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Daryl Patrishkoff
02 April 2014
Value Proposition Clean Abundant Domestic Jobs
Natural Gas Making Bio Natural Gas Compressed Natural Gas (CNG) Liquefied Natural Gas (LNG) LNG vs. CNG Vehicles
Natural Gas Value Proposition path to energy independence
Clean
Generating electricity burns cleaner with less pollutants and no mercury
Vehicles emit 25% less CO2 than gas or diesel
Abundant
US has more than 2,000 trillion cubic feet
More being discovered every day
Enough fuel to power America for generations
Domestic
98% of the natural gas we use comes from North America
Jobs
$385 billion contributed to US economy in 2008
2.8 million US jobs supported
3 www.cpspoly.com
Natural Gas Value Proposition natural gas
www.cpspoly.com 4
Fossil fuel that is essentially the remains of plants, animal and microorganisms that lived millions of years ago
Compression under the earth for a very long time created natural gas
Combustible, colorless, shapeless and odorless in its pure form
When burned puts out a great deal of energy with few emissions
Made up of a combustible mixture of hydrocarbon gasses
Delivered to your home as almost pure methane (CH4)
Mercaptan is added to give the “rotten egg” smell for leak detection
Source: www.naturalgas.org
Natural Gas Value Proposition making bio natural gas
Bio natural gas is also known as pipeline-quality biogas or renewable natural gas
Bio natural gas is produced during the decomposition process of organic matter and is produced in special fermentation plants
The most important substrates for creating biogas are regenerative raw materials such as corn, grain, and catch crops
The upgrading process consists mainly of removing carbon dioxide, water, and hydrogen sulfide
Bio natural gas has the same methane content and characteristics of natural gas
Can be injected into the natural gas pipeline system and used or stored just like natural gas
Bio natural gas plant (7:49)
www.cpspoly.com 5 Source: Schmack Biogas, AG
Natural Gas Value Proposition compressed natural gas (CNG) in vehicles
www.cpspoly.com 6
Compressing natural gas to less than 1% of its volume at standard atmospheric pressure
3,000 PSI
3,600 PSI
EPA and FMVSS regulates the safety aspects
Types 1, 2, 3 & 4 of CNG Fuel Tanks
Fuel line integrity
Emissions
Multiple safety protocols are integrated into the vehicle application to ensure safety
CNG use in vehicle fuels dates back to World War II as a proven technology
There are 15 million vehicles operating on CNG around the globe today
Only 120,000 of them are in the US
Source: www.cngnow.com
Natural Gas Value Proposition liquefied natural gas (LNG)
LNG is natural gas that is cooled to -260° F until it becomes a liquid and then stored at essentially atmospheric pressure
Converting natural gas to LNG, a process that reduces its volume by about 600 times allows it to be transported easily
Once delivered to its destination the LNG is warmed back into its original gaseous state so that it can be used just like existing natural gas supplies
LNG is essential to providing the U.S. with the ability to import or export natural gas depending on market conditions
LNG The Facts (8:26)
The LNG Chain (1:42)
www.cpspoly.com 7
Drilling for Natural Gas Liquefaction Plant
Shipping LNG Regasification Terminal
Source: www.lngfacts.org
Natural Gas Value Proposition LNG vs. CNG vehicles
LNG Vehicles CNG Vehicles
On-Board LNG fuel storage
30% less space than CNG
Thermally insulated storage tanks
Heat LNG to return to natural gas then deliver to the engine
Application
Heavy duty fleet vehicles
Refueling LNG
Fleet base filling stations
Public filling stations
Delivered by tanker truck
Stored in cryogenic tanks
Put in vehicle as cold liquid
LNG Fueled Trucks Hit the Road (5:53)
ISL G Engine Walk Around (5:19)
On-Board CNG fuel storage
Cylindrical steel tanks
Type 1, 2, 3 and 4 safety rated
3,000 PSI and 3,600 PSI
CNG Safe (9:28)
Application
Passenger cars
Sport Utility Vehicles (SUVs)
Medium duty
Heavy duty
Refueling CNG
Home filling stations
Fleet base filling stations
Public filling stations
www.cpspoly.com 8
Medium Duty Fleet Vehicles Heavy Duty Vehicles Aftermarket Conversions Passenger Vehicles Current CNG US Vehicles Coming CNG US Vehicles
Natural Gas Value Proposition medium duty fleet vehicles
10
Buses and Mass Transit
Transit agencies across the country are increasingly switching to NGVs
Taxis, Vans and Shuttles
Airport and hotel shuttles, taxi services, etc. are increasingly switching to NGVs
Service Provider Fleet Vehicles
Several major companies have invested heavily in natural gas fleet vehicles
Select Companies and Municipalities
UPS, AT&T, Ryder, Verizon, Utah, Kansas City, Seattle, Los Angeles, Washington DC, Long Island, and many more……
www.cpspoly.com
Natural Gas Value Proposition heavy duty fleet vehicles
11
Long range heavy transport
Using the cross country natural gas corridors
Engine manufacturers are certifying engines to run on CNG
Usage in both forms of natural gas
Liquefied Natural Gas
Compressed Natural Gas
www.cpspoly.com
Natural Gas Value Proposition aftermarket conversions
Individual consumers purchase an aftermarket CNG conversion kit
Install system on their own personal vehicle
Maintain the vehicle for safety and use
Many variables which increase risk
CNG conversion kit providers
Many companies providing these products at very different levels of volume and quality
There is no standard guiding the safety, quality and efficiency of these systems
Emerging Certifications
CNG Systems Installation Certificate
CNG Maintenance Certificate
CNG Vehicle Fuel Systems Inspector Certificate
12 www.cpspoly.com
Natural Gas Value Proposition CNG US production vehicles – 100% CNG
2014 Honda Civic GX
Introduced: 1997
MSRP: $26,305 to $30,860
Engine: 1.8 liter 16 valve SOHC
Horsepower: 110 HP @ 6,500
Torque: 106 ft lbs @ 4,300
Transmission: 5 speed automatic
Fueled By: 100% CNG
Fuel Tank: 8.03 GGE CNG
Mileage: 27 city
38 highway
31 combined
Range: 248 miles
13 www.cpspoly.com
Natural Gas Value Proposition CNG US production vehicles – 100% CNG
14 www.cpspoly.com
2014 GM Express / Savana Cargo Van
Introduced: 2011
MSRP: $14,620 CNG option
Engine: 6.0 liter V8
Horsepower: 282 HP @ 4,800
Torque: 320 ft lbs @ 4,400
Transmission: 6 speed automatic
Fueled By: 100% CNG
Fuel Tank: 15.8 – 22.0 GGE CNG
Range: 200 - 300 miles
Natural Gas Value Proposition CNG US production vehicles – 100% CNG
15 www.cpspoly.com
2014 Ford VPG MV-1 Sedan
Introduced: 2011
MSRP: $ TBD
Engine: 4.6 liter 2V EFI V8
Transmission: 4 speed automatic
Fueled By: 100% CNG
Fuel Tank: 21 GGE CNG
Mileage: 11 city
16 highway
13 combined
Range: 290 miles
Volume: 600 since 2011
VPG was sold to AM General and planning to resume production in 2014
Natural Gas Value Proposition CNG US production vehicles – bi-fuel
16 www.cpspoly.com
2014 Chevy and GMC 2500 HD
MSRP: $11,000 CNG option
Engine: 6.0L V8 SFI CNG gaseous
Transmission: 6 Speed Automatic
Fueled By: Bi-Fuel CNG & gasoline
Gas Fuel: 36 Gallon
CNG Fuel: 17.6 GGE CNG tank
Range: 436 miles gasoline
214 miles CNG
650 miles total range
Bi-Fuel system installed by IMPCO
Natural Gas Value Proposition CNG US production vehicles – bi-fuel
17 www.cpspoly.com
2014 Ford F-250 and F-350
MSRP: $10,950 CNG Option
Engine: 6.2 liter V8 engine
Transmission: 6 Speed Automatic
Fueled By: Bi-Fuel CNG & gasoline
Gas Fuel: 35 Gallons
CNG Fuel: 24 GGE Type 4
Range: 356 miles gasoline
244 miles CNG
600 miles total range
Bi-Fuel system installed by multiple Ford Qualified Vehicle Modifiers (QVM)
Westport, Landi Renzo, Venchurs and Altech Eco
Natural Gas Value Proposition CNG US production vehicles – bi-fuel
18 www.cpspoly.com
2014 Dodge Ram 2500 4X4
MSRP: $11,000 CNG Option
Engine: 5.7 liter hemi V8
Transmission: 6 Speed Automatic
Fueled By: Bi-Fuel CNG & gasoline
Gas Fuel: 35 Gallon
CNG Fuel: 18.2 GGE
Range: 592 miles gasoline
308 miles CNG
900 miles total range
Natural Gas Value Proposition CNG US production vehicles to be introduced – bi-fuel
2014 Ford F-150 with 3.7-liter V6 engine with a factory-installed
Bi-Fuel gaseous-fuel prep package
hardened valves, seats, pistons & rings
$7,400 - $9,500 for the CNG option
CNG engine package, it is capable of achieving more than 750 miles
Gas tank has 26 gallons
CNG tank has 13.0 GGE
Bi-Fuel system installed by Ford Qualified Vehicle Modifiers (QVM)
Westport
Landi Renzo
Venchurs
Altech Eco
www.cpspoly.com 19 Source: Tree Huger, 05 August 2013 article: 2014 Ford F150 pickup truck will run on compressed natural gas (CNG)
Natural Gas Value Proposition CNG US production vehicles to be introduced – bi-fuel
2014 Chevrolet Cruze, 1.4 liter four cylinder turbocharged engine
Add compressed natural gas as an aftermarket conversion
IMPCO will offer this bi-fuel aftermarket conversion
The added CNG tank gives the Cruze a 200-mile natural gas range
Packaging of the CNG fuel tank cuts cargo space roughly in half to under 7 cubic feet
A 2014 Chevrolet Cruze Eco has a base price of $19,835
The bi-fuel conversion is expected to add between $5,000 and $6,500 to the price
www.cpspoly.com 20 Source: Green Car Reports, 29 September 2013 article: 2014 Chevrolet Cruze: gasoline, diesel, now natural gas
Natural Gas Value Proposition CNG US production vehicles to be introduced – bi-fuel
2015 Chevrolet Impala Bi-Fuel vehicle
Will run on both gasoline and CNG and seamlessly switch between fuels
The added CNG tank gives the Impala a total 500 mile driving range
Packaging of the 7.7 GGE CNG fuel tank cuts into the trunk space
www.cpspoly.com 21
LNG Fuel Tanks CNG Fuel Tanks Testing Vehicle Incidents In-Service Incidents Home Fueling Stations Fleet Filling Stations Public Filling Stations Cross Country Filling Stations Vehicle Performance Comparisons
Natural Gas Value Proposition LNG fuel tanks
Cryogenic vessel to maintain LNG at -260 ° F
On-board tank
Heat exchanger
Pressure regulators
Diesel Gallon Equivalent (DGE)
1 DGE equals 1 gallon of diesel fuel
www.cpspoly.com 23 Source: www.chartindustries.com
Natural Gas Value Proposition CNG fuel tanks – safety rating types
Inspection and re-certification
Each CNG fuel container shall be permanently labeled
Inspected by a qualified container inspector every 36 months
Type 1
All metal (aluminum or steel)
Inexpensive but heavy
Type 2
Metal liner reinforced by composite wrap
Outside middle hoop wrapped
Less heavy, but more cost
Type 3
Metal liner reinforced by composite wrap around entire tank
Lightweight, but expensive
Type 4
Plastic liner reinforced by composite wrap around entire tank
Light weight, but expensive
www.cpspoly.com 24 Source: www.cleanvehicle.org
Natural Gas Value Proposition CNG fuel tanks – safety testing
www.cpspoly.com 25 Source: www.cleanvehicle.org
Hydraulic Pressure Cycle Test
Use water instead of gas
Can leak, but not rupture
Temperature Pressure Cycling Test
Pressure cycle while chilled to -40° F
Pressure cycle while heated to 149° F
Drop Test
Most severe condition is with an empty tank
Bonfire Test
Pressure Relief Valve (PRV) activates prior to cylinder rupture when exposed to fire
Permeation Test
Sealed chamber to measure amount of CNG that permeates over time
Natural Gas Value Proposition CNG fuel tanks – safety testing
www.cpspoly.com 26 Source: www.cleanvehicle.org
Gun Fire Test
First bullet made cut in wrap
Second bullet caused release of gas with no fire
Vibration of Fuel System Test
Simulate vehicle movement over time
Hydraulic Crush Test
Attempted crush of Type 3 tank
After 150,000 KGF the reinforced concrete wall failed along with testing equipment
Drop Impact Test
2 ton impact on pressurized tank
Natural Gas Value Proposition CNG fuel tanks – vehicle incidents
Abrasion Damage – Type 2 Tank
Dragged on road after support strap broke
No effect on burst strength
Abrasion Damage – Type 4 Tank
Dragged on road after support strap broke
No effect on burst strength
Collision Damage – Type 1 Tank
Vehicle impacted at 50 MPH, gasoline tank caused fire
CNG tank PRV vented the CNG without incident
Collision Damage – Type 4 Tank
Rear impact to vehicle, crushed to the B pillar
No rupture or leakage of the CNG tank
Collision Damage – Type 4 Tank
Bus roof collapsed and caused severe abrasion
CNG tank PRV vented the CNG without incident
Bus Fire – Type 2 Tank
Bus fire caused by engine
CNG tank PRV vented the CNG without incident
www.cpspoly.com 27 Source: www.cleanvehicle.org
Natural Gas Value Proposition CNG fuel tanks – in service incidents
www.cpspoly.com 28 Source: www.cleanvehicle.org
Stress Corrosion Cracks – Type 2 & 3 Tanks
Caused by exposure to acid environments
Keep batteries away from tanks
Impact Damage – Type 4 Tank
Difficult to detect
Replace tanks after impact
Liner Rust Stains – Type 2 Tank
Hoop cracks allowing moisture and rust
Aluminum Corrosion – Type 2 Tank
Exposed aluminum heads covered by steel end bracket causing galvanic corrosion
Composite Wrap Burn – Type 2 & 3 Tanks
Fire caused damage to composite wrap
Mounting Bracket Vibration – All Type Tanks
Insufficient rubber pad isolating steel from contact with glass fiber
Natural Gas Value Proposition fueling CNG vehicles at home
Phill Home Fueling
1-2 GGE per hour
93% fuel capacity
Units in development
General Electric
Whirlpool
Eaton
29 www.cpspoly.com
Natural Gas Value Proposition fueling CNG vehicles on the road
More than 1,100 NGV fueling stations in the US
Fast Fill Protocol just like gasoline
83% of fuel capacity
Natural gas fueling station corridors:
Las Vegas to California
Idaho to Arizona
City of Seattle
and growing…..
30
Source: US Dept of Energy
www.cpspoly.com
Natural Gas Value Proposition LNG/CNG fueling stations for on-highway trucks
Cross country LNG/CNG filling stations and corridors
Las Vegas LNG fueling station (3:07)
www.cpspoly.com 31 Source: www.cleanenergyfuels.com
Natural Gas Value Proposition CNG filling performance comparisons
GGE ratings list total CNG able to be put into the fuel tank
Due to CNG fuel tank properties, there must be a small amount of CNG left in the tank at empty
Ambient temperature has an impact on fill amount
Cooler temperatures allow more CNG fuel to be added
Varying fill protocols allow different amounts of CNG to be put into the fuel tank
Slow Fill Process
1 GGE per hour fill rate equals under 8 hours fill time
7.25 GGE usable, 93% of 7.8 GGE total capacity
Fast Fill Process
Less than 4 minute fill time
6.47 GGE usable, 83% of 7.8 GGE total capacity
Testing conducted on 6 different fills on the Mustang 7.8 GGE fuel tanks, used the lowest value for calculations
www.cpspoly.com 32
ANGA Passenger Car Project The Vehicles
BMW X3 GMC Acadia Denali Ford Mustang GT Hyundai Sonata
Return on Investment (ROI)
Natural Gas Value Proposition ANGA passenger car project
America’s Natural Gas Alliance (ANGA) funded this program to demonstrate the practicality of CNG usage in passenger vehicles
(6) 2012 US produced passenger vehicles were converted as bi-fuel vehicles
The execution had to be a seamless transition between the 2 fuels
Minimum of 50 mile range on CNG to accommodate 95% of public commutes
No impact to cargo space
Our technical team designed, engineered, built, tested and validated (4) of these vehicles
These vehicles are touring the country to bring awareness to the use of CNG in vehicles
www.cpspoly.com 34 Source: www.addnaturalgas.com
Natural Gas Value Proposition BMW X3
Engine:
3.0L I6/CNG Bi-Fuel Port Injection
CNG Control System:
Custom Bi-Fuel Controller
CNG Display:
Status, Tank Level, GGE Usage
CNG Capacity:
4.0 GGE @ 3600 psi
Fuel Economy:
21 MPG (combined)
Driving Range: 436 total miles
Gasoline: 359 miles
CNG: 77 miles
Weight: added 168 lbs
4,308 lbs www.cpspoly.com 35 Source: www.addnaturalgas.com
Natural Gas Value Proposition GMC Acadia Denali
Engine:
3.6L V6/CNG Bi-Fuel Direct Injection
CNG Control System:
Custom Bi-Fuel Controller
CNG Display:
Status, Tank Level, GGE Usage
CNG Capacity:
4.0 GGE @ 3600 psi
Fuel Economy:
19 MPG (combined)
Driving Range: 482 total miles
Gasoline: 418 miles
CNG: 64 miles
Weight: added 114 lbs
5,032 lbs www.cpspoly.com 36 Source: www.addnaturalgas.com
Natural Gas Value Proposition Ford Mustang GT
Engine:
5.0L V8/CNG Bi-Fuel Port Injection
CNG Control System:
Custom Bi-Fuel Controller
CNG Display:
Status, Tank Level, GGE Usage
CNG Capacity:
4.0 GGE @ 3600 psi
Fuel Economy:
20 MPG (combined)
Driving Range: 375 total miles
Gasoline: 320 miles
CNG: 55 miles
Weight: added 151 lbs
3,787 lbs www.cpspoly.com 37 Source: www.addnaturalgas.com
Natural Gas Value Proposition Hyundai Sonata
Engine:
2.4L I4/CNG Bi-Fuel Direct Injection
CNG Control System:
Custom Bi-Fuel Controller
CNG Display:
Status, Tank Level, GGE Use
CNG Capacity:
2.6 GGE @ 3600 psi
Fuel Economy:
28 MPG (combined)
Driving Range: 574 total miles
Gasoline: 518 miles
CNG: 56 miles
Weight: added 119 lbs
3,507 lbs www.cpspoly.com 38 Source: www.addnaturalgas.com
Natural Gas Value Proposition return on investment (ROI)
Fully loaded Bill of Materials (BOM)
Purchased components
Manufactured components
Modified components
Volume at normal “niche vehicle” amount
20,000 units per year
Return on Investment
Price of added components $2,600 to $2,900
Savings of CNG fuel vs. gasoline with normal commute
Just over 2 year payback of investment
Analysis
CNG fuel tank is the largest cost driver
Minimize fuel tanks size to deliver normal commute fuel requirements to maximize ROI
www.cpspoly.com 39 Source: Green Car Reports, 25 June 2013, Prototype Natural Gas Vehicles
Mustang Street Legal Muscle Car Program Management and Engineering Team Corporate Partners Stock 2003 Mustang GT Modified for Performance Modified for Bi-Fuel Safety Protocols CNG Fuel Storage CNG Fuel Distribution FMVSS Crash Protection Skid Marks
Mustang Street Legal Muscle Car Program bi-fuel conversion
Dramatically shatter the paradigm about CNG fuel usage and horsepower output
CNG is a high performance fuel
Begin with a highly modified 2003 Mustang GT that puts out 470 HP at the rear wheels with alcohol injection
Design, engineer, validate and build this vehicle to be a Bi-Fuel (Gasoline and CNG) conversion with alcohol injection
Develop this engineering program using the ISO/TS 16949 automotive standards
Debut the vehicle at the "2013 Woodward Dream Cruise”
We generated plenty of interest about CNG right here in the “Motor City”
www.cpspoly.com www.performcng.com 41
Daryl Patrishkoff
Owner and Chief Engineer
Vehicle Integration
Automotive Engineering Standards
Body Modifications
Company Partnerships
Todd Connolly
Owner and Build Technician
Engine Modifications
Fuel Mixing and Calibration
CNG Components
Hardware, Software
Doug Hall
Owner and Calibration Engineer
Engine Calibration
Hardware Installation
Software Modifications
Electrical Installations
Management Team experience, expertise, skills and manpower
www.performcng.com 42
Engineering Team experience, expertise, skills and manpower
Michael Pons Fuel pocket & critical component fabrication
Dustin Clifton Paint repair and body detailing
Rob Kuras IT computer software support
Dave Andre Support in all aspects of the build
Ronald Alkins Support in tools and equipment
Robert Murawski Sponsorship and build support
Chad Connolly Fabrication of custom parts
Jim Chaltron Fabrication of custom parts
Tim Connolly Consulting and build support
www.performcng.com 43
Corporate Partners experience, resources, equipment and components
The Center for Professional Studies (CPS) is a State of Michigan
vocational licensed school which focuses on engineering
technical training and consulting services. Since 1993 we have
certified over 7,000 technical professionals at over 400
companies in technical tools, techniques and methodologies.
The Woodward Warehouse is a new approach to your collector
car storage needs, with the added benefits of a club atmosphere.
It’s modern facility and professional staff provide state-of-the-art
security, climate controlled museum quality storage, convenient
access and car care services.
CNG United delivers products, services, and training to
government, commercial, and private owners to convert their
vehicles to run on compressed natural gas. CNG United helps
agencies and commercial enterprises managing the conversions
of their fleet of vehicles, both gasoline and diesel engines, to
compressed natural gas.
The EDAG Group, the world’s largest independent engineering
partner, develops ready for production solutions to ensure the
mobility of the future. They offer the integrated development of
vehicles, derivatives and modules, through to complete
production facilities to multiple industries around the globe.
Quality Metalcraft (QMC) is a rapidly expanding production and
prototype automotive supplier of sheet metal stamping and
assemblies . QMC has expanded its roster of satisfied customers
to defense, automotive aftermarket, architectural, agricultural,
and industrial lighting industries.
Exotic Automation & Supply is your single source solution for all
of your motion and control needs. Our customers cover the globe
and routinely involve us early in the planning stages of system
design due to our vast portfolio of components and knowledge of
what’s available on the market today.
www.performcng.com 44
Stock 2003 Mustang GT as purchased from the dealer
Built at the Flat Rock, MI plant
V8 4.6 liter SOHC
9.4 compression ratio
5 speed manual transmission
Multi-point injection fuel system
ABS four disc brakes
Electronic traction control
Limited slip differential
Strut front suspension with stabilizer bar independent with coil springs
Rear suspension with stabilizer bar & coil springs
260 HP @ 5,250 RPM
302 foot pounds @ 4,000 RPM
0 to 60 MPH in 5.5 seconds
Quarter mile in 14.1 seconds
www.performcng.com 45
Modified 2003 Mustang GT street legal muscle car modifications
Engine Modifications
Heads ported and polished
5 angle valve job with back cut valves
Trick flow camshafts
BBK valve covers
Professional Products Power air inlet and throttle body
75 mm throttle body and ported elbow
Vortech V-2 supercharger 10-12 PSI boot
Alky Controls alcohol injection
Anderson Motorsports through fender cold air and power pipe with 90mm mass air flow
Dyno tested 468.7 HP @ 6,500 RPM at wheels
Dyno tested 413.6 foot pounds @ 5,500 RPM
Headers and Exhaust
Pypes Violator mufflers
Pypes 2 1/2” stainless Y pipe
Pypes 1 3/4” primary stainless long tube headers
Pypes 3” slash cut stainless tips
Body Details
Cervini's hood, fascia, vents, ground effects and spoiler
Chassis Modifications
3.73 Posi Traction rear axle
Front tires Kumho Ecasta ASX 275/35R18
Rear tires Micky Thompson ET Street P305/35R18
18 Inch Cobra Replica chrome wheels
Front & rear BBK progressive rate lowering springs
Granatelli Motor Sports lower rear control arms
Adjustable spring perch and Delrin bushing
Edelbrock upper rear control arms
Adjustable with spherical links
BBK sub-frame connectors
BBK front cross car strut supports
Torque box reinforcement rates for control arms
Brakes
Roush front 14 inch drill slotted 2 piece rotors
Roush front 4 piston aluminum caliper
Roush rear 13 inch drill slotted rotors
5 Speed Manual Transmission
Centerforce dual friction clutch
BBK short throw shifter
Polyurethane transmission mount www.performcng.com 46
Modified 2003 Mustang GT street legal muscle car modifications
www.performcng.com 47
Video: High Performance on Gasoline with Alcohol Injection
Modified 2003 Mustang GT Street Legal Muscle Car bi-fuel modifications
Bi-Fuel Blends Port Injected Gasoline with Alcohol injection CNG with Alcohol injection
Seamless Transition Between Fuels
Dedicated CNG Port Injectors
100% Operation in CNG Mode Engine Startup Normal usage (idling and driving) Wide Open Throttle (WOT) 7.8 GGE CNG fuel on board 90 mile range during aggressive driving
No Reduction in Horsepower
Safety Approach (3) 2.6 GGE CNG Type 3 fuel tanks Managed various crash impact scenarios Robust tank mounting system Multiple automatic system safety protocols Multiple venting approaches
www.performcng.com 48
Video: High Performance on CNG with Alcohol Injection
Safety Protocols CNG fuel storage and plumbing
(3) CNG Type 3 Fuel Tanks
Total of 7.8 GGE CNG fuel on board
Plumbed in series for leveling
High pressure fuel filters
Fuel fill to CNG fuel tanks
CNG fuel tanks to engine
Ram air vented rear compartment
Side vents bring in outside air
Natural gas lighter than air
Exits at vents beyond seals
Pressure Relief Valve (PRV)
Releases natural gas in emergency
High pressure connectors and fitting
Ensures there are no leaks
www.cpspoly.com www.performcng.com 49
Safety Protocols FMVSS 100 series – crash avoidance
www.cpspoly.com www.performcng.com 50
FMVSS Standards Objective Mustang Impact
Definition
Design and performance requirements for vehicles and subsystems
Describe how vehicle subsystems and design characteristics function
Mustang Program Approach
All existing OEM key elements already meet this standard
All key elements support compliance to this standard
No body modifications impact crash avoidance compliance
Vehicle Modifications
Added display information
CNG fuel level
Fuel use control
FMVSS 101 – Controls and Displays
Instrument panel and console revisions have no impact to any FMVSS standards
Safety Protocols FMVSS 200 series – crashworthiness
www.cpspoly.com www.performcng.com 51
FMVSS Standards Objective Mustang Impact
Definition
Requirements to reduce the fatality or injury severity of occupants
Equipment that requires no action by the occupants
Mustang Program Approach
All existing OEM key elements already meet this standard
All key elements support compliance to this standard
No body modifications impact crashworthiness compliance
Vehicle Modifications
Placement of CNG Fuel Tanks
Revisions to the rear compartment adding structure to mount the CNG Fuel Tanks
FMVSS 208 – Occupant Crash Protection
CNG Fuel Tanks are in a protected rear crush zone of the vehicle
At rear impact the longitudinal mounting rails adds structural integrity
CNG Fuel Tanks are allowed to move to protect from crushing
Safety Protocols FMVSS 300 series – post crash standards
www.cpspoly.com www.performcng.com 52
FMVSS Standards Objective Mustang Impact
Definition
Requirements to prevent or reduce the severity of fires
Protect occupants from hazards during vehicle operation
Mustang Program Approach
All existing OEM key elements already meet this standard
All key elements support compliance to this standard
No body modifications impact post crash standards compliance
Vehicle Modifications
Added (3) Type 3 CNG Fuel Tanks
Low & High Pressure CNG Fuel Lines
Sealed & ram vented compartment
Pressure Relief Valve (PRV)
Manifold Absolute Pressure (MAP)
CNG Check Valve and Filter
301 – Fuel System Integrity CNG Vehicles
Fuel line routings are safely protected
304 – CNG Fuel Container Integrity
(3) Type 3 – 2.6 GGE CNG tanks are utilized to maintain safety level
Safety Protocols FMVSS 500 series – other regulations
www.cpspoly.com www.performcng.com 53
FMVSS Standards Objective Mustang Impact
Definition
Category of other regulations and standards vehicles must comply to
CNG Demonstrator Vehicle Approach
All existing OEM key elements already meet this standard
All key elements support compliance to this standard
No body modifications impact post crash standards compliance
Do no harm to vehicle emissions
Vehicle Modifications
Bi-Fuel vehicles operate on both Gasoline and CNG fuel
531 – Passenger Fuel Economy Standards
Document combined miles per gallon EPA 75 test
533 – Light Truck Fuel Economy Standards
Document combined miles per gallon EPA 75 test
EPA 75 Emissions Testing
Document emissions
Modified 2003 Mustang GT Street Legal Muscle Car testing and validation
“Skid Marks” on both fuels No difference in handling, performance, Noise, Vibration and Harshness (NVH)
www.performcng.com 54
Video: High Performance on both fuels
Economic Impact Mechatronics Workforce Required Workforce Development CNG Practitioner Curriculum
Natural Gas Value Proposition economic impact
56 www.cpspoly.com
Mechatronics Natural Gas Vehicles (NGV) rely on systems integration
Multidisciplinary field of engineering, it rejects splitting engineering into separate disciplines
Multiple engineering elements:
Mechanical engineering
Electrical engineering
Controls engineering
Computer engineering
Unites the principles of mechanics, electronics, and computing to generate a simpler, more economical and reliable system
The term "mechatronics" was coined by Tetsuro Mori, the senior engineer of the Japanese company Yaskawa in 1969
www.cpspoly.com Source: Wikipedia 57
Mechatronics Natural Gas Vehicles (NGV) elements
Mechanical Engineering
CNG Pressure Regulator
CNG Injectors
CNG Pressure Relief Valve (PRV)
High Pressure Fuel Filter
Electrical Engineering
CNG Fuel Gauge
Electronic Control Module (ECU)
Laptop Interface Porting
Controls Engineering
Electronic Control Module (ECU)
CNG Control and Information
Manifold Absolute Pressure (MAP)
Computer Engineering
Engine Calibration Model
Software Models
Safety Protocols www.cpspoly.com 58
Natural Gas Value Proposition workforce required
Program Managers $80-125k
Manage CNG program from initial development to production launch
Compliance to regulatory standards
Scope, time, cost and quality
Engineering Managers $80-125k
Manage engineers and designers as they develop the CNG vehicle
Compliance to engineering standards
Engineers $60-90k
Detailed development of engineering specs to assigned CNG components
Designers $60-90k
Detailed design files to engineering specs to assigned CNG components
Quality Engineer $60-90k
Quality assurance and control plans that meet specific CNG requirements
CNG Inspectors $40-60k
Perform inspection protocol on CNG conversion and production vehicles
Certify outcomes of the inspection
CNG Technicians $40-60k
Mock up and configure CNG system on demonstration vehicles
CNG Mechanics $30-50k
Perform maintenance protocol on CNG conversion and production vehicles
59 www.cpspoly.com
Natural Gas Value Proposition workforce development
The Center for Professional Studies
• Since it’s founding in 1993, CPS has trained and certified over 7,000 technical professionals at over 400 corporations served in multiple industries
• CPS is a Michigan based licensed vocational training institute
• Our methodology is a fast paced, hands-on approach which covers theory, industry application and then demonstrated on real life company projects
• In 2009 CPS applied this corporate training model to 255 unemployed technical professional with a 97% job placement rate in meaningful employment
Compressed Natural Gas (CNG) System – Practitioner Program
Using CPS’s highly successful Practitioner Certification model a unique program has been created to meet the specific needs of CNG systems in vehicles
This 3 course program includes all the key elements of understanding the theory, application and then hands-on real projects
This certification achieved by each participant demonstrate their competence
60 www.cpspoly.com
Natural Gas Value Proposition CNG practitioner curriculum
CNG Bi-Fuel System – Mechatronics Engineering Vehicle Integration Certification
Natural Gas value proposition and the Natural Gas Vehicles (NGV) global market
Key components function and optimal configuration with safety protocols
CNG fueling methods, analysis and infrastructure
NGV product development process ISO/TS 16949
Project – outline a NGV vehicle that meets a specific market segment
CNG Bi-Fuel System – Installation Certification
Overview of the various CNG conversion kits available in the US market
Detailed installation process, quality controls, testing and validation
Project – convert a vehicle to a bi-fuel configuration
CNG United Systems Installation Certification is achieved
CNG Bi-Fuel System – Inspection Protocols and System Certification
Inspection protocols for each type of bi-fuel application
Certification protocols for each type of bi-fuel application
Project – inspect and certify a bi-fuel vehicle
CSA Vehicle Fuel Systems Inspector Certification is achieved
61 www.cpspoly.com
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Optimizing performance by accelerating experience
Daryl Patrishkoff, PMP
Owner and CEO Center for Professional Studies 248-505-7426 [email protected]
Dennis Cavitt Owner and Managing Director Center for Professional Studies 248-376-6115 [email protected]
www.cpspoly.com www.performcng.com
Daryl Patrishkoff, PMP
Owner and Chief Engineer Performance CNG 248-505-7426 [email protected]
