Foreword

Welcome to value-conscious company. We are proud of the

advanced engineering and quality construction of each
equipment we manufacture.

This manual explains the working of equipment. Please read it

thoroughly and have all the occupants follow the instructions
carefully. Doing so will help you enjoy many years of safe and
trouble free operation.

When it comes to service remember that K.C. Engineers knows

your equipment best and is interested in your complete
satisfaction. We will provide the quality maintenance and any
other assistance you may require.

All the information and specifications in this manual are current

at the time of printing. However, Because of K.C. Engineers
policy of continual product improvement we reserve the right to
make changes at any time without notice.

Please note that this manual explains all about the equipment
including options. Therefore you may find some explanations
for options not installed on your equipment.

You must follow the instructions and maintenance instructions

given in the manual carefully to avoid possible injury or
damage. Proper maintenance will help ensure maximum
performance, greater reliability, and longer life for the product.

K.C. Engineers
 Contents

1. Objective …………………………………… 1

2. Aim …………………………………… 1

3. Introduction …………………………………… 1

4. Theory …………………………………… 2

5. Description …………………………………… 3

6. Utilities Required …………………………………… 4

7. Installation Procedure of Software …………………………………… 4

8. Method of Operating Software …………………………………… 5

9. Experimental Procedure …………………………………… 6

10. Specification …………………………………… 7

11. Formulae …………………………………… 7

12. Observation & Calculation …………………………………… 10

13. Nomenclature …………………………………… 13

14. Precautions & Maintenance Instructions …………………………………… 14

15. Troubleshooting …………………………………… 15

16. Reference …………………………………… 15

1 Cylinder 4 Stroke Diesel Engine Test Rig

 SINGLE CYLINDER FOUR STROKE DIESEL ENGINE TEST RIG
WITH ELECTRIC BRAKE DYNAMOMETER

01. OBJECTIVE:
To understand working and operation of a Diesel Engine.

02. AIM:
To determine:
• Brake Power
• BMEP
• Air Fuel Ratio
• BSFC
• Brake Thermal Efficiency
• Volumetric Efficiency
• IMEP
• Indicated Power
• Frictional Power
• Mechanical Efficiency

03. INTRODUCTION:

A Diesel engine is almost the same as a petrol engine but it burns a different type of fuel.
Diesel is named after its inventor Rudolf Diesel, a German who first developed this type
of fuel in the early 1900’s. Diesel engines have mainly been used in lorries and buses
because of their increased power and their reliability. They tend to be noisy and smelly
compared to a petrol engine but are more economical to run.
In a diesel engine the compression stroke only compresses air and not fuel. On the
ignition stroke the air is compressed to a very high pressure and then fuel is injected into
the engine cylinder with the help of a injector, resulting in generating enormous heat,
which then ignites the fuel that is injected into the combustion chamber at that precise
moment of maximum pressure. There is no need for a spark plug in a diesel engine. The

1 Cylinder 4 Stroke Diesel Engine Test Rig 1

 compressed air is hot enough to cause the fuel to explode. This is because a diesel engine
has a far higher "compression ratio" than does a petrol engine.

04. THEORY

04.1. Dead Center

The position of the working piston and the moving parts which are mechanically
connected to it at the moment when the direction of the piston reversed (at either
point of the stroke)
04.1.1. Bottom Dead Center (BDC)
Dead center when the piston in nearest to the crankshaft of the engine. In
horizontal engines it is also called Outer Dead Center.
04.1.2. Top Dead Center (TDC)
Dead center when the piston in nearest to the cylinder head. In horizontal
engine it is also called Inner Dead Center.

04.2. Clearance Volume

It is the volume in-between the piston and the cylinder head when piston is at
TDC.
The Four Stroke Cycle
The ‘stroke’ is simply when the piston moves either all the way up or all the way
down inside the cylinder or the nominal distance through which a working piston
moves between two successive reversals of its direction motion or the distance
counted for piston when it moves from TDC to BDC or reverse. In the four stroke
engine, four strokes accomplish a complete cycle and all the four strokes are
different in nature. These are defined as follows: -

04.2.1. Suction / Intake / Induction Stroke.

04.2.2. Compression Stroke.
04.2.3. Power / Working / Expansion / Ignition Stroke.
04.2.3. Exhaust Stroke.

1 Cylinder 4 Stroke Diesel Engine Test Rig 2

 Stroke Inlet Valve Exhaust Valve
Suction Open Close
Compression Close Close
Power Close Close
Exhaust Close Open

05. DESCRIPTION:
Present setup is single cylinder, four stroke, vertical, water cooled diesel engine. Flow
rate of water to engine jacket and exhaust gas calorimeter is measured with the help of
individual Rotameter provided. Test rig is also supplied with Air intake tank and fuel
supply tank. Proper instrumentation had been done to measure temperatures and flow
wherever required. Engine is connected with dynamometer (Electric Brake Type) with
load sensor.
A combustion pressure sensor is mounted on the cylinder to detect the pressure. Output
shaft of the engine is coupled with crank angle sensor for detecting crank angle and RPM
of the shaft. With the combination of pressure sensor and crank angle sensor, pressure
inside the cylinder at different angles of crank can be detected and pressure versus crank
angle and pressure versus cylinder volume can be calculated to plot P-V and P-θ
diagrams.
The whole assembly is fixed on a rigid MS channel frame.
The real time data acquisition can be done by interfacing the set up with computer using
software. The software is capable to tabulate the sample readings according to the
requirement of experiment under study and results obtained can be compared. Software
allows the user to have control on data logging, printing stored data, and preparing spread
sheet in Excel.

05.1. LOADING ARRANGEMENT:

An Electric Brake Dynamometer coupled to the engine shaft, provided with Load
Cell for torque measurement. The load can be varied by Switches provided on the
electrical panel.

05.2. ARRANGEMENT FOR MEASURING THE HEAT CARRIED AWAY BY

EXHAUST GASES

1 Cylinder 4 Stroke Diesel Engine Test Rig 3

 An exhaust gas calorimeter is used to measure the heat carried away by exhaust
gases. The calorimeter consists of a central shell with baffles and a cooling water
jacket. Exhaust gases passes through central shell and water is circulated in outer
jacket. The water is passed counter current to the flow of exhaust gases to get the
maximum temperature difference of exhaust gases at inlet and outlet of
calorimeter. Water flow rate is measured and controlled by the Rotameter and
control valve.

05.3. FUEL INPUT MEASURING ARRANGEMENT

A fuel supply tank mounted on a stand. The fuel supply system with
instrumentation facilitates the measurement of the fuel consumption.

06. UTILITIES REQUIRED:

06.1. Continuous Water supply: 1500 LPH @ 2 Bar.

06.2. Drain required.
06.3. Diesel 15 liters.
06.4. Lubricating oil SAE 20W-40, 1 Liters.
06.5. Electric power supply: 220VAC, single phase, 50Hz, 5Amp.
06.6. Computer Pentium IV, with CD Drive, Windows XP and MS Office XP Version
preloaded and one PCI slot for communication.

07. INSTALLATION PROCEDURE OF SOFTWARE:

Three CDs are provided with the equipments. Two CDs are of NI-DAQ Driver and one
for Operating Software. Before starting this operation, ensure that PC should be matching
with computer requirement mentioned in Section 06.6 of Article 6.

The NI-DAQ Driver has two CDs named as “Disc 1 of 2” and “Disc 2 of 2”. First, place
the “Disc 1 of 2” in CD-ROM and wait for 5 to 10 seconds. A blue-colored window
appears on the screen. Click “Browse CD” (i.e. third in row) and another window opens.
Open the file named as “DAQ Quickstartguide.pdf”. Read the installation part accurately.

1 Cylinder 4 Stroke Diesel Engine Test Rig 4

 Start following the instructions and install the software as per directions provided by the
guide. The computer would demand both CDs one by one. When installation is complete,
remove the CD from computer. When installation is finished, a shortcut would be created
on the desktop showing name as “Measurement & Automation”. Shutdown the
computer system. Open the chassis of the Central Processing Unit (CPU) and fix the PCI
card in empty PCI slot on the motherboard. Boot the computer. The computer would
indicate a new hard found, start clicking “Next” till “Finish” comes. This ends the
completion of loading of DAQ Card Driver.

Now, take third CD i.e. “1 Cylinder 4 Stroke Diesel Engine Test Rig” Operating
Software CD and place in CD-ROM. Open the CD and open folder “1 Cylinder 4 Stroke
Diesel Engine Test Rig” and then double click “Installer” folder, double click on
“Setup.exe”. Follow the instructions and do the installation.

Go to desktop and double click on “Measurement & Automation”. A window opens and
look at left side. Follow the path as “My System”  “Devices and Interfaces”  “NI-
DAQmx Devices”. Click it and PCI-6220: “Dev” appears. Right click and rename it as
“003” and press “enter”. Now, it appears as PCI-6220: “003” and close the window.

After completion of installation “restart” the computer system.

08. METHOD OF OPERATING SOFTWARE:

Open the exe of the software by clicking it from program menu of main Menu bar.
Click “Login”. Fill the relevant information in “Professor Name”, “Student Name” and
“Roll No” in appeared window. These are not mandatory and may be left blank if
desired. The “Password” for the software is “2313d1398” and press two times “enter” or
click “OK” to enter password.
In the entire software, a “NEXT” button is provided, at left front, which enables to go to
next step. Another button named as “BACK” is present. This facilitates to retrieve last
step taken. An “EXIT” button, at right bottom end, is there. It may be used to exit at any
session and finally, stopping the software.
1 Cylinder 4 Stroke Diesel Engine Test Rig 5
 09. EXPERIMENTAL PROCEDURE:

9.1 Ensure that oil sump of engine is filled with SAE 20W40 oil up to required level
with help of Dip Stick.
9.2 Fill diesel in the fuel tank and connect the fuel line to the engine.
9.3 Supply the diesel to the engine by opening the valves provided in the fuel supply
line.
9.4 Connect the panel/interfacing unit with the computer by data cable provided.
9.5 Open continuous cold water supply to the engine jacket and calorimeter.
9.6 Set flow rate of water through engine jacket and calorimeter using Rotameter.
9.7 Open water supply through pump, for cooling of dynamometer.
9.8 Start the engine with the handle provided and let it run for 2 minutes under no
load condition.
9.9 When engine start running smoothly, firstly load the engine slightly with the help
of panel and then gradually increase the load.
9.10 Run the engine for 2 minutes so that it can stabilize.
9.11 Note the flow rate of water to Engine jacket and Calorimeter with the help
Rotameter provided.
9.12 Repeat the experiment for different load.
9.13 When the experiment is over, reduce load on engine and stop the engine.
9.14 Close the fuel supply valve and cooling water supply to the engine.

10. FORMULA:

(1) Brake Power, BP

τ = m * g * R N-m

 2 * π * N *τ 
BP =   kW
 60 * 1000 

1 Cylinder 4 Stroke Diesel Engine Test Rig 6

 (2) Brake Mean Effective Pressure

 BP * n * 60 * 1000 
p bm = 
 L*A*N*N 
 N/m
2

 c 

(3) Fuel Consumed by Engine

 X* ρf 
Qf= 6  kg / s
 T * 10 

(4) Air-Fuel Ratio

A  Q a *ρ a 
= 
F  Q f 

(5) Brake Specific Fuel Consumption

Q 
BSFC =  f  kg / kW-s
 BP 

(6) Input power or Heat Supplied by Fuel

H f = ( Q f * CV ) kW

(7) Brake Thermal Efficiency

B.P. * 100
ηbt = %
Hf

(8) Swept Volume

 π * D 2 * L * N * Nc  3
V s= 
 
 m /s
 4 * 60 * n 

(9) Volumetric Efficiency

1 Cylinder 4 Stroke Diesel Engine Test Rig 7

  Qa 
η vol =  * 100  %
 Vs 

(10) Indicated Mean Effective Pressure

( )
 Area of PV diagram, mm 2 * ( Scale of the diagram, bar/mm ) 
p im =   Bar
 length of diagram, mm 

(11) Indicated Power

 p * A * L * N * Nc 
IP =  im  kW
 60 * 1000 * n 

(12) Friction Power

FP = ( IP − BP ) kW

(13) Mechanical Efficiency

 BP 
ηm=  * 10  %
 IP 
(14) Indicated Specific Fuel Consumption

Q 
ISFC =  f  kg / kW-s
 IP 

(15) Indicated Thermal Efficiency

 IP 
ηit = 
 * 100 

Hf 

(16) Heat rejected by

Exhaust Gases (Hexh)

Heat lost by exhaust gases in calorimeter = Heat gained by cooling

water in calorimeter

m eg *C peg *(T 3−T 4 ) =m CCW *C pw *(T 6−T 5 )

1 Cylinder 4 Stroke Diesel Engine Test Rig 8

 W CCW
m CCW = kg / sec
3600

m CCW *C pw *( T 6−T 5 )
m eg *C peg =
(T 3−T 4 )
H exh =m eg *C peg *(T 3−T 7 )

(17) Heat carried by cooling water from Engine jacket (HECW)

H ECW =m ECW *C PW *( T 2−T 1) kW

W ECW
m ECW = kg / sec.
3600

(18) Heat rejected due to radiation or air cooling (Hun)

H un =H f −( H exh +H ECW +BP + FP ) kW

11. OBSERVATION & CALCULATION:

DATA
R = 0.215 m.
n = 2
L = 0.110 m.
D = 0.080 m.
CV = 43500 kJ / kg.
Nc = 1
X = 40 ml
Cpw = 4.186 kJ / kg- oC.
ρf = 804 kg / m3
ρa = 1.21 kg / m3
ρw = 1000 kg / m3

g = 9.81 m / sec2

1 Cylinder 4 Stroke Diesel Engine Test Rig 9

OBSERVATION TABLE:

S.N.
1 2 3

RPM, N
Load acting On Dynamometer, m (kg)
Volume of Fuel Consumed, X (ml)
Time taken to consumed X ml of Fuel, T (sec)
Air Flow Rate, Qa (m3 / sec)
Flow rate of cooling Water to Engine, WECW (LPH)

Flow rate of cooling Water to Calorimeter, WCCW (LPH)

Temperature of Cooling water inlet to engine jacket, T1 oC

Temperature of Cooling water outlet from engine jacket, T2 oC

Exhaust gas inlet Temperature, T3 oC

Exhaust gas outlet Temperature, T4 oC
Cooling Water inlet Temperature, T5 oC
Cooling Water outlet Temperature, T6 oC
o
Ambient Temperature, T7 C

1 Cylinder 4 Stroke Diesel Engine Test Rig 10

CALCULATION TABLE

S.No. 1 2 3

RPM, N

BP

Pbm

Qf

A/F

BSFC

Hf

η bt

Vs

η vol

pim

IP

FP

η m

ISFC

η it

Hexh

HECW

Hun

1 Cylinder 4 Stroke Diesel Engine Test Rig 11

12. NOMENCLATURE:

BP = Brake Power of Engine Output Shaft, kW

N = Revolution of engine shaft per minute, RPM
m = Mass of load acting on dynamometer, kg
g = Acceleration due to gravity, m/s2
R = Arm length acting on dynamometer, m
IP = Indicated Power of Engine, kW
pim = Indicated mean effective pressure, N/m2
D = Bore of engine cylinder, m
A = Cross sectional area of Piston, m2
L = Length of stroke of engine, m
n = Number of revolution required to complete one engine cycle.
FP = Friction Power of engine, kW.
η m = Mechanical Efficiency, %.
pbm = Brake Mean Effective Pressure, N/m2
Qa = Flow rate of air intake by engine, m3/s.
Qf = Flow rate of fuel consumed by engine, kg/s.
X = Volume of fuel consumed, ml.
T = Time taken to consume X ml of fuel, sec.
A/F = Air Fuel Ratio.
BSFC = Brake Specific Fuel Consumption, kg/kW-s.
ISFC = Indicated Specific Fuel Consumption, kg/kW-s.
η bt = Brake Thermal Efficiency, %.
CV = Calorific value of Fuel, kJ/kg.
η it = Indicated Thermal Efficiency, %.
Vs = Volume swept by cylinder per second, m3/s.
Nc = Number of Cylinder.
η vol = Volumetric Efficiency, %
He = Heat Carried by Exhaust Gases, kW

1 Cylinder 4 Stroke Diesel Engine Test Rig 12

 T1 = Temperature of Cooling water inlet to engine jacket, oC
T2 = Temperature of Cooling water outlet from engine jacket, oC
T3 = Inlet temperature of Exhaust gas, oC.
T4 = Outlet temperature of Exhaust gas, oC.
o
T5 = Inlet temperature of cooling water to Calorimeter, C.
T6 = Outlet temperature of cooling water from Calorimeter, oC.
T7 = Ambient temperature, oC.
Cpeg = Specific Heat of Exhaust gases, kJ/kg oC.
meg = Flow rate of Exhaust gases from Calorimeter, m3/s.
Cpw = Specific Heat of water, kJ/kg oC.
WECW = Flow rate of cooling water to engine Jacket, LPH
WCCW = Flow rate of cooling water to Calorimeter, LPH.
mecw = Mass Flow rate of cooling water to engine Jacket, kg/s.
mccw = Mass Flow rate of cooling water from Calorimeter, kg/s.
Hf = Input power or Heat Supplied by Fuel, kW.
Hun = Heat rejected by radiation, kW.
Hexh = Heat rejected by exhaust gases, kW.
HECW = Heat carried away by cooling water from engine jacket, kW.
τ = Torque acting on dynamometer, N-m.
ρf = Density of fuel, kg/m3.
ρw = Density of water, kg/m3.
ρa = Density of Air, kg / m3.

13. PRECAUTION & MAINTENANCE INSTRUCTIONS:

• It is preferred to place the test rig at such a place where laboratory power supply,
water supply, drain and ventilation are easily available.
• Service the engine after every 50 hours of running.
• Always ensure the level of engine oil using dip stick at desired level, before stating
the engine. Fill engine oil SAE 40 once and change it after every 50 hours running of
engine.

1 Cylinder 4 Stroke Diesel Engine Test Rig 13

 • Keep away all hazardous material like chemical/highly inflammable from engine.
• The fuel and lubricating oil should be dirt free.
• Always use genuine spare parts only.

14. TROUBLE SHOOTING:

If engine is not starting:

Check fuel supply line.
Check fuel level in the tank.
Remove air bubbles from the fuel line and from fuel pump.
Start the engine again. If problem persists, contact service engineer.
If engine is getting overheating:
Check water supply line and ensure flow of water through engine jacket.
Reduce the load on the engine.

15. REFERENCES:

15.1 “A text Book of Thermal Engineering – II”, SS Theti, India Publishing House,
Delhi, 2nd Edition, 1985.
15.2 “A Course in Internal Combustion Engines”, ML Mathur, RP Sharma, Dhanpat
Rai Publications, New Delhi, 7th Edition, 2000.
15.3 “Internal Combustion Engine Fundamentals”, John B. Heywood, McGraw-Hill
International Editions, Singapore.
15.4 “Automobile engineering”, RB Gupta, Satya prakashan, New Delhi, 5th Edition,
1996.

1 Cylinder 4 Stroke Diesel Engine Test Rig 14