CHAPTER 1

INTRODUCTION

The free piston engine is basically a internal combustion engine which works on the principle of brayton cycle.it is a completely rotational power unit and first types of prime movers, prime movers means a mechanical arrangement which converts chemical energy into mechanical energy. It is a multifuel type of prime movers so that all type of fuel can be used in this project for example gasoline,diesel,l.p.g, c.n.g, kerosene e.t.c. it is also known as gas turbine engine. A gas turbine is a rotating engine that extracts energy from a flow of combustion gases that result from the ignition of compressed air and a fuel (either a gas or liquid, most commonly natural gas). It has an upstream compressor module coupled to a downstream turbine module, and a combustion chamber(s) module (with igniter[s]) in between. Energy is added to the gas stream in the combustor, where air is mixed with fuel and ignited. Combustion increases the temperature, velocity, and volume of the gas flow. This is directed through a nozzle over the turbines blades, spinning the turbine and powering the compressor Energy is extracted in the form of shaft power, compressed air, and thrust, in any combination, and used to power aircraft, trains, ships, generators, and even tanks. so gas turbine engine primilary contains three basic unit 1.compressor 2.turbine 3.combustion chamber Other units used are as 1. Pump for lubricating oil 2. Air blower for giving initial starting to the engine. 3. Regulator for regulating the oil pump.

In our project as we are going to make a small scale gas turbine engine so we are used a coupled unit of turbine and compressor i.e. the turbocharger instead of using the seprate unit of both turbine and compressor . we used the turbocharger of TATA Indica because it is smallest turbocharger available in the market, turbocharger in the car is driven by the exhaust of the vehicle piston diesel engine, in this project we replace the i.c engine by the combustion chamber and use the exhaust coming from it, combustion chamber is made by the mild steel hollow and thick pipe, and designed and fabricated by the help of turbocharger dimensions i.e the inducer diameter. In the turbocharger unit a radial airflow compressor and a radial imbulse turbine is used. as any type of fuel can be used in this engine so we select the LPG(liquid petroleum gas) as a fuel for

this engine for reducing the complexity of fuel injection, also it can easily mixed with the air and we get a perfect air fuel mixture for complete combustion it has also low combustion temperature and pressure so perfectly suited for this engine. In this engine combustion in the combustion chamber perform at constant pressure combustor connected with three unit first is compressor outlet for air flow , second one is LPG injection nozzle and third one is sparkplug for igniting the fuel . combustion chamber is used for producing high tempreture and pressure gases which is forced to the turbine unit and used for drive the turbine and for propulsion power, my project is turbojet type means to propel the vehicle by the propulsion power. For reducing the complexity of secondary turbine and reduction gear box we make turbojet type, otherwise we have also the option of turboshaft type project all the devices are connected in the series first is compressor after that combustion chamber than the turbine. at the outlet of the turbine we connect a nozzle which the propulsive thrust . The lubrication of turbocharger is of hydrodynamic type, which is performed by water cooler motor (water proof type), which is used for pumping the lubricating oil to the turbocharger inlet port . this pump is driven by the external electrical system . For starting the turbocharger we use a air blower which produces a high speed air flow on the compressor blade of the turbocharger, providing the intial rotation of the compressor unit, For ignition, we use a spark plug of two wheeler and sparking is made by the ignition system.

Types of Gas Turbine There are different types of gas turbines. Some of them are named below: 1. Aero derivatives and jet engines 2. Amateur gas turbines 3. Industrial gas turbines for electrical generation 4. Radial gas turbines 5. Scale jet engines 6. Micro turbines The main focus of this project is to fabricate a very small scale gas turbine which can propel a small vehicle.

Chronology Of Gas turbine Development :

Table 1.1

GAS TURBINE PARTS1.1 COMPRESSORGas compressor is a mechanical device that increases the pressure of a gas by reducing its volume. Compressors are similar to pumps: both increase the pressure on a fluid and both can transport the fluid through a pipe. As gases are compressible, the compressor also reduces the volume of a gas. Liquids are relatively incompressible; while some can be compressed, the main action of a pump is to pressurize and transport liquids.

TYPES OF COMPRESSOR-

FIGURE 1.1 Hermetically sealed, open, or semi-hermetic

Compressors are often described as being either open, hermetic, or semi-hermetic, to describe how the compressor and motor drive is situated in relation to the gas or vapour being compressed. The industry name for a hermetic is hermetically sealed compressor, while a semiis commonly called a semi-hermetic compressor. In hermetic and most semi-hermetic compressors, the compressor and motor driving the compressor are integrated, and operate within the pressurized gas envelope of the system. The motor is designed to operate and be cooled by the gas or vapour being compressed. The difference between the hermetic and semi-hermetic, is that the hermetic uses a one-piece welded steel casing that cannot be opened for repair; if the hermetic fails it is simply replaced with an entire new unit. A semi-hermetic uses a large cast metal shell with gasketed covers that can be opened to replace motor and pump components. The primary advantage of a hermetic and semi-hermetic is that there is no route for the gas to leak out of the system. Open compressors rely on either natural leather or synthetic rubber seals to retain the internal pressure, and these seals require a lubricant such as oil to retain their sealing properties.An open pressurized system such as an automobile air conditioner can leak its operating gases, if it is not operated frequently enough. Open systems rely on lubricant in the system to splash on pump components and seals. If it is not operated frequently enough, the lubricant on the seals slowly evaporates, and then the seals begin to leak until the system is no longer functional and must be recharged. By comparison, a hermetic system can sit unused

for years, and can usually be started up again at any time without requiring maintenance or experiencing any loss of system pressure. The disadvantage of hermetic compressors is that the motor drive cannot be repaired or maintained, and the entire compressor must be removed if a motor fails. A further disadvantage is that burnt out windings can contaminate whole systems requiring the system to be entirely pumped down and the gas replaced. Typically hermetic compressors are used in low-cost factory-assembled consumer goods where the cost of repair is high compared to the value of the device, and it would be more economical to just purchase a new device.

Centrifugal compressorsCentrifugal compressors use a rotating disk or impeller in a shaped housing to force the gas to the rim of the impeller, increasing the velocity of the gas. A diffuser (divergent duct) section converts the velocity energy to pressure energy. They are primarily used for continuous, stationary service in industries such as oil refineries, chemical and petrochemical plants and natural gas processing plants.Their application can be from 100 horsepower (75 kW) to thousands of horsepower. With multiple staging, they can achieve extremely high output pressures greater than 10,000 psi (69 MPa). Many large snowmaking operations (like ski resorts) use this type of compressor. They are also used in internal combustion engines as superchargers and turbochargers. Centrifugal compressors are used in small gas turbine engines or as the final compression stage of medium sized gas turbines. Sometimes the capacity of the compressors is written in NM3/hr. Here 'N' stands for normal temperature pressure (20C and 1 atm ) for example 5500 NM3/hr.

FIGURE 1.2(Compressor & Radial Turbine) Axial-flow compressorsAxial-flow compressors are dynamic rotating compressors that use arrays of fan-like airfoils to progressively compress the working fluid. They are used where there is a requirement for a high flow rate or a compact design. The arrays of airfoils are set in rows, usually as pairs: one rotating and one stationary. The rotating airfoils, also known as blades or rotors, accelerate the fluid. The stationary airfoils, also known as stators or vanes, decelerate and redirect the flow direction of the fluid, preparing it for the rotor blades of the next stage. Axial compressors are almost always multi-staged, with the cross-sectional area of the gas passage diminishing along the compressor to maintain an optimum axial Mach number. Beyond about 5 stages or a 4:1 design pressure ratio, variable geometry is normally used to improve operation.

Axial compressors can have high efficiencies; around 90% polytropic at their design conditions. However, they are relatively expensive, requiring a large number of components, tight tolerances and high quality materials. Axial-flow compressors can be found in medium to large gas turbine engines, in natural gas pumping stations, and within certain chemical plants.

Reciprocating compressors
Reciprocating compressors use pistons driven by a crankshaft. They can be either stationary or portable, can be single or multi-staged, and can be driven by electric motors or internal combustion engines. Small reciprocating compressors from 5 to 30 horsepower (hp) are commonly seen in automotive applications and are typically for intermittent duty. Larger reciprocating compressors well over 1,000 hp (750 kW) are commonly found in large industrial and petroleum applications. Discharge pressures can range from low pressure to very high pressure (>18000 psi or 180 MPa). In certain applications, such as air compression, multi-stage double-acting compressors are said to be the most efficient compressors available, and are typically larger, and more costly than comparable rotary units.[6] Another type of reciprocating compressor is the swash plate compressor, which uses pistons which are moved by a swash plate mounted on a shaft - see Axial Piston Pump. Household, home workshop, and smaller job site compressors are typically reciprocating compressors 1 hp or less with an attached receiver tank.

COMBUSTION CHAMBERThe compressed air from the axial flow compressor is piped to the combustion chamber. Each chamber consists of the following: -

1. The Fuel Burner. - Using Natural gas, no atomiser is required - the fuel however must have all liquid knocked out. 2. Swirl Vanes. - These are installed at the point of fuel injection in order to get thorough mixing of the fuel and Primary Air, (air for the combustion - 15 to 20% of the compressor discharge). This is done to prevent Hot-Gas Pockets in the hot-gas path to protect the metal of the turbine from excessive heat. 3. The Burner Basket - This is fitted around the burner and contains holes through which the Secondary Air (about 30% of the air), passes into the burning gases to ensure complete combustion of the fuel.

4. The Igniters. - Spark plugs are used for the initial ignition of the fuel/air mixture. The hot gases from the combustor mix with the remaining air from the compressor (about 50%). This is called ' Tertiary Air ' and cools the gases to a safe turbine inlet temperature - at about 1700 F. The hot, expanding gases pass into a ' Transition Piece ' which ensures the final mixing of the gases. The hot gases now pass to the six - fixed nozzle guide-vanes which direct the gas flow through the turbine assembly. Between the combustion chambers, 'Cross-fire' tubes are installed to ensure combustion in all chambers. (A flame detector system exists which will instantly shut down the fuel supply and therefore the turbine, should a flame failure occur in a chamber).

TURBINE
The simplest turbines have one moving part, a rotor assembly, which is a shaft or drum with blades attached. Moving fluid acts on the blades, or the blades react to the flow, so that they move and impart rotational energy to the rotor. Early turbine examples are windmills and water wheels. Gas, steam, and water turbines usually have a casing around the blades that contains and controls the working fluid. Credit for invention of the steam turbine is given both to the British engineer Sir Charles Parsons (18541931), for invention of the reaction turbine and to Swedish engineer Gustaf de Laval (18451913), for invention of the impulse turbine. Modern steam turbines frequently employ both reaction and impulse in the same unit, typically varying the degree of reaction and impulse from the blade root to its periphery. A device similar to a turbine but operating in reverse, i.e., driven, is a compressor or pump. The axial compressor in many gas turbine engines is a common example. Here again, both reaction and impulse are employed and again, in modern axial compressors, the degree of reaction and impulse typically vary from the blade root to its periphery. The word "turbine" was coined in 1822 by the French mining engineer Claude Burdin from the Latin turbo, or vortex, in a memoir, "Des turbines hydrauliques ou machines rotatoires grande vitesse" (Hydraulic turbines or high-speed rotary machines), which he submitted to the Acadmie royale des sciences in Paris. Benoit Fourneyron, a former student of Claude Burdin, built the first practical water turbine.

Table 1.2

TYPES OF TURBINESteam turbines are used for the generation of electricity in thermal power plants, such as plants using coal, fuel oil or nuclear power. They were once used to directly drive mechanical devices such as ships' propellers (for example the Turbinia, the first turbine-powered steam launch,[2] ) but most such applications now use reduction gears or an intermediate electrical step, where the turbine is used to generate electricity, which then powers an electric motor connected to the mechanical load. Turbo electric ship machinery was particularly popular in the period immediately before and during World War II, primarily due to a lack of sufficient gear-cutting facilities in US and UK shipyards. Gas turbines are sometimes referred to as turbine engines. Such engines usually feature an inlet, fan, compressor, combustor and nozzle (possibly other assemblies) in addition to one or more turbines. Transonic turbine. The gasflow in most turbines employed in gas turbine engines remains subsonic throughout the expansion process. In a transonic turbine the gasflow becomes supersonic as it exits the nozzle guide vanes, although the downstream velocities normally become subsonic. Transonic turbines operate at a higher pressure ratio than normal but are usually less efficient and uncommon. Contra-rotating turbines. With axial turbines, some efficiency advantage can be obtained if a downstream turbine rotates in the opposite direction to an upstream unit. However, the complication can be counter-productive. A contra-rotating steam turbine, usually known as the Ljungstrm turbine, was originally invented by Swedish Engineer Fredrik Ljungstrm (1875 1964) in Stockholm, and in partnership with his brother Birger Ljungstrm he obtained a patent in 1894. The design is essentially a multi-stage radial turbine (or pair of 'nested' turbine rotors) offering great efficiency, four times as large heat drop per stage as in the reaction (Parsons) turbine, extremely compact design and the type met particular success in backpressure power plants. However, contrary to other designs, large steam volumes are handled with difficulty and only a combination with axial flow turbines (DUREX) admits the turbine to be built for power

greater than ca 50 MW. In marine applications only about 50 turbo-electric units were ordered (of which a considerable amount were finally sold to land plants) during 1917-19, and during 1920-22 a few turbo-mechanic not very successful units were sold.[3] Only a few turbo-electric marine plants were still in use in the late 1960s (ss Ragne, ss Regin) while most land plants remain in use 2010. Statorless turbine. Multi-stage turbines have a set of static (meaning stationary) inlet guide vanes that direct the gasflow onto the rotating rotor blades. In a statorless turbine the gasflow exiting an upstream rotor impinges onto a downstream rotor without an intermediate set of stator vanes (that rearrange the pressure/velocity energy levels of the flow) being encountered. Ceramic turbine. Conventional high-pressure turbine blades (and vanes) are made from nickel based alloys and often utilise intricate internal air-cooling passages to prevent the metal from overheating. In recent years, experimental ceramic blades have been manufactured and tested in gas turbines, with a view to increasing Rotor Inlet Temperatures and/or, possibly, eliminating aircooling. Ceramic blades are more brittle than their metallic counterparts, and carry a greater risk of catastrophic blade failure. This has tended to limit their use in jet engines and gas turbines to the stator (stationary) blades. Shrouded turbine. Many turbine rotor blades have shrouding at the top, which interlocks with that of adjacent blades, to increase damping and thereby reduce blade flutter. In large landbased electricity generation steam turbines, the shrouding is often complemented, especially in the long blades of a low-pressure turbine, with lacing wires. These wires pass through holes drilled in the blades at suitable distances from the blade root and are usually brazed to the blades at the point where they pass through. Lacing wires reduce blade flutter in the central part of the blades. The introduction of lacing wires substantially reduces the instances of blade failure in large or low-pressure turbines. Shroudless turbine. Modern practice is, wherever possible, to eliminate the rotor shrouding, thus reducing the centrifugal load on the blade and the cooling requirements. Bladeless turbine uses the boundary layer effect and not a fluid impinging upon the blades as in a conventional turbine. Water turbines Pelton turbine, a type of impulse water turbine. Francis turbine, a type of widely used water turbine. Kaplan turbine, a variation of the Francis Turbine.

Turgo turbine, a modified form of the Pelton wheel. Cross-flow turbine, also known as Banki-Michell turbine, or Ossberger turbine. Wind turbine. These normally operate as a single stage without nozzle and interstage guide vanes. An exception is the olienne Bolle, which has a stator and a rotor