Cummins Westport Product OverviewApril 2011Explore Every Alternative.Gordon ExelVice President and General Manager Americas
CWI Corporate OverviewExplore Every Alternative.
Cummins Westport Inc. (CWI) is a Joint Venture of Westport & Cummins Cummins Inc. Westport Cummins Inc. Innovations Inc. 50/50 “CWI” Cummins Westport Inc. 3
Cummins Inc. More than 75 years –Leader in American diesel manufacturing World’s largest builder of commercial diesels Designs, manufactures, distributes, and services – electric power generation systems, engines, and related technologies, including fuel systems, controls, air handling, filtration, and emissions solutions. Headquartered in Columbus, Indiana (USA), – serves customers in approximately 190 countries and territories through a network of more than 500 company-owned and independent distributor locations and approximately 5,200 dealer locations. – Cummins reported sales of $14.3 billion in 2008 Cummins product development & manufacturing alliances include: – Case, New Holland, IVECO, Komatsu, Westport, and Scania.
Westport Innovations Inc. Recognized as the world leader in gaseous fuel engine technology Originated from research at UBC in early 1990’s Public company on TSE/NASDAQ, formed in 1995 Almost 300 people World-wide State-of-the-art facilities in Vancouver, BC, Canada Vancouver, Canada: 7,400 m2 (78,000 ft2) of laboratory and office space Leading Natural Gas expertise and industry relationships Technology Innovation and Application Award
Natural Gas Engine Reliability Improvement C8.3G / C Gas Plus - Reliability 7 C8.3 G C Gas Plus 6 5 Six FoldRelative Cost 4 Reliability 3 Improvement 2 1 0 1999 3 1999 4 2000 1 2000 2 2000 3 2000 4 2001 1 2001 2 2001 3 2001 4 2002 1 2002 2 2002 3 2002 4 Build Quarter Cummins Confidential
CWI: Fully integrated within Cummins. We areCummins’ automotive natural gas engine company Product Cummins Tech Center Engineering Cummins VPI Process Manufacturing Cummins Plants Cummins Account Sales Teams & Distributors Warranty Cummins Warranty Parts Cummins Distributors & Service It’s a Cummins Engine! Cummins Confidential
Why Use Heavy Duty Natural GasEnginesExplore Every Alternative.
Natural Gas Market Drivers Environmental Leadership Meets/beats Regulated 2010 EPA/Euro EEV Lower greenhouse gas emissionsEconomic Benefits Energy Security Improved Reliability Reduced reliance on oil Improved Efficiency Biomethane capable Lower total fuel costs Pathway to hydrogen Cummins Confidential
Growing Natural Gas Availability Will Keep Price Down Forecast: Delivered Energy Prices for Diesel & Gas Shale Plays are an Industry Changing Natural Gas Transportation Fuels, 2010-2035 Breakthrough2008 Equivalent U.S. Dollars Per Gallon Equivalent 4.00 3.50 3.00 2.50 2.00 1.50 North America Resource Estimates 2,119 Tcf of Total Resource 1.00 2010 2015 2020 2025 2030 2035 95+ Year Supply at 75 Bcf/d Natural Gas Diesel 70+ Year Supply at 100 Bcf/dSource U.S. Energy Information Administration, Annual Energy Outlook 2010 13
Traditional Focus-Regulated Emissions Euro 2 1996 EPA 1994 EPA 1998 5.0 Euro 3 2001 4.0 NOx [g/HP-hr] Euro 4 2006 EPA 2004 2.5 Euro 5 /EEV 2009 1.2 EPA 2007 JE05 0.2 EPA 2010/Euro 6 0.01 0.015 0.075 0.100.11 PARTICULATE [g/HP-hr]
California Air Resources Board Executive Order Cummins Westport Confidential 15
Tough California Emissions Standardsand Cummins Westport EnginesCalifornia Air Resources Board - Executive Order Shows Emissions ResultsISL G is under 2010 NOx and PM regulations NMHC NOx CO PM FTP EUR FTP EUR FTP EUR FTP EUR O O O O STD 0.14 0.14 0.2 0.2 15.5 15.5 0.01 0.01 CERT 0.13 0.04 0.13 0.01 1.2 0.4 0.002 0.000 FTP: Federal Test Procedure [ transient and steady state ] EURO: Euro III European Steady-State Cycle STD: standard or emissions test cap CERT: certification level Further Reductions are Being Explored • Sub Ambient 16 •“Zero” Emissions
Internal Combustion Engines &Green House Gases (GHG) Explore Every Alternative.
GHG & Fuel Economy ImprovementPhase 1 6 Sigma tools compared 2007 ISL G and 2001 C Gas Plus at Orange County Transit Authority (OCTA) Demonstrated + 5% improvementPhase 2 US GHG Regulations 2013 - No change 2017 – Another 3% Improvement 18
GHG Well to Wheel for Urban Bus - GH Genius 2010 Results (Vancouver, Canada) Extraction Processing Transportation End user Total and storage Natural Gas 1,402.4 g/km 115 g/km 49.5 g/km 53.9 g/km 1,183.9 g/km Diesel 1,811.7 g/km 268.8g/km 179.5 g/km 9.7 g/km 1,353.7g/km 22.6% GHG reduction Including vehicle material and assembly - 21.9% GHGSource:http://www.nrcan.gc.ca/es/etb/ctfca/PDFs/GHGenius/gh_genius_pamphlet0405_e.html
Biomethane Impact Bowerman Landfill Extraction Processi Transporta End user Total ng tion and WM Altamont storage Natura l Gas 1,402.4 g/km 115 g/km 49.5 53.9 g/km 1,183.9 g/km g/km Diesel Bio Fuel improves GHG impact 1,811.7 g/km Biomethane: 75-200% reduction 268.8g/km 179.5 9.7 g/km 1,353.7g/k Source:http://www. g/km m nsca.org.uk/assets/ biogas_ as_transport_fuel_j une06.pdf Compressed Natural Gas - 22% GHG reduction
Agriculture Waste Dairy farm uses Hilarides Dairy - Lindsay, California manure from 10,000 cows to generate Bio-Methane to power delivery trucks 1000 cows produce 78000 DGE/year of Bio-Methane (1)(1) Biomethane from Dairy Waste A Sourcebook for the Production and Use of Renewable Natural Gas in California (2005)
CWI Technology OverviewMarch 2011Explore Every Alternative.
We Start with Simple Cleaner FuelNatural gas is a low carbon fuel 14/30 = 1:2 1/4 = 1:4 24
Spark Ignited Technology• Fuel and air are premixed outside the Sparkcylinder Plug• Spark plug ignites the mixture• Air flow controls fuel flow• Air/Fuel ratio controls emissions Cummins Confidential
Coil on Plug Ignition Ignition coils mounted at 45 degree angle One coil per cylinder Left side of valve cover
Natural Gas Engine Technology Evolution 1201. Stoichiometric Rich Lean• Low NOx with TWC 100 Percent Maximum NOx• Combustion temperatures limitpower density, efficiency and 80durability•First technology used in HD natural Stoichiometricgas engines 602. Lean Burn 40 Lean Burn EGR• Introduced in ’90s•NOx control is in-cylinder 20•Lean combustion reduces in cylindertemperatures improving power 0density/efficiency 12 14 16 18 20 22 24 26 28 30•Proven reliability/durability in heavyduty applications Air / Fuel Ratio•Capable of EPA 07 Euro4/5 emissions 3. Stoichiometric with Cooled EGR • Combines & Improves the best attributes of Stoichiometric & Lean Burn combustion • TWC for NOx control - Sub-EPA 2010 emissions with passive aftertreatment •Cooled EGR in place of air in Lean Burn reduces in cylinder combustion temperatures • Improved low end torque and fuel economy Cummins Confidential
Cummins Westport Inc.B Gas Plus – C Gas PlusExplore Every Alternative.
C Gas Plus - Natural Gas History 1995 2001 C8.3G Mechanical C Gas Plus •Lean Burn Combustion •Introduced in 2001 •Lean Burn combustion Base Platform for C •Introduced in 1998 Gas and C Gas Plus •State of the art spark •Major improvement over 1st ignition/control system generation CNG L 10 Series •First engine 2004 EPA •Over 4000 still in service Certified- 1.8 NOx •Improved Reliability •Six fold reliability Increase
Why is Plus BetterEngine Designed for Gaseous Fuels – Improved drive by Wire actuator – Lower emissions – Wide range fuel composition capability • 65 Methane number for gas – Knock sensing and control – Robust oxygen sensor design – Adaptive learn through control system – Modern engine controller – Improved controls – More sensed parameters – Humidity sensing and compensation
Focal Point of Third Generation “Plus” Technology MIXER AIR/FUELCHARGE-COOLED DRIVE-BY WIRE AIR THROTTLE WASTEGATE TURBO Improved CONTROL VALVE ACTUATOR THROTTLE POSITION ENGINE POSITION Reliability Fuel INTAKE PRESSURE & Control Valve TEMPERATURE Operability Shutoff BOOST PRESSURE CM 556 ENGINE Serviceability Fuel Flow ENGINE CONTROLLER COOLANT TEMPERATURE Sensor CONTROLLER CM556 WIDEBAND OXYGEN Life Cycle Costs SENSOR Filter FUEL PRESSURE & TEMPERATURE Fuel Flexibility IGNITION IGNITION OIL PRESSURE/TEMP Fuel MODULE MODULE EXH. BACK PRESSURE Downtime Shutoff 6-C/L Gas Plus Coil Packs 2-B Gas Plus Fuel KNOCK SENSOR Maintenance Costs Pressure Regulator PC BASED DIAGNOSTICS Spark Plugs FUEL Improvement Areas
ISL G OverviewMarch 2011Explore Every Alternative.
ISL G Natural Gas Engine 8.9 Litre (540 cu. In.) In line 6 cylinder Charge Air Cooled (CAC) Spark ignition Peak Rating: – HP-320 hp Torque -1000 lb-ft Certified to 2010 EPA and CARB NOx and PM standards Three Way Catalyst Aftertreatment Manufactured by Cummins in Cummins Engine Plant- Rocky Mount, North Carolina Over 8,000 in service. LNG 34
ISL G - Three Key Emission Technologies Cooled Exhaust Gas Recirculation Cummins (CEGR) Stoichiometric Combustion Cummins Westport Cummins Three Way Catalyst (TWC) Emission Solutions 35
Three Way Catalyst TWC reduces three harmful emissions: NOX, CO, HC End products are: N2, CO2, H2O Packaged as a replacement muffler Simple, passive, maintenance-free Consistent performance across all duty cycles Catalyst Inlet Catalyst Outlet NOX N2 CO CO2 HC H2 O ISL G TWC - similar package size to current mufflers
TechnologyWhat is the Same? Major Engine Components 320, 300, 280, 260 and 250 – Block, crankshaft, main bearing, HP ratings piston rods, EGR Compatible with Cummins – Over 80% parts commonality Diagnostic tools 500 hour Maintenance Interval – Insite – Quickserve online Parts and Service Manufactured in Cummins – Global Cummins Distributor Engine Plant, North Carolina Network 37
TechnologyWhat is Different? Cylinder head Fuel Cost – 2 valve vs. 4 valve (diesel) – Natural gas costs less than diesel Ignition – Fuel cost per mile (KM) is lower – Spark Ignition (SI) vs. Compression – Total LCC can be less than diesel (diesel) Fuel System Lubricating Oil – Intake manifold vs. Common rail – Natural gas engines require a specific injection (diesel) oil that meets Cummins specification Aftertreatment CES 20074 – 3 way catalyst vs. Particulate Filter + Noise Selective Catalytic Reduction (diesel) – Natural gas engines are up to 10db Maintenance Cost quieter at idle – Incremental maintenance for ignition Compression Ratio and valve adjustments – can be offset with diesel fuel system – ISL G is 12:1 compression maintenance 38
Reduced Noise Noise Comparison 110 ISL G is 5.5 decibels Communities notice the quieter at peak torque natural gas noise and load advantage. 100ONE Diesel engine idling is louder than TEN natural Decibeles dB(A) ISL G is 9.9gas engines idling together decibels quieter 07 ISL 90 at Idle/no load 07 ISL G 80 70 Peak Torque / Full Load Idle / No Load Engine Test Mode
CWI Natural Gas Engines WorkSupported By Same Structure as Cummins Diesel•Cummins has one of the largest network of service providers in the world.•Local service and support for CWI Products is available at any authorizedCummins facility North America Europe and Middle East Japan and Korea 215 Distributor Locations 62 Distributor Locations 5 Distributor Locations 3860 Dealer Locations 308 Dealers 35 Dealers SE Asia and China 27 Distributor Locations 18 Dealers Australia and New Zealand 26 Distributor Locations 91 Dealers India Central and South American 30 Distributor Locations 88 Distributor Locations 104 Dealers 142 Dealers
Natural Gas andInfrastructureWhy CNGWhy LNGExplore Every Alternative.
Natural Gas is a Safe Fuel Natural Gas Liquid fuels Lighter than air Heavier than air Rises Descends Doesn’t accumulate in low places Accumulates in low places Rich mixture burns off slowly Rich mixture explodes Ignites at temperatures of approx. 600 C Gas and diesel vapors ignite at approx. 200 C Non toxic Toxic Odorless-detection fragrance is added Strong inherent odor Evaporates quickly Evaporates slowly at room temperature Drop Test • Tanks must pass extensive safety testing i.e. drop test • Natural gas is non-corrosive • Narrow flammability range and high auto-ignition temperature • Will not contaminate soil or water
Station Configurations Typical CNG Station Typical L/CNG Station 1. Compressor 1. LNG Storage 2. Gas Dryer 2. Vaporizer 3. Storage vessels 3. Odorizer 4. Dispensers, along with 4. Dispensers, underground piping along with underground piping
Volume and Range ComparisonDiesel Tank Space Range Per 100 per 100 mi Gallons Tank Space 650 mi 15 Gal.LNG 380 mi 26 Gal.CNG 170 mi 58 Gal.* Estimate based on 6.5 mpg diesel, and same efficiency for NG vehicle
LNG Tanks Tank internal design maintains a dedicated vapor space (aka “ullage”) – Net liquid capacity approx. 10% < gross capacity LNG tanks require 6” to 8” valve access at rear of tank – Need to allow for this when spec’ing frame-mounted components LNG tank Fuel valves behind shroud
Fuel or Vehicles First? Established North American ISL G Applications BUS REFUSE
Fuel or Vehicles First? North American Truck OEM’s OEM Freightliner Peterbilt Kenworth Volvo Model M2 - 112 320 T800SH VNM 384 W900S 365 T440 T470 Engine ISLG 320 ISL G 320 ISLG 320 ISL G 320 ISL G 300 Application 6x4 Tractor Tractor Tractor Tractor 4x2 Tractor Vocational Vocational 4x2 Truck Mixer Mixer 6x2 Truck Vocational OR LNG Cummins Westport Confidential 48
CNG & TrucksPaper Transport – Green Bay to Chicago •Hauling paper towels/napkins southbound (55,000 lbs GVW) •Scrap paper northbound (75,000 lb GVW) • Saving $1.50/gln vs. diesel •Averaging 5.6 mpg •Two trucks operating 5 days/week since Feb. 2010 logging approx. 160,000 miles each •Five more delivered in Sept. with 30,000 miles/each5X15 DGE CNG tanks (75 DGE total)
Kenworth T440 – CNG Rail Mount 2X 40.5 DGE CNG tanks = 81 DGE Total
Top North America CNG Transit Fleets 150 1500 BOSTON NYCT LA 300 WASHINGTON PHOENIX 400 600 400 300 250 250 500 SAN DIEGO SACRAMENTO SAN BERNADINO TACOMA ORANGE COUNTY Fort Worth, TX LA, CA — Foothill Santa Clara, CA over Toronto, ON LA, CA — DOT Hamilton, ON 8,000 Atlanta, GA Las Vegas, NV Vancouver, BC St. Louis, MO Seattle, WA Baton Rouge, LA San Antonio, TX engines in Corpus Christi, TX Ocean Side, CA Fresno, CA service Santa Monica, CA Culver City, CAAlbuquerque, NM Medford, OR Montgomery County, MD Port Huron, MI Long Island, NY Salem, OR Cape Cod, MA
“A Better Fuel for the Future” “I have a dream that will change the world” “I have a better engine design” “I have a better fuel for the future” …. Clessie Cummins Diesel power had half a century to perfect technology We’ve come all this way in only a decade!