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INGAS - Integrated GAS Powertrain24 months Meeting, 27-28 October, 2010
Project number: 218447Project number: 218447 27-28 October 2010 27-28 October 2010
Fiat 1.4L CNG performance - Presentation contentsFiat 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)
INGAS - Integrated GAS Powertrain24 months Meeting, 27-28 October, 2010
Project number: 218447Project number: 218447 27-28 October 2010 27-28 October 2010
Engine tests at bench : 1Engine tests at bench : 1stst phase with base engine phase with base engine
• Compression ratio : 9,8:1• Turbocharger : IHI 150 CV
INGAS - Integrated GAS Powertrain24 months Meeting, 27-28 October, 2010
Project number: 218447Project number: 218447 27-28 October 2010 27-28 October 2010
Engine tests at bench : 1Engine tests at bench : 1stst phase with base engine phase with base engine
• Partial load characterisation• Willans lines
0
2
4
6
8
10
12
14
16
18
20
22
24
0 20 40 60 80 100
Fuel flow (mg/cycle/L displacement)
BM
EP
(b
ar)
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
INGAS - Integrated GAS Powertrain24 months Meeting, 27-28 October, 2010
Project number: 218447Project number: 218447 27-28 October 2010 27-28 October 2010
Engine tests at bench : 1Engine tests at bench : 1stst phase with base engine phase with base engine
• Full load characterisation• Constraints : max temperature inlet turbine = 950 °C
max cylinder pressure (Pcyl max + 3) = 105 bars
0
50
100
150
200
250
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000Engine speed (tr/min)
To
rqu
e (N
.m)
Torque Nm
CRF Torque curve
0
20
40
60
80
100
120
1000 2000 3000 4000 5000 6000Engine speed (tr/min)
Bra
ke p
ow
er (
kW)
Brake power kWCRF Power curve
Max torque :
IFP : 226 N.m @ 2500 rpm
CRF : 218 N.M @ 2040 rpm
Max power :
IFP : 90 kW @ 5000 rpm
CRF : 94 kW @ 5000 rpm
INGAS - Integrated GAS Powertrain24 months Meeting, 27-28 October, 2010
Project number: 218447Project number: 218447 27-28 October 2010 27-28 October 2010
Engine improvements : CR = 11:0 + Turbo matchingEngine improvements : CR = 11:0 + Turbo matching
Turbo matching : Simulation of 4 turbocharger configurations :
Compressor Turbine
IHI 150 CV (conf 1) 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
y = 9E-07x2 - 9E-05x + 0.006
y = 3E-06x2 - 0.0003x + 0.0144
y = 2E-07x2 + 5E-05x - 0.0021
-0.05
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
0 50 100 150 200 250 300 350 400 450
Gaz flow (kg/h)
Pre
ss
ure
lo
ss
es
(b
ar)
Air filter
Exaust line
Air cooler
Pressure loss models :
INGAS - Integrated GAS Powertrain24 months Meeting, 27-28 October, 2010
Project number: 218447Project number: 218447 27-28 October 2010 27-28 October 2010
Turbo matchingTurbo matchingP
res
su
re R
ati
o (
t/t)
P2
c/P
1c
1.0
1.5
2.0
2.5
3.0
3.5
Corrected Air Flow (Kg/s)0.00 0.05 0.10 0.15 0.20
0.55
0.6
0.62
0.64
0.66
0.68
0.7
Pre
ss
ure
Ra
tio
(t/
t) P
2c
/P1
c
1.0
1.5
2.0
2.5
3.0
3.5
Corrected Air Flow (Kg/s)0.00 0.05 0.10 0.15 0.20
200000
220000
180000
160000
140000Pre
ss
ure
Ra
tio
(t/
t) P
2c
/P1
c
1.0
1.5
2.0
2.5
3.0
3.5
Corrected Air Flow (Kg/s)0.00 0.05 0.10 0.15 0.20
Compressor IHI RHF3 BRL315 04(Base TC)
2000 rpm
Pre
ss
ure
Ra
tio
(t/
t) P
2c
/P1
c
1.0
1.5
2.0
2.5
3.0
3.5
Corrected Air Flow (Kg/s)0.00 0.05 0.10 0.15 0.20
0.55
0.6
0.62
0.64
0.66
0.68
0.7
Pre
ss
ure
Ra
tio
(t/
t) P
2c
/P1
c
1.0
1.5
2.0
2.5
3.0
3.5
Corrected Air Flow (Kg/s)0.00 0.05 0.10 0.15 0.20
280000
200000
260000
240000
220000
180000
160000140000
Pre
ss
ure
Ra
tio
(t/
t) P
2c
/P1
c
1.0
1.5
2.0
2.5
3.0
3.5
Corrected Air Flow (Kg/s)0.00 0.05 0.10 0.15 0.20
4750 rpmCompressor C224(38) 60 Trim 0.38 A/R
Pre
ss
ure
Ra
tio
(t/
t) P
2c
/P1
c
1.0
1.5
2.0
2.5
3.0
3.5
Corrected Air Flow (Kg/s)0.00 0.05 0.10 0.15 0.20
0.55
0.6
0.62
0.64
0.66
0.68
0.7
Pre
ss
ure
Ra
tio
(t/
t) P
2c
/P1
c
1.0
1.5
2.0
2.5
3.0
3.5
Corrected Air Flow (Kg/s)0.00 0.05 0.10 0.15 0.20
120000
160000
180000
100000
140000
200000
220000
Pre
ss
ure
Ra
tio
(t/
t) P
2c
/P1
c
1.0
1.5
2.0
2.5
3.0
3.5
Corrected Air Flow (Kg/s)0.00 0.05 0.10 0.15 0.20
> 3000 rpm
Compressor C224(46) 55Trim 0.46 A/R
Pre
ss
ure
Ra
tio
(t/
t) P
2c
/P1
c
1.0
1.5
2.0
2.5
3.0
3.5
Corrected Air Flow (Kg/s)0.00 0.05 0.10 0.15 0.20
0.55
0.6
0.62
0.64
0.66
0.68
0.7
0.72
Pre
ss
ure
Ra
tio
(t/
t) P
2c
/P1
c
1.0
1.5
2.0
2.5
3.0
3.5
Corrected Air Flow (Kg/s)0.00 0.05 0.10 0.15 0.20
120000 140000
160000
180000
200000
220000
240000
Pre
ss
ure
Ra
tio
(t/
t) P
2c
/P1
c
1.0
1.5
2.0
2.5
3.0
3.5
Corrected Air Flow (Kg/s)0.00 0.05 0.10 0.15 0.20
Compressor C224 (44) 60 Trim 0.44 AR (associated with VGT)
11
22
33
44
INGAS - Integrated GAS Powertrain24 months Meeting, 27-28 October, 2010
Project number: 218447Project number: 218447 27-28 October 2010 27-28 October 2010
Turbo matchingTurbo matching
VGT turbocharger simulation :
0
5
10
15
20
25
30
500 1500 2500 3500 4500 5500
Engine speed (rpm)
BM
EP
(b
ar)
60 %
30 %
40 %
80%
100 %
Target
Allowed max. BMEP taking into account surge line
0
10
20
30
40
50
60
70
80
90
100
0 1000 2000 3000 4000 5000 6000
Engine speed (rpm)
VG
T p
osi
tio
n (
%)
?
• 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.
INGAS - Integrated GAS Powertrain24 months Meeting, 27-28 October, 2010
Project number: 218447Project number: 218447 27-28 October 2010 27-28 October 2010
Engine tests at bench : 2Engine tests at bench : 2ndnd phase with new hardware phase with new hardware
• Compression ratio : 11:1• Turbocharger : VGT Garrett GT1444
INGAS - Integrated GAS Powertrain24 months Meeting, 27-28 October, 2010
Project number: 218447Project number: 218447 27-28 October 2010 27-28 October 2010
• Partial load characterisation• Willans lines
Engine tests at bench : 2Engine tests at bench : 2ndnd phase with new hardware phase with new hardware
0
2
4
6
8
10
12
14
16
18
20
22
24
0 20 40 60 80 100
Fuel flow (mg/cycle/L displacement)
BM
EP
(b
ar)
1000 rpm : WMEP = 2,18 bar and WSFC (eq. Gasoline) : 209,8 g/kW/h - R2 = 0,99965
2000 rpm WMEP = 1,98 bar and WSFC (eq. Gasoline) : 208,6 g/kW/h - R2 = 0,99965
3500 rpm : WMEP = 2,22 bar and WSFC (eq. Gasoline) : 202,9 g/kW/h - R2 = 0,99995
5500 rpm : WMEP = 2,59 bar and WSFC (eq. Gasoline) : 213,9 g/kW/h - R2 = 0,99954
INGAS - Integrated GAS Powertrain24 months Meeting, 27-28 October, 2010
Project number: 218447Project number: 218447 27-28 October 2010 27-28 October 2010
Engine tests at bench : 2Engine tests at bench : 2ndnd phase with new hardware 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, …)
INGAS - Integrated GAS Powertrain24 months Meeting, 27-28 October, 2010
Project number: 218447Project number: 218447 27-28 October 2010 27-28 October 2010
• Full load characterisation : Torque• Constraints : max temperature inlet turbine = 850 °C
max cylinder pressure (Pcyl max + 3) = 105 bars
Engine tests at bench : 2Engine tests at bench : 2ndnd phase with new hardware phase with new hardware
Max torque :
• IFP CR 9.8:1 :
226 N.m @ 2500 rpm
• IFP CR 11:1 + TGV
227 N.m @ 2250 rpm
(limited by Tin turb = 850 °C)
Max torque at lower rev
40
60
80
100
120
140
160
180
200
220
240
500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000Engine speed (tr/min)
To
rqu
e (N
.m)
0.9
1
1.1
1.2
1.3
1.4
1.5
Lam
bd
a (
-)
CR 9.8:1 CR 9.8:1 CRF Curve
CR = 11:1 + VGT - Lambda = 1 CR = 11:1 + VGT - Lambda opti
INGAS - Integrated GAS Powertrain24 months Meeting, 27-28 October, 2010
Project number: 218447Project number: 218447 27-28 October 2010 27-28 October 2010
• Full load characterisation : Power• Constraints : max temperature inlet turbine = 850 °C
max cylinder pressure (Pcyl max + 3) = 105 bars
Engine tests at bench : 2Engine tests at bench : 2ndnd phase with new hardware phase with new hardware
Max power :
• IFP CR 9.8:1 :
90 kW @ 5000 rpm
• IFP CR 11:1 + TGV (=1)
76 kW @ 4500 rpm !!
strongly limited by
Tin turb 850 °C, not WOT
• IFP CR 11:1 + TGV ( opti)
92 kW @ 5000 rpm
limited by Tin turb = 850 °C 0
20
40
60
80
100
120
500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000
Engine speed (tr/min)
Bra
ke p
ow
er (
kW)
0.9
1
1.1
1.2
1.3
1.4
1.5
Lam
bd
a (-
)
CR 9.8:1 CRF Curve CR 9.8:1
CR = 11:1 + VGT - Lambda = 1 CR = 11:1 + VGT - Lambda opti
INGAS - Integrated GAS Powertrain24 months Meeting, 27-28 October, 2010
Project number: 218447Project number: 218447 27-28 October 2010 27-28 October 2010
• Full load characterisation : Thermomechanical constraints
Engine tests at bench : 2Engine tests at bench : 2ndnd phase with new hardware phase with new hardware
400
500
600
700
800
900
1000
500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000
Engine speed (tr/min)
Te
mp
era
ture
inle
t tu
rbin
e (
°C)
CR 9.8:1 CRF Curve
CR 9.8:1
CR = 11:1 + VGT - Lambda = 1
CR = 11:1 + VGT - Lambda opti
Pressure maximum in Cylinder 4 (Bar)
45
55
65
75
85
95
105
115
500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000
Engine speed (tr/min)
PC
yl m
ax
(b
ar)
CR 9.8:1
CR = 11:1 + VGT - Lambda = 1
CR = 11:1 + VGT - Lambda opti
Turbine inlet temperature Pcyl4 + 3
Performation limitation due to turbine inlet inlet temperature
INGAS - Integrated GAS Powertrain24 months Meeting, 27-28 October, 2010
Project number: 218447Project number: 218447 27-28 October 2010 27-28 October 2010
• Full load characterisation : Turbochargers duty zones
Engine tests at bench : 2Engine tests at bench : 2ndnd phase with new hardware phase with new hardware
IHI 150 CV
Pre
ssure
Ratio (t/t) P
2c/P
1c
1.0
1.5
2.0
2.5
3.0
Corrected Air Flow (Kg/s)0.00 0.05 0.10 0.15 0.20
0.55
0.6
0.62
0.64
0.66
0.68
0.7
Pre
ssure
Ratio (t/t) P
2c/P
1c
1.0
1.5
2.0
2.5
3.0
Corrected Air Flow (Kg/s)0.00 0.05 0.10 0.15 0.20
200000
220000
180000
160000
140000
VGT Garrett GT1444
Compressor of Garrett TC presents better efficiency than IHI oneIn return, surge limit is dramatically reduced
INGAS - Integrated GAS Powertrain24 months Meeting, 27-28 October, 2010
Project number: 218447Project number: 218447 27-28 October 2010 27-28 October 2010
• 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
ConclusionsConclusions