STANDARD OPERATING PROCEDURE AND SAFETY GUIDE FOR ROVER GAS TURBINE APPARATUS (Located in Rm.
Table of Contents 1. Scope ........................................................................................................................................4 1.1 Objective ............................................................................................................................4 1.2 Regulations ........................................................................................................................4 2.Apparatus Overview and objective ..................................
H-17, Head Hall floor plan Figure 1: H-17, Head hall floor plan 3
1. Scope 1.1 Objective This standard operating procedure is intended to provide operating instructions and safety information for the Department of Mechanical Engineering’s Rover Gas Turbine experiment apparatus located in H-17, Head Hall. This document is intended as a guideline and supplement to proper training that must be provided by qualified personnel before the apparatus is operated.
There is a fuel burner, fuel operating lever and fuel accumulator bulb on the apparatus. The fuel burner contains a fuel atomizer, which sprays jets of fuel into the combustion chamber for the combustion process. The fuel operating lever connects/disconnects the fuel supply to the combustion chamber by controlling a fuel shut-off valve in the fuel burner. The fuel accumulator stores fuel under pressure and ensures good fuel atomization for engine starting purposes.
Figure 2: Apparatus components overview 6
Figure 3: Apparatus components overview 7
Figure 4: Apparatus components overview 8
The hot gases from the combustion chamber are guided through volute (air passage assembly) to the turbine rotor, where the gases expand against the single stage axial turbine and work is done. The turbine is a nimonic forging in which the blades and disc are machined integrally. The blades are of free vortex design. The turbine rotor is attached to the compressor shaft by a single large diameter nimonic bolt.
Figure 5: Apparatus components overview 10
Figure 6: Apparatus components overview 11
Figure 7: Apparatus components overview The apparatus consists of a control desk, which has a fuel tank located at its top. The fuel is pumped in to the fuel tank by a fuel pump located at the bottom of control desk.
H-17 Lab) to the fuel pump is controlled by main fuel supply valve. There are number of pressure and temperature displays of the apparatus on the control desk during operation of the apparatus. The impeller tip pressure gauge and compressor delivery pressure gauge measure and display the impeller tip pressure of the compressor and entering air pressure of the compressor.
Figure 8: Apparatus components overview 14
Figure 9: Apparatus components overview 15
Figure 10: Apparatus components overview 16
The compressor housing consists of an oil return pipe in front and an oil sump at the bottom. The oil sump collects the oil already used by the IS/60 engine/Rover Gas Turbine and has the capacity of five pints. The used oil in the oil sump can be drained by unscrewing the oil sump drain plug. There is an oil temperature bulb screwed with the oil sump to measure the temperature of oil in the sump and the temperature is indicated on oil temperature gauge.
Figure 11: Apparatus components overview 18
Figure 12: Apparatus components overview 19
The pressure of oil pumped into the oil filter is measured and indicated on the oil pressure gauge. There is an oil level dipstick to check the oil level in the IS/60 engine.
The oil filler tube is situated at the top of the compressor housing together with the breather pipe. 3. Hazards and Controls Evaluation:3.1 Possible fire event The Rover gas turbine apparatus is associated with high temperature gases and combustible fuel. There may be a fire event if the apparatus is not handled carefully and instructions are not followed. In the event of fire, evacuate the room immediately. Pull the nearest fire alarm (located outside room).
Figure 14: Ventilation controls of room H-17 3.3 Kinetic, Thermal and Acoustic The moving parts associated with the apparatus are the load adjusting wheel, static weight, weight adjusting wheel and the output pinion shaft on which the compressor and turbine are mounted. Load is applied on the IS/60 engine by turning the load adjusting wheel. It does not pose any serious kinetic threat if handled carefully.
your hands away from the meshed gears assembly as meshed gears are also rotating. The applied load on the engine is balanced by a static weight, suspended by a spring (see figure 5). The weight adjusting wheel and the suspended static weight does not pose any kinetic threat if handled carefully during the operation. The output pinion shaft connected to the dynamometer however poses serious threat. Body parts should be kept away from the shaft while the engine is running.
The apparatus is associated with very high temperatures. The combustion chamber and the engine exhaust are associated with very high temperature gases approximately 600°C-700°C. Do not touch the main air casing, combustion chamber and engine exhaust while the engine is operating as they are an extreme thermal hazard. There is no risk associated with the effluent gases since the exhaust ductwork is extended to the roof top and exhausted to the atmosphere.
The IS/60 engine is associated with high intensity sounds and is an acoustic hazard if ear plugs are not worn by the operator while engine is in operation. (Wearing ear plugs is mandatory for the operator’s safety) 3.4 Electrical There is no electrical hazard associated with the apparatus if the apparatus is handled carefully and instructions are followed.
Figure 17: Electric outlet for fuel pump 3.5 Fuel and Water The fuel source that is used is diesel. Diesel fuel is combustible and reactive. The fuel is stored in the main fuel tank located outside the H-17 Lab. The fuel supply to the control desk fuel tank is controlled by the main fuel supply valve (see figure 20) and the fuel pump. The main fuel tank, fuel pipeline, control desk fuel tank and fuel pump should be checked for any leakage before proceeding with the experiment.
should be collected by proper means to prevent fuel spillage. Diesel is combustible and exposure of spilled diesel to a spark can cause an ignition. Water flow is supplied to the apparatus for the operation of the dynamometer and for the cooling of oil. A water/oil heat exchanger cools the oil. Water from the heat exchanger as well as the dynamometer is sent to water exhaust drain. Always make sure that water is flowing to drain.
Figure 18: Fuel and Water Figure 19: Main fuel tank location 3.6 General, physical and equipment concerns The apparatus is associated with high pressures and very high temperatures. The gas turbine incorporates a temperature control as an overriding safeguard to high temperatures. This device consists of a temperature sensing tube that projects into the exhaust stream. It is connected by capillary tubing to the fuel control unit.
the predetermined level, the temperature control automatically reduces the fuel supply to the fuel burner unit, until the temperature falls below the engine design limit. Excessive overheating of the engine results in a fuel supply termination and an automatic engine shut-down. Figure 20: Main fuel supply valve location The fuel control unit also has a mechanical governor to maintain the engine speed at 46,000 RPM.
properly adjusted first rather than the mechanical governor. The majority of maintenance operations will be conducted using the RPM indicator, so this device should be checked regularly for proper operation. 3.7 Access All personal in the H-17 laboratory should be preauthorized by the faculty in charge or under the supervision of authorized personal (lab technician or teacher assistant).
4.2 Experiment Preparation/Startup Following steps should be carried out to prepare for the experiment: • Ensure that the fuel drain assembly (See figure 7) is not faulty and that the apparatus is not inclined upwards at the exhaust end, so that complete fuel drainage is not impaired. If fuel drainage is affected, then there is a possibility of engine over speeding at start-up due to a large amount of residual fuel accumulation in the combustion chamber or main air casing.
• Ensure that the air intakes are clean and clear. • Turn on the water supply by opening the main water supply valve. The water pressure should be 15 psi minimum for oil cooling and can be checked by the water pressure indicator on the apparatus. Open the water flow to the apparatus 15 minutes prior to starting the experiment so that the water is at a constant room temperature (21°C). Also ensure that the water used by the apparatus for the cooling of oil and for the dynamometer is properly draining.
• • • • • Exhaust gases temperature indicator - (displays the temperature of exhaust gases leaving the exhaust). Impeller tip pressure gauge – (displays the compressor impeller tip pressure). Turbine inlet pressure manometer – (displays the pressure of gases entering the turbine). Turbine outlet pressure manometer – (display the pressure of gases leaving the turbine). Airmeter depression manometer – (displays the pressure drop across the airmeter venturi).
Figure 21: Data locations and functions 34
4.4 Operating Procedure 4.4.1 Experiment procedure After preparing for the experiment and following all the steps mentioned in section 4.2 to prepare for this experiment, follow the following steps to complete the experiment: • With the fuel operating lever (mounted on the fuel burner) in the closed position, turn the starter motor switch key clockwise through 60° (i.e. to Position 3) and hold against spring pressure when starter motor is operating.
• When the engine speed reaches a constant ≈ 400 RPM on the tachometer (RPM indicator), open the fuel burner (atomizer) by turning the fuel operating lever and the engine will fire up. The combustion of air in the combustion chamber will be indicated by the “ROARING” of the engine. • At approximately 2500 RPM, after the cut-out switch has disconnected the starter motor, turn the starter key to “OFF” and remove the key. • When the engine reaches a steady speed, check the following: a.
• Turn off the fuel pump. • Turn off the main fuel supply valve (see figure 20) and the control desk fuel control knob. • Turn off the water supply to the apparatus by turning the main water supply valve OFF. • Before leaving the lab, ensure that there are no objects left on the apparatus. Clean the apparatus with a piece of cloth. 4.4.3 Emergency Shutdown Follow the following procedure in given order to shut down the gas turbine apparatus in case of emergency: 1. 2. 3. 4. 5. 6. 7. 8.
5.1 Periodic & Operational Inspections Visual inspections are the responsibility of the person who is conducting experiments on a regular basis with the Rover Gas Turbine apparatus and should be carried out each time before operating the apparatus. A complete periodic inspection of the apparatus shall be performed by the person who is conducting experiments on a regular basis with this apparatus. That same person will alert the faculty supervisor of any deficiencies in the apparatus.
Appendix ‘A’ 39
Appendix ‘B’ 40
Appendix ‘C’ 41
Appendix ‘D’ 42
Appendix ‘E’ 43
