Energy Efficiency Lab, Centre for Energy, IIT Guwahati 2018

Aim: Performance analysis of a single cylinder four stroke spark ignition

engine

Setup Description:
The set up consists of single cylinder, water cooled, 4-stroke gasoline fuelled spark ignition engine.
The engine is attached with eddy current dynamometer for application of load. It is provided with
necessary equipments and instruments for measurement of load applied, fuel consumption for the
load applied, air consumption, the cooling water circulated through engine, exhaust gas temperature
before and after calorimeter. Water jacket temperature through calorimeter. The set up enables
study of brake power, brake thermal efficiency, brake specific fuel consumption, air –fuel ratio, heat
balance, energy carried away.

Fig.1 Schematic diagram of base (Gasoline) petrol engine setup with equipments.

Specifications
System specifications
Parameter Specification
Product Research engine test setup, Code 240
Type Research Engine test setup 1 cylinder, 4 stroke, Multi-fuel
Power 4.5 KW @ 1800 rpm, Speed range 1200-1800 rpm.
VCR with open ECU for petrol mode (Computerized)
Type of cooling Water cooled
CR range 6:1-10:1
Combustion chamber Hemispherical bowl in piston type
Dynamometer Eddy current type, water cooled with loading unit
Air box MS fabricated with orifice meter and manometer (100 - 0 -
Fuel tank Capacity 15 lit with measuring tube (0-450 ml)
100)
Calorimeter Pipe in pipe type
Rotameters Engine cooling 40-400 lph, calorimeter 25-250 lph

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 Energy Efficiency Lab, Centre for Energy, IIT Guwahati 2018

Data acquisition Software ‘Enginesoft’ engine performance analysis software

Transmitters, sensors and indicators

Fuel flow transmitter DP transmitter, range 0-500 mm WC
Air flow transmitter Pressure transmitter (-) 250 mm WC
Pressure sensors Piezo type, range 5000 PSI, with low noise cable
Temperature sensors and PT100 (RTD) type, range 0-100º C, output 4-20 mA (4 nos)
Load sensor and indicator Strain gauge type load cell with digital indicator, range 0-50
transmitters
Speed sensor and indicator Resolution 1º, range (5500 rpm) with TDC pulse
kg
Data acquisition device NI USB-6210, 16-bit, 250 kS/s
Setup constants
Pulse per revolution 360º
No. of cycles 10
Fuel measuring interval 60 s
Speed scanning intervals 2000 ms
Bore  Stroke 87.5 mm  110 mm
Capacity 661 cc
Orifice diameter 20 mm
Dynamometer arm length 185 mm
Connecting rod length 234 mm
Theoretical constants
Orifice coefficient of discharge 0.6
Specific heat of exhaust gas 1.00 – 1.25 kJ/kg-K
Specific heat of water 4.186 kJ/kg-K
Density of Air 1.174 kg/m3
EGR Specification
EGR flow rate orifice (ø16 mm)with manometer(100-0-100)mm
Treated EGR Three way catalytic converter
Calorimeter Pipe in pipe type

Theory
Following are the formulae used for calculation of various results.
Nomenclature
T1 Jacket water inlet temperature Deg.K
T2 Jacket water outlet temperature Deg.K
T3 Calorimeter water inlet temperature Deg.K
T4 Calorimeter water outlet temperature Deg.K
T5 Exhaust gas to calorimeter inlet temperature Deg.K
T6 Exhaust gas from calorimeter outlet temperature Deg.K
Tamb Ambient temperature Deg.K
F1 Fuel flow kg/hr
F2 Air flow kg/hr
F3 Jacket water flow kg/hr
F4 Calorimeter water flow kg/hr
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 Energy Efficiency Lab, Centre for Energy, IIT Guwahati 2018

W Dynamometer load Newton

N Speed of engine rpm
t Time for fuel consumption sec
System constant
D Engine cylinder diameter meter
L Engine stroke length meter
No.cyl Number of cylinders
1 for 2 stroke
N No. of revolutions per cycle
2 for 4-stroke
R Dynamometer level arm for loading meter
Cal.val
Calorific value of fuel. kJ/kg
.
d Orifice diameter meter
Cd Coefficient of discharge
ρf Fuel density kg/m3
ρa Air density kg/m3
ρw Water density kg/m3
h Manometer reading across orifice meter of water
Cpw Specific heat of water at constant pressure kJ/kg0K
Cpex Specific heat of exhaust at constant pressure kJ/kg0K
Formulae
1. Brake Power

BP
2. Brake specific fuel consumption

BSFC
3. Brake thermal efficiency

4. Air-fuel Ratio

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Energy Efficiency Lab, Centre for Energy, IIT Guwahati 2018

A/F
5. Heat Balance
2
F1 =ρ f × ×10−6 ×3600 kg /hr
a. Fuel Consumption t

b. Heat supplied by fuel

c. Air consumption

F2 =ρ air ×( π
4
×d )
orifice(√
2 ( ))
× 2×9 .81×h×
ρw
ρa
×3600

d. Heat equivalent to useful work

In percentage

e. Heat in jacket cooling water

In percentage

f. Heat in exhaust gas

So,

Heat in exhaust
In percentage

6. Heat to radiation loss etc.

Operating Procedure
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 Energy Efficiency Lab, Centre for Energy, IIT Guwahati 2018

1. Baseline performance tests were carried out with the engine operating on petrol fuel
only. The engine load ranges from a minimum of 0.1 kg to a maximum of 11 kg load.
The engine tests were conducted for the entire speed range i.e., 0 to 1800. Mainly it is
operated in part or full throttle condition.
2. First, engine was warmed up and run for few minutes at 1700 rpm under wide open
throttle condition to reach stable operating conditions. Then at the throttle position
was kept constant at WOT and the load was adjusted to attain the desired speed of the
engine.
3. The water flow was adjusted to 300 and 110 liters per hour for the engine cooling and
calorimeter respectively according to the engine supplier instructions.
4. Then, as per experimental design a the load was adjusted for engine operation. Once
the engine reaches the steady-state condition, the engine was ready to present the
baseline results.
5. For this, the following data were recorded manually:1) Engine jacket water (in/out),
calorimeter water (in/out) and exhaust gas temperature,2) The difference in liquid
level in the manometer for air flow, and 3) Volume of petrol fuel consumption by the
engine in one minute.4) temperatures at all points
6. This experimental measurement procedure was repeated for different engine speed by
adjusting the load on the engine like 1200, 1300, 1400,1500, 1600and 1700 rpm both
in part and full throttle condition. The load was varied in steps by means of the eddy-
current dynamometer with the help of a manually controlled knob with a digital load
indicator provided in the engine controller.
7. The engine efficiency, BP, bsfc, air and fuel flow rate, A/F ratio, heat balance, etc
will be calculated and accordingly plot the performance characteristics of the test.
System constants
Orifice diameter 20 mm
Dynamometer arm length 185 mm

for orifice 0.6

Specific heat of water (Cpw) 4.187 kJ/kg K

Specific heat of exhaust( ) 1.1 KJ/kg K

Air density 1.17 kg/m3

Fuel density 730 kg/m3
Calorific value of fuel 44000 KJ/kg
Ambient temperature 300C
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 Energy Efficiency Lab, Centre for Energy, IIT Guwahati 2018

Observation Table
Water Temp. Temp Temp.
Load Air Fuel Water flow
Speed flow Engine Jacket Calorimeter Exhaust Gas
Kg Consumed Consumed calorimeter
RPM Engine T1 T2 T3 T4 T5 T6
mmWC cc/min LPH
LPH K K K K K K

Emission from Engine

Speed O2 CO2 CO HC NOx

rpm % % % ppm ppm

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 Energy Efficiency Lab, Centre for Energy, IIT Guwahati 2018

Results
Performance Parameters

Speed BP FC BSFC BTE Air flow Volumetric

A/F Ratio
rpm kW Kg/hr Kg/kW-hr % Kg/hr Efficiency %

Heat Balance Sheet

Heat energy lost in Heat energy carried
Heat energy supplied Heat energy equivalent Unaccounted heat
Speed engine jacket cooling away by exhaust
from fuel burnt to useful work Energy Loss
water gases
rpm kJ/hr % age kJ/hr % age kJ/hr % age kJ/hr % age kJ/hr % age

Performance Characteristics Curves

1. Brake Power variation with Speed.
2. Brake specific fuel consumption variation with Speed
3. Brake thermal efficiency variation with Speed
4. Exhaust gas temperature variation with Speed
5. Energy carried by coolant variation with speed.
6. Air fuel ratio variation with speed.
7. BP variation with A/F ratio
8. Break thermal efficiency variation with A/F ratio.
9. Speed VS engine emission
10. A/F ratio VS engine emission

Conclusions: