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INSTRUCTION MANUAL
FOR
FOUR STROKE FOUR CYLINDER
PETROL ENGINE TEST RIG

Manufactured by:

ROORKEE EQUIPMENT & MODELS L PVT TD

Factory : C-18 Ram Nagar Industrial Area, Ram Nagar
Roorkee Distt-Haridwar,
Roorkee-247 667.
Email: rempvtltd@yahoo.in , remtender007@gmail.com
Website: www.rempvtltd.com
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FOUR STROKE 4 CYLINDER PETROL ENGINE TEST RIG

(With Rope Brake Dynamometer)

INTRODUCTION
Four stroke four cylinder Petrol Engine are widely used in light automobiles vehicles
e.g. In passenger cars. These engines are based on Otto cycle and also called spark
ignition engine. Because ignition takes place because of spark produced by spark
plugs. In case of four cylinder engines battery or coil ignition system is used to fire with
firing orders of 1,4,3,2 or 1,3,4,2. Engine are required to be tested mainly for two
purposes – Firstly on a 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 four stroke four cylinder petrol engine mounted over a
sturdy frame. Loading arrangement used is rope brake dynamometer which is coupled
to engine. A digital multichannel temperature indicator measures temperatures at
various points. Various measurements provided enables to evaluate the performance
of the engine at various loads.
Morse test can be performed on this engine.

SPECIFICATIONS
1. Engine : Four stroke four cylinder water cooled petrol engine developing 10.00
HP at 1500 RPM.
2. Rope Brake Dynamometer : Two spring balances - One fixed and another
adjustable. Diameter of Brake Drum = 0.266 m. Radius of Brake Drum = 0.133 m.
3. Measurements :
A) Calibrated fuel burette for fuel consumption measurement.
B) Orificemeter, fitted to air inlet tank with water manometer for air intake
measurement.
C) Multichannel Digital Temperature Indicator for temperatures at various
points.
D) Exhaust gas calorimeter to measure heat carried away by exhaust gases.
4. Performance of Morse Test : Electric switch is provided to cut the spark plug to
perform Morse test.
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EXPERIMENTAL PROCEDURE
1. Fill-up sufficient petrol in petrol tank.
2. Check oil level in the engine. It should be upto the top edge of t he flat portion
provided over the oil dipstick. If oil level is reduced, add up clean SAE-40 Oil to
the crank case by opening the valve cover at the top of the engine. Replace the
cover after filling the oil.
3. Fill-up water in manometer upto half of the manometer height.
4. Start the water supply and see that water is flowing through engine jacket,,
exhaust calorimeter.
5. There should be no load on engine.

6. Start the engine by using the ‘Self’ starter.

7. As the engine pickups the speed, apply load on engine and note the reading of both
the spring balances
9. Open burette filling cock, take sufficient petrol in burette and close the cock.

10. Now, turn selector cock to “BURETTE” position and note down time required for 10
ml. Fuel consumption.
11. Note down the speed with tachometer (tachometer is not supplied alongwith the
unit) and manometer difference.
12. Note down jacket cooling water and calorimeter water flow rates
13. Repeat the experiment for different loads and complete the observation table.
14. Performance of Morse Test : This test is applicable to multi-cylinder engine. The
engine is run at required speed and the torque is measured. One cylinder is cut-
out by shortening the spark plug. The speed falls because of loss of power with
one cylinder cut-out but is restored by reducing the load. The torque is measured
again when the speed has reached its original value. If the value of IP of cylinder
is denoted by I1, I2, I3, I4 . (Considering a four cylinder engine). Then these values
are calculated as below :
IP. of 1st Cylinder IP1 = BP -(BPn-1)

I.P. of 2nd Cylinder IP2 = BP -(BPn-1)

I.P. of 3rd Cylinder IP3 = BP -(BPn-1)

I.P. of 4th Cylinder IP4 = BP -(BPn-1)

I.P. of engine IP = IP1 + IP2 + IP3 + IP4

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OBSERVATION TABLE
Sr. No. 1 2 3 4

Load L, Kg W = (W1 – w2) 18 – 3 = 15

Time for 10 ml. Fuel tf, sec 28

Manometer diff, hw, cms 15.6–11 =5.6

Time for 1 lit calorimeter water, tc, sec 32

Time for 1 lit jacket water tj, sec 28

Water inlet temp, T1 24

Water output from calorimeter temp. T3 48

Water output from engine jacket temp T2 46

Exhaust gas outlet from engine 168

(before calorimeter) temp T4

Exhaust gas outlet from calorimeter 77

Temp. T5

RPM 1152
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CALCULATIONS

1. Brake Power
2  N.T.

BP = ------------- KW

1000 x 60

Where,

N = speed/rpm

T = torque, N-m

T = W x g x (D+d)/2

D = Radius of Drum = 0.30 meter

d = diameter of rope = 0.10 meter

T = W x g x (D+d)/2

2. Heat Equivalent to BP
HBP = BP x 3600 KJ/hr.

3. Fuel Consumption
Let time required for 10 ml. Fuel to Tf sec. And density of petrol is 0.7 gms/cc.

10 3600

FC = ---- x ------- x 0.7 kg/hr.

tf 1000

4. Heat supplied by fuel :

HF = FC x 45208 KJ/hr

Where, calorific valve of petrol is 45208 KJ/kg.

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5. Heat carried away by jacket cooling water.

HJW = m. CP. T

Where,

m = mass flow rate of water, kg/hr.

CP = Specific heat of water = 4.18 KJ/kg.

T = temperature rise of jacked cooling water = T3 – T1

6. Heat carried away by exhaust gases.

From the heat balance of the calorimeter.

Heat given by exhaust gases in calorimeter = Heat gained by water.

 meg. Cpeg. (T4 – T5) = mWC. CpWC. (T2 –T1)

mwc. Cpwc. (T2 – T1)

 meg.Cpeg = -------------------------------

(T4 – T5)

where

meg = mass flow rate of exhaust gases.

Cpeg = Specific heat of exhaust gases.

Mwc = mass flow rate of calorimeter water.

Cpwc = specific heat of water.

Hence, we can state that heat carried away by exhaust gases, on ambient
temperature basis.
Heg = meg. C peg. (T4 – T1)

7. Heat loss by radiation and unaccounted losses, is taken as difference.

Hua = HF – (HBP + HJW + Heg)
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8. HEAT BALANCE SHEET

Credit Debit

Heat 100% Heat equi to BP

supplied
Heat equi to Hjw
by fuel
Heat equi to Heg

Unaccounted heat

Total
100% Total

9. Specific fuel Consumption

FC

SFC = ---- = Kg/kw hr.

BP

10. Air Consumption

Air head across orifice

hw

Ha = ----- (1000 - a)

100

Where, hw is in cm

Where a = density of air

Or a = -----------
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287 x T

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

T = absolute ambient temp. in K.

Mass flow of air,

ma = 0.62 x 4.9 x 10-4  2 g ha x 3600 x a

where,

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

Dia of orifice = 25 mm

11. Air Fuel Ratio

ma

AFR = -------

FC

PERFORMANCE OF MORSE TEST

12. I.P. of 1st Cylinder IP1 = BP -(BPn-1)

13. I.P. of 2nd Cylinder IP2 = BP -(BPn-1)

14. I.P. of 3rd Cylinder IP3 = BP -(BPn-1)

15. I.P. of 4th Cylinder IP4 = BP -(BPn-1)

16. I.P. of engine IP = IP1 + IP2 + IP3 + IP4

17. Frictional power = IP – BP

18. Heat Equivalent to I P :

HIP = IP x 3600 x KJ/hr.

19. Mechanical efficiency

BP
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m = ---- x 100%

IP

20. Brake thermal efficiency :

Heat in BP

BT = ----------------------------- x 100%

Heat supplied by fuel

21. Indicated thermal efficiency

HIP

IT = ------ x 100%

HF

GRAPHS
Plot the graphs of BP Vs efficiency, SFC and FC.

PRECAUTIONS

1. Before starting the engine, oil level in sump and jacket cooling water supply must
be checked.

2. Never stop the engine on load and never use decompression lever for stopping.

3. Do not tamper with any of engine settings, like governor etc.

Note : Tachometer and barometer are to be made available by the customer and are not
supplied with the Test Rig.

CALCULATIONS
1. Brake Power
Where,

N = speed/rpm

T = torque, N-m
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T = W x g x (D+d)/2

D = Diameter of Drum = 0..30 meter

d = diameter of rope = 0.1 meter

T = W x g x (R+L) = 15 x 9.81 x 0.320 = 47.08

2  N.T. 2 x 3.14 x 1152 x 47.08

BP = ------------- KW = ------------------------------------ = 5.6 KW

1000 x 60 60000

2. Heat Equivalent to BP
HBP = BP x 3600 KJ/hr. = 5.6 x 3600 = 20160 KJ/hr

8. Fuel Consumption
Let time required for 10 ml. Fuel to Tf sec. And density of petrol is 0.7 gms/cc.

10 3600 36000

FC = ---- x ------- x 0.7 kg/hr. = ------------------ x 0.7 = 0.9 kg/hr

tf 1000 28 x 1000

9. Heat supplied by fuel :

HF = FC x 45208 KJ/hr = 0.9 x 45208 = 40687.20 KJ/hr

Where, calorific valve of petrol is 45208 KJ/kg.

9. Specific fuel Consumption

FC 0.9

SFC = ---- = Kg/kw hr. = ------------- = 0.120 Kg/kw hr

BP 5.6

10. Air Consumption

Air head across orifice

hw

Ha = ----- (1000 - a)

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100

Where, hw is in cm

Where a = density of air

Or a = -----------

287 x T

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

T = absolute ambient temp. in K.

Mass flow of air,

ma = 0.62 x 4.9 x 10-4  2 g ha x 3600 x a

where,

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

Dia of orifice = 25 mm

11. Air Fuel Ratio

ma

AFR = -------

FC

10. Heat carried away by jacket cooling water.

Where,

m = mass flow rate of water, kg/hr.

3600 3600

m = ------- kg/hr. = ----------- = 128.57 kg/hr

tJ 28

CP = Specific heat of water = 4.18 KJ/kg.

T = temperature rise of jacked cooling water = T2 – T1

HJW = m. CP. T

= 128.57 x 4.18 x (48 – 24) = 12898.28

11. Heat carried away by exhaust gases.

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From the heat balance of the calorimeter.

Heat given by exhaust gases in calorimeter = Heat gained by water.

 meg. Cpeg. (T4 – T5) = mWC. CpWC. (T3–T1)

mwc. Cpwc. (T3 – T1) 112.5 x 4.18 x (46 – 24)

 meg.Cpeg = ------------------------------- = -------------------------------- = 113.69

(T5 – T4) ( 168 -77 )

where

meg = mass flow rate of exhaust gases.

Cpeg = Specific heat of exhaust gases.

Mwc = mass flow rate of calorimeter water. = 3600 / 32 = 112.5

Cpwc = specific heat of water = 4.18 KJ/kgoK

Hence, we can state that heat carried away by exhaust gases, on ambient
temperature basis.
Heg = meg. C peg. (T4 – T3) = 113.69 x ( 77– 46 ) = 3524.39

12. Heat loss by radiation and unaccounted losses, is taken as difference.

Hua = HF – (HBP + HJW + Heg) - HF

= ( 25560 + 12898.28 + 3524.39) - 40687.20

= 41982.67 – 40687.20 = 1295.47

8. HEAT BALANCE SHEET

Credit Debit

Heat 100% Heat equi to BP 25560.00 59.06 %

supplied Heat equi to Hjw 12898.28 29.80 %
by fuel Heat equi to Heg 3524.39 8.15 %
Unaccounted heat 1295.47 2.99 %
Total 100% Total 43278.14 100 %
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PERFORMANCE OF MORSE TEST

12. I.P. of 1st Cylinder IP1 = BP -(BPn-1)

13. I.P. of 2nd Cylinder IP2 = BP -(BPn-1)

14. I.P. of 3rd Cylinder IP3 = BP -(BPn-1)

15. I.P. of 4th Cylinder IP4 = BP -(BPn-1)

16. I.P. of engine IP = IP1 + IP2 + IP3 + IP4

17. Frictional power = IP – BP

18. Heat Equivalent to I P :

HIP = IP x 3600 x KJ/hr.

19. Mechanical efficiency

BP

m = ---- x 100%

IP

20. Brake thermal efficiency :

Heat in BP

BT = ----------------------------- x 100%

Heat supplied by fuel

21. Indicated thermal efficiency

HIP
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IT = ------ x 100%

HF