QSV 81/91 Series Gas Engines
Module 2 - Gas Engine Technology
Cummins Corporate Training
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV .03.
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
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV. 03.
2
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.
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV. 03.
3
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.
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV. 03.
4
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.
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV. 03.
5
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
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV. 03.
6
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).
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV. 03.
7
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
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV. 03.
8
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.
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV. 03.
9
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
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV. 03.
10
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
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV. 03.
11
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
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV. 03.
12
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).
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV. 03.
13
Air to Fuel Ratio Influence
Emissions
The
QSV GAS 14
EP
goal
BM
BMEP
Stoichiometric
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV. 03.
14
Air to Fuel Ratio Influence The
Window
Emissions
The
QSV GAS 14
EP
goal
BM
BMEP
Stoichiometric
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV. 03.
15
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
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV. 03.
16
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.
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV. 03.
17
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.
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV. 03.
18
Typical Pre-Chamber Design
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV. 03.
19
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
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV. 03.
20
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 !
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV. 03.
21
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%
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV. 03.
22
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
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV. 03.
23
Module 2 - Gas Engine Technology
End
Cummins Corporate Training
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Technology / BMG / 01 - 01 / REV .03.
