Internal Combustion Engine Plant February 27, 2012

Problems and Solutions

Gabriel Dominic R. Baygan

Jovane Denden

Michael D. Evangelista

John Paul Layese

01.) Using problem 6-2 data, calculate (1) ideal thermal efficiency (with n = 1.35 in place of γ) ,
(2) mean effective pressure, (3) power from a 6-cylinder, 4- cycle, 327- RPM engine operating
on this cycle.

SOLUTION:

Data from prob. 6-2:

𝑘𝑔
P1 = 0.9 𝑐𝑚 2 abs

𝑘𝑔
P2 = 38.7 𝑐𝑚 2 abs

t1 = 15.6℃

R = cut-off ratio = 2.5

n = 1.35

D x L = 25 cm X 38 cm

a.) Ideal Thermal Efficiency

1 𝑅 𝑛 −1
𝜂𝑖 = 1 −
𝑛 𝑟 𝑛 −1 𝑅−1

1
𝑉1 𝑉1 𝑃2 𝑛
r=𝑉 𝑃1 𝑉12 = 𝑃2 𝑉22 =
2 𝑉2 𝑃1

1
38.7 1.35
r= = 16
0.9

1 2.51.35 −1
𝜂𝑖 = 1 − 1.35 16 0.25 1.5
 𝜂𝑖 = 0.54 𝑎𝑛𝑠

b.) Mean Effective Pressure

𝑛 𝑟 𝑛 −1 𝑅−1 − 𝑅 𝑛 −1
𝑃𝑚𝑖 = 𝑃𝑖 𝑟 𝑟−1 𝑛−1

𝑘𝑔 1.35(16)0.35 1.5 − 2.51.35 −1

𝑃𝑚𝑖 = 0.9 𝑐𝑚 2 𝑎𝑏𝑠(16) 15 0.35

𝑘𝑔
𝑃𝑚𝑖 = 7.95 𝑎𝑏𝑠 𝑎𝑛𝑠.
𝑐𝑚 2

c.) Power from 6 cylinders

𝑃𝑚𝑒𝑝 𝐿𝐴𝑁𝑝
𝐻𝑃 = 449.702

𝑘𝑔 𝜋 327 𝑆𝑡𝑟𝑜𝑘𝑒𝑠
7.95 𝑎𝑏𝑠 38 𝑐𝑚 25 𝑐𝑚 2 6 𝑐𝑦𝑙
𝑐𝑚 2 4 2 𝑚𝑖𝑛
𝐻𝑃 = 𝑘𝑔 −𝑐𝑚
449.702
𝑕 𝑝 −𝑚𝑖𝑛

𝐻𝑃 = 𝟑𝟐𝟑 𝒉𝒑

2.) The specific gravity of oil tested at 29.4 ℃. Find its API in degrees.

Solution:
141 .5
°𝐴𝑃𝐼 = 15.6 ℃ − 131.5
𝑆𝐺 @
15.6 ℃

SG @ 15.6 ℃

Volumetric coefficient of expansion of oil is 0.0007 per ℃

Volume at 15.6℃

= [1- 0.0007 per ℃ (29.4-15.6) ℃] x Volume at 29.4 ℃

= 0.99 x Volume at 29.4 ℃

𝜌𝑖 𝑚
𝑆𝑖 = =
𝜌𝐻2𝑂 𝑣𝜌 𝐻 𝑂
2

m= Mass of substance = constant

v= volume of substance
 𝜌𝐻2 𝑂 = density of water = constant

(SG) (V) @ 15.6 ℃ = (SG) (V) @ 29.4 ℃

(SG) @15.6 ℃ = (SG) @ 29.4 ℃ (V) @ 29.4 ℃ (V) @ 15.6 ℃

1
= (0.852) 0.49

= (0.86)

Therefore:
141 .5 141 .5
°𝐴𝑃𝐼 = 15.6 ℃ − 131.5 = −131.5 = 33.0
𝑆𝐺 @ 0.86
15.6 ℃

3.) Using median data from Fig. 6-15, find the oil storage volume, m3, needed for a two-week
3
supply of 25℃ API fuel oil to operate a 1014 hp Engine 70% of the time at full load, 10% at 4
load. It is idle 20% of the time

Solution:

From Fig. 6-15, p.164

For full load, upper limit of

𝑘𝑔
Fuel Rate = 0.19 𝐵𝐻𝑃 −𝑕𝑟

𝑘𝑔
Lower Limit = 0.17𝐵𝐻𝑃 −𝑕𝑟

3
For Load
4

𝑘𝑔
Upper Limit = 0.18𝐵𝐻𝑃 −𝑕𝑟

𝑘𝑔
Lower Limit = 0.16𝐵𝐻𝑃 −𝑕𝑟

Median Values:
 𝑘𝑔
@ Full Load : 0.18𝐵𝐻𝑃 −𝑕𝑟

3 𝑘𝑔
@ 4 Load : 0.17𝐵𝐻𝑃 −𝑕𝑟

Fuel Considered in two weeks

7 𝑑𝑎𝑦𝑠 24𝑕𝑟 𝑘𝑔
@ Full Load : 70% ( 2wk x x 1 𝑑𝑎𝑦 ) 0.18𝐵𝐻𝑃 −𝑕𝑟 x 1014 hp = 42,930 kg
1 𝑤𝑘

3
@4 Load:

7 𝑑𝑎𝑦𝑠 24𝑕𝑟 𝑘𝑔
10%( 2wk x x 1 𝑑𝑎𝑦 ) 0.17 𝐵𝐻𝑃 −𝑕𝑟 x 1014 hp
1 𝑤𝑘

= 5790 kg

Total fuel consumed = 42930 + 5790 = 48,720 kg

Specific Gravity
141 .5 141 .5
SG = 131 .5+°𝐴𝑃𝐼 = = 0.904
131 .5+25

Volume required for storage

48720 𝑘𝑔
= 𝑘𝑔
0.904 (1000 3 )
𝑚

= 53.9 m3

4.) An engine on test developed 154 bhp steadily for 30 min. during which it consumed 15.34 kg
fuel. This same fuel when tested at 23.9 ℃ a 15.6 ° hydrometer, showed SG of 0.905. Calculate
thermal efficiency, based on bhp and Qh.

Solution

Volumetric Coefficient of Expansion = 0.0007 per ℃

Specific Gravity of fuel at 15.6° / 15.6℃

0.905
= 1−0.0007 (23.9−15.6)

= 0.91

For heat value, Bureau of Standards Equation

 𝐽
Qh = 51,716- 8793.8 (SG)2 𝑔

Qh = 51,716 – 8793.8 (0.41)2

𝐾𝐽
Qh = 44,430 𝑘𝑔

Brake Thermal Efficiency

2648
𝜂𝑡𝑏 = 𝑤𝑏 𝑄

15.34 𝑘𝑔
𝑤𝑏 = 154 𝑏𝑕𝑝 𝑥 0.5 𝑕𝑟

𝑘𝑔
𝑤𝑏 = 0.189
𝑏𝑕𝑝−𝑕𝑟

𝜂𝑡𝑏 = 𝟑𝟎%

5.) Find the percent excess air represented by 32:1 A:F ratio with cetane as the fuel.

Solution:

Combustion Equation for Cetane

C16H34 + 24.5 O2 = 16 CO2 + 17H2O

Therefore 1 mol C16H34 + 24.5 mol O2 = 16 mol CO2 + 17 mol H2O

1 mol Carbon = 12 kg C

1 mol Oxygen = 32 kg O2

1 mol Hydrogen = 2 kg H2

1 mol C16H34 = 16(12 kg) + 34(1 kg) = 226 kg

1 mol CO2 = (12 kg) + (32 kg) = 44 kg

1 mol H2O = (2 kg) + (0.5) (32 kg) = 18 kg

226 kg C16H34 +24.5 (32) kg O2 = 16(44kg) (CO2) +17(18kg) H2O

Or
 24.5 𝑥 32 16 𝑥 44 17 𝑥 18
1 kg C16H34 + 𝑘𝑔 O2 = 𝑘𝑔 CO2 + 𝑘𝑔 H2O
226 226 226

1 kg C16H34 + 3.469 kg O2 = 3.115 kg CO2 + 1.354 kg H2

Amount of oxygen in air

𝑘𝑔 𝑂𝑥𝑦𝑔𝑒𝑛
= 0.232 𝑘𝑔 𝑎𝑖𝑟

Theoretical air required for each kilogram of cetane

3.469 𝑘𝑔 O 2
= 𝑘𝑔 O 2 = 15 kg air
𝑘𝑔 𝐴𝑖𝑟

Percentage air supplied in excess of theoretical requirement

32−15
% excess = 𝑥 100 = 𝟏𝟏𝟑. 𝟑%
15

6.) What ideal thermal efficiency is possible from a diesel having r= 15, A:F = 40:1, Q L = 42800
𝐽 𝐽
? Take Cp= 1.05 𝑔℃, t= 15.6℃.
𝑔

Solution:
𝑉1 𝑉3
𝑟= 𝑅=
𝑉2 𝑉2

𝑉1 𝑛−1 𝑛−1
𝑇2 = 𝑇1 or 𝑇2 = 𝑇1 𝑟 with r =15; 𝛾 = 1.4 = 𝑛
𝑉2

T2 = (15.6 +273)K (15)0.4

T2 = 852.6K = 579.6 ℃
 Heat input to Cycle = Heat from fuel

(wa + wf) cp (T3 – T2) = wfQ2

𝑤𝑎
+ 1 cp (T3 – T2) = Q2
𝑤𝑓

40 𝐽 𝐽
+ 1 1.05 (T3 - 579.6) ℃ = 42800 𝑔
1 𝑔℃

T3 = 1573.8 ℃

𝑉3 𝑉 𝑇3
For V3: = 𝑇2 𝑉3 = (V2)
𝑇3 2 𝑇2

𝑉 1573 .8+273 𝐾
R= 𝑉3 = = 2.17
2 852 .6𝐾

Ideal Efficiency
1 𝑅 𝛾 −1
𝜂𝑖 = 1 − 𝛾 𝑟 𝜆 −1 𝑅−1

1 2.17 1 .4 −1
𝜂𝑖 = 1 − = 𝟎. 𝟓𝟗𝟓
1.4(15)0.4 1.17

7.) A 39.37 cm x 55.88 cm x 327 –RPM, 16- cylinder, 4-cycle stationary diesel engine is
connected to a 3125- KVA (80% power factor) generator. IT also drives a 30-kw exciter.
Assume a generator efficiency of 92% and determine BMEP at rated load.

Solution:

a.)

Rated Load = KVA x Power Factor = 3125 KVA x 0.8

= 2500 kW

Exciter Load = 30 kW

Total Load = 2530 kW ans.

2530 𝑘𝑊
b.) Brake Horsepower of Engine = 𝑘𝑊 = 3690 𝑕𝑝
0.746 𝑥 0.92
𝑕𝑝

𝐵𝑚𝑒𝑝 𝐿𝐴𝑁𝑝
Bhp = 449702
 𝑘𝑔 −𝑐𝑚
𝐵𝐻𝑃 (449702 ) 3690 𝑕𝑝 449702 𝒌𝒈
𝑕 𝑝 −𝑚𝑖𝑛
𝐵𝑚𝑒𝑝 = = 𝜋 327 𝑠𝑡𝑟𝑜𝑘𝑒𝑠 = 𝟗. 𝟎𝟓 𝒄𝒎𝟐
𝐿𝐴𝑁𝑝 16 𝑐𝑦𝑙 55.88 𝑐𝑚 39.37 𝑐𝑚 2
4 2 𝑚𝑖𝑛

8.) Specifications of a 4-cylinder, 4-cycle gas engine are 10.16 cm x 15.24 cm 900 RPM.
Mechanical efficiency, 86%. Find the Kw output of a direct-connected generator of 90%
efficiency when the indicated MEP is 7.73 kg/cm2.

Solution:

𝑃𝑚𝑒𝑝 𝐿𝐴𝑁𝑝 𝑛𝑐
𝑖𝑛𝑑𝑖𝑐𝑎𝑡𝑒𝑑 𝐻𝑃 =
449,702

𝑘𝑔 𝜋 2
7.73 15.24 𝑐𝑚 4 10.16 𝑐𝑚 900/2 4
𝑐𝑚2
𝑖𝑛𝑑𝑖𝑐𝑎𝑡𝑒𝑑 𝐻𝑃 = = 38.2 𝑕𝑝
𝑘𝑔 − 𝑐𝑚
449,702 𝑕𝑝 − 𝑚𝑖𝑛

At 86% mechanical efficiency

𝐵𝐻𝑃 = 0.86 38.2 𝑕𝑝 = 32.85 𝑕𝑝

Kilowatt Output at 90% generator efficiency

0.746 𝑘𝑤
= 32.85 𝑕𝑝 0.9 = 𝟐𝟐. 𝟏 𝑲𝒘
𝑕𝑝

9.) An engine-type generator with 30 poles generates 3-phase 60-cycle current at 60V. Its rated
output is 400 kw. Engine specifications 40.64 cm x 50.8 cm. Find the brake MEP existing when
line current is 360 amp, power factor, 0.8.

Solution:

𝐾𝑤 𝑂𝑢𝑡𝑝𝑢𝑡 = 3 𝐸 𝐼 cos 𝜃 = 3 600 𝑉 360 𝐴 0.8 = 299298 𝑤 = 300 𝑘𝑤

Since rated output is 400 kw, the generator operates at ¾ load

120 𝑓 120 𝑥 60
𝑆𝑝𝑒𝑒𝑑 𝑜𝑓 𝑅𝑜𝑡𝑎𝑡𝑖𝑜𝑛 = = = 240 𝑅𝑃𝑀
𝑛 30
From Fig. A-16, P.675 Standard generator efficiency at ¾ load = 92.2% (for 400-kw, 240 RPM
Gen.)
From Table 6-3, P. 185 STD. deduction for generator efficiency =2.8% at ¾ load

Thus, Actual Generator Efficiency

= 92.2% − 2.8% = 89.4%

Brake Horsepower of engine:

𝐺𝑒𝑛. 𝑂𝑢𝑡𝑝𝑢𝑡 300 𝐾𝑤

𝐵𝐻𝑃 = = = 450 𝐻𝑝
𝐴𝑐𝑡𝑢𝑎𝑙 𝐺𝑒𝑛𝑒𝑟𝑎𝑡𝑜𝑟 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 0.894 (0.746 𝐾𝑤)
𝑕𝑝

Assume 6-cyclinders, 4-stroke

𝐵𝐻𝑃 449,702
𝐵𝑚𝑒𝑝 =
𝐿𝐴𝑁𝑝 𝑛𝑐

𝑘𝑔 − 𝑐𝑚
450 𝑏𝑕𝑝 449,702 𝑕𝑝 − 𝑚𝑖𝑛
𝐵𝑚𝑒𝑝 = 𝜋 = 𝟒. 𝟐𝟕 𝒌𝒈/𝒄𝒎𝟐
50.8 𝑐𝑚 4 40.64 𝑐𝑚 2 240/2 6

10.) Find ŋtb and bmep of an 8-cylinder, 4-cycle diesel engine which is direct-connected to a
2300V, 3-phase generator rated at 1250 kw. Engine specifications are 39.97 cm x 55.89 cm x
327 rpm. During a test this unit used 259.5 kg fuel oil of 44550 j/g heating value. Wattmeter
readings at the start and finish for the one-hour test were 25,156 and 26,378 kw. For electrical
efficiencies use NEMA data, corrected by table 6-3.

Solution:

Generator output

𝑤𝑎𝑡𝑡𝑚𝑒𝑡𝑒𝑟 𝑟𝑒𝑎𝑑𝑖𝑛𝑔 𝑎𝑓𝑡𝑒𝑟 𝑡𝑒𝑠𝑡 − 𝑟𝑒𝑎𝑑𝑖𝑛𝑔 𝑏𝑒𝑓𝑜𝑟𝑒 𝑡𝑒𝑠𝑡 (26,378 − 25,156)

= =
𝑁𝑜. 𝑜𝑓 𝐻𝑜𝑢𝑟𝑠 𝑜𝑓 𝑇𝑒𝑠𝑡 1
= 1,222 𝑘𝑤

Output in % of Rated Capacity

1,222
= = 0.978
1,250

From Fig. A-16, P 657 NEMA Efficiency at given RPM and Load = 95%

From table 6-3, Deduction = 0.83%

Net Efficiency = 95 % - 0.83 % = 94.17 %

Corresponding BHP required

 1222 𝑘𝑤
= = 1740 𝑕𝑝
𝑘𝑤
0.746 𝑕𝑝 (0.9417)

With fuel consumption of 259.5 kg in one hour

259.5 𝑘𝑔/𝑕𝑟 𝑘𝑔
𝐹𝑢𝑒𝑙 𝑟𝑎𝑡𝑒, 𝑤𝑓 = = 0.149
1740 𝑕𝑝 𝐵𝑕𝑝 − 𝑕𝑟

(a.) Brake thermal efficiency

2468 2468
ŋ tb = = = 𝟎. 𝟑𝟗𝟖
𝑤𝑓 𝑄 0.149(44550)

(b.)

𝐵𝐻𝑃 449,702
𝐵𝑚𝑒𝑝 =
𝐿𝐴𝑁𝑝 𝑛𝑐

𝑘𝑔 − 𝑐𝑚
1740 𝑏𝑕𝑝 449,702 𝑕𝑝 − 𝑚𝑖𝑛
𝐵𝑚𝑒𝑝 = 𝜋 = 𝟖. 𝟕𝟒 𝒌𝒈/𝒄𝒎𝟐
55.88 𝑐𝑚 4 39.37 𝑐𝑚 2 327/2 6

11.) Estimate the fuel storage tank capacity for a diesel plant having 5000 kw installed capacity.
Expected plant capacity factor, 55 %. Fuel contract is to made for semi-monthly delivery, but
allow 100% extra for contingency. Also determine the GPM transfer pump capacity.

Solution:

Form fig. 6-15, p 164 the greates fuel consumption to be expected at 55% capacity is 3.4 kw-hr/
liter

The minimum fuel rate = 2.3 kw-hr/ liter

Average value

3.4 + 2.3 𝑘𝑤 − 𝑕𝑟
= = 2.85
2 𝑙𝑖𝑡𝑒𝑟
At 55% plant capacity factor and without allowance for emergencies,

Quantity for 15 day storage

𝑕𝑟
5000 𝑘𝑤 24 𝑑𝑎𝑦 15 𝑑𝑎𝑦 0.55
= = 347,700 𝑙𝑖𝑡𝑒𝑟𝑠
𝑘𝑤 − 𝑕𝑟
2.85 𝑙𝑖𝑡𝑒𝑟
Allowing 100% for contingencies:

Total Storage Capacity = 694,800 liters

12.) Cooling water for a 500hp diesel engine is pumped to cooling tower at 60°C. it is desired to
cool the water to a maximum terature of 37.8° Dry bulb temperature, 27.8° wet bulb temperature.
Find the required capacity and efficiency of the cooling tower.

Solution:

If the brake thermal efficiency of the engine is taken as 30%, and the loss to cooling
water as 32%, then Eq 6-16 p. 178 may be used to find the amount of cooling water

𝐵𝐻𝑃 𝐿
𝑊 = 674.58 ; 𝑖𝑛
𝑡2 − 𝑡1 𝑕𝑟
(500)
𝑊 = 674.58 = 𝟏𝟓, 𝟐𝟎𝟎 𝑳/𝒉𝒓
60 − 37.8
Efficiency of cooling tower

𝑡𝑎 − 𝑡𝑏 60 − 37.8
𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = = = 0.689 = 𝟔𝟖. 𝟗 %
𝑡𝑎 −𝑡𝑤 60 − 27.8

13.) A diesel plant has a cooling system employing cooling tower that loses to the atmosphere
approximately 5% of the water circulating. When the two 507-hp engines are operated at full
load on an average day the tower cools the water from 54.4 to 35°. What should the capacity of a
water softening plant for the make-up be in L/mm.

Solution:

Assuming 30% brake thermal efficiency and 32 % less to cooling water, then from Eq 6-16

𝐵𝐻𝑃 (507) 𝐿 1𝑕𝑟

𝑊 = 674.58 = 674.58 = 17629.49 = 294 𝑙/𝑚𝑖𝑛
𝑡2 − 𝑡1 54.4 − 35 𝑕𝑟 60 𝑚𝑖𝑛
With 5% loss of water,

Minimum capacity of water softening plant

𝐿
= 0.05 294 = 𝟏𝟒. 𝟕 𝑳/𝒎𝒊𝒏
min