QSV 81/91 Series Gas Engines

Module 2 - Gas Engine Technology

Cummins Corporate Training

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 Gas Engine Technology
Learning Objectives
After completing this module you will be able to explain
basic gas engine technology and apply the theory to
practical applications.

Agenda
• Gas engine types and terminology
• Combustion
• Knock
• Emissions
• Air to Fuel Ratio
• Timing influence
• Open and Pre-chamber engines
• Equations

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 Gas Engine Types

• OTTO engines (4-stroke cycle)

– Spark-ignited: either Open chamber or Pre-chamber.

• Dual Fuel
– Diesel able to run on gas with Diesel pilot injection for ignition.

• Gas Diesel engines

– Gas engine running with high pressure pilot gas injection, able to
change over to run on diesel.

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 Gas Engine Terminology
• Stoichiometric Combustion
- The chemically perfect ratio of air and fuel to be burned in the engine.
• Lean-Burn Combustion
- Excess air enters the combustion chamber with the fuel.
• Excess Air Ratio (Lambda)
- A measure of the amount of excess air that is present (AF/AF Stoichiometric)
• Detonation (Knock)
- Occurs when combustion is not controlled. Fuel auto-ignites after the spark event,
which results in very high temperatures and pressure. Capable of causing extensive
engine damage.
• Pre-Ignition
- Similar to detonation, but in this case the fuel ignites before the spark. The result is
the same, multiple flame fronts and eventual engine damage.
• Hydrocarbon Fuel
- Fuel composed mainly of carbon, hydrogen. May contain other trace elements.

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 Gas Engine Terminology
• Methane Index
- A measure of the quality of the gas. Methane index increases with percentage of
Methane.
• Natural Gas
- Pipeline quality gas. Methane index greater than 75-80. When natural gas is
mentioned in this training, we are referring to pipeline gas. Cummins engines are not
currently designed to operate on bio-gas, digester gas, or landfill gas.

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 OTTO Working Cycle
• Thanks to this cycle, the thermal power produced by combustion is converted
into mechanical power. Theoretical diagram makes no account for losses.
Cylinder Note: Negative cylinder pressure is a
Pressure feature of gas engines as throttle plate
always gives some restriction.
C A/B = Compression
B/C = Ignition 30
C/D = Power
D/A = Exhaust

Action of
B Work Done Valve
8 Crossover
D
Ambient Work Required
For Compression
A 1
Pressure

TDC BDC Volume TDC BDC

Cycle theoretical diagram Cycle actual diagram
Thermo-dynamics of the four-stroke cycle

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 Combustion
• Chemical reaction between Carbon, Hydrogen
and Oxygen that's producing heat.

C and H provided by hydrocarbon fuel.

Air is needed to provide oxygen.

Some energy is compulsory to start the
combustion.

• According to the Air/fuel ratio, the reaction can

be rich, Stoichiometric or lean.

Lean combustion for our engines (more air).

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 Combustion Types Definition
Deflagration
• Name of normal combustion whose flame propagation
speed is below the speed of sound.
• Combustion start under control (spark or fuel injection)

Detonation or knocking or auto-ignition Normal Flame Propagation

• Ignition via ‘hot spots’ from previous combustion cycle
• Propagation speed supersonic.
• Start of combustion not controlled.
• Colliding flame fronts produce characteristic ‘knock’.
• Occurs after the spark event.
Causes : High cylinder P & T, Rich A/F mixture and
advanced timing. Knocking

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 Combustion Types Definition

Pre-ignition
• As percentage Propane increases over
1.7%, overall NG octane rating (burn
temp) is reduced.
• Ignition occurs at lower temperatures
due to reduced octane rating.
• Occurs before spark event.

REMEMBER !
Knock (detonation) Not to be confused with pre-ignition, results
are the same, i.e. high cylinder pressure / temperature and engine
damage. Pre-ignition occurs before the spark, Detonation occurs
after the spark.

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 Combustion Types Influence
• Without knocking • With knocking
Increased cylinder pressures results in increased
cylinder temperature.
Pressure
180
90 Bars 180
105 Bars 4,8

160 160
4,2
4
140 140 A

3,2 3,2
120 120

100 100 2,4

2,2

80 80
1,6
B B
60 1,2 60
0,8
40 40
0,2
0
20 20

0 -0,8 0 -0,8

QSV 91 Knock sensor output Time

Engine M<0.3 M>1
M - Speed
of sound Engine block designed for 200 Bars max.
Spark plugs & Pistons will be first to show signs of damage

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 Parameters That Influence Knocking
Increased / Likelihood
Parameter Decreased of knock

• Compression ratio (Rc) = V BDC / V TDC

• Inlet Manifold temperature (LT water circuit)

• Air/fuel ratio (decreasing = richer)

• Ignition timing (advanced)

• Methane index

• Load
Note: Piston and Cylinder design can also effect knock - No hot spots/Swirl

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 Emissions
Emissions
g / KWh EMISSIONS

12 C0 - Carbon Monoxide - forms with insufficient oxygen to form CO²

11 NOx - Nitrogen Oxide - forms at higher temperatures.

10 NMH - Non Methane Hydrocarbons - forms on incomplete combustion

or misfire.
9
8
7
Stoichiometric

6
5
NOx
4
3 Emissions
CO
2 (g/KWh)
1 RICH
NMHC LEAN

0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 Excess air ratio ( )
= (A/F) actual / (A/F) stoich

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 Engine Specification
The engine design specifications must;

• Account for all knocking parameters, and

• Meet the market requirements of ;

High power
High efficiency
Low Nox (emissions)

• This combination then determines the operational window.

(
=Operational window on the following diagrams).

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 Air to Fuel Ratio Influence
Emissions

The
QSV GAS 14

EP
goal

BM
BMEP

Stoichiometric

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 Air to Fuel Ratio Influence The
Window
Emissions

The
QSV GAS 14

EP
goal

BM
BMEP

Stoichiometric

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 Ignition Timing Influence
•Air excess ( )
QSV

Misfiring
Emission limit:
= 1.8 for TA LUFT
2
1.8
Knocking
1 Stoichiometric

Misfiring Ignition timing(°)

BTDC
10 20 30 40

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 QSV - Open Chamber Design
OC System Properties; Throttle Valve
• Electrical Efficiency in
Gas Mixer
the order of 35 - 38 %
• Emissions in the order of
0.6 TA LUFT.
• Lowest cost and
Turbo Air
complexity.
• Operates on a low gas
supply pressure.
• Typically used on Spark-Plug
generators 0.5 to 1.5 Mw. Duty Cycle Valve

Gas Mass Flow

Sensor
Piston * Low Pressure Gas
Supply

* The Gas and Air is mixed upstream of the turbocharger, therefore we are able to
use low a pressure gas supply system.

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 Other Combustion Systems - Comparison

Pre-Chamber Port Injection (PCPI)

• Benefits:
Spark-Plug
– Higher Ratings (10%) Pre-Chamber
– Better Transient Response Port
– Better Fuel Economy (10%) Injector
• Drawbacks:
– More complicated system and
control
– Higher Cost
PCPI System Properties;
• Electrical Efficiency in the order of 39 - 44%.
• Low emissions in the order of 0.5 TA LUFT. Piston
• High cost and complexity.
• Operates on a high gas supply pressure.
• Typically used on large generators 2.0 to 6.0 Mw.

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 Typical Pre-Chamber Design

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 Other Combustion Systems - Comparison
PCPM System Properties;
Pre-Chamber Pre Mix ( PCPM ) • Electrical Efficiency in the order of 39 - 43%.
• Low emissions in the order of 0.5 TA LUFT.
Pre-Chamber supply • Relatively low cost.
(approx 5%) Spark Plug • Operates on a low gas supply pressure.
• Typically used on generators 1.0 to 4.0 Mw.

Turbo Air

Throttle Valve
Duty Cycle Valve

Gas Mass Flow

Sensor
Piston * Low Pressure Gas
Supply

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 CHP - Medium Term Specification
Objective of Combined Heat and Power:
To provide more than one form of energy-
• Electricity.
• Pre-heat for boilers.
• Hot water for processes.
• To maximise the efficiency of the power plant.
New Combined Heat and Power Plants requirements:
• Highest exhaust temperature (to recover more).
• Highest lube-oil temperature (to enable recovery from its cooling).
• Highest water inlet temperature (just enough to cool wherever the
plant is).

TOTAL CHP SYSTEMS CAN BE UP TO 96 % EFFICIENT !

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 Approximate Gas Genset Energy Distribution
Total Gas Energy Consumption from Genset 100% Electrical Energy from Genset = 36%

50% 36% 36%

14%
Total Losses from Genset = 14%
• Radiated Heat losses
• Frictional losses
• Ancillary losses
• Electrical losses
14% - Windage
- Circulating currents

36%
50%
50%

Heat Energy Rejected to Engine Circuits = 50% Total Usable Gas Energy with CHP = 86%

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 Equations
Stoichiometric equation ( λ = 1) for any hydrocarbon fuel:
CxHy + (x + y/4)(O² + 3,78N2) xCO² + y/2H²O + 3,78(x+y/4) N2

General Stoichiometric equation ( λ =1) for methane only:

CH4 + 2(O² + 3.76N2) 1CO² + 2H²O + 7.56 N2

NOTE: Both equations assume ideal combustion conditions - no NOx or CO emissions

Air excess: λ = (m air / m gas) real / (m air / m gas) Stoichiometric

• Lean reaction Equation:
CxHy + λ (x+y/4)(O²+3,78N2)
xCO² + y/2 H²O + (λ-1)(x+Y/4)O² + λ (x+y/4) 3.78N2

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 Module 2 - Gas Engine Technology

End
Cummins Corporate Training

QSV Gas CUMMINS CORPORATION

CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV .03.