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Presented by the National Biodiesel Board Biodiesel Technical Training Course BIO 3A: Biodiesel Engine and Fleet Performance
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Bio 3A: Biodiesel fleet engine performance

Sep 11, 2014

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Page 1: Bio 3A: Biodiesel fleet engine performance

Presented by the

National Biodiesel Board

Biodiesel  Technical  Training  Course  

 BIO  3A:  Biodiesel  Engine  and  Fleet  Performance  

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Learning  Objec-ves  

•  Provide  access  to  industry  experts  for  more  detailed  ques-ons  and  answers  about  biodiesel  

•  Introduce  the  Na-onal  Biodiesel  Board’s  Diesel  Technician  Training  program  and  the  program  resources  to  the  audience  

•  Provide  informa-on  regarding  engine  performance  and  fleets  using  biodiesel  and  biodiesel  blends  across  the  US

2  

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Learning  Outcomes  

 

•  Be  able  to  iden-fy  which  public  and  private  fleets  use  biodiesel  and  why  

•  Be  able  to  explain  the  key  changes  made  to  a  fleet  preventa-ve  maintenance  program  when  switching  to  biodiesel.  

•  Be  able  to  properly  diagnose  and  make  recommenda-ons  regarding  biodiesel  use  and  vehicle  performance  

 3  

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 Key  Resources  

• Department of Energy (DOE)

• B100 & Blends

• Material Compatibility

• Engine Performance

• Diesel and Biodiesel Emissions

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   Fleet  Management    

Experiences  

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Fuel  proper-es  effects  on  Common  Rail  FIE  

•  Startability •  Accurate SOI •  Controlled HR

•  Leakage control •  Pressure control •  Durability/Fatigue •  Filter plugging

•  Gumming, sticking •  Deposits •  Filter plugging •  Corrosion / Wear

Specified Fuel properties: chemical, contamination, physical

Cetane # Density Aromatics & Volatility Sulfur Flash Pt

Hard Particle and ash contamination

Water contamination

Oxidation Stability Lubricity

Viscosity

Fatty Acid Methyl Esters

• Pressure control

• Quantity control

•  Elastomeric compatibility •  Cavitation

damage

•  Corrosion •  Acid oxidation •  Catalyst poisoning •  Smoke & Particulates

•  Fire Hazard •  Spill

Hazard •  Spark

Hazard

•  Wear •  Scuffing •  Seizure

•  Gumming, sticking •  Deposits •  Filter plugging •  Corrosion & Wear

•  Rough running (misfire) •  Corrosion •  Wear

• Abrasive Wear • Filter plugging

OTC and Refiner Additives •  Anticorrosion •  Cetane improvers •  Cold flow improvers •  Lubricity improvers •  Conductivity improvers

Refining process contaminants •  Catalysts •  Desulfurization agents •  Cross contamination

Distribution and storage process contaminants •  tank bottoms * pumps, pipes •  microbial * corrosion •  algae *varnish/sludge

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Biodiesel  Delivers  Important  Diesel  Proper-es  

•  Auto-­‐igni-on  =  Cetane  Number  over  50  •  BTU  Content  =  Similar  to  #1,  less  than  #2  •  Viscosity  =  Values  in  diesel  fuel  range  •  Cloud  Point  =  Current  biodiesel  higher  than  #2  •  Lubricity  =  Naturally  high  in  lubricity  •  Sulfur  =  Naturally  less  than  15  ppm  •  Cleanliness  =  ASTM  specs  same  as  petrodiesel    •  Stability  =  Spec  set  for  6  month  min.  shelf  life    •  Emissions  significantly  less  for  PM,  HC,  CO  

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Biodiesel  and  Engine  Manufacturers  

•  A]er  the  first  passage  of  ASTM  D6751  in  2001,  even  though  engine  manufacturers  voted  posi-ve  at  ASTM  most  were  not  yet  willing  to  put  their  name  behind  B20  

•  Na-onal  Biodiesel  Board  set  forth  on  intensive  effort  to  work  with  OEM’s  to  address  any  issues  and  concerns  

•  B20  Fleet  Evalua-on  Team  Formed:  Interna'onal,  John  Deere,  Na'onal  Biodiesel  Board,  Na'onal  Renewable  Energy  Lab,  Parker  –  Racor,  Siemens  Diesel  Systems,  Stanadyne  Corp,  Volkswagen  AG,  Volvo  Truck,  Fleetguard,  Bosch,  Case  New  Holland,  Caterpillar,  Cummins,  DaimlerChrysler,  Delphi  Diesel  Systems,  Department  of  Defense,  Engine  Manufacturers  Associa'on,  Ford  Motor  Co,  General  Motors  

 •  Develop  fact  based  informed  posi-on  on  B20  •  B20  Failure  Mode  and  Effects  Analysis  (FMEA)  

•  Detailed  iden-fica-on  of  everything  that  can  go  wrong  when  using  B20  •  Rank:    Severity,  Occurrence,  Detec-on  modes  •  Develop  RIN:    Risk  Iden-fica-on  Number  •  Develop  plan  to  address  high  RIN  areas    

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•  Ensure  the  B20  blend  meets  proper-es  for  ASTM  D  975,  Standard  Specifica-on  for  Diesel  Fuel  Oils  or  the  ASTM  specifica-on  for  B20  once  it  is  approved.  

•  Ensure  your  B20  supplier  provides  a  homogenous  product.    Avoid  long  term  storage  of  B20  to  prevent  degrada-on.  Biodiesel  should  be  used  within  six  months.  

•  Prior  to  transi-oning  to  B20,  it  is  recommended  that  tanks  be  cleaned  and  free  from  sediment  and  water.  Check  for  water  and  drain  regularly  if  needed.  Monitor  for  microbial  growth  and  treat  with  biocides  as  recommended  by  the  biocide  manufacturer.  See  the  NREL  Biodiesel  Storage  and  Handling  Guidelines  for  further  informa-on.  

B20 FET - Technical Guidance and Recommendations

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•  Fuel  filters  on  the  vehicles  and  in  the  delivery  system  may  need  to  be  changed  more  frequently  upon  ini-al  B20  use.  Biodiesel  and  biodiesel  blends  have  excellent  cleaning  proper-es.  The  use  of  B20  can  dissolve  sediments  in  the  fuel  system  and  result  in  the  need  to  change  filters  more  frequently  when  first  using  biodiesel  un-l  the  whole  system  has  been  cleaned  of  the  deposits  le]  by  the  petrodiesel.  

•  Be  aware  of  B20’s  cold  weather  proper-es  and  take  appropriate  precau-ons.  When  opera-ng  in  winter  climates,  use  winter  blended  diesel  fuel.  If  B20  is  to  be  used  in  winter  months,  make  sure  the  B20  cloud  point  is  adequate  for  the  geographical  region  and  -me  of  year  the  fuel  will  be  used.  

B20 FET - Technical Guidance and Recommendations

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•  Perform  regularly  scheduled  maintenance  as  dictated  by  the  engine  opera-on  and  maintenance  manual.  If  using  B20  in  seasonal  opera-ons  where  fuel  is  not  used  within  6  months,  consider  storage  enhancing  addi-ves  or  flushing  with  diesel  fuel  prior  to  storage.  

•  These  recommenda-ons  on  use  of  B20  are  preliminary  and  are  not  provided  to  extend  or  supplant  warranty  limita-on  provided  by  an  individual  engine  or  equipment  supplier.  Use  of  B20  blends  is  solely  at  the  discre-on  and  risk  of  the  customer  and  any  harm  effect  caused  by  the  use  of  B20  are  not  the  responsibility  of  the  engine  or  equipment  maker.  

B20 FET - Technical Guidance and Recommendations

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•  Biodiesel  is  the  pure,  or  100  percent,  biodiesel  fuel.  It  is  referred  to  as  B100  or  “neat”  biodiesel.  

•  A  biodiesel  blend  is  pure  biodiesel  blended  with  petrodiesel.  Biodiesel  blends  are  referred  to  as  BXX.  The  XX  indicates  the  amount  of  biodiesel  in  the  blend  (i.e.,  a  B20  blend  is  20  percent  by  volume  biodiesel  and  80  percent  by  volume  petrodiesel  ).  

•  Ensure  the  biodiesel  meets  the  ASTM  specifica-on  for  pure  biodiesel  (ASTM  D  6751)  before  blending  with  petrodiesel.  Purchase  biodiesel  and  biodiesel  blends  only  from  companies  that  have  been  registered  under  the  BQ-­‐9000  fuel  quality  program.  

B20 FET - Technical Guidance and Recommendations

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  B20  Fleet  Evalua-on  Team  NREL/NBB  B20  Bus  Fleet  Evalua-on  B20  Cummins  1000  hr.  Durability  Test  US  Postal  Service,  St.  Louis  Bus  System  Denver  Regional  Transit  Bus  System  Las  Vegas  Valley  Water  District  Clark  County,  NV  School  District  Connec-cut  DOT;  Keene,  NH;  NC  DOT;  Cedar  Rapids,  IA  Buses,  etc.  etc.  etc.    

 

Today’s Fleet examples

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Cummins  1000  Hour  Durability  B20  Study    

 The  objec-ve  was  to  operate  the  engine  for  1000  hr  using  B20  biodiesel  fuel,  and  do  a  compara-ve  analysis  with  engines  that  have  operated  under  the  same  type  of  condi-ons  using  #2D  diesel  fuel.    

hr

0 25 50 125 1000

Accelerated, high-load durability cycle

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Test  Engine  

  Cummins  prototype  2007  ISL    Six  cylinder  8.9  liter    Rated  power  of  330  BHP    Peak  torque  of  1150  ]•lb  at  1300  rpm    Diesel  Oxida-on  Catalyst  (DOC)    Diesel  Par-culate  Filter  (DPF)    Post  injec-on  (in-­‐cylinder)  for  ac-ve  regenera-on    Variable  geometry  turbocharger    Exhaust  gas  recircula-on  (EGR)  with  cooler    Cummins  fuel  injec-on  system  

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Test  Cycles  

Durability  Tes-ng   Accelerated   High-­‐load   Transient  cycle     Varying  load  and  speed   Cycle  repeated  for  1000  hr  

 Emissions  Tes-ng  

 Federal  Test  Procedure  (FTP)   One  cold  start  transient  FTP  test   Three  hot  start  transient  FTP  test   One  SET  Ramped  Modal  Cycle  

High Idle Low Idle

Peak Torque

Peak Power

>70% of durability cycle at full load

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Durability  &  Emission  Results  

  Approximately  17,000  gallons  of  B20  biodiesel  fuel  was  used  during  the  durability  test.  

  Test  went  well  and  was  successful.    There  were  no  biodiesel  related  failures  during  the  test,  and  no  reported  significant  changes  in  performance  of  the  engine.  

  Engine  performance  was  essen-ally  the  same  when  tested  at  125  &  1000  hr  of  accumulated  durability  opera-on.  

  Emission  results  indicate  that  THC,  CO,  and  PM  levels  were  not  significantly  different  between  the  B20  and  ULSD.      ~The  emission-­‐grade  B20  test  resulted  in  ≈6%  higher  NOx  (within  expected  range)  

  Fuel  consump-on  was  observed  to  be  ≈3%  higher  than  the  2007  cer-fied  ULSD  test  (within  expected  range).  

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Top of cylinder head No sludge deposits

Bottom of cylinder head Deposits comparable to #2D

Intake Valves Exhaust Valves

Results are typical for this type of test with #2D diesel fuel

Overhead  Components  

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Power  Transfer  Components  

Component   Comments  Crancksha]  Gear   Meets  rebuild  spec  

Cam  Gear   Meets  rebuild  spec  

Cam  Bushing   Meets  rebuild  spec  

Fuel  Pump  Gear   Meets  rebuild  spec  

Crancksha]   Meets  rebuild  spec  

Lower  &  Upper  Bearings  

Normal  wear  

Connec-ng  Rod   Meets  rebuild  spec  

Connec-ng  Rod  Bushing  

Meets  rebuild  spec  

During teardown, the crankshaft was found to be in very good condition, and results were comparable to #2D diesel fuel test.

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Power  Cylinder  Components  

Component   Comments  

Piston   Normal  light  wear  and  deposits.  

Cylinder  Liners   Normal  light  wear.  

Top  rings   Normal  uniform  face  wear.    Top  and  booom  side  look  typical.      

Middle  rings   Normal  face  wear.    Top  and  booom  sides  OK,  and  light  carboning.  

Oil  rings   Looked  good.    Very  liole  wear.  

Crosshatch visible in all six cylinders.

Results comparable to #2D diesel fuel test.

Ring Grooves Anti-Thrust Side

Cylinder 1

Top Piston Piston Bowl Front

Cylinder 1

Minor staining

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Cooling  and  Lube  Components  

Component   Comments  

Oil  pump   No  issues  

Oil  cooler  head   No  issues  

Oil  cooler  cover   No  issues  

Oil  pressure  regulator/bypass  

No  issues  

Piston  cooling  nozzles  

No  problems  due  to  B20.  

Oil  Pan   Normal  

Oil  suc-on  tube   Gasket  showed  good  imprint  of  seal  

Turbo  coolant/oil  lines  

Normal  

There were no failures found on the cooling and lube components. The wear and deposits found on the parts were normal and consistent with findings found on parts that ran with #2 diesel fuel in similar tests.

Bottom (Oil) Piston Rings

Cylinder 1 Top Cylinder 6 Bottom

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Air  Handling  Components  

Component   Comments  

Exhaust  Manifold   No  issues.  

EGR  Cooler   No  cracks,  light  coa-ng  of  soot  on  inlet  and  outlet  tubes.  No  soot  in  inlet  diffuser.  Findings  good  overall.  

EGR  Valve   Looked  good.    Normal  soot  accumula-on.      

EGR  gaskets,  hoses,  tubes,  shield,  moun-ng  plate,  crossover  

No  issues  found  due  to  running  with  B20.  

Carbon deposit layer was generated on the passage and inside parts of the EGR valve, but thickness was very thin and condition was dry which is normal for this durability test.

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A]ertreatment  Components  

Component   Comments  

Diesel  Oxida-on  Catalyst  (DOC)  

Looked  good.    No  face  plugging.  Blockages  found  appeared  like  debris  and  substrate  material.      Debris  was  analyzed  under  Electron  Dispersive  Spectroscopy  (EDS),  and  all  debris  found  is  expected  in  a  typical  DOC  a]er  1000  hr  of  opera-on,  whether  fueled  with  ULSD  or  biodiesel.    

Diesel  Par-culate  Filter  (DPF)  

Inlet  face  showed  signs  of  ash  build  up,  but  similar  to  diesel  fuel  for  this  type  of  test.    Outlet  looked  good  with  no  signs  of  soot.  No  failure  found.  

Inlet  and  outlet  sec-on  

Looked  good.  

Gaskets   Looked  good.  

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Fuel  System  Pictures  

Stage 1 Plunger Needle

No marks on needle surface or the edge.

Plunger Needle – Top View

Some slight staining.

Stage 2 Plunger Needle has some wear, but normal for this type of aggressive test.

Plunger Orifice not clogged with oil sludge or deposits

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Fuel  System  Components  

Rail  and  fuel  lines   Rail  –  No  abnormal  wear.    End  Fi?ng  –  No  unusual  wear.    HP  Fuel  Lines  –  No  visible  structural  deteriora-on  or  cracks  observed.  

Mechanical  Dump  Valve  (MDV)  

No  unusual  wear,  deteriora-on  or  sludge  buildup  observed  on  plungers,  plunger  seats  or  orifice.  1)  Stage  One  Plunger  –  No  wear  visible  on  the  needle  surface  or  the  edge.    Some  slight  staining  seen  on  plunger  base.  2)  Stage  Two  Plunger  –  Some  wear,  but  normal.    Plunger  orifice  not  clogged  with  oil  sludge  or  deposits.  

Injectors   Injector  performance  test  and  photos  indicate  that  the  injectors  were  consistent  with  injectors  that  ran  with  #2D  diesel  fuel.    

So]  Lines   No  visible  damage  to  any  sec-on  of  the  internal  wall  of  the  used  fuel  tubes  indica-ng  that  the  tubing  liner  material  is  resistant  to  the  B20  temperatures  and  pressures  during  the  engine  performance  test.    

Overall   There  were  no  signs  of  severe  or  aggressive  corrosion  pirng  damage  on  any  of  the  surfaces.  

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Summary  

  A  Cummins  2007  prototype  8.9  liter  ISL  diesel  engine  equipped  with  DOC,  DPF,  VGT,  and  EGR  with  cooler  was  operated  successfully  at  SwRI  using  a  high-­‐load  accelerated  durability  cycle  for  1000  hr  with  a  B20  blend  of      soy-­‐based  biodiesel  and  ULSD.  

  During  the  durability  tes-ng,  no  biodiesel  related  failures  occurred.  

  Engine  performance  was  essen-ally  the  same  when  tested  at  125  and  1000  hr  of  accumulated  durability  opera-on.    Emissions  measurements  indicate  the  HC,  CO,  and  PM  were  not  significantly  different  between  the  B20  and  ULSD  tests,  and  NOx  increased  with  B20  fuel.    Fuel  consump-on  also  increased  with  B20  fuel.  

  A  thorough  engine  teardown  evalua-on  of  the  overhead,  power  transfer,  cylinder,  cooling,  lube,  air  handling,  gaskets,  a]ertreatment,  and  fuel  system  parts  was  performed.  

  There  were  no  failures  found  on  the  engine  components  that  were  directly  aoributable  to  running  biodiesel  B20.  

  The  wear  and  deposits  found  were  normal  and  consistent  with  findings  from  parts  that  ran  with  #2  diesel  fuel  in  similar  tests.  

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Biodiesel  Resources  

 www.biodiesel.org  • Biodiesel  Training  Toolkit    • News  Releases  &  Informa-on  Resources  

• Technical  Library,  Spec  Sheets  &  Videos  • OEM  Warranty  Posi-ons  on  Biodiesel  

•   U.S.  Diesel  Vehicle  List  

 www.BQ-­‐9000.org    • Lis-ng  of  BQ-­‐9000  Cer-fied  Companies  

 www.biotrucker.com  • Lis-ng  of  BioTrucker  retail  sites    

 www.biodieselautomoNve.org  • Dedicated to information exchange for biodiesel & diesel technicians

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Rachel  Burton  NBB  Diesel  Technician  Training    Program  [email protected]  Tel:  919-­‐444-­‐3495    Call  NBB  at  1-­‐800-­‐841-­‐5849  Visit  www.biodiesel.org