Per Manual

A Practical Manual
for
Power Engineering and

Refrigeration
(22562)
Semester – V
(ME)
Maharashtra State
Board of Technical Education
Certificate
This is to certify that Mr. / Ms ………………………………….
Roll No……………………….of Fifth Semester of Diploma in
……………………………………………………….of Institute
…………………………………………………………………..
(Code ----------) has completed the term work satisfactorily in
course Power Engineering and Refrigeration (22562) for the
academic year 20…….to 20…..... as prescribed in the curriculum.
Place ………………. Enrollment No……………………

Date:…..................... Exam Seat No . ………………......
Course Teacher Head of the Department Principal
Seal of the
Institute
Power Engineering and Refrigeration (22562)
Preface
The primary focus of any engineering laboratory/ field work in the technical
education system is to develop the much needed industry relevant competencies and skills.
With this in view, MSBTE embarked on this innovative ‘I’ Scheme curricula for engineering
diploma programmes with outcome-base education as the focus and accordingly, relatively
large amount of time is allotted for the practical work. This displays the great importance of
laboratory work making each teacher; instructor and student to realize that every minute of
the laboratory time need to be effectively utilized to develop these outcomes, rather than
doing other mundane activities. Therefore, for the successful implementation of this
outcome-based curriculum, every practical has been designed to serve as a ‘vehicle’ to
develop this industry identified competency in every student. The practical skills are difficult
to develop through ‘chalk and duster’ activity in the classroom situation. Accordingly, the ‘I’
scheme laboratory manual development team designed the practical to focus on the
outcomes, rather than the traditional age old practice of conducting practical to ‘verify the
theory’ (which may become a byproduct along the way).
This laboratory manual is designed to help all stakeholders, especially the students,
teachers and instructors to develop in the student the pre-determined outcomes. It is expected
from each student that at least a day in advance, they have to thoroughly read through the
concerned practical procedure that they will do the next day and understand the minimum
theoretical background associated with the practical. Every practical in this manual begins by
identifying the competency, industry relevant skills, course outcomes and practical outcomes
which serve as a key focal point for doing the practical. The students will then become aware
about the skills they will achieve through procedure shown there and necessary precautions to
be taken, which will help them to apply in solving real-world problems in their professional
life.
This manual also provides guidelines to teachers and instructors to effectively
facilitate student-centered lab activities through each practical exercise by arranging and
managing necessary resources in order that the students follow the procedures and
precautions systematically ensuring the achievement of outcomes in the students.
Power producing and absorbing devices are essentials for mechanical engineering. It
is necessary for mechanical engineering technologists to analyze working and plot the
performance of devices like internal combustion engines, air compressors, gas turbines so
that he will be able to operate them effectively in an industrial situation. This knowledge is
also useful in selecting suitable prime mover for given application and to maintain and test
the same. This course also gives basic exposure of refrigeration and air-conditioning
equipment which play a vital role in maintaining controlled atmosphere in different domestic
and industrial applications. A separate elective course on Refrigeration and Air-conditioning
is also available in sixth semester for in-depth knowledge of the course.
Although all care has been taken to check for mistakes in this laboratory manual, yet
it is impossible to claim perfection especially as this is the first edition. Any such errors and
suggestions for improvement can be brought to our notice and are highly welcome.
Maharashtra state Board of Technical Education i

Programme Outcomes (POs) to be achieved through Practical of this

Course: Following POs and PSO are expected to be achieved through the practicals of the
(Power Engineering and Refrigeration) course.
PO 1. Basic knowledge : Apply knowledge of basic mathematics, sciences and basic

engineering to solve the broad-based mechanical engineering problems
PO 2. Discipline knowledge: Apply mechanical engineering knowledge to solve broad-based
mechanical engineering related problems.
PO 3. Experiments and practice: Plan to perform experiments and practices to use the results
to solve broad-based mechanical engineering problems.
PO 4. Engineering tools: Apply relevant mechanical technologies and tools with an
understanding of the limitations
PO 5. The engineer and society: Assess societal, health, safety, legal and cultural issues and
the consequent responsibilities relevant to practice in field of mechanical engineering.
PO 6. Environment and sustainability: Apply mechanical engineering solutions also for
sustainable development practices in societal and environmental contexts.
PO 7. Ethics: Apply ethical principles for commitment to professional ethics, responsibilities
and norms of the practice also in the field of mechanical engineering
PO 8. Individual and team work: Function effectively as a leader and team member in
diverse/ multidisciplinary teams.
PO 9. Communication: Communicate effectively in oral and written form.
PO 10.Life-long learning: Engage in independent and life-long learning activities in the
context of technological changes also in the mechanical engineering and allied industry.
Program Specific Outcomes (PSOs)

PSO 1: Modern Software Usage: Use latest mechanical related software for simple design,
drafting, manufacturing, maintenance and documentation of mechanical components and
processes.
PSO 2: Maintenance and selection of machines, equipment, instruments: Maintain and

select appropriate machine, equipment and instrument in field of Mechanical Engineering.
PSO 3: Manage Mechanical Process: Manage the mechanical process by selection and
scheduling right type of machinery, equipment, substrates, quality control techniques,
operational parameters and software for a particular mechanical process or job for economy
of operations.
Maharashtra state Board of Technical Education ii

List of Industry Relevant Skills

The following industry relevant skills of the competency Use Power Engineering and
Refrigeration are expected to be developed in you by undertaking the practical of this
laboratory manual.
1. Identify different components of I.C Engine
2. Test the performance of I C Engine
3. Test the performance of Air compressor
4. Test the performance of Vapour Compression system
5. Maintain Refrigeration and air conditioning system
Maharashtra state Board of Technical Education iii

Practical- Course Outcome matrix
Course Outcomes (COs)

a. Identify different components of I C engines and its auxiliaries.
b. Test the performance of I C Engine.
c. Maintain reciprocating air compressors.
d. Identify different components of gas turbines and jet engines.
e. Test the performance of refrigeration and air-conditioning systems
S. No. CO CO CO CO CO
Practical Outcome
a. b. c. d. e.
Assemble/Dismantle single cylinder IC
1. √ - - - -
Engine. (Part-I) *
Assemble/Dismantle single cylinder IC

√ - - - -
2. Engine. (Part-II) *
Assemble/Dismantle multi cylinder IC

3. √ - - - -
Engine. (Part-I)
Assemble/Dismantle multi cylinder IC

4. √ - - - -
Engine. (Part-II)
Assemble/Dismantle inline/rotary fuel

5. √ - - - -
injection pump in a diesel engine.
Perform test on the given IC Engine to

6. prepare heat balance sheet and plot - √ - - -
performance characteristics. (Part-I) *
7. Perform test on the given IC Engine to

prepare heat balance sheet and plot - √ - - -
performance characteristics. (Part-II) *
8. Perform Morse Test on the given IC

√ - - -
Engine. -
Use exhaust gas analyzer to

9. measurement and analyze pollutants in - √ - - -
the given IC engine.
Perform diagnosis test on given IC

10. √ - - -
engine using Engine Control Unit * -
Perform test on the given two-stage

reciprocating air compressor to find
11. - - √ - -
volumetric and isothermal efficiency.
(Part-I) *
Maharashtra state Board of Technical Education iv

Perform test on the given two-stage

reciprocating air compressor to find
12. - - √
volumetric and isothermal efficiency. - -
(Part-II) *
Assemble/Dismantle of Gas turbine

13. - - - √
model. -
Perform test on vapor compression

14. - - - - √
refrigeration cycle test rig to find COP *
Trace the refrigerant flow of domestic

refrigerator and measure temperatures
15. - - - - √
at critical points for different settings of
thermostat.
Assemble/Dismantle various
16. - - - - √
components of domestic refrigerator.
17. components of Water Cooler and - - - - √
Window/Split air conditioning units.
Maharashtra state Board of Technical Education v

Guidelines to Teachers
1. Teacher need to ensure that a dated log book for the whole semester, apart from the
laboratory manual is maintained by every student which s/he has to submit for
assessment to the teacher in the next practical session.
2. There will be two sheets of blank pages after every practical for the student to report
other matters (if any), which is not mentioned in the printed practicals.
3. For difficult practicals if required, teacher could provide the demonstration of the
practical emphasizing of the skills which the student should achieve.
4. Teachers should give opportunity to students for hands-on after the demonstration.
5. Assess the skill achievement of the students and COs of each unit.
6. One or two questions ought to be added in each practical for different batches. For this
teachers can maintain various practical related question banks for each course.
7. If some repetitive information like data sheet, use of software tools etc. has to be
provided for effective attainment of practical outcomes, they can be incorporated in
Appendix.
8. For effective implementation and attainment of practical outcomes, teacher ought to
ensure that in the beginning itself of each practical, students must read through the
complete write-up of that practical sheet.
9. During practical, ensure that each student gets chance and takes active part in taking
observations/ readings and performing practical.
10. Teacher ought to assess the performance of students continuously according to the
MSBTE guidelines
Instructions for Students

1. For incidental writing on the day of each practical session every student should
maintain a dated log book for the whole semester, apart from this laboratory manual
which s/he has to submit for assessment to the teacher in the next practical session.
2. For effective implementation and attainment of practical outcomes, in the beginning it
self of each practical, students need to read through the complete write-up including the
practical related questions and assessment scheme of that practical sheet.
3. Student ought to refer the data books, IS codes, Safety norms, Technical Manuals, etc.
4. Student should not hesitate to ask any difficulties they face during the conduct of
practical.
Maharashtra state Board of Technical Education vi

Content Page
List of Practical and Progressive Assessment Sheet
Date of Date of Dated Remarks

performan submi Assess sign. (if any)
S. Page
Practical Outcome ce ssion ment of
No No.
marks(25) teach
er
Assemble/Dismantle single
1.
cylinder IC Engine. (Part-I)
1
Assemble/Dismantle single
2.
cylinder IC Engine. (Part-II)
3. Assemble/Dismantle multi
cylinder IC Engine. (Part-I) 10
Assemble/Dismantle multi
4. 4
cylinder IC Engine. (Part-II)
Assemble/Dismantle
5. inline/rotary fuel injection 18
pump in a diesel engine.
Perform test on the given IC
Engine to prepare heat balance
6.
sheet and plot performance
characteristics. (Part-I)
Perform test on the given IC 26
Engine to prepare heat balance
7.
sheet and plot performance
characteristics. (Part-II)
Perform Morse Test on the 39
8.
given IC Engine.
Use exhaust gas analyzer for
measurement and analysis of
9. pollutants in the given IC 46
engine.
Perform diagnosis test on given

IC engine using Engine Control
10.
Unit 54
Perform test on the given two-

stage reciprocating air
11. compressor to find volumetric
and isothermal efficiency. 64
(Part-I)
Maharashtra state Board of Technical Education vii

Perform test on the given two-

stage reciprocating air
12. compressor to find volumetric
and isothermal efficiency.
(Part-II)
Assemble/Dismantle Gas
13.
turbine model. 76
Perform test on vapor
14. compression refrigeration cycle 82
test rig to find COP
Trace the refrigerant flow of
domestic refrigerator and
15. measure temperatures at critical 93
points for different settings of
thermostat.
16. components of domestic 101
refrigerator.
components of Water Cooler 118
17.
and Window/Split air
conditioning units.
Total
Note: To be transferred to Proforma of CIAAN-2017.
A suggestive list of PrOs is given in the above table. More such PrOs can be added to
attain the COs and competency. A judicial mix of minimum 12 or more practical need
to be performed, out of which, the practicals marked as ‘*’ are compulsory, so that the
student reaches the ‘Precision Level’ of Dave’s ‘Psychomotor Domain Taxonomy’ as
generally required by the industry.
Maharashtra state Board of Technical Education viii

Practical No.1and 2: Assemble/Dismantle single cylinder IC Engine.

(Part-I and II)
I Practical Significance
Internal combustion engine is a device in which combustion occurs inside the engine
cylinder. I.C. engine works in four strokes –suction, compression, expansion and
exhaust. If four stokes takes place in one cylinder then it is called as Single cylinder
I.C. engine. Dismantling is the process of removing all the engine parts to know
various sub-assemblies of engine, identify the parts and their location in the sub-
assemblies and inspect parts to know their physical and functional condition.
Dismantling of I.C. Engine is a feature of preventive as well as breakdown
maintenance. After dismantling or repair, all the parts are put back together. This is
called engine assembly (reassembly). Engine assembly mainly consists of three major
sub-assemblies’ like cylinder and related parts, piston and related parts and valve
mechanism components.
II Relevant Program Outcomes (POs)

PO1- Basic knowledge: Apply knowledge of basic mathematics, sciences and basic
Engineering to solve the broad-based Mechanical Engineering problems.
PO2-Discipline knowledge: Apply Mechanical engineering knowledge to solve
broad- based mechanical engineering related problems.
PO3- Experiments and practice: Plan to perform experiments and practices to use
the results to solve broad-based Mechanical Engineering problems.
PO4-Engineering tools: Apply relevant Mechanical technologies and tools with
an understanding of the limitations.
PO8- Individual and team work: Function effectively as a leader and team member
in diverse/ multidisciplinary teams.
III Competency and Skills

The aim of this course is to help the student to attain the following industry identified
competency through various teaching learning experiences:
 Maintain power engineering and refrigeration devices.
IV Relevant Course Outcome(s)

 Identify different components of I C engines and its auxiliaries
V Practical Outcome
 Assemble/Dismantle single cylinder IC Engine.
VI Relative Affective Domain-

 Follow safety practices.
 Practice good housekeeping.
 Maintain tools and equipment.
 Follow ethical Practices.
Maharashtra state Board of Technical Education 1

VII Minimum Theoretical Background

1. Know the construction and working of I.C. Engine.
2. Identify recommended tools.
3. Identify various subassemblies of I.C. Engine.
4. Identify accessories of I.C. Engine.
VIII Experimental setup
Figure No.1 Single Cylinder Diesel Engine(In section)
Figure No 2 Piston sub-assembly (exploded view)

Figure No 3 Tool Box
Figure No 4 Piston sub-assembly

Figure No 5 Dismantling of 4-stroke single cylinder petrol engine
Figure No 6 Pitting of Piston

IX Resources Required
Name of
S. No. Suggested Broad Specification Quantity
Resource
Adjustable wrench – 10/250 mm
Plier – 8”/200mm
Piston ring remover
Ball peen Hammer – 500 gm,
claw hammer- 1/4 LB 1
1 Tool box Allen key set – 1.5 to 10 inch
Screw driver set – 5 pieces
Open end jaw spanner set- 6-7 to 30-32
Round / box spanner set - 6-7 to 30-32
Rachet set – 10mm to 32 mm
X Precautions to be Followed
1. Avoid improper handling of I.C. Engine.
2. Use special and recommended tools for assembly and dismantling of I.C. Engine.
3. Use clean work bench for assembly and dismantling of I.C. Engine.
XI Procedure
1. Select the proper tools and equipment.
2. Apply recommended tools to remove engine accessories and components of I.C.
engine.
3. Identify the various subassemblies and accessories of the Engine.
4. Examine all the components carefully
5. Observe their physical and functional conditions
XII Resources Used - ( Use only Euro4 comply Engine)
S. Name of Broad Specifications Quantity Remarks

No. Resource Make Details (If any)
1.
2.
3.
4.
5.
6
7
8

XIII Actual Procedure Followed with Tools required

A. Dismantling of cylinder head and block
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B. Dismantling of piston sub - assembly
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C. Dismantling of valve mechanism
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D. Dismantling of accessories
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E. Assembly of cylinder head and block
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F. Assembly of piston sub - assembly

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G. Assembly of valve mechanism

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H. Assembly of accessories
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XIV Precautions Followed

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XV Observations and Calculations
Sr.
Particulars Remark
No.
1 Bore diameter
2 Piston diameter
3 Number of strokes
4 Length of stroke
a.
Names of damaged and b.
5 badly worn components
c.
6 No. of oil rings
7 No. of compression rings
Sr. Remark
Name of Component
No. (Functions/Observations/Specifications)
1 Cylinder head
2 Poppet valves/ports
3 Valve springs
4 Cam shaft
5 Head gasket
6 Cylinder block
7 Piston

8 Piston rings
9 Gudgeon pin
10 Connecting rod
11 Crank shaft ■•
XVI Results
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XVII Interpretation of Results

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XVIII Conclusions
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XIX Practical Related Questions

Note: Below given are few sample questions for reference. Teachers must design
more such questions so as to ensure the achievement of identified CO.
1. Draw a neat labeled sketch of piston.

2. Enlist the name of gasket material used in cylinder head.
[Space for Answer]

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XX References / Suggestions for Further Reading
1. https://www.youtube.com/watch?v=vvqiioLIXtU&list=PLET1GQlHfInNMkHF
DGaj7OLKhnzyRmQuV
2. https://www.youtube.com/watch?v=uJivC7452gE
3. https://www.youtube.com/watch?v=Pu7g3uIG6Zo
XX I Assessment Scheme
Performance Indicators Weightage

Process Related (10 Marks) 40%
1 Handling of the tools in tool kit 20%
2 Identification of I.C. Engine components 20%
Product Related (15 Marks) 60%
3 Interpretation of components of I.C. Engine 20%
4 Conclusions 20%
5 Practical related questions 20%
Total (25 Marks) 100 %
Names of Student Team Members

1. …………………………
2. …………………………
3. …………………………
Dated signature of
Marks Obtained
Teacher
Process Product Total
Related(10) Related(15) (25)

Practical No.3 and 4: Assemble and Dismantle Multi-Cylinder IC Engine.

(Part-I and II)
A multi-cylinder engine is a reciprocating internal combustion engine with
multiple cylinders. It can be either a 2-stroke or 4-stroke engine and can be
either Diesel or petrol engine. Multi-cylinder engines offer a number of advantages
over single cylinder engines, chiefly with their ability to neutralize imbalances by
having corresponding mechanisms moving in opposing directions during the
operation of the engine. Dismantling and reassembly of Multi-cylinder is similar to
that of Single cylinder I.C. Engine.

PO1-Basic knowledge: Apply knowledge of basic mathematics, sciences and basic
PO8-Individual and team work: Function effectively as a leader and team member
in diverse/ Multidisciplinary teams.


V Practical Outcome
 Assemble/Dismantle Multi cylinder IC Engine. (Part-I&II)


1. Identify various subassemblies of I.C. Engine.

3. Distinguish accessories of I.C. Engine.

4. Know the procedure of dismantling and assembly.
Figure No 1 Four cylinder engine with holder
Figure No 2 Schematic view of Four cylinder engine (In section)

Figure No 3 Four cylinder engine (In section)
Figure No 4 Four cylinder engine (In section-Pictorial view)

Name of
Resource
Piston ring remover
Ball peen Hammer – 500 gm,
claw hammer- 1/4 LB 1
1 Tool kit box Allen key set – 1.5 to 10 inch
Screw driver set – 5 pieces
2. Use special and recommended tools for assembly and dismantling of I.C. Engine.
3. Use clean work bench for assembly and dismantling of I.C. Engine.
XI Procedure
2. Apply recommended tools to remove engine accessories and components of I.C.
engine.
3. Identify the various subassemblies and accessories of the Engine.
4. Examine all the components carefully and observe their physical and functional
conditions for dismantling and assembly of I.C. Engine.
XVII Resources Used ( Use only Euro4 comply Engine)
S. Name of Resource Broad Specifications Qty. Remarks

No. Make Details (If any)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

XII Actual Procedure Followed with Tools required.
A. Dismantling of cylinder head and block

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B. Dismantling of piston sub - assembly
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C. Dismantling of valve mechanism
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D. Dismantling of accessories
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E. Assembly of cylinder head and block
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F. Assembly of piston sub - assembly
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G. Assembly of valve mechanism

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H. Assembly of accessories
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XIII Precautions Followed
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XIV Observations and Calculations
Sr.
Particulars Remark
No.
1 Bore diameter
2 Piston diameter
3 Number of strokes
4 Names of damaged and badly worn components
5 Type and quantity of oil required
6 No. of oil rings
7 No. of compression rings
Sr.
Name of Component Function
No.
1 Cylinder head
2 Poppet valves
3 Valve springs
4 Cam shaft
5 Head gasket
6 Cylinder block
7 Cylinder liner

8 Piston
9 Piston rings
10 Gudgeon pin
11 Connecting rod
12 Journal bearing
13 Crank pin bearing
14 Crank shaft
15 Oil pan ■•
XV Results
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XVI Interpretation of Results

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XVII Conclusions
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XVIII Practical Related Questions

more such questions
so as to ensure the achievement of identified CO.
1. Draw a sketch of connecting rod of an Engine
2. Name the different components of valve mechanism of an I.C. Engine
[Space for Answer]
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XIX References / Suggestions for Further Reading
1. https://www.youtube.com/watch?v=lR6ku_g_eNI
2. https://www.youtube.com/watch?v=BXQ27pU3_7E
3. https://www.youtube.com/watch?v=fTAUq6G9apg
XX Assessment Scheme

1 Handling of the tools in tool kit 20%
2 Identification of I.C. Engine components 20%
3 Interpretation of components of I.C. Engine 20%
4 Conclusions 20%
Total 100 %
1. …………………………
2. …………………………
3. …………………………
Dated signature of
Marks Obtained
Teacher

Practical No.5 : Assemble and Dismantle Inline/Rotary Fuel

Injection Pump In A Diesel Engine.
Fuel injection pump is required to deliver accurately metered quantity of fuel under
high pressure at the correct instant to the injector. Inline fuel pump- The eccentric
on the camshaft causes constant linear movement of the pushers - the plungers, by the
action of the pushers, push the fuel in the direction of the retention valve - the
pressure is high enough to open the retention valve and the fuel is conducted by pipes
to the injectors - the amount of fuel is controlled by the gear rack -The gear rack
causes rotation movement to the plunger that is function of the accelerator pedal
Rotary fuel pump -Send fuel to plungers - Time duration in close position of electro-
valve determines the injection flow Send fuel to injectors - The plungers are pressed
by cam -Fuel high pressure generated - Distributor rotates to injector flow position.
in diverse/ multi-disciplinary teams

Competency through various teaching learning experiences:

V Practical Outcome
 Assemble/Dismantle inline/rotary fuel injection pump in a diesel engine.


1. Know the construction and working of Fuel pump.
3. Identify various sub-assemblies of Fuel pump
Figure 1 Fuel pump in section
Figure 2 Fuel pump elements

Figure 3 Fuel pump elements (Cut-section-port)
Figure 4 Fuel pump elements (Cut-section-load)
Figure 5 Inline Fuel pump

Figure 6 Rotary Fuel pump
Figure 7 Rotary Fuel pump (cut - section )

S. Name of
Suggested Broad Specification Quantity
No. Resource
Allen key set – 1.5 to 10 inch
Tool box Screw driver set – 5 pieces
Round / box spanner set - 6-7 to 30-32 1
1
1. Avoid improper handling of Fuel pump.
2. Use special and recommended tools for assembly and dismantling of Fuel pump
3. Use clean work bench for assembly and dismantling of Fuel pump.
XI Procedure
A) Dismantling of fuel injection pump:

Note: Teacher shall allot assembling of fuel injection pump and writing of steps
involved in it as students activity.
1. Remove delivery valve holder.

2. Take out delivery valve spring and delivery valve.
3. Remove lock ring from lower side of pump.
4. Remove plunger return spring by removing plunger foot lock.
5. Remove plunger from barrel. Keep it in tray. Do not allow plunger to come in
contact with moisture otherwise it may corrode the plunger barrel.
6. Remove the gear quadrant and spring plate.
7. Remove the control-rack from the housing of pump.
8. Remove barrel fixing screw and remove the barrel from the housing of pump.
XII Resources Used

Sr. Broad Specifications Remark
Name of Resource Qty
No Make Details (If any)
1
2
3
4
5

XIII Actual Procedure Followed with Tools required

Dismantling of Fuel pump
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Assembly of Fuel pump

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Sr. Name of unit Function Tools used to
no dismantle
Plunger and barrel

01
sub-assembly
Delivery valve sub-

02
assembly
Housing
03
sub-assembly
'
XV Results
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XVII Conclusions
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1. Interpret if delivery valve spring is weak in fuel injection pump.

2. Conclude the injection pump plunger positions according to its motion.
[Space for Answer]
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1. https://www.youtube.com/watch?v=IjXnbFVJKRY
2. https://www.youtube.com/watch?v=091xsWZ2wHY
3. https://www.youtube.com/watch?v=vp7fE-e0hQs
4. https://www.youtube.com/watch?v=iYFfMWh_nP8
5. https://www.youtube.com/watch?v=HVIE36oIR1s

1 Handling of the tool kit tools 20%
2 Identification of Fuel pump components 20%
3 Interpretation of components of Fuel pump 20%
4 Conclusions 20%

1. …………………………
2. …………………………
3. …………………………
Dated
Marks Obtained signature of
Teacher

Practical No.6 and 7 : Perform Test On The Given I.C. Engine to Prepare
Heat Balance Sheet and Plot Performance
Characteristics.
Testing of an I.C. Engine is a process in which the engine is tested for various
parameters for efficient performance.
The purpose of testing an I.C. Engine is
a. To determine the information which cannot be obtained by calculations.
b. To confirm validity of the data used in engine design.
c. To satisfy the customer regarding the performance of the engine.
There are three types of test carried out for I.C. Engine.
a. Commercial test b. Thermodynamic test c. PUC test
Heat balance sheet is an account of heat supplied to the engine and heat utilized in
various ways by the engine. Thermodynamic test is carried out for the purpose of
comparing actual results with the theoretical or ideal performance.


 Test the performance of I C Engine.
V Practical Outcome
Perform test on the given I.C. Engine to prepare heat balance sheet and plot
performance characteristics.


 Work as a leader/a team member.

1. Identify parameters of I.C. Engine for Testing.
2. Know the procedure of Heat Balance Sheet.
3. Estimate Heat Balance Sheet.
Figure No 1 Schematic diagram of Diesel engine test rig with rope brake dynamometer
Figure No 2 Diesel Engine Test Rig With Rope Brake Dynamometer

Sr.
Name of Resource Suggested Broad Specification Quantity
No
1 Type – Single cylinder
Bore - 0.875 m
1
Engine Stroke – 0.017 m
Power developed- 7 HP
Torque -7.46 N-m At 1500 rpm
2 Diameter of rope brake drum, D = 0.3 m
Rope brake
1
dynamometer
Diameter of Rope, d = 0.015 m
OR
3 Hydraulic Dynamometer constant, K = 2000

dynamometer 1
OR
4 Eddy current Dynamometer constant, K = 200
dynamometer
5 Diameter of Orifice(d0) = 0.014 m
Orifice specification 1
Coefficient of discharge for orifice, Cd = 0.65
6 Tachometer Standard (Range-1000 to5000 rpm) 1
7 Calorimeter Type –Exhaust gas calorimeter 1
8 Fuel gauge Burette of 50 ml 1
9 Temperature RTD
gauge/Thermocoupl 1
e
10 Water manometer Glass U tube manometer 1
11 Glass /Fiber Jar Capacity - 1 lit. 1
Note: Specifications mentioned are for reference only.
2. Operate the I.C. Engine as per given procedure.
3. Before starting the engine, oil level in sump and jacket cooling water supply must
be checked.
4. Never stop the engine on load and never use decompression lever for stopping.
5. Do not tamper with any of engine setting, like governor, fuel injector.
XI Procedure
1. Fill up sufficient diesel in diesel tank.
2. Check oil level in the engine. It should be up to the top edge of the flat
portion provided over the oil dipstick. If oil level is reduced, add up clean

SAE-40 oil to the crankcase by opening the valve cover at the top of the
engine. Replace the cover after filling the oil.
3. Fill up water in Manometer up to half of the manometer height.
4. Start the water supply and see that water is flowing though engine jacket,
brake drum and exhaust gas calorimeter.
5. If diesel tank was empty before filling the diesel, remove air bubbles in fuel
pipe, by opening the vent screw provided at the right side, top of the fuel
pump.
6. Adjust the load on the dynamometer to zero, by releasing the loading screw,
so that there is no tension in the rope.
7. Start the engine. For starting, lift up decompression lever, at the side of the
valve cover. Put the handle over the starting shaft and rotate the shaft. As
engine picks up sufficient speed, drop the decompression lever. The engine
will start. Remove the handle immediately. Allow the engine to get
stabilized.
8. As engine picks up its rated speed, start water to the brake drum.
9. If required, adjust the fuel supply in order to bring the engine to the desired
test speed at which trials to be conducted (further, all the readings are to be
taken at this test speed).
10. Open burette filling cock, take sufficient diesel in burette and close the cock.
11. Now, turn selector cock to ‘BURETTE’ position and note down time
required to consume certain amount of fuel <10 ml or 20 ml etc.) with the
help of fuel gauge and stop watch i.e. ‘t’ second.
12. Note down engine speed with tachometer.
13. Take manometer reading h1and h2. ’
14. Measure quantity of jacket cooling water (mwc) in lit/min. and its inlet
temperature (t1°C) and outlet temperature (t2°C) across the engine jacket.
15. Measure engine room temperature (tr°C).
16. i) Measure temperature of exhaust gases from the engine (t10C)
ii) If exhaust gas calorimeter is used, then measure,
(a) Quantity of. water supplied to the exhaust gas calorimeter (mcc) in lit/min.
(b) Temperature of water inlet to calorimeter (tc1°C)
(c) Temperature of water outlet from the calorimeter (tc2°C)
(d) Temperature of exhaust gas entering the calorimeter (tg1°C)
(e) Temperature of exhaust gas leaving the calorimeter (tg2°C)
17. All the readings taken in step nos. 10 to 16 are for zero load, Note these
readings in the Observation table in the column of zero load.
18. Calculate full brake load capacity of the engine.
19. Apply certain load (say 1/4th of full load) on the dynamometer. In case of
constant speed governor, engine will attain the test speed. In case of variable
speed governor, adjust the fuel supply to bring the engine to test speed at
which test is to be conducted. Note this load in the observation table and take
all readings as in step nos. 10 to 16. Note these readings in the observation
table in the column for this load. .
20. Repeat the same procedure for different loads (say 1/2th of full load, 3/4th of full
load and full load).
21. Determine Frictional Power (F.P.) as follows -
22. On graph paper mark X and Y axis. On X axis take Brake Power (BP) in
KW to some scale. On Y axis take mass of fuel consumed in Kg / min (mf)
to some scale. Mark the points showing X and Y co-ordinates i.e. respective
BP and mfon graph. Draw straight line passing through maximum no. of
points on graph, as shown in the following figure. The plot is known as
Willam’s Line.
23. Distance OA represents FP to some scale. As the trial is conducted at
constant speed, FP is assumed to be same for all loads. Enter FP obtained as
above, in the tabular form of calculation (5.0) in the Sr. No. 11 for all loads.
24. Prepare heat balance sheet on minute and percentage basis for any one
brake load other than zero.
Figure No 3 William’s Straight Line method

XII. Resources Used
Sr. Name of Broad Specifications Qty Remarks

No Resource Make Details (If any)
1.
2.
3.
4.
5.
6.
7.
8.

XII Actual Procedure Followed

Please note: If the engine test rig available in laboratory is different from the test rig
given in the manual, then there will be change in layout diagram, stepwise procedure,
observation table and calculations. The teachers are advised to make the necessary
changes and guide the students accordingly
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Sr. Zero 1 /4th Half 3/4th Full

Load condition Particulars
No. load load Load Load Load
1 Weight (W) in kg
Spring balance reading (S) in kg (in case
2
of rope brake dynamometer)
3 Speed (N) in rpm
Time taken to consume specific quantity -
4
(10ml, 20 ml as suitable of fuel (t) in sec
5 Cooling water inlet temp, (t.,) in °C
6 Cooling water outlet temp. (t2) in °C
Quantity of jacket cooling water (mwc) in
7
lit/min
8 Exhaust gas temp. (tq) in °C
9 Engine room temp. (tr) in °C
h
1
Water manometer reading hw cm

10 h
2
cm
Quantity of water supplied to exhaust
11
gas calorimeter (mcc) in lit / min

Temp, of water inlet from calorimeter

12
(tc1) in °C
Temp, of water outlet from calorimeter
13
(tc2) in °C
Temp, of exhaustgases entering
14
calorimeter (tg1) in °C
Temp, of exhaust gases leaving
15
calorimeter (tg2) in °C
Calculations:
Calculation table for Efficiencies and Heat balance Sheet
Half
Sr Zero 1/4th 3/44h Full
Particulars Load Loa
No. load load Load Load
condition Formulae d
1 Weight (W) in N (W in kg x 9.81)
Spring balance reading (S)
2 in N (in case of rope brake (S in kg x 9.81)
dynamometer)
3 Speed (N) in rpm
For rope brake
2(w-s)πreN
dynamometer
60x1000
er
Brake For hydraulic
Power dynamometer WxN
4
(BP) in K
kW
For Eddy Current ----------

dynamometer
Quantity of fuel consumed Sp. Quantity of fuel(ml)
5
(mfc) in lit/sec 1000 x t
Mass of Fuel Consumed (mfc x sp. gr. of fuel)
6
(mf) in kg/min x 60
Mass of jacket cooling (mwc x sp. gr. of
7
water (mw) in kg/min water)
Manometer difference or (h2-h1)
8 ---------------
water head (mw) in meters
100

Frictional Power (FP) in Refer step no. 21 for

9
kW determination of FP
Indicated Power (IP) in
10 (BP + FP)
kW
Mechanical Efficiency
11 (BP / IP) x 100
ŋMech in (%)
Mass of water supplied to (mcc x sp. gr. of

'12
exhaust gas calorimeter water)
(mc) in kg/min
Calculations for heat balance sheet
Prepare heat balance sheet on minute and percentage basis for any one brake load other
than zero.
For load on engine = ................................. ............ N
1. Heat Supplied
Hf = Heat supplied by combustion of fuel = (mf) X CV
= …………… X …………………..
= ....................................................................................................................kJ / min
2. Heat Expenditure
i. Heat equivalent to brake power (HBP)
Brake power, BP ={ [ 2π (W-S) re N / 60] x 1000 }KW
=……………………………
BP = ………………………… kW or kJ/s
HBP = Heat equivalent to brake power = BP x 60
= ……………. X 60
=……………kJ / min
ii. Heat carried away by Jacket cooling water (Hcw)
Hcw= Heat carried away by Jacket cooling water
= (mw) x Cpw x (t2–t1 )
= ( …………)x 4.187 X (………– ... .. ….)
H c w = ……………….. kJ/min .

iii. Heat carried away by exhaust gases (Hg)By two methods,
a) By using Air box,
First determine the mass of exhaust gas as follows
ma = p a xQ = ……………………………. equation (i)
Density of air is calculated from general gas equation as follows:
We know, PV = RT
Where, P = Atmospheric Pressure = 1.01325 bar
= 1.01325 x 10s N/m2
R = Characteristic constant for air - 0.287 kJ/kg K .
T = Absolute temperature of air = (tr + 273)°K
P x (1 /ƿa)=RT
ƿa=P / RT
ƿa = ………….Kg/m3
Now quantity of air supplied is calculated as
Q = Cd x a0 x √2gha m3/s
2
a0= area of orifice =π / 4 x (d0 )
2
= π / 4 x ( ……………)
= ………………… m2
Here, ha = air head in meter = (p w h w /p a )
= [(1000 x……………….)/(.....................)]m of air
= ………………………… m of air.
Q = . ………. x...........,.x √ 2x9.81 x.................... .m3/s
Q =……………………. m3/sec

Thus, mass of air supplied in kg/s from equation (i) is
ma=Pa x Q =
= …………………. Kg/sec
mass of air supplied in kg/min
ma = mass of air supplied in kg/sec X 60
= ………………….. kg/min
Thus, mass of exhaust gases in kg/min
= mass of air consumed in kg/min + mass of fuel consumed in kg/min
mg = ma + mf
mg=……+ …….. .
mg = ……………. kg/min
Hence
Heat carried .away by exhaust gases = mg x Cpg x (tf - tr)
Hg = ……………………….. kJ/min
b) By using Exhaust gas Calorimeter
Exhaust Gas Inlet
Water outlet
Water Inlet
Writing the heat balance for calorimeter as -
Heat rejected by exhaust gases in the calorimeter = heat gained by the water in the
calorimeter
Now, Total heat carried away by exhaust gases =

Hg = mg x Cpgx (tg1 – tg2) =[mc x Cpw x (tc2 - tc1) ]
mg x Cpg= [mc x Cpw x (tc2 - tc1) ] / (tg1 – tg2)
Now, total heat carried away by exhaust gases = Hg = mg x Cpgx (tg - tr)
= { [mc x Cpw x (tc2 - tc1) ] / (tg1– tg2) } x (tg - tr)
Hg = …………………………. kJ / min
iv) Heat unaccounted (Heat Lost due to radiation, pumping losses, errors of
observation etc.) by difference
Hu= (Heat supplied by combustion of fuel) - [(Heat equivalent of BP) +
(Heat lost to jacket cooling water) + (Heat lost to exhaust gases)]
= Hf - [ HBP + Hcw + Hg ]
Hu =……..................... kJ/min
XV Results
Heat balance sheet for ............ .......... . N brake load
HEAT CREDIT HEAT DEBIT

Heat
kJ/min % Heat Expenditure kJ/min %
supplied
a) Heat equivalent to BP (HBP)
Heat
supplied by b) Heat lost to jacket cooling water (Hcw)
100
combustion c) Heat lost to exhaust gases '(Hg )
of fuel (Hf)
b) Heat unaccounted (Hu)
Total 100 100

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XVII Conclusions
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.
1. Compare the ignition temperature of diesel fuel and petrol fuel.
2. Identify costly engine of same capacity of petrol or diesel engine. Justify.
3. Draw performance characteristics based on calculations.
[Space for Answer]

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1. https://www.youtube.com/watch?v=wr5JsovSX_o
2. https://www.youtube.com/watch?v=HAFR9fVknso
3. https://www.youtube.com/watch?v=uOYslENZlnc

1 Ability to start, stop and operate the engine 20%
2 Ability to apply desired load on engine 20%
3 Calculate Heat balance sheet of I.C. Engine 20%
4 Conclusions 20%

1. ………………………….
2. ………………………….
3. ………………………….
Marks Obtained Dated signature of

Teacher

Practical No. 8: Perform Morse Test on the given IC Engine.
A Morse Test is a test conducted to determine the power developed in each cylinder
in multi cylinder I.C. Engine. Then the power of the individual cylinders are
determined by cutting- off the power supply to the spark plug of the cylinder
under test for petrol engine and fuel supply of the cylinder in diesel engine. Morse
Test is used to calculate Indicated power of Multi cylinder high speed engine.


V Practical Outcome
 Perform Morse Test on the given I.C. Engine.

 Work as a leader / a team member.

1.Know the procedure of Morse Test.
2.Identify performance parameters of Morse Test.
3.Determine the brake load in order to bring the engine to desired speed,
while cutting- off individual cylinders.

Figure No 1 Four stroke four cylinder petrol engine test rig with hydraulic
dynamometer
Figure No 2 Four stroke Four cylinder Petrol engine Morse Test rig

Sr.
No Name of Resource Suggested Broad Specification Quantity
.
Type – Multi- cylinder (3 or 4 ) Four Stroke
petrol/Diesel Engine
Engine Bore - 0.080 m 1
1
Stroke – 0.110 m
Power developed- 3.75 KW
Rope brake
Diameter of rope brake drum, D = 0.3 m
Dynamometer
1
2
Diameter of Rope, d = 0.015 m
OR
Hydraulic
Dynamometer constant, K = 2000
3 dynamometer 1
OR
Eddy current
4 Dynamometer constant, K = 200 1
dynamometer
Note: Specifications mentioned are for reference only.
1. Fill up sufficient fuel in the fuel tank.
2. Check oil level in the engine with the help of dipstick provided and ensure level
is appropriate.
3. Ensure battery water level is proper.
4. Jacket cooling water supply is appropriate.
5. Do not disturb any of the engine settings
XI Procedure
1. Insert the key in the ignition switch and start the engine. Allow it to get stabilized
warmed up.
2. Adjust the fuel supply and the load on the dynamometer to bring the engine to the
required speed at which test is conducted. This is test speed-N.
3 Note the speed with tachometer.
4 Note the load applied on engine from dynamometer load dial.
5. The speed and load measured in step no.6 and 7 are for all cylinders developing
power. Note readings in the observation table.
6. Now put off first knife switch to cut off ignition of cylinder 1. Speed of engine
will reduce. Adjust the load on the dynamometer to bring the engine to the test
speed N rpm. Allow it to get stabilized. Note this load in the observation table.
7. Reconnect ignition to cylinder 1. All cylinders are now developing power. Allow
the engine to run on all cylinders for a short time.

8. Cut off cylinder No. 2 adjust the load on the dynamometer to bring the engine to
the test speed. allow it to get stabilized. Note this load in the observation table.
9. Similarly, cut off remaining cylinders one by one. Adjust the load on the
dynamometer to bring the engine to the test speed. Note this load in the
observation table.
10. Complete observation table and calculations in the tabular form.
XII Resources Used
Sr. Name of Broad Specifications Qty Remarks

No Resource Make Details (If any)
1.
2.
3.
4.
5.
6.
7.
8.
XIII Actual Procedure Followed

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XIV Observations and Calculations:
Test speed of the engine, N =…………… rpm

(It will be constant for all sets of readings)
Readings for Brake power calculation
Sr. Particulars n Cylinder off Nil 1st 2nd 3rd 4th

No.
1 Load (W) kg
2 Load in N (W x 9.81) W= W1= W2= W3= W4 =

Sr. Particulars Formulae Quantity

No
1 Brake Power of engine with ail cylinders WN / K
Working (B)
.............. KW
2 Brake Power of engine when first cylinder cut-off W1N / K

. (B1)
.............. KW
3 Brake Power of engine when second cylinder cut- W2N / K

off (B2)
.............. KW
4 Brake Power of engine when third cylinder cut- W3N / K

off (B3)
.............. KW
5 Brake Power of engine when fourth cylinder cut- W4N / K

off (B4)
.............. KW
 Calculations for indicated power: ■I

IP of 1st Cylinder
I1= B - B1= ............. - ................
= ………… KW
IP of 2nd Cylinder
I2= B - B2= ............. - .............
= ………… KW
IP of 3rd Cylinder
I3 = B - B3= ............. - .............
= ………….KW
IP of 4th Cylinder
I4 = B –B4 = ............. - .............
= ………… KW
IP of all cylinders or engine, I =I1+ l2 + l3 + l4
=………. + ………… + ...... .... . + ……….
= …............. KW
Frictional power of the engine,
FP = I – B = .. .......... .. -...... ..................
= .....………… KW

Mechanical Efficiency of Engine,

ȠMech= (BP of all Cylinders) / (IP of all Cylinders)
= B/I x100
= ---------------- x 100
= ----------------
XV Results
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XVII Practical Related Questions

1. Identify which engine is more efficient diesel and petrol engine of same capacity,
2. Interpret Indian standard specification for testing for I.C. engines.
[Space for Answer]
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XVIII References / Suggestions for Further Reading

1. https://www.youtube.com/watch?v=lR6ku_g_eNI
2. https://www.youtube.com/watch?v=BXQ27pU3_7E
3. https://www.youtube.com/watch?v=fTAUq6G9apg

1 Ability to start,stop and operate the engine 20%
2 Ability to apply desired load on engine 20%
3 Calculate Mechanical efficiency of I.C. Engine 20%
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………
Dated signature of
Marks Obtained
Teacher

Practical No.9 : Use Exhaust Gas Analyzer for Measurement And Analysis
of Pollutants In The Given IC Engine.
Improved transportation and an improved economy made the automobile one of the
most important invention in past few decades. But besides that one more challenge
for our developed sector is facing that is generation of emissions, which is bi–product
of fuels. Emission from automobiles produce adverse effect on human being as well
as on our environment, so to check and regulate the emission from automobiles a
device like Exhaust gas analyzer/ Pollution Under Control (PUC) testing was
introduced. With the help of these equipment’s, automobile sector has certified their
vehicles for emission and health check-up which is valid for 6 months, this checking
is mandatory for all vehicles by Government of India. These regulation norms are
known as Bharat stage which is followed by Euro norms.

PO1-Basic knowledge: Apply knowledge of basic mathematics, sciences and basic
broad-based mechanical engineering related problems.
PO4-Engineering tools: Apply relevant Mechanical technologies and tools with an
understanding of the limitations.
PO5-The engineer and society: Assess societal, health, safety, legal and cultural
issues and the consequent responsibilities relevant to practice in field of Mechanical
engineering.
PO7 - Ethics: Apply ethical principles for commitment to professional ethics,
responsibilities and norms of the practice also in the field of Mechanical engineering.
in diverse/Multi-disciplinary teams.
 This practical is expected to develop the following skills for the industry
identified competency through various teaching learning experiences.
‘Maintain power engineering and refrigeration devices.’

V Practical Outcome
 Use exhaust gas analyzer to measurement and analyze pollutants in the given IC
engine.


 Practice energy conservation.
 Demonstrate working as a leader/a team member.
1. Know the purpose of PUC test

2. Know the emission norms in India
3. Apply the procedure of Exhaust gas analyzer
230volts/phase/50 hz
Make
Figure No 1 Layout of Exhaust Gas
Analyzer Stabilizer supply
Digital Receiving HC
CO HC
CO
Knob
HC knob
Fuel
filter Power ON/OFF
Gas selector switch Pump ON/OFF Printer cable
Plastic pipe Nozzle Printer
Silencer

Figure No 2 A Typical Exhaust Gas Analyzer Figure No 3 Dwell- tachometer
Figure No 4 Computerized PUC Testing for two wheeler

Figure No 5 Emission health check-up for four wheeler
Figure No 6- PUC Slip
Figure No 7 Health Check Slip
Check Slip

Figure No 8 Typical test /health certificate provided after PUC testing
S. No. Name of Resource Suggested Broad Specification Quantity

1 For CO(%)-Range 0-10 1
Exhaust gas Analyzer For HC (ppm)- Range 0-10000
RPM-Range 0-9000
2 Dwell- tachometer (RPM) RPM-Range 0-10000 1
3 Vehicle to be tested As per available 1
Note-Specifications mentioned are reference only
1. Avoid improper handling of Exhaust gas Analyzer
2. Select proper knob and selector switch
3. Provide proper warming period
XI Procedure
Note - The procedure may differ from machine to machine. Students shall refer the
manufacturer’s catalogue prior to the procedure.
1. Connect the power supply cable and exhaust gas probe to the exhaust gas
Analyzer/ PUC machine
2. Allow analyzer to warm up for 15 min
3. After warming up, calibration is automatically carried out and analyzer is ready
for measurement.
4. Start the engine and let it warm up at its idling speed.
5. Insert exhaust gas probe /nozzle into the exhaust muffler/silencer. Wait for few
minutes.
6. Set CO and HC value to zero by using the knob.

7. Switch on the pump. Operate the gas selector switch and put it to CO and HC
mode.
8. Note the reading of CO and HC or take print out.
9. Switch off the pump and remove the pipe from the exhaust muffler of the
vehicle.Take additional readings at higher speeds by adjusting air screw in the
carburetor or by accelerator.
XII Resources Used

Sr. Name of Resource Suggested Broad Specification Quantity Remarks
No. (If any)
1 Exhaust gas Analyzer Make- 1
Model No.-
For CO(%)-
For HC (ppm)-
RPM-
2 Dwell- tachometer (RPM) RPM- 1
3 Vehicle to be tested Make - 1
Model-
Registration no.-

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Sr. Engine Speed CO(%) HC(ppm)

No.
1 Idling =
2 Cruising speed =
3 High Power =
Note: For car, during test, measure the engine speed by the use of dwell-tachometer.

XVI Results
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XVIII Conclusions
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1. Illustrate the Bharat Stage standard norms.

2. State the necessity of exhaust gas analyzer for vehicle.
[Space for Answer]
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1. https://www.youtube.com/watch?v=W6dIsC_eGBI
2. https://www.youtube.com/watch?v=sGoW1OotFSc
3. https://www.youtube.com/watch?v=hpIxrWtxAJQ
4. https://www.youtube.com/watch?v=W9oVMzo5zgk
XXI Assessment Scheme

1 Handling of the measuring Instruments 20%
2 Compare final readings at different speed 20%
3 Interpretation of result 20%
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………
Dated signature of
Marks Obtained
Teacher

Practical No.10 : Perform Diagnosis Test On Given IC Engine Using

Engine Control Unit
ENGINE CONTROL UNIT or ECU is the brain of engine that controls all the
functioning of the engine by means of electronic control unit. The ECU is used to
operate the engine by using input sensors and output components/actuators to control
all engine functions since it is also work as management technique of engine and it
serves several functions which includes regulating and maintaining the amount of fuel
and air in the fuel injection part and helps in increasing horsepower of the engine.
On-Board Diagnostics -II (OBD II) is quickly, easily and safely ‘HACK’ your car,
to run better and faster perform advanced fault/health diagnostics and most of all save
money and time on repairs and maintenance.
Here are the most common symptoms of a bad ECU:
 Engine Light stays on after resetting.

 Car was jump started on reverse polarity.
 Engine turning off for no reason.
 Water Damage or Fire Damage on the ECU.
 Apparent loss of spark.
 Apparent loss of injection pulse or fuel pump.
 Intermittent starting problems.
 Overheating ECU.
 Engine performance issues.
understanding of the limitations
in diverse/ multidisciplinary teams
PO10- Life-long learning: Engage in independent and life-long learning activities in
the context of technological changes also in the Mechanical engineering and allied
industry.


 This practical is expected to develop the following skills for the industry identified
competency
‘Maintain power engineering and refrigeration devices.’

 Test the performance of I C Engine
V Practical Outcome
 Perform diagnosis test on given IC engine using Engine Control Unit

 Practice energy conservation.

1. Know ECU, sensors, actuators.
2. Identify the notation code on dash board and monitor of Computer
3. Inspect the health remedies for the vehicle problem
Figure Importance of ECU

Fig 2 Diagnostic car with OBD
Figure 3 OBD slot arrangement near clutch pedal

Figure 4 OBD II
Figure 5 OBD-II diagnostics trouble code

Figure 6 OBD-II diagnostics trouble code ( BMW )

Figure 7 ECU/OBD II through mobile phone
Figure 8 OBD II code reader

Figure 9 Engine Control Unit (ECU)

1. ECU Available in the vehicle 1
2. OBD II car diagnostic tool Grade II 1
3. Visit to official diagnostic Industrial visit 1
station of Nexa /Maruti / ECU
operating service station
4. Sensor and Actuator car/bike Available in the vehicle 1
1. Avoid improper handling of ECU/OBD II
2. Check connection is proper or not.
3. The diagnostic code may differ from car to car. Students shall refer the
manufacturer’s catalogue prior to the procedure.
4. History of problem stored in ECU is clear after maintenance of the problem
XI Procedure
1. OBD II is placed in the slot just above clutch pedal in the car.
2. Turn the ignition knob, you don’t need to turn on engine
3. Ensure that headlights are shut down.
4. Turn on Bluetooth on your mobile and find OBD II
5. Pair with OBD II pass is 1234 or 0000
6. Go to Torque App
7. For trial purpose Torque pro App can also be downloaded through internet
8. When blue car icon appears that means you are connected
9. Now tap to scan the faults or press menu for more options
10. Requesting for fault codes

11. Reading fault code

12. Fault code responses
13. If there is no fault codes stored in ECU , then your car diagnostic is OK
14. If there are fault codes observed in ECU , go for fault log manager and clear it
there .
15. By typing fault code provided by ECU, solution can be obtained through online.
16. Once the testing is done, turn off the ignition and remove the OBD II from the
slot.
(For more reference refer https://www.youtube.com/watch?v=JIa0nsrQXI0)
XII Resources Used
S. Name of Broad Specifications Quantity Remarks

1.
2.
3.
4.
5.

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S N Problem code Faults diagnose in car Remedies on problem

Generic Fault
1
2
Specific Fault
1
2

XVI Results
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XVIII Conclusions
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1. Enlist the sensors used with ECU for diagnosis test of vehicle.
2. Enlist the common faults in vehicle with their code and remedies
[Space for Answer]
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1. https://www.youtube.com/watch?v=_lAqQ7uXQTY
2. https://www.youtube.com/watch?v=49SjHjnnVn4
3. https://www.youtube.com/watch?v=U8j1mOPSDHM
4. https://www.youtube.com/watch?v=JIa0nsrQXI0

1 Handling of the Instruments 20%
2 Diagnostic faults 20%
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………
Dated signature of
Marks Obtained
Teacher

Practical No.11 and 12: Perform Test On The Given Two-Stage

Reciprocating Air Compressor To Find
Volumetric And Isothermal Efficiency
The air compressor is a machine which uses a drive motor to power the device, which
sucks in successive volumes of air from the atmosphere, compresses (squeezes) each
volume of air in the limited space to increase the pressure, resulting in a smaller
amount, and then transfers the air high pressure in the receiver tank. This high
pressure air is removed from the receiving tank for the electrical equipment. When
certain amount of constant discharge of air is displaced, then it is called as a positive
displacement air compressor
Performance of reciprocating compressor is improved by multi-staging. Here
number of staging represents number of cylinder. Two stage reciprocating air
compressor consist of two cylinders. One is called low-pressure cylinder and another
is called high-pressure cylinder. When piston in a low-pressure cylinder is at its outer
dead center (ODC) the weight of air inside a cylinder is zero (neglecting clearance
volume), as piston moves towards inner dead center (IDC) pressure falls below
atmospheric pressure & suction valves open due to a pressure difference.
Air compressors have many uses, including: supplying high-pressure clean air to
fill gas cylinders, supplying moderate-pressure clean air to a submerged surface
supplied diver, supplying moderate-pressure clean air for driving some office and
school building pneumatic HVAC control system valves, supplying a large amount of
moderate-pressure air to power pneumatic tools, such as jackhammers, filling high
pressure air tanks (HPA), for filling tires, and to produce large volumes of moderate-
pressure air for large-scale industrial processes (such as oxidation for petroleum
coking or cement plant bag house purge systems)


This practical is expected to develop the following skills for the industry identified
competency
‘Maintain power engineering and refrigeration devices ‘


 Maintain reciprocating air compressors.
V Practical Outcome
 Perform test on the given two-stage reciprocating air compressor to find
volumetric and isothermal efficiency


1. Know the working of two stage air compressor
2. Identify the different parts of two stage reciprocating air compressor
3. Know the efficiencies of compressor
Figure No 1 Pressure Gauge Figure No 2 Manometer

Figure No 3 Orifice plate Figure No 4 Thermocouple(K Type)
Figure No 4 Digital Temperature indicator Figure No 5 Tachometer
Figure No 6 Technical Illustration of a single-stage manual air compressor

Figure no 7 Technical Illustration of a two-stage air compressor with vertical storage

tank
Figure No 8 Typical experimental set up of two stage Reciprocating air compressor

test rig

S.
No.
Range
Pressure Gauge from 0-
10Kg/cm2
U-shaped
Water Manometer
glass tube
Air box -----
Diameter
Orifice plate size from
6-30mm
Two stage single acting Air receiver tank ------
1 reciprocating air Mercury in
compressor Thermometer/Thermocouple glass type/ 1
Type K
Pt100RTDs
Milli volt
Digital Temperature And
indicator 4-20 range
current
Speed up to
Tachometer
1000 rpm
2 Motor Speed upto 1200rpm 1
Note: These specifications are for reference only.
1. Avoid improper handling of Two stage air compressor.
2. Maintain the proper level of lubricating oil up to red mark
3. Checking for oil and air leaks.
XI Procedure
1. Fill the manometer with water up to half level.
2. Keep delivery valve and manometer cock on suction line in closed position.
3. Start the compressor and open the manometer cock. Then, let the air pressure
build-up in the tank. .
4. Maintain pressure of air inside the tank constant, by adjusting delivery valve.
Note this delivery pressure reading by pressure gauge mounted on tank.
5. With this constant delivery pressure, measure motor speed using tachometer
and note it down.
6. With the same delivery pressure, note down water manometer reading, intake
pressure, intermediate pressure, delivery pressure, intake temperature,
temperatures before and after intercooler and delivery temperature.

XII Resources Used
Sr.
No.
Pressure Gauge
Water Manometer
Air box 1
Two stage single acting

Orifice plate
1 reciprocating air
compressor Air receiver tank
Thermometer/Thermocouple
Digital Temperature
indicator
Tachometer
2 Motor Speed 1

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Sr.
Particulars Notations Unit Reading
No.
Intake Pressure (gauge) P1( gauge) Kg / cm2
Intake Pressure (absolute )
P1 (abs)=P(atm) +P1(gauge)
1 P1 bar
=( ……………)+(………X 0.9806)

Intercooler/Intermediate pressure
P2( gauge) Kg / cm2
(gauge)
Intermediate Pressure (absolute )
2
P2 (abs)=P(atm) +P2(gauge)
P2 bar
=( ……………)+(………X 0.9806)
Delivery pressure (gauge)

P3(gauge) Kg / cm2
Delivery pressure (absolute)
3 P3 (abs)=P(atm) +P3(gauge)
=( ……………)+(………X 0.9806) P3 bar
0
t1 c
4 Intake temperature 0
T1 = t1+ 273 K
0
t2 c
5 Temperature before intercooler 0
T2 = t2+ 273 K
0
t2’ c
6 Temperature after intercooler 0
T2’ = t2’+ 273 K
0
t3 c
7 Delivery temperature 0
T3 = t3+ 273 K
8 Motor speed N1 rpm
h1 mm
9 Manometer reading
h2 mm
.
A. Calculations for Volumetric Efficiency
1. Compressor Speed
As belt drive is used, D1x N1 = D2 x N2
Compressor Speed, N2 = D1 x N1 / D2 = ……………… rpm
= …………… rpm
Note: If compressor is directly coupled to motor, speed of motor is the speed of
compressor.
2. Density of air
Using characteristic gas equation,
P1 x V1 = ma x Ra x T1.
Where, ma = mass of air
Ra = Characteristic gas constant = 287 J/kg
ma = P1xV 1 /(R a xT 1 )
Now, density of air = ρa=ma / V1 = P1 / [RaxT1],

where P1 is in N/m2.
= P 1 /[R a x (t1 +273)]
ρa=……………………….. kg/m3
3. Water manometric head
hw= h1– h2= ................................
hw =........... mm of water
hw = ……….m of water
4. Air ahead causing the flow of air
ha = h w xρw/ρa Where,ρw = Density of water = 1000 kg/m3
Therefore, h a =( .......................... .. ....... x 1000) / ( .................... )
= ............................................................ m of air
5. Actual volume of free air delivered

Area of Orifice, a = (π/4)d2 = (π/4) x ( ........................ . ...... )2
a = ...... ............................................... ................. ... ....m2
Actual volume of free air delivered, Va .= Cd x a x √2𝑔ℎ𝑎 m3/s

Va= ……………………………………m3/s
6. Mass of air supplied ma= ρa x V a

ma= ..... kg/s.
7. Theoretical volume of air delivered
Volume of low pressure cylinder = VLP= (π/4) DLP2 x L1 m3 / cycle
= (𝜋/4) x ( ................................................................................................ ...)2
x(……….)
VLP = ............................................................................... .. ............. m3/cycle
Theoretical volume of air delivered at intake condition
vth = VLp x N2 / 60 m3 / s
Vth = ……….. ................ m 3 /s.
8. Volumetric efficiency
Volumetric efficiency =
(Actual volume of free air delivered) / (Theoretical volume of air Delivered)

ŋvol.= (Va / Vth ) x 100

= ( ………………../ …………………… ) X 100
ŋvol = ………………………….
B. Calculations for Isothermal efficiency

1. Index of compression
Compression follows the polytropic process i.e. PVn=C
a) Value of compression index ‘n’ for 1st stage compression –
We know for compression process 1-2,
T1 / T2 = (P 1 /P 2 ) ( n - 1 / n )
=……………………………………
n = …………..
Value of compression index ‘n’ for 2nd stage compression –
We know for compression process 2’-3
T 2 ’/T 3 =(P 2 /P 3 ) ( n - 1 / n )
=……………………..
n =
Actual work done
a) Work done in compressing air in low pressure (L.P.) cylinder is
WLP = (n / n-1) x {P1V1 [ (P2 / p1) (n-1/n) - 1]} J /s
= (n/n-1)x{m a R a T 1 [(P 2 /P 1 ) (n-1/n)-1]} J / s
=………………………………………………………..J / s
a) Work done in compressing air in high pressure (H.P.)

cylinder
WHP = (n/n-1) x {P 2 V 2 .[(P 3 / P2)](n-1/n)-1} J/s
= (n/n-1)x {m a R a T 2 ’[(P 3 /P 2 )] n-1/n)-1} J/s
=…………………………………………………………….J/S
1. Actual work done or indicated work ;

Wind: = wLP +WHp

Wind:=…………………………………………………………………..J/S
2. Isothermal Work
Wiso= P1V1[log e (P 3 /P 1 )]
=m a R a T 1 [(P 3 /P 1 )]J/s
Wjso = ............................ .......... .. ...... .... . ... J / s or W
=..... ............................... .......... .. ..kW.
3. Isothermal efficiency
ŋlso = (Isothermal work / Indicated work) x 100
= (………………./…………………) x 100
=………………..............
XVI Results
1. Volumetric Efficiency of this air Compressor = ... …….. %.

2. Isothermal Efficiency of this air Compressor =…………… %.

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XVIII Conclusions
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Note: Below given are few sample questions for reference. Teachers must design more
such questions so as to ensure the achievement of identified CO.
1. Illustrate the factors which limit the delivery pressure in reciprocating compressor.
2. Categorize the factors that influence the performance of compressor.
[Space for Answer]

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1. www.youtube.com/watch?v=rtrOcFq6QSs
2. www.youtube.com/watch?v=bJluUxA7aaY
3. www.youtube.com/watch?v=doDVrnV69CM
4. www.youtube.com/watch?v=rtrOcFq6QSs
5. www.youtube.com/watch?v=bJluUxA7aaY
6. www.youtube.com/watch?v=doDVrnV69CM

1 Handling of the measuring Instruments 20%
2 Calculation of final readings 20%
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………
Dated signature of
Marks Obtained
Teacher

Practical No.13 : Assemble/Dismantle Of Gas Turbine Model.
A gas turbine, also called a combustion turbine, is a type of continuous combustion,
internal combustion engine. There are three main components: An upstream rotating
gas compressor; a downstream turbine on the same shaft; a combustion chamber or
area, called a combustor, in between them.
A jet propulsion is the system of gas turbine plant which produces a high velocity jet
of hot gases to propel the vehicles. Jet propulsion systems are classified into two types
-.jet engines and rocket engines. Jet engines include turbojet engine, turbo-prop
engine and ram jet engine. Rocket engines include liquid propellant rocket engine and
Solid propellant rocket engine



 Identify different components of gas turbines and jet engines.
V Practical Outcome
 Assemble/Dismantle of Gas turbine model.


1. Know the construction and working of Gas Turbine Model
3. Identify various sub-assemblies of Gas Turbine Model

Figure No 1 A typical cut section model of Turbo jet engine
Figure No 2 Schematic diagram of Turbo jet Engine

Allen key set – 1.5 to 10 inch
Tool box Screw driver set – 5 pieces 1
1
Ratchet set – 10mm to 32 mm
1. Avoid improper handling of Gas Turbine model.
2. Use special and recommended tools for assembly and dismantling of Gas
Turbine model
3. Use clean work bench for assembly and dismantling of Gas Turbine model.
XI Procedure
2. Apply recommended tools to remove components of Fuel.
3. Identify the various subassemblies of the Gas Turbine model.
4. Examine all the components carefully.
5. Observe their physical and functional conditions.
XII Resources Used

Sr. Name of Broad Specifications Quantity Remarks
1.
2.
3.
4.
5.

Dismantling of Gas Turbine model
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Assembly of Gas Turbine model
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Sr. Name of unit Function Tools used to Parts in sub-

no dismantle assembly
Compressor
01
sub-assembly
Turbine sub-
02
assembly
Combustion
03 chamber
sub-
assembly
'
XV Results
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XVII Conclusions
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Note: Below given are few sample questions for reference. Teachers must design more
such questions so as to ensure the achievement of identified CO.
1. Interpret jet propulsion system which can travel through the vacuum.
2. Draw the jet engine in which compressor and turbine is absent.
[Space for Answer]
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1. https://www.youtube.com/watch?v=zcWkEKNvqCA
2. https://www.youtube.com/watch?v=KjiUUJdPGX0
3. https://www.youtube.com/watch?v=oYpG0HDcFsA
4. https://www.youtube.com/watch?v=XdQkt_Mtpd8

2 Identification of Gas Turbine components 20%
3 Interpretation of components of Gas turbine model 20%
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………

Teacher

Practical No.14: Perform Test On Vapor Compression Refrigeration Cycle

Test Rig To Find COP.
Vapor Compression Refrigeration cycle consisting of hermetically sealed compressor,
condenser, expansion devices and evaporator. The working medium called as
Refrigerant used in vapor form to obtain the cooling effect. Refrigerating effect is
the amount of cooling produced by the system. This cooling is obtained at the expense
of some form of energy. Vapor-compression refrigeration or vapor-compression
refrigeration system (VCRS), in which the refrigerant undergoes phase changes, is
one of the many refrigeration cycles and is the most widely used method for air-
conditioning of buildings and automobiles. Coefficient of performance is the ratio of
refrigerating effect to the compressor work.



 Test the performance of refrigeration and air-conditioning systems.
V Practical Outcome
 Perform Test on vapor compression refrigeration cycle test rig to find COP.

 Work as a leader / a team member.


1. Know the working of Vapour compression refrigeration system.
2. Identify and know the function of each component of vapor compression
refrigeration system.
3. Calculate refrigerating effect, compressor work and C.O.P.
Expansion valve
Figure 1 Line Diagram of vapor compression refrigeration Test Rig
Figure 2 Vapor compression refrigeration Test rig

Sr. Quan
Name of Resource Suggested Broad Specification
No. tity
1 Refrigerant used R-134 a 1
2 Compressor 1
Type – Hermetically sealed
3 Condenser: 1
Forced Air Cooled
4 Expansion device 1
Capillary Tube/Thermostatic Valve
5 Evaporator 1
Coil type
6 Devices used for 1
Pressure gauge
measurement
1
Temperature Indicator
7 Electric Energy 1
As per standard
8 Energy meter 1
For Heater = Nh, as per standard
For compressor = Nc , as per standard
X Precautions to be followed
1. Never operate the unit, keeping the condenser fan switched off.
2. Do not operate the unit if voltmeter on the panel reads less or more voltage
than specified.
XI Procedure
1. Refer the manual supplied by the manufacturer and identify different components
and controls of refrigeration test rig.
2. Select capillary tube or thermostatic expansion valve (TEV) by using manually
operated shut-off valves.
3. Fill three fourth of evaporator tank with water.
4. Switch on the condenser fan and after two minutes switch on the compressor.
5. Watch the thermometer reading of the water in the evaporator, it will go on
reducing.
6. As the temperature of the Water reaches around 20°C switch on the heater unit.
7. Adjust the dimmer stat of heater such that temperature of water does not further
fall.
8. Run-the unit till steady state is reached i.e. temperature of water remains constant.
9. Read the condenser & evaporator pressure gauges & enter in observation table.
10. Note the temperature reading on digital temperature indicator by turning the knob.
11. Measure the time taken for 10 revolutions of energy meter disc of the compressor
and heater (i.e. Tc & Th). (In case of electronic energy meter, measure the time
taken for 10 pulses)
12. Switch- off the unit in the following order - heater, compressor and condenser fan.
XII Resources Used
S. Broad Specifications Remarks

Name of
No Make Details Quantity (If any)
Resource
.
1.
2.
3.
4.
5.
6.
7.
8.

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XIV Observations and Calculations:
Sr.
Description Symbol Unit Reading
No.
1 Evaporator pressure Pe bar
2 Condenser pressure Pc bar

0
3 Evaporator Inlet Temperature tei C
0
4 Evaporator Outlet Temperature teo C
0
5 Condenser Inlet Temperature tci C
0
6 Condenser Outlet Temperature tco C
7 Time for 10 revolutions of pulses of Tc sec

energy meter of compressor
8 Time for 10 revolutions of pulses of Th sec
energy meter of Heater

a. Carnot COP :
Read from refrigerant property table and fill the following table for the calculation
Carnot COP
Sr.
No. Description
1 TL= Saturation temperature corresponding to Pe= ……….. + 273
= ……………….. K
TH= Saturation temperature corresponding to Pc = + 273
2 = ………………… K
Carnot COP = TL / (TH - TL) = ……………..
b. Theoretical COP -
Plot the cycle on P-h chart for the refrigerant used and fill the table given below for
calculation of theoretical COP
Figure 3 P-H Diagram for VCR cycle
(Note: Students shall draw refrigeration cycle on P-h diagram over a separate paper, if the
refrigerant conditions at various state points different than those shown in the above diagram)

Sr.
Description Symbol Reading in kJ / kg
N
o.
hei
Enthalpy at evaporator inlet
1
Enthalpy at evaporator outlet heo
2
hci
3 Enthalpy at condenser inlet
hco
4 Enthalpy at condenser outlet
Theoretical COP
= (Theoretical Refrigerating Effect) / (Theoretical Compressor Work)
= (heo-hei) /(hci-heo)
= ( ............. - ............... ) / ( ............... - .............. )
= …………………
Actual COP = (Actual Refrigerating Effect) / (Actual work supplied to

compressor)
Here, actual Refrigerating Effect = Heat produced by heater
RE = (10 / Nh) x (3600 / Th)kW
= …………………… kW
Or if heater is not used
RE = {Mw * Cpw * (T2 –T1)} / time required for cooling from initial to final
water temperature
Where T1 = Initial temperature of water
T2 = Final temperature of water
Mw = mass of water in evaporator
Actual energy supplied to compressor
W = (10 / Nc) x (3600 / Th) kW
Actual COP = RE / W =…………………… KW

Results:
• Carnot COP = ....................

Theoretical COP = …………….
• Actual COP = ……………

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XVII Practical Related Questions

.
1. Compare actual COP and theoretical COP of VCR cycle .
2. Illustrate the cooling medium used in hermetically sealed compressor.

Figure 4 P-H chart of HFC-134a Refrigerent

[Space for P-H Chart]

(Student should paste P-H chart of respective Refrigerant)

[Space for Answer]

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1. https://www.youtube.com/watch?v=F8kPHK2atR4
2. https://www.youtube.com/watch?v=v36FiXcxt0k
3. https://www.youtube.com/watch?v=dRuK7RBuqog

1 Ability to operate refrigeration test rig 20%
2 Ability to measure pressure & temperature at 20%
salient points of the system
3 Ability to use P-h Chart and property table of 20%
refrigerant
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………

Teacher

Practical No.15 : Trace The Refrigerant Flow Of Domestic Refrigerator

And Measure Temperatures At Critical Points For
Different Settings Of Thermostat.
Domestic (also household refrigerator), an appliance that is used for the short-term
preservation of food products in the home by means of refrigeration. A domestic
refrigerator is a metal cabinet with a built-in hermetically sealed refrigerating unit
When the hot gas in the coils of the condenser meets the cooler air temperature of
the kitchen, it becomes a liquid. Now in liquid form at high pressure, the
refrigerant cools down as it flows through the expansion valve into the evaporator
coils inside the freezer and the fridge. This process of conversion is in cyclic form
known as Vapour Compression Cycle (VCC). Modern refrigerators usually use a
refrigerant called HFC-134a (1,1,1,2-Tetra- fluoro- ethane), which does not deplete
the ozone layer, instead of Freon. The fundamental reason for having
a refrigerator is to keep food cold. Cold temperatures help food stay fresh longer.
The basic idea behind refrigeration is to slow down the activity of bacteria (which
all food contains) so that it takes longer for the bacteria to spoil the food.
A refrigerator does not cool items by lowering their original temperatures; instead,
an evaporating gas called a refrigerant draws heat away, leaving the surrounding
area much colder. Refrigerators and air conditioners both work on the principle of
cooling through evaporation. Thermostat is a component which senses
the temperature of a physical system and performs actions so that the system's
temperature is maintained near a desired set point. A thermostat operates as a
"closed loop" control device, as it seeks to reduce the error between the desired and
measured temperatures. Sometimes a thermostat combines both the sensing and
control action elements of a controlled system, such as in an automotive
thermostat.

engineering.
PO6-Environment and sustainability: Apply Mechanical engineering solutions also
for sustainable development practices in societal and environmental contexts.



V Practical Outcome
Trace the refrigerant flow of domestic refrigerator and measure temperatures at
critical points for different settings of thermostat.


1. Know the construction and working of refrigeration system.
2. Identify various subassemblies of refrigeration and refrigeration system.
3. Identify accessories of refrigeration and refrigeration system.
4. Know the Vapour Compression Cycle (VCC) on P-H and T-S diagram
5. Identify the parts of VCC
6. Know the thermodynamic analysis of domestic refrigerator
Figure No 1 Domestic refrigerator

Figure No 2 Line diagram of Domestic refrigerator
Figure No 3 Simple VCC diagram

Figure No 4 Pressure variation in VCC
Figure No 5 P-V diagram of VCC
Figure No 6 P-H and T-S diagram of VCC

Sr.
No.
1 Domestic Capacity – 165 lit. 1
Refrigerator Refrigerant –R 134a
2 Thermocouple RTD 4
1. Ensure that refrigerator is connected to with proper electric power supply.
2. Ensure that refrigerator door is tightly closed.
3. Inspect that there is proper distance between refrigerator and wall.
4 Avoid improper handling of domestic refrigerator.
XI Procedure
1. Identify and locate the components.
2. Locate the refrigerant tubes connecting different parts and trace the path
of refrigerant.
3. Observe and trace the path of refrigerant.
4. Mark temperature at critical points for different setting of thermostat by
thermocouple.
XII Resources Used

Sr. Name of Broad Specifications Quantity Remarks
1.
2.
3.
4.
5.
6.
7.
8.

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Sr. Description Symbol Unit Thermo Thermo

No. stat stat
setting 1 setting 2
1 Evaporator Inlet Temperature 0
tei C
2 Evaporator Outlet Temperature 0
teo C
3 Condenser Inlet Temperature
tci 0
C
4 Condenser Outlet Temperature
tco 0
C
Sr. Particulars Remark

No. (Functions /Type)
1 Compressor
2 Condenser
3 Evaporator
4 Thermostat valve
5 Expansion valve

XV Results
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XVII Conclusions
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1. Detect the location of sensing bulb of thermostatic switch.
2. Draw the expansion device used in domestic refrigerator.
[Space for Answer]

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1. https://www.youtube.com/watch?v=h5wQoA15OnQ
2. https://www.youtube.com/watch?v=L5jQqmaFKOE
3. https://www.youtube.com/watch?v=TPabv9iDENc

1 Draw line diagram of domestic refrigerator 20%
2 Identify the path of refrigerant 20%
3 Interpretation of result at different thermostat 20%
settings
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………
Dated signature of
Marks Obtained
Teacher

Practical No.16: Assemble/Dismantle Various Components Of Domestic

Refrigerator
Domestic. (also household refrigerator), an appliance that is used for the short-term
preservation of food products in the home by means of refrigeration. A domestic
refrigerator is a metal cabinet with a built-in hermetically sealed refrigerating unit
When the hot gas in the coils of the condenser meets the cooler air temperature of the
kitchen, it becomes a liquid. Now in liquid form at high pressure, the refrigerant cools
down as it flows through the expansion valve into the evaporator coils inside the
freezer and the fridge.
Modern refrigerators usually use a refrigerant called HFC-134a (1,1,1,2-
Tetrafluoroethane), which does not deplete the ozone layer, instead of Freon.

engineering.
PO10-Life-long learning: Engage in independent and life-long learning activities in
industry.


 Practical Outcome
 Assemble/Dismantle various components of domestic refrigerator.
V Relative Affective Domain-


VI Minimum Theoretical Background

 Know the construction and working of refrigeration system.
 Identify various subassemblies of refrigeration system.
 Identify accessories of refrigeration system.
VII Experimental setup
Figure No. 1 Schematic diagram of Domestic Refrigerator

Figure No. 2 Refrigerator flow diagram
Figure No. 3 Domestic Refrigeration

Piercing Pliers
Figure No. 4 Tools for Domestic Refrigerator

Figure No. 5 Compressor dismantling

Figure No. 6 Hermetically sealed compressor
Figure No. 7 Disassembly of Hermetically sealed rotary compressor

Figure No. 8 Condenser
Figure No. 9 Capillary Tube
Figure No. 10 Evaporator

Figure No.11 Bellows type Thermostatic Switch
Figure No.12 Thermostat
Figure No.13 Over load Protector

Figure No 14 Direct Acting Solenoid Valve
Figure No 15 Pilot operated Solenoid Valve

Figure No. 16 Actual Cut-section of household refrigerator representing

PUF insulating back panel, condenser coil.

Evaporator


PUF insulating door panel
VIII Resources Required

Old cut section of
1 household 165 litre 1
refrigerator
Failing tool
Spanner
Piercing Pliers
Hammer
Side cutter
Cordless screw driver
HVAC Tool Box
Drilling machine 1
2
Rounding tool
Visit to Refrigeration and air 1

3 Industrial Visit
conditioner service stations
Note : Above Resource table is for reference only
IX Precautions to be Followed
1. Avoid improper handling of refrigeration and air conditioning system.
2. Use special and recommended tools for refrigeration and air conditioning system.

3. Use clean work bench for assembly and dismantling of refrigeration and air
conditioning system.
4. Do not release Refrigerants ( harmful substances) into the atmosphere
5. Unplug the domestic refrigerator before dismantling
X Procedure
1. Visually inspect unit

2. Removal of loose parts of storage container of domestic refrigerator.
3. Inspect electrical wiring and components
4. Cut all visible protruding parts and store them separately
5. Remove the capacitor from the refrigerator
6. Unscrew the compressor manually with a spanner
7. Dismantling of compressor done by Cut the compressor using an angle grinder
8. Further dismantling of compressor is done on clean bench
9. Observe the Cut unit of the Compressor
10. Observe the Cut unit of the Condenser
11. Observe the Expansion unit
12. Observe the Cut unit of the Evaporator
13. Observe the Thermostatic switch
14. Observe the drier
15. Observe the OLP
16. Observe the cabinet with PUF insulation
XI Resources Used
Old cut section of

1 household
refrigerator
HVAC Tool Box
Industrial Visit
3
XII Actual Procedure Followed

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Sr.
Particulars Remark
No.
Capacity -
1 Compressor Make-
Type-
Capacity -
2 Condenser Type-
No. of coils-
Name-
Type-
Expansion valve Type-
3
No. of coils-
Type-
Drier Type-
4
Capacity(volt)-
Capacity(current)-
5 OLP (Over Load Protector)
Construction-
Type-
Observations
Draw Compressor, Condenser, Expansion, Evaporator and Thermostatic switch you observed

[Space for Diagram]
[Space for Diagram]

XV Results
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XVII Conclusions
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1. Enlist the common faults in refrigerator

2. Enlist the components of domestic refrigerator with their material
3. Enlist different Safety systems in Refrigeration system
[Space for Answer]
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1. https://www.youtube.com/watch?v=Y8sViu2zFnI
2. https://www.youtube.com/watch?v=0Ko23CLI_J0
3. https://www.youtube.com/watch?v=P72zJ6DrEpg
4. www.youtube.com/watch?v=nA-XbfxqgRo
5. www.youtube.com/watch?v=shFGqflIHtc
6. www.youtube.com/watch?v=GAUFvx_ac2Q

Process Related (10 Marks) 40 %
2 Identification of Refrigeration and air conditioning 20%
components
3 Interpretation of Refrigeration and air conditioning 20%
components
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………
Dated signature of
Marks Obtained
Teacher

Practical No.17 : Assemble / Dismantle Various Components Of Water

Cooler And Window / Split Air Conditioning Units.
Window air conditioning unit is a factory assembled air conditioning unit. Casing of
the unit is divided into indoor portion and outdoor portion. Indoor portion which faces
the room consists of evaporator, blower, filter and control unit. Outdoor portion
consists of compressor, condenser and its fan. The main components of a water cooler
and window/split air conditioning units are the compressor, the condenser, the
expansion valve and the evaporator. In summer due to hot climate ,the quench of
thrust is not satisfied by normal water. Since water cooler are developed. According
to their line of performance, they are broadly classified as storage type and
Instantaneous type. According to various climate zone ,the comfort zone is not
available without any external mode of comfort. The most popular comfort zone
provided by air conditioning system(A.C.) which is broadly classified as window
/split A.C. A.C. not only provide comfort zone ,but also it purifies air, maintain
humidity and temperature. All the above devices are also work on heart of
refrigeration system ,that is Vapour Compression Cycle (VCC)
understanding of the limitations.
engineering.
PO6-Environment and sustainability: Apply Mechanical engineering solutions also
for sustainable development practices in societal and environmental contexts.
PO7-Ethics: Apply ethical principles for commitment to professional ethics,
responsibilities and norms of the practice also in the field of Mechanical engineering.
PO10-Life-long learning: Engage in independent and life-long learning activities in
industry.



V Practical Outcome
 Assemble/Dismantle various components of Water Cooler and Window/Split air
conditioning units.


 Know the construction and working of refrigeration system.
 Identify various subassemblies of refrigeration system.
 Identify various sub-assemblies of water cooler and window/split air conditioning
units
 Identify recommended tools.
 Know the procedure of dismantling and assembly.
Figure No.1 Schematic diagram of Water cooler

Figure No.2 Water Cooler
Figure No.3 Window air conditioner unit

Figure No.4 Schematic diagram of Window air conditioner
Figure No.5 Diagram of Window air conditioner

Figure No.6 Circuit Diagram of Window air conditioner

Old cut section of
Water Cooler
1 or As per standard 1
Window/Split
air conditioning
Flaring tool
Spanner
Piercing Pliers
Hammer
Side cutter 1
HVAC Tool Box Cordless screw driver
Drilling machine
2
Rounding tool
Industrial Visit Visit to Water Cooler 1

3 Or air conditioner service stations
1. Avoid improper handling of refrigeration and air conditioning system.
2. Use special and recommended tools for refrigeration and air conditioning
system.
3. Use clean work bench for assembly and dismantling of refrigeration and air
conditioning system.
4. Do not release Refrigerants ( harmful substances) into the atmosphere
5. Unplug the water cooler and window/split air conditioning units before dismantling
6. Avoid improper handling of water cooler and window/split air conditioning units
7. Use special and recommended tools for assembly and dismantling of water cooler
and window/split air conditioning units
8. Ensure that water cooler and window/split air conditioning units is connected with
proper electric power supply.
XI Procedure
1. Visually inspect unit

2. Removal of loose parts of storage container of your system
3. Inspect electrical wiring and components
4. Cut all visible protruding parts and store them separately
5. Remove the capacitor from the refrigerator
6. Unscrew the compressor manually with a spanner
7. Further dismantling of compressor is done on clean bench
8. Observe the Cut unit of the Compressor
9. Observe the Cut unit of the Condenser
10. Observe the Expansion unit
11. Observe the Cut unit of the Evaporator
12. Observe the Thermostatic switch
13. Observe the drier
14. Observe the OLP
15. Observe the cabinet with PUF insulation
16. Observe the Blower
17. Observe the Fan motor
XII Resources Used

Name of
Resource
Old cut section
of
Water Cooler
1
or
Window/Split
air conditioning
HVAC Tool
Box
2


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Sr.
Particulars Remark
No.
Capacity -
1 Compressor Make-
Type-
Capacity -
2 Condenser Type-
No. of coils-
Name-
3
Expansion valve
Type-
Make-
4 Evaporator Type-
No. of coils-
Thermostatic switch Type -
5
Drier Type -
6
Capacity(volt)-
7 OLP
Capacity(current)-

Blower Type-
8
Capacity -
9 Fan Motor
Type-
Inside Panel -
10 Cabinet Outside Panel -
Insulation -
Figure No.7- Label on Compressor
[Space for student observation of Label on Compressor]
XVI Results
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XVIII Conclusions
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1. Compare split air conditioning unit with window air conditioner unit on the basis
of cost, noise produced, space occupied and electric power consumption.
2. Collect the names of Indian manufacturers of window air conditioners alongwith
their range of capacity in TR.
[Space for Answer]
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1. https://www.youtube.com/watch?v=qBbND6UcjOs
2. https://www.youtube.com/watch?v=NzCj_BPKv0U
3. https://www.youtube.com/watch?v=cDl90FQo-I8

2 Identification of water cooler and air conditioning 20%
components
3 Interpretation of water cooler and air conditioning 20%
components
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………
Dated signature of
Marks Obtained
Teacher

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A Practical Manual

Power Engineering and

Place ………………. Enrollment No……………………

Course Teacher Head of the Department Principal

Maharashtra state Board of Technical Education i

Programme Outcomes (POs) to be achieved through Practical of this

PO 1. Basic knowledge : Apply knowledge of basic mathematics, sciences and basic

Program Specific Outcomes (PSOs)

PSO 2: Maintenance and selection of machines, equipment, instruments: Maintain and

Maharashtra state Board of Technical Education ii

List of Industry Relevant Skills

Maharashtra state Board of Technical Education iii

Practical- Course Outcome matrix

Course Outcomes (COs)

Assemble/Dismantle single cylinder IC

Assemble/Dismantle multi cylinder IC

Assemble/Dismantle multi cylinder IC

Assemble/Dismantle inline/rotary fuel

Perform test on the given IC Engine to

7. Perform test on the given IC Engine to

8. Perform Morse Test on the given IC

Use exhaust gas analyzer to

Perform diagnosis test on given IC

Perform test on the given two-stage

Maharashtra state Board of Technical Education iv

Perform test on the given two-stage

Assemble/Dismantle of Gas turbine

Perform test on vapor compression

Trace the refrigerant flow of domestic

Maharashtra state Board of Technical Education v

Instructions for Students

Maharashtra state Board of Technical Education vi

Date of Date of Dated Remarks

Perform diagnosis test on given

Perform test on the given two-

Maharashtra state Board of Technical Education vii

Perform test on the given two-

Note: To be transferred to Proforma of CIAAN-2017.

Maharashtra state Board of Technical Education viii

Practical No.1and 2: Assemble/Dismantle single cylinder IC Engine.

II Relevant Program Outcomes (POs)

III Competency and Skills

IV Relevant Course Outcome(s)

VI Relative Affective Domain-

Maharashtra state Board of Technical Education 1

VII Minimum Theoretical Background

VIII Experimental setup

Figure No.1 Single Cylinder Diesel Engine(In section)

Figure No 2 Piston sub-assembly (exploded view)

Maharashtra state Board of Technical Education 2

Figure No 3 Tool Box

Figure No 4 Piston sub-assembly

Maharashtra state Board of Technical Education 3

Figure No 5 Dismantling of 4-stroke single cylinder petrol engine

Figure No 6 Pitting of Piston

Maharashtra state Board of Technical Education 4

XII Resources Used - ( Use only Euro4 comply Engine)

S. Name of Broad Specifications Quantity Remarks

Maharashtra state Board of Technical Education 5