Developing a Gas Turbine Test Rig for Educational and Research Purposes

Home > Case Studies > Developing a Gas Turbine Test Rig for Educational and Research Purposes

Engineering Challenge

The primary engineering challenge was to design a gas turbine test rig suitable for both teaching and research purposes while maintaining low running costs to appeal to universities and other educational institutions. Commercial-sized gas turbines are prohibitively expensive to operate, and manufacturers are reluctant to use them for educational and research purposes due to the distraction from their primary industrial applications.

SCITEK Consultants Ltd. addressed this challenge by utilising commercially available gas turbines typically used in model aeroplanes and drones. These smaller turbines are relatively inexpensive to purchase. However, the main engineering hurdle was installing instrumentation to measure pressure and temperature at various engine points to characterise its performance effectively.

Required Skillsets

To overcome this challenge, SCITEK leveraged its extensive skill set, including:

Anatomy of Small Gas Turbines: Detailed understanding of small gas turbines to disassemble and install numerous small sensors without affecting operation and performance.
Engine Balance: Ensuring the engine remains balanced after reassembly.
Instrumentation: Integrating instruments to measure fuel flow, thrust, and environmental parameters.
Control and Data Acquisition: Developing a robust control and data acquisition system.
Reliable Software Development: Creating control software capable of reliably starting the engine, a task particularly challenging for small gas turbines.

SCITEK’s Role

SCITEK identified the need for an affordable and versatile gas turbine test rig. The company was responsible for the design and manufacture of the mechanical and instrumentation components of the rig. SCITEK sourced engines from various suppliers to allow the test stand to be configured for different engine sizes based on customer requirements.

SCITEK stands out as the only company offering a heavily instrumented small gas turbine test stand, making it the preferred choice for this project.

Key Steps in Developing the Solution

Mechanical Design: Tailoring the test stand to fit customer test cell configurations.
Fuel Storage and Control: Ensuring compliance with safety regulations.
Control System Design: Developing a sophisticated control system.
Manufacturing: Producing the mechanical and electronic components.
Commissioning: Assembling and testing the rig.
Installation: Collaborating with the customer to install the rig at their facility.
Handover and Training: Providing comprehensive training to ensure effective use of the rig.

Technologies and Methodologies

SCITEK relied on its extensive experience and expertise in small gas turbine technology, mechanical and electrical design, software development, manufacturing, and testing. Innovative approaches included the installation of small-sized instrumentation in a compact engine format.

Overcoming Challenges

One significant challenge was adapting the control system to accommodate various types of engines required by customers. SCITEK overcame this by leveraging its deep technical knowledge and flexible engineering practices to ensure compatibility and reliable operation across different engine models.

Conclusion

SCITEK Consultants Ltd. successfully developed a versatile and cost-effective gas turbine test rig that meets the needs of educational and research institutions. This project highlights SCITEK’s unique capabilities in mechanical design, instrumentation, and software development, solidifying its position as a leader in the field.

For more information or to discuss how SCITEK can assist with your engineering challenges, please contact us. We look forward to exploring how our expertise can benefit your projects.