Capstone Project

TITLE OF THE PROJECT

Repair & Maintenance Of Twin Cylinder Diesel Engine

with development of water cooling system.

Program: Mechanical Engineering Program code:-ME6I (SS)

Course: Capstone Project Execution Course code: ( 22060 )

Name of Guide -: Mr. Rajiv Sakalkale

Project By :- 2632 , 2606 , 2611, 2616 , 2631 .
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
CERTIFICATE

This is to Certify Mr. Suryawanshi Shrinath Dilip, Jadhav Kishor Maroti , Puyad
Mahesh Pralhad, Sonkamble Gourav Goutam , Vaidya Sushant Subhash ; With
ROLL NO :-2632, 2606, 2611, 2631, 2616. Respectively of 6th Semester of Diploma
in Mechanical Engineering of Institute, Government Polytechnic Nanded has
completed the Micro Project satisfactorily in subject – Capstone Project Execution
( 22060 ) for the academic year 2023-2024 as prescribed in the Curriculum.

Place: Nanded Enrollment No:-

2100200271,
2100200267,
2200200603,
2100200316,
2200200622

SUBJECT TEACHER HEAD OF THE DEPARTMENT PRINCIPAL

RAJIV SAKALKALE R.M. SAKALKALE L.N. JANRAO
 AKNOWLEGMENTS
An acknowledgement section of a project or assignment is to thank all the People/institutions
who have helped and contributed during the project and In the completion of the project. They
can be teachers, mentors, principals, Fellow students, guides, parents etc. I would like to express
my special thanks Of gratitude to my teacher:- Mr .Rajiv Sakalkale sir as well as our L.N Janrao
sir who gave me the golden opportunity to do this wonderful project on the Topic Maintenance
of twin cylinder diesel Engine. Which also helped me in Doing a lot of Research and I came to
know about so many new things I am Really thankful to them and also like to thank my friends
who helped me a lot In finishing this project within the limited time.

ABSTRACT
This course on 'Capstone Project-Execution and Report Writing' is the continuation of the
previous semester course on 'Capstone Project-Planning'. So, in this semester, the students are
to implement the detailed Capstone Project Plan, which they have prepared in the preceding
semester. Therefore, to successfully complete this Capstone Project by the end of this semester,
it is necessary to incorporate the suggestions of the guide/examiners of the preceding semester.
Hence, it is of utmost importance for the student to again re-capitulate and comprehend the
importance, concept and need of the 'Capstone Projects' which are well explained in the
'Capstone Project-Planning' course in the previous semester. Such projects are generally an
integration of the various types of skills which cut across the three major domains of learning
i.e. cognitive, psychomotor and affective domain which must have acquired during their journey
from first semester to the last semester. Hence, it is essential that students are also given an
opportunity to do large projects which require more time compared to the micro- projects in
order to develop and integrate the highly essential industry oriented competencies and
associated skills in the students. Therefore, in this semester the 'Capstone Project - Execution
and Report Writing' will continue to integrate some more additional competencies along with
those in the previous semester and hence build up greater confidence to face such situations in
the world of work.

Government Polytechnic, Nanded

 Mechanical Engineering Department
Academic Year 2023-24 PART A – PLAN
Capstone project execution Proposal

TITLE OF MICRO-PROJECT:- Repair & Maintenance Of Twin Cylinder Diesel Engine with
Development of Water system.
1.Brief Introduction :- Study of Twin Cylinder Diesel Engine
2.Aim Of The Micro Project :- In this Project, Study, Repair and maintenance of diesel
engine

Action Plan:
Sr. Details of Activity Planned start date Planned Name of
No. finish responsible
date team member

1. Visit the teacher for kind

information
2. Prepare the Micro-
Project

3. Visit for showing the

Information to subject
teacher for
correction.
Sr. No Resources/Material used Quantity
1 https://en.m.wikipedia.org -
2
3

Capstone Project Evaluation Sheet

Name of Course and Code : Capstone Project Execution (22060)
Name Of Student:- Suryawanshi Shrinath Dilip Enrollment No:- 2100200271
Name of Programme:- Mechanical Engineering. Semester:- ME6I (SS)
Title of Micro Project :- Repair & Maintenance Of Twin Cylinder Diesel Engine with Devlopment of
water cooling system.

Course Outcomes:-

 Select, collect and use required information/knowledge to solve the identified problem.
Apply Ergonomic principle for designing simple mechanical component .
 Take appropriate decisions based on collected and analyzed information.

Capstone Project Evaluation Sheet

Name of Course and Code : Capstone Project Exhibition (22060)
Name Of Student:- Jadhav Kishor Maroti Enrollment No:- 2100200316
Name of Programme:- Mechanical Engineering Semester:- ME6I (SS)
Title of Microproject :- Repair & Maintenance Of Twin Cylinder Diesel Engine
with Devlopment of water cooling system.
Course Outcomes:-
 Select, collect and use required information/knowledge to solve the identified problem.
Apply Ergonomic principle for designing simple mechanical component .
 Take appropriate decisions based on collected and analyzed information.
 Capstone project Evaluation Sheet
Name of Course and Code : Capstone Project Execution (22060)
Name Of Student :- Sonkamble Gourav Goutam Enrollment No:- 2100200267
Name of Programme:- Mechanical Engineering. Semester:- ME6I (SS)
Title of Micro Project :- Repair & Maintenance Of Twin Cylinder Diesel Engine with Devlopment of
water cooling system.
Course Outcomes:-
• Select, collect and use required information/knowledge to solve the identified problem.
Apply Ergonomic principle for designing simple mechanical component .
• Take appropriate decisions based on collected and analyzed information.
 Capstone Project Evaluation Sheet
Name of Course and Code : Capstone Project Execution (22060)
Name Of Student :- Puyad Mahesh Pralhad Enrollment No:- 2200200603
Name of Programme:- Mechanical Engineering. Semester:- ME6I (SS)
Title of Micro Project :- Repair & Maintenance Of Twin Cylinder Diesel Engine with Devlopment of
water cooling system.
Course Outcomes:-
• Select, collect and use required information/knowledge to solve the identified problem.
Apply Ergonomic principle for designing simple mechanical component .
• Take appropriate decisions based on collected and analyzed information.
 Capstone project Evaluation Sheet

Name of Course and Code : Capstone Project Exhibition

Name Of Student:- Vaidya Sushant Subhash Enrollment No:- 2200200622
Name of Programme:- Mechanical Engineering Semester:- ME6I (SS) Title of
Microproject :- Repair & Maintenance Of Twin Cylinder Diesel Engine with Devlopment of water
cooling system.

Course Outcomes:-

 Select, collect and use required information/knowledge to solve the identified problem.
Apply Ergonomic principle for designing simple mechanical component .
 Take appropriate decisions based on collected and analyzed information.
 INTRODUCTION

What is Diesel Engine.

Diesel engine, any internal-combustion engine in which air is compressed to a
sufficiently high temperature to ignite diesel fuel injected into the cylinder,
where combustion and expansion actuate a piston. It converts the chemical
energy stored in the fuel into mechanical energy, which can be used
to power freight trucks, large tractors, locomotives, and marine vessels. A
limited number of automobiles also are diesel-powered, as are some electric-
power generator set. Diesel engines work by compressing only air, or air plus
residual combustion gases from the exhaust (known as exhaust gas
recirculation, “EGR”). Air is inducted into the chamber during the intake stroke,
and compressed during the compression stroke. This increases the air
temperature inside the cylinder so that atomised diesel fuel injected into the
combustion chamber ignites. With the fuel being injected into the air just before
combustion, the dispersion of the fuel is uneven; this is called a heterogeneous
air-fuel mixture. The torque a diesel engine produces is controlled by
manipulating the air-fuel ratio (λ); instead of throttling the intake air, the diesel
engine relies on altering the amount of fuel that is injected, and the air-fuel ratio
is usually high.
The diesel engine has the highest thermal efficiency (engine efficiency) of any practical internal or
external combustion engine due to its very high expansion ratio and inherent lean burn which enables
heat dissipation by the excess air. A small efficiency loss is also avoided compared with non-direct-
injection gasoline engines since unburned fuel is not present during valve overlap and therefore no
fuel goes directly from the intake/injection to the exhaust. Low-speed diesel engines (as used in ships
and other applications where overall engine weight is relatively unimportant) can reach effective
efficiencies of up to 55%.[1] The combined cycle gas turbine (Brayton and Rankine cycle) is a
combustion engine that is more efficient than a diesel engine, but it is, due to its mass and
dimensions, unsuited for vehicles, watercraft, or aircraft. The world’s largest diesel engines put in
service are 14-cylinder, two-stroke marine diesel engines; they produce a peak power of almost 100
MW each.
Diesel engines may be designed with either two-stroke or four-stroke combustion cycles. They were
originally used as a more efficient replacement for stationary steam engines. Since the 1910s, they
have been used in submarines and ships. Use in locomotives, buses, trucks, heavy equipment,
agricultural equipment and electricity generation plants followed later. In the 1930s, they slowly
began to be used in a few automobiles. Since the 1970s energy crisis, demand for higher fuel
efficiency has resulted in most major automakers, at some point, offering diesel-powered models,
even in very small cars.[3][4] According to Konrad Reif (2012), the EU average for diesel cars at the
time accounted for half of newly registered cars.[5] However, air pollution emissions are harder to
control in diesel engines than in gasoline engines, so the use of diesel auto engines in the U.S. is now
largely relegated to larger on-road and off-road vehicles.

Advantages of Twin Cylinder Diesel Engine

(1) Diesel engine has advantages such as high energy density of fuel, high efficiency, and relatively
low CO2 emission . However, it also has drawbacks including low power density due to the lean
mixture that allows less fuel to be induced in the cylinder
(2) As discussed above, twin cylinder engines are better balanced, and thus more refined than
single cylinder engines. The internal forces within a twin cylinder engine are better
counterbalanced by the movement of the two pistons, and thus they can rev higher while
being less vibration.
(3) Dual fuel engines perform best under moderate to high load, and can often equal or better the
fuel efficiency of a pure diesel under these conditions .

Disadvantages of Twin cylinder diesel Engine

1) Abysmal horsepower, slower speed.
 2) Expensive fuel, limited gas stations with diesel.
3) Noisier and more rugged ride than gasoline-powered engines.
4) Produce emissions that emit carcinogens, nitrous oxides, and soot into the atmosphe

Components of Twin Cylinder Diesel Engine:

(1) Piston – The piston transfers the expanding force of gases to the mechanical rotation
of the crankshaft through a connecting rod.

(2) Crankshaft – It converts the reciprocating motion to rotational motion.

(3) Connecting Rod – It transfers motion from a piston to the crankshaft and acts as a
lever arm.
(4) Flywheel – It is a mechanical device that is used to store energy.

(5) Fuel Injector :- A fuel injector is a device for atomizing and injecting fuel into an
internal combustion engine.
(6) Counter Weight – Counterweight on the crankshaft is used to reduce the vibrations
due to imbalances in the rotating assembly.

(7) Inlet and Outlet Ports – These ports allow fresh air with fuel to enter and exit from
the cylinder.

(8) Fuel System - The fuel system generally consists of a fuel tank with a pipe connecting
it to the engine. Here, diesel can be provided directly for the engine to start the
process explained earlier. The fuel tank size eventually manages the time a generator
can be active.
(9) Cooling System - These two parts both have essential functions. The responsibility of the
cooling system is to prevent the generator from overheating. The coolant is released in the
generator, which counteracts all the engine and alternator extra heat energy.

(10) Exhaust System- These two parts both have essential functions. The
responsibility of the cooling system is to prevent the generator from
overheating. The coolant is released in the generator, which counteracts all the
engine and alternator extra heat energy. The coolant then takes all of this heat
through a heat exchanger and discharges it outside the generator.
11. Lubrication System - The lubrication system is a part that connects to the engine and
pumps oil into it to ensure every part works smoothly and does not grind against
other parts. Without a suitable lubrication system, the machine will break down.etc

Diesel or oil engines:-

The defining characteristic of the diesel engine is that it relies on compression ignition. As air is compressed it
heats up. Fuel is then injected into the hot, compressed air and ignites spontaneously. This allows it to operate
with a lean mixture comprising mainly air. Together with the high compression ratio, this makes it more
economical than the petrol or gasoline Otto engine. It also does not require either a carburetor to mix the air
and fuel before delivery, or a spark plug or other ignition system. Another consequence is that to control speed
and power output, the airflow is not throttled but only the amount of fuel injected at each cycle is varied.

How many strokes does twin cylinder diesel generator have..?

4-stroke engines have become the standard in power generation due mostly to how
much cleaner they run than the 2-stroke engines. Separating the intake from the exhaust
stroke reduces the amount of unburnt fuel and expanding gases released through the
exhaust system.
A four-stroke (also four-cycle) engine is an internal combustion (IC) engine in which the
piston completes four separate strokes while turning the crankshaft. A stroke refers to
the full travel of the piston along the cylinder, in either direction. The four separate
strokes are termed :

1. Intake: Also known as induction or suction. This stroke of the piston begins at top
dead center (T.D.C.) and ends at bottom dead center (B.D.C.). In this stroke the intake
valve must be in the open position while the piston pulls an air-fuel mixture into the
cylinder by producing a partial vacuum (negative pressure) in the cylinder through its
downward motion.

2. Compression: This stroke begins at B.D.C, or just at the end of the suction stroke,
and ends at T.D.C. In this stroke the piston compresses the air-fuel mixture in preparation
for ignition during the power stroke (below). Both the intake and exhaust valves are
closed during this stage.

3. Combustion: Also known as power or ignition. This is the start of the second
revolution of the four stroke cycle. At this point the crankshaft has completed a full 360
degree revolution. While the piston is at T.D.C. (the end of the compression stroke) the
compressed air-fuel mixture is ignited by a spark plug (in a gasoline engine) or by heat
generated by high compression (diesel engines), forcefully returning the piston to B.D.C.
This stroke produces mechanical work from the engine to turn the crankshaft.

4. Exhaust: Also known as outlet. During the exhaust stroke, the piston, once again,
returns from B.D.C. to T.D.C. while the exhaust valve is open. This action expels the
spent air-fuel mixture through the exhaust port.
The remedies for maintaining a diesel engine include :
1. Regular Maintenance : Follow the manufacturer's maintenance schedule for oil
changes, filter replacements, and overall inspections.

2. Fuel Quality : Use high-quality diesel fuel to prevent fuel system issues and ensure
efficient combustion.

3. Proper Lubrication : Keep engine parts properly lubricated with clean oil to reduce
friction and wear.

4. Cooling System Maintenance : Maintain the cooling system to prevent overheating

and ensure efficient engine operation.

5. Air Filtration : Regularly inspect and replace air filters to prevent dirt and debris from
entering the engine, which can cause damage.

6. Monitor Fluid Levels : Check and maintain proper levels of coolant, oil, and other
fluids to ensure optimal engine performance.

7. Inspect Belts and Hoses : Regularly inspect belts and hoses for wear and tear, and
replace them as needed to prevent breakdowns

8. Address Issues Promptly : Address any unusual noises, vibrations, or performance

issues promptly to prevent further damage.

By following these remedies, diesel engines can operate efficiently and reliably over their
COOLING SYSTEMS

The cooling system in a diesel engine typically involves a radiator, coolant fluid, water pump, thermostat, and
sometimes an intercooler. The coolant circulates through the engine, absorbing heat, which is then dissipated
by the radiator. The water pump ensures proper circulation, while the thermostat regulates coolant flow to
maintain optimal engine temperature. Intercoolers are used in turbocharged engines to cool compressed air
before it enters the engine for improved performance.

1. Radiator : It's a heat exchanger that transfers heat from the coolant fluid to the air passing through it.
Radiators typically have a series of metal fins and tubes through which coolant flows.

2. Coolant : Usually a mixture of water and antifreeze, it prevents freezing in cold temperatures and boiling in
hot conditions. It also contains additives to prevent corrosion and lubricate the water pump.

3. Water Pump: It circulates coolant through the engine and radiator. The pump is typically driven by a belt
connected to the engine's crankshaft.

4. Thermostat: This regulates coolant flow to maintain the engine at its optimal operating temperature. It
opens and closes based on the temperature of the coolant.

5. Intercooler : In turbocharged diesel engines, an intercooler cools down the compressed air before it enters
the engine's combustion chambers. Cooler air is denser, leading to better combustion efficiency and increased
power output.

Together, these components ensure that the diesel engine operates within its optimal temperature range,
preventing overheating and maintaining performance and longevity.
What is the need of cooling system in engines

The cooling system is essential for an engine because it helps regulate its temperature,
preventing it from overheating. Engines generate a tremendous amount of heat during
operation, primarily due to the combustion process. Without proper cooling, this heat buildup
can cause damage to engine components, such as warping of cylinder heads, deterioration of
seals and gaskets, and even complete engine failure. The cooling system ensures that the
engine operates within its optimal temperature range, which is crucial for maintaining
efficiency, performance, and longevity.
To maintain the effectiveness of the cooling system in an engine, several remedies and
maintenance practices can be implemented:

1. Regular Coolant Checks : Ensure the coolant level is at the proper level and topped up when
necessary. Coolant should be replaced according to the manufacturer's recommendations to
prevent corrosion and maintain its cooling properties.

2. Inspect for Leaks : Regularly check for leaks in the cooling system, including hoses,
connections, radiator, water pump, and thermostat housing. Address any leaks promptly to
prevent coolant loss and overheating.

3. Keep Radiator Clean: Clean debris, dirt, and bugs from the radiator fins regularly to ensure
proper airflow and heat dissipation.

4. Check Belts and Hoses: Inspect belts for wear and tension and replace them as needed.
Also, check hoses for signs of damage, leaks, or deterioration and replace them if necessary.

5. Thermostat Maintenance : Test and replace the thermostat if it fails to regulate coolant flow
properly. A malfunctioning thermostat can lead to overheating or inefficient cooling.

6. Flush the Cooling System : Periodically flush and refill the cooling system to remove
sediment, rust, and contaminants that can impede coolant flow and heat transfer.

7. Inspect Cooling Fans : Ensure that electric cooling fans are functioning correctly and engage
when needed, especially during high temperatures or when the vehicle is stationary.

8. Maintain Proper Engine Tuning : A properly tuned engine operates more efficiently,
generating less heat. Regularly maintain the engine's ignition timing, fuel mixture, and air
intake system.

By following these remedies and maintenance practices, the cooling system in an engine can
operate efficiently, ensuring optimal performance and preventing overheating-related issues.