Engine Testing This Page Intentionally Left Blank Engine Testing Theory and Practice

Engine Testing This page intentionally left blank Engine Testing Theory and Practice Third edition A.J. Martyr M.A. Plint AMSTERDAM • BOSTON • HEIDELBERG • LONDON • NEW YORK • OXFORD PARIS • SAN DIEGO • SAN FRANCISCO • SINGAPORE • SYDNEY • TOKYO Butterworth-Heinemann is an imprint of Elsevier Butterworth-Heinemann is an imprint of Elsevier Linacre House, Jordan Hill, Oxford OX2 8DP 30 Corporate Drive, Suite 400, Burlington, MA 01803 First edition 1995 Reprinted 1996 (twice), 1997 (twice) Second edition 1999 Reprinted 2001, 2002 Third edition 2007 Copyright © 2007, A.J. Martyr and M.A. Plint. Published by Elsevier Ltd. All rights reserved The right of A.J. Martyr and M.A. Plint to be identified as the authors of this work has been asserted in accordance with the Copyright, Designs and Patents Act 1988 No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means electronic, mechanical, photocopying, recording or otherwise without the prior written permission of the publisher Permissions may be sought directly from Elsevier’s Science & Technology Rights Department in Oxford, UK: phone (+44) (0) 1865 843830; fax: (+44) (0) 1865 853333; email: [email protected]. Alternatively you can submit your request online by visiting the Elsevier web site at http://elsevier.com/locate/permissions, and selecting Obtaining permission to use Elsevier material Notice No responsibility is assumed by the publisher for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions or ideas contained in the material herein. Because of rapid advances in the medical sciences, in particular, independent verification of diagnoses and drug dosages should be made British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library Library of Congress Cataloging-in-Publication Data A catalog record for this book is available from the Library of Congress ISBN-13: 978-0-7506-8439-2 For information on all Butterworth-Heinemann publications visit our web site at http://books.elsevier.com Printed and bound in the UK 0708091010987654321 Working together to grow libraries in developing countries www.elsevier.com | www.bookaid.org | www.sabre.org Contents Preface vii Acknowledgements ix Introduction xi Units and conversion factors xv 1 Test facility specification, system integration and project organization 1 2 The test cell as a thermodynamic system 14 3 Vibration and noise 21 4 Test cell and control room design: an overall view 47 5 Ventilation and air conditioning 72 6 Test cell cooling water and exhaust gas systems 108 7 Fuel and oil storage, supply and treatment 129 8 Dynamometers and the measurement of torque 144 9 Coupling the engine to the dynamometer 170 10 Electrical design considerations 197 11 Test cell control and data acquisition 216 12 Measurement of fuel, combustion air and oil consumption 242 13 Thermal efficiency, measurement of heat and mechanical losses 263 14 The combustion process and combustion analysis 282 15 The test department organization, health and safety management, risk assessment correlation of results and design of experiments 308 16 Exhaust emissions 324 17 Tribology, fuel and lubrication testing 354 18 Chassis or rolling road dynamometers 368 19 Data collection, handling, post-test processing, engine calibration and mapping 395 20 The pursuit and definition of accuracy: statistical analysis of test results 408 Index 423 This page intentionally left blank Preface The preface of this book is probably the least read section of all; however, it is the only part in which I can pay tribute to my friend and co-author of the first two editions, Dr Michael Plint, who died suddenly in November 1998, only four days after the publication of the second edition. All the work done by Michael in the previous editions has stood up to the scrutiny of our readers and my own subsequent experience. In this edition, I have attempted to bring our work up to date by revising the content to cover the changing legislation, techniques and some of the new tools of our industry. In a new Chapter 1, I have also sought to suggest some good practices, based on my own 40 years of experience, aimed at minimizing the problems of project organization that are faced by all parties involved in the specification, modification, building and commissioning of engine test laboratories. The product of an engine test facility is data and byproduct is the experience gained by the staff and hopefully retained by the company. These data have to be relevant to the experiments being run, and every component of the test facility has to play its part, within an integrated whole, in ensuring that the test data are as valid and uncorrupted as possible, within the sensible limits of the facility’s role. It was our intention when producing the first edition to create an eclectic source of information that would assist any engineer faced with the many design and operational problems of both engine testing and engine test facilities. In the intervening years, the problems have become more difficult as the nature of the engine control has changed significantly, while the time and legislative pressures have increased. However, it is the laws of physics that rule supreme in our world and they can continue to cause problems in areas outside the specialization of many individual readers. I hope that this third edition helps the readers involved in some aspect of engine testing to gain a holistic view of the whole interactive package that makes up a test facility and to avoid, or solve, some of the problems that they may meet in our industry. Having spoken to a number of readers of the two proceeding editions of this book I have reorganized the contents of most of the chapters in order to reflect the way in which the book is used. Writing this edition has, at times, been a lonely and wearisome task that would not have been completed without the support of my wife Diana and my friends. Many people have assisted me with their expert advice in the task of writing this third edition. I have to thank all my present AVL colleagues in the UK and Austria, particularly Stuart Brown, David Moore and Colin Freeman who have shared many viii Preface of my experiences in the test industry over the last 20 years, also Dave Rogers, Craig Andrews, Hans Erlach and finally Gerhard Müller for his invaluable help with the complexities of electrical distribution circuits. A.J. Martyr Inkberrow 22 September 2006 Acknowledgements Figures 3.6, 3.13, 3.15 and 3.16 Reprinted from Industrial Noise Control, Fader, by permission of John Wiley and Sons Ltd Figure 3.9 Reprinted from technical literature of Type TSC by courtesy of Christie and Grey Ltd, UK Figure 3.14 Reprinted from Encyclopaedia of Science and Technology, Vol. 12, 1987, by kind permission of McGraw-Hill Inc., New York Figure 5.3 Reprinted from CIBSE Guide C, section C4, by permission of the Char- tered Institution of Building Services Engineers Figure 5.10 Reprinted from I.H.V.E. Psychometric Chart, by permission of the Chartered Institution of Building Services Engineers Figure 7.1 Reprinted from BS799. Extracts from British Standards are reprinted with the permission of BSI. Complete copies can be obtained by post from BSI Sales, Linford Wood, Milton Keynes, MK14 6LE, UK Figure 7.2 Reprinted from The Storage and Handling of Petroleum Liquids, Hughes and Swindells, with the kind permission of Edward Arnold Publishers Figure 7.3 Reprinted from ‘Recommendations for pre-treatment and cleaning of heavy fuel oil’ with the kind permission of Alfa Laval Ltd Figure 8.3 Reprinted from Drawing no. GP10409 (Carl Shenck AG, Germany) Figures 8.4 and 8.5 Reprinted from Technical Documentation T 32 FN, with the kind permission of Hottinger Baldwin Messtechnik GmbH, Germany Figures 8.6 and 8.7 Illustration courtesy of Ricardo Test Automation Ltd Figures 8.9, 8.10 and 8.11 Reprinted with permission of Froude Consine, UK Figure 8.12 Reprinted from technical literature, Wichita Ltd Figure 9.4 Reprinted from Practical Solution of Torsional Vibration Problems, 3rd edition, W. Ker-Wilson, 1956 Figure 9.7 Reprinted from literature, with the kind permission of British Autoguard Ltd Figures 9.8 and 9.11 Reprinted from sales and technical literature, with the kind permission of Twilfex Ltd Figure 12.2 Reprinted from Paper ISATA, 1982, R.A. Haslett, with the kind permission of Cussons Ltd Figure 12.4 Reprinted from Technology News with the kind permission of Petroleum Review Figure 14.7 Reprinted from SAE 920 462 (SAE International Ltd) Figure 17.1 From Schmiertechnik und Tribologie 29, H. 3, 1982, p. 91, Vincent Verlag Hannover (now: Tribologie und Schmierungstechnik) x Acknowledgements Figures 17.2 and 17.3 Reprinted by permission of the Council of the Institution of Mechanical Engineers from ‘The effect of viscosity grade on piston ring wear’, S.L. Moore, Proc. I. Mech. E C184/87 Figure 18.2 Illustration courtesy of Ricardo Test Automation Ltd Figures 2.3, 5.4, 5.5, 5.6, 5.7, 6.8, 7.5, 7.6, 10.5 10.8, 14.9, 14.10, 14.11, 16.1, 16.2, 16.5, 16.7, 16.8 and 18.4 Reprinted by kind permission of AVL List GmbH Introduction Over the working lifetime of the authors the subject of internal engine development and testing has changed, from being predominantly within the remit of mechanical engineers, into a task that is well beyond the remit of any one discipline that requires a team of specialists covering, in addition to mechanical engineering, electronics, power electrics, acoustics, software, computer sciences and chemical analysis, all supported by expertise in building services and diverse legislation.

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