A

Project Report
On
“DIESEL ENGINE TEST RIG”
In partial fulfillment of requirements for the diploma
engineering
In
Automobile Engineering
SUBMITTED
BY
TEAM
Under the Guidance of
Mr. MANJUNATH.D
 BOARD OF TECHNICAL EDUCATION
SRI JAYACHAMARAJENDRA (GOVT) POLYTECHNIC, SHESHADRI ROAD,
K.R.CIRCLE BANGALORE-560 001
ACADEMIC YEAR 2016-2017
BOARD OF TECHNICAL EDUCATION
Department of Automobile Engineering
SRI JAYACHAMARAJENDRA (GOVT) POLYTECHNIC Sheshadri road,
K.R.Circle Bangalore-560 001

CERTIFICATE
This is to certify that the project entitled “DIESEL ENGINE TEST RIG”
has been carried out by OUR TEAM in Automobile Engineering, of
S.J (GOVT) POLYTECHNIC in partial fulfillment for the award of Diploma in
Automobile Engineering during the academic year 2016-2017
(Semester-VI).. The project report has been approved as it satisfies the
academic requirements in respect of project work prescribed for the Diploma
Automobile engineering.

Signature of the HOD \ Guide

Mr. Manjunath. D
 DECLARATION
OUR TEAM students of sixth semester, diploma in Automobile Engineering,
hereby declare that the project work titled, “ DIESEL ENGINE TEST RIG” has
been carried by us and submitted to S J (GOVT.) POLYTECHNIC , for the
practical fulfilment of the course requirement for the award of diploma in
Automobile Engineering during the academic year 2016-2017

Date:
Place: Bangalore.

Kavya.A.D (102AT14023)
Madhan.K.L (102AT14027)
Manikanta.C (102AT14030)
Manoj kumar.R.K (102AT14032)
Manoj kumar.B.R (102AT14033)
Naveena.M (102AT14035)
Rakshith.K.C (102AT14040)
Sandeep.Y.V (102AT14046)
Sathya Narayana (102At14047)
Shivakumar.D.B (102AT14050)
Shwetha.D (102AT14053)
Sudarshan.E (102AT14054)
Vinayak Manakawad (102AT14060)
Basappa (102AT14301)
Keerthan.V (102AT14302)
Uday.S (102AT14307)
Babu Malakannavar (102AT15301)
Bharath.S (102AT15302)
Nagesh.K.M (102AT15305)
Prashantha.B (102AT15306)
Ravikumara.N (102AT15307)
Ravindrareddy.J (102AT15308)
Shakthiprasad.K (102AT15309)
Chethan kumar.M (136AT14007)
 ACKNOWLEDGEMENT

I owe our sincere thanks to many people who supported for completion of our
project. Without their hold up, assistance and persistence it would have been
never ending job.

I would like to express my genuine thanks to Mr.Manjunath. D , HOD of

Automobile Engineering in Shree jayachamarajendra govt. Polytechnic , for his
support in permitting me to carry out my project .

I would like to thank our lecturer Mrs. Kamar Taz, who has spent her valuable
time in guiding us at right way always and for her support in completing my
project.

Special thanks to Mr. B Shivamurthi, and B.M Manjunath, who supported with
proper guidance in completing my project.

Finally I would like to express my warm gratitude to all the staff members of
Automobile Engineering, for extending all the facilities required to the full
extent.

OUR TEAM

DIESEL ENGINE TEST RIG

TEAM MEMBERS:-

SATHYA NARAYANA (102AT14047)

SHIVAKUMAR.D.B (102AT14050)
SHWETHA.D (102AT14053)
SUDARSHAN.E (102AT14054)
VINAYAK MANAKAWAD (102AT14060)
BASAPPA (102AT14301)
KEERTHAN.V (102AT14302)
UDAY.S (102AT14307)

DEPARTMENT OF TECHNICAL EDUCATION

 SRI JAYACHAMARAJENDRA (GOVT) POLYTECHNIC
Sheshadri road, K.R.Circle Bangalore-560 001

Department of Automobile Engineering

Certificate that this project entitled “DISEL ENGINE TEST RIG”

This is been submitted by the SHAKTHIPRASAD.K (102AT15309)

A bona fide student of SRI JAYACHAMARAJENDRA (GOVT) POLYTECHNIC,
diploma AUTOMOBILE Engineering during the year 2017, is record of students
own work carried out under my /or guidance. The project report has been
approved as it satisfies the academic requirement in Respect of project work
prescribed for the said diploma. It is further understood that by this certificate
the under signed do not encores or approves any statements made, opinion
expressed or conclusion drawn there in but approves the project only for the
purpose for which it is submitted.

Signature of GUIDE Signature of

HOD

Examiner Signature
01.

02.
INDEX
Contents
Diesel engine test rig
Unit (1). Introduction
0.1 About dynamometer
0.2 About the diesel engine test rig
0.3 Technical details
0.4 Actual conditioning before restoration
0.5 Photo comparison
0.6 Modification of diesel engine

Unit (2). Parameters to be checked for performance of engine.

Unit (3). Performance test of diesel engine.

Unit (4). Heat balance sheet of diesel engine.

Unit (5). Estimation of diesel engine (project cost)

ABOUT THE “DIESEL ENGINE TEST RIG”

Specifications:
 Engine test setup for diesel Engine of 4 Stoke, 3 cylinder.
 generator has Torque Range from 1 Nm to massive 3500 Nm
 Air box: M S fabricated with Orifice meter and Manometer
 Coupling type of power transmission
 Fuel tank: Capacity having glass fuel metering column
 Calorimeter: Type Pipe in pipe construction
 Temperature sensor: RTD Thermocouple and K Type Sensor
 Temperature indicator: Digital, multi channel
 Selector switch or Individual Temp Indicators
 Speed indicator: Digital with non contact type speed sensor
 Torque sensor: Reaction type strain gauge
 Water Circulation Pump for Cooling
Unit(1). INTRODUCTION:-

0.1.ABOUT DYNAMOMETER

Dynamometer

Dynamometer is a device which is used to measure power

produced by any motor or any prime mover, force or speed
of that prime mover. Dynamometer helps in measuring
power required to run any engine as well as in measuring
power produced by an engine.

The dynamometer which is used to measure how much

power is needed to operate a machine or an engine, is
called as driving dynamometer. When someone has a
machine in his/her factory, it is important to know how
much power will be needed to run the factory, then this
driving dynamometer is used.

The dynamometer which is used to measure power

produced by an engine, is called as absorption
dynamometer. It absorbs the work produced by the engine
and measures the same.

Types of dynamometers
 Eddy current or electromagneticbrake

 Prony brake dynamometer

 Rope brake dynamometer

 Hydraulic dynamometer

Advantages of Eddy Current Dynamometer

 Precise Control

 Low Maintenance

 Widely accepted in the automotive industry

 Very Fast Response

 Fast Response

 Blower Cooled (No coolant required)

 Low Cost

Eddy current type absorber

Eddy current (EC) dynamometers are currently the most common
absorbers used in modern chassis dynos. The EC absorbers provide a
quick load change rate for rapid load settling. Most are air cooled, but
some are designed to require external water cooling systems.
Eddy current dynamometers require an electrically conductive core,
shaft, or disc moving across a magnetic field to produce resistance to
movement. Iron is a common material, but copper, aluminum, and other
conductive materials are also usable.
In current (2009) applications, most EC brakes use cast iron discs
similar to vehicle disc brake rotors, and use variable electromagnets to
change the magnetic field strength to control the amount of braking.
The electromagnet voltage is usually controlled by a computer, using
changes in the magnetic field to match the power output being applied.
Sophisticated EC systems allow steady state and controlled acceleration
rate operation.

Types of dynamometer test procedures

There are essentially 3 types of dynamometer test procedures:

1. Steady state: where the engine is held at a specified RPM (or

series of usually sequential RPMs) for a desired amount of time by
the variable brake loading as provided by the PAU (power
absorber unit). These are performed with brake dynamometers.

2. Sweep test: the engine is tested under a load (i.e. inertia or

brake loading), but allowed to "sweep" up in RPM, in a continuous
fashion, from a specified lower "starting" RPM to a specified "end"
RPM. These tests can be done with inertia or brake
dynamometers.

3. Transient test: usually done with AC or DC dynamometers, the

engine power and speed are varied throughout the test cycle.
Different test cycles are used in different jurisdictions. Chassis test
cycles include the US light-duty UDDS,

PERFORMANCE PARAMETERS
1. Indicated power
2. Indicated mean effective pressure
 3. Brake power
4. Frictional power
5. Mechanical efficiency
6. Thermal efficiency
7. Volumetric efficiency
8. Specific fuel consumption
9. Relative efficiency

1. Indicated power: the actual power developed inside the engine

cylinder during one mechanical cycle is called indicated power.

PmLAn
I.P = 60000 ∈KW

2. Indicated mean effective power: It is the hypothetical

pressure which is acting on the piston head during one cycle of
operation.

a× s
Pimep = l
∈ba

3. Brake power: The power available at the engine crankshaft is

known as brake power. It is calculated with the help of a device
called dynamometer connected to the engine crank/output shaft.

B.P =√3x V X I ¿ W

4. Frictional power: The power available at the engine crankshaft

is less than actual power developed inside the engine. FP= IP-BP.

5. Mechanical efficiency: It is the ratio of brake power to the

indicated power.it is an indication of mechanical losses to an
engine. The mechanical efficiency of engine should be around 80
to 85%.
BP
ηmech = IP ×100
 6. Thermal efficiency: It is the ratio of work output to the heat
input.
Work output
ηth = Heat input
×100

7. Indicated thermal efficiency: It is the ratio of indicated power

to the heat supplied to the engine.

8. Brake thermal efficiency: It is the ratio of brake power to the

heat supplied to the engine.

9. Specific fuel consumption: It is the amount of fuel consumed

per kilo-watt of power developed per hour.

mf × 60
S.F.C = IP∨BP ∈kg /KW −hr

10. Volumetric efficiency: Volumetric efficiency is the ratio of

actual amount of air or air fuel mixture sucked during suction
stroke to the amount of air or air fuel mixture equal to swept
volume.

Amt of air equal

ηvol = Actual amt of air sucked
swept volume ¿ ×100
¿
π
Amt of air equal to swept volume = 4 ×D2×L×K×n in m3/min

ma × R ×T
Actual amt of air sucked = p
in m3/min

.DIESEL ENGINE TEST RIG:-

Four Stroke Four Cylinder Diesel Engine Test Rig

Introduction
The test rig is designed to provide self-contained facility for teaching Internal
Combustion (Compression Ignition) engine principles. The equipment is
instrumented so that the following experiments could be performed.
1). Bhp Measurement
2). IHP Measurement
3). FHP Measurement
4). Fuel Consumption Measurement
5). Air Intake Measurement
6). Measurement of Heat Rejected To Water Jacket
7). Heat Balance Test

The engine test rig facilitate to evaluate the following

2). Heat Balance Sheet.
3). Performance (BHP Measurement) from no load to full load.

Description

Two main components from main parts of the test rig. Welded steel base plate,
complete with Dynamometer, drive shaft with safety guard, engine starting
battery of 12V capacity and cooling water arrangement Panel board positioned
over the base plate consisting of fuel system with flow measurement by
burette, air flow measurement system, temperature and speed indicator.
Dynamometer (as applicable)
1). The Dynamometer used is a Hydraulic Dynamometer capable of absorbing a
maximum load of 10 HP at a speed of 1500 RPM
2). The Loading device used is an water rheo stat of matching capacity to load
the engine up to 10 HP at 1500 RPM along with Resisistance loading
arrangement for ALTERNTOR..

Instrumentation (as applicable)

1). The following instrumentation is provided.

2). Engine oil Pressure gauge
3). Engine charging circuit ammeter
4). 'U' tube manometer for air flow rate
5). Burette for fuel flow rate
6). Digital Temperature Indicator- Multi point indicator with thermocouples.
7). Digital Voltmeter, Ammeter

Engine starting

The test rig incorporates a 12 V DC electrical system designed for use with
typical engine self starter system. The battery is included in the scope of supply.

Controls

The test rig is arranged for manual control with Ignition switch for engine
starting manual throttle control, manual control for hydraulic dynamometer
loading and a manual operated clutch actuator arrangement to drive the
engine with load or without load (For No Load testing)

Fuel measuring arrangement

Fuel Measuring Arrangement consists of fuel tank, burette and suitable cock all
mounted on a suitable framework and panel board and supplied with fuel
piping from fuel tank to Engine.
Air intake measurement & heat carried away by exhaust gas
Consisting of an air tank mounted on an iron stand fitted with a suitable orifice
plate, manometer, Thermocouple for measuring the exhaust gas temperature
with pocket connection with instruments suitably mounted on a panel board.
Heat carried away by cooling water Consists of suitable inlet and outlet piping
with flow control valve. Rota meter to measure the rate of flow of cooling
water and Thermocouple with pocket connections for measuring inlet and
outlet water temperature.

Engine

Three Cylinder Four Stroke Water Cooled Vertical Diesel Engine to develop 10
HP @ 1500 RPM (Make: Hindustan Stride/Isuzu)

Services

Electrical supply of 230V, Single Phase, 50Hz AC & external cooling water
supply.

DIESEL ENGINE TEST RIG

MODIFICATION AND RETROFIT FOR EARLIER TEST RIG
A. EARLIER TEST RIG :

1. Three cylinder Diesel engine –

2. Alternator
3. No measuring systems
4. Control panel as load
5. No battery,cables
6. Direct Radiator cooling
7. Many missing items to make it complete test Rig

B. MODIFICATIONS DESIGNED AND IMPLEMENTED :

1. Couple Dynamometer –
2. Proper coupling
3. Engine Reconditioning
4. Self starter wiring system
5. Control panel with all measuring systems
6. battery with all aceessories,auto electrical panel modified
7. New Water Loading Rheostat
8. Hoses, engine cooling system, exhaust pipe connections,etc provided
9. Radiator and Engine cooling by pass system provided

1. FABRICATION and NEW ITEMS WORK

INVOLVED :-
Welding,grinding and painting,machining,fittings,etc,

 ENGINE :
- Reconditioned
- Totally serviced
- Modification in air filter
- Filter element replaced
- Auto electrical panel repaired
- New Ignition switch ,lamps etc provided
- Ampere meter provided existing
- Engine Oil added
- All other parts serviced and made engine to run smoothly
- Bolts and nuts
 Auto Electricals

- New battery provided

- New battery cables with clamp
- New bracket and stand
- Bolts and nuts
-
 Changes in chassis (frame) : No changes

- Earlier legs were removed

- New C channels welded
- New Angles welded
- New bracket frame made for Morse Test

 Control Panel
 - Square tube stand to make it stand ,table cum Control panel
- Prelaminated wooden table top and control panel
- Powder coated stand
- Bolts and nuts

 Air Tank :

- Made from MS sheets, 400 mm x 400 mm x 400 mm

- Orifice plate provided
- Nozzle for Manometer provided
- Connecting tubes
- Diaphragm made from Rubber sheet
- Fixing frame for diaphragm
- Bolt kit

 Manometer

- Made from solid acrylic plate

- Scale provided
- Nozzles provided
- Fixing with fasteners

 Fuel Measuring System

- 3 way block provided

- Mini ball valve of ¼ inch provided
- New fuel tank provided
- New hose nipple provided
- New fuel pipes provided

 Engine Cooling system

- GI pipes of ½ inch NB
- Control Gate /Ball valve ½ inch
- Tee connections for thermo wells
- Ball valves 4 Nos
- Many fittings
- Clamps
 - Hoses
- Collar Bracket
- Water meter ½ inch size
- Flexible rubber hoses
- Hose clamps

 Temperature Measurement System

- Digital meter, 0-999 degree celcius

- For Chromel Alumel (K) type thermometer
- Thermocouples, K type, 6 mm dia stem,4 inch length – 3 Nos
- Ferrule and fittings for thermocouples

 Load measurement System

- Voltmeter - digital 0-500 V AC

- Ammeter -digiral 0- 30 A AC

 WATER LOADING RHEOSTAT

- Bakelite Top
- MS tank 500 x 500 x 500 mm
- Side angles
- Triangular Aluminium conductors
- Wheel and bolt
- Cable changes
 MANY ITEMS
- Air hose
- Clamps
- Battery cvable
- Clamps
- Servicing of Loading panel
- Painting of alternator
- Painting of base
- General service

Construction images of diesel engine test rig

WATER OUTLET TEMPERATURE SENSER WATER FLOW METER

AIR DUCT PIPE AIR CLENER STARTING PANNEL

CONTROLE PANNEL MANOMETER AND FUEL GAUGE

WATER LOADED REHOSTAT AIR DUCT BOX

 DIESEL TANK BATTERY

STARTER FOUNDATION

DISMANTLING ENGINE AND GENERATOR AT THE TIME OF REPIER

DIESEL ENGINE SETUP

DIESEL ENGINE TEST RIG

FOUR STROKE THREE CYLINDER –WITH ALTERNATOR

OBJECTIVE :
 To conduct Load test
 To Conduct Heat Balance Sheet Test
 To determine various efficiencies of the engine

INTRODUCTION :
Engines are basically Prime movers. They convert heat energy into mechanical
energy. Heat is derived or generated by burning fuel inside cylinder. This type
of engine where fuel is burnt inside is called INTERNAL COMBUSTION ENGINES.

Engine can single cylinder or multi cylinder, two stroke or four stroke, run on
different fuels like petrol, diesel, LPG etc. ,.

Test engine is Four cylinder Four stroke, run with Diesel ,variable speed,
coupled to a 3 phase alternator and both are mounted on a strong chassis. Test
rig is complete with measuring system for air, fuel, temperature, speed, load,
etc.

As set up is originally a DG set , its capacity is 20 KVA , but as a test rig it is

restricted 7.5 KVA.
With Change over switch set up can be used either as test rig or Generator
system to supply power to college. College to make arrangement for
change over switch and panel.

As radiator is required for continuous running as generator. But to make it test

rig, a continuous water supply is required. Hence 4 valves are provided and
closing and opening valves in certain position. It can be made either as for test
rig or for generator set.
Engine is loaded from Zero load to Full load, in which fuel consumed, air
consumed, different temperatures are measured.
By taking all readings total Fuel Consumption, SFC,Mechanical efficiency,Brake
thermal efficiency, Air fuel ratio, Heat Balance sheet can be computed.
A water loading rheostat is provided to load the engine.

TEST SET UP :
It comprises Engine coupled dynamometer,control panel,etc,.
1. Engine coupled to electric dynamometer
2. Self starter assembly
 3. Control Panel
4. Other accessories,pipes,water meter,etc,.

ENGINE : Four stroke,Three cylinder,water cooled,Compression ignition

Governed Engine
- With decompression levers

Make : KIRLOSKAR
Fuel : Diesel
Cylinders : three
Bore :
Stroke :
Compression : 17.0 : 1.0

ELECTRICAL DYNAMOMETER:
This dynamometer is Electrical type. It is foot mounted. Coupled directly to
Engine Flywheel.
Rating : 10 HP as test rig (actually 20 KVA)
Speed : 1500 rpm
Current : 10 to 15 A (as test Rig) otherwise 30 A for 20 KVA
Voltage : 440 V AC
Cooling : Air cooled

WATER LOADING RHEOSTAT:-

It is another type of electrical loading system.A water tank made of MS
contains water in it. Salt is added about 100 gms in the tank and stirred well.
Aluminium conductor of about 15 to 20 mm thick, 100 mm width and 120 mm
length making it triangle
Three such Conductors are placed side by side and Joined with Hylam sheet. All
three are isolated with sufficient distance.
Every where hylam sheets are used for insulation. A threaded bolt and
handwheel drives these conductors up and down.
If Tip of all three conductors are away from top level of water, there will not be
loaded. When all three conductors are dipped inside water, alternator is
loaded.More the depth of immersion of conductors more is the load.
There can be SPARKING in the water. Need Not be panic. Water also gets
heated while loaded at higher value.

MEASUREMENT AND CONTROL PANEL :

It is made from MS square Tubes. It is combination of stand , Table and Control
panel.
Powder coated. MDF (prelaminated) wood base and panel is provided. All the
instruments are fixed on to this.
Various measuring systems are mounted on this panel.

1. AIR MEASUREMENT SYSTEM:-

Here Air supply for engine is made through Air storage tank to air filter.
Air to the air tank enters through orifice ( A small opening in air tank). When
engine starts and all its air requirement has to be supplied through this air
tank.

As air is sucked by engine, volume of air in the tank reduces, a PARTIAL vacuum
is created, due to which fresh air from atmosphere enters air tank through
orifice.

Amount of air drawn depends upon orifice diameter. A U tube water

manometer is provided. Its one limb is connected to Nozzle. Another limb left
open. This nozzle gets partial vaccum pressure.
Hence difference between atmospheric pressure and air tank pressure make
manometer liquid (water) to change levels. Level difference gives Manometric
head. More the entry of air through orifice gives more level difference in
manometer.

Air Tank : made from ms sheets, with top rubber diaphragm.

400 mm X 400 mm X 400 mm
Orifice : sharp edged,circular ,18 mm diameter
Manometer : U tube,water filled,made from solid acrylic
With scale.
Nozzle : brass is fitted on tank , next to orifice

Tubes : transparent tube connects between manometer and

Nozzle
Hose : Flexible Hose with clamps connects Air filter of
engine and Air tank

2. FUEL MEASUREMENT SYSTEM:-

In Automobiles a fuel tank with sufficient volume is provided to store

fuel.It supplies fuel to engine. But this is being test rig and fuel
consumption is to be noted at various loading condition. .comprises fuel
tank,burette,3 way block,etc,.
Burette : 0-50 cc,glass,borosil/corning
3 way block : made from solid ms block,with T shaped tapped
hole,and top is connected to burette,left to
engine and right to valve and fuel tank
 Fuel tank : about 8 litres capacity,with breather filler cap.

3. SPEED MEASUREMENT :-

No need of speed measurement. It is Governed Engine. And None of the

calculation require data of speed. Hence RPM indicator is Not Provided.

4. TEMPERATURE MEASUREMENT :-

As Engine generates heat due to combustion while working, its heat is

transferred to many systems, like engine water cooling, exhaust,actual
conversion to work,radial losses.
Hence it is necessary to measure temperature at various locations to find out
Heat Balance of Engine.
System is provided with a digital indicator, thermo couples and selector
switch.

Indicator : Digital, 0-999 oC,multichannel

Thermocouples : Fe-K type
Stem type
4 inch, with ferrule fittings
Selector switch : Rotary, 2 pole, 6 way
With knob and numbers

T 1 – engine exhaust gases

T 2 – engine cooling water inlet
T 3 – engine cooling water outlet

5. WATER FLOW RATE :-

 In automobiles Engine cooling is done by Radiator,fan,etc. Test rig requires
continuous water flow to measure flow rate of water. Hence inlet to engine
cooling is provided directly through continuous water supply.
In order to findout water flow rate, a water meter along with control valve
is provided. Inlet and outlet water pipe lines are provided with thermo
wells to insert thermocouples.
Water meter : ½ inch pipe size
Valve : ½ inch ball valve

6. POWER MEASUREMENT :

Load is measured electrically

Power absorbed is measured by Voltmeter and Ammeter.
Voltmeter : 0-500 V AC
Ammeter : 0-30 A AC

7. AUTO ELECTRICALS:-

Ignition swich,solenoid, alternator,bottle ignition coil,indicater are

provided
Ampere meter - to know battery charging
Oil meter - to know oil pressure (optional)

TEST CONDUCTION PROCEDURE:

PRESTART AND INITIAL CHECKUPS:
1. Checkup all electrical connections
2. Checkup battery charge,fuel level,water in manometer,oil level,etc,.
 3. Keep all three decompression lever at DOWN position
4. Initially Rotate handwheel of water loading rheostat clockwise and
observe that Tips of all three conductors are NOT in the water(They
should be above water level)
5. Open inlet valve of engine cooling system . Note down time required
for 10 litres of water flow in the water meter. It can be around 8-10 lpm.
As this flow rate is kept constant through out experiment,reading once
taken need not be repeated every time.
6. TO START ENGINE :
- With ignition key switch ON engine
- Engine starts but not with full speed
- Open Decompression levers One by ONE
- Observe after some times Engine is running with full rated
speed

Unit(2).LOAD TEST: PERFORMANCE TEST:-

At this NO LOAD condition note down time for 10 cc fuel consumption, to

do this close mini ball valve fitted on 3 way block, now diesel supply to engine
by burette only. After reading DONOT FORGET to open mini ball valve so that
fuel supply is from Fuel tank to engine. If Valve is in closed position, then
engine may run dry and air is trapped in the fuel line,
1. Note down readings of manometer, Voltmeter, ammeter and all
temperatures.
2. To load engine (Or Alternator) rotate Hand wheel anti clock wise, Tips
of all conductors are dipped in side water.

3. At this load note down all readings of fuel,

temperature,manometer,water flow rate
4. Engine speed automatically adjusted with load.
5. For every load note down reading of fuel,speed,load,temperatures
6. Maximum load can be with 8 amps
7. After trial reduce load and bring to ZERO load
8. To stop engine
 TABULAR COLUMNS :-

LOAD TEST AND HEAT BALANCE TEST :

SL.NO MANOMETER TIME VOLTGE CURRENT TIME TEMPERTURES

0
FOR V I FOR C
10CC of Volts amps 5 ltrs of
fuel t1 water
sec t2 sec T1 T2 T3
EXT CWI CWO
h1 h2 GAS
CM CM
01 10.2 11.5 9.78 386 0 82 10 35 40

02 10.4 11.6 10.1 384 3.1 82 145 34 55

03 10.3 11.6 9,83 382 6.1 82 159 35 59

04 10.3 11.6 8.99 380 9.4 82 170 35.7 61

05 10.3 11,6 8.93 378 12.4 82 182 36 61

CALCULATIONS :

01. Area of Orifice Ao = (/4) x do sq.m

where do = Orifice diameter
= 15 mm = 0.015 m
Ao=(/4)xdo
=/4(0.015)2
=
Ao 1.767x10-4 m2

1. Mass flow rate of air

Ma = 140 Cda √(hpa Kg/sec)

Ma1 = 140x0.7x1.767x10-4x(√0.013x1.22)
= 0.0173x0.125
Ma1 = 2.178x10-3 kg/sec
Ma2 = 2.093x10-3 kg/sec
Ma3 = 2.178x10-3 kg/sec
Ma4 = 2.178x10-3 kg/sec
Ma5 = 2.78x10-3 kg/sec

Where,

Cd= Co-efficient of discharge of orifice= 0.7

a= area of orifice in m2
H= Head causing flow of air through orifice in meters of air
pa= Density of air under atmospheric conditions in Kg/m3
pw= Density of water in Kg/m3 = 1000 Kg/m3
h= Pressure difference measured in U-tube in meters of air
 0.3 Specific fuel consumption:
mf × 60
S.F.C = IP∨BP
∈kg /KW −hr

S.F.C1 =0
S.F.C2 = (7.843x10-4)/(2.33)x3600
S.F.C2 = 1.323 kg/BP-hr
S.F.C3 = 0.726 kg/BP-hr
S.F.C4 = 0.54 kg/BP-hr
S.F.C5 = 0.410 kg/BP-hr

Where,

mf= mass of fuel supplied in Kg/min

BP= Brake power in watts

0.4 Mass of fuel supplied

10 cc
mf = tx 10 6 x 800 Kg/sec
mf1 = (10x800)/ (9.78x106)
mf1 = 8.179x10-4 kg/sec
mf2 = 7.843x10-4 kg/sec
mf3 = 8.138x10-4 kg/sec
mf4 = 8.898x10-4 kg/sec
mf5 = 8.958x10-4 kg/sec

Where,

mf= mass of fuel supplied in Kg/sec

05. Brake Power BP in ‘Kw’

BP =√ 3(VxI) Cos φ ‘ kw’
 BP1 = 0
BP2 = √ 3x 385x3.3x1
=1.732x1232
=2133.82w
=(2133.82x103)/103
BP2 =2.133 kw
BP3 = 4.035 kw
BP4 = 5.907 kw
BP5 = 7.856 kw

06.Brake thermal efficiency:

BPX 60
nbth= mfxCV X 100

nbth1 = 0
nbth2= (2.133)/(7.843x10-4x38000)x100
nbth2 = 7.15%
nbth3 = 13%
nbth4 = 17%
nbth5 = 23%

Where,

BP= Brake power in watts

mf= mass of fuel supplied in Kg/min
Cv = Calorific value of fuel in KJ/Kg
HEAT BALANCE SHEET

CREDIT SIDE ( INPUT ) DEBIT SIDE ( OUTPUT )

Sl.no Particulars Heat, % Sl.n Particulars Heat, %
kj/sec o kj/min
1 Total heat 34.04 100 1 Heat 7.856 23.0
supplied to the equivalent to 7
engine BP
2 2 Heat loss to 6.3 18.5
cooling water 0
3 3 Het carried 0.473 1.3
away by the
exhaust gas
4 4 Un accounte 19.411 57

TOTAL 34.04 100 TOTAL 34.04 100

HEAT BALANCE SHEET: in Minutes basis

A . CREDIT SIDE : Heat input Hi in k.cal

Hi = mf x cv kJ/sec
 Hi1 = mf1 xcv1
= 8.179x10-4x 38000
Hi1 = 31.08 KJ/sce
Hi2 = 29.803 KJ/sec
Hi3 = 30.92 KJ/sec
Hi4 = 33.81 KJ/sec
Hi5 = 34.04 KJ/sec

B . DEBIT SIDE :
a. Heat equivalent to the BP = Hb1=BP1 KJ/se
BP1=0 or Hb1=0
BP2=Hb2=2.133 KJ/sec
BP3=Hb3=4.035 Kj/sec
BP4=Hb4=5.907 Kj/sec
BP5=Hb5=7.856 Kj/sec

b. Heat carried away by engine cooling water ( Hw)

Mw = 5L/t =5/82 =0.060 kg/sec

Hw =MW * CW (T3 –T2)
=0.060 X 4.2 ( 40-35)
Hw =1.26 Kj/sec
HW2 =5.292 Kj/sec
HW3 =6.048 Kj/sec
HW4 =6.375 Kj/sec
HW5 =6.3 Kj/sec
Where Cpw = specific heat of water = 4.186 , kJ/kg.K
t 2 = Time for 5 litres of water

c. Heat carried away by Exhaust gases : He in kJ/min

He = [ Me1 x Cpe x ( T1 – Tr )] kJ/min
 Where
Me = Mass flow of Exhaust gase in kg/min
Cpe = Specific heat of exhaust gases , kj/kg.K
T3 = Exhaust gas temperature, in o C
Tr = Room Temperature , in o C (To be noted as T3 before starting
engine

He =Hb= [ Me1 x Cpe x ( T1 – Tr )]

Me1 =Ma1+Mf1
= 2.178X10-3+8.179X10-4
Me1=2.995X10-3 Kg/sec
Me2 = 2.877X10-3 Kg/sec
Me3 = 2.91X10-3 Kg/sec
Me4 = 3.067X10-3 Kg/sec
Me5 = 3.073X10-3 Kg/sec

He1 = Me1XCpeX(T1-Tr)
= 2.995X10-3X1X82
=0.2455 Kj/sec
He2 =0.336 Kj/sec
He3 = 0.39 Kj/sec
He4 = 0.435 Kj/sec
He5 = 0.473 Kj/sec

d. Unaccounted heat losses , Hu in kJ/min

Hu = [ Hi ] – { Hb + Hw + He } , kJ/min
= 19.41 Kj/sec
Determination of Mass flow rate of Exhaust gases Me

1. Method 1 : Without Exhaust gas Calorimeter

Me = Ma + Mf in Kg/hr

2. Method 2 : With Exhaust Gas calorimeter- OPTIONAL

ESTIMATION AND COSTING FOR MODIFICATION

For
DIESEL ENGINE TEST RIG

A. FABRICATION and NEW ITEMS WORK INVOLVED :

Welding, grinding and painting, machining, fittings, etc,

 ENGINE
- Totally serviced Rs 4,000.00
- Modification in air filter 500.00
- Filter element replaced 300.00
- Auto electrical panel repaired 400.00
- New Ignition switch ,lamps etc provided 600.00
- Ampere meter provided existing
- Engine Oil added 900.00
- All other parts serviced and made engine to run smoothly 3,000.00
- Bolts and nuts 200.00
-------------------
Rs. 9,900.00
 Auto Electricals
- battery provided by college
- New battery cables with clamp 800.00
- New bracket and stand
- Bolts and nuts 600.00
------------------
Rs 1,400.00

 Changes in chassis (frame) : No changes

- Earlier legs were removed

- New C channels welded
- New Angles welded
- New bracket frame made for Morse Test

 Control Panel

- Square tube stand to make it stand ,table cum Control panel Rs 5,000.00
- Prelaminated wooden table top and control panel Rs 1,800.00
- Powder coated stand 1,500.00
- Bolts and nuts 300.00
--------------------

Rs. 8,600.00
 Air Tank :

- Made from MS sheets, 400 mm x 400 mm x 400 mm Rs 3,000.00

- Orifice plate provided 500.00
- Nozzle for Manometer provided 60.00
- Connecting tubes 80.00
- Diaphragm made from Rubber sheet 300.00
- Fixing frame for diaphragm 300.00
- Bolt kit 75.00

----------------
Rs 4,315.00
 Manometer

- Made from solid acrylic plate Rs 2,500.00

- Scale provided 40.00
- Nozzles provided 60.00
- Fixing with fasteners 100.00

-----------------
Rs 2,700.00

 Fuel Measuring System

 - 3 way block provided Rs 1,000.00
- Mini ball valve of ¼ inch provided 400.00
- New fuel tank provided 1,850.00
- New hose nipple provided 200.00
- New fuel pipes provided 400.00
- -----------------
Rs. 3,850.00

 Engine Cooling system

- GI pipes of ½ inch NB Rs 1,000.00

- Tee connections for thermo wells 200.00
- Ball valves 4 Nos 1,000.00
- Many fittings 3,000.00
- Clamps 200.00
- Hoses 500.00
- Collar Bracket 600.00
- Water meter ½ inch size 1,500.00
- Flexible rubber hoses 300.00
- Hose clamps 200.00

--------------------
Rs 8,500.00
 Temperature Measurement System

- Digital meter, 0-999 degree celcius Rs 3,000.00

- Selector For Chromel Alumel (K) type thermometer 1,000.00
- Thermocouples, K type, 6 mm dia stem,4 inch length 1,000.00
– 3 Nos
- Ferrule and fittings for thermocouples 900.00

-------------------
Rs 5,900.00

 Load measurement System

- Voltmeter - digital 0-500 V AC Rs 2,700.00

- Ammeter -digiral 0- 30 A AC 2,700.00
--------------------
Rs 5,400.00

 WATER LOADING RHEOSTAT

Rs. 15,000.00
- Bakelite Top
- MS tank 500 x 500 x 500 mm
- Side angles
- Triangular Aluminium conductors
- Wheel and bolt
 - Cable changes

 MANY ITEMS

- Air hose Rs 500.00

- Clamps 200.00
- Battery cable 900.00
- Clamps
- Servicing of Loading panel 1,000.00
- Painting of alternator 2,000.00
- Painting of base 2,000.00
- General service 3,000.00
---------------
Rs 9,600.00
 OTHERS

- Transportation Rs 1,000.00
- Misc expenses Rs 2,000.00
-
----------------------
Rs 3,000.00
TOTAL EXPENSES Rs. 77,165.00
 Conclusion
After all the modifications test were conducted on both the
engines in detail for performance and heat balance. It was
found that both the engines are performing o their
expectations. Hence this project of modification and
rectification of existing old engines has been fully utilized by
all of students of our batch to study about engines
methodology of testing, instruments and equipment used.
Because of this project we have achieved following
1. Detail study and analysis of existing engine.
2. Knowledge for the selection of instruments and other
equipment’s to make it as a test rig,
3. We our self-conducted trails on both engines
4. This is useful for the next upcoming batches of our
institution.
5. We request next batch to improvise further to get
maximum profit.
6. Because of financial the project to this level.