Basic Mechanical Engineering Unit 5 Reciprocating Machine@by V.P.Singh

UNIT-5
THERMODYNAMICS
NOTES
By
Mr. Varun Pratap Singh
Assistant Professor
Department of Mechanical Engineering
College of Engineering Roorkee

Unit V:
Reciprocating Machines
Working principle of steam Engine, Carnot, Otto, Diesel and Dual Cycles P-V & T-S diagrams
and its efficiency, working of Two stroke & Four stroke Petrol & Diesel engines. Working
principle of compressor.

STEAM ENGINE
Steam engine is a reciprocating device which converts heat energy into mechanical energy and
heat is supplied into the engine through the medium of steam. This is a machine where steam
is used as a working substance. Steam engine works on the principle, where work and heat are
mutually convertible. This is a very basic definition of steam engine.
Figure: Steam Engine
In a steam engine there is a cylinder fitted with a piston. Then steam from the boiler enters to
the engine cylinder and the cylinder is made act on the piston which thereby reciprocates to and
fro motion of the piston. So heat energy in the steam is converted into mechanical work, thus,
it is called Reciprocating steam engine.
First steam engine was invented in 1712 by Thomas Newcomer and his assistant John Calley.
TYPES OF STEAM ENGINE
Steam Engines are different categories. Here we will discuss some important categories:
1. According to the position of cylinder: -
a. Horizontal Steam Engine: When axis is horizontal position in steam engine, it is called
horizontal steam engine.
b. Vertical Steam Engine: When axis is vertical position in steam engine, it is called vertical
steam engine.
2. According to the number of working stroke: -
a. Single Acting Steam Engine: When steam is coming in one side of the piston and it
produces one single working stroke in each revolution of the crankshaft, is called single acting
steam engine.
b. Double Acting Steam Engine: When steam is coming in both side of the piston and it
produces double working stroke in each revolution, is called double acting steam engine. It
produces double power than single acting steam engine.
3. According to the number of cylinders in which steam expands:-
a. Simple Steam Engine: When expansion of steam is carried out in a single cylinder, called
simple steam engine.

b. Compound Steam Engine: When expansion of steam is carried out in a two or more
cylinders, called compound steam engine.
4. According to the type of exhaust: -
a. Condensing Steam Engine: When steam is exhausted in a condenser called condensing
steam engine.
b. Non-Condensing Steam Engine: When steam is exhausted in the atmosphere called non-
condensing steam engine.
5. According to the method of governing: -
a. Throttling Steam Engine: When steam engine speed is controlled by throttle valve in the
steam pipe which regulates the pressure of steam to the engine.
b. Automatic cut-off Steam Engine: When steam engine speed is controlled by an automatic
cut-off governor which controls the steam pressure to the engine.
6. According to the speed of crankshaft: -
a. Slow Speed Steam Engine: When the speed of the crankshaft is below 100 revolutions per
minute, called slow speed steam engine.
b. Medium Speed Steam Engine: When the speed of the crankshaft is in between 100-250
revolution per minute, called medium speed steam engine.
c. High Speed Steam Engine: When the speed of the crankshaft is above 250 revolutions per
minute, called high speed steam engine.
7. According to the field of application: -
a. Stationary Engine
b. Locomotive Engine
c. Marine Engine
8. According to the valve gear used: -
a. Slide Valve Engine
b. Corlis Valve Engine
9. Expansive Engine: -
10. Non-Expansive Engine: -
Working principle of steam Engine
In a steam engine, high-pressure superheated steam from is fed into the steam chest. Here a D-
shaped valve V, called D-slide valve, moves to and fro in a steam chest and this valve regulates
the supply of steam into the engine cylinder is operated by a mechanism E, called eccentric
which is situated on the crankshaft. There are two different ports A and B in which steam is led
into the cylinder on the two sides of the piston and K is the exhaust port in which steam is led
out of the cylinder.
When D slide valve moves to the right, steam from steam chest enters from the left side through
port A. This high-pressure steam pushes the piston to the right side of the crank end. This is
called the forward stroke of the piston. With the movement of piston, crosshead moves to the
right thus pushing the connecting rod which also pushes the crank to the right side. Now the
crank and crankshaft both rotate in clockwise direction, show in the picture.

When piston is in extremely right side or nearer to crank end cover, the V valve is moving
towards the left direction and open the steam port B in which steam is entering into the cylinder
through this port. So, the piston is now moving left side direction or away from the crank. This
is called the returned stroke of the piston. The piston is starting to move in left direction and
left side steam leaves the cylinder through the exhaust port K via port A.
Again when the piston is in the extreme left condition, the valve V are starting to move the
right direction and open the port A. As a result, steam enters the cylinder through port A and
piston starts to move at right direction. Now the right side cylinder's steam leaves the cylinder
through the exhaust port K via port B.
In this way, the piston is moving to and fro motion in the cylinder's chamber and it circulates
crankshaft through piston rod, connecting rod and crank. This process is continuously running
and as such the steam engine works. At the end of each stroke, the piston changes its direction
of motion and it is momentarily stopped. this is called dead centres of the crank. The above
steam engine is called single cylinder double acting horizontal reciprocating steam engine.
Figure: Working and Different parts of steam engine
Figure: Steam Engine and Working Cycle

What is Indicator Diagram of Steam Engine?
Indicator diagram of steam engine is nothing but a graphical representation which defines
with variation in pressure and volume of steam inside the engine cylinder denotes with PV
diagram.
Before developing the indicator diagram of steam engine, we should consider the following
points. It will help to understand the indicator diagram.
1. The steam enters in pressure and released at condenser pressure.
2. The opening and closing steam ports are instantaneous.
3. Steam is hyperbolic at the time of expansion or compression which is pv=c.
4. Steam pressure remains constant at the time of condensation and no wire drawing due to
restricted valve opening.
5. The expansion and compression of steam is hyperbolic nature (pv=c).
Figure: Theoretical or Hypothetical Indicator Diagram of Steam Engine
Theoretical indicator diagram or hypothetical indicator diagram is defined by the
modified pressure-volume curve. We can see, there is no pressure in the engine cylinder, so
clearance is zero but practically it is impossible, shown in the line diagram.

1.1st case point 1-2:- At a point 1 position, steam enters to the engine cylinder through inlet
ports at a constant pressure and piston moves towards the right direction. After that, steam is
cut-off at point 2 position, is called cut-off point.
2.2nd case point 2-3:- Point 2 position steam expand hyperbolically (pv=c) in the engine
cylinder and piston reach at dead end but pressure falls.
3.3rd case point 3-4:- At point 3, inlet steam is released from engine through exhaust ports.
As a result pressure in the engine cylinder falls down suddenly without change in volume. So
this point is called a release point.
4.4th case point 4-5:- At the point 4 position, piston starts to move in opposite direction and
used steam is released through exhaust ports at constant pressure till the Port is closed. At this
point steam pressure is called back pressure.
5.5th case point 5-1:-At the point 5 position, inlet ports are open and some steam enters to the
engine cylinder without change in volume which increases the steam pressure and again piston
moves towards the right position. this process continues till the original position is restored.
Actual Indicator Diagram of steam Engine
Actual indicator diagram of steam engine is different from the theoretical indicator diagram
in the picture shown below, drawn with firm line shows the actual indicator diagram and dotted
line show the theoretical indicator diagram.

1. When steam enters to cylinder there is some pressure drop at the steam. That's why, at the
beginning of the stroke is less than the boiler pressure.
2. due to the air drawing through the steam ports, forward stroke of the piston is always slightly
fallen in pressure shown by the line AB.
3. We can see in the picture that cut-off point B is slightly rounding and it is not same as point
because inlet port cannot close instantaneously due to its valve mechanism.
4. Point C position the curve is rounding off. this point the exhaust port opens before the end
of the forward stroke.
5. At the point, E position remaining steam in the cylinder is compressed and it goes along
through the curve EF before the end of the exhaust stroke. this reduces the wire drawing when
the inlet valve opens at F and also reduces initial condensation.
6. Due to wire drawing effect, the steam is admitted just before the end of exhaust stroke at F.
For this effect, it decreases the area of indicator diagram and work done by the engine is
reduced. the pressure produced by compression up to this point is raised to admission pressure
by the time and piston has reached at the end of the exhaust stroke.
Diagram Factor of steam Engine
Diagram factor(K) is the ratio of the area of actual indicator diagram to the area of theoretical
or hypothetical indicator diagram. The average value of diagram factor lies between 0.65 to 0.9
Indicator factor defines by the work done per stroke,
Work done per stroke also known as,
Actual work done per stroke is,
theoretical work done per stroke is,
So, the diagram factor is the ratio of actual mean effective pressure to the theoretical mean
effective pressure.

Power developed by a Steam Engine
Power developed by steam engine or power measurement of a steam engine is defined by
indicated power and break power. The actual power developed in the engine cylinder is called
indicated power and the power available at the crankshaft of the engine is called break power.
In the page, we will discuss the indicated power developed by steam engine.
Indicated power development of a Steam Engine
The main power generated in the engine cylinder is called indicated power (I.P.). Basically a
indicator is used to measure this power, that is why it's name is indicated power. Let,
We know that force on the piston,
and, work done per stroke,
Work done per minute,
and indicated power,
When the actual mean effective pressure is given in bar, then

Carnot Cycle
Carnot cycle is an ideal cycle as adopted for an ideal heat engine. It consists of two isothermal
process (expansion and compression) and two adiabatic process (expansion and compression).
The cylinder and piston of the engine are considered as perfect non-conductor of heat but the
cylinder cover head is a good conductor of heat. The hot body at a higher temperature is brought
in contact with the bottom 'B' of the cylinder. The cylinder is fitted with a weightless and a
frictionless piston.
The French engineer Nicolas Leonard Sadi Carnot was the first scientist who realize the
problem of the efficiency of heat engine and invented the Carnot cycle. The pressure-volume
(p-v) and temperature-entropy (T-S) graph are shown in the fig.
From the above two p-v and T-S graph, the horizontal axis represents volume 'v' and entropy
'S' and the vertical axis represents pressure 'p' and temperature 'T'. Let, engine cylinder contains
m kg of air at its original condition represented by point 1 on the p-v and T-S diagrams. At this
point, let p1,v1 and T1 be the pressure, temperature and volume.
First Stage (Isothermal Expansion)
Let, unit mass of perfect gas is admitted into the cylinder at the beginning of the outward
moment of the piston and the pressure, temperature, volume of the gas at a point 1 is p1, v1 and
T1 respectively. The bottom 'B' of the cylinder can be covered by an insulating cap .During the
movement of the piston, the heat Q1 is supplied to the perfect gas and the gas expands
isothermally keeping temperature T1 constant until the volume v2 and pressure p2.The heat
supplied by the hot body is fully absorbed by the air and is utilised by doing external work. So,
heat is supplied during this process is equal to the work done during this process. This
isothermal expansion is represented by the curve 1-2 on p-v and T-S diagram.

So, work done by the air
Since, there is no change of temperature from point 1 to 2, so, (T1=T2) and as per first law of
thermodynamics internal energy is also zero (E=0).
Then the heat supplied
Then change of entropy
Second Stage (Isentropic Expansion)
As the piston moves outward, the gas expands adiabatically till the pressure p3, volume v3 and
temperature T2 and the hot body is removed from the bottom of the cylinder 'B' and the
insulating cap is brought in contact. In this process, there is no interchange of heat of the
surrounding gasses (Q = 0) The reversible adiabatic expansion is represented by the curve 2-3
on PV diagram.

The change of internal energy E = - W and there is a no change of entropy, so S2 = S3.
Third Stage (Isothermal Compression)
Now the piston moves inward the gas and insulating cap I.C. is also removed from the bottom
of the cylinder and bring the cold body in its contact. The air pressure is compressed
isothermally keeping temperature constant T3 from v3 to v4.It means at a point 4 temperature
T4 is equal T3.That's why heat is rejected to the cold body is equal to the work done on the air.
The isothermal compression curve is represented by 3-4 on p-v curve.
Here change of entropy E = 0 and change of entropy
Fourth Stage (Isentropic Compression)

As the piston moves inwards the gas insides the cylinder is compressed adiabatically till the
pressure p1, volume v1, and temperature T1 such that the gas returns to its original condition to
complete the Carnot cycle and insulated cap I.C. is brought in contact with the bottom of the
cylinder B. The temperature of air increases from T4 to T1 and not heat is absorbed or rejected
by the air. The reversible adiabatic compression is represented by the curve 4-1 on P-V and T-
S diagram. So, work done by the air for adiabatic compression
From the above discussion, it is seen that the total internal energy decrease in reversible
adiabatic expansion shown in curve 2-3 is equal to the increase in internal energy during
reversible adiabatic compression 4-1. So, the net effect of the whole Carnot cycle is zero.
Net work done,
And Carnot efficiency
From the Carnot cycle efficiency equation, T1 is greater than T3. For the smaller value of T3,
the thermal efficiency will be maximum. That's why Carnot cycle has highest thermal
efficiency of all heat engine.
Why Carnot cycle can't be used in actual practice?
During the isothermal process, the piston should move very slowly within the cylinder. So that
insufficient time is available for the transfer of heat to the working medium within the cylinder
during expansion or from the working medium within the cylinder during isothermal
compression.
But during the adiabatic process, the piston moves very fast within the cylinder. So that no time
is available for the transfer of heat.
So, sudden change of speed (from low speed to high speed) of the piston is required to make
the cycle efficient. But this is not possible due to direction of the cylinder and the piston is none
conductor of heat and cover head of the cylinder is good conductor. Again there is a weightless
and frictionless piston fitted on a cylinder which is practically impossible. That's why Carnot
cycle cannot be used in actual practice.

Rankine Cycle Efficiency
The Rankine cycle is a model used to predict the performance of steam turbine systems. It was
also used to study the performance of reciprocating steam engines. The Rankine cycle is an
idealized thermodynamic cycle of a heat engine that converts heat into mechanical work while
undergoing phase change. It is an idealized cycle in which friction losses in each of the four
components are neglected. The heat is supplied externally to a closed loop, which usually uses
water as the working fluid. It is named after William John Macquorn Rankine, a Scottish
polymath and Glasgow University professor.
It is a reversible process. The Rankine cycle efficiency is much higher than Carnot cycle
efficiency as because the pump is used in the Rankine cycle, which gives higher work ratio by
doing significant proportion of turbinework.

A simple Rankine cycle is completed by following four processes. Steam is used as a working
substance in Rankine cycle, is shown the above p-v Rankine cycle diagram and T-s Rankine
cycle diagram.
The Rankine cycle is an ideal cycle if water passes through the four components without
irreversibility’s and pressure drops. The ideal Rankine cycle consists of the following four
processes, as shown on the T-s diagram on the left:
 1-2: Isentropic compression in a pump
 2-3: Constant pressure heat addition in a boiler
 3-4: Isentropic expansion in a turbine
 4-1: Constant pressure heat rejection in a condenser
The four processes in the Rankine cycle
There are four processes in the Rankine cycle. The states are identified by numbers (in brown)
in the T–s diagram.
Process 1–2: The working fluid is pumped from low to high pressure. As the fluid is a liquid
at this stage, the pump requires little input energy.
In other words, Process 1-2 is [Isentropic compression]
Process 2–3: The high-pressure liquid enters a boiler, where it is heated at constant pressure
by an external heat source to become a dry saturated vapour. The input energy required can be
easily calculated graphically, using an enthalpy–entropy chart (h–s chart, or Mollier diagram),
or numerically, using steam tables.
In other words, Process 2-3 is [Constant pressure heat addition in boiler]
Process 3–4: The dry saturated vapour expands through a turbine, generating power. This
decreases the temperature and pressure of the vapour, and some condensation may occur. The
output in this process can be easily calculated using the chart or tables noted above.
In other words, Process 3-4 is [Isentropic expansion]
Process 4–1: The wet vapour then enters a condenser, where it is condensed at a constant
pressure to become a saturated liquid. In other words, Process 4-1 is [Constant pressure heat
rejection in condenser]
In an ideal Rankine cycle the pump and turbine would be isentropic, i.e., the pump and turbine
would generate no entropy and hence maximize the net work output. Processes 1–2 and 3–4
would be represented by vertical lines on the T–s diagram and more closely resemble that of
the Carnot cycle. The Rankine cycle shown here prevents the state of the working fluid from
ending up in the superheated vapor region after the expansion in the turbine, [1] which reduces
the energy removed by the condensers.
Where

In general, the efficiency of a simple Rankine cycle can be written as
Where
Work done on pump, per kg of water, WPump= h2-h1
Energy added in steam generator, qin= h3-h2
Work delivered by turbine, WTurbine= h3-h4
Energy rejected in the condenser, qout= h4-h1
The thermal efficiency of the Rankine cycle is given by,
When dealing with the efficiencies of the turbines and pumps, an adjustment to the work terms
must be made:
The actual vapour power cycle differs from the ideal Rankine cycle because of irreversibilities
in the inherent components caused by fluid friction and heat loss to the surroundings; fluid
friction causes pressure drops in the boiler, the condenser, and the piping between the
components, and as a result the steam leaves the boiler at a lower pressure; heat loss reduces
the network output, thus heat addition to the steam in the boiler is required to maintain the same
level of network output.

Practical Rankine cycle
Pump and Turbine do not operate Isentropically in practice.
The practical Rankine cycle is shown as 1-2-3-4-1.
In the actual turbine, the work delivered is less than the isentropic turbine. Similarly, the work
consumed by an actual pump is greater than the work consumed by an isentropic pump.
That is,
h3-h4 < h3-h4
h2-h1 > h2-h1
Thermal efficiency of a practical Rankine cycle,
The performance of an actual turbine or pump is usually expressed in terms of isentropic
efficiency.
Isentropic efficiency of turbine (hT) is defined as the ratio of Work delivered by actual turbine
to Work delivered by an isentropic turbine.
Isentropic efficiency of pump (hP) is defined as the ratio of Work required by isentropic pump
to Work required by actual pump

Ideal Verses Actual Rankine Cycle
Rankine Cycle is a known mechanical cycle which is being commonly used in the power plants
for converting the pressure energy of steam into mechanical energy using steam turbines. Major
components of it are rotating steam turbine and boiler pump and stationary condenser and
boiler.
A boiler is used for heating the water for generation of steam at required pressure and
temperature as per the requirement of the turbine for power generation. Turbine exhaust is
directed to the radial or axial flow condenser for condensing the steam to condensate and
recycled back to the boiler through boiler pumps for heating again.
The efficiency of the ideal Rankine cycle as described in the earlier section is close to the
efficiency of Carnot Cycle. But in real plants, each stage of the Rankine cycle is associated
with some irreversible processes and thus the efficiency of the actual Rankine cycle is far lower
than the ideal Rankine cycle efficiency.
Given below Fig. 1-a and Fig 1-b represents the Rankine cycle on P-v and T-s diagram
Rankine Cycle Representation are as follows on P-v and T-s diagrams:
Ideal Rankine Cycle 1-2‘
-b-3‘
-4‘
-1
Actual Rankine Cycle 1-2-b-3-4-1
Critical Point (CP) is in centre of the curve as shown in Fig 1-a and 1-b above. The curved
lines on the left side of the CP are saturated- liquid lines and the region/area to the left of
these lines are called as sub-cooled liquid regions. Similarly curved lines on the right side of
the CP are saturated- vapour lines and the region/area to the right of these lines are called as
super-heat vapour regions.

Energy Analysis of Ideal Rankine Cycle
All components of Rankine cycle (boiler, turbine, condenser and pump) are examples of
steady flow process and to be analysed accordingly. Energy balance for the Ideal cycle is as
follows:
Ideal Rankine Cycle
Components
Heat Work
Boiler feed Pump Wpump-in
Boiler
/addpost/images/
4-10-15-6.gif
Turbine
Condenser
Thermal efficiency of Ideal
Rankine cycle
Energy Analysis of Actual Rankine Cycle
The actual vapour cycle differs from the ideal Rankine Cycle, as a result of irreversibility in
various components. Two major factors of irreversibility are Fluid friction and the heat loss.
Fluid Friction
It causes major pressure drop in the boiler circuitry and also in the condenser and the piping
circuit of the low pressure piping. Because of the fluid friction pressure drop in the boiler
circuitry, the pressure of the steam leaving the boiler will be at somewhat lower pressure. Also
the steam has to be conveyed to steam turbine via steam piping which also accounts for further
pressure drop. So the steam which reaches the turbine stop valve will be at lower pressure than
that of the boiler discharge pressure and the same is represented by 3’ (Fig-1a) in the actual
Rankine Cycle instead of 3 in the Ideal Rankine Cycle.
If we don’t want to compromise on the turbine output, then we must compensate for the
pressure drop/loss and restore the turbine inlet pressure to point 3 in Fig 1-a, by increasing the
boiler pump pressure sufficiently higher to compensate the losses/drop and in the process
increasing the size of the pump and the requirement of input power.
The other reason of irreversibility is the loss of heat in steam in its transportation and
malfunctioning of the steam traps etc. Thus in order to compensate for these losses we need to
generate more steam and that too at higher pressure for the desired rated power generation from
the turbine, as a result lowering the cycle efficiency.
Energy balance for the actual Rankine Cycle is as follows:

Actual Rankine Cycle
Components
Heat Work
Boiler feed Pump Wpump-in
Boiler
Turbine
Condenser
Thermal efficiency of Ideal
Rankine cycle
While calculating the overall cycle efficiency Turbine and pump irreversibilities needs to be
given due importance. For small units usually pump work are negligible and can be neglected
but in larger units pump work is appreciable and can’t be neglected like that.
Actual/Practical Rankine cycle is based on the deviation of flow in turbine and pressure
requirement in pump from the isentropic one and is defined as follows:
Where,
h2a Actual enthalpy at the pump exit
h4a Actual enthalpy at the turbine exit
h2s Ideal isentropic enthalpy at the pump exit
h4s Ideal isentropic enthalpy at the turbine exit
Other factors Irreversibility are
Other factors responsible for irreversibility of actual vapour power cycle are:
 Sub-cooling of condensate in
 Losses associated with bearings
 Steam leakages
 Condenser air-leaks

Methods to increase the efficiency of the Rankine cycle
Basic idea: Increase the average temperature at which heat is transferred to the working fluid
in the boiler, or decrease the average temperature at which heat is rejected from the working
fluid in the condenser.
1. Lowering the condenser Pressure: -
Lowering the operating pressure of the condenser lowers the temperature at which heat is
rejected. The overall effect of lowering the condenser pressure is an increase in the thermal
efficiency of the cycle.
2. Superheating the steam to high temperatures: -
The average temperature at which heat is added to the steam can be increased without
increasing the boiler pressure by superheating the steam to high temperatures.
Superheating the steam to higher temperatures has another very desirable effect: It decreases
the moisture content of the steam at the turbine exit.
3. Increasing the Boiler pressure:-

Increasing the operating pressure of the boiler, automatically raises the temperature at which
boiling takes place.
This raises the average temperature at which heat is added to the steam and thus raises the
thermal efficiency of the cycle..
4. Reheat Rankine Cycle
(a) schematic representation of a reheat Rankine cycle (b) T-s diagram of a reheat Rankine
cycle
The energy added ( per unit mass of steam ) in the steam generator is given by,
The energy rejected in the condenser,
The thermal efficiency,
5.Regenerative Cycle
(a) schematic diagram (b) T-s diagram

CLASSIFICATION AND WORKING OF I.C. ENGINE
Introduction
Up to now we have studied theoretically about the heat engines. One of the simple designs of
a heat engine is a cylinder and piston arrangement such that behind the piston there is a fixed
quantity of some working substance, such as air or any other ideal gas. Theoretically, it is a
closed system. The fixed mass of gas in engine, undergoes a cyclic change in conditions and
during each cycle it takes heat from a heat source, then expands doing work, rejects rest of heat
and again compressed to initial conditions using some amount of expansion work.
Net work done by gas in each cycle
= Expansion Work−Compression work
= Heat absorbed by Gas−Heat rejected by gas
The theoretical cycles, on which the heat engine, is assumed to work, have already been
explained as Carnot cycle, Otto cycle, Diesel cycle, Dual cycle etc.
But for making possible an actual heat engine which can continuously supply the useful
mechanical work, by using any practically available heat source, there are some practical
considerations like what type of heat source can be made available to a heat engine, which can
supply heat every time when required in each cycle of engine. Actually the bulk of heat energy
can be made available only by igniting some chemical fuel i.e. coal, petrol, diesel or gas etc.
Thus the fuel must be burnt for supply of required heat energy continuously in each cycle of
engine and, where this fuel should be burnt i.e. outside or inside the engine. The heat engines
are broadly classified as external combustion engines and internal combustion engines.
Classification of Heat Engines
Depending on the place of burning of fuel, i.e. where should it be burnt, there can be two
methods and based on that heat engines are broadly divided into two types
i) External Combustion engine
ii) Internal Combustion engine
Figure: i) External Combustion engine ii) Internal Combustion engine
External combustion (EC) engine
In this case the combustion of fuel takes place outside the engine as in case of steam engines.
The heat of combustion of fuel is used to generate high pressure steam which is supplied to the
engine through the valve, when it expands and pushes the piston, doing the mechanical work.
Examples of external combustion engine are old steam locomotives, steam turbines (Used in
Power Plants) etc.

Internal combustion engine
In this case, the combustion of fuel and mixture take place in the engine itself. Due to the heat
of combustion, the pressure and temperature of fuel and mixture increases tremendously and
thus high pressure mixture further expands and pushes the piston (or moves a turbine) and does
the mechanical work.
Examples are Petrol Engine, diesel Engine, Gas turbine, Jet engines etc.
Now, as in steam engines the steam and in I.C engine the fuel and air are supplied from outside
during each cycle of engine and after combustion, smoke in case of I.C. engine has to be
removed and fresh air fuel mixture to be sucked in new cycle, these engines are no more a
closed system as mass frequently enters and leaves the system. However, I.C. engine work as
a closed system during compression and expansion process, when valves are closed.
Working of an I.C. Engine Based on Air-Cycles
We have come to know that in an I.C Engine, which may be a petrol or diesel engine or a gas
turbine engine, the fuel is burnt inside the engine to supply heat energy to it. The working of
I.C engine is based on the standard air cycles as discussed before. Theoretically an engine
working on these cycles need to be closed system. But practically in an I.C engine, when fuel
is burnt in the presence of air, it releases heat energy and change into smoke after burning. The
burning content of fuel, which take part in combustion, consume all the oxygen and to burn
fuel again, in the next cycle, fresh air is needed. Thus after each cycle, the burnt gases/smoke
need to be thrown out and fresh air need to be sucked inside again by automatic operation of
exhaust valve and suction valve. Therefore, an actual I.C. engine becomes alternatively an open
system. The working of an actual I.C. engine differs from that of the theoretical air cycle by
two additional processes of suction of fresh charge in to the engine and discharges of burnt
gases form the engine. In this way, the complete cycle of an I.C. engine is comprised of the
following processes:
i) Suction of fresh charge (Process 5-1)
ii) Compression of fresh charge (Process 1-2)
iii) Heat addition by combustion of fuel (Process 2-3)
iv) Expansion of high pressure burnt gases (Process 3-4)
v) Heat Rejection (Process 4-1)
vi) Exhaust of burst fuel i.e. smoke (Process 1-5)
The working cycle of a 4-stoke Petrol Engine & Diesel Engine is shown in below mention
figure. During the suction and exhaust processes, the engine become an open system and works
like a pump as shown below:

Figure: 4- Stroke Petrol Engine
Figure: 4- Stroke Diesel Engine
Theoretically, the suction & exhaust processes are just opposite to each other. During suction,
the work is positive and during exhaust, work is negative and so network is zero. But practically
the fresh air or air-fuel mixture is sucked and combustion material is exhausted through narrow
valves, offering resistance to flow of air. Also there is internal friction and difference in
temperature inside and outside the engine, so net pumping work is negative, which reduces the
positive cyclic work. Thus the network output of working cycle of an I.C engine is less than
that of its air-standard cycle due to loss of work in its pumping action during suction and
exhaust process. It is also shown in actual P-V diagram of Petrol Engine and Diesel Engine
shown in figure.

Figure: Theoretical working cycle of 4-stroke petrol engine
Fig.: Theoretical working cycle of 4-stroke petrol engine
Fig. Theoretical working cycle of 4-stroke diesel engine

Combustion process
The heat addition process in an I.C engine is actually a fuel burning or combustion process
which is an exothermic reaction between carbon content of fuel and oxygen content of air. The
combustion process depends on the type of fuel and other conditions inside the engine and
so effecting the way in which heat is released inside the engine and so effecting its thermal
efficiency. Thus the overall thermal efficiency of an I.C engine depends on the combustion
process itself. In actual the maximum power output, minimum pollution and higher thermal
efficiency, all these parameters depend on that how efficiently the combustion process takes
place.
Classification of I.C Engine Based on Ignition Process
Let us now concentrate on I.C engines where the combustion of fuel takes place in the
confined volume created by cylinder walls and piston.
Let us understand the combustion process more clearly as:
Combustion may be defined as a relatively rapid chemical combination of hydrogen and carbon
in the fuel with the oxygen in atmospheric air and resulting in liberation of heat energy. It is a
very complicated phenomenon and has been a subject of intensive research for many years. In
fact the whole performance of I.C engine largely depends on the combustion process and
pattern of release of heat energy. Hence all scope of research moves around the phenomenon
of combustion.
The conditions necessary for combustion to take place are:
i) Presence of a combustible mixture i.e. fuel and air molecules should be in required
proportion and in physical contact with each other. Ideally each molecule of fuel should be in
close contact with required oxygen molecules.
ii) Some means of initiating combustion i.e. either there should be an external spark or the
temperature of fuel air mixture should be very high, well above the ignition temperature of fuel.
iii) Stabilization and propagation of flame in the combustion chamber, which depends on bulk
temperature of mixture.
Depending on the method of initiating combustion which further depends on the type of fuel
used the I.C engines are further classified as of two types.
i) Spark Ignition (S.I.) Engine or petrol or gas engine.
ii) Compression Ignition (C.I.) Engine-Diesel Engine
Spark ignition (SI) engine
In this type of engine, the combustion is initiated by producing a spark by some external means
as shown in fig 12.3. The fuel used is petrol, gas or any other liquid fuel which is volatile in
nature and the vapour of which can thoroughly mix with air at room temperature to prepare a
good combustible mixture. This mixture is prepared outside the engine cylinder in a device
called carburettor and sucked by piston in cylinder of engine through inlet valve, thus fulfilling
the first requirement of combustion. It is then compressed to a high pressure and temperature,
required to fulfil the third condition of combustion. Then last condition is achieved by
producing a spark by spark plug. As all the conditions are well achieved, the combustion takes
place instantly and sharply increases the pressure and temperature approximately at constant

volume at the end of compression stroke. The cycle of SI engines resembles OTTO cycle as
shown in figure.
Figure: 4- Stroke SI Engine
Compression Ignition (CI) Engine
In this type of engine, the combustion is initiated by compressing the air to such a high pressure
& temperature, which is above the ignition temperature of fuel. The fuel used generally is
Diesel, which generally does not form mixture with air. Thus the first condition is less achieved
due to less volatility of diesel. Hence in this type of engine, first the air only is compressed to
a high temperature & pressure and turbulent condition. And then at the end of compression
stroke, the fuel is injected and atomized at high pressure in this air as shown in the figure. Due
to atomization the contact area of fuel droplets increases and due to very high temperature
produced by compression they vaporize at once and as the temperature is above the ignition
temp the combustion starts at various points. This increases temperature and turbulence further
and helps in mixing of fuel and air. The mixing and combustion take place simultaneously and
also for a comparatively long time and nearly at constant pressure. Thus the actual engine cycle
resembles the Diesel cycle. In Diesel engine, combustion takes longer time by which piston
covers some distance and increases the volume of combustible gases in cylinder. The increase
in pressure due to release of heat energy is balanced by decrease in pressure due to increase in
volume. Thus practically, the pressure remains constant during combustion process in a slow
speed Diesel engine. A high speed Diesel engine however works on Dual Combustion Cycle.

Figure: CI Engine Diagram
Working of a Four Stroke Otto Cycle Spark Ignition (S.I.) Engine
We have come to know that the working cycle of an actual engine as shown in the figure, is
comprised of all the processes of an Otto cycle along with two addition processes of suction
and exhaust. Normally, to carry out a complete cycle of processes as suction, Compression,
Ignition, Expansion and Exhaust, piston in the cylinder of engine has to carry out four strokes
from one end to other end. Therefore, it is also called a four-stroke S.I. engine. The top end
position of piston towards the cylinder head is called top dead centre (TDC) and the bottom
end position towards crank is called bottom dead centre (BDC).
Figure: Theoretical working cycle of 4-stroke petrol engine

Process 5-1 (Suction stroke)
At the start of cycle the piston moves from TDC to BDC. The inlet valve (I.V.) is opened
automatically by valve operating mechanism at the start of this process. Due to increase in
volume inside the cylinder, a slight vacuum is created and, the fresh charge i.e. mixture of air
and petrol prepared in Carburetor is sucked inside the cylinder through inlet valve. At the end
of stroke, the piston reaches BDC position, total volume of cylinder is filled with fresh charge
and inlet valve is closed. Theoretically, the charge is filled at constant pressure P1 and it
occupies the total volume of cylinder V1.
Process 1-2 (Compression stroke)
During this stroke, both the valves remain closed and piston is moved from BDC to TDC by
the force of crank. As the piston moves up, volume of cylinder shrinks and the fresh charge is
compressed to a higher pressure P2 and volume V2 equal to clearance volume. Theoretically,
this process is adiabatic compression process. Temperature of fresh charge is also raised in
compression from T1 to T2.
Process 2-3 (heat addition)
This process is actually a constant volume heat addition process. At point 2, spark plug ignites
and starts the combustion of already compressed, high temperature charge. Due to very
favorable conditions of combustion, combustion of charge and heat release takes place in no
time (theoretically) and pressure & temperature further shoots up to P3 and T3. Theoretically
the volume remains constant from 2to3. So V2=V3=VC=Clearance Volume.
Process 3-4 (expansion or working stroke)
This is the process or stroke of piston in which positive work is obtained. The burnt gases at
high pressure and high temperature at point 3 expand and push the piston again from TDC to
BDC, thus doing work on the piston. This work is given to output shaft of engine through
connecting rod and crank shaft. A small portion of it is stored in the heavy rotating flywheel
mounted on crankshaft, which is used in movement of piston in three other idle stroke i.e.
Suction, Compression and Exhaust). When piston reaches BDC, cylindrical total volume is
filled with comparatively lower pressure and temperature burnt gases or smoke. At this point
4, the exhaust valve (EV) opens.
Process 4-1 (heat rejection)
In this process, as soon as the exhaust valve is opened at point 4, the burnt gases start escaping
to atmosphere and their pressure reduces to atmospheric pressure P1. Theoretically, this process
happens in no time and escaping of exhaust gases take away some heat from the engine.
Process 1-5 (exhaust stroke)
This stroke is just opposite to suction stroke. Piston moves from BDC to TDC and pushes away
or sweeps the remaining burnt gases out through E.V. As the piston reaches TDC most of burnt
gases escape and E.V. is closed. One cycle of the engine completes here. Simultaneously, the
I.V. opens and next cycle starts.
In this way, piston goes on moving or reciprocating from TDC to BDC and BDC to TDC with
a high speed and engine produces power continuously by burning of petrol or gas etc. The
power output and RPM of engine can be easily controlled by a throttling valve fitted in the
passage of air intake or in the carburettor where fuel and air are mixed together in the right
proportion. When throttle valve is fully open, maximum air and fuel will be sucked by engine

and maximum power will be produced. As throttle valve or accelerator is closed, lesser air and
fuel mixture will enter the engine per cycle and lesser power will be produced. The throttle
valve can be operated manually or automatically by a governor. In S.I. engine the power output
& RPM of engine are governed by varying the quantity of fuel air, mixture. This type of
governing is called Quantity Governing.
Actual cycle and valve timing diagram of a 4-s S.I. engine
In the previous article, the theoretical working of a 4-Stroke S.I. Engine based on Otto cycle
was discussed. But still there are some practical difficulties in operating the engine on
theoretical cycle as shown in above mentioned figure. Therefore, some changes or
modifications are required or have to be there to remove practical difficulties. These are being
discussed one by one.
1) As the suction of fresh charge and exhaust of burnt gases take place through valves which
are practically of far less area than that of piston, some pressure difference is created across
these valves. Because of this valve restriction, the processes 5-1 and 1-5 are not on the same
line. Suction Process 5-1 line is curved downward due to decrease in pressure in the cylinder
caused by valve restriction on one side and pull created by piston on other side. In this way
piston has to do extra work in pulling and pushing the gases against valve restriction and also
against friction. This work is called pumping work, which is negative and reduces the overall
output of engine per cycle. Pumping work is shown by loop 1-5-1 on actual cycle of engine
shown in figure.
2.) The piston is continuously moving with a high speed and is not stopping at any point. So,
volume in the cylinder is continuously changing. On the other hand, while operating valves
mechanically, they require some finite time to open and close and cannot be operated instantly
at a particular state as given in theoretical working. Also practically it is very difficult to suck
the fresh charge and throw out the burnt gases exactly within the limit of TDC & BDC.
Practically by doing so, these processes become very inefficient. Thus the timing at which
valves are operated have to be advanced or delayed from TDC & BDC as discussed in detail
below.
3) One more thing is that even the combustion process is very fast in S.I. Engine but it is not
completely instantaneous process and has some delay between the ignition of spark and
reaching of gases at peak pressure and temperature. Ideally the peak pressure of gases should
come just at the point, when piston is about to move from TDC to BDC, so that maximum
works is produced.
A typical example of timing of operating Inlet & Exhaust valves and spark plug in a 4-Stroke
S.I. Engine is given in terms of Angles of Crank before or after BDC or TDC. If can easily be
understood from diagram that when piston moves from TDC to BDC, crank rotates by 180° and
when it again goes back from BDC to TDC, crank further rotates by 180° and completes
360° or one revolution. But, one working cycle of 4-S Engine completes in four strokes of
piston during which crank shaft completes two revolutions. Also when piston is at BDC or
TDC, crank is exactly aligned with centre line of Cylinder of Engine.
In the above diagram, dark dot represents the position of crank pin also shown by angle of crank
at which valves are operated. The crank pin rotates exactly in circular path. The spiral path is

just shown to represent different strokes i.e. Suction, Compression, Expansion and Exhaust
separately. From this diagram, only angles are important.
At the start of cycle, inlet valve opens 20° before piston reaching at TDC. Here 20° means crank
is making angle 20° with the centre line of cylinder of engine at the moment of opening of inlet
valve. It ensures the I.V. is fully open, when piston is at TDC and about to move towards BDC
at the start of suction stroke.
The suction stroke ends theoretically when piston reaches BDC. But in actual the closing of
I.V. is retarded up to 35° after BDC. It is because during suction, the fresh charge enters the
cylinder through I.V. with high momentum due to which it keeps on entering the cylinder even
when piston starts moving upward if I.V. is open. So to trap this momentum and to adjust the
closing time of I.V., its closing is retarded 35° after BDC to ensure suction of maximum charge
in the cylinder.
After I.V. Closing, compression starts at the end of which charge is to be ignited. But to adjust
the delay between Ignition and peak pressure, spark is given to charge before the end of
compression stroke. It is shown here 35° before TDC. This advancing of spark ensures the peak
pressure at TDC position of piston to harness maximum mechanical work during expansion.
After Ignition, expansions of burnt gases take place. Theoretically it goes on up to BDC, where
E.V. Opens. But practical difficulty is that if E.V. starts opening at BDC, it will fully open after
some angle of crank and pressure of gases is still higher, so piston has to do negative work on
these gases and network of cycle will decrease. To avoid this the exhaust valve starts opening
35° before piston reaches BDC during the expansion stroke. It ensures that valve is fully open
before BDC and also self-escaping of some of burnt gases due to some higher pressure than
outside pressure.
At the end of exhaust stroke, E.V. should close theoretically. But to trap the momentum of
outgoing gases through E.V. and to ensure minimum exhaust gases left over in the cylinder,
exhaust valve closes 10° after TDC.
In this way, by operating the valves and spark before or after BDC/TDC to adjust the real
phenomenon, the power output of Engine is optimized. The actual cycle of a 4-S S.I. Engine
will look like as shown in figure.
Fig.: Actual cycle of 4-stroke S.I. engine

COMPARISON OF SI AND CI ENGINE
Working of a Four Stroke Diesel Cycle Compression Ignition (CI) Engine
A diesel engine is called compression Ignition engine because here the conditions of
combustion or ignition are achieved only by compression of air to a very high pressure. There
is no spark plug to initiate the combustion, but in place of that a fuel injector is there, which
injects and atomizes the fuel i.e. Diesel at a very high pressure in very hot compressed air after
compression stroke in engine. Due to high pressure and temperature above the ignition
temperature, fuel atomization, evaporation and self-ignition take place. The rest of the working
of Diesel Engine is same as that of Petrol or Gasoline Engine. Here also one complete cycle is
comprised of all the processes of Diesel cycle along with suction of fresh air and exhaust of
burnt gases. To carry out all these processes, here also normally 4 strokes of piston are required.
So, it is called a 4-stroke Diesel Engine. The complete theoretical working of it is explained
here and can be understood with the help of engine line-diagram shown in figure and complete
cycle diagram on P-V chart in fig 13.2.
Figure: 4- Stroke Diesel Engine

Process 5-1 (suction stroke)
At the start of cycle, the piston moves from TDC (point 2- 2 -5) to BDC (point 1- 2-4) and inlet
valve is opened at the start of process at point 5. Due to increase in volume of cylinder by the
movement of piston, the fresh air from atmosphere enters the cylinder and occupies all the
space inside the cylinder until piston reaches BDC. At the point 1, air filled in cylinder is at
volume V1 and its pressure & temperature are theoretically same as that of outside atmosphere.
Here inlet valve is closed and cylinder becomes a closed thermodynamic system.
Process 1-2 (compression stroke)
In this stroke, piston moves from BDC to TDC by the force of crank. As both valves are closed,
the air sucked in previous stroke is compressed to the clearance volume. Here in Diesel engine
the compression ratio r which is the ratio of total volume V1 to clearance volume VC is very
high as compared to SI Engine. So, naturally the rise in pressure and temperature of air at the
end of compression stroke is also more. The range of r in Diesel Engine is 15 to 22.
Theoretically, the compression process is adiabatic & isentropic Compression.
Process 2-3 (heat addition)
This process is actually a constant pressure heat addition process or a mix of constant volume
and constant pressure process as in case of high speed diesel engine. At the point 2 the fuel
injector injects a fix quantity of fuel in very hot & compressed air compressed to the clearance
volume. Due to that fuel spray ignites itself thus releasing of heat in the cylinder. As this heat
addition process is slow, piston moves back to some distance from TDC to point 3 shown in
fig 13.2 and the volume increases which nullifies the effect of increase in pressure due to heat
addition. Pressure remains constant theoretically upto point 3, where the injector stops injection
of fuel and so the addition of heat. Point 3 is also called cut-off point. A part of piston stroke
from 2 to 3 takes place along with this process and the burning fuel plus air mixture expand
and push the piston producing a positive work.

Fig. Theoretical working cycle of 4-stroke diesel engine
Process 3-4 (expansion stroke)
Actually the complete expansion stroke is from point 2 to point 4 but a part of it is along the
previous heat addition process 2-3. After point 3 heat addition stops and the hot and high
pressure burnt gases expand at the cost of their own internal energy and produce positive work
by pushing the piston to BDC. This stroke is called working stroke as here piston moves the
crankshaft and give mechanical energy. Major part of this energy is given to output shaft and a
small portion is stored in heavy flywheel in the form of its rotational kinetic energy and used
up during idle strokes of piston i.e. Suction, Compression & Exhaust.
Process 4-1 (heat rejection)
This process takes place at constant volume and heat is rejected directly by escaping of some
of burnt gases due to pressure difference inside and outside the engine as soon as exhaust valve
opens at point 4 i.e. just at the end of expansion or working stroke. Theoretically, piston remains
at BDC and gases escape in no time, taking away some heat from the engine. Pressure inside
the cylinder reduces to atmospheric pressure.
Process 1-5 (exhaust stroke)
In this process or stroke, piston is moved by crank from BDC to TDC. As the exhaust valve
remains open during this stroke, piston displaces or sweeps out the burnt gases through it and
only a small fraction of gases remains in the clearance volume finally. The piston reaches TDC
and the cycle completes as the initial conditions are again reached. AT this point, exhaust valve
closes and inlet valve opens and next cycle starts.
In this way piston moves or reciprocates from TDC to BDC and again from BDC to TDC with
a high speed and engine produces power continuously by burning of air and fuel mixture. The
power output and RPM of engine here can be controlled by controlling the quantity of fuel
injected only. There is no restriction on the quantity of air sucked by engine. There is a
mechanical or electric control on the fuel injection depending on fuel injection system used.
When more power is required more quantity of fuel is injected and when less power is required
accordingly fuel supply is reduced. There is no control on the quantity of air so air sucked
remains more or less same. In this way only the quality of combustible mixture changes in
different conditions of loading and so Quality Governing is used in CI Engine.

Actual cycle & valve timing diagram of a 4-s CI engine
In the previous article, the theoretical working of a 4-S Diesel Engine was discussed based on
Diesel Cycle. But like in a SI Engine, here also the same type of practical difficulties come in
operating the engine, which are to be removed by doing some changes or modifications in valve
operating timing and diesel injection timing as per the real phenomenon in a Diesel Engine. All
these changes are being discussed here in detail one by one.
1) The inlet and exhaust valves are practically of lesser cross-sectional area than that of piston
or cylinder. So they offer flow resistance to the incoming fresh air and outgoing burnt gases.
Wall friction & Internal friction is also there. To overcome these resistances, piston has to do
negative work for continuously pumping in fresh charge during suction stroke and pumping
out the burnt gases during exhaust stroke. So network is not as given by theoretical cycle shown
in fig 13.2. But it is less than that due to negative pumping work which is clear from actual
cycle diagram in figure.
2) Inlet and Exhaust valves are to be operated mechanically by a cam shaft which gives a
smooth opening & closing. Thus valves cannot be operated instantly at a particular position of
piston at BDC or TDC as shown in theoretical cycle in fig 13.2. Also to trap the momentum of
incoming air and outgoing burnt gases for the benefit of efficient and effective suction &
exhaust stroke, the operation of valves has to be advanced or delayed as discussed in detail
further below.
3) The combustion process in a CI Engine is entirely different than that in a SI Engine. Here
the fuel injection, its atomization, mixing & burning in air is a relatively slow process, which
is to be adjusted appropriately between compression & expansion process so that to maximize
the work output.
On removing these practical difficulties and inculcating the necessary changes or modification
the actual valve timing diagram of a 4-S CI Engine is shown in figure.
Fig.: Actual cycle of 4-S CI engine
At the start of cycle, inlet valve opens at crank position 25° before TDC to adjust the valve
operating period. It ensures the valve is fully open at the start of suction stroke just after TDC.
At the end of suction stroke at BDC, Inlet valve should close as per theoretical cycle. But as
discussed earlier also, it closes 30° after BDC i.e. after the piston has started moving upwards
to adjust the valve operating period and to trap the incoming momentum of fresh air at the end
of suction stroke.

As soon as the inlet valve closes, compression of air starts and at the end of it injection of fuel
should start theoretically. But to adjust the time delay between start of injection and start of
combustion, fuel injector starts injecting the fuel 15° before TDC. It keeps on injecting fuel up
to 25° after TDC. Rise in pressure due to combustion is somewhat adjusted by increase in
volume by downward movement of piston. Thus there is no steep rise in pressure as was in case
of SI Engine. It is clear from actual PV diagram shown in figure.
Like in SI Engine, exhaust valve starts opening 45° before piston reaching BDC so as to adjust
the valve operating timing and to decrease pumping work of piston during exhaust stroke.
However, opening of E.V. before end of expansion stroke is also a direct loss of power but that
will be lesser & safer than the piston would have to face an opposing thrust or jerk just at the
start of exhaust process.
At the end of exhaust stroke, when piston is at TDC, exhaust valve should close as per
theoretical cycle in fig. 13.2. But to trap the momentum of outgoing gases and also to adjust
the valve operating period, E.V. closes fully 15° after TDC.
In this way by operating the valves and fuel injector before and after BDC/TDC to adjust the
real phenomenon the power output of engine is optimized. After incorporating all these changes
or modifications, the actual cycle of a 4-S Diesel Engine will look like as shown in fig. 13.3
Table: Comparison of SI and CI engines
SI Engine CI Engine
Fuel used is petrol, LPG or CNG etc. Fuel used is Diesel oil.
It works on OTTO cycle. It works on Diesel or Dual combustion cycle.
Power Required to start the engine is less Power required to start the engine is more.
Compression ratio is low in the range of 7
to 9.
Compression ratio is high in the range of 15 to
24.
Fuel supply system is either through
carburettor or through Electronic Multi
Point Fuel Injection (MPFI) system.
Fuel supply system is any type of high pressure
fuel injection system like Direct Injection (D.I.),
Common Rail Diesel Injection (CRDI) etc.
Maximum pressure does not exceed 60
bars. So SI engine is comparatively light in
weight.
Maximum pressure exceeds up to 120 bar or
even more. So, more robust construction and
heavier than SI Engine.
High RPM, Low Torque Low RPM, High Torque
Power output is governed by controlling the
quantity of fresh charge supply to engine.
So SI Engine uses quantity governing.
Power output is governed by controlling the
quantity of fuel only to be injected while air
quantity remains same. So CI engine uses
quality governing.
Its running cost is high. (Less fuel
efficiency)
Its running cost is low. (More fuel efficiency)
Its initial cost is low. Its initial cost is high.
It’s maintenance cost is low. Its maintenance cost is high.

Not used in case of high power requirement
due to lesser fuel efficiency
Not used in case of low power requirement due
to bulky and costly.
It has high power to weight ratio. It has low power to weight ratio
Their use is limited to two wheeler
automobiles and personal cars only. May
also be used in some other small
applications where light engine is primary
requirement.
These are used in heavy duty vehicles, Electric
Gen Sets and other heavy duty power
applications where low running cost is primary
requirement.
Figure: Comparison of SI and CI engines
PARTS OF I.C. ENGINE
Parts and Construction of an I.C Engine
Until now after studying the heat engines, we know that work means movement of piston from
one end to other end in the cylinder of engine. It means the work is available in the form of a
straight movement of piston and that too only during the expansion or working stroke. Out of
this work some work has to be spent in the suction, compression & exhaust stroke. Thus work
available at the piston is not continuous. On the other hand, practical requirement from a heat
engine is continuous supply of mechanical work in the form of a moving wheel. Thus the actual
I.C engine is not merely a cylinder/piston arrangement but there are some other parts and
mechanism also which make it a complete machine producing power by burning of fuel.
Practically there are hundreds of different parts of an I.C engine and it is practically impossible
to explain each in the limited contents. However, the main components which form an integral
part of engine are explained here and also shown in the figure of a single cylinder air cooled
I.C. engine.
Cylinder block
It is the major part of an I.C engine which is casted of hard grade cast iron or aluminium alloy.
It has one or more cylindrical barrels/cylinders which guide the piston, depending on single
cylinder or multi-cylinder engine. The bore and length of cylinder depending on stroke length
are the two main design parameters of an I.C engine. Most of the time, separate cylindrical
sleeves of superior quality material i.e. steel or aluminium alloy are fitted in the cylinder blocks

to act as the cylinder. On wear and tear these can be replaced in the engine block during over
hauling of engine. In air cooled cylinder, fins are provided around the cylinder to
increase/facilitate dissipation of heat to air. In water cooled cylinder water jackets are there
around the cylinder through which cooling water flows. The manufacturing quality of the
cylinder or sleeve contributes mainly towards the life of engine as it has to bear a lot of
mechanical & thermal stresses.
Cylinder head
It covers the cylinder block & so the cylinder from top end is closed. It is filled tightly with
cylinder block with the help of studs and nuts. A gasket is also used between cylinder head and
cylinder to avoid any leakage of gases. It has a complicated design as it incorporates in it the
hemispherical shape combustion chamber, inlet and exhaust ports/ passage, valve & valve seat
and also valve guide mechanism. The spark plug for S.I engine or Fuel injector for C.I engine
is also screwed in at the appropriate place in cylinder head. In case of water cooled engine, the
cooling water galleries are also incorporated in the cylinder head which meet the corresponding
water galleries in cylindrical block. Thus it has a complicated design. It is also casted of high
grade C.I or aluminium alloy.
Piston
It is a moving component of cylindrical shape which remains slide fitted in the cylinder and
can reciprocate in the cylinder. Its outer diameter is within the limits and fits of inner diameter
of cylinder. The number of piston used is same as number of cylinders i.e. for each cylinder
there is one piston. It is made up of aluminium alloy and strong enough to bear the force of
expanding fuel gases on one side and transmit it to connecting rod on the other side. It is also
light in weight to minimize the energy loss due to inertia forces. It is a semi-hollow cylindrical
component with the solid face towards the cylinder head. Over the top solid face it bears the
force of burning & expanding gases and in the hollow space below connecting rod is hinged
with the help of a Gudgeon pin. On its circumference, it has rectangular slots/grooves to fit in
various types of piston rings. The O.D of piston is designed in such a way that even after
increase in size due to thermal expansion at high working temperature, it should easily slide in
the bore of cylinder.
Piston rings
Along with easy sliding, the piston should also give a sealing fit in the cylinder to avoid leakage
of gases in between the piston & cylinder. For this purpose, piston is equipped with piston
rings. Piston rings are made of fine grain cast iron or spring steel which gives high elasticity
even at higher temperature. These are circular in shape and sized as per the groove of piston.
They are split at one point for fitting in the grooves. When rings are put on piston and it
is slided inside the cylinder walls, their closed end comes close and due to elasticity they try to
expand outside and form a sealing fit with the cylinder walls. The split end of each ring is kept
at a different point than that of other ring. In case of a 4 stroke engine where more lubricating
oil is supplied between the piston and cylinder, a separate ring is there to scrap off all the oil
from the cylinder wall, before it is exposed to burning gases to prevent burning of lubricating
oil.
Piston pin (Gudgeon pin)
It is a hardened steel pin pressed through the piston and small end of connecting rod fitted in
between. By piston pin, connecting rod is connected to piston and can swivel on it.

Connecting rod
It is a forged component hinged between the piston and crankshaft. The small end is hinged to
the piston with the help of Gudgeon pin. Big end is hinged to the crank with the help of another
set of split bushes and crank pin. This big end is open able and closed by a rod cap after taking
in the crank pin with split bushes in between a shown in figure. The job of connecting rod is to
transmit reciprocating motion of piston to the crank in rotary form. Connecting rod is made up
of nickel/chrome vanadium steels. The assembly of piston, piston pin and connecting rod with
crank shaft as shown is figure.
Crankshaft
It is the main shaft of engine mounted over the main bearings in crankcase and has crank or
misaligned/eccentric crankpin hinged with big end of connecting rod. This shape facilitates the
conversion of reciprocating motion into rotary motion. The eccentricity between the crankshaft
and crank pin is half of the stroke length of piston. Thus during two complete stroke of piston,
crank shaft undergoes one complete revolution.
Crank case
Crank Case is made up of cast iron and covers the lower portion of cylinder block. It houses
the crankshaft, connecting rod, cam shaft, push rod etc and also stores lubricating oil at its
bottom. So, the bottom portion of crank case is called oil sump which can be dismantled
separately. At its bottom a drain plug is there to drain the lubricant oil during routine servicing
of engine. Lubricating oil pump is also installed inside the crank case.
Engine bearing
Any rotating mechanical part of a machine is supported by some type of bearing. The function
of bearing is to allow the required moment of parts and also to support or bear the load or force
exerted by moving parts. The bearing at the small end and bigger end of connecting rod are
sleeve and split-sleeve bearings. The main bearings in the crankcase on which crank shaft is
supported are ball bearings or roller bearing. All the bearings are lubricated continuously with
pressurized lubrication system of engine. If wear does take place, it is the bearing or sleeve that
wears and it can be replaced instead of whole crank shaft or other expensive engine part.
However, due to costly material, bearings are also costly parts but need to be replaced only
after a long time running of engine.
Flywheel
A flywheel mounted on the crankshaft outside the crank case has an important part to play in
the working of an I.C engine. It is a heavy part and rotates along with the crank shaft. It stores
the energy in the form of a heavy rotating mass, when it is available on crankshaft during
working stroke and gives it back when it is needed in the idle stroke. So it keeps on moving the
engine during idle stroke. It also facilitates the starting of engine, overcoming the starting over-
load. The weight of fly-wheel depends on the type and size of engine. Therefore, lighter
flywheel is required for a multi-cylinder engine than that in single-cylinder engine of same
displacement. Also lighter flywheel is required for a 2-stroke engine than that in 4-stroke
engine. Further lighter flywheel is needed in petrol engine as compared to Diesel Engine.
Governor
Governor is a device used for regulating automatically, the output of engine by regulating the
supply of fuel/fuel charge. In an engine running at a normal speed, if the load on output shaft

increases, rpm of engine tends to decrease. Conversely if the load decreases, rpm tends to
increase. If governor is, fitted on the engine, it senses its rpm and accordingly regulates the fuel
supply to the engine. If due to increased load, engine tends to slow down, governor increases
the fuel supply and if engine tends to rotate fast due to decreased load, governor decreases the
fuel supply and keeps engine rpm at a constant value by adjusting the power produced with
power required.
Valves and valve operating mechanism
The various components of valve operating mechanism are
i) Inlet and Exhaust Valves with extended Stem
ii) Valve Seat in the cylinder Head
iii) Valve bush
iv) Valve Spring
v) Rocker Arm or Puppets
vi) Push Rod
vii) Cam Shaft
viii) Timing Gear or Belt
The Inlet & Exhaust Valves of conical disc type are provided in the cylinder Head. Generally,
one Inlet Valve & One Exhaust Valve is there in each cylinder. But more than one Inlet &
Exhaust Valve can also be used. These valves rest on their seat made in the bottom face of head
with the help of valve stem, bush, spring retainer etc. Due to spring force, valve remains closed
by tightly fitting over its cone shaped seat. It can be made open by pushing valve stem with the
help of rocker arm downward. The rocker arm is actuated by means of a push rod and camshaft
resting on its bearings in the crankcase. On the camshaft, various cams are there in different
angles, one for each valve. The camshaft is rotated by engine crankshaft itself with the help of
timing gears. The relative position of crankshaft and camshaft is very important as it ensure the
correct timing of operation of valves with the help of already determined and fixed position of
cams on camshaft. Valves and rocker arms are fitted in cylinder head and camshaft is in the
crankcase. Push rods pass through cylinder block to pass on the actuating or pulsating moments
of cams to rocker arms.
Important Terms Related to an I.C. Engine
(a) Bore

It means the inside diameter of cylinder of Engine.
(b) Stroke
The distance moved by piston along the cylinder axis from one end to other end i.e. BDC to
TDC is called stroke.
(c) T.D.C.
The end position of piston in cylinder towards cylinder head side is called top dead centre or
TDC.
(d) B.D.C.
The end position of piston in cylinder towards crankcase side is called bottom dead centre or
BDC.
(e) Size
Size of engine means the stroke volume of all the cylinders of engine which is measured in cu
cm (c.c.) by multiplying the cross-section area of cylinder and stroke of piston. So 800 c.c. of
engine means total stroke volume of all cylinders in cu. cm
(f) Clearance Volume
The volume contained in the cylinder above the piston when it is at TDC is called Clearance
Volume. It is the least volume to which gases/air can be shrieked to.
(g) Total Volume
It is the volume contained in cylinder above the piston when position is at BDC. It is the
maximum volume, the gases can occupy in the cylinder.
(h) Swept Volume
It is the difference of total volume and clearance volume or it is the volume which the piston
can sweep in one stroke. It is also called stroke volume and stroke volume of all the cylinder
contribute to size of engine.
(i) Compression ratio
It is the ratio of total volume to clearance volume. It’s value in S.I. Engine is 7 to 9 and in C.I.
Engine is 15 to 24.
(j) Average piston speed
Due to slider crank mechanism and reciprocating motion of piston, it accelerates and de-
accelerates continuously. But its average speed can be calculated as 2LN, where L is the length
of stroke and N is rpm of engine.

TWO STROKE CYCLE ENGINE
Introduction
A 2-S cycle engine is one in which the complete cycle of engine comprising of all the six
processes i.e. suction, compression, heat addition, expansion, heat rejection and exhaust take
place within only 2 strokes of piston or one revolution of crankshaft. It was devised by Duglad
Clark in 1880. Actually the construction of engine is such that the compression and suction of
charge take place separately but simultaneously on the opposite side of piston in a single stroke
and expansion and exhaust also take place in a single stroke each consuming a part of piston
stroke. In this way power is produced in each revolution of crankshaft of engine unlike a 4-S
engine in which power is produced in alternate revolution of engine. Due to this reason a 2-S
engine produces more power as compared to a same size 4-S engine, which is beneficial in such
application where lighter engine producing more power is required.
Two Stroke Cycle Engine
Construction
A 2-S cycle engine is simpler in construction than a 4-S engine due to absence of valves and
valve operating mechanism. The construction of a 2-S engine as shown in figure basically same
as that of a 4-S engine.
Figure: 2-S cycle engine
The major components are same i.e. cylinder or cylinder block, crank case, cylinder head,
piston, connecting rod, crankshaft etc. The difference is that, in place of valves, only two ports
are there in the wall of cylinder. One port is named as transfer port which is connected to the
crankcase itself through a gallery in the cylinder block. Just opposite to transfer port but slightly
above is another port named as exhaust port which is connected to exhaust pipe for exhaust of
burnt gases. These ports are covered and uncovered by the movement of piston itself, thus there
is no separate valve operating mechanism. Due to these ports and absence of valves, the
construction of a 2-S engine is simple and so its initial cost is also less. Another change from a
4-S engine is that here in 2-S engine, crankcase is also used for suction of fresh charge. For that
a self-operating valve is there in the crankcase, which is operated by change in pressure within
crankcase due to upward and downward movement of piston. One more slight difference is in
the shape of piston that a hump is provided on its top face to facilitate or guide the movement

of fresh charge coming from transfer port upto the top portion of cylinder and escaping of
exhaust gases through exhaust port The importance of this hump in piston and upward direction
of transfer port line or gallery as shown in the figure is to facilitate minimum mixing of fresh
charge with exhaust gases and maximum replacement of exhaust gases with fresh charge. It
will be clear after understanding the working of a 2-S Engine.
Working of a 2-S engine
First of all, we must know that a 2-S Engine also may be classified as S.I. Engine and C.I.
Engine and what are the differences between a 4-S Engine S.I. and 4-S C.I. Engine, same are
here in 2-S S.I. Engine and 2-Stroke C.I. Engine. Let us discuss the working of a 2-S petrol
engine. Let us start from the position of piston at TDC. Above the piston, fresh charge in
compressed condition and occupying the clearance volume is present. As soon as the spark
occurs at the points of spark plug, combustion of fresh charge starts and heat energy is released.
These hot burning gases expand and push the piston downward and produces the work. This
expansion/working stroke continues upto four fifth of the piston stroke until the piston uncovers
the exhaust port. As soon as exhaust port is uncovered, burnt gases at some higher pressure
than atmosphere find their way out through exhaust port. On the down side of piston, fresh
charge is filled all over the cylinder and crankcase which was slightly compressed
simultaneously by downward movement of piston during expansion stroke.
With further downward movement of piston, transfer port is also uncovered just after partial
uncovering of exhaust port. As soon as the transfer port is uncovered, slightly compressed fresh
charge in the crank case rushes to the space in cylinder above the piston. As the gallery of
transfer port is inclined upwards and also because of hump in piston, fresh charge goes towards
the top space of cylinder and pushing directly the burnt gases out of exhaust port. This process
of sweeping away of burnt gases directly by incoming fresh charge is called scavenging. This

scavenging is actually the most inefficient part of a 2-S engine, because here fresh charge &
burnt gases directly meet and some fresh charge may also escape through exhaust port while
some burnt gases may remain inside the cylinder. The burnt gases remained with fresh charge
in cylinder will dilute the charge and reduce the power output. Also any amount of fresh charge,
if escapes with burnt gases through exhaust part without taking part in combustion & expansion
in next cycle is a direct loss of fuel. Thus due to poor scavenging process in a 2-S engine, it is
less fuel efficient than that a 4-S engine. Rather the efficiency of a 2-Stroke engine depends on
the efficiency of scavenging process.
The scavenging takes place during the last fifth part of down stroke and first fifth part of
upstroke of piston during which transfer port remains uncovered by piston. It means after the
expansion stroke and uncovering the transfer port, piston reaches at BDC and again moves
towards TDC. As the ports are at fixed position, so again after covering approximately one fifth
of stroke from BDC to TDC, Piston covers or closes the transfer port and then the exhaust port.
Now the space above the piston becomes a closed system and the fresh charge trapped inside
is compressed by the piston during remaining four fifth of stroke. As the piston reach TDC,
charge is fully compressed and is again ignited by the spark plug to start next working cycle.
Simultaneously, during the compression process above the piston, reverse is happening below
the piston. By the upward movement of piston from BDC the space below the piston in the
cylinder and crankcase increases due to which pressure decreases and the self-operating valve
in the crankcase opens. The fresh charge from the carburettor enters in the crankcase through
this valve due to low pressure created by piston. Thus the charge above the piston is compressed
and below it fresh charge is sucked in the crankcase from carburettor.
Ill effect of poor scavenging is however reduced in case of a 2-S Diesel engine because here
exhaust gases are to be replaced by pure air only and there is no loss of fuel which is injected
only afterwards scavenging.
In this way we have seen that there are no separate strokes for suction and exhaust processes,
but these happen simultaneously with the help of ports by taking last and first one fifth part
expansion and compression stroke. It became possible by using crankcase as an intermediate
chamber and bottom side of piston as a reciprocating pump to shift the fresh charge from
carburettor to cylinder of engine.
In a 2-stroke engine, as each alternate stroke is power/working stroke, the power output of the
engine increases very much. Theoretically, power produced by a 2-stroke engine is double than
that of a same size 4-stroke engine, but due to losses and poor scavenging efficiency, it is only
30% more in actual. Due to poor scavenging efficiency, fuel efficiency also decreases, but that
is bearable in small applications where small size or weight of engine is more important.
Unlike 4-S Engine, in a 2-stroke engine, there is no change in valve operating timing as the
ports are fixed. Thus the theoretical or actual valve timing diagrams are same. Port timing
diagram of a typical 2-S engine is shown in figure.

The actual working cycle of 2-stroke engine on P-V diagram is also shown in fig 16.3.
Fig. :Typical P-V cycle diagram of a 2-stroke engine

Table: Comparison of two stroke cycle and four stroke cycle engines
Four Stroke Cycle Engine Two-Stroke Cycle Engine
1) Working cycle of engine completes in four strokes of
piston or two revolutions of engine.
1) Working cycle completes in only two strokes of piston or
one revolution of engine.
2) One Stroke is working and next three strokes are idle. So
torque output is not so uniform hence heavy flywheel will
be needed to smooth the pulsating torque.
2) Each alternate stroke is power/working stroke. So more
uniform torque is obtained hence lighter flywheel is sufficient.
3) Due to only one working stroke in two revolutions of
engine, power output will be less.
3) Due to one working stroke for each revolution of engine,
power output will be more. Theoretically, it should be double
than that of a same size of 4-S Engine but in actual it is about
1.3 times of a 4-S engine
4) For a given power, the weight of engine is more because
of valve operating mechanism and also because of less
power output as discussed in previous point of comparison.
4) For a given power, the engine is light and compact due to
absence of valve operating mechanism and also due to more
power output of engine as discussed in previous point of
comparison.
5) Because of the above mentioned facts, the cooling and
lubrication requirements are less. Life is more because of
less wear and tear.
5) Because of above mentioned facts, the cooling and
lubricating requirements are more. Life is less because of more
wear and tear.
6) High Initial Cost. 6) Low Initial Cost.
7) High Thermal Efficiency. 7) Low Thermal Efficiency due to poor scavenging.
8) Part load efficiency better than 2-S Engine. 8) Part-load efficiency is poor than a 4-S Engine.
9) It is used where thermal efficiency and long life is more
important.
9) It is used where compactness and light weight of engine is
more important than to be fuel efficient.

AIR COMPRESSORS
Introduction
An air compressor is a mechanical device which produces the compressed air i.e. which
increases the pressure of air above the atmospheric pressure as per the requirement and stores
it in a high pressure vessel. In air compressor, normal atmospheric air is sucked and compressed
continuously. It can be run or derived by an electric motor, IC engine or steam engine etc. The
high pressure air or compressed air has numerous applications in industry as well as in our daily
life.
Figure: Schematic Diagram of Air-Compressor
Some of the applications of compressed air are given as below:
(i) Dusting/cleaning in home, shops etc.
(ii) Inflation of tires.
(iii) Operating tools in factories.
(iv) Operating heavy drills, execrators etc.
(v) Boring and developing of tube wells.
(vi) Starting Diesel engines with air starter motor.
(vii) Operating brakes of buses, trucks or other heavy vehicles.
(viii) Operation of pneumatic valves in automated processing industries
(ix) Drying industry.
(x) Air conditioning.

Use of Air Compressor in Dairy Industry
Dairy Industry is a type of food processing industry, where milk is processed to produce a
number of milk products. The process control is carried out by keeping the operating parameters
like pressure, temperature, concentration etc., in optimum range by automatically controlling
the flow rate of milk/ milk product, steam and cooling water or refrigerant etc. through
pneumatic (air operated) valves. Many a times, some other type of automated mechanical
movements are required to be carried out in a processing or packaging machine automatically
for the purpose of process control. These movements are carried out precisely with the help of
air-motors run by compressed air for example in a pouch filling and packing machine.
Compressed air is also used in general dusting and cleaning purpose in a plant. Compressed air
is also required in cleaning and drying of milk storage and processing equipment. Thus
compressed air finds very important application in modern dairy processing plants and is an
important utility.
Classification of Air Compressor
Air compressor is actually an air pump just like a water pump, which pumps the air
continuously from low pressure to high pressure. Air compressors may be classified on various
basis as mentioned below figure.

On the basis of principle of working
A. Positive Displacement Type
B. Centrifugal Type
On the basis of number of stages
Single stage
When the compressor compresses the air straightway from atmospheric pressure to discharge
pressure in a single stage is called a single stage compressor.
Multi stage
When the compressor compresses the air from atmospheric pressure to final discharge pressure
in more than one step by using more than one single stages of compressor is called Multi-stage
compressor. Here the discharge of first stage enters the suction side of next stage and so on
until the air is discharged to required pressure of final stage.
Positive Displacement Type Compressor
In positive displacement type compressor, a moving mechanical component, displaces or
compresses the air positively against high pressure. These are further of two types as discussed
below:
Reciprocating compressor
It is called so because here an air tight component i.e. piston reciprocates continuously in its
counterpart closed component i.e. cylinder. With the help of operation of automatic valves,
piston sucks fresh air inside cylinder in one stroke called suction stroke and pushes or
discharges it to high pressure air tank in the next discharge stroke. Thus piston is made to
reciprocate with the help of a connecting rod and crankshaft rotated by an electric motor. The
construction of a reciprocating air compressor is basically similar to an IC engine. Here also
the basic components are same i.e. cylinder piston, connecting rod, crankshaft, cylinder head
valves etc. One main difference is that the engine produces power but air compressor consumes
power. A reciprocating air compressor is further classified as single acting or double acting
based on that piston sucks and compress the air from one side only or from both the sides of
piston like IC engine, compressor may also be single cylinder type or multi cylinder type. Multi
cylinder compressor may also further be having many type of arrangements or designs like In-
line or V-type etc.

Figure: Reciprocating compressor
Rotary compressor
Figure: Rotary compressor
In this compressor a rotating mechanical component displaces the air positively and
continuously through the casing of air compressor in which it is rotating. By this rotating
movement, air cavities are formed which move from one place to another place or which shrink
continuously and compress the air. Based on the construction of casing, rotating part and
principle of cavity movement, these are further classified as:
a) Roots Blower Compressor or Lobe Type Compressor
b) Sliding Vane Compressor
c) Screw Compressor
d) Spiral Compressor

Centrifugal Compressor
Centrifugal compressor is one which imparts rotational energy to air. This rotational energy is
converted to centrifugal force by which the air flows against pressure in the discharge side. The
rotating mechanical component which imparts rotational energy to air is called impeller. The
impeller consists of curved vanes which facilitate the flow of air through it. The fixed vanes of
diffuser in the centrifugal casing convert a part of this rotational energy of air into pressure
energy and air is discharged against high pressure. The main components of centrifugal
compressor are centrifugal casing, impeller, main shaft, diffuser, suction and discharge ports
etc.
In a centrifugal compressor, the flow of air takes place through compressor in a direction
normal to the axis of rotating shaft. But if the flow takes place parallel to the axis of main shaft,
it is called axial flow compressor. Construction wise, centrifugal compressor can also be named
as rotary compressor or a rotary compressor can be of both types as positive displacement type
and centrifugal type.
Single Stage, Single Cylinder, Reciprocating Air Compressor
Construction
The basic construction is similar to as that of an IC engine i.e. there is cylinder, piston,
connecting rod, crankshaft and suction and discharge valves etc. as shown in figure. The main
shaft or crank shaft is rotated by some external prime over i.e. an IC engine or an electric motor.
The crank with the help of connecting rod gives the reciprocating motion to piston in the
cylinder. Where the piston moves away from the closed end of cylinder, where the suction and
delivery valves are located, it sucks the atmosphere air in the cylinder through suction valve
operated by pressure difference. During suction stroke, delivery valve which connects the
cylinder to compressed air tank remain closed due to high pressure in the tank and low pressure
in the cylinder but the suction valve remains open.
After the suction stroke, when the motion of piston is reversed, the volume in cylinder starts
decreasing thus increasing the pressure. Now the suction valve remains closed. When the

pressure reaches above a value as in compressed air tank, delivery valve opens and this high
pressure air is discharged in the air tank for the rest of stroke. The cycle on which air compressor
works is shown on PV diagram in figure.
The compression cycle 1-2-3-4 has four processes as:
Fig.: P-V diagram of single stage reciprocating air-compressor
V1 = Total volume of Cylinder
VC = Clearance volume of Cylinder
V1 - VC = Swept Volume (VS)
V1 − V4 = Effective Swept Volume
1-2: Pure-compression
This process is most important in the overall working of a compressor. During this process,
both suction and discharge valve remain closed and compressor acts as a closed system. On the
upwards movement of piston from BDC volume of air inside the cylinder shrinks and so
pressure rises. The compression may happen theoretically as any of the isentropic, isothermal

or polytrophic processes. In actual compressor it is always a polytropic process and try is made
to keep it as close to isothermal process as possible by external cooling. Piston work is least in
case of isothermal compression.
2-3: Compressed air discharge
When the pressure in the cylinder reaches to a value of pressure in compressed air vessel,
somewhere in between the stroke of piston, discharge valve opens and compression becomes
an open system. On further upward movement of piston, compressed air is simply discharged
to compressed air tank through the discharge valve. This process ends when the piston reaches
to the top end position, TDC and stroke is completed. During this process compressor acts like
a pump which discharges the compressed air but does not compress it further.
3-4: Expansion of air trapped in clearance volume
This process starts as soon as the piston starts moving down towards BDC and cylinder volume
starts increasing. Due to increase in volume pressure falls down and discharge valve close but
some high pressure air remains in the clearance volume which could not be discharged. On
downward movement of piston, this clearance volume air expands polytropically or
isothermally or Isentropically doing some work on the piston. When somewhere in between the
downward stroke of piston during expansion, pressure falls below the outside normal air
pressure, suction valve opens and expansion process ends. During this process compressor acts
as a closed system. This process is reverse of compression process 1-2 and it also takes place
for a part of the stroke of piston. Due to this process the effective suction of air is reduced and
volumetric efficiency becomes less than 1.
4-1: Suction of air
On further downward movement of piston after opening of suction valve, atmospheric air is
sucked in the cylinder until the piston reaches to bottom dead centre (BDC). In this process,
compressor acts as an open system and fresh mass of air is sucked from atmosphere. At the end
of this stroke cycle completes. The theoretical work consumed by compressor during one cycle
is given by area of enclosed cycle 1-2-3-4.
In this way, when the piston is reciprocated continuously in the cylinder by rotating the
crankshaft with the help of an electric motor, it completes one working cycle in two strokes of
piston or one revolution of crankshaft. The expansion of high pressure air, trapped in the
clearance volume (C.V.) in the previous stroke, and suction of fresh air from atmosphere takes
place during downward stroke of piston from TDC to BDC, then compression of air and its
discharge to air tank take place during upward stroke of piston from BDC to TDC.
With the running of compressor, normal atmospheric air is continuously compressed and
accumulated in high pressure air tank. The construction of suction valve and discharge valve is
geometrically similar but they act in the opposite direction under the action of two forces, one
is spring force and other is force due to pressure difference. Normally the spring keeps the
suction valve pressed on its seat in upward direction in closed position and it opens against
spring force only when vacuum is created inside the cylinder during suction stroke. Conversely
the spring keep the discharge valve pressed on its seat in downward direction in closed position
and it opens against spring force only when pressure in cylinder is higher than that in discharge
port or air tank. Suction valve opening is connected to an air filter placed in open atmosphere.
Discharge valve opening is connected to closed discharge port connected to air tank on other

side. Reciprocating air compressor is a similar but simpler machine than an I.C. engine.
Similarity exists only in basic design and construction but purpose of both are altogether
different.
Comparison of Adiabatic, Polytrophic and Isothermal Compression
We have discussed the working of an air compressor in the previous article. The working cycle
is shown on P-V chart in figure and work required by compressor in one cycle is given by area
of cycle 1-2-3-4 on P-V chart. If the compressor is considered as an open system, then the flow
work is given by compression work minus expansion work. This work depends on the pressure
ratio i.e. the ratio of discharge pressure to suction pressure and the type of compression process.
The compression process 1-2 is a non-flow process and may be any of the isothermal, adiabatic
and polytrophic processes. We know that isothermal compression line 1-2 is more flat than an
adiabatic and polytrophic line which depends on the value of polytrophic index n. The
compression index in isothermal compression is 1 and in adiabatic compression is γ. If n < γ,
polytrophic compression line will come in between isothermal and adiabatic line and if n > γ it
will be more steep than adiabatic line. From the figure, it is clear that work will be least in
flattest curve i.e. in isothermal compression. In adiabatic compression, work will be maximum.
However, an actual process with sufficient cooling of compressor will be polytrophic and fall
in between the two curves. More and more cooling is used, more and more it will be towards
isothermal line and work required will minimize. It shows the importance of external cooling
in air compressor.
Small air compressor is generally air-cooled for which the fins are provided on the cylinder
walls while large size air compressors are water cooled for which water jackets are provided
around the compressors cylinder and cylinder head.
: Polytropic Compression
: Adiabatic Compression
: Isothermal Compression
Figure: Single stage Air Compressor with zero clearance volume
In another way, it can be concluded that, in case of an isothermal compression i.e. compression
without any rise in temperature, compressor has to work against the rise in pressure of air or
gas due to shrinkage of volume only and so work is least. In case of isentropic compression,
compressor has to work against the rise in pressure due to shrinkage of volume of air or gas
and also due to rise in temperature thus more work is required. If some cooling is done,

temperature rise will be less and so pressure rise will also be less thus lesser work will be
required. In all these three cases, we are talking about the work required against compression
of gas only without considering any internal or external friction and other losses. Considering
all these losses, the actual work requirement will further increase. Overall, it can be concluded
that work required in compression can be minimized by choosing such design of compressor,
where friction and other losses are least and cooling is more and more effective.
Various Terms & Efficiencies Used in Air-Compressor
Free Air Delivery: (F.A.D.)
It is the volume flow rate of compressor expressed in m3
/min as reduced to intake pressure and
temperature.
Volumetric efficiency
It is the ratio of volume of free air delivered per stroke to the swept volume of compressor. As
some part of swept volume is used up in the expansion of clearance volume gas, volumetric
efficiency is always less than one. Volumetric efficiency is also reduced due to resistance
offered by suction valve and heating up of suction air in the compressor.
Isothermal efficiency
It is the ratio of work required by compressor in case of isothermal compression in an air
compressor to the actual indicated work of compression. Indicated work of compression means
the work represented by indicator P-V diagram of compressor.
Isentropic efficiency
It is the ratio of isentropic work of a compressor i.e. work consumed considering isentropic
compressor to the actual work required by compression. This term is mostly used in refrigerant
compressor.
Mechanical efficiency
It is the ratio of indicated power of compressor to the actual shaft power of compressor. Shaft
power of compressor means power required to be given to its driving shaft. It accounts for the
loss of power due to friction in moving parts.
Overall isothermal efficiency
It is the ratio of compression work in case of isothermal compression to the actual work required
by the compressor.
Clearance ratio
It is the ratio of clearance volume to the total swept volume of an air compressor. It is denoted
as K or C.
Pressure ratio
It is the ratio of discharge pressure to suction pressure of a compressor or one stage of a
multistage compressor. In general, in a compressor, the compression process is polytrophic and
it lies in between isothermal and isentropic, if effective cooling is done in compressor. In this
case efficiency of compressor (Ratio of theoretical work to actual work) used is isothermal

efficiency. Otherwise in real conditions, the actual work is even more than the isentropic work
due to friction and other losses and efficiency used is isentropic efficiency.
Multistage Compression
As mentioned up to now is the single stage compression i.e. the pressure is raised from
atmosphere to the required value in one stage. But when the requirement is of very high
pressure, single stage compression has some disadvantages as mentioned below:
1) With the increase in delivery pressure, the high pressure air remained in clearance volume
takes more part of piston stroke to expand up to suction pressure thus decreasing the effective
swept volume and hence the mass flow rate through compressor. It is clear from figure 31.4
that if the delivery pressure is too high, there may not be any discharge of air and the
compression and expansion processes 1-2 or 2-1 may take place in full strokes of piston. In that
case valve will not operate and delivery of air would become zero.
2) With the increase in delivery pressure delivery temperature also increases which if not
required is a dual energy loss.
Fig.:Compression cycles with different values of delivery pressure
3) High delivery pressure will also require heavy working parts and more unbalancing.
The only solution to this problem is to increase the delivery pressure not in single stage but in
multistage. First, the atmosphere air is compressed to a reasonable intermediate pressure level
in the first stage and is delivered as suction of 2nd
stage where the pressure is further increased
reasonably and so on until the final pressure is reached. There may be two, three or more stages
depending on the delivery pressure required. Between the stages, the air may be cooled so as
to keep the overall compression curve close to isothermal curve thus to decrease the
compression work also. The combined compression cycle of multistage compressor is shown
in fig 31.5

Fig.: Three stage compression cycle
In this way the multistage compression has various advantages over single stage as mentioned
below:
Advantages of multistage compression
 The air can be cooled at intermediate pressure between the stages of compression, thus
decreasing the work required for next stage. Hence, the power required to drive a multistage
compressor is less than that required for a single stage compressor delivering the same quantity
of air at the same delivery pressure.
 Multistage compressors have better mechanical balance. So lighter flywheel is required.
 The pressure and temperature range may be kept within desirable limits which results in
i). Reduced losses due to air leakage
ii). Improved lubrication
iii). Improved volumetric efficiency
 For higher delivery pressure, in a single stage compressor, cylinder, piston and other
moving parts must be robust enough to withstand the higher load. However, in multistage
compressor, the low pressure cylinder may be lighter in construction.
 The size of different stages of compressor may be adjusted and designed independently
depending on volume of air handled in different pressure range.
Disadvantages
The multistage compressor with intercoolers is more expensive in initial cost than a single
stage, compressor of same capacity, but its running cost is less.

AIR COMPRESSOR’S WORK, NUMERICAL PROBLEMS
Volumetric Efficiency in terms of Clearance Ratio K
Refer to the diagram. It is clear that after expansion, the clearance volume gas takes the volume
V4 at which suction valve opens. So, the fresh air is sucked only from volume V4 to V1.
Fig.: P-V Diagram of single stage reciprocating air-compressor
So effective volume sucked of fresh air = V1 - V4
The pressure and temperature of this volume are P1 and T1.
If this air is reduced to intake or outside atmospheric pressure and temperature Pa and Ta, the
actual volume of air sucked will be
As per the definition of volumetric efficiency:
.........
Consider the polytrophic expansion process 3-4
Or P2Vn
C = P1V4
n
Substituting this value in equation (1)
.........
If the ambient and suction conditions are same (i.e., considering only the effect of Clearance
Ratio)

P1 = Pa and Ta = T1
.........
This is the equation for volumetric efficiency in terms of Clearance Ratio.
Work Equation for Single Stage Compressor (Neglecting clearance Volume)
The theoretical cycle for single stage compressor without clearance volume is shown on P-V
diagram as:
: Polytropic Compression
Adiabatic Compression
: Isothermal Compression
Fig.: Compression cycle 1-2-3-4
Consider the polytrophic compression 1-2
Work done per cycle is area 1-2-3-4-1
W = Area under curve 1-2 + Area under curve 2-3
Area under curve 4-1.
/ *//
.........
Theoretical Work Considering Clearance Volume
The theoretical cycle of a single stage air-compressor with clearance volume is already shown
in figure. From the diagram, it is clear that
Work done per cycle = Area under 1 2 3 4 1
Or W = Area 1-2-5-6-1=Area 3-5-6-4-3

Now V1-V4 = Effective swept volume due to presence of clearance volume.
It usually varies between 60 to 85%
Multistage Compression with Inter Cooling
Figure: Multistage compression with zero value of C.V.
Neglecting clearance volume, the overall cycle diagram for multistage compression is as shown
in figure.
Work done in 2-stages of compression
= Work done in 1st
stage + work done in 2nd
stage
......... [Sub Eq. (i)]
We know P1V1= P3V3 for isothermal Process 1-3. Also for minimum work, pressure ratio per
stage is equal i.e.,
Putting this in equation (1)

For x number of stages of compression
When Pr= Total Pressure Ratio
Numerical Problems
1. A single stage reciprocating air compressor takes in 8m3/min of air at 1 bar and 300 C and
delivers it at 6 bar. The clearance is 5% of the stroke. The expansion and compression are
polytrophic with the value of n=1.3. Calculate: (a) the temperature of delivered air; (b)
volumetric efficiency, and (c) Power of the compressor.
Solution
Given that v1-v4 = 8 m3
/min
p1 = 1 bar = 1x105
N/m2
T1 = 300
C = 30+273 = 303 K
p2=6 bar = 6x105
N/m2
vc =5% vs = 0.05 vs
n= 1.3.
 Temperature of delivered air
Let T2= Temperature of the delivered air.
We know that for a polytropic compression process 1-2
 Volumetric efficiency
We know that clearance ratio,
Volumetric efficiency,
 Power of the compressor
We know that work done by the compressor,

2. A single stage single acting reciprocating air compressor is required to handle 50 cum of
free air delivery per hour measured at 1 bar pressure. The delivery pressure is 6.5 bar and
the speed is 500 r.p.m. Allowing a volumetric efficiency of 75%; an isothermal efficiency of
70% and a mechanical efficiency of 90%; Calculate the indicated mean effective pressure
and the power required to drive the compressor.
Solution
Given: v1=50 m3
/ hour
p1=1 bar = 1x105 N
/m2
p2=6.5 bar = 6.5 x 105 N
/m2
N = 500 r.p.m
ηv = 75% = 0.75
ηi = 70% =0.70
ηm = 90% = 0.9
1) Indicated mean effective pressure:
The expression for isothermal work done is given as
= 9359*103
J/h = 9359 kJ/hr
We know that swept volume of the piston,
= 200 kN/m2
= 2 bar (Ans.)
2) Power required in driving of the compressor:
Actual work done by the compressor is given as

3 A single stage double acting air compressor delivers 5 m3 of free air per minute at 1 ata
and 200 C to 7.5 bar with the following data;
R.P.M. = 300; Mechanical efficiency = 0.9; Pressure loss in passing through intake valves =
0.04 bar; Temperature rise of air during suction stroke = 120 C ; Clearance volume = 5% of
stroke volume; Index of compression and expansion, n=1.3; Length of the stroke = 1.3 times
the cylinder diameter.
Calculate: 1. Power input to the shaft; 2. The volumetric efficiency; and 3. The cylinder
diameter.
Solution
Given: Va= 5 m3
/min
pa =1 ata= 1.013 bar
Ta= 200
C =20 +273 = 293 K
p2= 7.5 bar;
N = 300 r.p.m
ηm=0.9
Pressure loss = 0.04 bar
Temperature rise = 120
C
vc = 5%
vs =0.05 vs
n = 1.3
L = 1.3 D
Let V1=Volume of free air at the suction conditions.
As there is a pressure loss of 0.04 bar in passing through intake valves, therefore net suction
pressure will be equal to
p1= pa-0.04 = 1.013-0.04 = 0.973 bar = 0.973 x 105
N/m2
Given that there is a temperature rise of 120
C of air during suction stroke, therefore temperature
at the beginning of compression of air will be
T1 = Ta + 12 = 20 + 12 = 320
C = 32 + 273 = 305 K
By Ideal gas equation
1. Power input to the shaft
We know that indicated work done
2. Volumetric efficiency
We know that clearance ratio,

3. Cylinder diameter
Let D = Cylinder diameter, and
L = Stroke length = 1.3 D. (Given)
We know that swept volume per stroke
Since the compressor is double acting, therefore number of working strokes per minute = 2N
=2x300=600 and swept volume per minute
We know that volumetric efficiency (ηv),
And

Basic Mechanical Engineering Unit 5 Reciprocating Machine@by V.P.Singh

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