A DISSERTATION PROGRESS REPORT

ON

STUDY AND TESTING OF CI ENGINE BY

ROPE BRAKE DYNAMOMETER

SUBMITTED BY

VEGAD G. M.(J2-00126-2006)

AND

KACHHAD M. N. (J2-00100-2006)

APPROVED BY

Dr. A. H. RAVAL

(PROJECT GUIDE)

SUBMITTED TO

Dr. G. R. SHARMA

Research Scientist (Agril. Engg.)

COLLEGE OF AGRICULTURAL ENGINEERING AND

TECHONOLOGY

JUNAGADH AGRICULTURAL UNIVERSTY

JUNAGADH 362 001

JANUARY - 2010

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CONTENTS

SR. NO. PARTICULARS PAGE NO.

I INTRODUCTION 1

II JUSTIFICATION 5

III OBJECTIVES 6

IV REVIWE OF LITERATURE 7

V PLAN OF WORK 11

VI WORK COMPLETED 17

VII WORK REMAINED 17

VIII REFERENCES 18

I. INTRODUCTION

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Diesel engines have been a major source of power in the industrial fields

for many years. This trend has continued and has been even more pronounced

in recent years with the increased use of diesel engines to reduce operating

costs in trucks, buses, farm tractors, marine and industrial power units.

Dr. Rudolf Diesel, a German inventor, patented the principle of the diesel

engine in 1893.

Diesel engines can be found in practically all heavy industry and in any

place that needs tremendous power. The diesel engine has been in use since

1900.

In the diesel engine, air alone is compressed in the cylinder; then after the

air has been compressed, a charge of fuel is vaporized by injection into the

cylinder and ignition is accomplished by the heat of compression.

A machine which uses heat energy obtained from combustion of fuel and

converts it into mechanical energy is known as a Heat engine. They are

classified as external and internal combustion engine. In an external combustion

engine, combustion takes place outside the cylinder and the heat generated from

the combustion of the fuel is transferred to the working fluid which is then

expanded to develop the power. An internal combustion engine is one where

combustion of the fuel takes place inside the cylinder and converts heat energy

into mechanical energy. IC engines may be classified based on the working

cycle, thermodynamic cycle, speed, fuel, cooling, method of ignition, mounting of

engine cylinder and application.

Diesel engine is an internal combustion engine which uses diesel oil as a

fuel and operates on two or four stroke cycle. In a 4-stroke diesel engine, the

working cycle takes place in two revolutions of the crankshaft or 4 strokes of the

piston. In this engine, pure air is sucked in the engine cylinder and the fuel is

injected at the end of the compression stroke. The power developed and the

performance of the engine depends on the condition of operation. So it is

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necessary to test an engine for different conditions based on the requirement.

The test rig has been designed to study the working principle and the

performance of a 4-stroke single cylinder diesel engine.

Major advantages of diesel

Diesel engines have several advantages over other internal combustion

engines:

They burn less fuel than a petrol engine performing the same work due to

the engine's high efficiency. Gasoline engines are typically 25 percent

efficient while diesel engines can convert over 30 percent of the fuel

energy into mechanical energy.

They have no high-tension electrical ignition system to attend to, resulting

in high reliability and easy adaptation to damp environments. The absence

of coils, spark plug wires, etc., also eliminates a source of radio frequency

emissions which can interfere with navigation and communication

equipment and the like, which is especially important in marine and aircraft

applications.

They can deliver much more of their rated power on a continuous basis

than a petrol engine.

The life of a diesel engine is generally about twice as long as that of petrol

engine due to the increased strength of parts used, also because diesel

fuel has better lubrication properties than petrol.

Diesel fuel is considered safer than petrol in many applications. Although

diesel fuel will burn in open air using a wick, it will not explode and does

not release a large amount of flammable vapour. The low vapor pressure

of diesel is especially advantageous in marine applications, where the

accumulation of explosive fuel-air mixtures is a particular hazard.

For any given partial load the fuel efficiency (mass burned per energy

produced) of a diesel engine remains nearly constant, as opposed to

petrol and turbine engines which use proportionally more fuel with partial

power outputs.

They generate less waste heat in cooling and exhaust.

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With diesel, boost pressure is limited only by the strength of the engine

components due to which predetonation of the fuel charge does not occur

as in petrol engines.

The carbon monoxide content of the exhaust is minimum therefore diesel

engines are used in underground mines.

Biodiesel:

Biodiesel is one of the available alternative fuels in the market. It is

derived from biomass, which is one of the sources of renewable energy. Due to

increasing environmental awareness, Biodiesel is gaining recognition in the world

as a renewable fuel which may be used as an alternative to diesel fuel without

any modifications to the engine. Biodiesel fuels can be produced by ethanol and

vegetable oil, both agriculturally derived products. Currently, the cost of fuel is a

primary factor that limits its use. One way to reduce the cost of Biodiesel is to use

a less expensive form of vegetable oil such as waste oil from a potato processing

plant.

Biodiesel is an alternative to petroleum diesel. The fuel is called biodiesel

because it is made from mostly biodegradable materials and can be used as fuel

in diesel engines. Biodiesel can also be used in boilers or furnaces designed to

use heating oils or in oil-fueled lighting equipment. It can be used neat, meaning

100 percent biodiesel, or it can be blended with petroleum diesel. Biodiesel is

made by chemically reacting vegetable oil or animal fat or a combination of oils

and fats with alcohol, usually nearly pure methanol, denatured ethanol or

ethanol.

Biodiesel is a clean burning fuel, produced from renewable resources. It

contains no petroleum, but can be blended at any level with petroleum diesel to

create a biodiesel blend. Biodiesel is biodegradable, nontoxic, and essentially

free of sulfur and aromatics. One of the biggest advantages of biodiesel

compared to many other alternative transportation fuels is that it can be used in

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existing diesel engines, which relieves manufacturers of having to make costly

engine modifications. Biodiesel can also be mixed, at any ratio, with conventional

petroleum diesel. As a result, the alternative fuel can be used in the current

distribution infrastructure, replacing petroleum diesel either wholly, or as a diesel

fuel blend with minimal integration costs. As per the most scientists, biofuels

including biodiesel will play an increasingly important role in diversifying energy

supplies to meet the world’s growing energy needs.

Advantages of Biodiesel:

Produced from sustainable / renewable biological sources.

Ecofriendly and oxygenated fuel.

Sulphur free, less CO, HC, particulate matter and aromatic compounds

emissions.

Income to rural community.

Fuel properties similar to conventional fuel.

Used in existing unmodified diesel engines.

Reduce engine exhaust smoke.

Non toxic, biodegradable and safety to handle.

Reduce expenditure on oil imports.

India is importing the oil of Rs. 2,72,699 crore per year, By mixing

biodiesel in to diesel, our country can save Rs. 54,540 crore.

(www.financialexpress.com)

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II. JUSTIFICATION

Diesel engines are widely used for various applications ranging from

agriculture to automobiles. Engines are required to be tested mainly for two

purposes - Firstly, on production line of engines, engines are tested to check the

proper operation, output, fuel consumption etc. and Secondly, in research or

design purposes, where the performance of new design is to be evaluated. The

apparatus consists of a single cylinder, vertical diesel engine mounted on a

sturdy frame. Loading arrangement used is rope brake which is connected to

engine through a coupling. A digital multichannel temperature indicator measures

temperatures at various points. Various measurements provided enables to

evaluate the performance of the engine at various loads.

An engine test facility is a complex of machinery, instrumentation and

support services, housed in a building adapted or built for its purpose. Engine

and vehicle developers now need to measure improvements in engine

performance that are frequently so small as to require the best available

instrumentation in order for fine comparative changes in performance to be

observed. This level of measurement requires that instrumentation is integrated

within the total facility such that their performance and data are not compromised

by the environment in which they operate and services to which they are

connected. Engine test facilities vary considerably in power rating and

performance.

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III. OBJECTIVES

1) To install and get acquaint with engine testing rig.

2) To evaluate the performance of diesel engine using diesel and biodiesel

blend (80:20) separately.

3) To analyze the data observed and report writing.

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IV. REVIEW OF LITERATURE

Dorado et al. (2002) determined the feasibility of running a 10 percent

waste vegetable oil-90 percent diesel fuel blend during a 500-h period in a 3-

cylinder direct-injection diesel engine. The results revealed an approximately 12

percent power loss, slight fuel consumption increase. Combustion efficiency

dropped slightly during the testing period. They concluded that the diesel engine,

without any modifications, ran successfully on a blend of 10 percent waste oil-90

percent diesel fuel without externally apparent damage to the engine parts.

Huzayyin et al. (2004) conducted experiment on evaluation of using

jojoba oil as an alternate diesel engine fuel has been conducted in the present

work. Measurements of jojoba oil chemical and physical properties have

indicated a good potential of using jojoba oil as an alternative diesel engine fuel.

Blending of jojoba oil with gas oil has been shown to be an effective method to

reduce engine problems associated with the high viscosity of jojoba oil.

Experimental measurements of different performance parameters of a single

cylinder, naturally aspirated, direct injection, diesel engine have been performed

using gas oil and blends of gas oil with jojoba oil. Measurements of engine

performance parameters at different load conditions over the engine speed range

have generally indicated a negligible loss of engine power, a slight increase in

brake specific fuel consumption.

Raheman et al. (2004) investigated the fuel properties of karanja methyl

ester (KME) and its blend with diesel from 20 percent to 80 percent by volume

and in running a diesel engine with these fuels. Engine tests have been carried

out with the aim of obtaining comparative measures of torque, power, and

specific fuel consumption. They reported that the reduction in exhaust emissions

together with increase in torque, brake power, brake thermal efficiency and

reduction in brake-specific fuel consumption made the blends of karanja

esterified oil (B20 and B40) a suitable alternative fuel for diesel.

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Kayisoglu et al. (2006) studied the effects on characteristics of a diesel

engine by using different diesel fuel and vegetable oil blends. As experimental

material diesel engine with single cylinder, direct injection, four cycles, 5.52 kW

defined power were used. Refined vegetable oils chosen to be added into fuel oil.

They observed that in the sunflower oil and diesel fuel blends were found better

than the soybean oil and diesel fuel blends. In addition, lubrication oil of the

engine by using the soybean oil and diesel fuel blends were get dirty excessively

and viscosity of the engine lubrication oil was reduced more than the others. The

results by using 75 percent diesel fuel + 25 percent sunflower oil blend showed

nearly the same results by using diesel fuel.

Das et al. (2006) worked to evaluate the performance of CI engine using

Jatropha methyl ester from non-edible vegetable oil and its blends with diesel.

The short-term engine (3.73 kW, 2- cylinder, 4-stroke, water cooled)

performance tests were done by using six different blends of Jatropha methyl

ester with diesel fuel from 10 percent to 100 percent by volume, Jatropha methyl

ester-diesel with respect to (10:90), (20:80), (30:70), (40:60), (50:50) and

(100:0). The engine performance parameters studied were power output, fuel

consumption and brake thermal efficiency using the above mentioned blend of

fuels. BHP measured with Jatropha methyl ester was found to be higher than the

diesel. Therefore, Jatropha methyl ester can be used as a diesel fuel

replacement with little sacrifice in brake thermal efficiency.

Chen-Hao et al. (2008) conducted experiment to investigate the

combustion performance of biodiesel on diesel engines. Comparative

experiments were conducted on a single cylinder direct-injected diesel engine.

Combustion pressure, ignition delay period, heat release ratio and emission

performance were evaluated. They concluded that Compared with diesel, the

ignition delay period of biodiesel was low, and continuous combustion period was

long. The maximum combustion pressure, pressure increase ratio and heat

release ratio of biodiesel decreased by 1.91, 30.1 and 29.32 percent,

respectively, at 1500 rpm. The specific fuel consumption of burning biodiesel

increased by 11.6 at 1500 rpm. Burning biodiesel will increase specific fuel

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consumption. Under the condition that the structure of engine is invariable,

biodiesel can be used on diesel engines as an alternative fuel.

Karhale et al. (2008) investigated the performance of Karanja methyl

ester and its blends with diesel from 20, 40 and 60 percent by volume for running

a diesel engine. They observed the increase in power output, brake thermal

efficiency and reduction in brake specific fuel consumption. Injection pressure

and fuel temperature were found to have significant effects on engine

performance parameters. The power output decreased with increase in the

concentration of karaja methyl ester in diesel and increased with the increase in

injection pressure and fruil temperature. Blend of karanja esterified oil (B2O) was

found a suitable alternative fuel for diesel.

Ji-Wei et al. (2008) investigated the mutual solubility and the

physicochemical properties of the ethanol-diesel-biodiesel blend fuel were

investigated, and the power and fuel economy of the diesel engine were

measured under the condition of burning diesel fuel and the ethanol-diesel-

biodiesel blend fuel. Results showed that ethanol and diesel fuel and biodiesel

can steadily mutually solubilize when the temperature was higher than 10℃ and

the volume fraction of biodiesel was more than 17.6 percent. As the mixed

proportion of alcohol gets larger, the combustion and emission circumstances of

diesel engine burning the ethanol-diesel-biodiesel blend fuel include: the brake

specific fuel consumption increased gradually; the brake specific energy

consumption did not change significantly; the torque increased gradually at

medium and high loads the peak value of the maximum combustion pressure

and the rate of heat release gradually increased as well as moving back.

Deepak Agarwal et al. (2008) studied on the performance and emission

characteristics of linseed oil, mahua oil, rice bran oil and linseed oil methyl ester

(LOME), in a stationary single cylinder, four-stroke diesel engine and compare it

with mineral diesel. The linseed oil, mahua oil, rice bran oil and LOME were

blended with diesel in different proportions. Baseline data for diesel fuel was

collected. Engine tests were performed using all these blends of linseed, mahua,

rice bran, and LOME. Straight vegetable oils posed operational and durability

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problems when subjected to long-term usage in CI engine. These problems are

attributed to high viscosity, low volatility and polyunsaturated character of

vegetable oils. However, these problems were not observed for LOME blends.

Hence, process of transesterification is found to be an effective method of

reducing vegetable oil viscosity and eliminating operational and durability

problems. Economic analysis was also done in this study and it is found that use

of vegetable oil and its derivative as diesel fuel substitutes has almost similar

cost as that of mineral diesel.

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V. PLAN OF WORK

METHODOLOGY:

INSTALLATION OF ENGINE:

Preparation of foundation:

Platform for CI engine was prepared in the workshop of farm machinery

department of College of Agril. Engg. & Tech., Junagadh. In the foundation holes

were drilled with hand drill so that engine was fixed with nails.

Installation of CI engine:

Specifications:

1) Engine : Single Cylinder, vertical, water cooled, self-governed diesel

engine developing 5 HP at 1500 rpm

2) Brake Dynamometer: Rope brake with spring balances and loading

screw. Brake drum diameter = 0.400 m.

The CI engine with rope brake dynamometer manufactured by Kirloskar

Oil Engine Ltd. India was selected and installed in the Department of FMP,

College of Agril. Engg. and Tech., Junagadh.

The engine was installed on the platform. Initially rubber sheet was placed

between engine and platform to absorb unnecessary socks and vibration. The

proper alignment of the engine was made and nails were fixed properly around

the engine so that engine can’t make unnecessary vibration.

Installation of diesel engine test rig:

The test rig was placed near the engine with proper alignment for getting

accurate observation and to reduce unnecessary vibration.

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Calibrated fuel burette was joined with the engine through small pipe. The

engine air inlet was joined with test rig air inlet tank. The temperature sensors

fixed in the engine at various locations and were connected with the test rig

through thermocouples. The gas calorimeter was joined with exhaust pipe of the

engine.

Measurements:

1) Fuel consumption measurement (ml/s) will be measured by Calibrated fuel

burette and digital stopwatch.

2) Air intake measurement with help of Orifice meter, fitted to air inlet tank

with water manometer to measure air intake capacity.

3) Temperature measurement at various locations of the engine with the help

of multichannel digital temperature indicator.

4) Heat carried away by exhaust gases will be measured by exhaust gas

calorimeter.

Testing of the CI engine:

Testing of the engine will be carried out by following tests using diesel and

blend of biodiesel (B20).

Data collection:

Fixed parameters:

1) Fuel (diesel and blend of biodiesel (20 percent))

2) Load (100, 75, 50 percent)

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Dependent parameter:

1) Time for 10 ml fuel consumption tf, (sec)

2) Manometer difference hw, (cm)

3) Time for 1 lit calorimeter water tc, (sec)

4) Time for 1 lit jacket water tj, (sec)

5) Water inlet temperature T1

6) Water output from engine Jacket temperature T2

7) Water output from calorimeter temperature T3

8) Exhaust gas outlet from engine (before calorimeter) temperature T4

9) Exhaust gas outlet from calorimeter temperature T5

10) RPM

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The performance evaluation of diesel engine will be determined by following

formulae.

Calculations:

1) Brake Power

BP = 2πNT

1000×60 kW

Where,

N = brake speed, rpm

T = torque, N-m

= Force × Distance

= (W1 – W2) 9.81 × 0.3 Nm

2) Fuel Consumption

FC = 10t f×

36001000 ×0.78

= 28.08t f

Kg / hr

3) Specific fuel Consumption

SFC = FCBP Kg / kW hr.

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4) Heat supplied by fuel

Hf = FC × 42630 KJ/hr

Where, calorific value of diesel is 42630 KJ/kg.

5) Graph will be plotted for Fuel consumption Vs. Brake power so as to

determine friction power.

6) Indicated Power

IP = FP + BP kW

7) Heat Equivalent to BP

HBP = BP × 3600 KJ/hr

8) Heat Equivalent to IP

HIP = IP × 3600 KJ/hr

9) Efficiency

i) Mechanical efficiency

nm = BPIP × 100 %

ii) Brake thermal efficiency

nBT=HBP

HF

× 100%

iii) Indicated thermal efficiency

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n¿=H IP

H F

× 100%

10) Air consumption

Air head across orifice

H a=hw100

(1000−ρa)

Where, hw is in cm

Where ρa=¿ density of air

Or ρa = P

287×(T+273)

P = atmospheric pressure, N/m2 = 105 N/m2

T = absolute ambient temp. in K

Mass flow of air,

ma = 0.62 × 4.9 × 10-4 × √2gha ×3600 × ρa

Where,

Cd of orifice = 0.62 and Area of orifice = 4.9 × 10-4 m2

11) Air Fuel Ratio

AFR = maFC

VI. WORK COMPLETED

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1) Reviews were collected regarding different methods of diesel engine

testing and performance evaluation with diesel and biodiesel blend as a

fuel.

2) Installation of diesel engine and test rig has been over.

3) Preliminary test on engine using diesel was conducted and the setup was

made ready so as to carry out the actual experiment with diesel and

biodiesel both.

VII. WORK REMAINED

1) The evaluation of the diesel engine will be carried out using diesel and

biodiesel blend at different load conditions and the observations for

dependent parameters will be done.

2) The performance evaluation of diesel engine using diesel and biodiesel

blend at different load condition will be determined in terms of brake

power, fuel consumption, specific fuel consumption, heat supplied by fuel,

indicated power, heat equivalent to brake power and indicated power,

efficiencies i)Mechanical ii)Brake thermal iii)Indicated thermal, air

consumption and air fuel ratio.

3) The collected data will be analyzed and report writing will be done.

VIII. REFERENCES

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Chen-Hao, Geng-LiMin, Qi-DongHui and Bian-YaoZhang, (2008). Performance

research of biodiesel on a single cylinder direct-injected diesel engine, Journal-

of-Northwest-A-and-F-University-Natural-Science-Edition, China. 36(7): 219-223.

Das, D.K., Ghosal, M.K. and Yadav, G.V. 2006. Study on the performance of CI

engine by using Jatropha methyl ester, Department of Farm Machinery and

Power, College of Agriculture Engg. and Tech., Orissa Uni. of Agril. and Tech.

Deepak-Agarwal, Lokesh-Kumar and Agarwal, A.K., (2008). Performance

evaluation of a vegetable oil fuelled compression ignition engine, Renewable-

Energy. UK, 33(6): 1147-1156.

Dorado, M.P., Arnal, J.M., Gomez, J., Gil, A. and Lopez, F.J.,(2002). The effect

of a waste vegetable oil blend with diesel fuel on engine performance,

Transactions-of-the-ASAE. USA, 45(3): 519-523.

Huzayyin, A.S., Bawady, A.H., Rady, M.A. and Dawood, A., (2004). Experimental

evaluation of Diesel engine performance and emission using blends of jojoba oil

and diesel fuel, Energy-Conversion-and-Management, UK, 45(13/14): 2093-

2112.

Ji-Wei, Fu-TaiJun, Yao-YaGuang, Zhou-QingHui, (2007). Experimental study on

diesel engine burning ethanol-diesel-biodiesel blend fuel, Transactions-of-the-

Chinese-Society-of-Agricultural-Engineering. China, 23(3): 180-185.

Karhale, S.S., Nadre, R.G., Das, D.K. and Dash, S.K. (2008). Studies on

comparative performance of a compression ignition engine with different blends

of biodiesel and diesel under varying operating conditions, Karnataka-Journal-of-

Agricultural-Sciences, India, 21(2): 246-249.

Kayisoglu,-B., Ulger, P. and Akdemir, S. (2006). A research on determining some

performance values by using proportional mixture of vegetable oils and diesel

20

fuel at a diesel engine, Journal-of-Tekirdag-Agricultural-Faculty (Turkey). v. 3(1)

p. 16-24.

Raheman, H. and Phadatare, A.G., (2004). Diesel engine emissions and

performance from blends of karanja methyl ester and diesel, Biomass-and-

Bioenergy. UK, 27(4): 393-397.

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