INSTRUCTIONS:

1. Read carefully and understand the discussions.

2. Study the sample problems.
3. Solve the exercises given. (To be submitted on or before May 01 , 2020)

II. INTERNAL COMBUSTION ENGINE (DIESEL POWER PLANT)

A. Diesel Engine Performance Analysis

WK

WNet
WB WI

Diesel-Generator Set

a. Power Conversion Efficiency, η

WK
ηg = Generator efficiency =
WB

WB
ηB = Brake Engine efficiency =
WNet

WI
ηI = Indicated Engine efficiency =
WNet

WB
ηm = Mechanical efficiency =
WI

IPm L A NP
WI = HP
449702
=
Mecha BPm L A NP
WB = 2π F ln =
nical HP
449702 449702
efficie
= =
ncy
Mecha = Mecha
nical nical
efficie efficie
ncy = ncy = 1
 Where: IPm = Indicated mean effective pressure, kg/cm2
BPm = Brake mean effective pressure, kg/cm2
L = Piston of stroke, cm
A = Piston face area, cm2
NP = Number of power strokes per minute
NP = NC x n/2 ----- For 4-stroke cycle engine
NP = NC x n ----- For 2-stroke cycle engine
NC = Number of cylinders
n = Engine speed, rpm
F = Net dynamometer or prony brake force, kg
l = Dynamometer or prony brake arm length, cm

b. Engine Thermal Efficiency, e

2648
eI = Indicated engine thermal efficiency = w q
I H

2648
e=B Mechanical efficiency
= Brake engine thermal=efficiency =
wB qH
= Mechanical efficiency =
wI, wB = Fuel consumption or fuel rate, kg/Ihp=hr or kg/Bhp=hr

qH = Higher heating value of fuel, J/g

qH = 41,130 + 139.6(OAPI)

qH = 51,716 – 8793.8(S.G.@15.6OC)2

141.5
O
API = – 131.5
S.G.@15.6
O
C
140
O
Bé = – 130
S.G.@15.6
O
C
S.G.@15.6OC = ρ @ 15.6OC, kg/L

ρt = Density of fuel at any temperature t = S.G.@ tOC

S.G.@ 15.6OC
S.G.@ tOC =
1 – [0.0007(t – 15.6)]

2
B. Elements of a Diesel Electric Power Plant

1. Diesel Engine Generator Set:

a. Diesel Engine: This is the main component of the power plant which develops power. It
is the prime mover of the power plant.
Classifications:
i) According to number of strokes per cycle.
- Four stroke cycle
- Two stroke cycle

ii) According to number and arrangement of cylinders.

- In line
- V-type
- Single up to 16 cylinders

iii) According to compression action

- Single acting
- Double acting

iv) According to frame arrangement

- Vertical
- Horizontal
b. Generator (Alternator): Electrical machine mainly with stator and rotor in which
mechanical energy is converted to electrical power. It is either directly coupled to the
diesel engine or belt connected.
Speed --- 214 to 1200 rpm
Number of poles --- 6 to 28
Capacity --- 25 to 30000 kVA at 0.8 PF lagging
Output voltage --- 440 to 2200 V
Voltage regulation is about 30%
Exciter rating --- 2 to 4% of the alternator rating at 115 to 230 volts DC

2. Air Intake System: This system is provided to supply the necessary fresh air to the engine
cylinder for fuel combustion. It includes air filter, silencer, ducts, supercharger and charged
air cooler.

Wind box

Silencer
Fresh air Air Ducts

Louvers Air Filter

Building
Supercharger
Wall Charge
Air Cooler
3
 3. Fuel System: Handles the fuel from receiving to the delivery of clean fuel to the injector
atomization. It includes receiving facility, storage tank, fuel transfer pumps, pipe works,
strainers, fuel treatment, heaters, day tank and fuel injection system.
Functions of fuel injection system:
a. Filter the fuel
b. Meter the correct quantity of fuel to be injected
c. Time the ignition process
d. Secure proper atomization
e. Distribute the atomized fuel to the engine combustion chamber.

Lorry
Truck Treatment
Unloading Land Storage Facility
or Tank Tank
Train
Receiving
Facility Purifier Clarifier

Sea
Day Tank
Barge
Injector
Injection
Pump

4. Exhaust System: This system is provided to discharge the products of combustion from the
combustion chamber to the atmosphere outside the engine building. It includes exhaust
manifold, connecting pipe, muffler, heat recovery systems and smoke stack (chimney)

Primary
Heat Secondary
Recovery Heat
Recovery
Gas Turbine
Or
Boiler

Heater
Combustion
Exhaust
Chamber
Manifold
Air/Water Preheaters
Muffler Steam Treatment Smoke
Stack

4
5. Cooling System: This system removes the remaining heat that is not converted to work such
as exhaust gases and heating of the engine block including cylinder liners, pistons and other
moving parts inside the engine. It includes surge tank, cooling pumps, cooling towers or
spray ponds, water treatment or filtration plant and connecting pipes.
Two circuits of cooling system:

a. High temperature circuit – Responsible to cool down cylinder liners, exhaust

manifold, heads, walls, piston, piston rings,
superchargers and primary charge air coolers.

Surge
Tank Water
Pump

•
• Cooling
Diesel Tower
Engine

Primary Raw
Charge Supercharger
Water
Air cooler Pump

b. Low temperature circuit - Cools down the auxiliaries of the engine such as lube oil
cooler and secondary charge air cooler.

6. Lubricating System: Provided for lubricating the moving parts in the engine.
Functions of lubrication:
a. To keep the moving parts sliding freely, reducing friction and wear.
b. To keep the rubbing surfaces cool by taking away the heat generated by friction.
c. To keep the bearings and piston rings clean of the products of combustion as well as
wear by washing them away.
d. To form a good seal between piston rings and cylinder walls.
e. Minimize metal contact and thus reducing noise.

Diesel Oil
Engine Filter
• •

Oil Oil
Lubricating Pump
Oil Tank Cooler
Oil
Purifier
5
7. Starting System: This is provided to rotate the engine initially until the firing starts and the
engine runs under its own power.
Methods:
a. By manual crank
b. By battery operated motors
c. By auxiliary engines
d. By compressed air - For large capacity engines usually at 75 kW and above.
Compressed air at about 20 atmospheres is admitted to a few of the engine
cylinders making them act as reciprocating air motors to turn the engine shaft.

Compressor Air Bottle

Air Filter
Starting Air
Valve

6
Schematic arrangement of a Diesel Power Plant

7
C. Heat Balance of Internal Combustion Engine

The total energy supplied to the engine in the form of the total higher heating value of the fuel
input QH is generally broken down into the following for heat balance purposes.
a. Useful work – the brake power of the engine, WB
b. Cooling loss – the heat transferred to the cooling water jackets, QC
c. Exhaust gas loss – the heat carried off as sensible heat and latent heat in the products of
combustion, QEx
d. Mechanical losses – Friction loss in rotating and rubbing parts such as piston rings,
crankshaft, connecting rods, bearings, bushings and energy loss through engine mounted
accessories such as pumps (cooling water pump, lube oil pump and fuel pump), governors,
etc.
e. Radiation and unaccounted losses – Heat radiation from engine and incomplete combustion
loss due to presence of unburned fuel in the products of combustion.
` Usually, items d and e are considered as one called friction and other unaccounted loss
denoted as QFU.
QFU
QEx Wk

QH

QC
٠to WB

٠ti

QH = mf x qH = WB + QW + QEx + QFU ---- kJ/hr

mf = fuel consumption, kg/hr

qH = Higher heating value of fuel, kJ/kg
2π F ln WK
WB = Brake engine output, kJ/hr ; WB = = ηg
449702
=
For generator efficiency, use Fig. A-15 page 675, Morse
For efficiency correction factor, use Mecha
Table 6-3 page 185, Morse
nical
QC = Heat absorbed by cooling water jackets, kJ/hr
efficie
QC = mw x CPW x ΔtW
ncy =
mw = weight of circulating water, kg/hr
CPW = Specific heat of water at constant pressure = 4.1868 kJ/kg-OC
ΔtW = Temperature difference of water going out, to, and water entering the engine, ti
ΔtW = (to – ti), OC
QEx = Exhaust gas Heat loss, kJ/hr
QEx = QSE + QLE
QSE = Sensible heat of exhaust gas = mg x CPg x (tg – ta)
mg = Weight of flue gas = (mf + ma), kg/hr
8
 ma = Weight of air = mf x A:F, kg/hr
mg = mf + (mf x A:F)
mg = mf x (1 + A:F)
QLE = Latent heat of exhaust gas = mf (qH – qL)
qL = Lower heating value of fuel, kJ/kg
qL = qH – qLH2O = mf (qH – qH + qLH2O)
Therefore,
QLE = mf x qLH2O
qLH2O = Latent heat of water vapour present in the flue gas = 2442.7 x 9H2, kJ/kg
H2 = Hydrogen content of fuel, % by weight based on ultimate analysis of fuel oil
H2 = 26 – 15(S.G. @ 15.6OC), %
QFU = Friction, radiation and unaccounted heat losses, kj/hr

Typical full-load heat balances, % (Based on QH)

Otto Cycle Diesel Cycle

(Spark Ignition) (Compression Ignition)
1. Useful work 25 34
2. Cooling 30 30
3. Exhaust 37 26
4. Friction, Radiation and
8 10
Unaccounted
Input; Heating value of fuel 100 100

Sample Problems:
1. A Diesel-engine power plant was given a test of 45-minute duration, with results here given. The
engine is 8-cylinder, 2-cylce, 37.47 cm x 45.72 cm x 267 rpm, direct connected to a 750-kW
generator. Electrical output was read by watt-hour meter, W1 = 7562 kW-hr, W2 = 8087 kW-hr. Fuel
quantity was measured by direct weighing, 168.7 kg for the run. Water by venturi meter 1136 l/min
in at 35OC, out at 46.1OC. Average fuel temperature, 23.9OC; S.G. = 0.921. Atmospheric
temperature, 18.3OC; exhaust gas, 398.9OC. Average mean effective pressure of indicator cards
taken during the test, 5.73 kg/cm2. Power used for plant pumps, 4.0 kW. During the test exhaust gas
analysis determined that the air-Fuel ratio was 26.62. Prepare a report on the various performance
quantities of the said engine.

2. The following are the observations made for a 20-minute trial for a 2-stroke, 2-cylinder Diesel
engine-generator set rated at 30 Kw and using 21.57OAPI fuel oil: Generator output = 23.92 kW, net
brake load = 750 N, indicated mean effective pressure = 3.0 Bar, fuel consumption = 2.51 kg, cooling
water = 338 kg, water inlet = 32OC, water outlet = 57OC, air to fuel ratio = 34 kga/kgf, engine room
temperature = 27OC, exhaust gas temperature = 310OC, engine specifications: 210 mm x 290 mm x
320 rpm, brake arm length = 1000 mm, cp of gas = 1.01 kJ/kg-K. Make an evaluation of the
performance of this engine taking into consideration of the power developed, efficiencies and heat
balance.ms 39 and 40 page 190, Power Plant Engineering by F. T. Morse.

9
Solutions:

Problem 1:

A. Power Calculations:
1. Generator Rating = 750 kW
2. Generator Output = (W2 – W1)/T
(8087 – 7562) kW-hr x 60min/hr
Generator Output =
45 min
Generator Output = 700 kW

700 kW
% Load = = 93.33 %
750 kW
=
From Fig. A-15, page 675, Morse, based on 93.33% load, 267 rpm and 750 kW rating,
Mechanic
al NEMA Generator Efficiency = 94% (by triple interpolation)
efficiency
From Table 6-3, page 185, Morse, based on 94% NEMA Efficiency and 93.33% load,
=
Deduction Factor = 1.73% ------ By interpolation between full load and ¾ load.
Generator Efficiency, ηg = 94 – 1.73 = 92.3%

10
 700 kW
3. Brake Power, WB = = 759.5 kW / 0.746 = 1018.1 HP
0.923
= Mechanical efficiency
2
= (5.73) (45.72) (π) (37.47) (8) (267)
IPm L A Nc n 4
4. Indicated Power, WI = =
449702 449702
= Mechanical efficiency = =
WI = 1372.13 HP M
ec
= Mechanical efficiency =
ha
B. Efficiency Calculations:
nic
1. eI = Indicated engine thermal efficiencyal = 2648
wI qH
eff
= Mechanical
mf efficiency = ici
wI =
WI en
= cy
Mechani (168.7 kg) (60 min/hr) =
mf = = 225 kg/hr
cal 45 min
=
efficiency = Mechanical
Mechani
=w 225 kg/hr efficiency =
I = = 0.164 kg/ IHP - hr
cal 1372.13 HP
efficiency
=
=
Mechani
qH = 51,716 – 8793.8(S.G.@15.6OC)2
cal
efficiency
= 0.921
S.G.@15.6OC = = 0.926
1 – [0.0007(23.9 – 15.6)]

qH = 51,716 – 8793.8(0.926)2 = 44175.53 kJ/kg

2648
eI =
(0.164) (44175.53)
=
eI = 36.55%
Mecha
nical
= Mechanical
efficie 2648
2. e B = Brake engine thermal efficiency =
efficiency = wB qH
ncy =
= Mechanical
mf efficiency =
wB =
WB
=
Mechani 225 kg/hr
wB = = 0.221 kg/ BHP - hr
cal 1018.1 HP
efficiency
=
=Mechani 11
cal
efficiency
 2648
eB =
(0.221) (44175.53)
=
eB = 27.12%
Mecha
nical
= Mechanical
efficie
WB
3. ηm == Mechanical
efficiency
ncy = Efficiency =
WI
= Mechanical efficiency =
1018.1
ηm = = 74.2%
1372.13
= Mechanical efficiency =
Generator Output – Pump Works
4. ηP = Plant Efficiency =
m f x QH
= Mechanical efficiency
=ηP = (700 – 4) kW
(225 kg/hr) (3600 sec/hr) (44175.53) kJ/kg
=
ηMechani
P = 25.2%
cal
efficienc
= Mechanical
y =
efficiency =
C. Engine Heat Balance
1. Total Heat Absorbed = Total Higher Heating Value of Fuel = QH = mf x qH
QH = (225 kg/hr) x (44175.53 kJ/kg) = 9,939,494.25 kJ/hr

2. Useful Output = WB in kJ/hr = (1018.1 HP) x (0.746 kW/HP) x (3600sec/hr)

Useful Output = 2,734,209.36 kJ/hr
Useful Output = 2,734,209.36/9,939,494.25 = 27.5%

3. Cooling Loss = QC = mw CPw (to – ti)

mw = ρ x V = (1000 kg/m3) x (1136 L/min) x (60 min/hr) / (1000 L/m3) = 68,160 kg/hr
QC = 68,160 kg/hr x 4.1868 kJ/kg-OC x (46.1 – 35)OC
QC = 3,167,632.32 kJ/hr
Cooling Loss = 3,167,632.32/9,939,494.25 = 31.9%

12
4. Exhaust Gas Loss = QEX = QSE + QLE
QSE = Sensible Heat of Exhaust Gas = mg x Cpg x (tg – ti)
mg = mf x (1 + A:F) = 225 kg/hr x (1 + 26.62) kgg/kgf = 6,214.5 kg/hr
Cpg = Taken as 1.03 kJ/kg-OC to 1.09 kJ/kg-OC, assume 1.06 kJ/kg-OC
QSE = (6,124.5 kg/hr) x (1.06 kJ/kg-OC) x (398.9 – 18.3)OC
QSE = 2,507,153.02 kJ/hr

QLE = mf x QLH2O
QLH2O = 2442.7 – 9H2
H2 = 26 – 15(S.G. @15.6OC) = 26 – 15(0.926) = 12.11% = 0.1211 kgH2/kgf
QLH2O = 2442.7 x 9 x 0.1211 = 2662.3 kj/kg
QLE = 225 kg/hr x 2662.3 kJ/kg = 599,017.5 kJ/hr
QEX = 2,507,153.02 + 599,017.5 = 3,106,170.52 kJ/hr
Exhaust Gas Loss = 3,106,170.52/9,939,494.25 = 31.25%

5. Friction, Radiation and unaccounted Losses = QFU = QH – WB – QC – QEX

QFU = 9,939,494.25 – 2,734,209.36 – 3,167,632.32 – 3,106,170.52
QFU = 931,482.05 kJ/hr
Friction, Radiation and unaccounted Losses = 931,482.05/9,939,494.25 = 9.37%

13
Summary

A. Powers
Diesel Engine:
WI = 1018.1 HP
WB = 1372.13 HP

Generator: Rating = 750 kW

Output = 700 kW
% Load = 93.33%

B. Efficiencies

Plant Efficiency 25.2%

Generator Efficiency 92.2%
Engine Mechanical Efficiency 74.2%
Engine Indicated Thermal Efficiency 36.55%
Engine Brake Thermal Efficiency 27.12%

C. Engine Heat Balance

Total Heat Available = 9,939,494.25 kJ/hr

ITEMS QUANTITY, kJ/hr PERCENT

1. Useful Output 2,734,209.36 27.51
2. Cooling Loss 3,167,632.32 31.87
3. Exhaust Loss 3,106,170.52 31.25
4. Friction, Radiation & Unaccounted Losses 931,482.05 09.37
TOTAL 9,939,494.25 100.00

14
Problem 2:

A. Power Calculations:
1. Generator Rating = 30 kW
2. Generator Output = 23.92 Kw
23.92 kW
3. % Load = = 79.73 %
30 kW
=
Brake Power, WB = 2 π F l n
4. Mechanic
449702
al
= efficiency
Mechanical
F = 750 N / (9.8 N/kg) = 76.53 kg
efficiency
= =

2 x π x 76.53 x 100 x 320

WB = = 34.22 HP x (0.746 kW/HP) = 25.53 kW
449702
= Mechanical efficiency =
IPm L A Nc n
5. Indicated Power, WI =
449702
= Mechanical efficiency =
1.02 kg/cm2
IPm = 3 Bar x = 3.06 kg/cm2
1 Bar

2
(3.06) (29) (π) (21) (2) (320)
4
WI = = 43.74 HP
449702
= Mechanical efficiency =

B. Efficiency Calculations:
2648
1. eI = Indicated engine thermal efficiency = wI qH

= Mechanical
mf efficiency =
wI =
WI
=
Mechani (2.51 kg) (60 min/hr)
mf = = 7.53 kg/hr
cal 20 min
=
efficiency = Mechanical
Mechani
=w 7.53 kg/hr efficiency =
I = = 0.172 kg/ IHP - hr
cal 43.74 HP
efficiency
=
=
qH = 41,130 + 139.6(OAPI) = 41,130 + 139.6(21.57) = 44,141.172 kJ/kg
Mechani
cal
efficiency
=

15
 2648
eI =
(0.172) (44,141.172)
=
eI = 34.88%
Mecha
nical
= Mechanical
efficie 2648
2. ency
efficiency
B = Brake engine
= = thermal efficiency = wB qH

= Mechanical 7.53 kg/hr

wB = efficiency = = 0.22 kg/ BHP - hr
34.22 HP
= 2648
eB = Mechani
(0.22) (44,141.172)
cal
=
eB = efficiency
Mecha 27.27%
=
nical
= Mechanical WB
3. ηefficie
= Mechanical
efficiency
m = Efficiency =
ncy = WI
= Mechanical efficiency =
34.22
ηm = = 78.24%
43.74
= Mechanical efficiency =
WK
4. ηg = Generator Efficiency =
WB
= Mechanical efficiency =
23.92
ηg = = 93.6%
25.53
= Mechanical efficiency =
C. Engine Heat Balance
1. Total Heat Absorbed = Total Higher Heating Value of Fuel = QH = mf x qH
QH = (7.53 kg/hr) x (44,141.172 kJ/kg) = 332,383.025 kJ/hr

2. Useful Output = WB in kJ/hr = (34.22 HP) x (0.746 kW/HP) x (3600sec/hr)

Useful Output = 91,901.23 kJ/hr
Useful Output = 91,901.23/332,383.025 = 27.65%

3. Cooling Loss = QC = mw CPw (to – ti)

mw = (338 kg) x (60 min/hr) / (20 min) = 1014 kg/hr
QC = 1014 kg/hr x 4.1868 kJ/kg-OC x (57 – 32)OC
QC = 106,135.38 kJ/hr
Cooling Loss = 106,135.38/332,383.025 = 31.93%

16
4. Exhaust Gas Loss = QEX = QSEX + QLEX
QSEX = Sensible Heat of Exhaust Gas = mg x Cpg x (tg – ti)
mg = mf x (1 + A:F) = 7.53 kg/hr x (1 + 34) kgg/kgf = 263.55 kg/hr
QSEX = (263.55 kg/hr) x (1.01 kJ/kg-OC) x (310 – 27)OC
QSEX = 75,330.50 kJ/hr
QLEX = mf x QLH2O
QLH2O = 2442.7 – 9H2
H2 = 26 – 15(S.G. @15.6OC)

141.5 141.5
S.G.@15.6OC = = = 0.924
O
API + 131.5 21.57 + 131.5

H2 = 26 – 15(S.G. @15.6OC) = 26 – 15(0.924) = 12.14% = 0.1214 kgH2/kgf

QLH2O = 2442.7 x 9 x 0.1214 = 2668.89 kJ/kg
QLEX = 7.53 kg/hr x 2668.89 kJ/kg = 20,096.77 kJ/hr
QEX = 75,330.50 + 20,096.77 = 95,427.27 kJ/hr
Exhaust Gas Loss = 95,427.27/332,383.025 = 28.71%

5. Friction, Radiation and unaccounted Losses = QFU = QH – WB – QC – QEX

QFU = 332,383.025 – 91,901.23 – 106,135.38 – 95,427.27
QFU = 38,919.145 kJ/hr
Friction, Radiation and unaccounted Losses = 38,919.145/332,383.025 = 11.71%

17
Summary

D. Powers
Diesel Engine:
WI = 43.74 HP
WB = 34.22 HP

Generator: Rating = 30 kW
Output = 23.92 kW
% Load = 79.73%

E. Efficiencies

Generator Efficiency 93.60%

Engine Mechanical Efficiency 78.24%
Engine Indicated Thermal Efficiency 34.98%
Engine Brake Thermal Efficiency 27.35%

F. Engine Heat Balance

Total Heat Available = 332,383.025 kJ/hr

ITEMS QUANTITY, kJ/hr PERCENT

5. Useful Output 91,901.23 27.65
6. Cooling Loss 106,135.38 31.93
7. Exhaust Loss 95,427.27 28.71
8. Friction, Radiation & Unaccounted Losses 38,919.145 11.71
TOTAL 332,383.025 100.00

18
Exercises:

1. The following are the observations made for a 20-minute trial for a 2-stroke, 2-cylinder Diesel
engine-generator set rated at 30 Kw and using 21.57OAPI fuel oil: Generator output = 23.92 kW, net
brake load = 750 N, indicated mean effective pressure = 3.0 Bar, fuel consumption = 2.51 kg, cooling
water = 338 kg, water inlet = 32OC, water outlet = 57OC, air to fuel ratio = 34 kga/kgf, engine room
temperature = 27OC, exhaust gas temperature = 310OC, engine specifications: 210 mm x 290 mm x
320 rpm, brake arm length = 1000 mm, cp of gas = 1.01 kJ/kg-K. Make an evaluation of the
performance of this engine taking into consideration of the power developed, efficiencies and heat
balance. Make an Engineering report of this power plant by filling up the necessary data prescribed
below.

Summary

G. Power Developed
Diesel Engine:
WI = ______ HP
WB = ______ HP

Generator: Rating = _____ kW

Output = _____ kW
% Load = _____ %

H. Efficiencies, %

Generator Efficiency
Engine Mechanical Efficiency
Engine Indicated Thermal Efficiency
Engine Brake Thermal Efficiency

I. Engine Heat Balance

Total Heat Available = _____________ kJ/hr

ITEMS QUANTITY kJ/hr PERCENT

9. Useful Output
10. Cooling Loss
11. Exhaust Loss
12. Friction, Radiation & Unaccounted Losses
TOTAL

19