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13·1. Introduction
Diesel plants are more efficient than any other heat engine of
comparable size. These plants are cheap by way of initial cost, can
be started and stopped quickly and can burn a wide range of fuels.
A Diesel plant does not require any warming period; it need not be
kept running for a long time before peaking up loads. As a result
there is no standby losses. Another advantage of such a plant is
that it does not need large amount of water for cooling. A diesel
plant can be commissioned in such a much little time compared
with a hydro, steam or nuclear power station.
In view of these advantages a Diesel station is suitable for
localities where fuel costs are low, where water supply is limited,
where oil is cheaper than coal and where loads are of such magnitudes
that they can be handled by a plant of small capacity.
Another means of generating electricity (i.e. hydro, thermal,
nuclear) are rivals to Diesel plants and can be attractive under
certain conditions. Also a gas turbine plant for continuous power
generation is superior to a diesel plant where fuel is very cheap (as
at a refinery or where load factors are very poor).
Not withstanding competition from its rivals a diesel plant
provides the most economical means of generating electricity on
sman scale particularly where there is no convenient site for micro-
hydroplants, cheap fuels are not available and load factors are
considerably large.
The important fields of applications of diesel engines are as
rail road locomotives, ship propulsion, road building and farm
machinery, electric generators for small supply units for public,
industrial and institutional purposes e.g. cinema halls, hospitals,
municipalties etc. These are used in freight trucks, and buses.
However, since diesel engines can make efficient use of fuels that
are cheaper than gasoline, they are being utilized increasingly in
automobiles.
Diesel electric power plants have been chiefly used as peak
load and standby units, for the hydroelectric power plants. These
554 POWEH PLANT TECHNOLOGY
t
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CD
a
o
v
Fig. ]8·2·1. Di('se] cycle.
port because the fuel is not added until both ports are closed.
Consequently, because of its design simplicity and increased power
for a given engine speed, the two-stroke diesel engine is quite common,
whereas the corresponding spark ignition engine has found only
limited use.
Thus advantages of two stroke cycle over four stroke cycle are:
more power output, less frictional loss per horse power, compact
and simple mechanical design, no trouble from valves, lighter fly-
wheel due to improved turning moment. But a two stroke engine
overheats on heavy loads and under light loads the running is erratic.
Moreover, there is always a certain loss of fuel which escapes through
the exhaust port before the compression. A four stroke engine is
economical on lubricating oil and fuel consumption. Moreover, the
engine cooling is simple and better as more time is available for the
removal of heat. Also, the combustion gases can be completely cleared
from the cylinder. The arrangement of cylinders is also important
since it effects the foundations, building space and maintenance
problems. Vertical in line arrangement is most commonly used. To
make the engine more compact, the cylinders may be arranged in
V-shape. Two stroke radial diesel engines require minimum space
and foundations.
Engines in the speed range of 200-1000 r.p.ro. are more common.
Each cylinder is designed for around 75 kW and multi-cylinder engines
having upto 16 cylinders; arranged vertically, are used for higher
outputs.
Diesel Fuels. A diesel engine can use a wide variety of
fuels, ranging from natural gas to fairly heavy petroleum distillate
oils which are cheaper than gasoline. High-speed diesel engines
use lighter fuels than do those operating at lower speeds. The
heavier fuels require larger times to be injected and to vaporize
prior to combustion and hence are more suited to low speed
engines.
A mixture of liquid hydrocarbons used as fuel in diesel (C 1)
engines. Diesel fuels are either various distillates obtained in
petroleum refinning operations or blends of such distillates with
residual ojl. The boiling range (200-360°C) and specific gravity (0·82
to 0·92 ; 40 to 20 API) are higher than for gasoline; diesel fuels are
also more viscous.
An important criterion of diesel fuel is the ignition quality as
indicated by the cetane number. The cetane numbers of diesel fuels
are usually in the range of 30 to 60. A high cetane number is
desirable for easy starting and smooth operation.
558 POWER PLANT TECHNOLOGY
Raw watc..'r
purnD
DIESEL POWER PLANTS 559
Fuel from
Bulk storage Unloading line
Strainers
Meters
Day tanl"J
To Engines
Fig. 13·3·2. Fuel supply system for a diesel power plant.
Spring loaded
spray valve
Fuel lines to
other cy linders
Pump drive
shown in Figr1.4.
\ (r~f It is also called nnit injector method, in which
Metering ~
pressure
pump
Primary
Cam pump
InjectIon
nozzles
High pressu~
fuel lines
Control rack
\\\\\ \h\\ ,',
Pump with
individualcyllnd/
for each nozzle
Fig. 13·3·5. Typical pump and pressure operated nozzcl system.
Exhaust
stack
Diesel engine .~
//
Cylinder
Cylinder Radiator
Jacket
piston Fins
(0)
Cap
- ~tl
Radiator
-~-
Water
in
Wate~
in--=t:.
Jacket water
pump pump
(b) Closed or dou.hle circuit system.
Fig. 13·3·8. Water cooling systems for stationalY diesel plants.
566 POWER PLANT TECHNOLOGY
greater than that at the crank shaft due to engine losses, thus
BHP
TIm = DfP
In power plants which operates at constant speed, the mechanical
efficiency increases with increasing power output.
Engine losses (FHP) that occur are pumping losses of tbe engine,
windage loss at flywheel, mechanical losses in the bearings and
power required to drive the auxiliaries fitted on the engine. These
losses may amount to 10 to 30% of the internal pOWH developed by
the engine.
The efficiency of conversion of the heat energy of fuel into work
is known as indicated thermal efficiency. It is the ratio of heat
equivalent of IHP per minute to heat energy supplied in fuel per
minute.
IHP x 4500
TltCMKS) = W X Cu x J .,. (13·1)
where W = Weight of the fuel supplied in kg per minute
Cv = Lower calorific value of fuel oil ir. kcallkg
J = Joules equivalent = 427
r-Lj,
B.H.P. Mechanical
r-~-t
Heat in water Heat in
etc.
A typical heat balance sheet at full load for Diesel engine eel)
is as follows:
Us~ul output -40%
Heat lost to cooling water 30%
Heat lost in exhaust gases 24%
Heat lost in friction, radiation etc. 6%
Total 100%
Example 13.5.1.During a test on a single cylinder oil engine,
250 mm bore, 600 mm stroke, working in 4 stroke cycle, the following
observations were made. -
Duration of test = 1 hr.
Area of indicator diagram = 4·51 cm2
Length of the indicator diagram = 7·1 cm
Spring index = 8·30 kgf/ cm2 / cm of compression
Load on hydraulic dynamometer = 100 kg
Hydraulic dynamometer constant = 700
Fuel consumptio,: per min. = 0·1867 kg
Calorific value offuel used = 10,000 Kcal/kg
Mass of cooling water = 17 kg / mill,
Inlet temperature of cooling water = 20°C
Outlet temperature of cooling water = 45°C
Temperature of the exhaust gases = 400°C
Weight of dry exhaust gases -= 5·50 kg / mill,
Room temperature = 25°C
Specific heat of exhaust gases = 0·24
Determine mechanical efficiency and draw up heat balance sheet
in Kcal / min.
Solution. Heat supplied by the fuel per min.
= WC"
= 0·1867 x 10,000 = 1867 Kcal
4·517·1
x 8·31 = 5.278 kgfJcm2
574 POWER PLANT TECHNOLOGY
pm LAN
IHP::: 4500
BHP = NT =
21C 21C 300 x 921 x 0·92 - 354
4500 4500 -
= 30 + ~~ = 31·25 kg/min
Heat carried away by exhaust gases = 31·25 x 0·28 x (450 - 25)
= 3718 kcal/min = 29·75%
Unaccounted = 12500 - (3730 + 2800 + 3718) = 2252 = 19·5%
[SI unit] :
Indicated power = 4 (100 pm LA n) kW
[_ PmZ ah kW
- 60
As the engine works on four stroke cycle principle and it is
single cylinder the number of working cycles per min will be 4g0 =
200. I x A is equal the swept volume of the cylinder, which 14litres
i.e. 0·014 cubic metre.
_ 2n 400 x (W-8) R
- 60
= 2,3·14,400,750, ()'7
60
= 2200 watts = 22kW
= Brake power
Mechanical efficiency
indicated power
22
= - =0·84
2&2
i.e. 84% Ans.
Heat from fuel = mass of the fuel x calorific value
7·2
= . , 60 x 44000
60 = 88 kJ/sec .
DIESEL ~OWER PLANTS 579
Storage .-_.
and : =,pace for future Water
shop ~u Unil no 4 ._" cooling
tanks
Wash
Room
1_-__ U_~_;t=~;2~~~=J
Switch
board
Oil storage
tanks
Off Ice
Hall
I \
Inlet ~ I '-\---
\-.
\
, _}
,,
Outlet
these rotary types, a volume of our is taken from the intake and
discharged at the outlet end. The air is compressed as it is forced
against the higher pressures at the outlet side of the compressor.
The 'Screw' arrangement traps air between the intermeshing helical
shaped 'gears' and forces it axially toward the outlet end. The 'gears'
are in some cases designed so that the volume of the pocket of
entrapped air is reduced as it proceeds through the compressor
axially thus producing compression of the air. Positive displacement
superchargers are used with many reciprocating engines in stationary
plants, vehicles, and marine installations. The piston and cylinder
arrangement is generally limited to use on large, low speed C.!.
engines.
The centrifugal compressor is widely used as the supercharger
for reciprocating engines, as wen as the compressor for gas turbines.
It is found in both stationary plants and in the power plants
for vehicles. It is almost exclusively used as the supercharger
with reciprocating power plants for aircraft, because it is
relatively light and compact, and produces continuous flow-rather
than pulsating flow as in some positive displacement types.
The centrifugal type consists of an impeller which rotates in a
housing at a high speed, maximum speed used being of the order
of 16000 to 30000 r.p.m. They have high capacity for small size
and low weight, and are suitable for automobiles or aircraft
engines.
The axial flow compressor consists of sevefl~lstages of altemating
fixed and moving blades which compress the air as it moves axially
along the compressor. While it is seldom used to supercharge
reciprocating engines, it is widely used as the compressor unit of
gas turbines.
The power required to drive the supercharges increases rapidly
if the discharge pressure is increases, and the increased in power
output as a result of supercharging is not proportional to increase
in fuel rate. For maximum advantage the supercharger blower may
be coupled to an exhaust turbine and by driven by the velocity of
exhaust gases. Such a combination is known as 'Turbo-charger' and
is used in many heavy diesel engines. Thus the waste energy of the
flue gases in utilized in improving the engine output. Manifold air.
pressure is automatically increased varying with engine load and
speed. Air flow into the turbo-charged engine may be about double
that of a naturally aspirated engine of the some displacement, rotating
at the same speed. More air makes it possible to bum more fuel,
and this results in greater engine power.
584 POWER PLANT TECHNOLOGY
Disadvantages
(1) The capacity of the plant in this case is limited, large
capacity units as available in case of steam power plants, are usually
not possible. '
DIESEL POWER PLANTS 585
Clearance Volume
(c) (d) none of the above.
Total Volume
20%.
13·11.70%
30%
In a(ii)
(i)F (vii) F
9.5. 7.(c)(c)
11.
(v)
(iv)
((viii)
4. T
iii)
8.
3.
diesel2. T
(b)
(b)F
T(a).
engine
(c) (b) lost to the cooling water is about
the heat
(a) Answers