Internal Combustion Engine (ICE)

GTU # 3171923

Unit-5
Rating, Testing &
Performance

Mechanical Engineering Department

Shree Swami Atmanand Sarswati Institute of Technology, Surat
mrmayurgohil91@gmail.com
9904275064
 Looping
 Outline
• Introduction
• Basic Measurement
• Air Consumption
• Power
• Mechanical Efficiency
• Thermal Efficiency
• Specific fuel consumption
• Indicated power
• Brake power
• Friction power
• Heat balance sheet
• Introduction to standards
• Adjustment factors for atmospheric conditions
• Governing test for constant speed IC engines
• Engine troubleshooting
• Engine overhaul
Introduction
 Performance is a important term in human life as well as machine or engine.

 Engine performance indicates degree of output against the input energy.

 The energy stored in fuel in form of chemical energy is first converted into heat energy in I.C.
engine.

 Heat energy is low grade energy and can not be fully converted into work. Only 15% to 45% heat
energy released by combustion of fuel can be utilized and converted in to work.

 Rest of the heat goes to the atmosphere so it increases the temperature of universe. This is one
of the major reasons for global warming.

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Various Performance Parameters for IC Engine
 Mean effective pressure [Pm]
 Indicated power [IP]
 Brake Power [BP]
 Brake Mean Effective Pressure [BMEP]
 Friction Power [FP]
 Mechanical Efficiency [ηmech]
 Brake thermal Efficiency
 Indicated thermal Efficiency
 Specific Fuel consumption [SFC]
 Fuel - Air ratio [ F/A]
 Thermal Efficiency
 Air Standard Efficiency
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Objectives of Testing of IC Engine
 To obtain actual information about the engine which cannot be determined
by theoretical calculations.
 To confirm data used in design and validate.
 To satisfy the customers as to the rated power output with the guaranteed rate of fuel
consumption.

The majority of tests on internal combustion engines are carried out for commercial purposes in
order to check the following.
 Rated power (brake power) with the guaranteed fuel consumption (kg/kW-hr.)
 The quantity of lubricating oil required on brake power basis per kW-hr.
 The quantity of cooling water required on brake power basis in kg per kW-hr.
 The steadiness of the engine when loaded at different loads.
 The overload carrying capacity of the engine.
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Basic Measurement
 Speed

 Fuel Consumption

 Air consumption

 Power
 Input energy, efficiency
 Indicated power
 Brake power
 Friction power

 Heat balance sheet

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Fuel consumption per minute can be measured by:

 Volumetric type device: Volume of fuel consume per minute is measured in fuel tank
and that volume (𝑚3 /min) x density (kg/m³) gives fuel consumption in kg/min.

 Gravimetric type device: The weight of fuel consumed per minute kg/min directly measured by
fuel weight scale. It may be mechanical type or electronic weight cell.

 Continuous flow meter (Rota meter): It indicates the fuel consumption at any instant.

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Speed of engine can be measure by:

 Revolution counters

 Tachometer

 Stroboscope

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 Air Consumption

 In I.C engine there are four main processes as suction, compression expansion
and exhaust; and air is supplied only during suction. That's why, flow of air is not
continuous. So measurement of air flow is very difficult. The air box method is commonly used
for measuring pulsating air flow.

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 Air Consumption

 Let,
d = diameter of orifice, m
ℎ𝑤 = manometer water head causing the air flow, m
ℎ𝑎 = manometer air head, m
𝜌𝑤 = density of water, kg/𝑚3
𝜌𝑎 = density of air, kg/𝑚3
𝐶𝑑 =Coefficient of discharge of orifice,
𝜋
A = Area of orifice (= 𝑑2 ), 𝑚2
4
g= gravitational force

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 Air Consumption

 Volume flow rate of air through the orifice is given by,

Q = Area * Velocity
= A * 𝐶𝑑 * 2𝑔ℎ𝑎 𝑚3 / sec
where, ℎ𝑎 * 𝜌𝑎 = ℎ𝑤 *𝜌𝑤
𝒉𝒘 ∗𝝆𝒘
So, 𝒉𝒂 =
𝝆𝒂

 Mass flow rate of air (𝑚𝑎 ) is given by,

3
𝑚𝑎 = discharge Q ( 𝑚
𝑠𝑒𝑐 )*density 𝜌𝑎 (𝑘𝑔 𝑚3 )

= A*𝑪𝒅 * 𝟐𝒈𝒉𝒂 *𝝆𝒂 , 𝒌𝒈 𝒔𝒆𝒄

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 Power

(A) Input energy or Input Power

 The combustion of fuel take place inside the engine cylinder, the chemical energy of fuel
Is converted in to heat energy.

Let, 𝑚𝑓 = mass of fuel supplied (kg/sec)

CV =calorific value of fuel (J/kg)

 Input energy to the engine is given by,

Energy supplied per second = 𝑚𝑓 * CV, J/S or W

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 Power

(A) Input energy or Input Power

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 Power

(B) Indicated Power (ip) = It is an actual power received by the piston.

(C) Breake Power (bp) = Part of indicated power is utilized to run different accessories like
lubricating pump, cam shaft, cooling pump, fan etc and part of power is lost due to friction. The
net available power at output is known as brake power.

(D) Friction Power (fp) = fp = ip-bp

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 Efficiency

 Mechanical Efficiency= Its Indicates percentage of power loss due to friction

𝑏𝑝
ƞ𝑚𝑒𝑐ℎ =
𝑖𝑝

 Volumetric efficiency: For a thermal engine, the combustion process depends on the air-fuel
ratio inside the cylinder. If more air enters inside the combustion chamber, the more fuel can
burn, results in higher output engine torque and power.

 The volumetric efficiency is defined as the ratio between the actual (measured) volume of
intake air 𝑉𝑎 ( 𝑚3 ) drawn into the cylinder/engine and the theoretical volume of the
engine/cylinder 𝑉𝑡ℎ (𝑚3 ), during the intake engine cycle.

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 Thermal Efficiency

 Thermal efficiency is very important, since it shows how efficiently the fuel is being
utilize in the engine or it gives the percentage loss of energy supplied.

 By experiment it is observed that we can utilize only 20 to 40 percentage of energy which is

generated by combustion of fuel and there is wide scope of research for an engineer to improve
this.

 There are two type of thermal efficiency which are related with ip and bp.

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 Thermal Efficiency

 Indicated thermal efficiency:

 Brake Thermal efficiency:

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 Specific fuel consumption
 It gives the mass of fuel consumed to produce unit indicated power or unit brake
power. The fuel consumption given per unit ip is called indicated specific fuel
consumption (isfc) and per unit bp called brake specific fuel consumption (bsfc).

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 Indicated Power (ip)

 Indicated power can be measured by three ways:

1. By using indicator diagram
2. By measuring bp and fp separately and add both (ip = bp + fp)
3. By morse test

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 Indicator diagram
 The pressure inside the engine cylinder of IC engine is continuously changing during
suction, compression, expansion and exhaust.

 The variation of pressure during entire cycle can be measured by indicator.

 The graph obtained by this indicator may be in form of pressure-volume (p-V) or pressure –
crank angle (p-𝜃) known as indicator diagram.

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 Indicator diagram

• The area of the indicator diagram

represents the indicated power of the
engine.

• The different types of indicator are-

• Piston indicator
• Balance diaphragm type indicator
• Electronic indicator

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 Indicator diagram

 p-V and p-𝜃 diagrams are very important and by analysis of it various aspects can be
studied like process of combustion, rise of pressure, ignition timing, knocking, power
required during suction/ exhaust etc.

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 Indicated mean effective pressure imep (𝒑𝒊𝒎 )
 As shown in Fig of p-V diagram, pressure inside the cylinder is varried continuously.
 The imep (𝒑𝒊𝒎 ) is a imaginary average pressure which may be acting on a piston
throughout the cycle.

 Calculation of indicated power (ip):

Let, 𝒑𝒊𝒎 = imep, 𝑁 𝑚2 c=no. of cylinder
1
D = Bore of cylinder, m X= 1 for two stroke, and for four stroke
2
L=Length of stroke, m
N=Speed of engine, rev/sec
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 Indicated mean effective pressure imep (𝒑𝒊𝒎 )
 Force on piston = 𝑝𝑖𝑚 * A

 Work done/stroke =Force * distance = 𝑝𝑖𝑚 * A *L , Nm or Joules(J)

𝑤𝑜𝑟𝑘 𝑑𝑜𝑛𝑒 𝑛𝑜.𝑜𝑓 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑠𝑡𝑟𝑜𝑘𝑒

 Work done/Sec = *
𝑆𝑡𝑟𝑜𝑘𝑒 𝑆𝑒𝑐

 Indicated power (ip)= 𝑝𝑖𝑚 * A *L *N*x*c, J/S or W

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Indicated Power by Morse Test
 The indicated power (ip) of multi cylinder engine can be found out by this method.

 It is not possible to find ip for single cylinder, that is the limitation of this method.

 Also, in this method the indicator or indicator diagram is not required.

 For multi cylinder engine, power developed in any one cylinder is cut off and out put power (bp) is
measured.

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Indicated Power by Morse Test

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Indicated Power by Morse Test

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Indicated Power by Morse Test
 Let, 𝑖𝑝1 , 𝑖𝑝2 , 𝑖𝑝3 = Indicated power of each individual cylinder
𝑓𝑝1 , 𝑓𝑝2 , 𝑓𝑝3 = Friction power of each individual cyclinder.

 If all cylinder are working then brake power is given by,

bp = ip – fp
bp = (𝑖𝑝1 + 𝑖𝑝2 + 𝑖𝑝3 ) – (𝑓𝑝1 + 𝑓𝑝2 + 𝑓𝑝3 )

 lf power supply to cylinder number 1 is cut off then power developed by that cylinder is lost.
 The engine speed reduces as power is cut off. The main requirement of Morse test is that speed
should remain constant whether all cylinder are working or any one cylinder cut off..
 To maintain constant speed, load on the engine shouldreduce, means brake power reduces (bp)
(keeping air/fuel mixture supply constant).

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Indicated Power by Morse Test
 At constant speed before and after cut off, friction power (𝑓𝑝. = 𝑓𝑝1 + 𝑓𝑝2 + 𝑓𝑝3 )
Remains constant because it is assumed that friction power is depending only on speed.

 For normal operating condition, i.e. all cylinders are working,

 ……………………….(1)

 When cylinder 1 is cut off and engine runs at same speed, 𝑖𝑝1 =0, fp remains same and brake
power reduces. Let, 𝑏𝑝1 is brake power of the engine when cylinder-1 out off.

…………………… (2)

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Indicated Power by Morse Test
 Similarly cylinder 2 is cut off,
………………………(3)

 Similarly, cylinder 3 is cut off,

…………………….(4)

 Subtracting equation (2) from (1),

 Subtracting equation (3) from (1),

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Indicated Power by Morse Test
 Subtracting equation (4) from (1),

 By this way 𝑖𝑝1 , 𝑖𝑝2 & 𝑖𝑝3 can be determined and total ip is given by

𝒊𝒑 = 𝒊𝒑𝟏 + 𝒊𝒑𝟐 + 𝒊𝒑𝟑

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Brake Power
 Engine is a prime mover which is used to drive any equipment/machine of different
size.
 This equipment requires different torque so it important to know how much torque the engine can
deliver at the various running conditions.

 Torque is explained as by applying the force (N), the object will move the distance (m) as –
Torque = Force(N) * distance (m)

 The torque is measured in Newton-meter and device used to measure it is known as Brake
dynamometer or simply dynamometer.

 here are basically two types of dynamometers as absorption dynamometer and transmission
dynamometer.
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Brake Power
 Absorption dynamometer absorbs the power output of the engine and is usually
dissipated as heat by some means.

 Pony brake, rope brake, eddy current and hydraulic dynamometers are examples of absorption
type dynamometer.

 The transmission dynamometer, also called torque meter, in which power is transmitted to the
load which is coupled to the engine.

 This dynamometer is more accurate.

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Prony Brake Dynamometer

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Prony Brake Dynamometer
 Let, M= mass on hanger (kg)
r = distance between center of rotor and load (m)
T = Torque developed by engine (Nm)

 Force on the hanger, F = M*g

 Torque is given by, T = Force * Distance

=F*r

 Work done during one revolution of shaft = F*2𝜋r

= 2 𝜋 (F*r)
= 2 𝜋T
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Prony Brake Dynamometer
 If the engine is running at N revolution per second then
work done per second = 2 𝜋T* N

 Brake power bp= 2𝜋NT

 Brake power can also be given as

𝑊∗𝑁
bp = kw
𝐶

Where, W = load on dynamometer (N)

N = Speed (rpm)
C = Dynamometer Constant

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Friction Power
 Friction power is a power loss due to friction in the engine.
 Some of the power also utilize to run the different accessories like water pump,
air conditioning, fuel pump etc.
 The difference between power gain by piston (ip) and power available at output shaft is known as
friction power.
𝒇𝒑 = 𝒊𝒑 − 𝒃𝒑

 The power consumed by friction should be as low as possible to increases performance of an

engine and gives fuel economy.

 Therefore, in order to know the performance of an engine, measurement of friction power is very
important.

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Friction Power
 The friction power of an engine can be determined by the following methods:
 Morse test
 Motoring test
 Willan's line method
 Difference between ip and bp.

Motoring test-
 In motoring test, engine is first run at some desired speed by its own power for
some time so that the parameter like oil, water, engine component reach to steady
state condition and temperature remain constant with respect to time.

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Friction Power
Motoring test-

 Then fuel supply is cut off and engine is allowed to run with help of electrical motor
with same speed.

 As speed of engine is same in both the cases, friction power is also same in both the cases.

 So power supply by electric motor to run the engine at same speed will be measured which is
equivalent to friction power

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Willan's line method

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Willan's line method
 From the graph during idling condition engine produces no power/torque. There is
some fuel required to overcome friction of an engine.

 In order to get frictional torque, graph is extrapolated on back side to zero fuel consumption.

 The point of intersection to torque or brake power axis indicates the friction torque (𝑇𝑓 )or friction
power.

 Friction power = 2𝜋𝑁𝑇𝑓 where, 𝑇𝑓 = frictional torque

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 Heat Balance Sheet
 Heat balance sheet is very important in each and every stage of human life, whether
it is man, machine or engine.

 If 100 Rs is given to children, it is essential that you should know where and how this money is
spent. Whether this money is spent in correct manner or not.

 Similarly it is very much essential to know in I.C engine that whatever heat supplied to engine (by
combustion of fuel) from which how much energy is converted into useful work.

 From experiment it is observed that only 20 to 40% of heat can be converted into useful work and
rest of the heat is lost in the atmosphere.

 A heat balance sheet is an account of heat supplied and heat utilized in various ways in the system.

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Heat Balance Sheet

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Heat Balance Sheet
 The various ways in which heat is used up in the system is given as follows:
 Energy equivalent to bp
 Energy equivalent to cooling water
 Energy equivalent to exhaust
 Unaccounted losses

 The heat carry away by cooling water is usually measured by measuring the cooling
water flow rate and temperature of cooling water at water jacket inlet and outlet.

 An exhaust gas calorimeter is usually used in the laboratory for the measurement of
heat carry by exhaust gases.

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Laboratory set up to measure heat carry away in cooling water and exhaust gases

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Calculation for heat balance sheet
𝑚𝑐𝑤 = Mass flow rate of cooling water in engine, kg/s
𝑡𝑤𝑖 = Inlet temperature of engine cooling water, K
𝑡𝑤𝑜 = Outlet temperature of engine cooling water, K
𝑚𝑤𝑐 = Mass flow rate of water in calorimeter, kg/s
𝑡𝑤𝑐𝑖 = Inlet calorimeter water temperature, K
𝑡𝑤𝑜 = Outlet calorimeter water temperature, K
𝑡𝑔𝑐𝑖 = Inlet calorimeter gas temperature, K
𝑡𝑔𝑐𝑜 = Outlet calorimeter gas temperature, K
𝐶𝑝𝑤 = Specific heat of water, kJ/kg K
𝐶𝑝𝑔 = Specific heat of gas, kJ/kg
𝑚𝑓 = Mass flow rate of fuel, kg/s 𝑡𝑓 = Ambient temperature,K
CV =Lower calorific value of fuel, kJ/kg K 𝑚𝑔 = Mass flow rate of exhaust gases, kg/s

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Calculation for heat balance sheet
 Energy supplied to engine by combustion of fuel,

 Energy equivalent to bp,

 Energy lost in cooling water,

 Energy lost by exhaust gases,

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Calculation for heat balance sheet
𝑚𝑓 = Mass flow rate by exhaust gases can be found out by two way---
1. Mass of exhaust gases = mass of fuel supplied+ mass of air supplied
𝑚𝑔 = 𝑚𝑓 +𝑚𝑎

2. By exhaust gas calorimeter

Heat lost by exhaust gases in calorimeter=Heat gain by water in calorimeter

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Calculation for heat balance sheet

 Unaccounted energy loss—

 It can not be directly measured. It may include heat losses due to convection, radiation etc. So
unaccounted energy losses can be calculated as:

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Summery of equations:
 Volume flow rate of air where,

 Mass flow rate of air 𝑚𝑎 = kg/s

𝑊𝑁
 bp = 2𝜋NT or bp= where, C = Constant, W = load and N=rpm
𝐶

bp = 𝑝𝑏𝑚 LANxc, Watt, where 𝑝𝑏𝑚 = brake mean effective pressure

 ip= 𝑝𝑖𝑚 LANXc, watt

 fp= ip – bp, watt

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Summery of equations:
 Mechanical efficiency, ƞ𝑚𝑒𝑐ℎ =
𝑏𝑝
or
𝑝𝑏𝑚
𝑖𝑝 𝑝𝑚𝑖

 Indicated thermal efficiency,

 Brake thermal efficiency,

 Indicated specific fuel consumption

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Summery of equations:
 Brake specific fuel consumption-

 Air standard efficiency-

 Relative efficiency based on

 Relative efficiency based on 𝑏𝑝

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Problem 1

 A single cylinder four stroke C.l. engine has bore and stroke 100 mm and
120 mm respectively. The engine speed is 1000 rpm with mechanical
efficiency of 80%. An indicator diagram has a length of 100 mm and its
area is 2000 𝑚𝑚2 . The indicator pointer defects a distance of 11mm for
a pressure increment of 2.1 bar inside the cylinder. Calculate
(i)Indicated mean effective pressure(imep)
(ii)Indicated power(ip) and
(iii) brake power (bp).

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Solution
Given Date-
 Single cylinder c = 1,
 Four stroke x =1/2,
 Bore D = 100 mm = 0.1 m,
 Stroke L= 120 mm =0.12 m,
1000
 Speed N= 1000 rpm = rps,
60

 η𝑚 = 80%

 For Indicator Diagram: Length of Diagram= 100 mm, Area of Diagram=2000 𝑚𝑚2 , Pointer deflect
11 mm for pressure increment of 2.1 bar, imep = ?, ip=? And bp=?

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Solution
(i) Indicated mean effective pressure, (imep)-

𝐴𝑟𝑒𝑎 𝑜𝑓 𝑖𝑛𝑑𝑖𝑐𝑎𝑡𝑜𝑟 𝑑𝑖𝑎𝑔𝑟𝑎𝑚 2000

The mean height of indicator diagram = = = 20mm
𝐿𝑒𝑛𝑔ℎ𝑡 𝑜𝑓 𝑖𝑛𝑑𝑖𝑐𝑎𝑡𝑜𝑟 𝑑𝑖𝑎𝑔𝑟𝑎𝑚 100

Mean height of indicator diagram

Imep (𝑝𝑖𝑚 ) = * Pressure increment _
Pointer deflection

20
= * 2.1 = 3.818 bar
11

= 3.818*105 N/ 𝑚2

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Solution
 (ii) Indicated power (ip)-
𝝅 𝟐 𝟏𝟎𝟎𝟎𝟎 𝟏
ip = 𝑝𝑖𝑚 𝐿𝐴𝑁𝑥𝑐 = 3.818*𝟏𝟎 𝟓
*0.12* (𝟎. 𝟏 )* ∗ *1
𝟒 𝟔𝟎 𝟐

= 2.9986 kW

 (iii)Brake Power (bp)-

bp = η𝑚 * ip
= 0.8 * 2.9986
= 2.396 kW

Prof. Mayur B. Gohil #3171923 (ICE)  Unit 5 – Rating, Testing & Performance 56
 Principles of Economics and Management (PEM)
GTU # 3140709

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