CHAPTER-3 EXPERIMENTAL SETUP. The experimental set up is made with necessary. instrumentations to evaluate the performance, emission and

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1 95 CHAPTER-3 EXPERIMENTAL SETUP The experimental set up is made with necessary instrumentations to evaluate the performance, emission and combustion parameters of the compression ignition engine at different prerequisite conditions. The complete setup is arranged in the engines laboratory of mechanical engineering, JNTUHCEH. The overall view of experimental setup is shown in Fig.3.1.and its layout also shown in fig 3.2.In this chapter the details of the experimental setup & instrumentation used for the work has been presented. The setup consists of single cylinder four stroke water cooled diesel engine coupled to eddy current dynamometer with the help of flexible rubber coupling and is mounted on a centrally balanced base frame made of mild steel channels. The set up has stand alone fully powder coated panel box consisting of air box, fuel tank, and manometer, fuel measuring unit, digital indicators and transmitters for measuring various parameters. It is also provided with necessary sensors with transmitters for combustion pressure and crank angle measurements. All these signals are interfaced to computer through signal conditioner and signal converter.

2 THE TEST ENGINE A single cylinder four stroke, naturally aspirated, direct injection and water cooled diesel engine with a displacement volume of 562 cc, compression ratio of 16.5:1 and rated power output of 3.68 kw at 1500 rpm is used for conducting experiments. The technical specifications of the test engine are given in Appendix-II. The engine is run at its rated speed of 1500 rev/min. Engine is directly coupled to an eddy current dynamometer that permit engine motoring either fully or partially. The engine and the dynamometer are interfaced to a control panel which is connected to a digital computer. The computer software supplied for the test rig is used for recording the test parameters such as fuel rate, temperatures, air flow rate, load, brake power etc. From these parameters the engine performance characteristics such as brake thermal efficiency, brake specific fuel consumption, volumetric efficiency and mechanical efficiency are calibrated. The calorific value and the density of the fuel under test are given as input to the computer software. The specifications of engine are: Engine Power : 5.2 kw Engine Max. Speed : 1500 rpm Cylinder Bore : 87.5 mm

3 97 Stroke Length : 110 mm Connecting rod length : 234 mm Compression Ratio : 17.5 Stroke type : Four No. of Cylinders : One Speed Type : Constant Cooling Type : Water Dynamometer Type : Eddy Current Indicator Used Type : Cylinder Pressure 3.2. DYNAMOMETER (LOADING UNIT) It consists of stator on which numbers of electromagnets are fitted & rotor disc coupled to output shaft of the engine. When rotor rotates in stator eddy currents are produced due to magnetic flux setup by passage of field current in the electromagnets. Eddy currents oppose the rotor motion thus loading the engine. This type of dynamometer needs cooling arrangement as eddy currents dissipates heat. Moment arm measures the torque, regulating the current in electromagnets controls the load.

4 FUEL INJECTION PUMP MICO BOSCH make fuel injection pump is used. Pump is having plunger which is operated with the help of cam shaft MEASUREMENT OF INJECTION PRESSURE To change fuel injection timing shims are used. This device changes fuel injection timing from 23 0 btdc to 28, 32, 36 0 btdc. This device is employed with cam type mechanism in injection pump rocker arm. The fuel injection pump rocker arm which oscillates between the fuel injection timing cam in the cam shaft and fuel injection pump plunger is hinged on cylindrical shaft at its center. In place of cylindrical shaft eccentric shaft is placed which is connected to a worm wheel gear assembly with reduction ratio 30:1. This advances the short of fuel injection system DATA ACQUISITION SYSTEM To study the processes of inside the cylinder data acquisition system is used. This system is used analyze the measured cylinder pressure data and to quantity the combustion parameters with cyanic angle variation. The various components of this system are pressure pick up, change amplifier, TDC position sensor, A/D card, and personal computer. Various parameters such as start of combustion, fuel injunction pressure, peak cylinder pressure, occurrence of peak pressure with this system.

5 FUEL SUPPLY AND MEASUREMENT A fuel tank having a capacity of 3.51 liters is mounted on a cantilever type load cell which helps in measuring the fuel consumption. The loss in weight of the fuel is converted to the flow rate in kg/hr and is directly indicated on the digital fuel indicator. A burette is also connected in parallel as stand by option AIR CONSUMPTION MEASURING SYSTEM An air tank mounted below the control panel is connected to the manometer across an orifice of 20 mm diameter and the pressure tapings are connected to a differential pressure transducer. The manometer difference is correlated to the actual volume in m 3 /hr and the same is directly indicated on the air rate indicator SPEED AND CRANK ANGLE MEASUREMENT The proximity sensors are mounted below the coupling with a reference for measuring the speed and the crank angle. Speed sensor is connected to the speed indicator and the crank angle sensor is connected to a signal conditioner TEMPERATURE MEASUREMENT A multi channel temperature indicator is used for sensing the low temperatures with PT-100 type temperature sensors. The other temperature indicator is used for sensing high temperature of the exhaust gas with k-type thermocouple.

6 100 Other supporting instrumentation Wide varieties of instruments are used during experimentation. They are shown in appendix Data Processing Unit The data is to be analyzed to get valuable information from experimentation. Data processing is an important step in this experimental investigation. During experimentation large data is collected and processed systematically. These are the important steps in processing data Processing Stages The engine cylinder pressure, crank angle history has generally cycle to cycle variations, hence one cycle cannot be used to represent a particular operating conditions minimum 100 cycles of pressure, and crank angle data is required for quantitative analysis. The average number of cycles is depending upon the repeatability of pressure data. The calibration factor (appropriate) is calculated for conversion of the pressure in voltages to conventional unit. Now calibration factor is applied to the average cycle and relative pressures calculated. These relative pressures calibrated again with reference pressure which set equal to the cylinder pressure in take Mani is told pressure as the piston is at BDC and for the average cycle absolute pressure is obtained Absolute Pressure (Signal) With the help of the address the average pressure tracings which are recorded are stored in computer memory. During

7 101 experimentation the pressure signals are converted into digital by considering the transducer sensitivity and charge amplifier setting. Generally transducer provides relative pressures. Therefore it is necessary to determine absolute pressure at some point in the cycle. Which is taken as reference. The input pressure (Manifold) pressure is taken as reference pressure, usually is an accurate indicator cylinder pressure when piston is at BDC. Hence the pressure trace is collected on this basis to give absolute pressure Indicated Work Estimation From the pressure volume diagram indicated work of each cycle is estimated. Indicator diagram is obtained from a dynamic pressure sensor (piezo electric sensor) is fitted in the cylinder head to sense the combustion pressure. For crank angle signal a rotary encoder is fitted on the engine shaft. Simultaneously both signals are scanned by electronic unit (engine indicator) and it is communicated to the computer. The software which is in computer draws the pressure cranks angle plot and computers indicated power of the engine Performance Parameters Indicated power, Brake power, indicated mean effective pressure, brake mean effective pressure, mechanical efficiency, brake thermal efficiency, indicated thermal efficiency, brake specific energy consumption,volumetric efficiency, Mass of fuel flow are calculated at each load.

8 Combustion Characteristics Ignition start, combustion duration are treated as combustion characteristics. Parameters are estimated with the help of computer. Peak pressure occurrence and maximum peak pressure rise also can be found EXHAUST GAS ANALYZER MARS 6 Quintox Kane International exhaust gas analyzer is used for the measurement of engine exhaust gas pollution. The exhaust gas pollutants such as CO, CO 2 and NO X are measured by continuous online monitoring mode for all performance trials. Quintox exhaust gas analyzer used in this work is shown in Fig Specifications of exhaust gas analyzer are presented in Appendix IV.

9 103 Fig. 3.3 Exhaust Gas Analyzer Physical And Chemical Properties Of Oils Kinematic Viscosity Measurement (Red Wood Viscometer) Kinematic Viscosity Measurement (Red Wood Viscometer) In this work viscosity is measured using red wood viscometer as shown in Fig.3.4. This method is applicable for viscosity determination of oils in Newtonian manner. Fig.3.4. Red Wood Viscometer Flash Point And Fire Point Measurement (Pensky Martin s Apparatus) Flash point and Fire point are measured by pensky martin apparatus as shown in Fig.3.5.In this brass test set up is filled with fuel sample, where it is heated and stirred to a specific rates based on the requirement. An ignition source is directed into the cup at regular

10 104 internals until a flash that spreads through out the inside of the cup. The corresponding temperature is Flash point. The rise in temperature after Flash point fire catches. That point is Fire point. Fig.3.5. Pensky Martin s Apparatus Calorific Value Measurement (Toshniwal Bomb Calorimeter) Toshniwal bomb calorimeter is used to measure calorific values of fuel samples as shown in fig.3.6.in this amount of heat generated is calibrated when matter is burned in a sealed chamber (bomb) Acid Value Measurement In vegetable oils free fatty acids present may be corrosive to engine parts. At elevated temperatures Fatty acids metal salts leads to in increase in wear. Therefore acid value is important to be measured. Acid value acid number is defined as the mg of KOH

11 105 required to neutralize the fatty acid present in one gram sample. Fatty acid content is expressed as oleic acid equivalents. Fig.3.6. Toshniwal bomb calorimeter Specific Gravity Measurement (Hydrometer) The Specific gravity is measurement can be done using hydrometer as shown in Fig3.7.pour sample into a clear cylindrical jar, make sure that sample is mixed thoroughly, immerse hydrometer into the liquid to a point slightly below the place where it floats

12 106 naturally, take readings at the point where the surfaces of the liquid cross the hydrometer. Fig.3.7.hydrometer EXPERIMENTAL PROCEDURE All experiments are carried out at the rated speed of 1500 rev/min at different load conditions. Readings are always taken after the engine attained stability of operation. Exhaust gas analyzers are switched on and allowed to stabilize before measurements. Instruments are periodically calibrated. Initially, experiments are conducted using diesel, methyl esters of mutton tallow, palm stearn, safflower with different pistons of combustion geometry at the rated speed under variable load conditions. Load, speed, air flow rate, fuel flow rate, exhaust gas temperature, exhaust emissions of unburnt hydrocarbon,carbon monoxide, carbon dioxide, and oxides of nitrogen are observed. Cylinder pressure and top dead center (TDC) position signals are recorded for processing the data to obtain combustion parameters.

13 107 In the second phase, based on the optimum combustion geometry, the performance, emission and combustion parameters of engine using methyl esters of mutton tallow, palm stearn, safflower as fuels are analyzed and compared with neat diesel operation. In the third phase, methyl esters of mutton tallow, palm stearn, safflower as fuels are used in the LHR developed engine Performance, emissions and combustion parameters are analyzed and compared with neat diesel and methyl esters of mutton tallow, palm stearn, safflower as fuels operation. In this work five different piston configurations are developed and are shown in Fig.3.8 (a) to Fig.3.8 (e) Fig. 3.1 Experimental set up

14 108 Fig Schematic layout of the test setup Fig.3.8 (a) Hemi Spherical Open Combustion Chamber

15 109 Fig.3.8 (b) Re-entrant Open Combustion Chamber Fig.3.8 (c) Double Wedge Shallow Open Combustion Chamber

16 110 Fig.3.8 (d) Toroidal Open Combustion Chamber Fig.3.9 (e) Shallow Depth Open Combustion Chamber

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