Task No.

1
Explain the properties of diesel fuel?
Diesel Fuel
No. Explanation
Properties
Diesel fuel viscosity refers to its resistance to flow. Higher
1 Viscosity
viscosity can lead to poor fuel atomization and combustion.
The flash point is the lowest temperature at which diesel fuel
2 Flash Point vapor can ignite when exposed to high pressure and temp., or open
flame.
Diesel fuel should ideally be free from water and sediment, as
Water and
3 these can cause engine problems and fuel system corrosion. But
Sediment Present
there is an allowance rate for water that the filter can handle.
The pour point is the lowest temperature at which diesel fuel
4 Pour Point remains fluid. It is important in cold weather, as low pour points
prevent fuel from solidifying and clogging fuel lines and filters.
Lower ash and sulfur content are desirable to reduce engine wear
Ash and Sulphur
5 and minimize emissions. Sulfur content is also regulated for
Content
environmental reasons.
Boiling Range The boiling range indicates the temperatures at which various
6
(Distillation) components of diesel fuel vaporize.
Specific gravity is the ratio of the density of diesel fuel to the
7 Specific Gravity density of water. It provides an indication of the fuel's weight
relative to water.
Carbon residue is the amount of carbonaceous material left after
8 Carbon Residue
evaporation and combustion of diesel fuel.
Diesel fuel should not be corrosive to engine components.
9 Corrosiveness
Corrosion can lead to fuel system and engine damage.
The Cetane rating is a measure of the ignition quality of diesel
10 Cetane Rating fuel. Higher cetane ratings indicate lighter diesel and better
ignition characteristics.
Heat value, or energy content, is the amount of energy released
11 Heat Value
during the combustion of diesel fuel.
Knock resistance is relevant for diesel engines. Higher knock
12 Knock resistance ensures smooth combustion without abnormal pressure
increases.
Diesel fuel density indicates the amount of energy it contains
13 Density
denser fuel have higher heat value.
Low Temperature This property is related to the fuel's ability to perform well in low
14
Operability temperatures, preventing issues like waxing and gelling.

1
2. Explain the phases of combustion process for compression ignition engines?

Figure 1.

Phase Phase
Phase Phase Explanation
Points Name
The time interval between the start of diesel injection and
Ignition
First A to B the actual start of combustion, which divides into 2 stages:
delay
Physical and Chemical delay.
Rapid increase in pressure from any point at any time right
Uncontrolled after the delay period ends. Can’t be controlled as in the CI
Second B to C
combustion engine there no spark to control the exact time and place of
combustion.
After the previous stage the high heat, pressure, and air
Controlled swirls will cause any injected fuel to ignite without delay,
Third C to D
combustion which makes it possible to control the combustion by the
rate of injection.
After Burning of any poorly distributed fuel particles or big
Fourth D to F
burning molecules.

2
Compare between normal and abnormal combustion in CI engine?
Normal Combustion Abnormal Combustion
Normal combustion in a diesel engine
Abnormal combustion refers to
is the controlled and timed ignition due
uncontrolled or premature ignition,
to compression. It follows the designed
occurring outside the intended
combustion process, initiated by fuel
Definition injection into the highly compressed air
combustion process. This often
leads to pressure spikes and a
in the combustion chamber with the
distinctive knocking sound, which
lowest noise and highest efficiency
can cause critical engine damage.
possible.
1. Proper injection timing and rate
1. Hot spots and carbon residue
2. Fuel quality
2. Excessive temperature
Factors that 3. Cetane rating
3. Too high compression ratio
affects 4. Swirls
4. Speed and load
5. Injection pressure

Normal combustion is efficient,
Effect on
providing a smooth power stroke that
engine contributes to engine efficiency,
performance performance, low noise, and much less
wear to engine parts.
 Abnormal combustion is
inefficient and can lead to a
reduction in engine efficiency. The
pressure spikes may not contribute
effectively to the engine's work
output.
 Produces a distinctive knocking or
pinging noise, which is
undesirable and can indicate
potential engine damage.
 Sharp pressure rises associated
with abnormal combustion can
increase mechanical stress on
engine components, potentially
leading to damage.

3
Evaluate the relationship between diesel fuel properties and the performance of a
compression ignition engine?
Engine Performance definition:
No. Diesel Fuel
Performance of the Engine
Properties
 Definition: Viscosity is a measure of a fluid's resistance to flow. In the
context of diesel fuel, it indicates how easily the fuel can be pumped
and atomized. Diesel viscosity is typically measured in units of
centistokes (cSt) at a specific temperature.

 Importance: Proper atomization of diesel fuel is crucial for efficient

combustion in the engine. The viscosity of diesel fuel affects how
well it can be atomized into small droplets, facilitating better mixing
with air and combustion.
Viscosity influences the ease of fuel injection. If the fuel viscosity is
too high, it may result in poor spray patterns and incomplete
combustion. On the other hand, low viscosity can lead to issues like
fuel leakage and improper injection timing.
Extreme viscos conditions can lead to increased wear on fuel injection
components. High viscosity may strain the fuel pump, while low
viscosity can lead to metal-to-metal contact in the injector nozzles.
Viscosity

1
 Specification: A diesel fuel with Cetane rating of 41:48 have viscosity
rating of 2.04:3.23 cSt.

 Performance effect: Higher viscosity can improve lubrication

properties, reducing friction and wear in certain engine components.
But excessively high viscosity, especially at low temperatures, can
impede fuel flow, affecting atomization and combustion. This can lead
to poor engine performance, increased emissions, and potential
damage.

Lower viscosity enhances fuel flow and atomization, promoting

efficient combustion and better engine performance.
Extremely low viscosity may lead to inadequate lubrication and
increased wear on fuel system components.
This is why every diesel engine runs best on its determined Cetane
rating.

4
  Definition: The flash point of a substance, including diesel fuel, is the
lowest temperature at which it can vaporize to form an ignitable
mixture in air.

 Importance: flash point affects both the combustion and the safety of
fuel transport.
Low flash point decreases ignition delay thus better combustion but
very low flash point will increase the risk of fire while transporting and
handling the fuel.
Flash Point

 Specification: flash point of diesel varies from 68:94oC depending on

2 the fuel quality

 Performance effect: Fuels with higher flash points are generally safer
in terms of reduced fire risk during handling, storage, and
transportation.
But extremely high flash points might lead to challenges in ignition
during the combustion process, potentially affecting engine
performance.
Lower flash points ensure easier ignition, promoting efficient
combustion in the engine.
Extremely low flash points can pose safety risks, particularly in terms
of increased flammability during fuel handling and storage.
 Definition: boiling range of diesel fuel refers to the temperature range
over which the various components of the fuel vaporize during the
distillation process. It is typically expressed in terms of the initial
boiling point (IBP) and the final boiling point (FBP).

 Importance: boiling range, especially the lower portion, is crucial for

Boiling Range

cold weather operability. Low-temperature volatility ensures that the

fuel remains liquid and can be easily atomized in cold conditions.
3
 Specification: 307-352oC is the FBP of diesel of 41:48 Cetane rated

 Performance effect: narrow boiling range can result in more

consistent combustion characteristics and better engine performance.
It may lead to improved ignition and combustion efficiency.
But extremely narrow boiling ranges may lead to challenges in
achieving reliable engine start-up, especially in cold weather.

5
  Definition: cetane rating of diesel fuel is a measure of its ignition
quality. It indicates how fast the fuel ignites under compression in a
diesel engine.

 Importance: Cetane rating is a crucial factor influencing the ignition

delay period.
Fuels with higher cetane ratings typically result in better combustion
efficiency, leading to smoother engine operation.
Cetane Rating

 Specification: Diesel fuel have wide range of Cetane rating from

4 41:55 depending on fuel properties and distillation process.

 Performance effect: Fuels with a high cetane rating generally result in

quick and efficient ignition, leading to improved combustion, reduced
emissions, and enhanced fuel efficiency.
But extremely high cetane ratings may have diminishing returns and
could lead to challenges in terms of other combustion characteristics.
Lower cetane fuels may be suitable for certain engines and conditions
but might lead to longer ignition delays and potentially less efficient
combustion, but may not deliver enough torque at high load-low speed
engines
 Definition: Density is a measure of the mass per unit volume of a substance, it
provides information about the compactness of the fuel.

 Importance: Density influences the calibration of the fuel injection

system. It affects the amount of fuel delivered per injection event, also
Density is related to the energy content of the fuel. Higher-density
Density

fuels generally contain more energy per unit volume

5
 Specification: Diesel density varies from 0.83 to 0.94 Kg/L

 Performance effect: Higher-density fuels can contain more energy per

unit volume, potentially leading to increased fuel efficiency and
longer driving ranges
Lower-density fuels may facilitate better fuel atomization, promoting
efficient combustion and reducing emissions.

6
  Definition: Refers to its ability to perform effectively in cold weather
conditions, especially at temperatures below the cloud point and the
cold filter plugging point.
Low Temperature Operability

 Importance: Engine start reliably in cold conditions. Low-temperature

operability ensures that the fuel remains fluid, preventing issues like
fuel filter clogging and fuel line blockages during engine start-up.

6  Specification: Diesel cloud point varies from 0:-55oC depending on

fuel quality, additives, and Cetane number

 Performance effect: Inadequate low-temperature operability can lead

to starting difficulties, reduced fuel flow, and potential engine
performance issues in cold weather, but over-reliance on additives
(like cold flow improvers)without considering fuel properties may not
fully address low-temperature operability issues.

7
 Task No. 2
1. Describe the function and operation of inline fuel injection system?

Figure 2.

Component
No. Description
Name

Figure 3.
Diesel Tank

 Function: Storage of diesel fuel and be, durable and secure to

1 withstand road conditions, impacts, and the safe containment of fuel.
 Types: traditional steel tanks, polymer tanks (polyethylene), and
composite tanks (fiberglass and plastics), aluminum alloy.
 Description: Constructed from materials that are resistant to
corrosion and can safely contain the fuel. Capacity can range from
small tanks for residential generators to large tanks must have 3 ports
at least : Fill, Transfer, and Return one of them must allow entrance of
air

8
 Figure 4.
Transfer Pump

 Function: Transfer of fuel from tank to the injection pump.

2  Types: Mechanical plunger (single and double room), vane, and gear
pump.

 Description: function of the feed pump is to lift or draw fuel from

the fuel tank and deliver it to the high-pressure pump or the fuel
injection system mechanical feed pumps, a diaphragm or plunger
mechanism is often used to create suction and discharge fuel. The
movement of these components is typically driven by a camshaft or
the injection pump. Including check valves to ensure a one-way flow
of fuel, preventing it from flowing back into the tank when the pump
is not operating.

9
 Figure 5.
 Function:
Diesel Filter

 Types: big particles (50:10 microns) – small particles (20:3 microns)

3 – water separator (using density differential)

 Description: Big particle filters, often referred to as primary or

coarse filters, are designed to capture larger particles and debris
present in the diesel fuel.
Small particle filters, also known as secondary or fine filters, are
designed to capture smaller particles that may have passed through the
big particle filter.
Water separator filters are designed to separate and remove water from
the diesel fuel. Water in the fuel can lead to microbial growth,
corrosion, and injector damage.

10
 Inline Injection Pump

Figure 6.
4  Function: increasing diesel fuel pressure and delivering the high
pressure fuel charge to the specific injector at the right time.

 Types: multi plunger inline pump, and single plunger pump (used in
common rail system)

 Description: In this type of inline pump, each cylinder has its own
individual plunger and fuel delivery valve. The plungers are driven by
a camshaft as the camshaft rotates, it causes the plungers to
reciprocate. During the compression stroke, fuel is drawn into the
cylinder, and during the power stroke, fuel is pressurized and injected
into the engine cylinder.

11
 Diesel Injector

Figure 7.
5
 Function: deliver a precise amount of atomized and pressurized fuel
into each cylinder.

 Types: Direct, indirect, [electronic, and piezoelectric] only in modern

engines

 Description: the injector uses the high pressure of diesel to push the
needle and start spraying pressurized fuel as pressure decreases the
needle spring pushes it to close the nozzle, any excess fuel returns to
tank throw return line.

12
 Low Pressure Line

6 Figure 8.
 Function: Carry fuel from tank to transfer pump and from injectors
to tank (return line) as in these cases the fuel is often at low or
medium pressure

 Description: they mostly made of hoses or tubes with flares at their

ends, must be suitable to withstand relative high temperatures and
vibrations
High Pressure Line

7 Figure 9.
 Function: Deliver high pressure fuel from injection pump to
injectors.

 Description: Heavyweight, or high pressure, fuel lines are usually

made of heavy-wall steel tubing and must be capable of handling high
fuel pressures.

13
2. Discuss the injection unit operation for inline pump, and High-pressure fuel
and distribution of distribution pump?
Inline Pump Distribution Pump

Figure 10.

Inline Pump Component

1. Plungers
Figure 13.
2. Hand priming pump
3. Timing pointer
Distribution Pump Component
4. Shut off screw and lever
1. Drive shaft
5. Idle stop screw
2. Distributer rotor
6. Aneroid (boost compensator)
3. Transfer pump
7. Throttle lever
4. Plungers
8. Governor housing
5. Cam ring
9. Governor
6. Hydraulic head
10. Cam shaft
7. Pressure regulator
11. Sliding rack
8. Governor
12. Delivery valves
9. Automatic advance
10. Housing
11. Metering valve

14
 injection unit High-pressure fuel and distribution

Figure 11.
Figure 14.

injection unit Component High-pressure fuel distribution Component

1. Delivery valve 1. Cam
2. Delivery valve spring 2. Distributer rotor
3. Inlet port 3. Discharge fitting
4. Plunger helix 4. Discharge port
5. Plunger 5. Discharge passage
6. Control sleeve 6. Pressure chamber (plunging)
7. Control arm 7. Charging passage
8. Return spring 8. Inlet port
9. Plunger seat 9. Transfer pump (vane)
10. Roller tappet 10. Metering valve
11. Cam lobe 11. Circular fuel passage (return)
12. Cam shaft 12. Plungers
13. Sliding rack and control rod
injection unit operation Discussion High-pressure fuel and distribution operation
Discussion

Figure 12.
Figure 15.

15
 The control rack or rod transmits the
governor action to the pumping plunger.
Each pump plunger is connected to a
control sleeve. The upper end of the
control sleeve has a gear segment installed
on it. The control rod teeth and gear
segment engage one another, It is possible
to adjust the fuel delivery for each plunger
by turning the control rod clamping
sleeve. Each plunger and barrel assembly
must be adjusted for equal delivery as the
pump plunger is turned by the control rod,
regulating the fuel delivery from shutoff
to maximum.
Fuel is supplied to the metering valve under low
pressure from a vane fuel transfer pump, through
a drilled hole in the hydraulic head. When the
metering port and the charging port align, fuel is
passed via the metering valve and head to the
rotor and pumping plungers. The quantity of fuel
is controlled by the governor and the throttle
lever. As the rotor rotates, fuel is isolated in the
rotor. The amount of fuel delivered to the
pumping plungers depends on the position of the
metering valve and its angular groove. If the
groove has a large part of the supply drilling
from the transfer pump covered, fuel delivery to
the pumping plungers during charging is light. If
the groove covers very little of the supply
drilling, a large amount of fuel will be delivered
to the pumping plungers during charging. As the
rotor continues to rotate, one of the distributor
ports aligns with one of the outlet ports. At this
point in the cycle, the plungers are brought
quickly together by the action of the cam ring
lobes and pressurized fuel is forced through high
pressure piping to the injector, the whole cycle is
repeated once for each engine cylinder per pump
revolution.
16
 3. Compare between Mechanical governor and Pneumatic governor in terms of
their modes of operation and levels of sensitivity at low and high-speed of CI
engine?
No. Terms Mechanical governor Pneumatic governor
Photo

Figure 16. Figure 17.

1. Plunger control sleeve

1. Throttle pedal
2. Rack spring
2. Throttle valve
3. Sliding rack (control rack)
3. Start/cut off lever
Component

4. Cut off lever

4. Vacuum chamber
5. Throttle lever
2 6. Cam shaft rod
5. Vacuum diaphragm
6. Diaphragm return spring
7. Fly weights
7. Atmospheric pressure chamber
8. Fly weights return spring
8. Sliding rack (control rack)
9. Air filters

17
  At low Speed: at engine start no
vacuum is present so the rack is at
 At low Speed: at engine start the
full fuel position
governor is in max fuel position
at low engine speed the throttle
affected by the spring but as the
valve is nearly closed increasing
engine starts the weights (moved by
vacuum which pulls control rack
centrifugal force from engine) start
away from cam decreasing the fuel
to counter spring force, thus
quantity if the load increases
moving the control rack and
(throttle valve starts to open) the
reducing fuel quantity when both
vacuum decreases returning the
forces balance engine speed
control rack to its position, thus
stabilizes. If engine load increases
increasing fuel quantity.
rpm will drop, thus reducing
operation

 At High Speed: at high speed and

centrifugal force and moving the
3 rack to increase fuel quantity until
low load (throttle 20:40%) the
vacuum is moderate, thus balancing
the forces balance.
against spring force which stabilizes
engine speed and fuel efficiency.
 At High Speed: as the engine speed
At high speed and high load (throttle
increases (centrifugal force) the fly
60:100%) vacuum is very low, thus
weights move away from camshaft
the spring moves the rack towards
decreasing the quantity of fuel until
the cam increasing fuel quantity to
the governor reaches rated speed,
meet the load demand.
but if the load increases (like
At High speed and no load (throttle
uphill) the throttle linkage will pull
100%) the vacuum is very high at the
the control rack against the weights
sub venture due to air speed moving
increasing fuel quantity.
the rack to decrease fuel quantity till
cutoff at engine rpm limit.
 Relatively simple design
Advantages

 Reliability  Higher accuracy

 Cost effective  Adaptive to changes in pressure
4
 Easy maintenance  Faster response
 Predicted response (linear to  Better fuel economy
engine load)
 Can’t be used in large engines due
to higher loads at low engine speeds,
Disadvantages

 Limited accuracy
thus increased demand of fuel
 Less adaptive
 Unpredictable response
5  Slow time of response
 More complex
 Fuel consumption issues
 Less reliable

18
 Sensitivity is the change in engine
speed necessary before the governor
begins making a change in the
amount of fuel delivered to the
Sensitivity

injectors. Sensitivity is often Pneumatic governors are more

expressed as a percentage. A responsive to changes in engine speed
6 governor that responds to a speed compared to mechanical governors
change of 3% is more sensitive than making them more sensitive.
one that requires a 6%
Mechanical governors have
sensitivity range of 3:8% making
them the slowest in response time

19
Compare between Supercharger and Turbocharger in terms of operation,
advantages, disadvantages and levels of sensitivity?
No. Terms Supercharger Turbocharger
Photo

Figure 18. Figure 19.

1. Exhaust inlet port

1. Inlet port 2. Exhaust outlet port
Component

2. Lobes 3. Exhaust turbine

Device

2 3. Rotors 4. Turbine to compressor rod

4. Housing 5. Air inlet port
5. Outlet port 6. Air outlet port
7. Intake compressor
1. The blower (super charger) 1. Turbo charger
Component

2. Air cleaner (filter) 2. Air cleaner

System

3. Intercooler (charge cooler) 3. Air to air charge cooler

3 4. Intake manifold
5. Driving belt
6. Belt pulley
As the engine rotates it drives the
supercharger pulley that moves the
Operation
4. Intake manifold
5. Exhaust manifold
6. Exhaust to turbo flange
The exhaust gases of the engine
rotates the turbine, which is

rotors, which suck in and connected to the compressor that

4 compresses the air to intake sucks and compresses air to intake
manifold throw the intercooler, manifold throw charge cooler,
thus increasing the amount of air, increasing the amount of air, and
and volumetric efficiency. volumetric efficiency.

20
  Increased power output
 Increased power output
Advantages
 Improved torque at low RPMs
 Improved fuel efficiency
 Better high altitude performance
5  Better altitude performance
 Better engine efficiency compared
 Down-seizing potential
to naturally aspirated
 Improved efficiency at high RPMs
 Instant response
 Increased mechanical load
 Complex system design
 More complex
Disadvantages

 High heat generation

 More cost
 Turbo lag at low RPMs
 Higher heat generation
6  Increased maintenance
 Increased fuel consumption at
 Increased mechanical stress (pistons
high loads
and exhaust valves)
 Limited efficiency at high RPMs

Slower response than super charger

The turbo lag is present at low RPM as
Very sensitive at low engine RPM
the exhaust gases is not spooling the
as it rotates with the engine and
Sensitivity

turbine fast enough to generate boost at

have nearly no lag in low speeds
the compressor
7 Super chargers start making
Most turbos start making considerable
considerable boost at engine idle
boost at 750 RPM and max boost at
575:650 RPM and max boost at
1200:1800 RPM and can be set reach
1200:1500 RPM
higher boost pressure by controlling the
waste gate

21
 References & Sources

Task Question References& Sources

1. DIESEL FUEL PROPERTIES AND CHARACTERISTICS.pdf
One 2. diesel fuel property.pdf (MDEC Conference Toronto, Ontario October, 2016) by Suncor
3. Personal research and lectures hand writing
Task No. (1)

1. DIESEL FUEL PROPERTIES AND CHARACTERISTICS.pdf

Two
2. Personal research and lectures hand writing
1. Abnormal Combustion Phenomenon - an overview | ScienceDirect Topics
Three 2. DIESEL FUEL PROPERTIES AND CHARACTERISTICS.pdf
3. Personal research and lectures hand writing
1. diesel fuel property.pdf (MDEC Conference Toronto, Ontario October, 2016) by Suncor
Four 2. DIESEL FUEL PROPERTIES AND CHARACTERISTICS.pdf
3. Personal research and lectures hand writing
1. Diesel Fuel Tank Design - PassageMaker
2. Fuel feed pump diesel engine : construction and working (theautotechnical.com)
3. Fuel Filter: A Detail Information on Fuel Filter Used In Diesel Engine (engihub.com)
One 4. Diesel Fuel Systems LEBW4976-08.pdf
5. Andrew Norman & John Corinchock - Diesel Technology_ Fundamentals, Service, Repair
(2014, Goodheart-Willcox) - libgen.li.pdf
6. Diesel Injection Systems.pdf
Task No. (2)

1. Andrew Norman & John Corinchock - Diesel Technology_ Fundamentals, Service, Repair
Two (2014, Goodheart-Willcox) - libgen.li.pdf
2. Personal research and lectures hand writing
1. Andrew Norman & John Corinchock - Diesel Technology_ Fundamentals, Service, Repair
(2014, Goodheart-Willcox) - libgen.li.pdf
Three 2. Diesel Injection Systems.pdf
3. Personal research and lectures hand writing
1. Andrew Norman & John Corinchock - Diesel Technology_ Fundamentals, Service,
Repair (2014, Goodheart-Willcox) - libgen.li.pdf
Four 2. What's the Difference Between Turbocharging and Supercharging? (jdpower.com)
3. Personal research and lectures hand writing

22