INTRODUCTION

This project is based on repairing and maintain the twin cylinder four stroke diesel
engine test rig to increase the performance i.e. brake power produced by an engine
and remove losses in various components connected to the engine for better working,
to improve performance and to increase life of an engine by properly repairing and
maintain the test rig.

Some required components like water tank, fittings, pipes etc. were
purchased and repaired in the test rig.

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 CONSTRUCTION & WORKING OF MODEL

Fig no.1:- Experimental Setup

COMPONENTS OF TEST RIG:

1. Four Stroke Twin Cylinder Water Cooled Diesel Engine

Fig. no. 2

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2. Fuel Tank/ Fuel Measuring Tube

Fig. no. 3

3. U-Tube Water Manometer

Fig. no. 4

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4. Electrical Water Heating System

Fig. no. 5

5. Energy Meter

Fig no. 6

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DESCRIPTION OF APPARATUS:

Apparatus consists of Diesel engine, Air supplying unit, Fuel supply unit
and electrical water heating system. A governor is connected to diesel engine to
maintain constant speed at varying load.

Air is supplied to engine from air box. Air enters the air box via orifice to
which differential ‘U’ tube water manometer is attached. Flow rate of air supplied to
diesel engine is determined from the reading of differential ‘U’ tube water
manometer.

Fuel supply unit consists of fuel tank and burette. Fuel will flow to engine
either from burette or from tank which depends upon the position of valve situated at
the bottom of burette.

Electrical water heating system consists of generator which supplies

electrical power to heaters immersed in water in a tank. Since above system is three
phase system, electrical heater consists of three copper plates. Copper plates are
immersed in water and heats water. (Water acts as a media through which current
flows and quantity of current flowing through the water depends upon the area of
copper plates submerged in water). Rate of heating of water depends upon the depth
to which copper plates are immersed. More the plates immersed, greater is the rate at
which water is heated and more is the electrical power generated. Therefore there is a
knob at the top of tank to control the depth of immersion of copper plate; to set the
power output from generator.

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 PROBLEM FACED DURING PROJECT WORK

During the completion of project work on Diesel Engine Test Rig, the Problem faced
were :
1. Problems related to assembly:
While starting the project, the diesel engine test rig available in lab was not
properly assembled. So, we assembled it properly.

2. Problems related to water supply:

For cooling purpose of engine, jackets and cooling water required a water tank
arrangement and piping connections were repaired.

3. Problems related to electrical water heating plates:

Initially the copper plates were highly corroded. The corrosion was removed
with the help of sand paper.

4. Problem related to water tank:

New water tank was purchased and fitted for electrical water heating system
with all the fittings and piping connections.

Fig. no. 7: Repaired Water Tank

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 PROBLEM OF LEAKAGES

Initially the plastic tank used in electrical water heating system had very less
thickness. Due to this it was expanding at the holes when the copper plates
were immersed at more depth as rate of heating of water depends upon the
depth to which copper plates are immersed. More the plates immersed, greater
is the rate at which water is heated. This would loosen the fitting of coupling
and it caused the leakage of water from the tank.

Also, the holes done for fitting the pipe couplings were of larger diameter than
the coupling diameter. Due to this there was leakage of water from the tank.

The fitting of pipe which connected the pump outlet and cooling water tank
inlet was not done properly i.e. teflon tape was not used to cover the threads at
pump outlet and cooling water tank inlet and because of which water was
leaking through the threads.

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 REPAIR OF LEAKAGES

First of all, we purchased a used industrial thinner tank as it had more

thickness and could survive higher temperature water without expanding.
Then, we cut it with hacksaw blade from the required height and washed it
thoroughly.

For inlet and outlet of water in the tank we needed two holes; one at the
bottom and other at the top respectively. The top hole was made at a height
such that the plates were less immersed in water. After doing the marking for
the two holes for couplings as well as four holes for nuts and bolts for
supporting electrical water heating system we went to the foundry shop.
We did the holes by using a hot rod of diameter (0.90”) slightly less than the
diameter of coupling (1”). This ensured a tight fitting between the pipe
coupling and tank.

After making holes of appropriate diameter, we fitted the in and out pipe
coupling in both the holes. The inlet of tank with electrical water heating
system was connected with the outlet of cooling water tank with the help of 1”
pipe and the outlet was connected with the reservoir. The pump outlet was also
connected with inlet of the cooling water tank with a 0.75” 6 feet pipe. During
all these connections, we ensured the sealing of threads with the Teflon tape so
that no leakages could occur through the threads. Also, we used hose clamps
to attach and seal the pipe onto the fitting.

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 COST ESTIMATION

SR. NO. PURCHASING ITEMS QUANTITY COST

1 Water Tank 1 Rs.450/-
2 1”Pipe Couplings 2 Rs.60/-
3 UPVC Solution 1 Rs.48/-
4 Thread Seal Tape 1 Rs.20/-
5 0.5” Pipe 1 Rs.50/-
6 Nut & Bolt 4 Rs.12/-
7 Hacksaw Blade 2 Rs.30/-
8 Hose Clamp 2 Rs.20/-
Total Rs.680/-
Table no. 1

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 PHOTOGRAPHS

Fig. no. 8: Diesel Engine Test Rig

Fig no. 9

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Fig. no. 10

Fig. no. 11

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