Use of Exhaust Gas Testing to Reduce Engine Emissions, Fuel Consumption and Improve Equipment Management

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1 Use of Exhaust Gas Testing to Reduce Engine Emissions, Fuel Consumption and Improve Equipment Management Edwin Downer General Manager Whayne is the Cat Dealer for KY and S. Indiana. We have 24 underground Mines in our area. Exhaust Gas Testing experience has grown over past 5 years. We are working with other Cat Dealers to provide Mirenco Services in North America. 1

2 The price of oil has corrected significantly. $85+ per barrel Green is becoming more important. Diesel Emissions Regulation Trends

3 We are Using 3 Tools to Lower Emissions 1. Exhaust Gas Analysis Evaluates engine combustion efficiency Report recommends possible repairs Repairs help to reduce fuel & emissions 2. Throttle Management Controller Black box between throttle pedal and fuel computer. Regulates throttle application on acceleration and WOT to reduce over-fueling. 3. Mirenco Exhaust Gas Test Database Benefits of Exhaust Gas Testing Lower Diesel Emissions Enhanced Equipment Management Lower Fuel Consumption Exhaust Gas Testing can being used as Diagnostic Tool like Scheduled Oil Sampling! 3

4 ExhaustGas Test Equipment * 5 Gas Test Equip. * Smoke Meter for DPMs We test Engine Exhaust for Carbon Dioxide Carbon Monoxide Hydro Carbons Oxides of Nitrogen NOx Oxygen Diesel Particulate Matter (DPMs) 4

5 High DPMs = Over fueling = Black Smoke = High Emissions = Wasted Fuel Exhaust Gas Test work on all Sizes 5

6 Haul Truck Emissions look Good! Carbon Dioxide is higher than Carbon Monoxide Good! Hydro Carbons are below 10ppm Good! Diesel Particulate Matter is below 20%. Good! Haul Truck Emissions Very Poor! Carbon Monoxide is higher than Carbon Dioxide Poor Combustion! DPMs were low when truck was new. DPMs are very high now that the truck has higher hours! Wasted Fuel! Possible Repairs are suggested. 6

7 Some Machines have Multiple Problems Typical Combustion Related Issues that contribute to DPM Density: 7

8 By performing Exhaust Gas Audits on the Fleet, Significant Progress can be made! Several Machines Out of Tune Improvements over 4+ months Annual DPMs are a Problem Fuel Loss is 6.8% of total annual consumption. Annual DPMs reduced by 34% Annual Fuel consumption reduced by 3200 gallons or 2.3% Exhaust Gas Tests Cost vs. Benefit Recommend every 2000 hours or at TA2 time Underground Applications could be every 6 months Budget $ per test of $375 $375/2000 hrs = $.19/hr! 8

9 If the Engine is Rebuilt, consider Exhaust Gas Test before Installing in Machine Engine repair costs while in a vehicle can be 5 times higher than when the Engine is on the Dyno! Lets look at C-Max and D-Max Throttle Application Management 9

10 C-Max / D-Max Device helps to move the Style of Throttle Application from the Machine Operator to the Equipment Manager. C-Max & D-Max can turn a Spirited operator into a Conservative operator with no loss of power or productivity! C-Max or D-Max Method 1. Control Fuel Injection during machine acceleration. 10

11 Fuel Injection vs. Time Fuel injection rate is controlled by the ECM. Once the operator depresses the accelerator pedal to the floor, the throttle position signal is sent to the engine computer. In this case, the operator is asking for wide open throttle. Time Fuel Injection & Turbo Boost vs. Time The turbo takes time to spool up to match the fuel injection rate. Turbo Boost Curve Fuel Injection Rate Time 11

12 Fuel Injection & Turbo Boost vs. Time If the turbo is not able to spool up fast enough to match the fuel delivery rate, the engine will have too much fuel and not enough air to burn the fuel. The result is over fueling of the engine. This shows up as black smoke or soot exiting the exhaust pipe. Turbo Boost Curve Fuel Injection Rate Time Fuel Injection & Turbo Boost vs. Time With a Mirenco C-Max installed, the fuel delivery rate can be adjusted to better fit the turbo boost curve. (The operator could do the same by slowly depressing the throttle pedal). The result is far less over fueling of the engine resulting in less emissions and fuel consumption. Turbo Boost Curve Fuel Injection Rate Time 12

13 C-Max or D-Max Method 2. Control Fuel Injection at wide open throttle Pedal to the Metal Diesel Fuel Consumption over the life of an Engine. ECM Max Throttle (set at Engine Factory) Ability of Engine to convert fuel to horsepower degrades over time due to wear. Fuel Injectors Replaced. (this helps combustion efficiency). Over Fueling Time or Life of Engine 13

14 Diesel Fuel Consumption over the life of an Engine. ECM Max Throttle (set at Engine Factory) Fuel $avings Longer Engine Life Over Fueling Reduced by C-Max Installation. Fuel Injectors Replaced Over Fueling is Reduced! Time or Life of Engine Applications and C-Max benefits! 14

15 Field Testing C-Max D9R Dozer Study 15

16 C-Max D9R Dozer Study On Off Blade Volume per pass - BCY Tractor Cycles per hour Production Yard per hour Fuel Consumption - Gal per hour Fuel Efficiency - BCY per gallon Fuel Efficiency Advantage 11 % Wheel Loader C-Max Off 16

17 Wheel Loader C-Max turned ON User Access to MDEP History Click here Equipment Managershave access to their own ExhaustGas tests to help evaluate trends in engine combustion health. 17

18 Exhaust Gas Test & C-Max Applications Underground Mining Quarries, Metal, etc. Emissions Sensitive Jobs Federal Sites Surface Mining Coal, Gold, Quarries Heavy Construction Sites On Highway Trucks Machine Rebuilds Engine Rebuild Centers Stationary Engines Marine Enhanced Equipment Management Lower Fuel Consumption Lower Diesel Emissions 18