T J Turbocharger Jet

Turbine Engine Turbine Engine

James Ravesi Brandon Berntsen
Tony Cerqueira
Group 1
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Presentation Overview PresentationOverview
ProposalofSeniorDesignProject/Objectives p g j / j
Estimated/ActualBudget
How Does a Jet Engine Work? HowDoesaJetEngineWork?
PartsRequired
HypotheticalDataandAcquisitionMethods
BuildProcessandSpecifications p
TestingProblems/Ramifications
What We Would Do Differently WhatWeWouldDoDifferently
2
Proposed Project ProposedProject
Turbocharger Jet Engine TurbochargerJetEngine
Objectives
Design and build a jet Designandbuildajet
turbineengineutilizinga
standardautomotiveturbo
Haveafunctioningjet
enginethatwecanuseto
measure power output, measurepoweroutput,
shaftspeed,exhaustgas
temperature,andthrust.
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Homemade Jet Turbine Engine HomemadeJetTurbineEngine
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Were Objectives Met? WereObjectivesMet?
Were we successful at building a working jet Werewesuccessfulatbuildingaworkingjet
engine?
Yes Yes
W f l t tt i i l ? Werewesuccessfulatattainingvalues?
No?
5
Budget Budget
Estimated: $300400 Estimated:$300 400
Actual:
Item Supplier Quantity Cost
($)
pp y
Turbocharger Rick'sTruckCenter 1 Free
FuelPump JimRavesi 1 Free
OilPump JimRavesi 1 Free
FuelNozzle AES BMA 1 Free
EGT Digital Readout AES BMA 1 Free EGTDigitalReadout AES BMA 1 Free
StainlessSteel:Tubingand
Flanges
AES BMA 23ft Free
3/8"BallValve Lowe's 1 7.58
FittingsandRubberTubing Lowe's 5 8.40
1.5"FlexibleCoupling Lowe's 1 3.80
SparkPlugBung ConsumerAutoParts 1 8.49
LongThrowPlug HomeDepot 1 12.99
OmronSensor Ebay 1 29.99
Misc.Hardware/Materials TonyCerqueira N/A Free
Total $71.25
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How Does a Jet Engine Work? HowDoesaJetEngineWork?
AJetengineiscomprisedof: Jet e g e s co p sed o :
o Anaircompressor comprisedoffanbladesthat
rotateinordertoincreasethemassflowofairinto
th i theengine;
o Acombustionchamber wherefuelisinjectedand
mixedwiththecompressedairtoinitiatethe p
combustionprocess;
o Anexhaust alsocomprisedoffanbladesthatusethe
h t d i f th b ti h b t t t exhaustedairfromthecombustionchambertorotate
theshaftthatrotatesthecompressorbladestoallow
forselfpropulsionofthejetengine.
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PartsRequiredtoBuildaWorkingJet
Engine
Major components: Majorcomponents:
aTurbocharger
Combustion Chamber CombustionChamber
CombustionShell
Flame tube Flametube
IgnitionSystem
Fuel Pump Motor FuelPumpMotor
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Hypothetical Data HypotheticalData
PrimaryValues:
Thrust=23.2lbs
ShaftSpeed=144,000RPM
MaxMassFlowRateofAir=0.558lbs/s
ExhaustGasTemperature(EGT)=1195F
ValueswereattainedusingaprogramcalledJetSpecs
TurboAnalysis y
Valuesweredependentondiametersofinducer,hub,and
exhaustoutlet.
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Sensors for Data Acquisition SensorsforDataAcquisition
Omron Optical Sensor connected to a OmronOpticalSensorconnectedtoa
Multimeter
RecordRotationalShaftSpeed p
ThermocouplewithaDigitalReadout
RecordEGT
AnalogPressureGage
Combustion Chamber Pressure CombustionChamberPressure
LiquidFilledAnalogFuelPressureGage
Record Fuel Inlet Pressure RecordFuelInletPressure
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Omron Optical Sensor OmronOpticalSensor
To determine EGT Thrust Fuel Pressure and TodetermineEGT,Thrust,FuelPressureand
CombustionPressureatgivenRPMto
determine efficiencies determineefficiencies.
OpticalSensor/PhotoInterruptor
H f h f 5000 l d Hasarefreshrateof5000cyclespersecond
Howwoulditwork:
Hookeduptomultimetertomeasurefrequency
(Hz),multiplythisvalueby60toattainRPMvalue
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Series40TDigitalThermocouple/RTD
h TemperatureSwitch
JseriesThermocouple p
TemperatureRange:40 1500F
ConnectedtoaLoveController
120Voltinput
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Analog Pressure Gage AnalogPressureGage
Measure Air Pressure of air entering Combustion MeasureAirPressureofairenteringCombustion
Chamber
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Liquid Filled Analog Pressure Gage LiquidFilledAnalogPressureGage
Measure Fuel Pressure MeasureFuelPressure
goingintoFuelNozzle
HelptoregulateFuel p g
Pressure
Allowforgraph
correlationsofShaft
SpeedandEGTafter
steadystatehasbeen steady state as bee
reached
PressureRange:0100psi
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Build and Specifications BuildandSpecifications
Turbocharger Turbocharger
CombustionChamber
Shell and Flame tube ShellandFlametube
IgnitionSystem
Fuel Pump System FuelPumpSystem
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Turbocharger Turbocharger
Type: Garrett Turbo TB28 Type:GarrettTurboTB28
AcquiredfromRicksTruckCenter
C ff f t t l d Ni UD120 4 6L 4 l CameoffofatotaledNissanUD1204.6L4cyl
TurboDieselboxtruck
R i d di bl d l b f Requireddisassemblyandcleanupbefore
properfunctioncouldbeachieved.
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Sandblasting Sandblasting
Before After Before After
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Corrosion Clean CorrosionClean
Before After Before After
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Combustion Chamber CombustionChamber
CombustionShell
Comprised of 304L 0.060 Stainless Comprisedof304L0.060 Stainless
Steel.
Lasercuttospecifications,rolledand
weldedtocombustionchamber
shape.
Di i 6 Di X 12 L th Dimensions 6Dia.X12Length
Flametube
Comprisedof304L0.125wall
StainlessSteeltubing.
Required drilling of holes to allow for Requireddrillingofholestoallowfor
airflowintoflametube.
Dimensions 5Dia.X11.5Length
HoleSpecifications:
Primary 24 x 0.201 Dia. Primary 24x0.201 Dia.
Secondary 15x0.209Dia.
Tertiary 21x0.2813Dia.
o Specificationsacquiredfrom
Combustorprogram p g
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Combustion Shell CombustionShell
Combustion Shell Flame tube CombustionShell Flametube
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Ignition System IgnitionSystem
ForcedAir Heater Spark Plug and Fuel Nozzle Forced AirHeaterSparkPlugandFuelNozzle
Comprisedofafuelnozzleandasparkplug
inserted in the back of the flame tube insertedinthebackoftheflametube.
Nozzleatomizesdieselfuelforcombustion,
h f 0 8 h 80 hasasprayrateof0.8gphat80.
Sparkplugusedtoignitefuel.
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Ignition System IgnitionSystem
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Fuel Delivery System FuelDeliverySystem
Sundstrand Oil Burning SundstrandOilBurning
FurnacePump
100psipumping
pressure
Pumprotatesat3450
RPM RPM
120Volts
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Turbocharger Jet Engine Assembly TurbochargerJetEngineAssembly
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Testing Obstacles TestingObstacles
Initialconditionofturbocharger
Ignitionandcombustionissuesduetoplacementoffuelinjectorandspark
plug
Modifiedsparkplugdidnotthreadinwithoutbending p p g g
Neededastrongsparkandacapandrotorwasntworking
0.6gphnozzledidnthaveenoughspread.0.8gphdistributedthefuel
better for more efficient combustion betterformoreefficientcombustion
Fuellinesrupturing/blowingofffittings
StartingissuesduetoinsufficientRPMs
W i d h h i b i ll d li d f l Wenoticedthattheenginewasnotcombustingalldeliveredfuel
Fuelpumpfailurebecauseofinternalissuesandbleeding
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Preliminary Testing PreliminaryTesting
Testing Stages TestingStages
Stage1 IgnitionSystem:Testedhowtogenerate
enough voltage for the spark plug to function enoughvoltageforthesparkplugtofunction
Stage2 Testedhowtoeffectivelyignitespecified
fuels (gasoline and diesel) fuels(gasolineanddiesel)
Stage3 Testedplacementoffuelnozzleand
sparkplug:determiningsufficientairflowthrough p p g g g
flametubeorifices
Stage4 TestedwhetherJetEnginewasself
sustaining
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What Went Wrong WhatWentWrong
Although it is unknown the exact cause of the failure, Althoughitisunknowntheexactcauseofthefailure,
themostlikelyreasonsare:
ExcessiveRPMsthatweremuchhigherthanwhatthe
turbowascapableofpossiblyproducedadestructive
rotationalresonanceoftheshaft.
Intense heat rate without letting metal gradually increase Intenseheatratewithoutlettingmetalgraduallyincrease
intemperature.
Destructivefailureinwhichtheheatcausedthemetal
bladestoexpandandcomeincontactwiththeturbine
housingwalls.
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What We Would Do Differently WhatWeWouldDoDifferently
Add another spark plug to burn fuel more Addanothersparkplugtoburnfuelmore
symmetrically.
Have water cooling set up to reduce the heat Havewatercoolingsetuptoreducetheheat
withintheturbinebearings.
U l l l ll f i Useacontrolpaneltocontrolallfunctions
andindicatorsoftheenginestatus.
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Future Direction FutureDirection
Use a larger turbo to attain higher thrust Usealargerturbotoattainhigherthrust
value.
Have full instrumentation rigged during all Havefullinstrumentationriggedduringall
testingphases.
T i b i h b i Tryvariouscombustionchambersizesto
acquirepeakefficiencyforthespecified
bi turbine.
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Was Our Project Successful? WasOurProjectSuccessful?
Ourprojectwasasuccessbecauseweresearched,designed, p j , g ,
built,andfullyunderstoodthemethodsandprocessinvolved
inengineeringajetturbineengine.
Alth h bl t if d t i d l Althoughwewereunabletoverifyourpredeterminedvalues,
weareconfidentthat,givenanotheropportunity,wewould
meetallofourgoals.
Wehavelearnedtheriskandpossiblemalfunctionsthatcan
ariseduringturbineoperation.
F k d d i W h FromourcourseworkandeducationatWentworthwewere
abletosuccessfullycompletetheengineeringprocess
involvedindesigningaprototypefromwhichwecouldcollect
data.
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Summary Summary
Successfully researched designed and built a Successfullyresearched,designedandbuilta
functioningJetTurbineEngineutilizingan
automotive Turbocharger automotiveTurbocharger.
Wewereunabletoacquireexpecteddatadue
to the physical failure of the engine tothephysicalfailureoftheengine.
Providedadetailedbuildlogofallnecessary
d d i difi i componentsanddesignmodificationsto
illustratetheabilitytoconstructajetengine.
OurWebsite
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Special Thank to: SpecialThankto:
AssociatedEnvironmentalSystems BMA y
BeranPeter
DavidRockyRockwood
Matt Linder MattLinder
JimNolan
NathanSimmers
MikeAmato
RowlandInstituteatHarvard
Don Rogers DonRogers
Family
VictorPereira
AntonioCerqueira
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Visual Representation VisualRepresentation
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