1 apta bus maintenance webinar part 1 introducing the 2013 diesel engine speaker: tom hodek,...
TRANSCRIPT
1
APTA Bus Maintenance Webinar
• Part 1
Introducing the 2013 Diesel Engine
Speaker: Tom Hodek, Cummins, Inc
• Part 2
Long Beach Transit: Embracing CNG
Speaker: Rolando Cruz, LBT
APTA Maintenance Webinar- Introducing the 2013 Engine
Tom Hodek
January 24, 2013
Special Thanks
3
Discussion Topics
Emissions Regulation– Past and Present
– How it has driven technology
2013 Impact on Maintenance– OBD / Fault Codes
– Hardware Changes
– Service Tools
Future Regulations– GHG Regs
– Predicted Maintenance Changes
4
2010: Near-Zero NOx and PM
NOx / NOx+HC Particulate
0
2
4
6
8
10
12
1988 1990 1995 2000 2005 2010 2015 2020
10.7g/HP-hr
6.0g/HP-hr
5.0g/HP-hr
4.0g/HP-hr
2.5g/HP-hr
1.2g/HP-hr*0.2g/HP-hr
0
0.1
0.2
0.3
0.4
0.5
0.6
1988 1990 1995 2000 2005 2010 2015 2020
0.6g/HP-hr
0.25g/HP-hr
0.1g/HP-hr
0.01g/HP-hrUrban Bus 0.05g/HP-hr
5
Emissions Reduction Impact
=
2000
1990 2000 2010
Nox (g/hp-hr) 11 4 0.2
PM (g/hp-hr) 0.59 0.05 0.01
6
Emissions Reduction Impact
=
2000 2013 (2010)
(20)
1990 2000 2010
Nox (g/hp-hr) 11 4 0.2
PM (g/hp-hr) 0.59 0.05 0.01
7
Emissions Reduction Impact
=
1990
1990 2000 2010
Nox (g/hp-hr) 11 4 0.2
PM (g/hp-hr) 0.59 0.05 0.01
8
Emissions Reduction Impact
=
2013 (2010)
(55)
1990
1990 2000 2010
Nox (g/hp-hr) 11 4 0.2
PM (g/hp-hr) 0.59 0.05 0.01
9
Evolution of Technology
10
Air to Air Aftercooling
Diesel Particulate Filter
Selective Catalytic Reduction
Cooled Exhaust Gas Recirculation
Electronic Fuel Systems
1990 2000 2010 2020
NOx, PM
Over 9
0% R
educ
tion
of
Nitrog
en O
xides
and
Par
ticula
te M
atte
r
Evolution of Technology
11
CO2
and
FuelEfficiency
Aftercooling
Diesel Particulate Filter
Selective Catalytic Reduction
Cooled Exhaust Gas Recirculation
Electronic Fuel Systems
1990 2000 2010 2020
NOx, PM
Over 9
0% R
educ
tion
of
Nitrog
en O
xides
and
Par
ticula
te M
atte
r
12
13
Aftertreatment System
Filtration and Diesel Exhaust Fluid
Integrating Critical Subsystems
Turbochargers
Electronic Controls
CombustionTechnology
Fuel Systems
Cummins 2013 Engines
Same NOx and PM emissions regulations as 2010– 0.2g NOx and 0.01g PM
Same base engine and aftertreament as 2010 - 2012– New ECM
• Integrated engine and aftertreatment controls
– Intake air throttle for closed loop control (emissions)
OBD (On-Board Diagnostics) required – Diesel Only– New fault codes added to monitor emissions sytems
14
15
New ECMNew ECM
Pictures of Air Intake and ECM
16
New Air Intake ThrottleNew Air Intake Throttle
What is OBD?
On-Board Diagnostics– Monitors nearly every component that can affect the
emissions control system
– Tests emissions-related components and systems to detect malfunctions
– Similar to passenger car systems or Cummins Turbodiesel in RAM Pick-up / Chassis Cab which have OBD-II systems for many years
17
Malfunction Indicator Lamp (MIL)
Located on the dash of the vehicle
It illuminates to indicate an OBD related fault
Simplifies diagnostic and repair procedures for the technician and servicing location
18
On-Board Diagnostics (OBD)
19
Engine System Monitoring
Aftertreatment System Monitoring
ECM Monitoring
MIL
Service Tools
What Does OBD Mean For The Transit Industry?
Better monitoring of emissions systems
Increased accuracy in determining the root cause of emissions-related faults
Provides early warning of malfunctions
20
Maintenance Changes for 2013
Fuel Filter change intervals (now at every oil change)
– NanoNet fuel filter medium
Inspection intervals reduced
– Radiator cap and SCA levels (20K to 15K miles)
– Engine drive belts & tensioner (40K to 30K miles)
– Air compressor discharge line (80K to 60K miles)
Aftertreatment servicing
– Frequent regeneration faults
OEM Coolant Recover Tanks
– Add Coolant to recovery tank, not top tank
OBD Fault Codes
– New fault codes all added for emissions compliance
– Cummins Insite / Generic Scan Tool21
Service Tools
22
INSITE – Maintains ability to perform Cummins specific special tests whereas a generic scan tool cannot.
QSOL (QuickServe OnLine)
EDS – Next Generation Diagnostic Tool product offered through Cummins certified repair locations.
OBD connector style will be the same 9-pin connector used previously
23
Evolution of Technology
CO2
and
FuelEfficiency
Aftercooling
Diesel Particulate Filter
Selective Catalytic Reduction
Cooled Exhaust Gas Recirculation
Electronic Fuel Systems
1990 2000 2010 2020
NOx, PM
Over 9
0% R
educ
tion
of
Nitrog
en O
xides
and
Par
ticula
te M
atte
r
Future Regulations
2014 GHG Standards
– CO2 Limits: Reduce by 3% in 2014 to 9% total in 2017 over a 2010 industry baseline
– N2O and CH4 Limits (already met in 2010)
Cummins EPA 2013 compliant engines meet 2014 Greenhouse Gas and Fuel Efficiency standards
OEM (TVM) needs to use tires that are certified for compliance with GHG reduction (rolling resistance)
24
Hybrid Engine Regulations
Cummins will offer Hybrid engines that meet both EPA and ARB 2013 certification requirements.
Hybrid ratings will be distinct from conventional (non-Hybrid) ratings
Hybrid ratings with Engine Start Stop (ESS) capability will be distinct from non ESS Hybrid ratings and will be limited to one ISB Transit Bus rating. (First availability: July 2013)
25
Future Development
Vehicle Manufacturer Integration– All subsystems
Cooling System Improvements
Fuel Economy– GHG Compliance in 2014 and 2017
Aftertreatment– Improved Efficiency
Future Maintenance Requirements– None at this time
26
Thank You
27
Long Beach TransitEmbracing CNG
APTA WebinarJanuary 24, 2013
Agenda
Background Why CNG? Procurement
– CNG Station / Site Modification
– CNG Buses
Training SCRTTC
LBT Mission Long Beach Transit is
in business to provide public transportation services that enhance and improve the quality of life for the people in our community.
We serve Long Beach, along with 11 other cities – 98 square miles
29 million ridership
Quality of Life Sustainability – drives our decision to clean
up emissions on our vehicles Diesel Coaches – all purchases prior to 2003
– Installed particulate traps on diesel buses in 2001
– Early adopter of ultra-low sulfur diesel
2003 made a decision to go gas hybrid– Procured 89 gasoline hybrid electric buses to date
– Staff and operations vehicles are actively being replaced with hybrids
2010 – completed alternative fuel study with WVU – essence maintain diverse fuel choice
CNG Plans LBT planned on CNG for 2015 CNG economically good vs gas hybrid
– Lower Operating Costs w/ tax credit– Infrastructure costs - break even point at one
property for 40 coaches & other 70
ISE bankruptcy in late 2010 CNG purchases moved to 2012
– Must build a CNG station within one year– Modify both facilities to accommodate CNG– Procure 64 buses with CNG engines
Fleet Makeup Revenue Fleet
– 171 – 40’ New Flyer buses (89 gasoline electric hybrid)– 13 – 60’ New Flyer articulated buses– 64 CNG – 40’ Gillig BRT– 10 Electric buses in 2014
Other Services– 17 Dial-A-Lift vans (Paratransit)– 4 boats (2 AquaBus & 2 AquaLink)– 1 Charter (Prevost)
Support Vehicles– 31 service veh for supervisor, staff & operators– 25 maintenance service vehicles
TOTAL of 326 VEHICLES 4 Propulsion Systems (Diesel, Gasoline Hybrid,
CNG & All-Electric)
CNG Station, Infrastructure Modification & Buses
Project Plan
CNG Project Goals Provide CNG fueling station able to fuel
77 – 95 coaches Upgrade infrastructure to accommodate
repairs in entire shop & fuel island Prepare utilities for CNG (gas &
electricity) Buy 64 CNG buses Get LBT transitioned to CNG Environmental understanding - ESMS
Project Constraints Goal 1 year – anticipating delivery of
new CNG coaches Budget for station was tight – need to
keep within $6.2 million Heavy workload on facility team
– Limited Staff Experience for CNG – Limited Staff Time for Project
Need City approval & cooperation (including LB Fire Department) – avoid EIR if at all possible
CNG Station Contract Awarded 4 qualified proposals received ranging
from $4.5 to $6.18 million– Contract Awarded to Amtek Construction,
Lowest bid at $4.5 million
Proposed Angi Energy Systems– Compressors – five (500-scfm/250-hp)
– Gas Dryer - accommodate 3000 scfm
– Two (2) Buffer Storage paks– 2 CNG fast-fill Dispensers & 1 slow
Modify all of LJ facility (12 bays) & 3 bays at AA facility
Maintenance Impact Station Need Daily inspections & scheduled
PM’s LBT chose to contract out
– Amtek – 1 year maintenance agreement– Clean Energy – doing daily & oversight
Going out to bid to award long-term contract, still need some facility training
Need to train all employees on Safety & Maintenance on fueling
CNG Coach Purchases Piggy Back - contract with Gillig for 64
coaches (after full evaluation)– Cummins Engine – ISL G - 280– ZF Transmission – Eco Life 6AP 1400B– CNG Tanks & Fueling System– Gas Detection w/ Fire suppression
Maintenance Impact Buses Fluids resulting from CNG / ISLG:
– A low ash engine oil– A premium long life coolant
Material Review & order Preventative Maintenance Impact
– Gas detectors & system health
– Inspection of CNG components, valves, piping, leak detection, filter draining & replace
– CNG tank inspection at 3 yrs or 36,000 miles by a “certified” inspector, required training and CSA test for cert. LBT will do once per year.
CNG Training
Project Plan
Training Training Needs
– CNG Station / Site Safety– CNG Tanks / Safety– CNG Engine
No one Stop Shopping LBT staff looked at all options
– Amtek / ANGI– Natl Gas Vehicle Institute (NGVI)– Gillig, Cummins, Amerex– SCRTTC
CNG Site Awareness & Safety Facility - ANGI
(Fuel Station) Utility - CNG Safety
& Fueling Maintenance - CNG
Safety / Methane detection
Staff – CNG Awareness
612 Total Hours
Bus Safety / Tank Certification Gillig CNG Safety,
PM, Air systems Amerex Fire &
Methane Detection NGVI Safety and
Tank inspection Tank Inspection –
SCRTTC via LB City College1,224 Total Hours
CNG Engine Cummins – 2 days
– Crash course - Cradle to Grave– Taught by skilled technician
SCRTTC Course– 4 courses – total of 6 days– Spread out over time and can do at a slower
pace with standardized course & trained instructor
LBT limited the amount of mechanics in courses intends to expand
SCRTTCSouthern California Regional Transit Training Consortium
The Future in Training
The SCRTTC Purpose
To provide a training resource network, comprised of public and
private organizations, focused on the development and employment of the
transit industry’s workforce that is proficient in the standards, practices and procedures for incumbent and
new workers.
The SCRTTC Overview California Corporation and 501 c (3) Non-Profit –
formed in 2005 Partnership of 48 members consisting of Transit
Systems, Community Colleges, Affiliate Members and Private Partners
Provide research to demonstrate feasibility of a new transit workforce development ‘Learning Model’
Develop and deliver Transit Training providing the workforce knowledge of ITS standards, practices, and procedures.
The SCRTTC Goals Develop a new “Learning Model” to increase the
professional and technical competency of the Southern California public transit workforce
Assure that this new “Learning Model” includes the elements of Intelligent Transportation Systems (ITS)
Develop industry driven, competency based courses that meet present and future needs
Deliver standard courses to mechanics throughout the region via colleges
SCRTTC Transit MembersSouthern CA Members
•Antelope Valley Transit Authority•Arcadia Transit•Beach Cities Transit•Claremont Dial-a-ride / Pomona Valley Transportation Authority•Commerce Municipal Bus Lines•Culver City Municipal Bus Lines•Foothill Transit•Gardena Municipal Bus Lines•Gold Coast Transit•LA DOT•La Mirada Transit•LA METRO•Long Beach Transit
• Montebello Bus Lines• Norwalk Transit• OCTA• OMNITRANS• Santa Clarita • Santa Monica Big Blue Bus
(BBB) • Torrance Transit Systems• Sunline Transit
Other Transit Agencies• Fresno Area Express• Monterey-Salinas Transit District• Roaring Forks Transit Authority• San Joaquin RTD
SCRTTC College & PartnersCollege Members
Cerritos College Citrus College College of the Desert Colorado Mountain College Cypress College El Camino College Golden West College Kern Community College
District LA Trade Tech College Long Beach City College Rio Hondo College Saddleback College San Diego Miramar College Santa Ana College
Affiliate Members & Partners American Public Transportation
Association Advanced Transportation
Technology and Energy Initiative (ATTEi)
California State University - LB Colorado Transit Association UC, San Diego USC - Mettrans ATech Training Inc., Walton, KY Proterra, Golden CO Clean Energy Complete Coach Works New Flyer of America
SCRTTC Training Hours Training Delivered - Life To Date
– Total Hours of training delivered: 50,184
– Total Participants trained: 3,504
Cummins 8.9 Series (Level I, Insite, Level II):– Total Hours of training delivered: 4,816
– Total Participants trained to date: 342
CNG 1-day Safety:– Total Hours of training delivered: 96
– Total Participants trained to date: 12
CNG Cylinder tank inspection:– Total Hours of training delivered: 576
– Total Participants trained: 36
CNG Training CNG Transit Vehicle Safety
Training - #SC-CG-4100-I– Basic fuel characteristics regarding
flammability
– Basic fuel characteristics regarding pressure
– Basic pressure system design
– Safety related pressure system components
– Basic cylinder care & damage
– Proper depressurization techniques
– Pressure system component servicing
– High pressure fitting servicing
– Leak detection techniques
Cummins INSITE Diagnostic Software - #SC-EN-1712-I
– Select, add and connect proper adapters to a bus
– Access, custom group, and verify parameters
– Access, define, research, and clear fault codes
– Produce snapshots, data logging, and Graphing
– Look up engine derate, enabling criteria and other troubleshooting technique information
– Navigate the Electronic service tools for Cummins
Cummins ISL-G Engine Mgmt System Level I - #SC-EN-1710-I
– Define Mass Air Flow Fuel Mgmt Systems– Identify, locate & test parameters with:
• DVOM
• Temperature Sensors
• a Pressure Sensors
• Position Sensors
• Voltage Producing Sensors
• Mass Gas & Air Flow Sensors
– Use INSITE to verify parameters
Cummins ISL-G Engine Mgmt System Level II - #SC-EN-1711-I
– Diagnose faults using INSITE for:• Ignition Systems
• Temperature Sensors
• Pressure Sensors
• Position Sensors
• Voltage Producing Sensors
• Mass Gas & Air Flow Sensors
– Use INSITE to verify parameters
The Difference in Courses Courses developed with the learning model
– College collaborates with transit agency (& vendors) to develop curriculum
– Standard set of materials created & approved
Beta Testing of course with Subject Matter Experts – changes made to coursework
Train-the-Trainer delivered to ensure quality of trainers
Courses refreshed every 3 years
Transit’s benefit in use of SCRTTC Standardized course Manage Technicians Time
– Less time off floor – can spread out (2–3 at a time)
– New Technicians come in, can get training
Sharing of Resources – – Reduced cost to each agency
– Multiple agencies come to course
Technicians get to Network Colleges are familiar with transit agencies /
– Great recruitment for future
– Students can learn skills required for transit
The Future of Training Continued course development of
advanced technology More Partnerships with Vendor
– Vendor use of SCRTTC to develop course will provide standardized, transit approved courses
– Standard material (pre/post test, objectives, student material/exercises, instructor material)
Sharing of Material & TTT with non-regional members - expansion
For More
Information
• History & info of SCRTTC at finger tips
• Ability to look at any class curriculum
• On-line registration for one or group
http://scrttc.com/
Rolando [email protected]