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INGAS - Integrated GAS Powertrain
24 months Meeting, 27-28 October, 2010
Fiat 1.4L CNG performance - Presentation contents
• Engine tests at bench : 1st phase with base engine
• Engine characterization with CR 9.8 (full load + Willans)
• Engine improvements : CR = 11:0 + Turbo matching
• Engine tests at bench : 2nd phase with new hardware
• Engine characterization with CR 11 + VGT (full load + Willans)
Project number: 218447
27-28 October 2010
INGAS - Integrated GAS Powertrain
24 months Meeting, 27-28 October, 2010
Engine tests at bench : 1st phase with base engine
• Compression ratio : 9,8:1
• Turbocharger : IHI 150 CV
Project number: 218447
27-28 October 2010
INGAS - Integrated GAS Powertrain
24 months Meeting, 27-28 October, 2010
Engine tests at bench : 1st phase with base engine
• Partial load characterisation
• Willans lines
24
1000 rpm : WMEP = 1.78 bar and WSFC (eq. Gasoline) : 212.9 g/kW/h - R2 = 0.99992
2000 rpm WMEP = 2.05 bar and WSFC (eq. Gasoline) : 196.4 g/kW/h - R2 = 0.99995
3500 rpm WMEP = 2.29 bar and WSFC (eq. Gasoline) : 196.6 g/kW/h - R2 = 0.99990
5500 rpm : WMEP = 2.43 bar and WSFC (eq. Gasoline) : 210.4 g/kW/h - R2 = 0.99994
22
20
18
BMEP (bar)
16
14
12
10
8
6
4
2
0
0
Project number: 218447
20
40
60
Fuel flow (mg/cycle/L displacement)
80
100
27-28 October 2010
INGAS - Integrated GAS Powertrain
24 months Meeting, 27-28 October, 2010
Engine tests at bench : 1st phase with base engine
• Full load characterisation
• Constraints : max temperature inlet turbine = 950 °C
max cylinder pressure (Pcyl max + 3s) = 105 bars
120
250
100
Brake power (kW)
Torque (N.m)
200
150
Torque Nm
100
CRF Torque curve
50
80
60
40
Brake power kW
CRF Power curve
20
0
1000
1500
2000
2500
3000 3500 4000 4500
Engine speed (tr/min)
5000
5500
6000
0
1000
2000
3000
4000
Engine speed (tr/min)
Max torque :
Max power :
IFP : 226 N.m @ 2500 rpm
IFP : 90 kW @ 5000 rpm
CRF : 218 N.M @ 2040 rpm
CRF : 94 kW @ 5000 rpm
Project number: 218447
5000
27-28 October 2010
6000
INGAS - Integrated GAS Powertrain
24 months Meeting, 27-28 October, 2010
Engine improvements : CR = 11:0 + Turbo matching
Turbo matching : Simulation of 4 turbocharger configurations :
Compressor
Turbine
RHF3_BRL315_04
RHF3_TTW62P105NR
Garrett GT1238 (conf 2)
C224(38) 60 Trim 0.38 A/R
-
Garrett GT1446 (conf 3)
C224(46) 55 Trim 0.46 A/R
T202(43) 72 Trim 0.67 A/R
VGT Garrett GT1444 (conf 4)
C224(44) 60 Trim 0.44 A/R
T213(39)T84AR074vh65
IHI 150 CV (conf 1)
Pressure loss models :
0.5
Air filter
0.45
Exaust line
Pressure losses (bar)
0.4
Air cooler
0.35
0.3
2
y = 3E-06x - 0.0003x + 0.0144
0.25
0.2
2
y = 9E-07x - 9E-05x + 0.006
0.15
0.1
2
0.05
y = 2E-07x + 5E-05x - 0.0021
0
0
50
100
150
200
250
300
350
400
450
-0.05
Gaz flow (kg/h)
Project number: 218447
27-28 October 2010
INGAS - Integrated GAS Powertrain
24 months Meeting, 27-28 October, 2010
Turbo matching
3.5
3.0
0.7
0.7
2000 rpm
0.68
220000
0.66
2.5
0.64
200000
2.0
Compressor
C224(46) 55
Trim 0.46 A/R
180000
0.62
160000
0.6
1.5
140000
Pressure Ratio (t/t) P2c/P1c
Compressor IHI
RHF3 BRL315 04
(Base TC)
Pressure Ratio (t/t) P2c/P1c
3.5
3.0
0.68
200000
0.05
0.10
0.15
Corrected Air Flow (Kg/s)
0.20
3.5
180000
0.64
2.0
0.6
1.5
1
3
2
4
1.0
0.00
240000
0.66
4750 rpm
220000
0.64
2.0
0.62
200000
180000
0.6
140000
0.05
0.10
0.15
Corrected Air Flow (Kg/s)
160000
0.20
3.5
0.72
240000
0.68
260000
0.55
> 3000 rpm
3.0
1.5
120000
100000
Compressor
C224 (44) 60
Trim 0.44 AR
(associated with
VGT)
Pressure Ratio (t/t) P2c/P1c
Pressure Ratio (t/t) P2c/P1c
Compressor
C224(38) 60
Trim 0.38 A/R
0.62
160000
140000
0.7
280000
2.5
0.66
2.5
0.55
1.0
0.00
220000
3.0
0.7
220000
2.5
0.68
200000
0.66
0.64
180000
2.0
160000
0.62
1.5
120000
0.6
140000
0.55
0.55
1.0
0.00
Project number: 218447
0.05
0.10
0.15
Corrected Air Flow (Kg/s)
0.20
1.0
0.00
0.05
0.10
0.15
Corrected Air Flow (Kg/s)
27-28 October 2010
0.20
INGAS - Integrated GAS Powertrain
24 months Meeting, 27-28 October, 2010
Turbo matching
VGT turbocharger simulation :
Allowed max. BMEP taking into account surge line
BMEP (bar)
25
Target
60 %
20
80%
30 %
15
10
100 %
5
40 %
VGT position (%)
30
100
90
80
70
60
50
40
30
20
10
0
?
0
0
1000
2000
3000
4000
5000
Engine speed (rpm)
500
1500
2500
3500
4500
5500
Engine speed (rpm)
• VGT is the best competitor to improve the full load engine performances.
• VGT offers the potential to improve the low speed engine performance, in spite
of the surge line of the compressor from 1000 to 1500 rpm
• For engine speed higher that 2500 rpm, the VGT turbine also offers an higher
efficiency than a fixed geometry turbine with an opened waste gate.
Project number: 218447
27-28 October 2010
6000
INGAS - Integrated GAS Powertrain
24 months Meeting, 27-28 October, 2010
Engine tests at bench : 2nd phase with new hardware
• Compression ratio : 11:1
• Turbocharger : VGT Garrett GT1444
Project number: 218447
27-28 October 2010
INGAS - Integrated GAS Powertrain
24 months Meeting, 27-28 October, 2010
Engine tests at bench : 2nd phase with new hardware
• Partial load characterisation
• Willans lines
24
1000 rpm : WMEP = 2,18 bar and WSFC (eq. Gasoline) : 209,8 g/kW/h - R2 = 0,99965
22
2000 rpm WMEP = 1,98 bar and WSFC (eq. Gasoline) : 208,6 g/kW/h - R2 = 0,99965
20
3500 rpm : WMEP = 2,22 bar and WSFC (eq. Gasoline) : 202,9 g/kW/h - R2 = 0,99995
BMEP (bar)
18
5500 rpm : WMEP = 2,59 bar and WSFC (eq. Gasoline) : 213,9 g/kW/h - R2 = 0,99954
16
14
12
10
8
6
4
2
0
0
Project number: 218447
20
40
60
Fuel flow (mg/cycle/L displacement)
80
100
27-28 October 2010
INGAS - Integrated GAS Powertrain
24 months Meeting, 27-28 October, 2010
Engine tests at bench : 2nd phase with new hardware
CR 9.8
CR11 + VGT
WMEP
(bar)
WSFC
(g/kW.h)
WMEP
(bar)
WSFC
(g/kW.h)
1000 rpm
1.78
212.9
2.18
209.8
2000 rpm
2.05
196.4
1.98
208.6
3500 rpm
2.29
196.6
2.22
202.9
5500 rpm
2.43
210.4
2.59
213.9
Differences observed at partial load could be due to :
• New compression ratio
• New turbine permeability
• New engine parts (piston rings, crankshaft bearings, …)
Project number: 218447
27-28 October 2010
INGAS - Integrated GAS Powertrain
24 months Meeting, 27-28 October, 2010
Engine tests at bench : 2nd phase with new hardware
• Full load characterisation : Torque
• Constraints : max temperature inlet turbine = 850 °C
max cylinder pressure (Pcyl max + 3s) = 105 bars
240
1.5
Max torque :
220
Torque (N.m)
180
1.4
• IFP CR 9.8:1 :
1.3
226 N.m @ 2500 rpm
160
1.2
140
Lambda (-)
200
• IFP CR 11:1 + TGV
227 N.m @ 2250 rpm
120
1.1
100
80
1
60
40
500
1000
CR 9.8:1
CR 9.8:1 CRF Curve
CR = 11:1 + VGT - Lambda = 1
CR = 11:1 + VGT - Lambda opti
1500
2000
Project number: 218447
2500 3000 3500 4000
Engine speed (tr/min)
4500
5000
5500
(limited by Tin turb = 850 °C)
 Max torque at lower rev
0.9
6000
27-28 October 2010
INGAS - Integrated GAS Powertrain
24 months Meeting, 27-28 October, 2010
Engine tests at bench : 2nd phase with new hardware
• Full load characterisation : Power
• Constraints : max temperature inlet turbine = 850 °C
max cylinder pressure (Pcyl max + 3s) = 105 bars
120
Max power :
1.5
CR 9.8:1 CRF Curve
CR 9.8:1
CR = 11:1 + VGT - Lambda = 1
CR = 11:1 + VGT - Lambda opti
100
• IFP CR 9.8:1 :
1.4
80
1.3
60
1.2
40
1.1
20
1
0
500
1000
1500
2000
Project number: 218447
2500
3000
3500
4000
Engine speed (tr/min)
4500
5000
5500
0.9
6000
• IFP CR 11:1 + TGV (l=1)
Lambda (-)
Brake power (kW)
90 kW @ 5000 rpm
76 kW @ 4500 rpm !!
 strongly limited by
Tin turb 850 °C, not WOT
• IFP CR 11:1 + TGV (l opti)
92 kW @ 5000 rpm
limited by Tin turb = 850 °C
27-28 October 2010
INGAS - Integrated GAS Powertrain
24 months Meeting, 27-28 October, 2010
Engine tests at bench : 2nd phase with new hardware
• Full load characterisation : Thermomechanical constraints
Turbine inlet temperature
Pcyl4 + 3s
Pressure maximum in Cylinder 4 (Bar)
115
900
105
800
700
600
CR 9.8:1 CRF Curve
500
CR 9.8:1
CR = 11:1 + VGT - Lambda = 1
CR = 11:1 + VGT - Lambda opti
400
PCyl max (bar)
Temperature inlet turbine (°C)
1000
95
85
75
65
55
CR 9.8:1
CR = 11:1 + VGT - Lambda = 1
CR = 11:1 + VGT - Lambda opti
45
500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000
500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000
Engine speed (tr/min)
Engine speed (tr/min)
Performation limitation due to turbine inlet inlet temperature
Project number: 218447
27-28 October 2010
INGAS - Integrated GAS Powertrain
24 months Meeting, 27-28 October, 2010
Engine tests at bench : 2nd phase with new hardware
• Full load characterisation : Turbochargers duty zones
IHI 150 CV
VGT Garrett GT1444
3.0
Pressure Ratio (t/t) P2c/P1c
0.7
220000
2.5
0.68
0.66
200000
2.0
0.64
180000
0.62
160000
1.5
0.6
140000
0.55
1.0
0.00
0.05
0.10
0.15
Corrected Air Flow (Kg/s)
0.20
Compressor of Garrett TC presents better efficiency than IHI one
In return, surge limit is dramatically reduced
Project number: 218447
27-28 October 2010
INGAS - Integrated GAS Powertrain
24 months Meeting, 27-28 October, 2010
Conclusions
• New hardware configuration (VGT + CR 11:0)
• offers similar performances regarding maximum torque and power.
No improvement was obtained because the lower maximum
turbine inlet temperature (850°C vs. 950°C)
• reduces maximum torque engine speed (VGT effect)
• does not reduce the fuel consumption because the turbine is
undersized
• GT 1444 compressor works with a better efficiency …
• … but the safety margin regarding surge is not sufficient with the
GT1444
Project number: 218447
27-28 October 2010