To and Develop Lubricator for Gas Generators - Research Proposal Example

Proposal to Research and Develop Lubricator for Gas Generators Indiana [Publish Proposal to Research and Develop Lubricator for Gas Generators Analysis Problem Statement Internal combustion engines running on natural gas tend to suffer from early fatigue of valves. The exhaust valves tend to wear out very early compared to the inlet valves. Other internal combustion engines running on other fuels such as gasoline, heavy fuel oil, light fuel oil and diesel do not experience such rapid failure of valves.

The constant need to replace gas engine valves increase maintenance costs and reduces the reliability of such engines. Research and Development Objective This research aims to formulate a practical method to prolong the working life of gas internal combustion engine valves. Hypothesis Phase Root Cause Identification A number of different factors may be responsible for early gas engine valve failure. Literature reviews would include a number of different kinds of gas engines operating in differing conditions which would lead to a wide range of factors responsible for gas engine valve failures.

A review of the available literature would be undertaken to identify recognised reasons for failure of gas engine valves. The classified factors would then be investigated systematically in order to categorize what factors are pertinent for the current investigation. The classified factors would be reviewed for their applicability to the current investigation to allow simplicity during implementation and testing phase. Identified causes for gas engine valve failure would be solved using solutions from the literature review, expert opinions as well as personal ingenuity.

Implementation and Testing Implementation Implementation of solutions in the current research could take a number of different forms. The implementation could involve modified valves, lubrication systems or other forms of solutions. These solutions will be implemented on a gas genset manufactured by Green Power, producing 5 kVA (4.2 kW) of electrical power at 1,600 rpm. The engine powering this genset is a 150 cc natural gas engine (in comparison to gasoline and natural gas hybrid engines). It is clear that any form of solutions implemented would be restricted to the gas inlet plenum, the carburettor and the valve assembly (also known as the “head”).

Moreover, the implementation of solutions would require light fabrication involving lathe, milling and some welding operations. Therefore, the implementation phase would require direct access to a machine shop and fabrication facilities. Testing The core objective is to prolong the life of gas engine valves. The primary object of interest during testing would be the effective life of the gas engine valves. A number of established symptoms are available to gauge the aging process of gas engine valves.

The final measure of gas engine valve failure is enough leakage of either the air fuel mixture or the exhaust gases to cause interruptions in the controlled combustion processes. Once gas engine valve failure occurs, synchronised combustion is not possible anymore leading to a failed engine. The various solutions would be tested to the point of failure, keeping in mind that the gas engine will not be run continuously but in a periodic fashion with a defined frequency. This would allow a replication of actual running conditions without accelerating the actual gas engine valve wear process.

Analysis Data concerning gas engine valve failure period would be collected from a number of different runs in order to compare the efficacy of various solutions. Implemented solutions that produce the longest gas engine valve life compared to original failure periods would be taken as successful solutions. Literature Review Research has firmly established that one of the chief causes for power loss in engine performance is engine valve failures. As engine valves deform due to excess heat flux at the valve surface, they are more likely to deform.

This in turn leads to deformed valve seating surfaces which causes the air fuel mixture and the exhaust gases to leak (Duan, Li, & Zhang, 2012). In terms of vulnerability, the exhaust valve is more susceptible to failure than the inlet valve. The exhaust valve has to deal with heated gases coming out of the cylinder after combustion. This leads to greater heat flux faced by the exhaust valve as compared to the inlet valve. Hence, it is more common to notice exhaust valve failures rather than inlet valve failures (Munro, 2103).

Internal combustion engines may be able to operate even when valves have begun to leak. However, continuous operation of such engines often leads to spectacular failures such as the valve dislodging and damaging the piston (Tai, 2006). Valve replacement is a necessity once valve leakage begins to express itself through signs such as delayed start up, loss of engine power etc. Accumulated experience and gas flow testing indicates that natural gas engine valves are more prone to failure than other fuel powered internal combustion engines (Hu, 1944).

A number of techniques exist for prolonging valve life such as better metal hardening techniques, better alloy composition to allow for higher temperature operation, greater valve material and seat material hardness as well as lubrication. References Duan, C. F., Li, W., & Zhang, J. L. (2012). Simulation Study on Heat Transfer Performance of Engine Exhaust Valve. Advanced Materials Research 591-593 , 639-643. Hu, S.-C. (1944). Study of Exhaust-Valve Design from Gas Flow Standpoint. Journal of the Aeronautical Sciences 11(1) , 13-24. Munro, C. D. (2103). Analysis of a failed Detroit Diesel series 149 generator.

Engineering Failure Analysis . Tai, C. (2006). US10 Capable Prototype Volvo MG11 Natural Gas Engine Development: Final Report: December 16, 2003-July 31, 2006. Diane Publishing Co.