The Chicago Infrastructure Trust CNG Industry Forum: CWI Natural Gas Engineschicagoinfrastructure.org/wp-content/uploads/2015/04/... · · 2015-04-29The Chicago Infrastructure Trust

April 28, 2015

The Chicago Infrastructure Trust CNG Industry Forum:

CWI Natural Gas Engines

Cummins Westport Inc. (CWI)A Cummins JV Company

CWI is a 50:50 joint venture company based in Vancouver, BC Established in 2001 – 14 Years Experience Cummins Inc. - world’s largest builder of commercial

diesels, Westport Innovations Inc. - world leader in gaseous

fuel engine technology

CWI offers 6 and 12 liter spark ignited alternative fuel automotive engines.

Engines are manufactured by Cummins in Rocky Mount, North Carolina and Jamestown, New York.

Local parts and service support through Cummins Distributor network.

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•Based on Reliable Cummins Engine Platforms

•Common parts and design provide heavy duty performance

•Engineered and Optimized Specifically for Alternative Fuel

•Continued improvement in reliability and cost of ownership

•Service Support through the Global Cummins Distributor network

Heavy Duty Engines Designed Specifically for Alternative Fuels

Cummins Westport

Four Generations of Natural Gas Engines1998

C8.3G

Mechanical

• Introduced in 1998

• Major improvement over 1st generation CNG L10 Series

• Over 4000 still in service

• Improved Reliability

2001

C Gas Plus


• State of the art spark ignition/control system

• First engine 2004 EPA Certified

• Six fold reliability Increase

2004

L Gas Plus


• Improved Ignition control system

• VG Turbo

• Based on 8.9 L ISL Block

• 2007 NOx and 2010 PM levels

2007

ISL G and ISX12 G

• Introduced in June 2007

•ISX 12 G in 2013

• Stoichiometric EGR combustion, three way catalyst

• First HD engine certified 2010 NOx and PM levels

2015/16 Cummins Westport Products.

2016

6.7 Litre Spark Ignited

SEGRThree Way Catalyst



Up to 60,000 miles/year66,000 lb. GVW



Up to 80,000 lb. GVW

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Historical Success:Urban Return-to-Base Fleets

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Cummins/Cummins Westport have delivered over 55,000 on–highway NG engines

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North America, Europe, Asia CombinedCWC On Hwy Meeting Calgary May 14

For these reasons, natural gas adoption rate will continue to increase. Continued low NG fuel costs

Increased fueling infrastructure

More NG engines & vehicles available

Cummins Confidential

Market Segment NG Market Adoption Rate

2014 2018 Projection

Transit Bus 26% 25-30%

Refuse Truck 50% 50-60%

HD Truck < 1% 4-10%

The Next Opportunity:Regional and Long Haul Fleets

9Cummins Westport Feb 2015

How Does Fuel Price Drop effect NG?

Input Sheet – Reduce fuel price to Jan’15Customer Name:

Miles per Year 60,000 50 Labor Rate ($/Hr) $100.00 # of Operating Days/Yr. 260 - IRR or Discount Rate 6%# Years for Calculation 6 0Total Miles for Calculation 360,000 7,200

===> Use 12L engineBaseline Baseline

Labels: Engine Model ISL9 ISX12 ISX12 G

Fuel EconomyFuel Price ($/Gal) (Diesel or Natural Gas*) $3.16 $3.16 $2.16Engine MPG - driving (Note 1) 6.00 7.30 6.20Idle Fuel Consumption DGE/hour 0.81 0.94 1.24

Diesel Exhaust Fluid (DEF)DEF Cost ($/Gal) $3.00 $3.00DEF Usage 3.5% 3.5%

Vehicle Acquisition Costs:Quoted Price $100,000 $110,000 $150,000Alternative Fuel Funding $0 $0 $0

Total Acquisition Costs $100,000 $110,000 $150,000 B(W) vs Baseline ($40,000)

* Natural gas fuel cost (DGE) includes commodity cost, station capital, maintenance, and electricity

ISL G

$2.165.101.07

$140,000$0

$140,000 ($40,000)

N/A N/A

Fleet Name

Total Idle Time (hours)

Vehicle Avg Speed (mph)

Total Hours

Idle Time (hours/day)

Customer Name

Incremental Vehicle Cost Payback (Years) 3.2 3.9

Baseline BaselineEngine Model ISL9 ISL G ISX12 ISX12 G

Net Vehicle Acquisition Cost 100,000$ 140,000$ 110,000$ 150,000$ B(W) vs Baseline ($40,000) ($40,000)

Operating CostsFuel Costs $237,600 $165,176 $195,288 $135,871 DEF Fuel Costs $6,300 $5,178 Maintenance Costs $9,308 $13,447 $7,486 $9,845

Total Operating Costs for a Single Unit 253,208$ 178,624$ 207,952$ 145,716$ B(W) vs Baseline $74,584 $62,236

Operating Costs Per MileFuel Costs $ 0.660 $ 0.459 $ 0.542 $ 0.377 DEF Fuel Costs $ 0.018 $ 0.014 Maintenance Costs $ 0.026 $ 0.037 $ 0.021 $ 0.027

Total Operating Cost per Mile $0.70 $0.50 $0.58 $0.40B(W) vs Baseline $0.21 $0.17

Payback Calculation DetailSavings per year/Vehicle $12,431 $10,373

Incremental Cost ($40,000) ($40,000)Payback Years 3.2 3.9

Incremental NPV $21,126 $11,006

Total Fleet # of Units 10 10 10 10 Total Operating Costs for 10 Units $2,532,080 $1,786,237 $2,079,520 $1,457,160 B(W) vs Baseline (Diesel) $745,843 $622,360

Total Fleet # of Units 50 50 50 50 Total Operating Costs for 50 Units $12,660,400 $8,931,184 $10,397,600 $7,285,798 B(W) vs Baseline $3,729,216 $3,111,802

SUMMARYFleet Name Customer Name










Incremental NPV -$7,800 -$12,762



SUMMARYFleet Name

ValuSpec – Impact of Fuel Price Change

Sept ‘14 - Diesel $3.96 CNG $2.34 Jan ‘15 - Diesel $3.16 CNG $2.16

Jan Fuel Price - Increase Annual Mileage to 100,000/yr

Customer Name










Incremental NPV $14,973 $7,322



SUMMARYFleet Name

Natural Gas Engines: Features

ISX12 G : 12 Liters, 80,000 lb GVW

ISL G : 9 Liters, 66,000 lb GVW

Use 100% Natural Gas

– Stored as CNG, LNG

Spark Ignited, In-line 6 cylinder

Wastegate Turbocharger

Charge-Air Cooled (CAC)

Stoichiometric EGR Combustion

Three Way Catalyst Aftertreatment– Maintenance Free

Base Warranty: 2 yr/250,000 miles

Extended Coverage Available

First Production ISX 12 G on Cummins assembly line in Jamestown, NY (April 9, 2013)

First ISX 12 G 400 HP built August 1, 2013

4/28/2015 14

2015 Engines Aftertreatment Comparison

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Cummins TWC

HeatedUrea Tank Urea

Dosing Control Unit

ECM

SCR Catalyst Particulate Filter

2015 Diesel

Three Way Catalyst

Reduced Noise

Noise Comparison

70

80

90

100

110

Peak Torque / Full Load Idle / No Load

Engine Test Mode

Dec

ibel

es d

B(A

)

07 ISL

07 ISL G

ISL G is 5.5 decibels quieter at peak torque

and load

ISL G is 9.9 decibels quieter at Idle/no load

Spark ignition provides quiet operation

Communities notice the natural gas noise

advantage.

ONE Diesel engine idling is louder than TEN natural

gas engines idling together

* ISX12 G Noise Data TBA

*

ISX12 G and ISL G Cold Weather Operation

Cold weather affects CEGR SI natural gas engines differently compared to CEGR CI diesel engines

Natural gas engines are susceptible to sub-freezing intake air

Too cold intake air forms condensation in charge air coolers and freezes intake components

Measures MUST be taken to insure adequate intake air temperatures are maintained

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Cold Weather Operating Aids

Coolant, Oil and Battery Heaters, Warm Intake Air,as well as Radiatior Shutters/Winter Fronts are required for engine operation below 11 F (-12 C)

Starting Fluid

Due to potential engine damage, starting fluid should not be used.

The use of starting fluid in a gaseous fueled engine has no practical purpose.

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Excerpt from ISL G

Owners manual.

Powerspec 5.4

Software Application– Gearing calculator

– Electronic features- settings and descriptions

– Customized engine ‘specs’

– “Easy Spec” available for fleets

– Collects valuable trip information

– Reporting feature

http://www.powerspec.cummins.com

For more information or to download PowerSpec, visit:

19Cummins Westport March 2014

Natural Gas Range Natural gas engine mpg lower than diesel

– Lower compression

– Throttled inlet versus fuel injected

Example:

– Diesel fuel economy 5 mpg

– Natural gas fuel economy 4.5 mpg

Diesel Fuel Storage 60 g = range 300 miles

CNG Fuel Storage 60 dge = range 270 miles

Important to look at cost per mile as natural gas fuel cost is typically less than diesel.

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Diesel vs Natural Gas Fuel Cost Comparison (example – Class 8 Truck)

Diesel Natural Gas

Truck life (miles) 800,000 800,000

MPG 6.4 5.7

Fuel used (gallons) 125,000 140,000

Fuel cost / gallon $3.15 $2.00

Fuel cost $393,750 $280,000

Total Fuel Savings$150,000

0.14 / mile

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ISLG and ISX12 G Warranty Coverage

•Base Warranty for ISL G and ISX12 G Engines are similar to Cummins diesel

engines

•Extended Coverage options are available for all engines:

Example:

•3 to 5 yr. 100,000 to 500,000 mile - Protection Plan 1 - Truck

•3 to 5 yr. 100,000 to 500,000 mile – Protection Plan 2 –Truck

•5 yr. 500,000, 6 yr. 600,000, 7 yr. 700,000 mile Major Component

•All Extended Coverage warranty programs posted on Cummins CIRCUIT

Transit AvailabilityTRANSIT BUS

OEM New Flyer NABI Nova ElDorado Gillig

Model 30/35/40/60 Low Floor

35/40 Low Floor

60 BRT

LFS EZ Rider II 30/35/40 Low Floor

Engine ISLG 280/320 ISLG 280/320 ISL G 280 ISLG 250/280 ISLG 280

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COACH

OEM MCI

Model Commuter Coach

Engine ISLG 320

ISX12 G 400

ISL G Refuse Availability

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LOW CAB FORWARD / REFUSE

OEM AutoCar Mack Peterbilt American Lafrance

Crane Carrier

Model Xpeditor TerraPro LE

Terra Pro CO

320 Condor LET

Engine ISLG 300/320 ISLG 320 ISL G 320 ISL G 320 ISLG 320

CWI Natural Gas Webex July 2014

OEM Freightliner Peterbilt Kenworth Volvo Navistar

Model M2 – 112

SD - 114

320

384

365

T800SH

W900S

T440

T470

VNM TranStar

Engine ISLG 320

ISL G 300

ISL G 320 ISLG 320 ISL G 320 ISL G 320

Application 6x4 Tractor

4x2 Tractor

4x2 Truck

6x2 Truck

Vocational

Tractor

Vocational

Mixer

Tractor

Vocational

Mixer

Tractor Tractor

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ISL G Conventional Truck Availability

OEM

Freightliner Peterbilt Kenworth Volvo Mack Autocar

Model Cascadia

Day Cab, Sleeper *

320

384

365

579 *

567*

W900S

T660

T800 SH

T680 *

VNL Pinnacle Xpeditor

Engine ISX12 G ISX12 G ISX12 G ISX12 G ISX12 G ISX12 G

Application Tractor Refuse

Tractor

Vocational

Tractor

Vocational

Tractor Tractor

Vocational

Refuse

ISX12 G Availability

* New chassis in 2014

Mid America Announcements – 2014/15

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The T680 was introduced in day cab and 76-inch sleeper configurations, and a 52-inch mid-roof sleeper option was added last year.

Kenworth T680Peterbilt introduced a natural gas version of its two newest vehicles – the on-highway Model 579 and the vocational Model 567 ideal for customers in short- and regional-haul, refuse and construction applications.

Peterbilt Model 337 and 579 Peterbilt Model 567

Freightliner Cascadia SleeperFreightliner Trucks will make its Freightliner Cascadia® natural gas-powered tractors available with a 48-inch sleeper cab, available with factory-installed compressed natural gas (CNG) and liquefied natural gas (LNG) tanks

Peterbilt Model 579

Cummins Westport Confidential April 2015

Cummins Westport Natural Gas Playbook Available only from Cummins, the 5 step Playbook provides information

and resources for the key steps involved when implementing natural gas into a fleet.

Contact your Cummins or Cummins Westport representative for details.

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Conduct fuel quality test

Implement

Conduct pilot truck test

Develop rollout plan

Confirm fuel economy & range

Conduct driver training

Truck delivery & PDI

Conduct fuelling training

Test problem resolution processes

Infant care support

Kick off event

4Operate &MaintainConduct daily

maintenance & inspections

Monitor fuelling procedures

Monitor fuel consumption

Conduct scheduled maintenance &

inspections

Conduct scheduled fuel quality inspections

Manage & resolve problems

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Fleet profile

Assess

Routes & loads

Current fuel profile

NG fuel availability

Fuel price expectations

Environment & terrain

Incentives

Regulations & codes

Service capability

Facility requirements

Previous experience

Business case

Risks & mitigation

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OEM

Specify

Chassis

Engine

Transmission & gearing

Fuel type & quality

Fuelling procedure

NG fuel system type, capacity &

configuration

Safety equipment

Warranty package

Delivery dates

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Confirm fuel availability

Prepare

Confirm service & parts availability

Obtain permits, licenses & approvals

Complete facility modifications

Operations & maintenance training

Define driver training process

Safety training

Fire & emergency response plan

Define problem resolution processes

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Learn more @ cumminswestport.comFeaturing the Natural Gas Academyvideos covering:

• What is Natural Gas?• Natural Gas Engines• Natural Gas Fuel Systems• How to Fuel a Vehicle• ISL G Engine Walk-Around• ISX12 G Engine Walk-Around• ISX12 G Driver Familiarization• Natural Gas Engine Maintenance• Upgrading Your Facility for NGVs

Links & Resources

29Cummins Westport Confidential June 2014

Natural Gas Customer Benefits

Lower Fuel Costs and Emissions

Diesel-like responsiveness

– Throttle response is comparable to diesel

Strong power density

– Similar torque curves to diesel

Improved Fuel Economy vs. other NG engines

– 5% fuel economy improvement

Maintenance-Free aftertreatment

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Thank You!

For more information:

Bill Boyce

East Regional Manager

(330) 720-9785

or

[email protected]

Or visit www.cumminswestport.com

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Documents

The Chicago Infrastructure Trust CNG Industry Forum: CWI Natural Gas Engineschicagoinfrastructure.org/wp-content/uploads/2015/04/... · · 2015-04-29The Chicago Infrastructure Trust