Applied Thermodynamics

TESTING OF IC ENGINES
Dr Avinash Kolekar
Asst. Professor
Department of Mechanical Engineering

Vidya Pratishthan’s
Kamalnayan Bajaj Institute of Engineering and Technology, Baramati,
Pune, India
UNIT-IV : TESTING OF IC ENGINES and
Emission
• CO4: DETERMINE performance parameters of IC
Engines and emission control.
• Engine Testing: Engine Testing Procedure,
Measurement of indicated power, Brake power,
fuel consumption, Air Consumption,
Measurement of friction power by Willan’s Line
Method and Morse Test, calculation of mean
effective pressure, various efficiencies, specific
fuel consumption, heat balance sheet of IC
Engines and performance Characteristic curves.
 Learning Objectives:
• To understand objectives of engine testing
• To learn about engine performance parameters
 Objectives of Testing

• Engine performance during development

• Engine performance after development/

sample testing after production by
manufacturers

• Engine performance testing by Govt Testing

Agencies for certification like ARAI
 Objectives of Testing
• Whether engine is performing as per design?
➢ Indicated Power (IP)
➢ Brake Power (BP)
➢ Frictional Power (FP)
➢ Mechanical Efficiency
➢ Thermal Efficiency
➢ Brake Specific Fuel Consumption (bsfc)
➢ Heat Balance Sheet
• Whether engine is meeting emission norms?
➢ CO
➢ HC
➢ NOx
➢ PM
➢ Soot
 Performance Parameters
Indicated Power (IP)/ Theoretical Power :
Power produced within engine cylinder

Brake Power (BP)

Power available at output shaft/ crank shaft

Mechanical Losses/Frictional Power (FP)

Sum of frictional losses and pumping losses
incl power required to operate engine
accessories like water pump, dynamo etc
IP = BP + FP
Indicated Power (IP)
Let p= Pressure (N/cm2); L= Length of stroke (m)
A= Piston top area (cm2)=Лd2/4; N= RPM
n= Cycle/min (=N/2 for 4 S engine as one cycle per
2 rev & N for 2S engine)
k= No of Cylinders
Hence, Force on Piston= Pm x A (Newton)
WD per Cycle= p x A x L (Nm)
Hence, IP = p x A x L x n (Nm/min)/Cylinder

pLAn
= (Nm / s / cylinder)
60
p LAnk
 IP = (kW )
60,000
 Indicated Mean Effective Pressure (Pimep)
• IMEP is the average pressure, which if acted over the
entire stroke length, would produce the same work
done by the piston as is actually produced by the
engine during a cycle

Avinash Kolekar VPKBIET Baramati 8

Mean Effective Pressure
• Let ‘a’ be the net area of indicator diagram (cm2)
‘l’ be length of diagram (cm) and
‘k’ be spring stiffness N/cm2/cm
Hence, mean height of
diagram = a/l

a
 p m (imep) = X k N/cm 2

l
 Engine/ Mechanical Indicator
Indicator Paper
Wrapped Drum

p-V diagram
Stylus

Rope connected
To Piston Rod
Pulleys
Weight
Piston

Coupling Nut

To Combustion Chamber
Measurement of IP on Mech/Eng Indicator
• To determine IP, p-V diagram is required, the area of
which represents work developed by engine per cycle
• Apparatus used for drawing actual p-V diagram is
called Mechanical/ Engine Indicator
• Eng indicator consists of a cylinder, piston, piston rod
coupling nut, straight line linkage with stylus, spring
of required stiffness, indicator card wrapped drum,
pulley, rope and weights .
• Vertical movement of stylus and horizontal movement
of the cord combines to produce a closed figure
called Indicator diagram
• Area of indicator diagram can be measured by
Planimeter to a definite scale giving work developed
 Learning Objectives:

• To learn working out/ measurement of Brake Power (BP) &

Friction Power (FP)
 Measurement of BP
1. Rope Brake Friction Dynamometer

S Spring Balance

Rope

Flywheel/Brake Drum

W Weight
Rope Brake Friction Dynamometer (Contd.)
Let W=Dead Weight (mg) in Newton (N)
S=Spring Balance Reading (N)
Rb=Radius of Brake Drum (D+d)/2 (m)
D=Brake Drum dia and ‘d’ rope dia
N=Engine RPM
Hence, net Brake Load= (W – S)
Braking Torque = (W-S) x Rb
(W − S )xRb x2N
Hence, Brake Power (BP) = (kW )
60,000
Brake Mean Effective Pressure (bmep)
pbmep LAn
BP = xNo of Cylinders (kW)
60,000
 2. Prony Brake Dynamometer

Flywheel/ Load
Brake Drum Arm

Brake Length, L
Shoes

Weight
W
Prony Brake Dynamometer (Contd.)
Let W (=mg) be the weight (N)
Let L be the distance from centre of brake drum to
hanger, called load arm (m)
Then, Torque=W x L (Nm)
B P = T x
2N
&  =
60
Hence,

BP =
(W x L )2N
(kW )
60,000
 Frictional Power (FP)
• Difference between IP and BP is called FP
• FP includes:
- Pumping losses due to intake & exhaust processes
- Frictional losses in bearings, rotary/sliding parts
- Power required to drive auxiliaries like governor,
water, lub oil, fuel pumps, alternator/dynamo,
valve operating mechanism etc
• FP increases as square of N but practically FP ∞ N1.6
• Higher FP results in:
- Reduced power output
- Decreased mech efficiency
- Increased bsfc
- Increased requirement of cooling
Methods of Measurement of FP

1. By measurement of IP and BP

2. Willan’s Line Method

3. Morse Test

4. Motoring Test
 FP by Willan’s Line Method
( Fuel Rate Extrapolation Method )

At Constant Eng Speed, say

1500 RPM
4

Fuel Flow 3
Rate (kg/h)
2

1
A
-8 -4 0 4 8 12 16 20
BP (kW)
FP by Willan’s Line Method
• A graph between fuel consumption rate (kg/h) taken
on y-axis and BP (kW) on x-axis is drawn, while
engine is made to run at some constant speed, say
1500 RPM
• The graph is extrapolated back to zero fuel
consumption, which cuts on –ve x-axis at point ‘A’
• The –ve intercept on x-axis represents FP at that
speed of the engine
• Although when BP=0, some fuel consumption is there.
This fuel is consumed to overcome engine friction
• Only for CI engine to be run at constant speed as
Fuel consumption rate v/s BP plot is almost straight
line in case of diesel engine, hence can be extrapolated
 FP by Morse Test
• Morse Test can be used for determining FP/IP of
multi-cylinder IC engines, generally 3 cyl and more
by cutting off each cylinder in turn
• In SI engines, each cylinder is rendered in-operative
by short-circuiting the SP or cutting off fuel supply
in MPFI systems. In CI engines, fuel supply is cut off
• Consider 4 stroke, 4 cylinder SI engine coupled with
dynamometer
• Engine is run at constant speed N throughout one
set of test parameters, as FP ∞ N2
• It is assumed that pumping & mech losses are same
whether a cylinder is working or not
• Throttle position is kept fixed, however, to attain
same speed N, load is decreased by dynamometer
 FP by Morse Test
• Let B=BP of eng when all cylinders are working
B1=BP of eng when Cylinder No 1 is cut off
Similarly, B2=BP of eng when Cylinder No 2 is cut off
B3=BP of eng when Cylinder No 3 is cut off

B4=BP of eng when Cylinder No 4 is cut off

• Let I1, I2, I3 & I4 be the IPs developed by Cylinder

Nos 1, 2, 3 & 4 respectively and their corresponding
FPs be F1, F2, F3 & F4

• Total BP(B) = (I1+I2+I3+I4) - (F1+F2+F3+F4)

 FP by Morse Test
BP(B) = (I1+I2+I3+I4) - (F1+F2+F3+F4)
Hence, B1=(I2+I3+I4) – (F1+F2+F3+F4)

On subtracting; B – B1 = I1
Similarly,
B – B2 = I2
B – B3 = I3
B – B4 = I4
On adding; IP = I1 + I2 + I3 + I4
= 4B – (B1+B2+B3+B4)
B, B1, B2, B3 & B4 can be measured by Dynamometer,
Hence IP can be calculated

Therefore, FP = IP - BP
 Learning Objectives:

• To understand working out of heat balance sheet

• To learn measurement of air/fuel consumption
 Theoretical/ Air Std Efficiencies
1
Otto Cycle:
 =1−  −1
r

1    −1 
 = 1 −  −1  
Diesel Cycle: r   ( −1)

1 
 = 1 −  −1 
( . 
−1 ) 

 ( − 1) +  . ( − 1)
Dual Cycle:
r
 Some Definitions
Thermal Efficiencies:
IP
i) Indicated Thermal Efficiency i =
m f xCV

BP
ii) Brake/Overall Thermal Efficiency  b =
m f x CV

- Where mf is fuel consumed in kg/sec

- CV is Calorific Value of fuel in kJ/kg
- IP/BP is in kW
 Some Definitions
Mechanical Efficiency:

BP
mech = x100
IP

Relative Efficiency : Defined as the ratio of Brake

Thermal Efficiency to Air Standard Efficiency at same
Compression Ratio(CR)
b
r = x100
a
 Some Definitions
Volumetric Efficiency:
• Ratio of actual mass of charge inducted during
suction stroke to mass of charge corresponding to
swept volume of the engine at atm pr & temp
Massof actualcharge inducted
v =
Massof charge corresponding to sweptvolat Atm Pr&Temp
• Reduced Volumetric Efficiency causes reduction in
Power Output
ActualVol of Charge inhaledat suctionconditions
Also,v  =
SweptVolume

• Volumetric Efficiency puts a limit on the amt of fuel

that can be burnt and hence on its power, since
output of eng depends on amt of air inducted
 Some Definitions
(Brake) Specific Fuel Consumption (bsfc/sfc):
• bsfc is defined as the amount of fuel required to be
supplied to eng to develop 1kW of power per hour at
crankshaft
m f x 3600
 bsfc = (kg / kWh)
BP
Specific Output:
• BP per unit of piston displacement

BP
SpecificOutput =
AxL
 Heat Balance Sheet
• Heat Balance Sheet is an account of heat released
on combustion of fuel in the combustion chamber
and its utilization in the engine
• To draw heat balance sheet, tests are carried out
on engine, while it is run at some constant speed

Heat Supplied:

Heat Supplied = mf x CV (kJ/min)

Where mf = mass flow rate of fuel (kg/min)
CV = Calorific Value of fuel (kJ/kg)
 Heat Balance Sheet
Heat Expenditure/Utilization:
1) Heat Equivalent to BP:
Heat Equivalent to BP = BP x 60 (kJ/min)
2) Heat Rejected to Cooling Water:
Heat carried away by water =mwCpw(Two – Twi) kJ/min
Where mw=cooling water circulation kg/min
& Cpw=4.187 kJ/kgK
3) Heat carried away by Exhaust gases
Heat carried by exh gases=mgCpg(Tge – Tsa) kJ/min
Where mg=(ma+mf ) =flue gases flow rate (kg/min)

4) Unaccounted Heat:
By difference
 Heat Balance Sheet
Heat kJ/ % Heat Utilization kJ/ %
Supplied min min
100
Heat a) Heat to BP=BPx60
Supplied
by comb b) Heat to water
of =mwxCpw(Two – Twi)
Fuel
c) Heat carried
=mf x CV
away by exhaust
gases
=mgxCpg(Tge – Tsa)

d) Heat Unaccounted
(By difference)
Total 100 100
Volumetric Fuel Flow Meter(Burette Type)

Fuel from Tank 3-Way Cock

Start Start

100cc 200cc

Stop Stop

3-Way Cock
Fuel to Eng
 Fuel Measurement
• Time required to supply given volume of fuel is noted

• Mass Flow Rate of Fuel Supply:

Volume
mf = xDensityof Fuel
Time
• Density of Fuel = Sp Gravity of fuel x Density of water

Densityof material
SpecificGravity=
Densityof Water
• This method does not give very accurate mass flow
rate due to variation in density with temp
Gravimetric Fuel Flow Meter
Fuel Tank
A
Fuel to Engine
Valves

Flask

Weighing Machine
 Air Flow Meter
Thermometer

Air
Orifice Plate (A, Cd)
Surge
Tank

Manometer
ΔH

Air Intake to Eng

Measurement of Air Consumption by
Air Flowmeter
• Surge tank is connected to intake side of the engine
• Manometer measures the pressure difference

• Vol Flow Rate = Cd x A x 2g.H w

-Cd – Coeff of discharge for given orifice

-A – Orifice cross sectional area
-ΔHw-Head of water to be converted to air head
 Learning Objectives:

• To understand working out of engine parameters through

numerical problems
Q1. Obtain cylinder dimensions of a twin-cylinder, 2-S
IC engine from the following data:
Engine speed=4000RPM; Volumetric efficiency=77%;
Mech Efficiency=75%; Fuel consumption=10 lit/hr;
Sp. Gr. Of fuel=0.73; A/F ratio=18;
Piston speed= 600m/min; imep=5 bar.
Also, determine power output at STP conditions
Solution:
Given: p=101325 N/m2; Ta=25˚C; R for air=0.287
kJ/kgK
Find: Cylinder Dimensions=? D & L
Piston speed=2LN Since speed & N are given, L=?

Now, to find out D=? Vs = 

D 2 L foronestroke/ Cylinder
4
TotalVol Flow Rate = Vs xNo of cyl xNo of power strokes/ min
(Power StrokesN for 2 S & N / 2 for 4S engine)
Solution(Contd): Va Va
v =  Vs =
Vs v
For actualVol Flow Rate Va  pa.Va = ma.R.Ta
ma
For ma  = A / F Ratio = 18 ( given)
mf
 lit  −3  m 
3
m f = 10   x10   x f
 h   h 
3
−3 m x Sp. gr of fuel x  w
= 10x10
h
= 10x10−3 x0.73x1000kg / h
= 7.3kg / h
Solution(Contd):
m a = 18
m f  ma = 18x7.3 kg / h = 131.4 kg / h
pa.Va = ma.R.Ta
131.4x287x (25 + 273)
Hence, Flow RateVa =
101325
= 110.9 m 3 / h
Va
Since  v =
Vs
Va 110.9
 Vs = = = 144m 3 / h
v 0.77
Solution(Contd):

Vo l Flo w Ra teVs = 4 D 2 L x N x 2C y lin d e r s
144  m 3   2 600
 = D x xNx2
60  min  4 2N
 D 2 = 5.094x10 − 3 m 2
 D = 0.0714m = 71.4mm
600
And L = = 0.075m
2x4000
= 75mm
Q2. A 6 cylinder gasoline engine operates on 4 stroke
cycle. Bore of cylinder is 80mm and stroke 100mm.
Clearance volume per cylinder is 70CC. At 4000 RPM,
Fuel consumption is 20kg/hr and the torque developed
is 150Nm. Calculate:-
(a)BP (b) Brake mean effective pressure (c) Brake
thermal efficiency
If CV of the fuel is 43000kJ/kg, find relative efficiency
on brake power basis, assuming engine works on
Constant volume cycle and gamma for air =1.4.
Solution:

2NT 150x2x4000
BP = kW = = 62.83kW
60,000 60000
bmep = ?

bmep x AxLxn
BP = x noof cyliders
60000

bmep x (0.08) x 0.1x
2 4000
62.83 = 4 2 x6
60000
= 6.25x10 N / m = 6.25bar
5 2
 BP 62.83
b = =
20
= 0.263= 26.3%
m f x CV x43000
3600
b a = 1 −
1
r =  −1
a r
Vs +Vc ; V =  0.8 2 x10 = 502.6CC
r= s
Vc 4
502.6 + 70 1
r= = 8.18; a = 1− 1.4−1
= 0.5686
70 8.18
0 .2 6 3
r = = 0 .4 6 2 5 = 4 6.2 5%
0 .5 6 8 6
 Learning Objectives:

• To understand working out of engine parameters and heat

balance sheet through numerical problems
 Q3. During trial of a single cylinder, 4 stroke oil engine
the following results were obtained:
Cyl bore=200mm, Stroke=400mm, mep=6 bar,
Torque=407Nm, speed=250 RPM,
Oil consumption=4kg/hr, CV of fuel=43MJ/kg,
Cooling water rate=4.5kg/min, Air used per kg of fuel=
30kg, Rise in cooling water temp=45°C, Temp of
Exhaust gases=420°C, Room temp=20°C, mean sp.
heat of exhaust gases=1kJ/kgK, Sp. Heat of water=
4.18kJ/kgK, Barometric pressure=1.01325 bar
Find IP, BP and draw up heat balance sheet in kJ/hr.
Solution:
imep x AxLxn
IP = x no of cyl ( kW )
60,000
 5 
6 x10 x (0.2 ) x0.4 x
2 250
IP = 4 2 x1= 15.7 kW
60,000
2NT 407 x2 x250
BP = = = 10.65kW
60000 60000

Heat Balance Sheet

1. Heat supplied by fuel to eng =mfxCV

=4x43000kJ/hr=172,000kJ/h
2. Heat utilized
(i) Heat to Power Output=BPx3600kJ/h
=10.65x3600=38,358kJ/h

(ii) Heat to cooling water=mw x Cpw x ∆Tw

=4.5x60x4.18x45 = 50,787 kJ/h

(iii) Heat to exhaust gases=mg x Cpg x (Te-Ta )

To find mg : ma=30kg/kg of fuel; hence mg=31kg
Since fuel consumption is 4kg/h; mg=31x4kg/h

Hence, Heat to exhaust gases=31x4x1(420-20)

=49,600kJ/h
(iv) Unaccounted Heat=33,255kJ/h (by difference)
 Heat Balance Sheet
Heat kJ/hr % Heat Utilized kJ/hr %
Supplied

Heat 172,000 100 To BP= 38,358 22.3

supplied by BPx3600
fuel= mfxCV
To Cooling 50,787 29.5
Water
=mw.Cpw.∆Tw

To exhaust 49,600 28.8

gases
=mg.Cpg.∆Tg

Unaccounted 33,255 19.3

Heat

Total 172,000 100 Total 172,000 100

Q4. During a test on a 4 stroke oil engine,
the following data were obtained:
Mean height of indicator diagram = 21mm
Indicator spring number/stiffness=27kN/m2/mm
Swept volume=14 lit, effective brake load=77kg,
Effective brake radius= 0.7m, speed=6.6 rev/s,
fuel consumption=0.002kg/s, CV of fuel=44MJ/kg,
Cooling water rate=0.15kg/s, water inlet temp=38°C,
cooling water outlet temp=71°C, Sp. heat of water=
4.18kJ/kgK, energy carried by exhaust gases=33.6kJ/s
Determine IP, BP and mech efficiency and draw up
heat balance sheet in kJ/s and %.
Solution:
imep x AxLxn
IP = x no of cyl ( kW )
60,000
 IP = Pimep.L.A. n. k (no of cyl) ( kW )
a
imep = x k = 21(mm)x27kN / m 2 .mm
l
= 21(mm) x27kN / m 2 .mm = 567kN / m 2
6.6
IP = 567(kN / m ).14(l)x10 (m ).
2 −3 3
= 26.2kW
2
(W − S )R b x 2N = 77x9.81x0.7x2  x6.6
BP =
1,0 0 0 1,000
= 21.92kW
21.92
 mech = x 100 = 83.65%
26.2
 Heat Balance Sheet
Heat kJ/s % Heat Utilized kJ/s %
Supplied

Heat supplied 88 100 To BP 21.92 24.9

by fuel=
mf x CV = To Cooling 20.69 23.5
0.002x44000 Water
(=88kJ/s) =mw.Cpw.∆Tw
0.15x4.18x
(71-38)
To exhaust 33.6 38.2
gases (given)

Unaccounted 11.79 13.4

Heat

Total 88 100 Total 88 100

Q5. A 4 cylinder 4 stroke SI engine has a bore of
5.7cm and stroke 9cm. Its rated speed is 2800 RPM
and it is tested at this speed against a brake which
has a torque arm of 356mm. The net brake load is
155N and fuel consumption is 6.74 lit/hr. Sp gravity of
petrol is 0.735 and CV is 44200kJ/kg. A Morse test is
carried out and cylinders are cut off in order of 1, 2, 3
& 4 with corresponding brake loads of 111, 106.5,
104.2 and 111N. Determine engine torque, bmep,
brake thermal efficiency, sfc, mech efficiency and imep.
Solution:

Engine torque= (W-S).Rb=WxL

= 155x0.356=55.18Nm
 bmep x AxLxn Tx2N
BP = x no of cyl = ( kW )
60,000 60000
5 5 .1 8 x 2  .2 8 0 0
BP = = 1 6 .1 7 k W
60000
 2
bmep x (0.057) x0.09x
2800
4 2 x 4 = 16.17kW
60,000
bmep = 7.55bar
BP
b =
m f xCV
 6.74(lit / h)x10 −3 (m 3 )x0.735x1000
mf =
3600
= 1.376x10 −3 kg / s
BP 16.17
b = = −3
m f xCV 1 . 3 7 6 x 1 0 x44200
= 0.2658or 26.58%
mf 1.376x10 − 3 x3600
b sfc = =
BP 1 6.1 7
= 0.3 0 6kg / kW h
We know that IP = 4BP - (BP1+BP2+BP3+BP4)
WxRb x2N
BP =
60000
R b x2N
IP = 4W − (W1 + W 2 + W 3 + W 4 )
60000
0.356x2 x2800
IP = 4x155− (111+106.5 +104.2 +111)
60000
=19.54kW
BP 16.17
m = = x100 = 82.75%
IP 19.54
bmep.LAn 7.55
m = = = 0.8275
imep.LAn imep  imep = 9.12 bar
 Q6. During trial of a 4 cylinder 4 stroke SI engine
running at 50 rev/s, the brake load was 267N when all
cylinders were working. When each cyl was cut off in
turn and speed returned to same 50 rev/s, brake
readings were 178N, 187N, 182N and 182N.
Determine BP, IP and mech efficiency of the engine.
For brake, BP=F.N/455(kW), where F is brake load in Newtons and N
rev/s. The following results were obtained: Fuel
consumption=0.568lit in 30 seconds, SG of fuel=0.72,
CV=43000kJ/kg, A/F ratio=14:1,
Exh temp=760°C, Cpg=1.015kJ/kg, Water inlet temp=
18°C and outlet temp=56°C, water flow rate=0.28kg/s,
Ambient temp=21°C. Draw heat balance sheet in kJ/s.
Solution:
F.N 267x50
BP = = = 29.34kW
455 455
We know that IP = 4BP - (BP1+BP2+BP3+BP4)
F .N 178x50
BP1 = = = 19.56kW
455 455
F.N 187x50
BP2 = = = 20.55kW
455 455
F.N 182x50
BP3 = = = 20kW = BP4
455 455
Therefore IP= 4x29.34 - (19.56+20.55+20+20)
=37.25kW

BP 29.34
 mech = = x100 = 78.76%
IP 37.25
 Heat Balance Sheet
Heat supplied =mfxCV 0.568x10−3 x0.72x1000
= x43000
30
= 0.01363x43000= 586.2kJ / s
Heat utilized
(i) Heat to BP=BP= 29.34kJ/s (5%)
(ii) Heat to cooling water=mw x Cpw x ∆Tw
=0.28x4.187x(56-18) =44.55 kJ/s (7.6%)
(iii) Heat to exhaust gases=mg x Cpg x (Te-Ta )
To find mg :(ma +1)xmf=(14+1)x0.01363=0.204kg/s
Hence, Heat to exhaust gases=0.204x1.015(760-21)
=153kJ/s (26.1%)
(iv) Unaccounted Heat=356kJ/s (61%) (by difference)