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.
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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
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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
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Technology ►560 ‐ 900 bkW
NOx Reduction System
Engine only, proven technology: ACERT + additional air management
Compact and cost‐effective design
1/5/2011 Electrical Generating Systems Association Fall Conference
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
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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)
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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.
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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.
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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
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Transitioning from Tier 3 to iT4 Engines
Kyle TingleSr. Accounts Manager
John Deere Power SystemsWaterloo, IA
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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
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iT4 Technology:Turbocharging, Air Management
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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)
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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
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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
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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
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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
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Large Diesel Gendrives of Tomorrow
Christine UenoManager, Regulatory Compliance
MTU Detroit Diesel, Inc.
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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
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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
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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
1/5/2011 Electrical Generating Systems Association Fall Conference
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)
1/5/2011 Electrical Generating Systems Association Fall Conference
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
1/5/2011 Electrical Generating Systems Association Fall Conference
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?
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How are MTU distributors getting ready?
Provide training Emission regulations
Installation of aftertreatment
Delegated assembly
Availability of prototype engines
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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
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Tier 4 Panel Discussion
By Vivek MalapatiSenior Product Planner, Cummins Power Generation
1/5/2011 Electrical Generating Systems Association Fall Conference
Agenda
Tier 4 technology path
Distributor/Dealer Readiness
Ongoing market challenges
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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
1/5/2011 Electrical Generating Systems Association Fall Conference
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
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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.
1/5/2011 Electrical Generating Systems Association Fall Conference
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%.
1/5/2011 Electrical Generating Systems Association Fall Conference
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
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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
1/5/2011 Electrical Generating Systems Association Fall Conference
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
1/5/2011 Electrical Generating Systems Association Fall Conference
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
1/5/2011 Electrical Generating Systems Association Fall Conference