Military Institute of Science &Technology

(MIST)

Department of Mechanical Engineering

ME-402
Heat Engine Sessional
LEVEL-4, TERM-I
Contact Hr:3.00hr Credit:1.5

Name of the Experiments:

1. Study of Automotive Engines
2. Detailed study of an Automotive Engine parts.
3. Analytical Study of cooling and lubrication
systems of Automotive Engine.
4. Analytical study of fuel and ignition system
of Automotive Engine.
5. Performance Test of a High-Speed Diesel Engine
6. Dismantling and Assembling a Diesel (CI) Engine
7. Dismantling and Assembling a Petrol (SI) Engine.
8. Study of Diesel Power Plant of MIST
General Safety Notes for the Students:

1. The students must always use an apron and close-toed shoes in the laboratory.
2. Keep your tools and hands free of grease and oil.Wearing mechanic gloves is smart,but do not
wear gloves when moving parts are present. Keep your hands away from moving parts. Never use
your hands to stop components that are moving.
3. Female students should keep their hair tied and their scarfs pinned so that they do not come in
contact with the rotating and moving parts.
4. Use proper lifting procedures to avoid injury. Use your legs ,not your back.

Operational Safety Notes:

1. Do not work on a hot engine.
2. Do not touch sparkplug wires while the engine is running. Tens of thousands of volts are
present.
3. Never put your hands on or near the cooling fan. Many fans are electric and can start at
any time, even if the ignition is off.
4. Never open a hot radiator cap.
5. Do not touch a rotating turbocharger
6. Keep the working area around the IC engine neat & clean.
7. Do not put tools on top of a vehicle’s battery. Accidentally touching both terminals will
cause a spark, which could lead to an explosion
8. Inspect system integrity before operating any pressure/vacuum equipment. Gas cylinders
must be secured at all times.

Potential Hazards
Hot Metal, Sparks, Noise, High Pressure Air/Cylinder/Vacuum, Rotating Equipment
 EXPERIMENT 01
Study of Automotive Engines

Objectives:
1. To study the various types of automotive engines
2. To study the basic principle of two stroke and four stroke engines
3. To study the different arrangements of SI and CI engine cylinders

Theory:
Engine: An engine is a power generating machine. It converts the potential
energy of the fuel into heat energy and then into rotary motion. An
automotive engine that produces power also runs on its own power.

Heat Engine: It can be defined as any engine that converts thermal energy to
mechanical work output. On basis of how thermal energy is being delivered to
working fluid of the heat engine, heat engine can be classified as-

a. Internal Combustion Engines:

Combustion of fuel takes place inside the
engine cylinder Example: Petrol, Diesel,
Gas Engine

b. External Combustion Engines:

Combustion of an air-fuel mixture transfers heat to a second fluid which becomes
the motive (working) fluid that produces power.
Example: Steam driven engine

Steam Engine IC Engine

1) Engine smooth & silent running
2) Working pressure & temperature inside
the cylinder are low
3) Requires a boiler and other components
to transfer energy, thus cumbersome
4) 15-20 % efficiency
5) Cannot be started instantaneously
1) Engines are noisy
2) Working pressure & temperature inside
the cylinder are high
3) Does not require a boiler or other
components, thus light and compact.
4) 35-40 % efficiency
5) Can be started instantaneously
Classification of Internal Combustion Engines:

1. According to the type of fuel used:

a) Petrol Engine
b) Diesel Engine

2. According to the method of ignition of fuel:

a) Spark Ignition Engine (SI Engine)

b) Compression Ignition Engine (CI Engine)

3. According to the number of strokes per cycle:

a) Four Stroke Engine

b) Two Stroke Engine

4. According to the cooling system:

a) Air-Cooled Engine
b) Water-Cooled Engine

5. According to the type of lubrication system:

a) Wet Sump Lubrication

b) Dry Sump Lubrication
c) Splash Lubrication

6. According to number of cylinders:

a) Single Cylinder Engines

b) Multi Cylinder Engines

7. According to the arrangement of cylinders:

a) Vertical Engines
b) Horizontal Engines
c) Radial Engines
d) V-Type Multi-Cylinder Engines
e) In-Line Multi-Cylinder Engines

8. According to the arrangement of camshaft:

a) Single Overhead Camshaft (SOHC)

b) Dual Overhead Camshaft (DOHC)

There are many types of classifications available. We will mainly focus on these 8 types.
 Two Stroke Engine:
A two-stroke engine completes a power cycle in just two strokes of the piston.
• 1st stroke (the Suction and the Compression strokes)
• 2nd stroke (the Power and the Exhaust strokes)

The two-stroke engine has following three ports:

1. Exhaust port
2. Transfer port
3. Intake port

Application: Off-road motorcycles, lawn mowers, bikes, ships, chainsaws, railway engines

Lubrication: Two-stroke engines use their crankcase to pressurize the air-fuel

mixture before transferring to the cylinder. Unlike four-stroke engines, they cannot be
lubricated by the oil contained in the crankcase and sump: lubricating oil would be
swept up and burnt with the fuel. Fuels supplied to two-stroke engines are mixed with
oil so that it can coat the cylinders and bearing surfaces along its path. The ratio of
gasoline to oil ranges from 25:1 to 50:1 by volume. In general, two-stroke engines are
known to wear more quickly than four-stroke engines because they don’t have a
dedicated lubricant source; however, high quality two-stroke
oil significantly reduces engine wear.
Four Stroke Engine:
4-stroke engines deliver a good balance of power, reliability and efficiency. When it
comes to emissions, 4-strokes separate each event mechanically, which reduces
unburned fuel emissions. It also separates oil from fuel, which significantly reduces
carbon monoxide emissions. This combination of desirable traits has earned the 4-
stroke the top spot in passenger vehicles today.

The output power of the engine depends on the amount of air drawn in. The
performance of a piston engine (whether it is a 4-stroke engine or a 2-stroke engine)
depends on the speed (RPM), the calorific value of the fuel, loss, air-fuel ratio,
volumetric efficiency, oxygen content in fuel-air mixture and combustion chamber size.
Ultimately, the speed of the engine controls through lubrication and material strength.

Valves: Valves open and close at predetermined times in relation to the piston,
allowing for reliable and efficient power generation. Engine and valve train
configurations vary, but the goal remains consistent—a camshaft is precisely timed to
the crankshaft, and they work together to manage the mechanical operation of the
engine.
While the engine crankshaft controls the up and down motion of the piston inside the
cylinder, the camshaft is responsible for opening and closing the valves.
Petrol Engine:

Diesel Engine:
Arrangement of Cylinders:

Cooling Methods:
Assignment:
1. Why special alloys are required to manufacture the cylinder of IC engines?
2. Shortly describe the lubrication system in 2-stroke SI engines?
3. Which engine produces less pollution, 2-stroke or 4-stroke? Why?
4. Which engine is faster, 2-stroke or 4-stroke? Why?
5. Differentiate between 2-stroke and 4-stroke engines.
6. Differentiate between petrol engine and diesel engine.
7. What will happen if you use diesel fuel in petrol engine?
8. What will happen if you use petrol fuel in diesel engine?
9. What is scavenging?
10. What is knocking? What are the reasons behind this?
11. How can you reduce knocking phenomenon?
 EXPERIMENT 02
Detailed Study of Automotive
Engine Parts

Objectives:
1. To study construction of different engine components
2. To study the basic function of an IC engine parts
3. To study the principle of Wankel Engine

Theory:
An internal combustion engine (IC engine) works by converting energy from combustion into
work. The engine has a fixed cylinder and a moving piston. The combustion gases expand and push
the piston, which rotates the crankshaft. The crankshaft's motion is then driven by the vehicle's
wheels through a power train's gears.

The construction of an engine varies little, regardless of size and design. The intended use of the
engine determines its size and design, and the temperature at which the engine will operate
determines the type of metal it will be built from.

The stationary parts of an engine include the cylinder block and cylinders, the cylinder head or
heads, and the exhaust and intake manifolds. These parts furnish the framework of the engine. All
movable parts are attached to or fitted into this framework.
Engine Construction:

• Parts common to both Petrol and Diesel Engine:

• Cylinder • Cylinder head • Piston
• Piston rings • Gudgeon pin • Connecting rod
• Crankshaft • Crank • Engine bearing
• Crank case • Flywheel • Governor
• Valves

• Parts for Petrol engines only:

• Spark plug • Carburetor • Fuel pump

• Parts for Diesel engines only:

• Fuel pump • Injector
Cylinder Block:
• Foundation of the engine
• Contains coolant passages
Material: Gray Cast iron or
iron mixed with other metals

Cylinder:

• Hole inside the cylinder block

Cylinder Sleeve / Liner:

• Used inside the cylinder to prevent permanent wear of cylinder bore

• Two types: (a) Dry Liner, (b) Wet Liner
Material: Gray cast iron

Crankcase:

• Holds the cylinder and crankshaft

• Also serves a reservoir for lubricating oil
• Two parts:
a. Upper crankcase
b. Lower crankcase

Material: Cast iron

Cylinder Head:
• A detachable unit of an engine bolted to the top of the cylinder block
• Contains: Water Jacket, Valves, Valve Seats, Valve Guide, Injector/Spark Plug, Pre-
combustion Chamber, Intake and Exhaust Manifold etc.
Material: Cast iron or aluminum alloy

Combustion Chamber:
• Space enclosed between the piston head and the
cylinder head when the piston is at top dead center
position.

Pre-combustion Chamber:
• A small combustion chamber where combustion begin
• Causes high turbulence and good combustion in the
main combustion chamber.

Gasket:
• Head Gaskets: seal the combustion gases within the cylinders and avoid coolant or
engine oil leaking into the cylinders
• Oil Pan Gasket: seal between the bottom of the oil pan
and the engine block
• Manifold Gaskets: prevent air, oil, and coolant leaks by sealing
off the gaps between the manifold and the engine
• Pump Gasket: seals the water pump and the engine block
together .
Material: Stainless steel, cork, rubber, silicone, fiberglass
Intake Manifold:
• Petrol Engine: Supply air-fuel mixture during suction stroke
• Diesel Engine: Supply air during suction stroke
Material: Cast iron, aluminum, composite plastic

Exhaust Manifold:
• Waste products of combustion are expelled to the
atmosphere by the exhaust manifold
Material: Cast iron

Intake and Exhaust Valve:

• Intake valves lets air in and exhaust valves expels burnt gas to go out of the cylinder
• Intake Valves are always larger than exhaust valves
Material: Intake valves, because of their lower
operating temperatures, are typically made of
materials such as chrome, nickel, or tungsten steel.
The higher temperature exhaust valves may use
more heat-resistant metals such as nichrome,
silicon-chromium, or cobalt-chromium alloys.

Cams and Camshafts:

• Controls the opening and closing of the intake and exhaust valves as required
• For two complete rotation of the crankshaft, camshaft rotates once
• Rotary motion into linear motion
• Arrangement: (a) SOHC, (b) DOHC
• Operate the fuel pump, oil pump etc.
Material: Cast iron
Crankshaft:
• Backbone of an engine
• Convert reciprocating motion of the piston into rotary motion with the help of
connecting rod
• Contains one or more eccentric portions called cranks
• Consists of crankpins, crank webs (crank arms or cheeks), balancing weights, and
main journals
Material: Forged steel or cast iron

Flywheel:
• Bolted to the rear end of the crankshaft
• Stores energy from the power strokes and smoothly
delivers it to the drive train of the vehicle
• Helps to avoid the rough running of the engine
• Helps to start the engine
• Serves as a driving member of the engine clutch
Material: Cast or nodular iron, steel or aluminum

Connecting Rod:
• Used to transmit the motion from the piston to the
crankshaft
• Subjected to tension, compression, bending and
buckling
Material: Forged steel or cast iron
Piston:
• A cylindrical plug that moves up and down in the
engine cylinder and receives the energy or force of
combustion and transmits that energy to the crankshaft
through the connecting rod
• Expansion control in piston
a. Use of vertical or T slot
b. Cam ground piston
c. Bi metal piston
Material: Aluminum alloy, cast steel or cast iron

Piston Rings:
• Circular rings fitted in the piston ring grooves
• Two types:
a. Compression Ring
b. Oil Control Ring
• Provide a seal between the piston and cylinder wall
• Keep the lubricating oil from bypassing the piston and
getting into combustion chamber from the crankcase
• Provide a solid bridge to conduct the heat from piston to
the cylinder wall
Material: Cast iron or steel

Bearings:
• Main crankshaft bearings
• Connecting rod bearings
• Small end bushes
• Camshaft bearings
Material: Aluminum alloy or copper alloy
Wankel Engine:

Mazda- Wankel rotary engines

Assignment:
1. Write functions of the following engine components:
a) Cylinder block h) Intake and exhaust valve
b) Cylinder sleeve/liner i) Cams and camshafts
c) Crankcase j) Crankshaft
d) Cylinder head k) Flywheel
e) Pre-combustion chamber l) Connecting rod
f) Gasket m) Piston
g) Intake and exhaust manifold n) Piston rings
2. Why is it not practical to use Aluminum in making cylinder blocks?
3. What are the types of cylinder liners? Describe with figures?
4. How can you differentiate between intake and exhaust valves?
5. How would you select materials for making intake and exhaust valves?
6. Differentiate between SOHC and DOHC.
7. Write functions of the different types of bearings used in engine.
8. What causes white smoke from the exhaust?
9. What causes black smoke from the exhaust?
 EXPERIMENT 03
Analytical Study of cooling and
lubrication system of Automotive
Engine.
Objectives:
a. To familiarizing cooling subsystems of engines.
b. To familiarizing lubrication subsystems of engines.
c. To understanding the construction and function of components of different subsystems.
d. To analyzing significance of these subsystems in automotive engines.

Theory:
Lubrication System
Engine lubrication is the process in which robing metal parts are separated by the flow of
lubricating substance between them. Lubricants are available in liquid, solid or gas, but the liquid
is the most form of lubrication used in engines. The functions of lubrication system are-
• The primary purpose of engine lubrication is to minimize wear by securely closing the
clearance between moving parts such as shafts, bearings, etc. Lubrication also avoids the
moving parts not to come in direct contact with each other.
• Oil serves as a cleaning agent in an engine as it moves the dirt particle to the oil pan.
Smaller particles are filtered out by the oil filters while larger ones are retained in the oil
pan.
• Another purpose of engine lubrication is that it serves as a cooling system. Lubricating oil
cools the moving parts of the engine and transferred the hot oil into the cooler oil in the oil
pan.
• The oil creates a seal between the cylinder walls and the piston rings. It also reduces the
exhaust gas blowby.
• Clearance between the rotating journals and bearing is filled with oil. The oil acts as a
cushioning agent when the bearing suddenly experiences heavy loads. Oils reduce the wear
on bearings
The following are lubrication system components:

Oil pan/sump: An oil sump is a reservoir in the shape of a bowl that stores the engine oil. With
the sump, the oil circulates within the engine. The part is located below the crankcase which is the
beneath of the engine, making the oil to be easily removed through the bottom.
Oil Pump: The oil pump is a component that helps to push the lubricating oil to all the moving
parts in the engine. It’s located at the bottom of the crankcase, close to the oil sump. It supplies oil
to the oil filter before sending it further.
Oil pumps can eventually stop working, which may lead damages to the engine. It can be caused
by small particles inside the lubricating oil, which choke the oil pump and galleries.
Oil filter: The oil filter helps to keep small particles, separating them from the oil so that clean oil
can flow to the engine parts. The oil pump allows the oil flow through the oil filter to the galleries
before reaching the engine parts.

Oil Galleries: The function of oil galleries in the engine lubrication system is to circulate oil
quickly to reach all moving parts in automobiles. So, the performance of an oil gallery determines
how fast your engine parts received oil.
Oil cooler: An oil cooler is a device that works as a radiator as it cools down the hot oil. Coolers
transfer the heat from the engine oil to the engine coolant using its fins. Oil coolers stabilize the
temperature of the engine oil, keeps its viscosity under control, prevents the engine from
overheating, minimize wear and tear as well as retaining the lubricant quality.
Some engine lubricating system circulates oil within the engine with the recycling process. The
following are the parts that oil is supplied during the process:
• Crankshaft main bearings
• Big end bearings
• Piston pins and small end bushes
• Piston rings
• Timing Gears
• Air-compressor piston and bearings (in commercial vehicles for air-brake)
• Camshaft and bearings
• Valves
• Cylinder walls
• Oil pump parts
• Water pump bearings
• Turbocharger bearings (if available)
• Vacuum pump bearings (if available)
• In-Line Fuel Injection Pump bearings
• Tappets and push-rods
Below are the types of engine lubrication system:

Mist Lubrication System is the type used in the two-stroke engines where oil and fuel are mixed.
The mixture is generated through the carburetor. The fuel gets vaporized while the oil in the form
of a mist enters the cylinder through a crank base. In the crank base, the oil lubricates the
connecting rod along with the piston ring, piston, and cylinder.
Wet Sump Lubricating System is generally located next to or near the crankshaft. it’s the lower
part of the engine and it has a single oil pump. This pump moves the oil through the oil galleries.
The construction is easier and it’s unexpansive.
Dry Sump Lubricating System has an oil reservoir that is not located at the bottom of the engine.
It uses two oil pumps to keep the oil circulating within the engine. The system is more complex
and expensive to design. However, there’s more flexibility to the design of the pan as it’s located
in an unusual place. It is often found in performance engines.
 Engine Cooling System
All the I.C engines require a cooling system because the combustion of fuel takes place inside the
engine itself. All the heat produced by the combustion of fuel in the engine cylinders is not
converted into useful power at the crankshaft. Only about 30% of the heat is converted into
mechanical work. About 40% goes off through the exhaust. The remaining 30% is useless to waste
heat.
It is seen that the quantity of heat given to the cylinder walls is considerable and if this heat is not
removed from the cylinders, it would result in the seizing of the piston, high fuel consumption,
pre-ignition, and burning of lubricant, etc.
Keeping the above facts in view, it is observed that suitable means must be provided to dissipate
that excess heat from the cylinder walls so as to maintain the temperature below certain limits.
Therefore, the method of removing away the excess heat from the engine cylinder is called a
cooling system.

Following are the two types of cooling systems for engines:

1. Air cooling system
2. Water cooling system

Air cooling system

An air-cooled system is generally used in small engines say up to 15-20 kW. The air system is used
in the engines of motorcycles, scooters, airplanes, and other stationary installations. In countries
with cold climates, this system is also used in car engines.
 In this system, the heat is dissipated directly to the atmospheric air by conduction through the
cylinder walls. In order to increase, the rate of cooling, the outer surface area of the cylinder and
cylinder head is increased by providing radiating sins and flanges. In bigger units, fans are
providing to circulate the air around the cylinder walls and cylinder head.

Advantages of Air-Cooled System

• The air-cooled system has no radiator or pump so the system is light.
• In case of water-cooling system there are leakages, but in this case, there are no leakages.
• Coolant and antifreeze solutions are not required.
• This system can be used in cold climates, where if water is used it may freeze.
Disadvantage of Air-Cooled System
• Comparatively, it is less efficient. It is useful only in aero planes and motorcycle engines
where the engines are exposed to air directly.
Water cooling system
The water cooling system is used in the engines of cars, buses, trucks, etc. In this system, the water
is circulated through water jackets around each of the combustion chambers, cylinder, valve seats,
and valve stems.
The water is kept continuously in motion by a centrifugal water pump which is driven by a V-belt
from the pulley on the engine crankshaft. After passing through the engine jackets in the block and
cylinder heads.
The water is passing through the radiator. In the radiator, the water is cooled by air drawn
through the radiator by a fan. Usually, the fan and water pump are mounted and driven on a
common shaft. After passing through the radiator, the water is drained and delivered to the water
pump through a cylinder inlet passage. The water again circulated through the engine jackets.
 Parts of Water Cooling System
1. Radiator.
2. Thermostat valve.
3. Water pump
4. Fan.
5. Water Jackets.
6. Antifreeze mixtures.

Types of water cooling:

1. Thermosyphon cooling system or Impeller circulation system.
2. Pump circulation system or Pressurized cooling system.
Advantages of Water Cooling System
• Uniform cooling of the cylinder, cylinder head and valves.
• Specific fuel consumption of engine improves by using a water cooling system.
• The engine need not be provided at the front end of moving vehicle.
• The engine is less noisy as compared with air-cooled engines, as it has water for damping
noise.
Disadvantages of Water Cooling System
• It depends upon the supply of water.
• The water pump which circulates water absorbs considerable power.
• If the water cooling system fails then it will result in severe damage of the engine.
• The water cooling system is costlier as it has a number of parts. Also, it requires more
maintenance for its parts.
 Fig: Water cooling system

In cooling system for IC engine, the following point is important for the comparison of air
cooling and water cooling system.

Air Cooling System

1. The design of this system is simple and less costly.

2. Weight of the cooling system (per b.h.p. of the engine) is very less.
3. The fuel consumption (per b.h.p. of the engine) is more.
4. Its installation and maintenance are very easy and less costly.
5. There is no danger of leakage or freezing of the coolant.
6. It works smoothly and continuously. Moreover, it does not depend on any coolant.

Water Cooling System

1. The design of this system is complicated and more costly.

2. Weight of the cooling system (per b.h.p. the engine) in much more.
3. The fuel consumption (per b.h.p. the engine) is less.
4. Its installation and main tenace in difficult and more costly.
5. There is a danger of leakage or freezing of the coolant.
6. If the system fails, it may cause serious damage to the engine within a short time.
 EXPERIMENT 04
Analytical study of fuel and ignition system
of Automotive Engine
Objectives:
To understand the functioning and analyze the performance of the fuel and ignition system of an
automotive engine.

Fuel Supply System

The fuel supply system of spark ignition engine consists of:

(I) Fuel tank

(ii) Fuel filter

(iii) Sediment

(iv) Fuel lift pump

(v) Carburetor

(vi) Fuel pipes

(vii) Inlet manifold

Fuel injection system can be divided into two basis types:
• Manifold: a) Throttle body b) Port Injection
• Gasoline Direct Injection

Carburetor
The carburetor is a mixing device that delivers the
engine a combustible air-fuel mixture continuously. The main functions of the carburetor are:
(I) To mix the air and fuel thoroughly

(ii) To atomize the fuel

(iii) To regulate the air-fuel ratio at different speeds and loads and

(iv) To supply correct amount of mixture at different speeds and loads.

Carburation Subsystem
• Float system to maintain a constant level of fuel in the reservoir.
• Idle & low speed system to deliver rich air-fuel mixture during starting and low speed operation.
• Main metering system to deliver air-fuel mixture of desired A/F ratio.
• Power system to deliver rich A/F mixture for high speed, full-power, wide-open throttle(WOT)
operation.
• Accelerator pump system to deliver extra fuel during acceleration

**Learn short note above these subsystems from Automotive Mechanics Chap 21

Ignition System

Purpose of Ignition System is toDeliver an electric spark that jumps the spark plug gap and ignite
theair fuel mixture.

Two types of ignition systems are:

• Contact-point ignition system

• Electronic ignition system

SPARK PLUG:

It has two solid metal conductors (electrodes)positioned to form a gap. The wider the gap, the higher
voltage required. The heat from the arc ignites the air-fuel mixture. Spark plug has a metal outer shell
enclosing a ceramic insulator through which there is a center electrode. The spark gap varies from 0.9
mm to 2.03 mm.

SPARK PLU

G SPARK PLUG

Contact-point ignition system and Electronic ignition system:

The primary difference between contact point ignition system and electronic ignition system is that
in electronic ignition, the contact points in distributor is replaced with electronically controlled contact
switch which is done via a control module.

Report Writing/ Assignments:

1. Discuss ignition system with types, components, working principle, and schematic
diagrams.
2. Suppose you are checking your engine oil level one day before getting into your car. You
see that the oil level is above the maximum mark of the dipstick. What problem could it
cause for the engine had you not checked before starting your car and what should you do
now that you know the situation? Again, another day you see that the oil level is below the
minimum mark of the dipstick. What problems can be caused if you run your car without
taking any steps?
3. Suppose one day you get in your car and turn the key. Surprisingly, the car does not start
through you made sure that the battery is not dead. Your car has coil ignition system. What
parts of the ignition system should you check to find the issue?
 EXPERIMENT 05
Performance Test of a High-speed Diesel
Engine
OBJECTIVES:
a) Study the engine specification and performance parameter.

b) Do the performance test and measure Bhp, Bsfc and BMEP.

THEORY:
Engine can be defined as a device which converts the heat energy of a fuel to mechanical energy. The
conversion rate of engine is never 1, i.e. engines can never convert all the energy of the fuel to
mechanical energy due to losses in friction, cooling etc. So, engine’s performance is associated with
efficiency. Engine is also defined by the brake horsepower, which is the available power at the
flywheel.

Diesel engines work by Air standard Diesel cycle. The efficiency of the diesel engine can be expressed
from the P-v and T-s diagrams as

1 𝜌𝑘 − 1
𝜂 = 1 − 𝑘−1 ( )
𝑟 𝑘(𝜌 − 1)

Where, 𝜌= Fuel cut off ratio, and k = (Cp/Cv)

The output power expressed as brake power (bP) or mechanical power is the value given by the
dynamometer, calculated from the value of torque. The input power is the power given by the fuel. So,
the calorific value of total fuel in the cylinder indicates the input power. So, the thermal efficiency can
be calculated.

Volumetric efficiency is the ratio of actual volume flow rate of air into the cylinder to the theoretical
volume flow rate of air. It generally possesses a value lower than 1 but using turbocharger,
supercharger, and intercooler it is possible to feed the engine more air than the theoretical value and
so, its value can go as high as 1.3.

Engine performance is usually plotted in with respect to engine speed. The values of power, torque,
fuel consumption is plotted with respect to speed. A typical engine performance curve is shown below:

As it can be seen here, brake specific fuel consumption is least at a specific speed and the value of
brake thermal efficiency will be maximum for that point It is known as rated speed. Below that point,
inertia forces are too high and so, more fuel is consumed. Above that point, the air friction would be
too high, and the vehicle needs to burn a significant amount of fuel to propel.
ENGINE SPECIFICATION & AMBIENT DATA:

Brand Name Lubrication

System
Model Cooling
Engine No. Exhaust
Country of Lub Oil Filter
Make
Manufacturer Fuel Filter
Rated Output Air Cleaner
Rated rpm Oil Press.
Indicator
No of Cylinder Coupling
Lub. Oil Used Starting
Fuel Used Dry Valve Temp.
Dynamometer Atm. Pressure
Rotation (ffs) Relative
Humidity

ENGINE PERFORMANCE TEST:

Calorific value of fuel, CL = 43.8 MJ/Kg

Co-efficient of discharge of the orifice, Cd=O.6

Orifice diameter, d=0.0185 m

Gas constant for air, R= 287 Jkg-1K-1

Specific heat of air at constant pressure, CP =1004.5 J/Kg

Fuel Density= 840 kg/m 3

Engine capacity= 232cc

Ambient pressure, P= mbar= N/m2

EQUATIONS USED:

𝜋𝑑2 2𝑃𝐴 Δ𝑃
Mass flow of air, ma(Kg/s)= 𝐶𝑑 × ×√
4 𝑅𝑇𝐴

𝑚
Air fuel ratio= 𝑚𝑎
𝑓

2𝜋𝑁𝑇
Mechanical (/Brake) Power bP= watt
60

𝑚𝑓 ×3600
Specific fuel consumption= 𝑏𝑃

𝑏𝑃
Thermal efficiency ηth= 𝑚 × 100
𝑓 ×𝐶𝐿

60×𝑏𝑃×(𝑠𝑡𝑟𝑜𝑘𝑒𝑠⁄2)
Break mean effective pressure in Bar = 0.1×𝑠𝑝𝑒𝑒𝑑(𝑟𝑝𝑚)×𝐸𝑛𝑔𝑖𝑛𝑒 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦(𝑐𝑐)

𝐸𝑛𝑔𝑖𝑛𝑒 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦(𝑚3 )×𝑁

Calculated volume flow rate= 𝑠𝑡𝑟𝑜𝑘𝑒𝑠
×60
2

𝑚𝑎 ×𝑅×𝑇𝐴
Measured volume flow rate= 𝑃𝐴

𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑎𝑖𝑟

Volumetric efficiency ηv = 𝑐𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑎𝑖𝑟 × 100

Heat energy of combustion for fuel (Watts) Hf= 𝑚𝑓 × 𝐶𝐿

𝑚𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑝𝑜𝑤𝑒𝑟
Thermal efficiency ηT = × 100
𝐻𝑓
ASSIGNINMENT:

a) Plot engine speed (rpm) vs Exhaust temp, torque, power, Bsfc, Thermal efficiency.

b) Find the rated speed of the engine

bowl

(iv) Fuel lift pump

(v) Carburetor

(vi) Fuel pipes

(vii) Inlet manifold

 EXPERIMENT 06
Dismantling and Assembling a Diesel (CI) Engine

Objectives
a) To identify & study functions of different engine components.

b) To understand the process of disassembling and reassembling the engine

c) To test the assembly procedure by starting the engine.

Engine Specification
Bore
Stroke
No of cylinder
Arrangement of cylinders
Cam shaft type
Injection type
Type of fuel pump

Methodology
1. Study the engine in order to identify different components of it.
2. Dismantling
a. Drain out the lubricating oil and water.
b. Remove the head cover.
c. Remove fuel line (also disconnect at the injector)
d. Remove intake and exhaust manifold
e. Remove cylinder head cover
f. Remove rocker arm along with push rod.
g. Remove lub. oil line
h. Remove timer cover
i. Remove rear cover.
j. Remove piston
3. Draw the necessary schematic diagram and note the different types of bearing.
4. Assembling: Almost reverse the sequence of dismantling of followed during assembling.
 5. Test the assembly procedure by starting the engine.

Report writing
Identify the missing components of the following systems and briefly state their functions.

1. Fuel supply system

2. Air intake and exhaust system

3. Lubricating oil system

4. Cooling water circuit

5. Fuel Control System

Assignment
Provide following information regarding to your observation in the experiment.

1. No of cylinder rings, their types and functions

2. No of bearings, their types and functions

3. No of valves and mention which one was bigger, why?

4. Location of pump in cooling water circuit

5. Fuel injection type, no. of holes in each nozzle.

6. How you differ diesel engine from petrol engine

 EXPERIMENT 07
Dismantling and Assembling a Petrol (SI) Engine

Objectives
a) To identify & study functions of different engine components.

b) To understand the process of disassembling and reassembling the engine

c) To test the assembly procedure by starting the engine.

Engine Specification
Bore
Stroke
No of cylinder
Arrangement of cylinders
Cam shaft type
Spark plug gap

Methodology
1. Study the engine in order to identify different components of it.
2. Dismantling
a. Drain out the lubricating oil and water.
b. Remove the head cover.
c. Remove fuel line.
d. Remove intake and exhaust manifold
e. Remove cylinder head cover.
f. Remove lub. oil line
g. Remove timer cover
h. Remove rear cover.
i. Remove piston
3. Draw the necessary schematic diagram and note the different types of bearing.
4. Assembling: Almost reverse the sequence of dismantling of followed during assembling.
5. Test the assembly procedure by starting the engine.
Report writing
Identify the missing components of the following systems and briefly state their functions.

1. Fuel supply system

2. Air intake and exhaust system

3. Lubricating oil system

4. Cooling water circuit

Assignment
Provide following information regarding to your observation in the experiment.

1. No of cylinder rings, their types and functions

2. No of bearings, their types and functions

3. No of valves and mention which one was bigger, why?

4. Location of pump in cooling water circuit

5. Carburetor type, how the shape of the venturi creates a pressure difference, causing fuel to be drawn.

6. Condition of the spark plug to detect signs of wear or fouling.

 EXPERIMENT 08
Study of Diesel Power Plant of MIST

Objectives:

1. To understand the basic working principle of a diesel powerplant.

2. To identify & study functions of different engine components and power plant
components.

Theory:

Diesel power uses a diesel engine to rotate alternators and produce electrical energy. The diesel
engine is used as a prime mover and this powerplant is known as a diesel power plant.
Due to the combustion of diesel, rotational energy is generated. The alternator is connected with the
same shaft of the diesel engine. And the alternator is used to convert the rotational energy of the
diesel engine into electrical energy.
In most cases, the diesel power plant is used to generate electrical energy for small-scale production
and at the load end. When grid power is not available, the diesel engine is used to supply load in
emergency conditions. Generally, the capacity of diesel power plants is between 2to 50 MW.
Layout of a diesel power plant:

Schematic of a diesel power plant:

Cycle P-V and T-s diagram:

The required capacity of a diesel power plant can be calculated by the below equation.

Capacity of Plant=(Connected Load × Demand Factor)/(Diversity Factor)

The diesel engine power plant below 3 MW capacity is used as standby plants and 3 to 25 MW
plants are used as base load plants. Generally, in this type of plant, four-stroke engines are used.
The plants used for baseload plants have a capacity of above 10 MW capacity and for these
plants, two stroke engines are used.

Site Selection of Diesel Power Plant:

The factors affecting a selection of a location for a diesel power plant are listed below.

I. Bearing capacity: The diesel engine is placed on a foundation. If the bearing capacity of
selected land is high, then it does not require high depth for a foundation. And it will
save the initial cost of a powerplant.
II. Transportation facility: The plant requires heavy pieces of machinery. Hence, the
selected site must have an adequate transportation facility. Labor: Large capacity diesel
powerplant requires several labors. Availability of water: The diesel power plant requires
water for cooling purposes.
III. Future expansion: There is some extra land available for future expansion. Availability of
fuel: This plant requires a high volume of fuel (diesel). So, a site should be selected
where fuel is available easily.
IV. Distance from the populated area: The operation of a diesel engine pollutes nearby areas.
Hence, the plant must be located at a far distance from the human being.
V. Distance from load center: To avoid transmission loss, the site should be selected near the
load center.

Engine Specification (Data):

Brand Name Lubrication System

Model Cooling System

Engine No. Exhaust

Country of Lube Oil Filter

Make

Manufacturer Fuel Filter

Rated Output Air Cleaner

Rated rpm Oil Press. Indicator

No. of Cylinder Coupling

Lube-Oil Used Ignition System

Fuel Used
Assignments:
1. Calculate the plant capacity.
2. Analyze the MIST power plant site selection on the basis of given site selection criteria.
3. Fill out the engine specification table.
4. Suppose you are a senior engineer of the MIST power plant. What improvements would
you like to bring to increase the overall thermal efficiency of the power plant?