T J Turbocharger Jet Turbine EngineTurbine Engine

James Ravesi Brandon Berntsen

Tony Cerqueira

Group 11

Presentation OverviewPresentation Overview

• Proposal of Senior Design Project/ Objectivesp g j / j

• Estimated/ Actual Budget

• How Does a Jet Engine Work?• How Does a Jet Engine Work?

• Parts Required

• Hypothetical Data and Acquisition Methods

• Build Process and Specificationsp

• Testing Problems/Ramifications

• What We Would Do Differently• What We Would Do Differently2

Proposed ProjectProposed Project

Turbocharger Jet EngineTurbocharger Jet EngineObjectives

• Design and build a jetDesign and build a jet turbine engine utilizing a standard automotive turbo

• Have a functioning jet engine that we can use to measure power output,measure power output, shaft speed, exhaust gas temperature, and thrust.

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Homemade Jet Turbine EngineHomemade Jet Turbine Engine

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Were Objectives Met?Were Objectives Met?

• Were we successful at building a working jetWere we successful at building a working jet engine?– Yes– Yes

W f l t tt i i l ?• Were we successful at attaining values?– No?

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BudgetBudget

• Estimated: $300‐400Estimated: $300 400

• Actual:Item Supplier Quantity Cost ($)pp y

Turbocharger Rick's Truck Center 1 Free

Fuel Pump Jim Ravesi 1 FreeOil Pump Jim Ravesi 1 FreeFuel Nozzle AES ‐ BMA 1 FreeEGT Digital Readout AES BMA 1 FreeEGT Digital Readout AES ‐ BMA 1 Free

Stainless Steel: Tubing and Flanges

AES ‐ BMA 2‐3ft Free

3/8" Ball Valve Lowe's 1 7.58 Fittings and Rubber Tubing Lowe's 5 8.40 

1.5" Flexible Coupling Lowe's 1 3.80 

Spark Plug Bung Consumer Auto Parts 1 8.49 

Long Throw Plug Home Depot 1 12.99 

Omron Sensor Ebay 1 29.99 Misc. Hardware/ Materials Tony Cerqueira N/A Free

Total $71.25 6

How Does a Jet Engine Work?How Does a Jet Engine Work?

• A Jet engine is comprised of:Jet e g e s co p sed o :o An air compressor – comprised of fan blades that rotate in order to increase the mass flow of air into th ithe engine;

o A combustion chamber – where fuel is injected and mixed with the compressed air to initiate the pcombustion process;

o An exhaust – also comprised of fan blades that use the h t d i f th b ti h b t t texhausted air from the combustion chamber to rotate 

the shaft that rotates the compressor blades to allow for self‐propulsion of the jet engine.

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Parts Required to Build a Working Jet Engine

• Major components:Major components:– a Turbocharger

Combustion Chamber– Combustion Chamber• Combustion Shell

• Flame tubeFlame tube

– Ignition System

– Fuel Pump MotorFuel Pump Motor

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Hypothetical DataHypothetical Data

• Primary Values:– Thrust = 23.2 lbs– Shaft Speed = 144,000 RPM– Max Mass Flow Rate of Air = 0.558 lbs/s– Exhaust Gas Temperature (EGT) = 1195°F

• Values were attained using a program called “JetSpecs –Turbo Analysis”y– Values were dependent on diameters of inducer, hub, and 

exhaust outlet.

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Sensors for Data AcquisitionSensors for Data Acquisition

• Omron Optical Sensor connected to aOmron Optical Sensor connected to a Multimeter– Record Rotational Shaft Speedp

• Thermocouple with a Digital Readout– Record EGT

• Analog Pressure Gage– Combustion Chamber PressureCombustion Chamber Pressure

• Liquid‐Filled Analog Fuel Pressure Gage– Record Fuel Inlet PressureRecord Fuel Inlet Pressure

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Omron Optical SensorOmron Optical Sensor

• To determine EGT Thrust Fuel Pressure andTo determine EGT, Thrust, Fuel Pressure and Combustion Pressure at given RPM to determine efficienciesdetermine efficiencies.

• Optical Sensor/ Photo Interruptor

H f h f 5000 l d• Has a refresh rate of 5000 cycles per second

• How would it work:– Hooked up to multimeter to measure frequency (Hz), multiply this value by 60 to attain RPM value

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Series 40T Digital Thermocouple/RTD hTemperature Switch

• J‐series Thermocouplep– Temperature Range: ‐40 ‐ 1500°F

• Connected to a Love Controller– 120 Volt input

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Analog Pressure GageAnalog Pressure Gage

• Measure Air Pressure of air entering CombustionMeasure Air Pressure of air entering Combustion Chamber

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Liquid Filled Analog Pressure GageLiquid Filled Analog Pressure Gage

• Measure Fuel PressureMeasure Fuel Pressure going into Fuel Nozzle

• Help to regulate Fuel p gPressure– Allow for graph correlations of Shaft Speed and EGT after steady state has been steady state as beereached

– Pressure Range: 0‐100psi

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Build and SpecificationsBuild and Specifications

• TurbochargerTurbocharger

• Combustion Chamber– Shell and Flame tubeShell and Flame tube

• Ignition System

• Fuel Pump SystemFuel Pump System

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TurbochargerTurbocharger

• Type: Garrett Turbo TB28Type: Garrett Turbo TB28

• Acquired from Rick’s Truck CenterC ff f t t l d Ni UD120 4 6L 4 l– Came off of a totaled Nissan UD120 4.6L 4‐cyl Turbo Diesel box‐truck

R i d di bl d l b f• Required disassembly and clean‐up before proper function could be achieved.

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SandblastingSandblasting

Before AfterBefore After

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Corrosion CleanCorrosion Clean

Before AfterBefore After

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Combustion ChamberCombustion Chamber• Combustion Shell

– Comprised of 304L 0.060” StainlessComprised of 304L 0.060  Stainless Steel.

– Laser cut to specifications, rolled and welded to combustion chamber shape.Di i 6” Di X 12” L th– Dimensions – 6” Dia. X 12” Length

• Flame tube– Comprised of 304L 0.125” wall 

Stainless Steel tubing.Required drilling of holes to allow for– Required drilling of holes to allow for air flow into flame tube.

– Dimensions – 5” Dia. X 11.5” Length– Hole Specifications: Primary – 24 x 0.201” Dia.Primary  24 x 0.201  Dia.  Secondary – 15 x 0.209” Dia. Tertiary – 21 x 0.2813” Dia.o Specifications acquired from  

“Combustor” programp g

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Combustion ShellCombustion Shell

Combustion Shell Flame tubeCombustion Shell Flame tube

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Ignition SystemIgnition System

Forced‐Air Heater Spark Plug and Fuel NozzleForced Air Heater Spark Plug and Fuel Nozzle

• Comprised of a fuel nozzle and a spark plug inserted in the back of the flame tubeinserted in the back of the flame tube.

• Nozzle atomizes diesel fuel for combustion, h f 0 8 h 80°has a spray rate of 0.8 gph at 80°.

• Spark plug used to ignite fuel.

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Ignition SystemIgnition System

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Fuel Delivery SystemFuel Delivery System

• Sundstrand Oil BurningSundstrand Oil Burning Furnace Pump– 100 psi pumping pressure

– Pump rotates at 3450 RPMRPM

– 120 Volts

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Turbocharger Jet Engine AssemblyTurbocharger Jet Engine Assembly

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Testing ObstaclesTesting Obstacles

• Initial condition of turbocharger

• Ignition and combustion issues due to placement of fuel injector and spark plug

• Modified spark plug did not thread in without bendingp p g g

• Needed a strong spark and a cap and rotor wasn’t working

• 0.6 gph nozzle didn’t have enough spread. 0.8 gph distributed the fuel better for more efficient combustionbetter for more efficient combustion

• Fuel lines rupturing/blowing off fittings

• Starting issues due to insufficient RPM’s

W i d h h i b i ll d li d f l• We noticed that the engine was not combusting all delivered fuel

• Fuel pump failure because of internal issues and bleeding

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Preliminary TestingPreliminary Testing

• Testing StagesTesting Stages– Stage 1 – Ignition System: Tested how to generate enough voltage for the spark plug to functionenough voltage for the spark plug to function

– Stage 2 – Tested how to effectively ignite specified fuels (gasoline and diesel)fuels (gasoline and diesel)

– Stage 3 – Tested placement of fuel nozzle and spark plug: determining sufficient air flow through p p g g gflame tube orifices

– Stage 4 – Tested whether Jet Engine was self‐sustaining

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What Went WrongWhat Went Wrong

Although it is unknown the exact cause of the failure,Although it is unknown the exact cause of the failure, the most likely reasons are:– Excessive RPM’s that were much higher than what the turbo was capable of possibly produced a destructive rotational resonance of the shaft.

Intense heat rate without letting metal gradually increase– Intense heat rate without letting metal gradually increase in temperature.

– Destructive failure in which the heat caused the metal blades to expand and come in contact with the turbine housing walls.

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What We Would Do DifferentlyWhat We Would Do Differently

• Add another spark plug to burn fuel moreAdd another spark plug to burn fuel more symmetrically.

• Have water cooling set up to reduce the heat• Have water cooling set up to reduce the heat within the turbine bearings.

U l l l ll f i• Use a control panel to control all functions and indicators of the engine status.

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Future DirectionFuture Direction 

• Use a larger turbo to attain higher thrustUse a larger turbo to attain higher thrust value.

• Have full instrumentation rigged during all• Have full instrumentation rigged during all testing phases.

T i b i h b i• Try various combustion chamber sizes to acquire peak efficiency for the specified 

biturbine.

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Was Our Project Successful?Was Our Project Successful?

• Our project was a success because we researched, designed, p j , g ,built, and fully understood the methods and process involved in engineering a jet turbine engine.

Alth h bl t if d t i d l• Although we were unable to verify our predetermined values, we are confident that, given another opportunity, we would meet all of our goals.

• We have learned the risk and possible malfunctions that can arise during turbine operation.

F k d d i W h• From our coursework and education at Wentworth we were able to successfully complete the engineering process involved in designing a prototype from which we could collect data.

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SummarySummary

• Successfully researched designed and built aSuccessfully researched, designed and built a functioning Jet Turbine Engine utilizing an automotive Turbochargerautomotive Turbocharger.

• We were unable to acquire expected data due to the physical failure of the engineto the physical failure of the engine.

• Provided a detailed build log of all necessary d d i difi icomponents and design modifications to 

illustrate the ability to construct a jet engine.

Our Website31

Special Thank to:Special Thank to:

• Associated Environmental Systems – BMAy– Beran Peter

– David “Rocky” Rockwood

Matt Linder– Matt Linder

– Jim Nolan

– Nathan Simmers

– Mike Amato

• Rowland Institute at Harvard– Don RogersDon Rogers

• Family– Victor Pereira

– Antonio Cerqueira

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Visual RepresentationVisual Representation

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