Common Rail Injection for CAT MaK Engines

Transcription

1 Stefan Haas Engineering Supervisor Fuel Systems / Control & Monitoring Caterpillar Motoren GmbH & Co. KG Off-Highway Engines Conference Frankfurt/Main, Germany 28 June

2 Content Introduction Systems Overview (Generation 1) Technical Data Mechanical System Electronical System Performance Results Operational Experience Examples Further Improvements Future Developments (Generation 2) 2

3 Introduction Development of Caterpillar Common Rail - Why? Development of a fully flexible fuel injection system Part of a technology tool box for future products Enabling key objectives of upcoming products Maintain or improve current engine performance at more stringent emission levels (i.e. acceleration, fuel consumption, smoke reduction) Enable future power density increase Easy fuel system adaptation to different engine types, applications, emission technology, special customer needs 3

4 Introduction NOx Emissions Legislation 16 IMO I N O x E m is s io n (g /k W h ) Incentives IMO II IMO III, Open Sea? Incentives? ECA s Time (Year) 4

5 Introduction SOx Emissions Legislation 5 Sulphur Content in Fuel (%) Average Today ECA s Open Sea Time (Years) 5

6 Content Introduction Systems Overview (Generation 1) Technical Data Mechanical System Electronical System Performance Results Operational Experience Examples Further Improvements Future Developments (Generation 2) 6

7 Technical Data Joint development of L Orange GmbH and Caterpillar Motoren GmbH & Co. KG for engine types M 32 and M 43 Rated rail pressure: bar Injection quantity per stroke at rated condition: / mm³ Multi-shot capability (pre, main, post) All fuels acc. ISO8217 F-DMA up to ISO8217 F-RMK55 Fuel temperature at pump inlet: C Typical fuel viscosity operating range: 2,5 16 cst Maximum cold start viscosity: 145 cst (F-RMK55 HFO at 80 C) 7

8 Mechanical System Leak Detection Unit Combination Valve Safety Valve High Press. Line Rail - Rail Flow Limiter Connection to High Pressure Pumps 8

9 Electronical System Core System Injector booster High pressure closed loop control Speed Timing Measurement Performance System Intake manifold pressure (Charge air) Intake manifold temperature Exhaust temperature Turbine inlet temperature Engine coolant temperature Fuel rail pressure Atmospheric pressure 9

10 Content Introduction Systems Overview (Generation 1) Technical Data Mechanical System Electronical System Performance Results Operational Experience Examples Further Improvements Future Developments (Generation 2) 10

11 Performance Results Fuel Consumption 11

12 Performance Results Engine Behaviour Improved torque at lower speed and part load compared to standard combinator curve 12

13 Performance Results Soot Emissions 13

14 Content Introduction Systems Overview (Generation 1) Technical Data Mechanical System Electronical System Performance Results Operational Experience Examples Further Improvements Future Developments (Generation 2) 14

15 Operational Experience Installation Parallel running on power grid Preheating and start ability on HFO Fuel system reliability Mechanical parts (fuel types, operation regime) Electrics & Electronics (vibrations, fault identification) Fuel filtration Cleanliness 15

16 Operational Experience - Examples Engine start ability in HFO mode Extended customer requirement 20 sec from engine start to rated speed (Standard: 30 sec) Modifications made on Fuel injection system preheating Software Improvements achieved on Engine start ability from initially 28.5 sec to less than 20 sec 16

17 Operational Experience - Examples Engine start ability Engine start after 8.5 hrs standstill on HFO RPM in approx sec Blue: actual speed Green: desired speed 17

18 Operational Experience - Examples High Pressure Pump Seized pump elements due to formation of deposits Composition of fuels in use suspected Modifications on pump element introduced No further pump failures 18

19 Operational Experience - Examples Injector Stable injector behavior over the entire lifetime 19

20 Further Improvements Fuel filtration (to prevent sudden injector failures) Mesh size Specific filter load, especially under HFO conditions Cleanliness during assembly / maintenance High requirements on procedures Maintainability / servicability Fault finding, cable and pipe routing and fastening 20

21 Content Introduction Systems Overview (Generation 1) Technical Data Mechanical System Electronical System Performance Results Operational Experience Examples Further Improvements Future Developments (Generation 2) 21

22 Future Developments (Generation 2) Further rail pressure increase For EGR technology to prevent smoke To improve full load fuel consumption Rail volume close to injector to enable higher pressures maintaining multi-shot capability Further fine tuning to improve NOx-fuel consumption tradeoff To allow higher power densities Low-sulphur-fuel capability increase 22

23 Thank you for your attention! 23