In the Name of Almighty, the Most

Beneficent, the Most Merciful and the Most

Gracious

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Welcome To
My
Presentation
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“A Study on Internal Combustion Engine at
Akij Cement Company Ltd”

Presented By
Name : Prince Sarker
ID : 14307004
Program : BSME

Department of Mechanical Engineering

IUBAT-International University of Business Agriculture
and Technology
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 Contents
• Objectives
• Limitation
• Company Overview
• Engine Operation
• Types of I.C. Engine
• Components of IC Engine
• Working principle of four Stroke petrol engine
• Valve Timing Diagram
• Engine Shut Down Procedure
• Turbocharger
• The Pollutants and Emission control
• Problem Findings
• Recommendation
• Conclusion

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Objectives
The objectives are
• To study about Internal Combustion Engine
• To study about every parts of IC engine
• To know about Engine Working principle
• To know about the concept of valve timing.
• To know about Turbocharger
• To know about various kinds of troubleshooting related to IC engine

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Limitation
In Akij Cement company there are some limitations. The limitations are stated
below:
• In absence of instructor to touch any machinery and equipment is strictly
prohibited.
• For safety purpose, they didn’t give to touch all parts also.
• All documents are not provide by admin to maintain their confidentiality.
• Sometimes or in some emergency cases they could not provide enough time due to
their business.
• All the departments of the company were not covered due to shortage of time.

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Akij Cement Company Ltd

• Akij Cement Company Ltd has a strong supply chain with a very well planned distribution network to
assure door to door supply of cement to the clients. All these quality and venture of Akij Cement Company
Ltd has made them one of the most emerging cement brand in Bangladesh. AKIJ has always operated and
continue to operate their businesses only on Quality with a deep rooted obligation to the Society. That is
why, AKIJ mean’s “The Full of Trust”.

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Mission:
“To actively contribute to the social and economic development of Bangladeshi Communities . In so
doing, build a better, sustainable way of life for the weaker sections of society and raise the country’s
human development index.”
Vision:
“To be the best in Quality, Trust & Services in Cement Industry.”

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Akij Power Generation Limited:

• Akij Power Generation ensured Continuous power supply of total 12 Mega Watt from gas driven of three
captive power generator to ensure smooth production. Hereafter, Akij Power generation reduced REB usage
in their plant .Though, the captive power generation requires high capital investment in the beginning, they
have built them to ensure customer service in-time.

Rolls Royce (6.7 MW) MWM (4.3 MW) Caterpillar(1.0 MW)

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Company profile of akij Power Generation Company Ltd.
• Owners : Akij Group
• Customer : 1.Akij Cement Company Ltd,
2. Akij Poly Fiber Industries Ltd,
3. Akij Flour Mills Ltd
• Workers : 1.Engineer (2)
2.Ass. Engineer (6)
3. Workers (7)
• Location : Kadam rasul, Bandor, Narayngonj
• Net Generation Capacity : 12 MW.
• Engine : 1.Rolls Royce (6.7 MW)
2. MWM (4.3 MW),
3. Caterpillar (1.0 MW)
• Type of Fuel : Natural Gas
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Organogrm:

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 Engine
• An engine is defined as a device which converts one form of energy into mechanical energy. A heat engine is a
machine, which converts heat energy into mechanical energy. The combustion of fuel such as coal, petrol, and diesel
generates heat. This heat is supplied to a working substance at high temperature. By the expansion of this substance in
suitable machines, heat energy is converted into useful work. Heat engines can further be divided into two types:

(i) External combustion and

(ii) Internal combustion.

External combustion Engine

An engine in which combustion of fuel take place outside of the cylinder is
known as EC engine.
In this type of engine heat, which is generated by burning of fuel is used to
convert the water or other low boiling temperature fluid into steam.
Fig : External combustion Engine
This high pressure steam used to rotate a turbine. In this engine we can use all
solid, liquid and gases fuel.
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Internal Combustion (I.C.) Engine:
 It is an engine in which combustion of fuel take place inside the engine.
 When the fuel burns inside the engine cylinder, it generates a high temperature
and pressure.
 In these engines we can use only gases and high volatile fuel like petrol.

Fig : Internal Combustion (I.C.) Engine

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Types of I.C. Engine:
a) According to number of stroke

b) According to design of engine

c) According to fuel used

d) According to method of ignition

e) According to number of cylinder

f) According to arrangement of cylinder

g) According to air intake process

h) Based on the type of cycle

Fig: Rolls Royce
i) Based on application

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Components of IC Engine

1) Cylinder Block:
• Cylinder is the main body of IC engine
• It is a container fitted with piston, where the fuel is burnt and power is
produced.
• The main function of cylinder is to guide the piston.
Fig: Cylinder cover(Rolls Royce)
2) Cylinder Head/Cylinder Cover:
• The main function of cylinder head is to seal the cylinder block and not
to permit entry and exit of gases on cover head valve engine.
• The inlet valve, exhaust valve, spark plug, injector etc are bolted on the
cylinder head.

Fig: Cylinder cover(MWM) 16

Components of IC Engine
3) Cylinder Bore:
• The bore or cylinder bore is a part of a piston engine.
• The value of a cylinder's bore, and stroke, is used to establish the displacement of
an engine.
• The bore also represents the size, in terms of diameter, of the cylinder in which a
piston travels.

4) Cylinder liner
• Cylinder liner is a cylindrical part to be fitted into an engine block to form a
cylinder.
These are main functions of Cylinder Liners
i. Formation of sliding surface
ii. Heat transfer
iii. Compression gas sealing Fig: Cylinder liner
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Components of IC Engine
5) Piston:
• Piston is used to reciprocate inside the cylinder.
Piston Rings
• The main function of piston is to give tight seal to the cylinder through bore
and slide freely inside of cylinder.
• Piston features include the piston head, piston pin bore, piston pin, ring
grooves, and piston rings.

6) Piston Rings:
• These are used to maintain a pressure tight seal between the piston and
cylinder walls .
• It transfer the heat from the piston head to cylinder walls.
• Sealing the combustion chamber.
• Improving heat transfer
Fig: Piston
• Types: compression ring, wiper ring, and oil ring

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Components of IC Engine
7) Connecting Rod:
• Connecting rod connects the piston to crankshaft
• Transmits the motion and thrust of piston to crankshaft.
• It transmits the reciprocating motion of piston to rotary crank.

8) Crank Shaft:
• To transform reciprocating motion in to a rotary motion.
• Converts the reciprocating motion of piston into rotary motion of crankshaft. Fig: Connecting Rod & Crank Shaft
• The shape and size depends on the number and arrangement of cylinders.

9) Cam Shaft:
• To control the opening and closing of valves at proper timing.
• For proper engine output inlet valve should open at the end of exhaust stroke
and closed at the end of intake stroke.
• It is drive by the timing belt which drives by crankshaft.
Fig: Camshaft 19
Components of IC Engine
10) Crank Case:
• In which the cylinder are attached and which contains the crankshaft and
crankshaft bearing is called crankcase.
• It is used to store the lubricating oil.
• All the oil for lubrication is placed in it.

11) Fly wheel:

• Fly wheel is a rotating mass used as an energy storing device.
• The main function of flywheel is to rotate the shaft during stroke.
• It also makes crankshaft rotation more uniform.

12 Poppet Valves:
• A device that regulates, directs or controls the flow of a fluid.
• Obstructing various passage ways.
Fig: Poppet Valves
• The intake and exhaust valves open at the proper time to let in air and fuel and to
let out exhaust. 20
Components of IC Engine

13) Spark Plug:

• To conduct the ignition system into the combustion chamber.
• A device designed to fit in each cylinder of a gasoline-powered internal-
combustion engine .
• To produce the electric spark for igniting the mixture of gasoline and air.

14) Engine Bearing:

• The crankshaft is supported by bearing. Fig: Spark Plug
• Bearings are used to support the moving parts.
• Its purpose is reduce the friction .
• Allow parts to move freely.

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Components of IC Engine
15) Governor:
• A governor, or speed limiter or controller.
• A device used to measure and regulate the speed of a machine
• The function of a governor is to control the fluctuations of engine speed due to
changes of load.

Mechanical Governor Working procedure:

• It has two balls of equal weights attached to the arms of the Governor. These balls
called Governor Balls Fig: Governor
• These balls revolve when spindle of governor rotates.
• This makes the ball to move up and down while rotating
• The lower side arms are linked to the sleeve which revolves along with the spindle.
• When speed increases the sleeve goes upward and tends to go downwards with the
decrease in speed.
• This mechanism controls the fuel supply appropriately
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Components of IC Engine

16) Carburetor:
• It converts petrol in fine spray and mixes with air in proper ratio.
• The function of a carburetor is to atomize and meter the liquid fuel mix it with
the air as it enters the induction system of the engine.
• Maintaining fuel-air proportion

17) Fuel Atomizer or Injector:

• Fuel injection is a system for mixing fuel with air in an internal combustion Fig: Carburetor
engine.
• The primary fuel delivery system used in automotive petrol engines
• The power to inject the fuel comes from a pump or a pressure container.

Fig: Fuel Atomizer 23

Components of IC Engine
18) Manifold:
• The main function of manifold is to supply the air fuel mixture and
• Collects the exhaust gases form all cylinder.
• In an IC engine two manifold are used, one for intake and other for exhaust.

Fig : Inlet and exhaust manifold (Rolls Royce engine, MWR & Caterpilar)

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Components of IC Engine
19) Gudgeon pin or piston pin:
• It connects the piston to connecting rod.
• It is made hollow for lightness.
• These are hardened steel parallel spindles fitted through the piston.

20) Pushrod:
• Pushrod is used when the camshaft is situated at the bottom end of cylinder.
• It carries the camshaft motion to the valves which are situated at the cylinder head.

21) Rocker Arm:

• Rocker Arms are typically in between the pushrod and the intake and exhaust
valves.
• They allow the pushrods to push up on the rocker arms.
• And therefore push down on the valves.
Fig : Rocker arm
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Components of IC Engine
22) Valves:
• To allow the air fuel mixture to enter into the cylinder or the exhaust
gases to escape from the cylinder
• Valves are provided, known as inlet and exhaust valves respectively.
• In gas engine gas valve also used.

Function of the valves::

The valves in an engine have numerous functions.
 First, they must permit the intake of fuel and air.
 Then they must seal compression.
 After the explosion the exhaust valve must permit the burned gases.
 And then leaving the combustion chamber.

Fig : Rolls Royce- inlet, exhaust and gas

valves
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Components of IC Engine

Figure:1 Figure:2

Fig : 1) Rolls Royce- inlet, exhaust and gas valves

2) Caterpillar & MWM (inlet and exhaust valves)
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Components of IC Engine
23) Relief valve:
• A valve used to control or limit the pressure in a system.
• The relief valve is designed or set to open at a predetermined set pressure to protect pressure vessels.
Function of relief valve in Engine:
• Pressure relief valves are used in hydraulic systems to limit the system pressure
• The pressure relief valve responds and feeds the excess flow from the system
• The pressure relief valve is a normally closed pressure control valve.

1 2

Fig : Relief valve 1) Rolls Royce. 2) MWM 28

Components of IC Engine
24) Silencer:
• To suppress that unbearable sound
• Controls the flowing direction of the high pressure exhaust gases.
• And release them into the atmosphere in such a manner so that minimum noise is produced.
Function of a silencer:
• A muffler or a silencer is a device for decreasing the amount of noise emitted by the exhaust
of an internal combustion engine.

27) Pre-chamber
• A pre-chamber in an engine is a small area, usually in the cylinder head.
• In which combustion is started before fuel enters into the main combustion chamber.
• The combustion chamber is divided into a pre-chamber and a main chamber.

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Components of IC Engine
25) Tappet:
• It is most commonly encountered as a maintenance task for overhead valve engines
• ‘Adjusting the tappets', the tappet, also termed a cam follower, or valve lifter, is that part that runs on the camshaft.

Tappet clearance and its importance:

• Clearance between the rocker arms and the point where they rest on the valves.
• The clearance increases the valve will open late and close early
• If the clearance decreases the valve will open early and close late.

Fig 3.20: Engine Tappet clearance

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Components of IC Engine

26) Gasket:
• A seal which fills the space between two or more mating surfaces,
• To prevent leakage from or into the joined objects while under compression.

Different uses for Gaskets:

1. Sealing:
2. Environmental Seals
3. Anti-Vibration

Head gasket:
• A sealant between the engine block and head .
Fig : Gasket
• Some engines use liquid head gaskets.

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Components of IC Engine
27) Valve spring:
• A coil spring used to hold the valve.
• Its strong enough to keep the lifter in contact with the camshaft lobe.
• To maintain contact between cam follower and cam lobe .

Main purpose of valve spring:

• In controlling the breathing in internal combustion engines.
• Lifting the weight of the valve. Fig : Valve spring
• Valves are closed by the valve springs.

28) Valve seat:

• The surface against which an intake or an exhaust valve rests during
the portion of the engine operating cycle when that valve is closed.
Fig :Valve seat

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Components of IC Engine

29) Vibration damper:

• A device fitted to the free (accessory drive) end of the crankshaft
• To counter torsional and resonance vibrations from the crankshaft.
• Fit to the crankshaft in order to operate in an effective manner.

30) Fan:
• To increase air flow through the radiator
• To increase air flow through the engine compartment. Fig :Vibration damper

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Materials used for engine parts:
SL. Name of the Parts Materials of Construction
1. Cylinder head Cast iron, Aluminium
2. Cylinder liner Cast steel, Cast iron
3. Engine block Cast iron, aluminium, Welded steel
4. Piston Cast iron, Aluminium alloy
5. Piston pin Forged steel, Casehardened steel.
6. Connecting rod Forged steel. Aluminium alloy.
7. Piston rings Cast iron, Pressed steel alloy.
8. Connecting rod bearings Bronze, White metal.
9. Main bearings White metal, Steel backed Babbitt base.

10. Crankshaft Forged steel, Cast steel

11. Timing gears Cast iron, Fiber, Steel forging.

12. Push rods Forged steel.

13. Engine valves Forged steel, Steel, alloy.
14. Valve springs Carbon spring steel.
15. Manifolds Cast iron,
16. Crankcase Cast iron, Welded steel
17. Flywheel Cast iron.
18. Studs and bolts Carbon steel.
19. Gaskets Cork, Copper, Asbestos.
20. Camshaft Forged steel, Cast iron, cast steel, 34
Working principle of four Stroke petrol engine:
The four stroke-cycles refers to its use in petrol engines, gas engines, light oil engine and heavy oil engines in which
the mixture of air fuel are drawn in the engine cylinder. Since ignition in these engines is due to a spark, therefore
they are also called spark ignition engines.

Fig 3: Four stroke cycle petrol engine 35

 Working principle of four Stroke petrol engine:

Piston Piston rod

Crankshaft

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Working principle of four Stroke petrol engine:

Camshaft

Valves

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Working principle of four Stroke petrol engine:

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Working principle of four Stroke petrol engine:

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Working principle of four Stroke petrol engine:

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Working principle of four Stroke petrol engine:

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Working principle of four Stroke petrol engine:

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Valve Timing Diagram

Fig : Valve timing Diagram 43

Ventilation Fan
• The ventilation fan is used to keep the engine room cool.
• There are two engine rooms with Three engines.
• There are 4 fans to keep an engine room air circulating with atmosphere.
• The power required to drive the fan is taken from the generating power of the unit.
• Only a small portion is used for this purpose.

Fig : Ventilation Fan

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 All Three types of generator at akij power plant

Rolls Royce MWM Caterpillar

16 Cylinder engine 16 Cylinder engine 16 Cylinder engine
Cooling System: radiator closed Open + Closed circuit river cooling Open+ Closed circuit river cooling
circuit
Air Enter from Manifold & Gas + Air mixing entering cylinder Gas + Air mixing entering cylinder
Gas entering in cylinder
Oil bath filtration system Combination Of oil and Air bath Air filtration system
filtration system
Governor: Mechanical &Electrical Electrical Governor Electrical Governor
both
Pressure: 3.5 bar (1 bar=14.5 psi). Pressure: 1.5 psi Pressure: 0.5 psi
Low R.P.M (750) Medium R.P.M(1000) High R.P.M.(1400)
Turbocharger used with VTG Turbocharger used Turbocharger used
Coolant: Nel Fel 2000 & Nelco Nel Fel 2000 & Nelco 7330 Catelli
7330 45
Turbocharger
• It increases the amount of air entering the engine to create more power.
• A turbocharger has the compressor powered by a turbine.
• The turbine is driven by the exhaust gas from the engine. It does not use a direct mechanical drive.

Fig : Turbocharger line of Rolls Royce

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Turbo charger working procedure:

Fig : Turbo charger working system 47

Turbo charger working procedure:

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Turbo charger working procedure:

Turbine Wheel

Exhaust gas
Compressor Wheel

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Turbo charger working procedure:

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Turbo charger working procedure:

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Turbo charger working procedure:

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Turbo charger working procedure:

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Engine Shut Down Procedure
In the case of any emergency, where we need to shut down the engine,
we need to consider,
• lubricating oil system,
• waste heat recovery unit,
• synchronization with REB

For manually shut down the plant

• First we need to cut off the power supply from REB
• Then closing VCB line.
• Next the main fuel supply should be gradually turned off using the governor control.
• Then, the turbine rpm will start to decrease.

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Losses in internal combustion Engine
During the operation of the internal combustion engines only a fraction of the chemical energy is
converted into mechanical work. The "lost work" can mainly be attributed to the following:

1. Heat loss:
• The heat loss of the hot burned gases, which occurs during combustion and expansion.
2. Mass loss:
A fraction of the high pressure unburned gases flows from the combustion chamber into the
crankcase (blow by) thus
• The cylinder pressure drops and
• The output work decreases
3. Incomplete combustion:
• The exhaust gases usually contain unburned particles (H2, CO, CH) carrying a fraction of the fuel's
chemical energy.

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Losses in internal combustion Engine
4. Friction:
The most significant source of this loss is the friction between
• the piston skirt,
• rings and
• the cylinder.
The other sources of frictional losses are
• the crankshaft, camshaft,
• valve mechanism,
• gears,

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The Pollutants and Emission Control:
The Pollutants:
The SI engines have several pollution emitting sources (e.g.: exhaust pipe, crank shaft, brake system, etc. The
exhaust pipe emission is the most important. The major polluting materials within the exhaust gases are the
following:
1. Unburned hydrocarbons (CH):
• It damages the brain cells and the breathing organs.
• It is the result of the lack of oxygen or the uncompleted combustion process.
2. Carbon monoxide (CO):
• The inhalation of this gas can cause suffocation.
• It is the result of the lack of oxygen or the uncompleted combustion process.
5. Carbon dioxide:
• This is a so called "hot house gas", experts state that this gas is one of those which are responsible for
the global warming.
4. Heavy metals :
• The lead is responsible for several diseases, damage the brain and lethal in big dose.
• Most of the fuels contain lead originated from the crude oil and some fuels containing lead as an additive, which
reduces the knock phenomenon.
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The Pollutants and Emission Control:
The Emission:
1.Design of the combustion process
Combustion chamber
• The surface of the combustion chamber cools the flame
• Thus the smaller surface to volume ratio the combustion chamber has the lower CH emission occurs.
• The higher turbulence causes faster flame propagation and reduced combustion time. Therefore less thermal NO
is produced.

2. Optimization the operating parameters

The following parameters have the strongest influence on the exhaust emissions:
• - Fuel - air ratio
• - spark advance

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The Pollutants and Emission Control:
3. After treatment
The catalytic conversion is the most common after treatment. The converters are called catalysts. Within the
catalyst the NO is converted to N2 and O2 by CO and CH which are transformed to CO2 and H2O.
Classification of catalyst systems:
- Closed loop system
•There is an oxygen sensor built in the exhaust pipe which controls the injection to keep the air to fuel
equivalence ration within the limits for satisfactory conversion.
- Open loop system
•There is no feedback in the system. This is cheaper but its conversion efficiency generally is significantly lower
than using the closed loop system.
4. Special techniques.
•The exhaust gas recycling (EGR) is one of these techniques.
It is found that about 15% recycled exhaust gas gives the best achievable emission reduction.

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Problem Analysis and Solution
SL Problem Analysis Solution
1. Cylinder Temperature Engine pre-chamber ball is lock and Adjusting the ball and spark plug
Deviation. Spark Plug damaged. changed
2. Cylinder temperature Turbocharger temperature is high, Air Turbocharger motor and air flow line
low. flow is not working. checking.
3. Engine start failure. Staring motor pressure control module Pressure control module maintenance.
don’t work.
4. Exhaust temperature After open cylinder cover and observing All spark plug gap adjust with Pre-
(cylinder) deviation. all thing we see Spark plug gap increases. chamber ball change.

5. Engine is not taking Engine Governor Calibration and charger Maintenance calibration and charger
load. cooler damaged. cooler replace.
6. Engine Vibration. Engine vibrations happens due Checking combustion lines and
combustion problems, Vibration damper maintenance it. Vibration damper and
problems, ball bearings failure etc. bearing replaced

7. Knocking Alarm in Engine Spark plug damaged. Just Spark Plug changed for this case.
engine.
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Recommendation

• Students must complete the courses related to their internship before beginning the program.
Completing the related courses before the internship helps the students to understand the topic
better.

• During training period there may be any fault in the general activities of power plant. It is
necessary to learn about fault and how the engineers repair the faulty part. Students should visit
that faulty section and should try to get a brief lecture on that fault from their Organizational
supervisor.

• If there is a rotation system in the internship program then the learning scope of the interns would
be greater.

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Conclusion:
We realized that theoretical knowledge and practical knowledge are not same. As my own interest, our one
of the major academic side is power and I also interested to do job in power sector. In Akij Power
Generation Company under Akij Cement Company Limited they are not giving only knowledge about
mechanical field but also gave other practical things like how to maintain a power plant discipline, safety
rules which will help in our job life. We also learnt how to work under pressure which will also help our
future life.

Internal combustion engines are among the most important engineering applications. They are categorized
either according to the operating cycle, or due to the mechanism of working.

We passed very interesting 12 weeks in Akij cement company Ltd (power Plant). Because there was chance
to achieve a new knowledge in every moment. The ACCL officer’s behavior was very friendly which is very
essential to make a comfortable environment in working place. At last i think ACCL is very good place for
internship program
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Thank You
Everyone

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