure = 1.01325×105 N/m2
R = Characteristic gas constant of air = 287 J/kg-K

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5. Percentage of brake power, % BP = (BP/Qs) x 100

6. Percentage of heat carried by engine cooling water, % Qw = (Qw/Qs) x 100

7. Percentage of heat carried by calorimeter cooling water, % Qc = (Qc/Qs) x 100

8. Percentage of heat carried by exhaust gas, % Qg = (Qg/Qs) x 100

9. Percentage of unaccounted loss = % Qs- (% BP + % Qw +% Qc + % Qg)

10. Unaccounted heat loss = Qs- (BP + Qw + Qg + Qg) kW

PROCEDURE
1. Calculate maximum load to be applied for a selected engine
2. Check the fuel supply, water circulation in the water system and lubricating
oil in the oil sump.
3. Ensure no load condition.
4. The engine is started and allowed to run on idle speed for a few minutes and
note readings for no load condition.
5. Gradually the engine is loaded mechanically by tightening the yoke and
applying load to the brake drum coupled to engine shaft.
6. The speed is maintained constant. After applying load, allow the engine to run
for few minutes to attain steady state.
7. Make sure the cooling water is supplied to the engine.
8. Load the engine in steps of 500W to be applied and consecutively & note the
readings for each step of load.
9. Note the corresponding readings of mass flow rate of water, time for 10 cc fuel
consumption, manometer reading, cooling water inlet and outlet temperature,
exhaust gas temperature & room temperature.
10. After taking the readings, unload the engine, allow it to run for few minutes and
then stop the engine by cutting off the fuel supply with the cut-off switch near
engine fuel pump.

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TABULATION

I- READING MEASUREMENT

S. Manomete Load Mass of Time taken Mass Engine Exhaust gas Engine
no r reading air for 10 ccfuel flow rate Cooling temperatu speed ‘N’
consum consumpti ofwater water re
ed on mw temperatu Tg
ma ‘t’ re
h h H Am kg/s s kg/s Tin Tout 0 Rpm
1 2 w ps 0C 0C C
m m m
m m m

II -RESULT TABULATION

S.no Load Heat QBP Qw Qc Qg Qunacc

A input kW % kW % kW % kW % kW %
kW

RESULT

Thus the Heat balance Test on a Four Stroke Single Cylinder Diesel Engine Test
Rig has been studied and characteristic curve were drawn.

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Cylinder pressure analysis

Parameter Units Value

Electrical load kW
Engine Brake power kW
Engine RPM
Fuel flow rate Kg/hr
Calorific value kJ/kg
Total fuel energy input kW
Indicated power kW
Closed cycle (IVC to EVO) kW
Open cycle (EVO to IVC) kW
Friction power kW
Thermal efficiency %
Mechanical efficiency %
Peak cylinder pressure kPa
Occurrence of Peak pressure CA, aTDC
Start of combustion CA, aTDC
End of combustion CA, aTDC
Ignition delay CA
Combustion duration CA
Cumulative heat release Joules
Total heat input Joules
Heat transferred Joules
Heat transferred kW

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Emission Measurement & Analysis

Exhaust Gas Measurement principle Range Resolution Accuracy
HC NDIR 0-15% 0,00t% ±5%
CO NDIR 0-20000 ppm 1 ppm ±5%
CO2 NDIR 0-20% 0.01% ±5%
O2 Electrochemical 0-25% 0.01% ±5%
NOx Electrochemical 0-5000ppm 1 ppm ±5%
SOx Electrochemical 0-5000ppm 1 ppm ±5%
Smoke (HU) Light Absorption 0-99.99% 0.01%
HU = Hartridge smoke units

Air fuel ratio & fuel composition calculations

CxHy + a O2 + 3.76a N2 ➔ (%CO2) CO2 + (% CO) CO+(%O2) O2+ (%N2) N2 +y/2 H2O

N2 balance: 3.76a = (1-%CO2-%CO-%O2)

O2 balance: 2a = %CO2*2+% CO +%O2*2+y/2

Product composition by vol %

CO2
CO
O2
N2 N2=1 -CO2 -CO -O2
Molar O2 input a
H2O y
Use N2 balance for a= a=N2/3.76
Use O2 balance for y= 2a = %CO2*2+% CO +%O2*2+y/2
Use Carbon balance for x= %CO + %CO2
Formula (CxHy)
C wt % x*MWC/(x*MWC+y*MWH)
H% y*MWH/(x*MWC+y*MWH)
Air-fuel ratio (AFR) =a (MWO2+3.76*MWN2) /(x*12+y)
Stoichiometric Air-fuel ratio (x+y/4)*(MWO2+3.76*MWN2)/(x*12+y)
Excess air =(AFR-AFR stoic)/AFR stoic

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Plots
1. Brake Power Vs Total fuel consumption (kg/hr) for friction power
2. Brake Power Vs Specific fuel consumption
3. Brake Power Vs Mechanical efficiency
4. Brake power vs Volumetric efficiency
5. Brake Power Vs Brake thermal efficiency
6. Brake Power Vs Exhaust Temperature
7. Brake power vs Energy distribution ie Total Energy input, brake power,
cooling power, exhaust power, friction, unaccounted
8. Brake power for emissions (HC, CO, CO2, NOx, Smoke)
9. Brake power vs Air-fuel ratio

Friction measurement using Willian’s line

• Constant speed and variable load test esp CI Engines+ Dynamometer to
measure Brake power
• Fuel consumption (g/s) vs brake power (kW) plot
• Fuel rate extrapolation method: 5-40% load
• -ve x-axis intercept is friction power @ given rpm

1.4
fuel consumption, kg/hr

1.2
1.0
0.8
0.6
0.4
0.2
0.0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
Brake Power, kW

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Brake power
Cooling

% of Total Fuel Energy input

Calorimeter-Exhaust
Unaccounted
Friction

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5
Brake Power, kW

Mechanical& Electrical Eff., %

Volumetric efficiency, %

Volumetric Eff
Mech Eff
Elec. Efficiency

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5
Brake Power, kW

MU-Test
Air-Fuel ratio

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5
Brake Power, kW

MU-Test
Exhaust temperature, C

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5
Brake Power, kW

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Date
Time

Dsl level Electrical Water Ambient Engine

Elec. Power factor 1 Density, kg/m3 1000 Pamb, kPa 101.325 Bore, m 0.08
End Gen efficiency 0.85 Specific heat, kJ/kg-K
4.187 Tamb, C Stroke, m 0.11
Diesel fuel Air-tank Rair, J/Kg-K 287 Vdisp, m3 0.000553
Density (sg) 820 Cd of orifice 0.64 Air density, kg/m3 CR 16.5
Cal. Val, kJ/kg 43000 Orifice plate, mm16 Sp. Heat of exh,1.3
kJ/kg-K friction, kW 1.2

Energy (from Elec Load Volts Amps Time for Utube Mano Rotameter,
energy meter) (Meter) Rpm (Meter) (Meter) T1 T2 T3 T4 T5 T6 10Cc reading LPHl Below
C (Water C (Water C (Exh Eng C (Exh C (Water C (Water Calorime
Reading Time kWh kW Volts Amps Eng_in) Eng_out) out) Cal out) Cal_in) Cal_out) s h1, mm h2, mm Engine ter
1 No Load
2 500
3 1000
4 1500
5 2000
6 2500
7 3000
8 3350

Electrical Brake Friction Fuel flow Pressure Actual air Th. Flow Airflow
Elec eff power (V x I) power power rate SFC SFC head flowrate rate rate Act AFR Vol. eff Mech Eff Ind Power Ind Eff
Ser No Elec. Power % kW kW kW kg/hr kg/kWhr g/kWhr H, m m3/s m3/s kg/hr % % kW %
1 No Load 1.2
2 500 1.2
3 1000 1.2
4 1500 1.2
5 2000 1.2
6 2500 1.2
7 3000 1.2
8 3350 1.2
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Energy balance, kW Energy balance, %

Friction Engine Calorime Calorime Engine exh, Brake Friction Engine Calorime Calorime Engine exh, unaccont
Ser No Elec. Power Heat input Brake power power cooling ter water ter exh tot unacconted Heat in power power cooling ter water ter exh tot ed
1 No Load
2 500
3 1000
4 1500
5 2000
6 2500
7 3000
8 3350

Ser No Elec. Power CO CO2 O2 HC Nox smoke K

% % % ppm ppm HU 1/m a Carbon Hydrogen AFR
1 No Load
2 500
3 1000
4 1500
5 2000
6 2500
7 3000
8 3350
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