Transcript 2013 APTA First bus maintenance webinar

APTA Bus Maintenance Webinar
• Part 1
Introducing the 2013 Diesel Engine
Speaker: Tom Hodek, Cummins, Inc
• Part 2
Long Beach Transit: Embracing CNG
Speaker: Rolando Cruz, LBT
1
APTA Maintenance Webinar
- Introducing the 2013 Engine
Tom Hodek
January 24, 2013
Special Thanks
3
Discussion Topics
 Emissions Regulation
– Past and Present
– How it has driven technology
 2013 Impact on Maintenance
– OBD / Fault Codes
– Hardware Changes
– Service Tools
 Future Regulations
– GHG Regs
– Predicted Maintenance Changes
4
2010: Near-Zero NOx and PM
NOx / NOx+HC
Particulate
0.6g/HP-hr
0.6
12
10.7g/HP-hr
0.5
10
0.4
8
6.0g/HP-hr
6
0.3
5.0g/HP-hr
0.25g/HP-hr
4.0g/HP-hr
0.2
4
2.5g/HP-hr
0
1988 1990
5
0.1g/HP-hr
1.2g/HP-hr*
0.2g/HP-hr
2
1995
2000
2005
2010
2015
2020
0.1
0.01g/HP-hr
Urban Bus 0.05g/HP-hr
0
1988 1990
1995
2000
2005
2010
2015
2020
Emissions Reduction Impact
2000
=
6
1990
2000
2010
Nox (g/hp-hr)
11
4
0.2
PM (g/hp-hr)
0.59
0.05
0.01
Emissions Reduction Impact
2000
2013 (2010)
=
(20)
7
1990
2000
2010
Nox (g/hp-hr)
11
4
0.2
PM (g/hp-hr)
0.59
0.05
0.01
Emissions Reduction Impact
1990
=
8
1990
2000
2010
Nox (g/hp-hr)
11
4
0.2
PM (g/hp-hr)
0.59
0.05
0.01
Emissions Reduction Impact
1990
2013 (2010)
=
1990
2000
2010
Nox (g/hp-hr)
11
4
0.2
PM (g/hp-hr)
0.59
0.05
0.01
(55)
9
Evolution of Technology
NOx, PM
Selective Catalytic
Reduction
Diesel Particulate
Filter
Cooled Exhaust Gas
Recirculation
Electronic Fuel Systems
Air to Air Aftercooling
1990
10
2000
2010
2020
Evolution of Technology
CO2
NOx, PM
and
Fuel
Efficiency
Selective Catalytic
Reduction
Diesel Particulate
Filter
Cooled Exhaust Gas
Recirculation
Electronic Fuel Systems
Aftercooling
1990
11
2000
2010
2020
12
Integrating Critical Subsystems
Filtration and
Diesel Exhaust Fluid
Electronic
Controls
Combustion
Technology
Aftertreatment
System
Turbochargers
13
Fuel
Systems
Cummins 2013 Engines
 Same NOx and PM emissions regulations as 2010
– 0.2g NOx and 0.01g PM
 Same base engine and aftertreament as 2010 - 2012
– New ECM
• Integrated engine and aftertreatment controls
– Intake air throttle for closed loop control (emissions)
 OBD (On-Board Diagnostics) required – Diesel Only
– New fault codes added to monitor emissions sytems
14
New ECM
15
Pictures of Air Intake and ECM
New Air Intake Throttle
16
What is OBD?
 On-Board Diagnostics
– Monitors nearly every component that can affect the
emissions control system
– Tests emissions-related components and systems to
detect malfunctions
– Similar to passenger car systems or Cummins
Turbodiesel in RAM Pick-up / Chassis Cab which
have OBD-II systems for many years
17
Malfunction Indicator Lamp (MIL)
 Located on the dash of the vehicle
 It illuminates to indicate an OBD related fault
 Simplifies diagnostic and repair procedures for the
technician and servicing location
18
On-Board Diagnostics (OBD)
Aftertreatment System Monitoring
ECM Monitoring
Engine System
Monitoring
Service Tools
19
MIL
What Does OBD Mean For The Transit Industry?
 Better monitoring of emissions systems
 Increased accuracy in determining the root cause of
emissions-related faults
 Provides early warning
of malfunctions
20
Maintenance Changes for 2013
 Fuel Filter change intervals (now at every oil change)
– NanoNet fuel filter medium
 Inspection intervals reduced
– Radiator cap and SCA levels (20K to 15K miles)
– Engine drive belts & tensioner (40K to 30K miles)
– Air compressor discharge line (80K to 60K miles)
 Aftertreatment servicing
– Frequent regeneration faults
 OEM Coolant Recover Tanks
– Add Coolant to recovery tank, not top tank
 OBD Fault Codes
– New fault codes all added for emissions compliance
21
– Cummins Insite / Generic Scan Tool
Service Tools
 INSITE – Maintains ability to perform Cummins specific
special tests whereas a generic scan tool cannot.
 QSOL (QuickServe OnLine)
 EDS – Next Generation Diagnostic Tool product offered
through Cummins certified repair locations.
 OBD connector style will be the same 9-pin connector
used previously
22
Evolution of Technology
CO2
NOx, PM
and
Fuel
Efficiency
Selective Catalytic
Reduction
Diesel Particulate
Filter
Cooled Exhaust Gas
Recirculation
Electronic Fuel Systems
Aftercooling
1990
23
2000
2010
2020
Future Regulations
 2014 GHG Standards
– CO2 Limits: Reduce by 3% in 2014 to 9% total in 2017 over
a 2010 industry baseline
– N2O and CH4 Limits (already met in 2010)
 Cummins EPA 2013 compliant engines meet 2014
Greenhouse Gas and Fuel Efficiency standards
 OEM (TVM) needs to use tires that are certified for
compliance with GHG reduction (rolling resistance)
24
Hybrid Engine Regulations
 Cummins will offer Hybrid engines that meet both EPA
and ARB 2013 certification requirements.
 Hybrid ratings will be distinct from conventional (nonHybrid) ratings
 Hybrid ratings with Engine Start Stop (ESS) capability will
be distinct from non ESS Hybrid ratings and will be limited
to one ISB Transit Bus rating. (First availability: July
2013)
25
Future Development
 Vehicle Manufacturer Integration
– All subsystems
 Cooling System Improvements
 Fuel Economy
– GHG Compliance in 2014 and 2017
 Aftertreatment
– Improved Efficiency
 Future Maintenance Requirements
– None at this time
26
Thank You
27
Long Beach Transit
Embracing CNG
APTA Webinar
January 24, 2013
Agenda
 Background
 Why CNG?
 Procurement
– CNG Station / Site Modification
– CNG Buses
 Training
 SCRTTC
LBT Mission
 Long Beach Transit is
in business to provide
public transportation
services that enhance
and improve the quality
of life for the people in
our community.
 We serve Long Beach,
along with 11 other
cities – 98 square miles
 29 million ridership
Quality of Life
 Sustainability – drives our decision to clean
up emissions on our vehicles
 Diesel Coaches – all purchases prior to 2003
– Installed particulate traps on diesel buses in 2001
– Early adopter of ultra-low sulfur diesel
 2003 made a decision to go gas hybrid
– Procured 89 gasoline hybrid electric buses to date
– Staff and operations vehicles are actively being
replaced with hybrids
 2010 – completed alternative fuel study with
WVU – essence maintain diverse fuel choice
CNG Plans
 LBT planned on CNG for 2015
 CNG economically good vs gas hybrid
– Lower Operating Costs w/ tax credit
– Infrastructure costs - break even point at one
property for 40 coaches & other 70
 ISE bankruptcy in late 2010
 CNG purchases moved to 2012
– Must build a CNG station within one year
– Modify both facilities to accommodate CNG
– Procure 64 buses with CNG engines
Fleet Makeup
 Revenue Fleet
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171 – 40’ New Flyer buses (89 gasoline electric hybrid)
13 – 60’ New Flyer articulated buses
64 CNG – 40’ Gillig BRT
10 Electric buses in 2014
 Other Services
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17 Dial-A-Lift vans (Paratransit)
4 boats (2 AquaBus & 2 AquaLink)
1 Charter (Prevost)
 Support Vehicles
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31 service veh for supervisor, staff & operators
25 maintenance service vehicles
 TOTAL of 326 VEHICLES
 4 Propulsion Systems (Diesel, Gasoline Hybrid,
CNG & All-Electric)
CNG Station, Infrastructure
Modification & Buses
Project Plan
CNG Project Goals
 Provide CNG fueling station able to fuel
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77 – 95 coaches
Upgrade infrastructure to accommodate
repairs in entire shop & fuel island
Prepare utilities for CNG (gas &
electricity)
Buy 64 CNG buses
Get LBT transitioned to CNG
Environmental understanding - ESMS
Project Constraints
 Goal 1 year – anticipating delivery of
new CNG coaches
 Budget for station was tight – need to
keep within $6.2 million
 Heavy workload on facility team
– Limited Staff Experience for CNG
– Limited Staff Time for Project
 Need City approval & cooperation
(including LB Fire Department) – avoid
EIR if at all possible
CNG Station Contract Awarded
 4 qualified proposals received ranging
from $4.5 to $6.18 million
– Contract Awarded to Amtek Construction,
Lowest bid at $4.5 million
 Proposed Angi Energy Systems
– Compressors – five (500-scfm/250-hp)
– Gas Dryer - accommodate 3000 scfm
– Two (2) Buffer Storage paks
– 2 CNG fast-fill Dispensers & 1 slow
 Modify all of LJ facility (12 bays) & 3 bays
at AA facility
Maintenance Impact Station
 Need Daily inspections & scheduled
PM’s
 LBT chose to contract out
– Amtek – 1 year maintenance agreement
– Clean Energy – doing daily & oversight
 Going out to bid to award long-term
contract, still need some facility training
 Need to train all employees on Safety &
Maintenance on fueling
CNG Coach Purchases
 Piggy Back - contract with Gillig for 64
coaches (after full evaluation)
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Cummins Engine – ISL G - 280
ZF Transmission – Eco Life 6AP 1400B
CNG Tanks & Fueling System
Gas Detection w/ Fire suppression
Maintenance Impact Buses
 Fluids resulting from CNG / ISLG:
– A low ash engine oil
– A premium long life coolant
 Material Review & order
 Preventative Maintenance Impact
– Gas detectors & system health
– Inspection of CNG components, valves, piping,
leak detection, filter draining & replace
– CNG tank inspection at 3 yrs or 36,000 miles by
a “certified” inspector, required training and
CSA test for cert. LBT will do once per year.
CNG Training
Project Plan
Training
 Training Needs
– CNG Station / Site Safety
– CNG Tanks / Safety
– CNG Engine
 No one Stop Shopping
 LBT staff looked at all options
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–
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Amtek / ANGI
Natl Gas Vehicle Institute (NGVI)
Gillig, Cummins, Amerex
SCRTTC
CNG Site Awareness & Safety
 Facility - ANGI
(Fuel Station)
 Utility - CNG Safety
& Fueling
 Maintenance - CNG
Safety / Methane
detection
 Staff – CNG
Awareness
612 Total Hours
Bus Safety / Tank Certification
 Gillig CNG Safety,
PM, Air systems
 Amerex Fire &
Methane Detection
 NGVI Safety and
Tank inspection
 Tank Inspection –
SCRTTC via LB
City College
1,224 Total Hours
CNG Engine
 Cummins – 2 days
– Crash course - Cradle to Grave
– Taught by skilled technician
 SCRTTC Course
– 4 courses – total of 6 days
– Spread out over time and can do at a slower
pace with standardized course & trained
instructor
 LBT limited the amount of mechanics in
courses intends to expand
SCRTTC
Southern California Regional Transit
Training Consortium
The Future in Training
The SCRTTC Purpose
To provide a training resource
network, comprised of public and private
organizations, focused on the
development and employment of the
transit industry’s workforce that is
proficient in the standards, practices and
procedures for incumbent and new
workers.
The SCRTTC Overview
 California Corporation and 501 c (3) Non-Profit –
formed in 2005
 Partnership of 48 members consisting of Transit
Systems, Community Colleges, Affiliate
Members and Private Partners
 Provide research to demonstrate feasibility of a
new transit workforce development ‘Learning
Model’
 Develop and deliver Transit Training providing
the workforce knowledge of ITS standards,
practices, and procedures.
The SCRTTC Goals
 Develop a new “Learning Model” to increase the
professional and technical competency of the
Southern California public transit workforce
 Assure that this new “Learning Model” includes
the elements of Intelligent Transportation
Systems (ITS)
 Develop industry driven, competency based
courses that meet present and future needs
 Deliver standard courses to mechanics
throughout the region via colleges
SCRTTC Transit Members
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Southern CA Members
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Antelope Valley Transit
Authority
Arcadia Transit
Beach Cities Transit
Claremont Dial-a-ride / Pomona
Valley Transportation Authority
Commerce Municipal Bus Lines
Culver City Municipal Bus Lines
Foothill Transit
Gardena Municipal Bus Lines
Gold Coast Transit
LA DOT
La Mirada Transit
LA METRO
Long Beach Transit
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Montebello Bus Lines
Norwalk Transit
OCTA
OMNITRANS
Santa Clarita
Santa Monica Big Blue Bus
(BBB)
Torrance Transit Systems
Sunline Transit
Other Transit Agencies
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Fresno Area Express
Monterey-Salinas Transit District
Roaring Forks Transit Authority
San Joaquin RTD
SCRTTC College & Partners
College Members
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Cerritos College
Citrus College
College of the Desert
Colorado Mountain College
Cypress College
El Camino College
Golden West College
Kern Community College
District
LA Trade Tech College
Long Beach City College
Rio Hondo College
Saddleback College
San Diego Miramar College
Santa Ana College
Affiliate Members & Partners
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American Public Transportation
Association
Advanced Transportation
Technology and Energy
Initiative (ATTEi)
California State University - LB
Colorado Transit Association
UC, San Diego
USC - Mettrans
ATech Training Inc., Walton,
KY
Proterra, Golden CO
Clean Energy
Complete Coach Works
New Flyer of America
SCRTTC Training Hours
 Training Delivered - Life To Date
– Total Hours of training delivered: 50,184
– Total Participants trained: 3,504
 Cummins 8.9 Series (Level I, Insite, Level II):
– Total Hours of training delivered: 4,816
– Total Participants trained to date: 342
 CNG 1-day Safety:
– Total Hours of training delivered: 96
– Total Participants trained to date: 12
 CNG Cylinder tank inspection:
– Total Hours of training delivered: 576
– Total Participants trained: 36
CNG Training
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CNG Transit Vehicle Safety
Training - #SC-CG-4100-I
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Basic fuel characteristics regarding
flammability
Basic fuel characteristics regarding pressure
Basic pressure system design
Safety related pressure system components
Basic cylinder care & damage
Proper depressurization techniques
Pressure system component servicing
High pressure fitting servicing
Leak detection techniques
Cummins INSITE Diagnostic
Software - #SC-EN-1712-I
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Cummins ISL-G Engine Mgmt
System Level I - #SC-EN-1710-I
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Define Mass Air Flow Fuel Mgmt Systems
Identify, locate & test parameters with:
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Select, add and connect proper adapters to a
bus
Access, custom group, and verify parameters
Access, define, research, and clear fault codes
Produce snapshots, data logging, and
Graphing
Look up engine derate, enabling criteria and
other troubleshooting technique information
Navigate the Electronic service tools for
Cummins
DVOM
Temperature Sensors
a Pressure Sensors
Position Sensors
Voltage Producing Sensors
Mass Gas & Air Flow Sensors
Use INSITE to verify parameters
Cummins ISL-G Engine Mgmt
System Level II - #SC-EN-1711-I
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Diagnose faults using INSITE for:
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Ignition Systems
Temperature Sensors
Pressure Sensors
Position Sensors
Voltage Producing Sensors
Mass Gas & Air Flow Sensors
Use INSITE to verify parameters
The Difference in Courses
 Courses developed with the learning model
– College collaborates with transit agency (& vendors)
to develop curriculum
– Standard set of materials created & approved
 Beta Testing of course with Subject Matter
Experts – changes made to coursework
 Train-the-Trainer delivered to ensure
quality of trainers
 Courses refreshed every 3 years
Transit’s benefit in use of SCRTTC
 Standardized course
 Manage Technicians Time
– Less time off floor – can spread out (2–3 at a time)
– New Technicians come in, can get training
 Sharing of Resources –
– Reduced cost to each agency
– Multiple agencies come to course
 Technicians get to Network
 Colleges are familiar with transit agencies /
– Great recruitment for future
– Students can learn skills required for transit
The Future of Training
 Continued course development of
advanced technology
 More Partnerships with Vendor
– Vendor use of SCRTTC to develop course
will provide standardized, transit approved
courses
– Standard material (pre/post test, objectives,
student material/exercises, instructor
material)
 Sharing of Material & TTT with non-
regional members - expansion
For More
Information
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History & info of
SCRTTC at finger tips
Ability to look at any
class curriculum
On-line registration
for one or group
http://scrttc.com/
Rolando Cruz
[email protected]