EXHAUST DUCT FABRICATION 2014....2

FABRICATION OF ENGINE EXHAUST DUCT FOR CYLINDER NINE TO PROCTECT TURBO CHARGER

RESEARCH AND DEVELOPMENT PROPOSAL FOR FABRICATION OF

ENGINE EXHAUST DUCT

BY

KENYA ELECTRICITY GENERATING COMPANY LIMITED

TEAM.

JULIUS ODUMBE

IBRAIM ILIGA

JUMA NGAO.

YEAR: January, 2014

RESEARCH AND DEVELOPMENT PROPOSAL FOR FABRICATION OF

ENGINE EXHAUST DUCT

1.0 Abstract

Studies have shown the new model engines have re disgned the exhaust duct to save the turbo charger damages as shown below.

2.0Table of Contents

1.0 Abstract..................................................................................................................................... 1 2.0 Table of Contents .....................................................................................................................2 3.0 Definitions ............................................................................................................................... 3 4.0 Introduction .............................................................................................................................4 5.0 Background ..............................................................................................................................5 6.0 Overall Objectives of the project .............................................................................................6 7.0 Description of the proposed project .................. .....................................................................7

8.0 Plan of Action ...........................................................................................................................8 9.0 Estimated Budget for the Initial Experiment ............................................................................9 10.0 Project Timetable ...................................................................................................................10 11.0 KenGen personnel..............................................................................................................11 12.0 Conclusion ............................................................................................................................ 12 13.0 References ............................................................................................................................. 13 14.0 Appendices ............................................................................................................................ 14 14.1 Comparison of original exhaust duct and newly redigsned at Kipevu......................... ........15 14.2 Photograph of the original spare exhaust duct and the fabricated one in Kipevu............... 16 14.3 A typical 5 megawatt modular total flow turbine generator by Langson Energy ........... ...... 17

3.0Definitions

1. Duct : - means the connecting pieces from one expansion bellow to another and act as manifold for cylinder head. 2. Gases: - means exhaust leaving the combustion chamber heading to the chimmey. 3.Ccollection trap: - is a recesses curved to collect any particles from engine heading to turbo charger turbine. 4.Aarrows Flow: - means flow of exhaust gases direction.5. Debris:- collection of particles from engine or along the exhaust duct.

4.0 Introduction

Kipevu engines were designed with straight exhaust duct which collect the exhaust gases from online cylinder heads to turbo charger. The gases drive the turbo charger and extract the hot gases out to the exhaust chimmeys and the same time compressor wheel draw in fresh air to the engine combustion chamber.

When the above operation takes and any failure of engines like valve stems shear due to fatique stress or debris from the exhaust duct, they carried straight to the turbo charger and hence the failures of several turbo charger rotors since the power station was commissioned.

PROPOSED SOLUTION

The designed duct is to replace the original designed on cylinder nine in a way with which can trap the debris from the cylinders and the exhaust duct before they damage the rotor.

FUNDING

The proposed duct can be fabricated from local materials and within Kipevu facilities assembled and installed at the cost of ksh.800.00, Or can be tendered to the moulding factory at an approxiamately ksh.1.8million per duct.

EXPERTISE

The proposed exhaust duct will save the damaging of turbo charger rotary parts which the cost of a new one is approaximately ksh.35million. The duct designed with an off cut and near the main flange to turbo charger bellow and inclined to enable debris fall in and later removed by opening the bottom flange.

TABLE OF CONTENTS

a. 1 pc of 260mm dia.x 12mm thick mild steel elbowb. Two pcs mild steel l flanges machined and drilled to sizec. Welding rods low hydrogend. Other preparation tools e.g. welding machine, grinding etc.

ORIGINAL DUCT

SHOWING THE FACE WHICH IS IN CONTANT CYLINDER

PROPOSED DESIGN

DIRECTION OF FLOW

INTIAL FABRICATION

.

PHOTO SHOWS TRAPPING GAP AND MACHINING OF THE FLANGE FACES