interim tier 4 panel discussion - egsa tier 4 panel... · interim tier 4 panel discussion ... kyle...

Interim Tier 4 Panel Discussion

Tim Cresswell – Caterpillar, Inc.

Kyle Tingle – John Deere Power Systems

Christine Ueno – MTU Onsite Energy

Vivek Malapati – Cummins Power Generation

Electrical Generating Systems Association Fall Conference

Tim Cresswell

Tier 4 Product Definition Manager

Caterpillar Electric Power

1/5/2011 Electrical Generating Systems Association Fall Conference

Regulatory Environment

Electric Power is different.

Regulations are more stringent for generator sets than other types of “off‐road” equipment.

Only N. America regulates EP applications to Tier 4 levels.

Current EP products will continue for certain applications in N. America.

Understanding the requirements of regulatory bodies is essential.

EPA, CARB, Local Air Boards, etc.


EP Stationary Market

Majority of market will operate as Emergency

Tier 4 driven by:State Requirements• California• Others?

Prime power / Continuous

Non‐Emergency Standby• Utility curtailment• Peak Shaving• Storm Avoidance

Corporations valuing sustainability

Tier 4 Uptake50 ekW

3000 ekW


Technology Optimization

Clean Emissions Module(CEM)

Diesel Oxidation Catalyst(DOC)

Diesel Particulate Filter(DPF)

Selective Catalytic Reduction(SCR)

Jan

120

11Ja

n 1

2008

>560 bkW ≤900

>900 bkW

≥19 bkW <56

≥130 bkW ≤560

Emissions Control

Engine Technology Aftertreatment(CEM)

RegulationEffective

Date

PowerRange

DOC + SCR

In-Cylinder

In-Cylinder

None

CatNOx

ReductionSystem None

DOC + DPF

July 23, 20101/5/2011 Electrical Generating Systems Association Fall Conference

Clean Emissions Module (CEM)

Highly integrated packages

Engines ≤560 bkWPrimarily for PM controlIncorporates DOC, DPF & regeneration system

EP Engines >900 bkWPrimarily for NOx controlIncorporates DOC & SCR system

July 23, 20101/5/2011 Electrical Generating Systems Association Fall Conference

Technology ►130 ‐ 560 bkW

NOx Reduction System + Clean Emissions Module

Engine + PM Aftertreatment (DPF)

Automatic DPF regeneration – maximizing uptime

Minimum impact on operation and maintenance


Technology ►560 ‐ 900 bkW

NOx Reduction System

Engine only, proven technology: ACERT + additional air management

Compact and cost‐effective design


Technology ►900+ bkW

Clean Emissions ModuleEngine + PM and NOx Aftertreatment (DOC and SCR)

Uses Diesel Emissions Fluid (DEF) and air injection system

Optimized for Cat generator sets ‐ designed specifically for Cat engines (catalyst size, exhaust flow, noise characteristics)

Reliable, compact, light weight

Flexible configuration

Packages for rentalapplications


World‐Class Service & SupportEmissions Solutions

Design and deliver turn key solutionsUtilize proven technology to meet new regulationSCR has been in the field for years, our dealers know how to install/service it

Dealer Network24/7 Parts and Service

99.8% same day parts shipping$2 Billion Worldwide Parts Inventory57 Dealers in U.S.A. and Canada/Over 800 Dealer Branch Stores22,000 skilled and factory‐trained technicians5,000 service trucks

Maintenance Agreements/ Cat Insurance Customer Support Agreement (CSA)

Preventive Maintenance, Parts, Diesel Emissions Fluid (DEF), TM&R, Priority Emergency Repair StatusInsure the product meets or exceeds emissions minimum useful life (10yr/8000 hr) on P ≥ 37 kWEliminate exposure for emissions non‐compliance risk through O&MM adherenceOne Phone Call!

Extended Service Coverage (ESC)Complete Caterpillar Package Coverage including Rental (Platinum Plus for Standby)


Delegated Final Assembly

General Rule:

Engines must be in their certified configurations when introduced into US commerce (i.e., shipped from engine manufacturers' factory), meaning that the engine and aftertreatment must be assembled prior to shipment or shipped together.

Exemption:

EPA regulations provide the Delegated Final Assembly (DFA) exemption, which allows engine manufacturers to ship the engine and aftertreatment separately.


Delegated Final Assembly

To take advantage of the DFA exemption, EPA regulations require engine manufacturers to take certain steps to ensure that proper engine and aftertreatment pairing takes place, including:

Supplying equipment manufacturer with robust A&I guidelines.

Entering into DFA contract with dealers/distributors and OEMs.

Collecting data from dealer/distributor or OEM that provides evidence or proper pairing of engines and aftertreatment .

Collecting annual affidavits, whereby dealer/distributor or OEM attests to validity of pairing data.

Performing DFA audits required by EPA regulations.


End‐User Compliance

Requirements defined in 40CFR Parts 60, 89, 1039 & 1068End user compliance requirements include, but are not limited to:

Purchase correct engine ‐ which complies with requirements for the application/installationUse the correct fuelsInstall, operate & maintain in accordance with manufacturer’s instructionsDo not change settings unless permitted by manufacturerInstall prior‐tier engines within the defined windowMonitor and/or record required parameters, including operating hours & DPF backpressure

The information is NOT COMPREHENSIVE and DOES NOT address specific manufacturers’ circumstances. There is no substitute for reading and understanding the rules; companies are strongly encouraged to investigate and apply the regulations accordingly. Regulations may change, and these materials may not be updated to reflect the latest regulatory revisions. Companies relying on this information do so at their own risk and assume any liability for so doing. The information IS NOT intended to be and should not be construed as legal advice or as a substitute for competent legal advice. Please consult your legal advisor if you have questions or need assistance


Transitioning from Tier 3 to iT4 Engines

Kyle TingleSr. Accounts Manager

John Deere Power SystemsWaterloo, IA


EGR system• Larger EGR cooler & valve• Venturi ‐ dynamic EGR control

Air System• Series turbo ‐maintain performance• Air throttle ‐ exhaust temperature control• Open Crankcase Ventilation (OCV) filtration

Fuel System • Higher injection pressure ‐ lower PM emissions

Cooling & Lube Systems• Increased coolant flow ‐ higher heat rejection from EGR • Increased lube pump & cooler capacity

Aftertreatment• DOC & DPF• DPF regeneration system

Electronic Controls• New sensors/actuators ‐ air system , aftertreatment

IT4 Technology:Engine Change Summary from Tier 3

Building Block Approach…

…Start w/ Tier 3 Power Tech Plus


iT4 Technology:Turbocharging, Air Management


iT4 Technology:

13.5L PSX 9.0L PSX

6.8L PVX 4.5L PWX1/5/2011 Electrical Generating Systems Association Fall Conference

iT4 Technology: Exhaust Filter

Maintain 572oF (300oC) inlet temp ‐ into DOCCatalyst (Platinum, Palladium) ‐ Increase temp 2x to 1100oF (600oC)Only gases out the tailpipe (CO2 + N2 ) – Diffuser often requiredInitial service life without cleaning ‐ 5000 hour goal (EPA: 4500, 3000)


13.5LSize 89.0L

Size 76.8LSize 5

9.0LSize 6

175 hp – 750 hpWeight (75-150 lbs)Diameter (12-15”)Length (34-39”) 4.5L 4.5L 4.5L,6.8L

Size 2 Size 3 Size 4

75 hp - 175 hpWeight (44-68 lbs)Diameter (9.8”-12.6”)Length (22.6”-25”)

Exhaust Filter:Size per Engine Family

Exhaust Filter:Packaging, Special Handling

Use appropriate lifting devices

Slings and hoist

Ensure balanced – prevent tipping

Use fixture for sub‐assembly

Wear gloves

Do not drop!

Sizes 5, 6, 7 and 826 ¼” Wide x 40 ¾ “ Long x 33 ½” Tall

Sizes 3 and 422 5/8” Wide x 30 5/8” Long x 28 3/8” Tall

Boxes are tri-walled cardboardMeant to be shipped up to 3 timesStackable up to 5 high


Delegated Assembly :Exhaust Filter Tracking

Why?Regulations require engine manufacturer to track every EF

Including changes/replacementsSupplier > Factory > Service

What?Every EF by serial number (DPF + DOC + Parent engine)Heat‐Cycle and other aging data for each DPF & DOC

How?Programming tools now support putting EF data into the ECUAll programming events return EF dataWithout EF data the engine will de‐rate

EF = Exhaust FilterDPF = Diesel Particulate FilterDOC = Diesel Oxidation CatalystECU = Engine Control Unit


Delegated Assembly:OEM/Distributor Process

Marry Exhaust Filter with Engine1.Order EF with Engine ‐ 1 for 1Invoice & Ship separately to OEM/Distributor

2.Install EF with engine into power unit / vehicle

3.Perform Programming EventScan Serial Numbers – Engine, DOC, PDF

EF programming process – additional 1 minute

The tool automatically Sets “Ash Model”

Retrieves ECU data

Carries out mistake proofing (DPF size check, SN check)

4.Return file sent back to engine manufacturer

5.Software server manages dataSoftware payload available ‐ service reprogramming


iT4 Power Unit


Emission Labels: 2010 to 2011 Label Changes

Tier 340 CFR 89

Tier 340 CFR 89

2010

Emergency T340 CFR 60

2011

Flex - Tier 340 CFR 1039

Interim Tier 440 CFR 1039

Export

Replacement

Other Labeling Requirements:Duplicate emission label - if not visible during normal maintenanceSupplemental vehicle label – if using engine under Tier 4 flex provisionFuel inlet label – fuel sulfur level requirements


Large Diesel Gendrives of Tomorrow

Christine UenoManager, Regulatory Compliance

MTU Detroit Diesel, Inc.


Emission Limits Gendrives (g/kW‐hr)

NOx

* combined NOx+HC limit

Tier 2 2006*

0.1 0.2 PM

2

4

US EPA Regulation (40 CFR 89 and 1039)Genset Pe > 900 kW

Tier 4i2011

Tier 42015

6


Product Baseline and Key TechnologiesSeries 4000 Tier 2 Engine

Aim of Tier 4i/4 engine development is to retain as much tried and tested technology as possibleCurrent Series 4000 Tier 2 engine will be retained for Emergency Standby Engines in 2011 and beyond


Development Highlights for Tier 4i/Tier4 Series 4000 / 1,250‐3,250 kW

New Technologies

SCR Low NOx Emissions (2011)Considerations must be made for DEF

DPF Low Particulate Emissions (2015)

3rd Generation Common Rail System (2011)

Higher injection pressure reduced emissions and fuel consumption

‐ Improved multi injection capability reduced noise and smoke


DEF Quality & Availability


Technical Concept Of The New Engine Exhaust Aftertreatment For Tier 4 Final

Target: No DPF for Tier 4 final

Advantages of a DPF freeNo fuel consumption penalty due to DPF backpressureand regeneration fuel

Weight and volume savings(more installation flexibility)

Installation cost savings

Maintanance cost savingsDecision on Tier 4 final aftertreatmentconcept later

0.350.300.250.200.150.100.050.00

NOx emissions (g/kWh)0 1 2 3 4 5 6

Tier 4iTier 4f

Par

ticle

em

issi

ons

(g/k

Wh)


What does this mean for MTU products?

Emergency Stationary Power applications‐ Modifications not necessary for S4000 product

• 1250kW through 3250kW‐ Current product line platform remains the same through 2014

‐ No exhaust after‐treatment requiredPrime and Contiuous Power applications‐ Exhaust aftertreatment will be required‐ SCR catalyst strategy

•2015 possible addition of DPF‐ Minor modifications to current engine platform


Emergency Standby Power applications‐ Current product line platform will remain the same through 2014

‐ Familiar product‐ Favorable for facility expansions‐ Favorable cost and design requirementsPrime and Continuous Power applications‐ Exhaust aftertreatment will be required – SCR

•2015 possible addition of DPF‐ Added cost‐ Substantial design consideration

What does this mean to MTU customers?


How are MTU distributors getting ready?

Provide training Emission regulations

Installation of aftertreatment

Delegated assembly

Availability of prototype engines


Summary and Conclusions

Emergency stationary engines will not change in the forseeable future

Tier 4i non‐emergency/non‐stationary engines will require additional aftertreatment

Additional customer interaction for DEF

Potential to meet Tier 4 final without additional hardware


Tier 4 Panel Discussion

By Vivek MalapatiSenior Product Planner, Cummins Power Generation


Agenda

Tier 4 technology path

Distributor/Dealer Readiness

Ongoing market challenges


Tier 4 Technology Path

Cummins has gained experience on the technology learning curve since on‐highway EPA 2002 and EPA 2007 regulations

The emissions requirement for later off‐highway markets were part of the initial design profile for on‐highway low emissions technologies

Where applicable, we leverage our on‐highway experience while validating technologies for the off‐highway market


Emission Control Options

Diesel Oxidation Catalyst (DOC)

Catalyzed Soot Filter

Active regenerating filter

Miller Cycle

EGR

Lean NOx

Lean NOx + HC

Plasma assisted lean NOx

NOx adsorber

Selective Catalytic Reduction (SCR)

NOx

Exhaust and Emission Control Systems

PM

RED: Most commonly used

Controls Reduction %Diesel Oxidation Catalyst (DOC) PM 20 - 40Catalysed Soot Filter PM above 90CRT PM above 90EGR NOx up to 50SCR NOx up to 90

PM 20 - 40


NOx Control Technologies

Exhaust Gas Recirculation (EGR):Technology that diverts a percentage of the exhaust gas back into the cylinder, lowering combustion temperatures and reducing NOx.

Selective Catalytic Reduction (SCR):An aftertreatment technology that uses a chemical reductant (Diesel Exhaust Fluid) injected into the exhaust stream where it transforms into ammonia and reacts with NOx on a catalyst, converting the NOx to harmless nitrogen gas and water vapor.


Particulate Matter Control Technologies

Diesel Particulate Filter (DPF):Captures particulate matter in a semi‐porous medium as they flow through the exhaust stream. Ceramic wall‐flow monoliths are used as filter material in most cases.

Diesel Oxidation Catalyst (DOC):Consists of a catalytic coating on a honeycomb substrate for oxidizing particulate matter (PM). Operates in a passive‐only mode without active regeneration, so is less efficient at PM reduction than a DPF. Typically reduce PM by 20‐30%.


Tier 4 & Aftertreatment

SCR

AM

OX

Urea (DEF)Injector/Pump/Control Module

SCR Catalyst

Urea (DEF) TankAfte

rcoo

ler

Base Engine

Inte

rcoo

ler

LTAWater

Urea(DEF)

Line Heaters

Tank Heater

Air Intake

Exhaust

Single or 2-stage turbocharging same as Tier 2

DPF

HC Injector

DO

C

DOC Catalyst &Particulate Filter

JW Cooling Circuit

SCR

SCR

AM

OX

Urea (DEF)Injector/Pump/Control Module

SCR Catalyst

Urea (DEF) TankAfte

rcoo

ler

Afte

rcoo

ler

Base Engine

Inte

rcoo

ler

LTAWater

(DEF)

Line Heaters

Tank Heater

Air Intake

Exhaust

Single or 2-stage turbocharging same as Tier 2

DPF

HC Injector

DO

C

DOC Catalyst &Particulate Filter

JW Cooling Circuit


Impact

PackagingSlightly increased space claim ‐ cooling systems and aftertreatment components. However, the DPF can often replace the muffler with same sound attenuation

InstallationUnderstand how to optimize your installation with new technology with additional aftertreatment.

Operation and MaintenanceUnderstand O&M impact due to DPFs, SCRs etc


Channel Readiness

T4 interim and final will require both engine & aftertreatment to be certified

Initial design and aftermarket

Distributor workshops to educate on Tier 4 regulations and compliance

Fuel Requirements – 15ppm ULSD

Service and Parts Training


Ongoing Market Challenges

Education on regulatory requirements to customers emergency vs. non‐emergency

EPA vs. Local

Different product offering for different markets

Different solutions for different power ranges

Need to work with customers on impact to design, installation, operation and maintenance, aftermarket and compliance


Questions?

Questions?


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