Turbocharger J

T
Jet
Turbine Engine

James Ravesi
Brandon Berntsen
Tony Cerqueira
Group 1

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
Designandbuildajet
and build a jet
turbineengineutilizinga
standardautomotiveturbo
Haveafunctioningjet
enginethatwecanuseto
measure power output,
measurepoweroutput,
shaftspeed,exhaustgas
temperature,andthrust.

Homemade Jet Turbine Engine

HomemadeJetTurbineEngine

Were Objectives Met?

WereObjectivesMet?
Were
Werewesuccessfulatbuildingaworkingjet
we successful at building a working jet
engine?
Yes

Werewesuccessfulatattainingvalues?
W
f l t tt i i
l ?
No?

Budget
Estimated:$300
Estimated: $300400
400
Actual:
Item
Turbocharger
FuelPump
OilPump
FuelNozzle
EGT Digital Readout
EGTDigitalReadout
StainlessSteel:Tubingand
Flanges
3/8"BallValve
FittingsandRubberTubing
1.5"FlexibleCoupling
SparkPlugBung
LongThrowPlug
OmronSensor
Misc.Hardware/Materials

Supplier
pp
Rick'sTruckCenter
JimRavesi
JimRavesi
AES BMA
AES BMA
AES
AES BMA

Quantityy
1
1
1
1
1
23ft

Cost ($)
Free
Free
Free
Free
Free
Free

Lowe's
Lowe's
Lowe's
ConsumerAutoParts
HomeDepot
Ebay
TonyCerqueira

1
5
1
1
1
1
N/A

7.58
8.40
3.80
8.49
12.99
29.99
Free

Total

$71.25

How Does a Jet Engine Work?

HowDoesaJetEngineWork?
AJetengineiscomprisedof:
Jet e g e s co p sed o :
o Anaircompressor comprisedoffanbladesthat
rotateinordertoincreasethemassflowofairinto
th
theengine;
i
o Acombustionchamber wherefuelisinjectedand
mixedwiththecompressedairtoinitiatethe
p
combustionprocess;
o Anexhaust alsocomprisedoffanbladesthatusethe
exhaustedairfromthecombustionchambertorotate
h t d i f
th
b ti
h b t
t t
theshaftthatrotatesthecompressorbladestoallow
forselfpropulsionofthejetengine.
7

PartsRequiredtoBuildaWorkingJet
Engine
Majorcomponents:
Major components:
aTurbocharger
CombustionChamber
Combustion Chamber
CombustionShell
Flame tube
Flametube

IgnitionSystem
FuelPumpMotor
Fuel Pump Motor

Hypothetical Data
HypotheticalData
PrimaryValues:

Thrust=23.2lbs
ShaftSpeed=144,000RPM
MaxMassFlowRateofAir=0.558lbs/s
ExhaustGasTemperature(EGT)=1195F

ValueswereattainedusingaprogramcalledJetSpecs
TurboAnalysis
y
Valuesweredependentondiametersofinducer,hub,and
exhaustoutlet.

Sensors for Data Acquisition

SensorsforDataAcquisition
Omron
OmronOpticalSensorconnectedtoa
Optical Sensor connected to a
Multimeter
RecordRotationalShaftSpeed
p

ThermocouplewithaDigitalReadout
RecordEGT

AnalogPressureGage
CombustionChamberPressure
Combustion Chamber Pressure

LiquidFilledAnalogFuelPressureGage
RecordFuelInletPressure
Record Fuel Inlet Pressure
10

Omron Optical Sensor

OmronOpticalSensor
To
TodetermineEGT,Thrust,FuelPressureand
determine EGT Thrust Fuel Pressure and
CombustionPressureatgivenRPMto
determine efficiencies
determineefficiencies.
OpticalSensor/PhotoInterruptor
Hasarefreshrateof5000cyclespersecond
H
f h
f 5000
l
d
Howwoulditwork:
Hookeduptomultimetertomeasurefrequency
(Hz),multiplythisvalueby60toattainRPMvalue
11

Series40TDigitalThermocouple/RTD
TemperatureSwitch
h
JseriesThermocouple
p
TemperatureRange:40 1500F

ConnectedtoaLoveController
120Voltinput

12

Analog Pressure Gage

AnalogPressureGage
Measure
MeasureAirPressureofairenteringCombustion
Air Pressure of air entering Combustion
Chamber

13

Liquid Filled Analog Pressure Gage

LiquidFilledAnalogPressureGage
Measure
MeasureFuelPressure
Fuel Pressure
goingintoFuelNozzle
HelptoregulateFuel
p
g
Pressure
Allowforgraph
correlationsofShaft
SpeedandEGTafter
steady state as bee
steadystatehasbeen
reached
PressureRange:0100psi
14

Build and Specifications

BuildandSpecifications
Turbocharger
CombustionChamber
ShellandFlametube
Shell and Flame tube

IgnitionSystem
Fuel Pump System
FuelPumpSystem

15

Turbocharger
Type:GarrettTurboTB28
Type: Garrett Turbo TB28
AcquiredfromRicksTruckCenter
CameoffofatotaledNissanUD1204.6L4cyl
C
ff f t t l d Ni
UD120 4 6L 4 l
TurboDieselboxtruck

R
Requireddisassemblyandcleanupbefore
i d di
bl
d l
b f
properfunctioncouldbeachieved.

16

Sandblasting
Before

After

17

Corrosion Clean
CorrosionClean
Before

After

18

Combustion Chamber
CombustionChamber

CombustionShell
Comprised
Comprisedof304L0.060
of 304L 0.060Stainless
Stainless
Steel.
Lasercuttospecifications,rolledand
weldedtocombustionchamber
shape.
Dimensions
Di
i
6 Di X 12 L th
6Dia.X12Length

Flametube
Comprisedof304L0.125wall
StainlessSteeltubing.
Requireddrillingofholestoallowfor
Required drilling of holes to allow for
airflowintoflametube.
Dimensions 5Dia.X11.5Length
HoleSpecifications:
Primary
Primary 24x0.201
24 x 0.201Dia.
Dia.
Secondary 15x0.209Dia.
Tertiary 21x0.2813Dia.
o Specificationsacquiredfrom
Combustorprogram
p g

19

Combustion Shell
CombustionShell
Combustion Shell
CombustionShell

Flame tube
Flametube

20

Ignition System
IgnitionSystem
Forced AirHeaterSparkPlugandFuelNozzle
ForcedAir
Heater Spark Plug and Fuel Nozzle
Comprisedofafuelnozzleandasparkplug
inserted in the back of the flame tube
insertedinthebackoftheflametube.
Nozzleatomizesdieselfuelforcombustion,
h
hasasprayrateof0.8gphat80.
f 0 8 h 80
Sparkplugusedtoignitefuel.

21

Ignition System
IgnitionSystem

22

Fuel Delivery System

FuelDeliverySystem
Sundstrand
SundstrandOilBurning
Oil Burning
FurnacePump
100psipumping
pressure
Pumprotatesat3450
RPM
120Volts

23

Turbocharger Jet Engine Assembly

TurbochargerJetEngineAssembly

24

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
Wenoticedthattheenginewasnotcombustingalldeliveredfuel
i d h h
i
b i
ll d li
df l
Fuelpumpfailurebecauseofinternalissuesandbleeding

25

Preliminary Testing
PreliminaryTesting
TestingStages
Testing Stages
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
26

What Went Wrong

WhatWentWrong
Althoughitisunknowntheexactcauseofthefailure,
Although
it is unknown the exact cause of the failure,
themostlikelyreasonsare:
ExcessiveRPMsthatweremuchhigherthanwhatthe
turbowascapableofpossiblyproducedadestructive
rotationalresonanceoftheshaft.
Intenseheatratewithoutlettingmetalgraduallyincrease
Intense heat rate without letting metal gradually increase
intemperature.
Destructivefailureinwhichtheheatcausedthemetal
bladestoexpandandcomeincontactwiththeturbine
housingwalls.

27

What We Would Do Differently

WhatWeWouldDoDifferently
Add
Addanothersparkplugtoburnfuelmore
another spark plug to burn fuel more
symmetrically.
Havewatercoolingsetuptoreducetheheat
Have water cooling set up to reduce the heat
withintheturbinebearings.
Useacontrolpaneltocontrolallfunctions
U
l
l
l ll f
i
andindicatorsoftheenginestatus.

28

Future Direction
FutureDirection
Use
Usealargerturbotoattainhigherthrust
a larger turbo to attain higher thrust
value.
Havefullinstrumentationriggedduringall
Have full instrumentation rigged during all
testingphases.
Tryvariouscombustionchambersizesto
T
i
b i
h b i
acquirepeakefficiencyforthespecified
turbine.
bi

29

Was Our Project Successful?

WasOurProjectSuccessful?
Ourprojectwasasuccessbecauseweresearched,designed,
p j
,
g
,
built,andfullyunderstoodthemethodsandprocessinvolved
inengineeringajetturbineengine.
Althoughwewereunabletoverifyourpredeterminedvalues,
Alth
h
bl t
if
d t
i d l
weareconfidentthat,givenanotheropportunity,wewould
meetallofourgoals.
Wehavelearnedtheriskandpossiblemalfunctionsthatcan
ariseduringturbineoperation.
FromourcourseworkandeducationatWentworthwewere
F
k d d
i
W
h
abletosuccessfullycompletetheengineeringprocess
involvedindesigningaprototypefromwhichwecouldcollect
data.
30

Summary
Successfully
Successfullyresearched,designedandbuilta
researched designed and built a
functioningJetTurbineEngineutilizingan
automotive Turbocharger
automotiveTurbocharger.
Wewereunabletoacquireexpecteddatadue
to the physical failure of the engine
tothephysicalfailureoftheengine.
Providedadetailedbuildlogofallnecessary
componentsanddesignmodificationsto
dd i
difi i
illustratetheabilitytoconstructajetengine.
OurWebsite
31

Special Thank to:

SpecialThankto:
AssociatedEnvironmentalSystems
y
BMA

BeranPeter
DavidRockyRockwood
Matt Linder
MattLinder
JimNolan
NathanSimmers
MikeAmato

RowlandInstituteatHarvard
DonRogers
Don Rogers

Family
VictorPereira
AntonioCerqueira
32

Visual Representation
VisualRepresentation

33