Transcript Natural Gas Engines

Natural Gas 101
CNG vs LNG what is the difference?
Presented by:
Cal Macy Project Director
Pete Sparks Project Coordinator
Why study natural gas?
None of my friends drive one….
• Presented by:
– Cal Macy -Long Beach City College
ADVANCED TRANSPORTATION
TECHNOLOGY CENTER
Green Port Program
• Ports of LB and LA are going green
ATTE has been teaching “green” before it was a term
What will be the
propulsion for the new
Millennium??
NGV
NGV
CNG
Heavy-Duty
Fuel Cell
Natural
Hybrid
Cng/Lng
NGV
Gas
Motor
Natural
Vehicle
Gas
Vehicle
Direct
Injection
Common
Gaseous/
Series/
FCEV
Rail
Direct
parallel
Fuel Cell
alcohol
Injection
Lean
Hybrid
EV
based
Burn
fuels
Emerging
Alternative
Energies
Diesel
Engines
Gasoline
Engines
Hybrid
Cars
EV
Electric
Vehicles
•Natural gas is today’s key to a healthier tomorrow
What will be the
propulsion for the new
Millennium??
Range and Reliability are the two biggest
challenges for Alternative Fuels
Cost of fuel and availability are the
operator’s concerns
Where can I get CNG/LNG
for my car or truck?
Clean Energy
announced plans to
install LNG/CNG
fueling stations
across the nation at
existing Pilot/Flying
J Truck Stops in 33
states
Phase 1
150
new stations
$2.79/DGE
LB
1/25/2012
70 in 2012
80 in 2013
•Natural gas is today’s key to a healthier tomorrow
Where can I get
my car or truck serviced?
We can train the next generation of fleet technicians
The ATTE Centers have trained over 5000 fleet
technicians from all over the US, Canada, and
Mexico
ADVANCED TRANSPORTATION
TECHNOLOGY CENTERS
ALTERNATIVE
FUELS TRAINING
PROGRAMS
ADVANCED TRANSPORTATION
TECHNOLOGY CENTERS
•Long Beach was the first Clean City in California
•LBCC provided initial CNG & LNG Training for City fleets
•10 ATT Centers were established in 1993
ADVANCED TRANSPORTATION
TECHNOLOGY CENTERS
ATTE is a Consortium of 8 Regional Colleges Statewide
Providing Alternative Fuels Training since 1995
ATTE is the Statewide Training Solution
We make the complicated Simple!
Computerized Engine
Management
Cummins John Deere Detroit Caterpillar
•We have decades of experience on CEM systems
Electronic Engine Fuel
Management Systems
DETROIT DIESEL
DDEC& GFI SYSTEMS
•ATT provided training for the 1996 Olympics in Atlanta
Customized Training Programs:
In-Center seminars held in a manufacturer-style
classroom environment with an attached lab
Customized Training Programs:
OEM trainers for Kenworth & Peterbilt LNG drayage trucks
We WROTE the program!!
Live Engine Training on CNG & LNG
Demonstrators:
•Hands-on Training with Heavy Duty electronics training engines
•Cummins ISL G CNG/LNG
We WROTE the
•Cummins/Westport GX LNG
programs!!
•DDEC IV series 50/60G
•John Deere
Natural Gas Safety
•Cylinder Safety Inspection
•We stress safety & regulations
Natural Gas Properties
• Odorless
– Odorant (Ethyl Mercaptan) added
• Colorless
• Lighter than air
• Flammability range: 5-15%
– Compare with: diesel 1-6%, propane 2.2-9.5%,
hydrogen 4.1-74%
• High auto-ignition temperature
– 900-1170°F
• Non-toxic
– Displaces oxygen
Natural Gas Vehicle Storage
• Compressed Natural Gas: CNG
– Up to 3600- 5000 psi
– High pressure storage vessel
• 200:1 STP storage volume
• Liquefied Natural Gas: LNG
– Cryogenic temperatures (-250°F) up to 230
psi
– Well insulated storage vessel
• 600:1 STP storage volume
Compressed Natural Gas
Considerations
• Fueling infrastructure
– Strong
• Engine type
– SI or dual fuel
• Vehicle range
• Cylinder quantity and configuration
• Fast fill or slow fill
Compressed Natural Gas
• High pressure gas cylinders
– Flexible sizes and configurations
– Light weight (relative to LNG tanks)
• Safety
– Extreme high pressures
– Frequent CNG system inspections
Cylinder Type 1
• All steel or aluminum construction
• 100% pressure is held by the metal
• Vulnerable to rust and corrosion
Type 1 Cascade
Cylinder Type 2
• Hoop-wrapped aluminum or steel
• 55% pressure is held by metal, 45% is held by
the wrap
• Vulnerable to corrosion and wrap damage
Cylinder Type 3
•Fully wrapped aluminum
•80% pressure is held by the wrap, 20%
is held by the metal
•Vulnerable to cuts and abrasion
Cylinder Type 4
• All composite cylinder with a plastic liner
• 100% pressure is held by composite wrap
• Liner sealed to metal domes used for valve
threads
• Light weight, vulnerable to impact & cuts
Liquefied Natural Gas
Considerations
• Fueling infrastructure
– In development
– Mobile units available
• Engine type
– HPDI, SI or duel fuel
• Vehicle range
• LNG tank weight and size
• Vehicle utilization should be frequent
Liquefied Natural Gas
• Cryogenic storage tank
• Somewhat limited configurations and sizes
• Safety
– Extreme cold temperature
• Down to - 250°F
– Pressures up to 230 psi
– Robust design
Liquefied Natural Gas Tanks
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Stainless steel construction
Vacuum insulation
Specialized valves and components
Sizing typically 50- 150 gallons
Two distinct types
– Integrated LNG pump and vaporizer
– Pressure flow with external vaporizer
Liquefied Natural Gas Tanks
• Integrated LNG pump and vaporizer
– Utilization of any temperature LNG
– Up to 5000 psi CNG output
• Electronically regulated
– HPDI equipped engines
Liquefied Natural Gas Tanks
• Pressure flow with external vaporizer
– Requires utilization of “warm” LNG
– Up to tank pressure output
• < 230 psi
• Mechanical regulation
– SI or dual fuel equipped engines
Natural Gas Engines
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Westport HD15
CWI ISL G
CWI ISX12 G
Other engines/ options
– John Deere
– Detroit Diesel
– CAP dual fuel
Westport HD15 Engine
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15 liter compression ignition
Direct injection diesel pilot
Up to 475 HP, 1750 lb-ft torque
Active emissions aftertreatment system
CWI ISL G Engine
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8.9 liter spark ignition
Mass air/ gas electronic fuel injection
Up to 320 HP, 1000 lb-ft torque
Passive three way catalyst emissions system
CWI ISX12 G Engine
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12 liter spark ignition
Mass air/ gas electronic fuel injection
Up to 400 HP, 1450 lb-ft torque
Passive three way catalyst emissions system
How does Natural Gas
work in the Engine?
Operating Pressures and
Safety
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Non-toxic
Lighter than air
CNG can displace oxygen
CNG highly flammable?
– Must be contained to be dangerous
– Window of flammability very narrow
• No open flames in the shop
• Safest fuel of all other fuels
• Pressure in system must be respected
Major
Components
of a
Compressed
Natural Gas
System
Fill Valve and Coalescent Filter
• NGV1 Fuel fill device needs to match pressure of cylinder
Must have dust cap installed after filling vehicle
Coalescing filter can be on fill inlet or supply line
One-Way Check Valve
•Allows fuel to flow in one direction only
Usually on fill line to prevent leakage in case of drive-away
Fuel Storage Cylinders
•3000 PSI
•Type 4
•3600 PSI
•Type 2
•High pressure storage
4 different types available
Several pressures available
Should all be matching pressure
Cylinder Shut-Off
Valve
•Isolates cylinder for servicing
•Special tool needed to open dead electronic valves
•Destroys seals in valve
Caution: pressure may still be present!
Pressure Relief Device
(PRD)
•Releases in case of excessive heat or pressure
Mounted on cylinder IN DIRECT PRESSURE
One-time failure--- vented to outside of vehicle
Cannot be removed and reused on another cylinder
Special design for type 4—all composite cylinders
Manual Shut-Off Valve
(Quarter Turn)
•Shuts off fuel to engine compartment
Emergency shut-off accessible from outside
Stainless Steel Fuel
Lines
•Seamless Stainless Steel Lines
Fittings and lines must be rated to withstand
3 times their system pressure
Relief loops to prevent vibration failures
Some vehicles use flexible lines with stainless weave
Pressure
Regulator(s)
Reduces cylinder pressure to system operating pressure
May have two regulators to drop pressure in stages
Pressure typically 120 psi or less depending upon system
Shut off Valves (Lock-Offs)
Prevents fuel flow unless engine RPM is present
• Controlled by PCM
Fuel Delivery to Engine
High pressure direct injection
Cummins ISL G Fuel Control Valve
Westport GX injector
Introduces fuel to intake air stream
Powerplant & Fueling Options
• Cummins/Westport ISL-G Natural Gas Engine
• Cummins/Westport ISX12-G Natural Gas
Engine
• Westport GX 15 liter Diesel/Natural Gas Hybrid
Engine
Powerplant & Fueling Options
ISL-G 8.9L Natural Gas Engine
Powerplant & Fueling Options
Cummins/Westport ISL-G
•Type - 4-cycle, spark-ignited, inline 6-cylinder, turbocharged
•8.9 Liter, coil on plug ignition (300v primary)
•Compressed Natural Gas (CNG – 3600psi) or Liquefied Natural Gas
(LNG)
•Dedicated & Optimized for natural gas fuel (105 parameters)
•Meets EPA and CARB 2010 emission requirements
•EGR and Catalyst (stoiciometric)
•Advertised Horsepower 250–320 hp
•Peak Torque 660–1,000 lb-ft
•PM’s differ from diesel
Powerplant & Fueling Options
ISX12-G 11.9L Natural Gas Engine
Powerplant & Fueling Options
Cummins/Westport ISX12-G
•Type - 4-cycle, spark-ignited, inline 6-cylinder, turbocharged
•11.9 Liter Compressed Natural Gas (CNG – 3600psi) or Liquefied
Natural Gas (LNG)
•Dedicated & Optimized for natural gas fuel (stoiciometric)
•Meets EPA and CARB 2010 emission requirements
•Advertised Horsepower 330 – 400 hp
•Peak Torque 1150 – 1450 lb-ft
•First time available engine braking option
•Available early 2013
Powerplant & Fueling Options
•LNG tank and pump
•(chassis mounted)
•Fuel injectors
•(under valve cover)
•Fuel conditioning
module
•Common-rail
•Hydraulic
•diesel
•pump
•fuel pump
•Control units
(drives LNG Pump) •(firewall mounted)
Westport GX 15 liter HPDI Diesel/NG Engine
Powerplant & Fueling Options
Westport GX HPDI Diesel/NG Hybrid
•Type - 4-cycle, pilot ignition, inline 6-cylinder, turbocharged
•15 Liter
•Proprietary Liquefied Natural Gas (LNG) design
•Dedicated & Optimized for natural gas fuel
•Meets EPA and CARB 2010 emission requirements
•Advertised Horsepower 400 – 475 hp
•Peak Torque 1450 – 1750 lb-ft
•Proven reliability since 2006
•Requires PM trap & SCR (urea) injection for EPA/CARB 2010
What Regulations Should I Be Training
my students to be aware of?
Regulations & Guidelines for CNG & LNG
Vehicle Operation and Maintenance
 NFPA 52
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-Covers installations of cylinders and components
CHP Title 13
-Covers state certification of installations and vehicles
CGA 6.4
-Covers visual inspection and qualifications of inspectors
ANSI/NGV-2/FMVSS 304
-Covers design, construction and testing of new cylinders
Manufacture’s Printed Guidelines
-Covers inspection, repair and condemnation
NFPA 52
Vehicle Installation Guidelines
 Covers proper installation and
system safety
 Hard copy or downloadable
 “Industry standard”
 California makes it a law
 OEM’s adhere to it
 Fire Dept. recognized
 Updated every few years
- www.nfpa.org
NFPA 52 Sections
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2.
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5.
6.
7.
8.
Administration
Referenced Publications
Definitions
General CNG Requirements
& Equipment Qualifications
General GH2 Requirements &
Equipment Qualifications
CNG Engine Fuel Systems
Service & Maintenance of
GH2 Engine Fuels Systems
CNG Compression, Gas
Processing, Storage, and
Dispensing Systems
9. GH2 Compression, Gas
processing, Storage, Dispensing
10. CNG Residential Fueling
Facilities
11. LNG Engine Fuel Systems
12. LNG Fueling Facilities
13. LH2 Fueling Facilities
14. LNG Fire Protection
15. Installation Requirements for
ASME Tanks for LNG
16. LNG and CNG on Commercial
Marine Vessels and Pleasure
Craft
CGA 6.4
Inspection Procedures
• Inspection procedures and damage
assessment
• Criteria for the acceptance or
rejection of containers
• Qualifications of inspectors
• CGA 6.4
Inspection Procedures
• Recommended minimum: inspection every 3
or 36,000 miles for life of container
• Defines 3 levels of damage and appropriate
actions for each
• Provides guidance on what the inspector must
look for and how to make service/disposal
determinations
• Manufacturer’s instructions take precedence
•Proper documentation and labels required
• CGA 6.4
Inspection Procedures
In addition, CGA 6.4 will provide what you need to know about:
• Brackets, straps, and mounting systems as recommended by the
container manufacturer
• Labeling information
• Appropriate inspection equipment
Compressed Gas Association, Inc.
4221 Walney Road, 5th Floor
Chantilly, VA 20151
703-788-2700
www.cganet.com
Hard copy or downloadable
Facility Considerations
Local laws and regulations vary
•NO Open flames or spark emitting equipment
•Sealed lighting
•Ventilation requirements
•Methane detectors and alarms
Each facility should obtain an Engineering survey by a
company specializing in CNG facilities to determine what is
needed at that location
Facility Considerations
•Local laws and regulations vary
•Each facility should obtain an Engineering survey
by a company specializing in CNG facilities to
determine what is needed at that location
Regulations & Guidelines for CNG & LNG
Vehicle Operation and Maintenance
• Know the codes
• Consult the experts
Questions? Contact one of the
Advanced Transportation Technology
& Energy Centers statewide
THANK YOU