First Grade Engineer (Internal Combustion Engine)

First Grade Engineer (Internal Combustion Engine)

Internal Combustion Engine

Under the Factories and Machinery Act, 1971. All "internal combustion engines" (ICE) have to be under the charge of persons holding a Certificate of Competency except for an ICE installed in a hoisting machine, an ICE with a capacity of not more than forty (<40hp)>

· Practical Mathematics which includes Applied Mechanics, Strength of Materials, Heat and Heat engines, and Applied Thermodynamics.

· Engineering Knowledge which include Gas Turbine Power Plant Fundamentals Operational Systems, Fuel and Combustion, Materials, Mechanical Working of Steel Theory of Lubrication, Welding and Non-Destructive Testing.

· Oral examination on the knowledge of managing the plant in terms of safe operation and maintenance, and related requirements of Acts and Regulations.

4.0 FIRST GRADE ENGINEER (INTERNAL COMBUSTION ENGINE)

EXAMINATION SYLLABUS)

4.1 PART A - PRACTICAL MATHEMATICS

This part will consist of two (2) papers namely –

Paper I - 3 hours

Paper II - 2 hours

and candidates will be examined for their knowledge in Applied Mechanics,

Strength of Materials, Heat and Heat Engines and Applied Thermodynamics

Detail of these are as follows –

(a) Applied Mechanics

(i) Forces, Mass, Impulse, Momentum, Work and Energy, Power.

Forces acting on rigid body; Moment of forces; Moments and couples;

Composition and resolution of forces; Polygon of forces; Laws of solid

and liquid friction (friction angle and inclined plane); Friction between

unlubricated surfaces (friction angle, friction clutches, friction on

inclined plane); Inertia forces on elements of plane mechanism;

Mechanical advantage and efficiency of simple machines; Belt and

rope drives; Engine turning moment diagrams, flywheels, governors;

Condition of equilibrium of solids and simple frame structures and

beams; Moment of momentum, moment of inertia, their relation and

measurement; Conservation of energy and momentum; Rectilinear

motion of body in a cicular path with uniform speed.

(ii) Vibration

Body with single degree of freedom; Transverse vibration of beam; and

Torsional oscillations.

(ii) Pressure and velocity change along a stream line

Bernoulli's theorem; Flow through orifice.

(b) Strength of Materials

(i) Hooke's Law; Young's Modulus; Poisson's Ratio; Modulus of

Rigidity; Thermal Stress; Theory of Simple Bending; Bending

Moment and Shearing Force Diagram; Theory of Torsion of

Solid and Hollow Round Shafts; Analysis of Stress;

(ii) Stress and Strain

In tension, compression and shear; Relation between elastic

constants; Co-planar principal plane and stresses; Maximum

shear stress; and Theory of thin shells and strength of rivetted

and welded joints.

(iii) Beams

Direct and shear stresses in beams; Relationship between

slope, curvature and deflection; Determination of shear force

(SF), bending moment, slope and deflection of cantilevers, and

freely supported and built-in beams for simple types of loading.

(iv) Torsion

Transmission of power; Closed coil helical springs; Combined

bending, torsion and thrust; Principal stresses in shafts; Strain

energy in tension, bending and torsional and combined loading.

c) Applied Thermodynamics

(i) First and Second Law of Thermodynamics

(ii) Heat units

B.Th.U., C.H.U., gm-cal and Joules; Specific heat, mec equivqlent of

heat.

(iii) The Law of Perfect Gas

Absolute temperature; Isothermal, adiabatic and pol expansion and

compression; Specific heat c and c and rela' between them; Internal

energy, enthalpy and entropy.

(iv) Heat transfer

Heat transfer by conduction, convection and radiation application);

(v) Reciprocating Steam Engine

Indicator diagrams (hypothetical, actual); Diagram factor; M.e.p,h.p,

b.h.p.; Compounded engines (thermal, mechanical and efficiency)

(vi) Heat Balance for Engine

Elementary principles and cycles of operations of internal combustion

engine and air compressors; Constant volume, diesel and dual cycles;

Calculation of work done; Cam (cam diagram for ICE, angles of cam

peak centre lines relative to crank).

(vii) Combustion of Solid and Liquid Fuel

Higher and lower calorific values; Chemical equations (stoichiometry);

Excess air; Incomplete combustion of carbon.

(viii) Refrigeration -Vapour Compression Cycle

Coefficient of performance; Capacity.

3.2 PART B - ENGINEERING KNOWLEDGE

This part consist of two (2) papers namely –

(i) Paper I - 3 hours

(ii) Paper II - 2 hours

and candidates will be examined for their knowledge on the following subjects

(a) Gas Turbine Power Plant Fundamentals

Basic theory of gas turbine systems (e.g. open, close and combine

cycle; TS diagram, Carnot cycle; Bray ton cycle); Gas turbine process;

Major components and Functional description of typical gas turbine

power plant (Compressor, Type of combustor/burner, Turbine,

Generator); Constructional details; Mounting and fittings; Operational

procedures (Pre-start check, Start-up; Check during normal operation

and emergency); Troubleshooting; and Idling procedure.

(b) Operational Systems

Various operational systems in a gas turbine plant ( Lubrication and

Emergency oil system, Jacking oil system, Ignition fuel system, Fuel

gas system, Exhaust gas system, Power oil system, Gas turbine drain

system, Hydraulic rotor barring system, Air intake and compressor

systems, Fuel oil and water injection systems).

(c) Combustion and Fuels

Types of fuel (Liquid -petroleum oil, and other chemical derivatives;

Gaseous fuel -LPG, natural gas and waste heat); Composition and

properties of different types of fuel; Advantage and disadvantage;

Theory of combustion (Condition, constant temperature, constant

volume and constant pressure); Combustion process (supply air, airfuel

mixture, combustion temperature, combustion time, combustion

gases and temperature of combustion gases).

(d) Materials

Chemical (carbon, phosphorus, silicon, manganese, chromium, nickel,

molybdenum, cadmium) and physical properties of construction

materials; Mechanical testing (tensile, bend, hardness, nick break and

charpy test); Stress-straln relationship (proportional limit, yield point,

ultimate stress, permanent set, breaking stress point and elastic limit);

Heat treatment (annealing, normalising, spheroidising, hardening and

tempering) and effect on microstructure; Iron-carbon equilibrium

diagram.

(e) Mechanical Working of Steel

Hot work (forging and rolling) and cold work (cold roll and cold

working).

(f) Creep and Fatigue

Creep and fatigue behaviour, factors affecting and testing method.

(g) Corrosion and Control

Causes (chemical attack, electro-chemical attack and stress

influenced); Prevention and control (surface protection, metal clading,

electroplating, surface modification (e.g. cladding and chroming), metal

spraying, painting, cathodic protection and water treatment.

(h) Theory of Lubrication / Friction (Tribology)

The importance of lubrication in turbo generating systems and hoe they

are being applied (Engine oil system, Jacking oil system, Hydraulic

rotor bearing and Power oil system); Type of seals; Other type of

cooling systems.

(i) Welding

Basic principles and different types (shielded-arc, gas shielded metal

arc, gas shielded tungsten-arc, plasma-arc, electroslag, stud and gas

welding); Weld joint and preparation (butt, lap, fillet ann nozzle);

Welding defects (cracks, cavities, inclusions, lack of penetration, and

fusion, imperfect shape), methods of detection and repairs; Destructive

testing (tensile test, bend test, hardness test, proof test, fatigue test),

Welding procedure qualification and welder performance qualification

test.

(j) Non-Destructive Testing

Non-destructive testing (radiography, ultrasonic, magnetic particle test,

dye penetrant test and eddy-current); NDT operator qualification

programme (national and international);

(k) Internal Combustion Engine (Petrol, Diesel and Gas Engine)

Ideal and actual cycles for Internal Combustion Engines and their

representation by pressure-volume and temperature-entropy diagrams;

The process of combustion in spark ignition and compression ignition

engines (Flame propagation and detonation in spark ignition engines,

Effect of dissociation and changes in specific heats, Ignition delay and

utilisation of the air in compression ignition engines. Air-fuel ratio, The

composition of exhaust gases and the control of power output from

ICE)

The principles underlaying the working of Internal Combustion Engines

(Petrol, Gas and Oil Engines; Two stroke and Four stroke);

Constructional details of ICE in general use; Use of Indicator diagram;

Supercharging; Governor and governor gears; Starting gears;

Construction of engine foundations; Vibration and noise; The testing

and performance of ICE (Apparatus and procedures, indicator diagram,

fuel consumption and heat distribution; dynamometer and useful power

output, engine losses, accuracy of measurement); Utilisation of waste

heat; Energy balance of installation in service.

The nature and properties of the fuel (Liquid and gases, chemical

composition, calorific value and its determination, properties of

importance in relation to combustion in engines, methods of

determining octane and cetane values); Purification, filtration, handling

and storage of fuels; Lubricating oils generally used in Internal

Combustion Engines; The supply of air and fuel to cylinders of engine

of different types; The constructional details of apparatus for

carburetting and atomising fuel; The means of cooling the cylinders

and pistons; Constructional details and working of pumps and

compressor.

Air compressors (reciprocating and rotary blower and supercharger);

Adiabatic and isothermal efficiency; Heat transferin intercoolers;

Charging and exhausting the cylinders of two-stroke and four-stroke

reciprocating engines; volumetric and scavanging efficiency; Silencing.

Supervision required during operation; maintenance of various parts of

machinery; The use and management of valves, pipes, connections

and safety devices employed.

Troubleshootings; Enumeration and description of defects arising from

the operation of ICE and the remedy for such defects.