March 2018

ePCC System Waukesha VHP Engine Upgrade Packages

Division Engines

6/21/2018 2

Lean Burn Combustion

The Challenge

A leaner mixture is more difficult to ignite and has typically a slower

flame propagation

The Obvious Idea

Improved ignition (key issue)

The solution

Pre Combustion Chamber

Order of magnitude higher ignition energy

BUT, it requires precise air/fuel ratio control to ensure stable main

chamber combustion

6/21/2018 3

PCC Ignition

PCC – Pre Combustion Chamber

Small cavity providing an easy to ignite environment (stoichiometric)

Order of magnitude higher ignition energy compared to open chamber

ignition

State of the Art

Check valves

Problems:

Inconsistent fueling

Frequently clogged / quit working

Varying Air/Fuel ratio

Too rich Air/Fuel ratio during startup

Fuel slip

6/21/2018 4

Combustion Stability at Lean Mixtures

Ignition (Pre Chamber)

Evaluation of PCC performance – MCC pressure and PCC ion sense

170 180 190 200 210 220 230

200

250

300

350

400

450

500

550

600

650

700

Crank angle, deg ABDC

Cylin

de

r p

ressu

re, P

SI

Pressure

Avg pressure

PCC A

PCC B

170 180 190 200 210 220 230

200

250

300

350

400

450

500

550

600

650

700

Crank angle, deg ABDC

Cylin

de

r p

ressu

re, P

SI

Pressure

Avg pressure

PCC A

PCC B

Slow and late main

chamber combustion due

to delayed PCC firing

Stable main chamber

combustion due to

perfect PCC firing

6/21/2018 5

Combustion Stability with ePCC

0 5 10 15 20 25 302.5

3

3.5

4

4.5

5

5.5

6x 10

6

loc PP, colVar: IonA.caVmax-IonB.caVmax

PP

cyl4CycleNewberry060508@1151.mat

0.0E+000

5.0E+000

1.0E+001

1.5E+001

2.0E+001

2.5E+001

3.0E+001

3.5E+001

4.0E+001

4.5E+001

5.0E+001

Peak pressure location

Peak p

ressure

Stable combustion

Poor combustion due

to late or missing

ignition of one or both

pre chambers (Check

valve)

Perc

enta

ge o

f po

or

com

bustion c

ycle

s

Check valve ePCC0

1

2

3

4

Avg fra

ction o

f cycle

s p

er

run

Slow burning

PCC not firing

PCC late

Sum of both

ePCC tested at

even leaner

combustion

Perc

enta

ge o

f po

or

com

bustion c

ycle

s

Check valve ePCC0

1

2

3

4

Avg fra

ction o

f cycle

s p

er

run

Slow burning

PCC not firing

PCC late

Sum of both

ePCC tested at

even leaner

combustion

Check Valve Performance Check Valve vs.

Electronic Valve

The real solution is a pre combustion chamber with

electronic fuel injection

ePCC

6/21/2018 6

Implementation on High-Speed Engines

Results Waukesha 7042GL

Bulk engine PCC fueling optimization (same pulse width for all cylinders,

individual adjustment possible)

Improvements with ePCC could be demonstrated compared to new and

optimal adjusted check valve fueling

CV PP vs TER, engine average

1000 rpm, 100% torque

0.00

1.00

2.00

3.00

4.00

5.00

6.00

0.500 0.510 0.520 0.530 0.540 0.550 0.560 0.570 0.580

TER

CV

PP

Check valve

ePCC

Increasing with check valve runtime

Leaner AFR

Co

mb

us

tio

n

sta

ble

u

ns

tab

le

6/21/2018 7

ePCC Waukesha 7042GL Package

Field and Lab Test Results

Improved combustion stability at rated

operating conditions as well as

reduced hydrocarbons emission and

slightly improved fuel consumption

Achieved stable combustion down to

0.5g/bHp-hr NOx

6/21/2018 8

ePCC Waukesha 7042GL Package

Field Installation

6/21/2018 9

ePCC Installation Experience

Slow Speed Engines

100+ engines are running successfully in the field

Very positive customer feedback due to outstanding performance

First installation in operation for more than 10 years

High Speed Gas Engines

20+ installations on Superior 825 and Waukesha VHP engines

Combustion performance improvements are identical to large bore

engine results

First installation in operation since Nov 2011

6/21/2018 10

ePCC Highspeed Package – Summary

The Need

Most lean burn engines require pre combustion chambers for igniting the lean

mixture. The fueling is controlled via check valves, which perform poorly:

Frequently clogged / quit working

Inconsistent fueling; varying Air/Fuel ratio

Too rich Air/Fuel ratio during startup; fuel slip

Root cause #1 for combustion issues

The Solution

Electronically controlled pre chamber fuel valve – ePCC

No maintenance issues

Precise and consistent fueling (each cycle)

Stable combustion even at very lean mixtures

Improved startup, smooth and efficient idling

Small Fuel Saving’s

Pre Chamber

Check Valve

Controller

ePCC

We are Engine.