Engine Operation

Four Cycle
Engine Theory

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Component Identification

Cylinder Liner

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Component Identification

Cylinder Liner

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Component Identification

Crosshatch

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Component Identification

Cylinder Head

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Component Identification

Intake & Exhaust

Valves

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Component Identification

Camshafts, lifters
Push Rods, Rocker Arms

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Component Identification

Cylinder Head
Assembly

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Component Identification

Piston

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Component Identification

Piston

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Component Identification

Connecting Rod

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Component Identification

Connecting Rod

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Component Identification

Spark Plug

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Component Identification

Spark Plug

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 4 STROKES OF A 4 CYCLE ENGINE
INTAKE VALVE OPENS
17 DEG. BTDC TDC
0 deg. 360 deg. 720 deg.

IGNITION AT APPROX.
10 DEG. BTDC.

EXHAUST VALVE
OPENS 47 DEG. BBDC

EXHAUST VALVE
CLOSES 20 DEG.
ATDC
AIR AND FUEL ENTER
POWER CYLINDER
ON INTAKE STROKE

INTAKE CLOSES 50 DEG. ABDC

180 deg. 540 deg.
BDC
“From The Wellhead Through The Pipeline…Hanover People Perform.”
 4 STROKES OF A 4 CYCLE ENGINE
INTAKE VALVE OPENS
17 DEG. BTDC TDC
0 deg. 360 deg. 720 deg.

IGNITION AT APPROX.
10 DEG. BTDC.

EXHAUST VALVE
OPENS 47 DEG. BBDC

EXHAUST VALVE
CLOSES 20 DEG.
ATDC
AIR AND FUEL ENTER
POWER CYLINDER
ON INTAKE STROKE

INTAKE CLOSES 50 DEG. ABDC

180 deg. 540 deg.
BDC
“From The Wellhead Through The Pipeline…Hanover People Perform.”
 Intake Stroke

•Air and fuel enter

the power cylinder

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Air & Fuel Induction
INTERCOOLER
C
O
O
L
A TURBOCHARGER
N
T

FROM FILTER

WASTEGATE

BUTTERFLY
VALVE

CARB

FUEL
REGULATOR

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Intake Stroke

•Cylinder full of
air and fuel

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 4 STROKES OF A 4 CYCLE ENGINE
INTAKE VALVE OPENS
17 DEG. BTDC TDC
0 deg. 360 deg. 720 deg.

IGNITION AT APPROX.
10 DEG. BTDC.

EXHAUST VALVE
OPENS 47 DEG. BBDC

EXHAUST VALVE
CLOSES 20 DEG.
ATDC
AIR AND FUEL ENTER
POWER CYLINDER
ON INTAKE STROKE

INTAKE CLOSES 50 DEG. ABDC

180 deg. 540 deg.
BDC
“From The Wellhead Through The Pipeline…Hanover People Perform.”
 Compression Stroke

•Air and fuel get

compressed into
smaller volume

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Ignition

•Air and fuel ignite

at prescribed deg.

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Start of Combustion

•Air and fuel

start to burn

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Breakdown of Total Thermal Energy (Heat)
Generated by Combustion

Flywheel BHP = 39%

Radiation = 1%

Oil = 4%

Intercooler = 10%

Exhaust = 30%

Jacket Water = 16%

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 4 STROKES OF A 4 CYCLE ENGINE
INTAKE VALVE OPENS
17 DEG. BTDC TDC
0 deg. 360 deg. 720 deg.

IGNITION AT APPROX.
10 DEG. BTDC.

EXHAUST VALVE
OPENS 47 DEG. BBDC

EXHAUST VALVE
CLOSES 20 DEG.
ATDC
AIR AND FUEL ENTER
POWER CYLINDER
ON INTAKE STROKE

INTAKE CLOSES 50 DEG. ABDC

180 deg. 540 deg.
BDC
“From The Wellhead Through The Pipeline…Hanover People Perform.”
 Power Stroke

•Combustion causes
pressure which
pushes piston down

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Power Stroke

•Combustion/power
ends approximately
40-60 deg. ATDC

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Engine P.V. Card
PRESSURE, PSIA

START OF
COMBUSTION END OF COMBUSTION

Pressure
IGNITION
SPARK

Volume

30 TDC 30 60
TIME, DEGREES OF CRANKSHAFT ROTATION

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 NORMAL
COMBUSTION

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Compression

•Air and fuel is

compressed

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Flame-front Starts

•Flame-front starts
at source of ignition

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Flame-front Spreads

•Flame-front spreads
toward the un-burned
fuel (end gases)

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Flame-front Spreads

•The flame-front
progresses toward
end gases

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 End of Combustion

•End of flame-front
and combustion

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 4 STROKES OF A 4 CYCLE ENGINE
INTAKE VALVE OPENS
17 DEG. BTDC TDC
0 deg. 360 deg. 720 deg.

IGNITION AT APPROX.
10 DEG. BTDC.

EXHAUST VALVE
OPENS 47 DEG. BBDC

EXHAUST VALVE
CLOSES 20 DEG.
ATDC
AIR AND FUEL ENTER
POWER CYLINDER
ON INTAKE STROKE

INTAKE CLOSES 50 DEG. ABDC

180 deg. 540 deg.
BDC
“From The Wellhead Through The Pipeline…Hanover People Perform.”
 Exhaust Stroke

•Spent air and

fuel (exhaust)
remain in cylinder

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Exhaust Stroke

•Exhaust is pushed
out of cylinder

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Valve Overlap

•Scavenging during
“Valve Overlap”

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Intake Starts Again

•Cycle starts again

Click Here To Animate

“From The Wellhead Through The Pipeline…Hanover People Perform.”

THE AIR/FUEL RATIO IS ONE OF THE
FACTORS THAT DETERMINE THE
HORSEPOWER OF THE ENGINE

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Air & Fuel System
INTERCOOLER
C
O
O
L
A TURBOCHARGER
N
T

FROM FILTER

WASTEGATE

BUTTERFLY
VALVE

CARB

FUEL
REGULATOR

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 THE RICHER THE MIXTURE, THE MORE
HEAT ENERGY PRODUCED.
(UNTIL THERE IS NOT ENOUGH OXYGEN TO SUPPORT
COMBUSTION)

MORE HEAT ENERGY = MORE CYLINDER

PRESSURE = MORE HORSEPOWER

“From The Wellhead Through The Pipeline…Hanover People Perform.”

THE LEANER THE MIXTURE, THE LESSER
THE HEAT ENGERGY PRODUCED.
(UNTIL THERE IS NOT ENOUGH FUEL TO SUPPORT
COMBUSTION)

LESS HEAT ENERGY = LESS CYLINDER

PRESSURE = LESS HORSEPOWER

“From The Wellhead Through The Pipeline…Hanover People Perform.”

WHAT IS A RICH BURN ENGINE ?

“From The Wellhead Through The Pipeline…Hanover People Perform.”

WHAT IS A LEAN BURN ENGINE ?

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 STOICHIOMETRIC?

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Pollutants

AIR AND FUEL IN NOX, CO, O, HC

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Pollutant Levels
EXHAUST GAS COMPOSITION
4000 0.4

3000 0.3

PERCENT BY VOLUME
ACTUAL PPM

2000 0.2

1000 0.1

CO
0 0
16.08 :1
14.00:1

15.00:1

17.00:1

18.00:1

19.00:1

20.00:1
RICH LEAN

AIR / FUEL RATIO STOICHIOMETRY

( theoretical )

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Pollutant Levels
EXHAUST GAS COMPOSITION
4000 0.4

THESE LEVELS ARE NO

3000 0.3

PERCENT BY VOLUME
LONGER ACCEPTABLE IN
ACTUAL PPM

2000 0.2

SOME STATES
1000 0.1

CO
0 0
16.08 :1
14.00:1

15.00:1

17.00:1

18.00:1

19.00:1

20.00:1
RICH LEAN

AIR / FUEL RATIO STOICHIOMETRY

( theoretical )

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 HOW CAN THESE
LEVELS BE LOWERED?

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 HOW CAN THESE
LEVELS BE LOWERED?

•CATALYTIC CONVERTER

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Catalytic Converter

NOX, CO, O2 N2, CO2, O2

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 HOW CAN THESE
LEVELS BE LOWERED?

•CATALYTIC CONVERTER
•LEAN BURN ENGINE

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 28:1 Air Fuel Ratio
EXHAUST GAS COMPOSITION
4000 0.4

3000 0.3

PERCENT BY VOLUME
ACTUAL PPM

2000 0.2

1000 0.1

CO
0 0
16.08 :1
14.00:1

15.00:1

17.00:1

18.00:1

19.00:1

20.00:1
RICH LEAN

28:1
AIR / FUEL RATIO STOICHIOMETRY
( theoretical )

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 IS IT POSSIBLE TO IGNITE A 28:1
FUEL MIXTURE WITH A SPARK?

NO BUT IT CAN BE IGNITED WITH AN OPEN FLAME.

THIS IS THE CONCEPT BEHIND THE PRE-CHAMBER

TYPE LEAN BURN ENGINE.

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Rich Burn Fuel System

(APPROX. 8” HG.)

MIXER

MAIN
CHAMBER
REGULATOR

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Lean Burn Fuel System

(APPROX. 30” HG.)

MIXER
PRE-CHAMBER
REGULATOR
INTER-COOLER MAIN
CHAMBER
REGULATOR

HIGHER VOLUME
TURBOCHARGER

“From The Wellhead Through The Pipeline…Hanover People Perform.”

 Pre-chamber Type Head
Admission Valve
(pure fuel)

Pre-chamber
(rich mixture)

Main chamber
(lean mixture)

“From The Wellhead Through The Pipeline…Hanover People Perform.”