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Engines and Energy Conversion Laboratory
DOE Project DE-FC26-04NT42270:Systematic Engine Uprate Technology Development and Deployment through
Increased Torque
“Engine Uprates”
DOE/ NETL Project KickoffApril 21, 2005
Engines and Energy Conversion Laboratory
Outline
• Executive Summary (Ted)• Previous Work done with GTI Funds (Dan)• DOE Year 1 Results To-Date (Dan)• Planned Research Activities (Dan)
Engines and Energy Conversion Laboratory
“The overall objective of this project is to develop new engine up-rate technologies that will be applicable to a large inventory of existing pipeline compressor units for the purpose of increasing pipeline
throughput with the same footprint of existing facilities”
•Increase Output by 10% •Target Cost ~ $500/HP
Engine Uprates: Motivation
Engines and Energy Conversion Laboratory
Objectives by Year
• Year 1: Laboratory Demonstration of Candidate Technologies– Demonstrate that the technologies developed during the
background research phase to achieve the performance targets under controlled, laboratory conditions and using the Engines and Energy Conversion Laboratory's (EECL's) Clark TLA research engine.
• Year 2 (Phase 2): Demonstration of Optimal Technologies– Demonstrate that the technologies tested under phase 1 can
migrate to an operating engine in pipeline service with similar, or better, performance and that the durability of the retrofit equipment will be acceptable.
Engines and Energy Conversion Laboratory
Issues to Keep in Balance
• OEM Business Strategy– Dresser-Rand– Cooper Compression
• Enabling Technologies• Air Emissions Permits• FERC Capacity Certification
Engines and Energy Conversion Laboratory
Guidance from manufacturer
perspective
Guidance from user perspective
Engine Manufacturer, Dresser-Rand
(Doug Bird)
PRCI CAPSTC
Project Lead: Ken Gilbert, Dominion Pipeline
Department of Energy
Colorado State University
PI: Dan Olsen
Reporting
Project Team
Engines and Energy Conversion Laboratory
Year 1 Project Schedule
Task O04
N04
D04
JO5
FO5
M05
A05
M05
J05
J05
A05
S05
O05
1.1 Research Management Plan complete
1.2 Technology Assessment complete
1.3 Optical Engine Evaluations
1.4 Component Procure & Fab
1.5 System Test Plan M1
1.6 Uprate Systems Installation
1.7 Testing of Uprate Systems M2
1.8 Annual Contractor Review
Semi-Annual Progress Report
Engines and Energy Conversion Laboratory
Year 2 Project Schedule
Task O05
N05
D05
JO6
FO6
M06
A06
M06
J06
J06
A06
S06
O06
2.1 Selection of Field Test Unit
2.2 Component Procure/ Fab
2.3 Field Test Plan
2.4 Component Procure & Fab
2.5 Uprate System Field Install
2.6 Uprate System Field Test
2.7 Technology Transfer Plan
2.8 Annual Contractor Review
Semi-Annual Progress Report
Engines and Energy Conversion Laboratory
Funding Sources
2003 2004 2005 2006GTI Only $240,000(FERC funds)GTI Cost-Share$100,000(FERC funds)
1 1
PRCI$160,000(Industry funds)
2 2 2 2
DOE$150,000 (Yr 1)$250,000 (Yr 2)
1 1 1 1 2 2 2 2
Engines and Energy Conversion Laboratory
Expenditures
DOE Project DE-FC26-04NT42270CSU Expenditures of DOE Funds
0
20000
40000
60000
80000
100000
120000
140000
160000
1 2 3 4 5 6 7 8 9 10 11 12
Months
Cum
mul
ativ
e Fu
nds,
$
BudgetedActual
Chart1
1250012500
2500025000
3750037500
5000050000
6250074858
7500099720
87500124575
100000
112500
125000
137500
150000
Budgeted
Actual
Months
Cummulative Funds, $
DOE Project DE-FC26-04NT42270CSU Expenditures of DOE Funds
Sheet1
MonthsBudgetedActual
11250012500
22500025000
33750037500
45000050000
56250074,858
67500099,720
787500124,575
8100000
9112500
10125000
11137500
12150000
Sheet2
Sheet3
Engines and Energy Conversion Laboratory
Outline
• Executive Summary• Previous Work done with GTI Funds• DOE Year 1 Results To-Date• Planned Research Activities
Engines and Energy Conversion Laboratory
Identify Potential Engines: Engine Candidates
Desired Engine Candidate Requirements• BMEP vs. Quantity
Want to find engines with:• Low BMEP• Significant Installed Base• 2-Stroke
Engines and Energy Conversion Laboratory
Identify Potential Engines: Engine Uprates Survey Table
Manufacturer Family #Units Total HP Type (2/4 stroke) Cyl. Dims.Cylinder
Configurations Air Delivery BMEP
BA 145 203507 2 17x17 5,6,8,10 Piston Scavenged 68.3HBA 245 410644 2 17x17 5,6,8,10 Piston Scavenged 75.3HLA 44 91950 2 17x19 5,6,8,10 Nat. Asp. 76.5TLA 284 665074 2 17x19 5,6,8,10 Turbocharged 103.3KVG 286 310588 4 15.25x18 6,8,10,12 Nat. Asp. 80.34KVS 225 411235 4 15.25x18 6,8,10,12 Elliott Turbo. 121.7GMV 305 305219 2 14x14 4,6,8,10 Piston Scavenged 61.3
GMVA 136 170539 2 14x14 4,6,8,10,12 Blower 79.2-84.3GMW 189 422080 2 18x20 6,8,10 Blower 74.5
GMWA 216 453100 2 18x20 6,8,10,12 Blower 77.5
Clark
Ingersoll-Rand
Cooper-Bessemer
Sheet1
Engine Uprates Survey Table
ManufacturerFamily#UnitsTotal HPType (2/4 stroke)Cyl. Dims.Cylinder ConfigurationsAir DeliveryBMEP
ClarkBA145203507217x175,6,8,10Piston Scavenged68.3
HBA245410644217x175,6,8,10Piston Scavenged75.3
HLA4491950217x195,6,8,10Nat. Asp.76.5
TLA284665074217x195,6,8,10Turbocharged103.3
Ingersoll-RandKVG286310588415.25x186,8,10,12Nat. Asp.80.34
KVS225411235415.25x186,8,10,12Elliott Turbo.121.7
Cooper-BessemerGMV305305219214x144,6,8,10Piston Scavenged61.3
GMVA136170539214x144,6,8,10,12Blower79.2-84.3
GMW189422080218x206,8,10Blower74.5
GMWA216453100218x206,8,10,12Blower77.5
Sheet2
ManufacturerFamily#UnitsTotal HPType (2/4 stroke)Cyl. Dims.Cylinder ConfigurationsAir DeliveryBMEPCost
ClarkBA145203507217x175,6,8,10Piston Scavenged68.3
HBA245410644217x175,6,8,10Piston Scavenged75.3
HLA4491950217x195,6,8,10Nat. Asp.76.5
TLA284665074217x195,6,8,10Turbocharged103.3
K5X11652218.5x196 (3 disabled)Turbocharged129.2
Ingersoll-RandKVG286310588415.25x186,8,10,12Nat. Asp.80.34
KVS225411235415.25x186,8,10,12Elliott Turbo.121.7
Cooper-BessemerGMV305305219214x144,6,8,10Piston Scavenged61.3
GMVA136170539214x144,6,8,10,12Blower79.2-84.3
GMW189422080218x206,8,10Blower74.5
GMWA216453100218x206,8,10,12Blower77.5
Sheet3
Engines and Energy Conversion Laboratory
Identify Potential Engines: Target Engines
Based upon the engine survey table, the following engines meet the requirements:•Clark HBA•Clark TLA•Cooper-Bessemer GMV series
Engines and Energy Conversion Laboratory
• Turbocharger Upgrade or Installation• High Pressure Fuel Injection• Micro Pilot Injection• Pre-Combustion Chambers• Intercooling• Piston Crown Re-design• Exhaust Tuning
Technical Considerations: Potential Technologies
Engines and Energy Conversion Laboratory
Block Diagram
Engines and Energy Conversion Laboratory
B.S. NOx vs Load
0
2
4
6
8
10
12
14
240 290 340 390 440 490
Load (BHP)
B.S
. NO
x (g
/bhp
-hr)
MGAV @ 7.5"HPFI @ 7.5"HPFI @ 12"Adv. Ign. Sys. @ 16"
MGAV -> HPFI
Turbo Upgrade
Adv. Ign. Sys.& More Boost
IncreasedLoad
Overall Reduction in NOx
Final OperatingPoint
Projected Reduction In NOx After Uprating Methods
Data
BS NOx @ 7.5" BoostBSFC @ 7.5" Boost
LoadHPFI @ 7.5"MGAV @ 7.5"HPFI @ 7.5"MGAV @ 7.5"
2650.41.91085011800
3100.72.2955010300
35512.586009300
3802.13.184008800
4003.24.582508600
4409.711.881008400
BS NOx @ 12" BoostBSFC @ 12" Boost
LoadHPFI @ 12"MGAV @ 12"LoadHPFI @ 12"
3150.25330012000
3600.52.33309500
4151.22.73609000
4302.13.13908300
4402.43.54208100
4503.24.54408030
4909.711.8
Adv. Ign. Sys. @ 16"
3150.05
3600.15
4150.25
4300.45
4400.75
4702.2
4904
BHPBFSC
4408100HPFI @ 7.5"
8400MGAV @ 7.5"
8050Adv. Ign. Sys. @ 12"
8010Adv. Ign. Sys. @ 16"
8200Adv. Ign. Sys. @ 20"
8400MGAV @ 16"
4847850Adv. Ign. Sys. @ 16" & 484 bhp
Data
HPFI @ 7.5"
MGAV @ 7.5"
HPFI @ 12"
HPFI @ 7.5"
MGAV @ 7.5"
HPFI @ 12"
Load (BHP)
BSFC (btu/bhp-hr)
BSFC vs Load
BS NOx vs Load Graph
265265315315
310310360360
355355415415
380380430430
400400440440
440440450470
490490
MGAV -> HPFI
Turbo Upgrade
Adv. Ign. Sys.& More Boost
IncreasedLoad
Overall Reduction in NOx
Final OperatingPoint
HPFI @ 7.5"
MGAV @ 7.5"
HPFI @ 12"
Adv. Ign. Sys. @ 16"
HPFI @ 7.5"
MGAV @ 7.5"
HPFI @ 12"
Adv. Ign. Sys. @ 16"
Load (BHP)
B.S. NOx (g/bhp-hr)
B.S. NOx vs Load
0.4
1.9
0.25
0.05
0.7
2.2
0.5
0.15
1
2.5
1.2
0.25
2.1
3.1
2.1
0.45
3.2
4.5
2.4
0.75
9.7
11.8
3.2
2.2
9.7
4
BSFC Bar Chart
840081008050801082007850
Potential Fuel SavingsAfter IncreasedBoost & Load
MGAV @ 7.5"440 bhp
HPFI @ 7.5"440 bhp
Adv. Ign.Sys. @ 12"440 bhp
Adv. Ign.Sys. @ 16"440 bhp
Adv. Ign.Sys. @ 20"440 bhp
Adv. Ign.Sys. @ 16"484 bhp
MGAV @ 7.5"
HPFI @ 7.5"
Adv. Ign. Sys. @ 12"
Adv. Ign. Sys. @ 16"
Adv. Ign. Sys. @ 20"
Adv. Ign. Sys. @ 16" & 484 bhp
BSFC (btu/bhp-hr)
Brake Specific Fuel Consumption
Engines and Energy Conversion Laboratory
Brake Specific Fuel Consumption
7700
7800
7900
8000
8100
8200
8300
8400
8500
BSF
C (b
tu/b
hp-h
r) Potential Fuel Savings
After IncreasedBoost & Load
MGAV @ 7.5"440 bhp
HPFI @ 7.5"440 bhp
Adv. Ign.Sys. @ 12"
440 bhp Adv. Ign.Sys. @ 16"
440 bhp
Adv. Ign.Sys. @ 20"
440 bhp
Adv. Ign.Sys. @ 16"
484 bhp
Projected Fuel Savings withUprating Methods
Data
BS NOx @ 7.5" BoostBSFC @ 7.5" Boost
LoadHPFI @ 7.5"MGAV @ 7.5"HPFI @ 7.5"MGAV @ 7.5"
2650.41.91085011800
3100.72.2955010300
35512.586009300
3802.13.184008800
4003.24.582508600
4409.711.881008400
BS NOx @ 12" BoostBSFC @ 12" Boost
LoadHPFI @ 12"MGAV @ 12"LoadHPFI @ 12"
3150.25330012000
3600.52.33309500
4151.22.73609000
4302.13.13908300
4402.43.54208100
4503.24.54408030
4909.711.8
Adv. Ign. Sys. @ 16"
3150.05
3600.15
4150.25
4300.45
4400.75
4702.2
4904
BHPBFSC
4408100HPFI @ 7.5"
8400MGAV @ 7.5"
8050Adv. Ign. Sys. @ 12"
8010Adv. Ign. Sys. @ 16"
8200Adv. Ign. Sys. @ 20"
8400MGAV @ 16"
4847850Adv. Ign. Sys. @ 16" & 484 bhp
Data
HPFI @ 7.5"
MGAV @ 7.5"
HPFI @ 12"
HPFI @ 7.5"
MGAV @ 7.5"
HPFI @ 12"
Load (BHP)
BSFC (btu/bhp-hr)
BSFC vs Load
BS NOx vs Load Graph
265265315315
310310360360
355355415415
380380430430
400400440440
440440450470
490490
MGAV -> HPFI
Turbo Upgrade
Adv. Ign. Sys.& More Boost
IncreasedLoad
Overall Reduction in NOx
Final OperatingPoint
HPFI @ 7.5"
MGAV @ 7.5"
HPFI @ 12"
Adv. Ign. Sys. @ 16"
HPFI @ 7.5"
MGAV @ 7.5"
HPFI @ 12"
Adv. Ign. Sys. @ 16"
Load (BHP)
B.S. NOx (g/bhp-hr)
B.S. NOx vs Load
0.4
1.9
0.25
0.05
0.7
2.2
0.5
0.15
1
2.5
1.2
0.25
2.1
3.1
2.1
0.45
3.2
4.5
2.4
0.75
9.7
11.8
3.2
2.2
9.7
4
BSFC Bar Chart
840081008050801082007850
Potential Fuel SavingsAfter IncreasedBoost & Load
MGAV @ 7.5"440 bhp
HPFI @ 7.5"440 bhp
Adv. Ign.Sys. @ 12"440 bhp
Adv. Ign.Sys. @ 16"440 bhp
Adv. Ign.Sys. @ 20"440 bhp
Adv. Ign.Sys. @ 16"484 bhp
MGAV @ 7.5"
HPFI @ 7.5"
Adv. Ign. Sys. @ 12"
Adv. Ign. Sys. @ 16"
Adv. Ign. Sys. @ 20"
Adv. Ign. Sys. @ 16" & 484 bhp
BSFC (btu/bhp-hr)
Brake Specific Fuel Consumption
Engines and Energy Conversion Laboratory
The Effect of Combustion Stabilization
Combustion stabilization through enhanced ignition
ReducedVariability
Variability
Potential increase in average peak pressure without increasing
maximum peak pressure
Engines and Energy Conversion Laboratory
Micro Pilot Ignition System
Using a micro-liter quantity of a compression ignitable pilot fuelas the ignitionsource
Engines and Energy Conversion Laboratory
Micro Pilot Ignition System
• No Misfires• Lower THC• Lower BSFC• Achieved
Engines and Energy Conversion Laboratory
Misfire Elimination
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
100 90 80 70Load (%)
Misfi
res (
%)
φ=
0.85
φ=
0.85
Pilot IgnitionSpark Ignition
φ=
0.78
φ=
0.78
φ=
0.73
φ=
0.73
φ=
0.71
φ=
0.67
Micro Pilot Ignition System
Engines and Energy Conversion Laboratory
THC Reduction
0
2
4
6
8
10
12
14
100 90 80 70Load (%)
THC
(g/h
p-hr
)
φ=
0.85
φ=
0.85
Pilot Ignition
Spark Ignition
φ=
0.78
φ=
0.78
φ=
0.73
φ=
0.73
φ=
0.71
φ=
0.67
Micro Pilot Ignition System
Engines and Energy Conversion Laboratory
7000
7500
8000
8500
9000
9500
100 90 80 70Load (%)
BSFC
(BTU
/hp-h
r)
BSFC Reductionφ
= 0.
85
φ=
0.85
Pilot IgnitionSpark Ignition
φ=
0.78
φ=
0.78
φ=
0.73
φ=
0.73
φ=
0.71
φ=
0.67
0.8% Pilot
Micro Pilot Ignition System
Engines and Energy Conversion Laboratory
Micro Pilot Ignition System
Currently, key components are provided by Woodward and Delphi
Engines and Energy Conversion Laboratory
The current injectors used will work better for the Clark engine than for the GMV
Micro Pilot Ignition System
Impinging Sprays
No Impingement
This was shown to reduce pilot fuel quantity with custom fuel injector testing
Engines and Energy Conversion Laboratory
Clark TLA Piston Crown Re-Design Example
Engines and Energy Conversion Laboratory
• Developed using Ricardo WAVE– Engine simulation software– Models compressible flow effects (1-D)– Computes emissions – 2-zone combustion model
• Engine is first modeled under nominal operating conditions, matching efficiency, cylinder pressure profile, NOx emissions, and other parameters
• Manifold is optimized using 7 variable Design of Experiments technique, adapted for this application
Clark TLA Exhaust Tuning Example
Engines and Energy Conversion Laboratory
Tuned Exhaust Manifoldfor Clark TLA Engine
Original Exhaust Manifold New Exhaust Manifold Design
Engines and Energy Conversion Laboratory
Tuned Exhaust Manifoldfor Clark TLA Engine
Engines and Energy Conversion Laboratory
Parameters Nominal Optimized ModifiedDelivery Ratio 1.771 1.777 1.77
Scavenging Efficiency 0.87 0.871 0.869Trapping Efficiency 0.491 0.49 0.491
IMEP (psi) 120.3 120.3 121.4Peak Pressure (psi) 752.7 765.8 758.6Location of PP (CA) 18.01 18.02 17.97
Brake Power (hp) 2000 2000 2020BMEP (psi) 102 102 103.1
Mass Flow of Fresh Air (lb/hr) 34580 35640 35090Trapped Equivalence Ratio 0.7259 0.7016 0.7212
Fuel (g) 3.275 3.23 3.275NOx (g/bkW-hr) 12.81 8.45 10.59
• The first optimized case produced NOx reduction of 34%• The modified optimized case produced NOx reduction of 17.3%
Tuned Exhaust Results
Sheet1
ParametersNominalOptimizedModified
Delivery Ratio1.7711.7771.77
Scavenging Efficiency0.870.8710.869
Trapping Efficiency0.4910.490.491
IMEP (psi)120.3120.3121.4
Peak Pressure (psi)752.7765.8758.6
Location of PP (CA)18.0118.0217.97
Brake Power (hp)200020002020
BMEP (psi)102102103.1
Mass Flow of Fresh Air (lb/hr)345803564035090
Trapped Equivalence Ratio0.72590.70160.7212
Fuel (g)3.2753.233.275
NOx (g/bkW-hr)12.818.4510.59
Sheet2
Sheet3
Engines and Energy Conversion Laboratory
CFD Modeling of D-R Research Engine, K5X
Engines and Energy Conversion Laboratory
Cost Analysis
• Project target cost was to achieve
Engines and Energy Conversion Laboratory
EECL’s Clark TLA Engine –Donated by Dresser-Rand
• Currently being modified from 3-cylinder to 6-cylinder configuration
Engines and Energy Conversion Laboratory
Engine Specific Uprate Strategy
Family Type (2/4 stroke) Original Air Delivery Method
BMEP Enhanced Mixing
Improved Air
Delivery
Improved Ignition
Exhaust Tuning
BA 2 Piston Scavenged 68.3 HPFI TC X1 TBDHBA 2 Piston Scavenged 75.3 HPFI TC X1 TBDHLA 2 Piston Scavenged 76.5 HPFI TC X1 TBDTLA 2 Turbocharged 103.3 HPFI TU X1 XK5X 2 Turbocharged 129.2KVG 4 Nat. Asp. 80.34 HPFI TC X1 TBDGMV 2 Piston Scavenged 61.3 HPFI TC X1 TBD
GMVA 2 Blower 79.2-84.3 HPFI TC X1 TBDGMW 2 Blower 74.5 HPFI TC X1 TBD
GMWA 2 Blower 77.5 HPFI TC X1 TBDNote:1 If CR > 8.5:1 Then pilot injection
TC = Turbocharger
If CR < 8.5:1 Then PCC's
Ingersoll-Rand
Cooper-Bessemer
N/A
Engine Uprates Technique Table
Manufacturer
Clark
Sheet1
Engine Uprates Survey TableEngine Uprates Technique Table
ManufacturerFamily#UnitsTotal HPType (2/4 stroke)Cyl. Dims.Cylinder ConfigurationsAir DeliveryBMEPManufacturerFamilyType (2/4 stroke)Original Air Delivery MethodBMEPEnhanced MixingImproved Air DeliveryImproved IgnitionExhaust Tuning
ClarkBA145203507217x175,6,8,10Piston Scavenged68.3ClarkBA2Piston Scavenged68.3HPFITCX1TBD
HBA245410644217x175,6,8,10Piston Scavenged75.3HBA2Piston Scavenged75.3HPFITCX1TBD
HLA4491950217x195,6,8,10Nat. Asp.76.5HLA2Piston Scavenged76.5HPFITCX1TBD
TLA284665074217x195,6,8,10Turbocharged103.3TLA2Turbocharged103.3HPFITUX1X
K5X11652218.5x196 (3 disabled)Turbocharged129.2K5X2Turbocharged129.2N/A
Ingersoll-RandKVG286310588415.25x186,8,10,12Nat. Asp.80.34Ingersoll-RandKVG4Nat. Asp.80.34HPFITCX1TBD
Cooper-BessemerGMV305305219214x144,6,8,10Piston Scavenged61.3Cooper-BessemerGMV2Piston Scavenged61.3HPFITCX1TBD
GMVA136170539214x144,6,8,10,12Blower79.2-84.3GMVA2Blower79.2-84.3HPFITCX1TBD
GMW189422080218x206,8,10Blower74.5GMW2Blower74.5HPFITCX1TBD
GMWA216453100218x206,8,10,12Blower77.5GMWA2Blower77.5HPFITCX1TBD
Note:TC = Turbocharger
1If CR > 8.5:1 Then pilot injection
If CR < 8.5:1 Then PCC's
Sheet2
ManufacturerFamily#UnitsTotal HPType (2/4 stroke)Cyl. Dims.Cylinder ConfigurationsAir DeliveryBMEPCost
ClarkBA145203507217x175,6,8,10Piston Scavenged68.3
HBA245410644217x175,6,8,10Piston Scavenged75.3
HLA4491950217x195,6,8,10Nat. Asp.76.5
TLA284665074217x195,6,8,10Turbocharged103.3
K5X11652218.5x196 (3 disabled)Turbocharged129.2
Ingersoll-RandKVG286310588415.25x186,8,10,12Nat. Asp.80.34
KVS225411235415.25x186,8,10,12Elliott Turbo.121.7
Cooper-BessemerGMV305305219214x144,6,8,10Piston Scavenged61.3
GMVA136170539214x144,6,8,10,12Blower79.2-84.3
GMW189422080218x206,8,10Blower74.5
GMWA216453100218x206,8,10,12Blower77.5
Sheet3
Engines and Energy Conversion Laboratory
Industry Involvement
• Dresser-Rand support – TLA engine donation, engineering drawings, and commitment for some conversion parts
• Altronic, Enginuity, and Hoerbiger commitment for hardware support/donations
• Industry personnel assistance –interviews, documentation, etc.
Engines and Energy Conversion Laboratory
Industry Experience (Summary)
• Large bore NG 2-stroke engines are believed to have large safety factors
• Field data demonstrates safe operation at greater than 100% load
• Many of the large bore NG 2-stroke engines capable of increased speeds and loads without structural modifications
• No increase in failures noted for these engines
Engines and Energy Conversion Laboratory
Industry Experience (Interviews)
• Power Cylinder Porting Change• New Heads & Pistons• Scavenging Air Elbow• No Turbo Upgrade• 110% of Rated Load• Ran Better, No Increased Failure Rates
Chevron-Texaco - Clark RA Series
Engines and Energy Conversion Laboratory
Industry Experience (Interviews)
• Installed ABB Marine Turbocharger (19” Hg Boost)
• Intercooler w/ Wet Cooling Tower – Intake Air Temp. of 97°F
• Peak Pressure Balance w/ Std. Dev. < 30 psi.• 115% of Rated Load Since 1958 w/ No
Increase in Failure Rates or Maintenance
SoCal Gas – Clark TLA-6 (7)
Engines and Energy Conversion Laboratory
Industry Experience (Interviews)
• Std. Turbocharger• Intercooler Upgrade w/ Cooling Towers• 105% of Rated Load for 20 yrs w/ No
Increase in Failure Rates
Williams Pipeline – Clark TLA-6 (12)
Engines and Energy Conversion Laboratory
Industry Experience
• Reviewed TLA-6 crankcase and upper block solid models
• Provided feedback on common TLA-6 failure modes and locations
• Will provide similar input for GMV and HBA engines
Terry Smith – Industry Field Repair Expert
Engines and Energy Conversion Laboratory
OEM Communications
• Memo from Clark to Texaco (1959) communicated results from a vibration analysis for an RA-6.
• Results indicated a resonant frequency exists at 340-350 RPM with a 7°amplitude.
• Clark recommended a max. speed of 320 RPM or flywheel modifications.
Engines and Energy Conversion Laboratory
OEM Communications
• Report from Cooper-Bessemer to Texaco(1989) regarding increasing speeds of GMV-6 (3) and GMVL-6 (1).
• Increased speed from 300 – 330 RPM.• Balance study indicated that one of the
GMV-6 engines needed to have additional reciprocating weight added.
Engines and Energy Conversion Laboratory
• Increasing torque, not speed, can avoid approaching critical speeds.
• Industry data supports the conclusion that the engines have a large factor of safety, which will allow for the safe operation at the increased loads.
• Improved air delivery has long been demonstrated to reduce fuel consumption and emissions through leaner operation.
GTI Project Conclusions (1/2)
Engines and Energy Conversion Laboratory
• Enhanced mixing can help reduce emissions, increase combustion stability, extend the lean limit, and decrease fuel consumption.
• Improved ignition techniques can reduce emissions, improve combustion stability, extend the lean limit, and decrease fuel consumption.
• HPFI, micro pilot ignition, and increased boost are proven technologies and are planned for implementation in Year 1 of the DOE program.
• Exhaust tuning benefits are engine specific and would have to be analyzed for each case.
GTI Project Conclusions (2/2)
Engines and Energy Conversion Laboratory
Year 1 Project Schedule
Task O04
N04
D04
JO5
FO5
M05
A05
M05
J05
J05
A05
S05
O05
1.1 Research Management Plan complete
1.2 Technology Assessment complete
1.3 Optical Engine Evaluations
1.4 Component Procure & Fab
1.5 System Test Plan M1
1.6 Uprate Systems Installation
1.7 Testing of Uprate Systems M2
1.8 Annual Contractor Review
Semi-Annual Progress Report
Engines and Energy Conversion Laboratory
Outline
• Executive Summary • Previous Work done with GTI Funds• DOE Year 1 Results To-Date• Planned Research Activities
Engines and Energy Conversion Laboratory
Task 1.2: Technology Assessment Summary Table
ENGINE MODEL
(Percent of Overall Fleet)BA, HBAHLA
TLA KVG KVS GMV, GMVA
GMW, GMWA
(7.5) (7.1) (3.1) (4.4) (5.1) (9.3)
UPRATE TECHNOLOGY Indicates Uprate Technology is applicable to engine model (subject to change per study)Turbo Installation/ Upgrade•Pro: can help reduce emissions, increase engine output and extend the lean limit.•Con: may not be economical for units
Engines and Energy Conversion Laboratory
Task 1.3: Optical Engine (1/15): Description
Engines and Energy Conversion Laboratory
Laser Sheet
Acetone SeedingSystem
Laser
ICCD Camera
OpticalEngine
Fuel Valve
Task 1.3: Optical Engine (2/15): PLIF Imaging Setup
Engines and Energy Conversion Laboratory
Task 1.3: Optical Engine (3/15): CFD Validation
Engines and Energy Conversion Laboratory
Task 1.3: Optical Engine (4/15): Clark TLA CFD Analysis
• Optical engine has 14” bore; TLA has 17” bore• Not practical to modify for larger bore• Performed mixing studies using CFD, previously
validated with optical engine results– Case #1 - OEM TLA with standard mixing model– Case #2 - TLA with enhanced mixing model and OEM
piston– Case #3 - TLA with enhanced mixing model with
modified crown piston
Engines and Energy Conversion Laboratory
Task 1.3: Optical Engine (5/15): CFD Flow Field @ IGNITION
Engines and Energy Conversion Laboratory
Task 1.3: Optical Engine (6/15): CFD Fuel Distribution @ IGNITION
Engines and Energy Conversion Laboratory
Task 1.3: Optical Engine (7/15): CFD Flame Propagation & Fuel Consumption
-6 -2 2 6
Engines and Energy Conversion Laboratory
Task 1.3: Optical Engine (8/15): CFD Flame Propagation & Fuel Consumption
10 14 18 22
Engines and Energy Conversion Laboratory
0 10 20 30
Task 1.3: Optical Engine (9/15): CFD Temperature & NO
Engines and Energy Conversion Laboratory
40 50 60 70
Task 1.3: Optical Engine (10/15): CFD Temperature & NO
Engines and Energy Conversion Laboratory
90° BTDC100° BTDC110° BTDC120° BTDC
HPFI
HPFI w/ modified piston
Nominal TLA
Task 1.3: Optical Engine (11/15): Mixing Comparison
Engines and Energy Conversion Laboratory
50° BTDC60° BTDC70° BTDC80° BTDC
Nominal TLA
HPFI
HPFI w/ modified piston
Task 1.3: Optical Engine (12/15): Mixing Comparison
Engines and Energy Conversion Laboratory
10° BTDC20° BTDC30° BTDC40° BTDC
Nominal TLA
HPFI
HPFI w/ modified piston
Task 1.3: Optical Engine (13/15): Mixing Comparison
Engines and Energy Conversion Laboratory
• CFD work provides required information on mixing
• To examine micropilot ignition, utilize combustion test chamber (CTC)
• CTC will allow imaging of pilot injection with new injectors prior to engine testing
Task 1.3: Optical Engine (14/15)
Engines and Energy Conversion Laboratory
Task 1.3: Optical Engine (15/15): Combustion Test Chamber
Engines and Energy Conversion Laboratory
Task 1.4: Component Procurement & Fabrication (1/15)
• Request for OEM components has been submitted to Dresser-Rand
• Hoerbiger and Enginuity have offered to provide high pressure fuel injection systems
• Enginuity is donating an Impact cylinder pressure monitoring system
• Altronic is donating CPU 2000 spark ignition system with add-on module for micropilot injection control
Engines and Energy Conversion Laboratory
Task 1.4: Component Procurement & Fabrication (2/15): Modal and Dynamic Stress Analysis
• Modal analysis (Pro Mechanica) performed to assess possibility of utilizing speed increases
• Stress analysis performed to examine effects of increasing torque
• Dynamic forces accounted for by utilizing Working Model and simulation feature in Pro Mechanica
• High stress locations identified using Finite Element Analysis
Engines and Energy Conversion Laboratory
Task 1.4: Component Procurement & Fabrication (3/15): TLA Crankshaft Modal Analysis• Added ‘mass’ (lobes) to
crankshaft to simulate piston/connecting rod weight.
• Constrained bearing at non-flywheel end to 1 rotational DOF, all other bearing supports to 1 rotational and 1 translational DOF.
• Modal Analysis results indicate the first resonant frequency occurs at 34Hz (2040RPM).– The 5th, 6th, and 7th order critical speeds are 408, 340,
and 291 RPM, respectively.
Engines and Energy Conversion Laboratory
Task 1.4: Component Procurement & Fabrication (4/15): TLA-6 Stress Analysis
• Given the forces of the power and compressor pistons, the frame stresses are examined.
• The frame stresses of standard TLA configuration are compared to the frame stresses of the uprated TLA configuration.
GMV crankcaseSuperior crankcase(Reynolds-French)
Engines and Energy Conversion Laboratory
Task 1.4: Component Procurement & Fabrication (5/15): TLA-6 Dynamic Analysis
• Developed dynamic model using Working Model 2D software
• Determined dynamic forces on crankshaft bearings
• These forces used as the loading forces for the crankcase FEA modeling
Engines and Energy Conversion Laboratory
Task 1.4: Component Procurement & Fabrication (6/15): TLA-6 Dynamic Analysis
Working Model Simulation of TLA Power Piston and Compressor Piston Forces on Crankshaft Bearings
-80000
-60000
-40000
-20000
0
20000
40000
60000
80000
100000
120000
140000
160000
0 30 60 90 120 150 180 210 240 270 300 330 360
Crank Angle (deg)
Forc
e (lb
)
FxFyCombustion ForceCompression ForceSuction Force
Chart3
00000
0.250.250.250.250.25
0.50.50.50.50.5
0.750.750.750.750.75
11111
1.251.251.251.251.25
1.51.51.51.51.5
1.751.751.751.751.75
22222
2.252.252.252.252.25
2.52.52.52.52.5
2.752.752.752.752.75
33333
3.253.253.253.253.25
3.53.53.53.53.5
3.753.753.753.753.75
44444
4.254.254.254.254.25
4.54.54.54.54.5
4.754.754.754.754.75
55555
5.255.255.255.255.25
5.55.55.55.55.5
5.755.755.755.755.75
66666
6.256.256.256.256.25
6.56.56.56.56.5
6.756.756.756.756.75
77777
7.257.257.257.257.25
7.57.57.57.57.5
7.757.757.757.757.75
88888
8.258.258.258.258.25
8.58.58.58.58.5
8.758.758.758.758.75
99999
9.259.259.259.259.25
9.59.59.59.59.5
9.759.759.759.759.75
1010101010
10.2510.2510.2510.2510.25
10.510.510.510.510.5
10.7510.7510.7510.7510.75
1111111111
11.2511.2511.2511.2511.25
11.511.511.511.511.5
11.7511.7511.7511.7511.75
1212121212
12.2512.2512.2512.2512.25
12.512.512.512.512.5
12.7512.7512.7512.7512.75
1313131313
13.2513.2513.2513.2513.25
13.513.513.513.513.5
13.7513.7513.7513.7513.75
1414141414
14.2514.2514.2514.2514.25
14.514.514.514.514.5
14.7514.7514.7514.7514.75
1515151515
15.2515.2515.2515.2515.25
15.515.515.515.515.5
15.7515.7515.7515.7515.75
1616161616
16.2516.2516.2516.2516.25
16.516.516.516.516.5
16.7516.7516.7516.7516.75
1717171717
17.2517.2517.2517.2517.25
17.517.517.517.517.5
17.7517.7517.7517.7517.75
1818181818
18.2518.2518.2518.2518.25
18.518.518.518.518.5
18.7518.7518.7518.7518.75
1919191919
19.2519.2519.2519.2519.25
19.519.519.519.519.5
19.7519.7519.7519.7519.75
2020202020
20.2520.2520.2520.2520.25
20.520.520.520.520.5
20.7520.7520.7520.7520.75
2121212121
21.2521.2521.2521.2521.25
21.521.521.521.521.5
21.7521.7521.7521.7521.75
2222222222
22.2522.2522.2522.2522.25
22.522.522.522.522.5
22.7522.7522.7522.7522.75
2323232323
23.2523.2523.2523.2523.25
23.523.523.523.523.5
23.7523.7523.7523.7523.75
2424242424
24.2524.2524.2524.2524.25
24.524.524.524.524.5
24.7524.7524.7524.7524.75
2525252525
25.2525.2525.2525.2525.25
25.525.525.525.525.5
25.7525.7525.7525.7525.75
2626262626
26.2526.2526.2526.2526.25
26.526.526.526.526.5
26.7526.7526.7526.7526.75
2727272727
27.2527.2527.2527.2527.25
27.527.527.527.527.5
27.7527.7527.7527.7527.75
2828282828
28.2528.2528.2528.2528.25
28.528.528.528.528.5
28.7528.7528.7528.7528.75
2929292929
29.2529.2529.2529.2529.25
29.529.529.529.529.5
29.7529.7529.7529.7529.75
3030303030
30.2530.2530.2530.2530.25
30.530.530.530.530.5
30.7530.7530.7530.7530.75
3131313131
31.2531.2531.2531.2531.25
31.531.531.531.531.5
31.7531.7531.7531.7531.75
3232323232
32.2532.2532.2532.2532.25
32.532.532.532.532.5
32.7532.7532.7532.7532.75
3333333333
33.2533.2533.2533.2533.25
33.533.533.533.533.5
33.7533.7533.7533.7533.75
3434343434
34.2534.2534.2534.2534.25
34.534.534.534.534.5
34.7534.7534.7534.7534.75
3535353535
35.2535.2535.2535.2535.25
35.535.535.535.535.5
35.7535.7535.7535.7535.75
3636363636
36.2536.2536.2536.2536.25
36.536.536.536.536.5
36.7536.7536.7536.7536.75
3737373737
37.2537.2537.2537.2537.25
37.537.537.537.537.5
37.7537.7537.7537.7537.75
3838383838
38.2538.2538.2538.2538.25
38.538.538.538.538.5
38.7538.7538.7538.7538.75
3939393939
39.2539.2539.2539.2539.25
39.539.539.539.539.5
39.7539.7539.7539.7539.75
4040404040
40.2540.2540.2540.2540.25
40.540.540.540.540.5
40.7540.7540.7540.7540.75
4141414141
41.2541.2541.2541.2541.25
41.541.541.541.541.5
41.7541.7541.7541.7541.75
4242424242
42.2542.2542.2542.2542.25
42.542.542.542.542.5
42.7542.7542.7542.7542.75
4343434343
43.2543.2543.2543.2543.25
43.543.543.543.543.5
43.7543.7543.7543.7543.75
4444444444
44.2544.2544.2544.2544.25
44.544.544.544.544.5
44.7544.7544.7544.7544.75
4545454545
45.2545.2545.2545.2545.25
45.545.545.545.545.5
45.7545.7545.7545.7545.75
4646464646
46.2546.2546.2546.2546.25
46.546.546.546.546.5
46.7546.7546.7546.7546.75
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47.2547.2547.2547.2547.25
47.547.547.547.547.5
47.7547.7547.7547.7547.75
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48.2548.2548.2548.2548.25
48.548.548.548.548.5
48.7548.7548.7548.7548.75
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49.2549.2549.2549.2549.25
49.549.549.549.549.5
49.7549.7549.7549.7549.75
5050505050
50.2550.2550.2550.2550.25
50.550.550.550.550.5
50.7550.7550.7550.7550.75
5151515151
51.2551.2551.2551.2551.25
51.551.551.551.551.5
51.7551.7551.7551.7551.75
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52.2552.2552.2552.2552.25
52.552.552.552.552.5
52.7552.7552.7552.7552.75
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53.2553.2553.2553.2553.25
53.553.553.553.553.5
53.7553.7553.7553.7553.75
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54.2554.2554.2554.2554.25
54.554.554.554.554.5
54.7554.7554.7554.7554.75
5555555555
55.2555.2555.2555.2555.25
55.555.555.555.555.5
55.7555.7555.7555.7555.75
5656565656
56.2556.2556.2556.2556.25
56.556.556.556.556.5
56.7556.7556.7556.7556.75
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57.2557.2557.2557.2557.25
57.557.557.557.557.5
57.7557.7557.7557.7557.75
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58.2558.2558.2558.2558.25
58.558.558.558.558.5
58.7558.7558.7558.7558.75
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59.2559.2559.2559.2559.25
59.559.559.559.559.5
59.7559.7559.7559.7559.75
6060606060
60.2560.2560.2560.2560.25
60.560.560.560.560.5
60.7560.7560.7560.7560.75
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61.561.561.561.561.5
61.7561.7561.7561.7561.75
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62.562.562.562.562.5
62.7562.7562.7562.7562.75
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63.7563.7563.7563.7563.75
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64.564.564.564.564.5
64.7564.7564.7564.7564.75
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65.565.565.565.565.5
65.7565.7565.7565.7565.75
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66.566.566.566.566.5
66.7566.7566.7566.7566.75
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67.7567.7567.7567.7567.75
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68.7568.7568.7568.7568.75
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79.579.579.579.579.5
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80.7580.7580.7580.7580.75
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81.581.581.581.581.5
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82.582.582.582.582.5
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83.7583.7583.7583.7583.75
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84.584.584.584.584.5
84.7584.7584.7584.7584.75
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85.585.585.585.585.5
85.7585.7585.7585.7585.75
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86.586.586.586.586.5
86.7586.7586.7586.7586.75
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94.594.594.594.594.5
94.7594.7594.7594.7594.75
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103.5103.5103.5103.5103.5
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104.25104.25104.25104.25104.25
104.5104.5104.5104.5104.5
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105.25105.25105.25105.25105.25
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106.25106.25106.25106.25106.25
106.5106.5106.5106.5106.5
106.75106.75106.75106.75106.75
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107.25107.25107.25107.25107.25
107.5107.5107.5107.5107.5
107.75107.75107.75107.75107.75
108108108108108
108.25108.25108.25108.25108.25
108.5108.5108.5108.5108.5
108.75108.75108.75108.75108.75
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109.25109.25109.25109.25109.25
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110.25110.25110.25110.25110.25
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112.25112.25112.25112.25112.25
112.5112.5112.5112.5112.5
112.75112.75112.75112.75112.75
113113113113113
113.25113.25113.25113.25113.25
113.5113.5113.5113.5113.5
113.75113.75113.75113.75113.75
114114114114114
114.25114.25114.25114.25114.25
114.5114.5114.5114.5114.5
114.75114.75114.75114.75114.75
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115.25115.25115.25115.25115.25
115.5115.5115.5115.5115.5
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116116116116116
116.25116.25116.25116.25116.25
116.5116.5116.5116.5116.5
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118.25118.25118.25118.25118.25
118.5118.5118.5118.5118.5
118.75118.75118.75118.75118.75
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119.25119.25119.25119.25119.25
119.5119.5119.5119.5119.5
119.75119.75119.75119.75119.75
120120120120120
120.25120.25120.25120.25120.25
120.5120.5120.5120.5120.5
120.75120.75120.75120.75120.75
121121121121121
121.25121.25121.25121.25121.25
121.5121.5121.5121.5121.5
121.75121.75121.75121.75121.75
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122.25122.25122.25122.25122.25
122.5122.5122.5122.5122.5
122.75122.75122.75122.75122.75
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123.25123.25123.25123.25123.25
123.5123.5123.5123.5123.5
123.75123.75123.75123.75123.75
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124.25124.25124.25124.25124.25
124.5124.5124.5124.5124.5
124.75124.75124.75124.75124.75
125125125125125
125.25125.25125.25125.25125.25
125.5125.5125.5125.5125.5
125.75125.75125.75125.75125.75
126126126126126
126.25126.25126.25126.25126.25
126.5126.5126.5126.5126.5
126.75126.75126.75126.75126.75
127127127127127
127.25127.25127.25127.25127.25
127.5127.5127.5127.5127.5
127.75127.75127.75127.75127.75
128128128128128
128.25128.25128.25128.25128.25
128.5128.5128.5128.5128.5
128.75128.75128.75128.75128.75
129129129129129
129.25129.25129.25129.25129.25
129.5129.5129.5129.5129.5
129.75129.75129.75129.75129.75
130130130130130
130.25130.25130.25130.25130.25
130.5130.5130.5130.5130.5
130.75130.75130.75130.75130.75
131131131131131
131.25131.25131.25131.25131.25
131.5131.5131.5131.5131.5
131.75131.75131.75131.75131.75
132132132132132
132.25132.25132.25132.25132.25
132.5132.5132.5132.5132.5
132.75132.75132.75132.75132.75
133133133133133
133.25133.25133.25133.25133.25
133.5133.5133.5133.5133.5
133.75133.75133.75133.75133.75
134134134134134
134.25134.25134.25134.25134.25
134.5134.5134.5134.5134.5
134.75134.75134.75134.75134.75
135135135135135
135.25135.25135.25135.25135.25
135.5135.5135.5135.5135.5
135.75135.75135.75135.75135.75
136136136136136
136.25136.25136.25136.25136.25
136.5136.5136.5136.5136.5
136.75136.75136.75136.75136.75
137137137137137
137.25137.25137.25137.25137.25
137.5137.5137.5137.5137.5
137.75137.75137.75137.75137.75
138138138138138
138.25138.25138.25138.25138.25
138.5138.5138.5138.5138.5
138.75138.75138.75138.75138.75
139139139139139
139.25139.25139.25139.25139.25
139.5139.5139.5139.5139.5
139.75139.75139.75139.75139.75
140140140140140
140.25140.25140.25140.25140.25
140.5140.5140.5140.5140.5
140.75140.75140.75140.75140.75
141141141141141
141.25141.25141.25141.25141.25
141.5141.5141.5141.5141.5
141.75141.75141.75141.75141.75
142142142142142
142.25142.25142.25142.25142.25
142.5142.5142.5142.5142.5
142.75142.75142.75142.75142.75
143143143143143
143.25143.25143.25143.25143.25
143.5143.5143.5143.5143.5
143.75143.75143.75143.75143.75
144144144144144
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144.5144.5144.5144.5144.5
144.75144.75144.75144.75144.75
145145145145145
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145.5145.5145.5145.5145.5
145.75145.75145.75145.75145.75
146146146146146
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146.5146.5146.5146.5146.5
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147147147147147
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147.5147.5147.5147.5147.5
147.75147.75147.75147.75147.75
148148148148148
148.25148.25148.25148.25148.25
148.5148.5148.5148.5148.5
148.75148.75148.75148.75148.75
149149149149149
149.25149.25149.25149.25149.25
149.5149.5149.5149.5149.5
149.75149.75149.75149.75149.75
150150150150150
150.25150.25150.25150.25150.25
150.5150.5150.5150.5150.5
150.75150.75150.75150.75150.75
151151151151151
151.25151.25151.25151.25151.25
151.5151.5151.5151.5151.5
151.75151.75151.75151.75151.75
152152152152152
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152.5152.5152.5152.5152.5
152.75152.75152.75152.75152.75
153153153153153
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153.5153.5153.5153.5153.5
153.75153.75153.75153.75153.75
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154.5154.5154.5154.5154.5
154.75154.75154.75154.75154.75
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155.5155.5155.5155.5155.5
155.75155.75155.75155.75155.75
156156156156156
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156.5156.5156.5156.5156.5
156.75156.75156.75156.75156.75
157157157157157
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157.5157.5157.5157.5157.5
157.75157.75157.75157.75157.75
158158158158158
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158.5158.5158.5158.5158.5
158.75158.75158.75158.75158.75
159159159159159
159.25159.25159.25159.25159.25
159.5159.5159.5159.5159.5
159.75159.75159.75159.75159.75
160160160160160
160.25160.25160.25160.25160.25
160.5160.5160.5160.5160.5
160.75160.75160.75160.75160.75
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161.25161.25161.25161.25161.25
161.5161.5161.5161.5161.5
161.75161.75161.75161.75161.75
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162.25162.25162.25162.25162.25
162.5162.5162.5162.5162.5
162.75162.75162.75162.75162.75
163163163163163
163.25163.25163.25163.25163.25
163.5163.5163.5163.5163.5
163.75163.75163.75163.75163.75
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164.5164.5164.5164.5164.5
164.75164.75164.75164.75164.75
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165.5165.5165.5165.5165.5
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166.5166.5166.5166.5166.5
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167.5167.5167.5167.5167.5
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168.5168.5168.5168.5168.5
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169.5169.5169.5169.5169.5
169.75169.75169.75169.75169.75
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170.25170.25170.25170.25170.25
170.5170.5170.5170.5170.5
170.75170.75170.75170.75170.75
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171.25171.25171.25171.25171.25
171.5171.5171.5171.5171.5
171.75171.75171.75171.75171.75
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172.25172.25172.25172.25172.25
172.5172.5172.5172.5172.5
172.75172.75172.75172.75172.75
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173.5173.5173.5173.5173.5
173.75173.75173.75173.75173.75
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174.5174.5174.5174.5174.5
174.75174.75174.75174.75174.75
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175.5175.5175.5175.5175.5
175.75175.75175.75175.75175.75
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176.5176.5176.5176.5176.5
176.75176.75176.75176.75176.75
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177.5177.5177.5177.5177.5
177.75177.75177.75177.75177.75
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178.5178.5178.5178.5178.5
178.75178.75178.75178.75178.75
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179.25179.25179.25179.25179.25
179.5179.5179.5179.5179.5
179.75179.75179.75179.75179.75
180180180180180
180.25180.25180.25180.25180.25
180.5180.5180.5180.5180.5
180.75180.75180.75180.75180.75
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181.25181.25181.25181.25181.25
181.5181.5181.5181.5181.5
181.75181.75181.75181.75181.75
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182.25182.25182.25182.25182.25
182.5182.5182.5182.5182.5
182.75182.75182.75182.75182.75
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183.5183.5183.5183.5183.5
183.75183.75183.75183.75183.75
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184.25184.25184.25184.25184.25
184.5184.5184.5184.5184.5
184.75184.75184.75184.75184.75
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185.5185.5185.5185.5185.5
185.75185.75185.75185.75185.75
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186.5186.5186.5186.5186.5
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187.25187.25187.25187.25187.25
187.5187.5187.5187.5187.5
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188.25188.25188.25188.25188.25
188.5188.5188.5188.5188.5
188.75188.75188.75188.75188.75
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189.25189.25189.25189.25189.25
189.5189.5189.5189.5189.5
189.75189.75189.75189.75189.75
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190.25190.25190.25190.25190.25
190.5190.5190.5190.5190.5
190.75190.75190.75190.75190.75
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191.25191.25191.25191.25191.25
191.5191.5191.5191.5191.5
191.75191.75191.75191.75191.75
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192.5192.5192.5192.5192.5
192.75192.75192.75192.75192.75
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193.5193.5193.5193.5193.5
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194.5194.5194.5194.5194.5
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195.5195.5195.5195.5195.5
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196.5196.5196.5196.5196.5
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198.5198.5198.5198.5198.5
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201.5201.5201.5201.5201.5
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202.5202.5202.5202.5202.5
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203.5203.5203.5203.5203.5
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204.5204.5204.5204.5204.5
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208.75208.75208.75208.75208.75
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210.75210.75210.75210.75210.75
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211.75211.75211.75211.75211.75
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213.5213.5213.5213.5213.5
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218.75218.75218.75218.75218.75
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221.5221.5221.5221.5221.5
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222.5222.5222.5222.5222.5
222.75222.75222.75222.75222.75
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223.5223.5223.5223.5223.5
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228.5228.5228.5228.5228.5
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229.5229.5229.5229.5229.5
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230.5230.5230.5230.5230.5
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231.5231.5231.5231.5231.5
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233.5233.5233.5233.5233.5
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234.5234.5234.5234.5234.5
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235.5235.5235.5235.5235.5
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241.5241.5241.5241.5241.5
241.75241.75241.75241.75241.75
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258.25258.25258.25258.25258.25
258.5258.5258.5258.5258.5
258.75258.75258.75258.75258.75
259259259259259
259.25259.25259.25259.25259.25
259.5259.5259.5259.5259.5
259.75259.75259.75259.75259.75
260260260260260
260.25260.25260.25260.25260.25
260.5260.5260.5260.5260.5
260.75260.75260.75260.75260.75
261261261261261
261.25261.25261.25261.25261.25
261.5261.5261.5261.5261.5
261.75261.75261.75261.75261.75
262262262262262
262.25262.25262.25262.25262.25
262.5262.5262.5262.5262.5
262.75262.75262.75262.75262.75
263263263263263
263.25263.25263.25263.25263.25
263.5263.5263.5263.5263.5
263.75263.75263.75263.75263.75
264264264264264
264.25264.25264.25264.25264.25
264.5264.5264.5264.5264.5
264.75264.75264.75264.75264.75
265265265265265
265.25265.25265.25265.25265.25
265.5265.5265.5265.5265.5
265.75265.75265.75265.75265.75
266266266266266
266.25266.25266.25266.25266.25
266.5266.5266.5266.5266.5
266.75266.75266.75266.75266.75
267267267267267
267.25267.25267.25267.25267.25
267.5267.5267.5267.5267.5
267.75267.75267.75267.75267.75
268268268268268
268.25268.25268.25268.25268.25
268.5268.5268.5268.5268.5
268.75268.75268.75268.75268.75
269269269269269
269.25269.25269.25269.25269.25
269.5269.5269.5269.5269.5
269.75269.75269.75269.75269.75
270270270270270
270.25270.25270.25270.25270.25
270.5270.5270.5270.5270.5
270.75270.75270.75270.75270.75
271271271271271
271.25271.25271.25271.25271.25
271.5271.5271.5271.5271.5
271.75271.75271.75271.75271.75
272272272272272
272.25272.25272.25272.25272.25
272.5272.5272.5272.5272.5
272.75272.75272.75272.75272.75
273273273273273
273.25273.25273.25273.25273.25
273.5273.5273.5273.5273.5
273.75273.75273.75273.75273.75
274274274274274
274.25274.25274.25274.25274.25
274.5274.5274.5274.5274.5
274.75274.75274.75274.75274.75
275275275275275
275.25275.25275.25275.25275.25
275.5275.5275.5275.5275.5
275.75275.75275.75275.75275.75
276276276276276
276.25276.25276.25276.25276.25
276.5276.5276.5276.5276.5
276.75276.75276.75276.75276.75
277277277277277
277.25277.25277.25277.25277.25
277.5277.5277.5277.5277.5
277.75277.75277.75277.75277.75
278278278278278
278.25278.25278.25278.25278.25
278.5278.5278.5278.5278.5
278.75278.75278.75278.75278.75
279279279279279
279.25279.25279.25279.25279.25
279.5279.5279.5279.5279.5
279.75279.75279.75279.75279.75
280280280280280
280.25280.25280.25280.25280.25
280.5280.5280.5280.5280.5
280.75280.75280.75280.75280.75
281281281281281
281.25281.25281.25281.25281.25
281.5281.5281.5281.5281.5
281.75281.75281.75281.75281.75
282282282282282
282.25282.25282.25282.25282.25
282.5282.5282.5282.5282.5
282.75282.75282.75282.75282.75
283283283283283
283.25283.25283.25283.25283.25
283.5283.5283.5283.5283.5
283.75283.75283.75283.75283.75
284284284284284
284.25284.25284.25284.25284.25
284.5284.5284.5284.5284.5
284.75284.75284.75284.75284.75
285285285285285
285.25285.25285.25285.25285.25
285.5285.5285.5285.5285.5
285.75285.75285.75285.75285.75
286286286286286
286.25286.25286.25286.25286.25
286.5286.5286.5286.5286.5
286.75286.75286.75286.75286.75
287287287287287
287.25287.25287.25287.25287.25
287.5287.5287.5287.5287.5
287.75287.75287.75287.75287.75
288288288288288
288.25288.25288.25288.25288.25
288.5288.5288.5288.5288.5
288.75288.75288.75288.75288.75
289289289289289
289.25289.25289.25289.25289.25
289.5289.5289.5289.5289.5
289.75289.75289.75289.75289.75
290290290290290
290.25290.25290.25290.25290.25
290.5290.5290.5290.5290.5
290.75290.75290.75290.75290.75
291291291291291
291.25291.25291.25291.25291.25
291.5291.5291.5291.5291.5
291.75291.75291.75291.75291.75
292292292292292
292.25292.25292.25292.25292.25
292.5292.5292.5292.5292.5
292.75292.75292.75292.75292.75
293293293293293
293.25293.25293.25293.25293.25
293.5293.5293.5293.5293.5
293.75293.75293.75293.75293.75
294294294294294
294.25294.25294.25294.25294.25
294.5294.5294.5294.5294.5
294.75294.75294.75294.75294.75
295295295295295
295.25295.25295.25295.25295.25
295.5295.5295.5295.5295.5
295.75295.75295.75295.75295.75
296296296296296
296.25296.25296.25296.25296.25
296.5296.5296.5296.5296.5
296.75296.75296.75296.75296.75
297297297297297
297.25297.25297.25297.25297.25
297.5297.5297.5297.5297.5
297.75297.75297.75297.75297.75
298298298298298
298.25298.25298.25298.25298.25
298.5298.5298.5298.5298.5
298.75298.75298.75298.75298.75
299299299299299
299.25299.25299.25299.25299.25
299.5299.5299.5299.5299.5
299.75299.75299.75299.75299.75
300300300300300
300.25300.25300.25300.25300.25
300.5300.5300.5300.5300.5
300.75300.75300.75300.75300.75
301301301301301
301.25301.25301.25301.25301.25
301.5301.5301.5301.5301.5
301.75301.75301.75301.75301.75
302302302302302
302.25302.25302.25302.25302.25
302.5302.5302.5302.5302.5
302.75302.75302.75302.75302.75
303303303303303
303.25303.25303.25303.25303.25
303.5303.5303.5303.5303.5
303.75303.75303.75303.75303.75
304304304304304
304.25304.25304.25304.25304.25
304.5304.5304.5304.5304.5
304.75304.75304.75304.75304.75
305305305305305
305.25305.25305.25305.25305.25
305.5305.5305.5305.5305.5
305.75305.75305.75305.75305.75
306306306306306
306.25306.25306.25306.25306.25
306.5306.5306.5306.5306.5
306.75306.75306.75306.75306.75
307307307307307
307.25307.25307.25307.25307.25
307.5307.5307.5307.5307.5
307.75307.75307.75307.75307.75
308308308308308
308.25308.25308.25308.25308.25
308.5308.5308.5308.5308.5
308.75308.75308.75308.75308.75
309309309309309
309.25309.25309.25309.25309.25
309.5309.5309.5309.5309.5
309.75309.75309.75309.75309.75
310310310310310
310.25310.25310.25310.25310.25
310.5310.5310.5310.5310.5
310.75310.75310.75310.75310.75
311311311311311
311.25311.25311.25311.25311.25
311.5311.5311.5311.5311.5
311.75311.75311.75311.75311.75
312312312312312
312.25312.25312.25312.25312.25
312.5312.5312.5312.5312.5
312.75312.75312.75312.75312.75
313313313313313
313.25313.25313.25313.25313.25
313.5313.5313.5313.5313.5
313.75313.75313.75313.75313.75
314314314314314
314.25314.25314.25314.25314.25
314.5314.5314.5314.5314.5
314.75314.75314.75314.75314.75
315315315315315
315.25315.25315.25315.25315.25
315.5315.5315.5315.5315.5
315.75315.75315.75315.75315.75
316316316316316
316.25316.25316.25316.25316.25
316.5316.5316.5316.5316.5
316.75316.75316.75316.75316.75
317317317317317
317.25317.25317.25317.25317.25
317.5317.5317.5317.5317.5
317.75317.75317.75317.75317.75
318318318318318
318.25318.25318.25318.25318.25
318.5318.5318.5318.5318.5
318.75318.75318.75318.75318.75
319319319319319
319.25319.25319.25319.25319.25
319.5319.5319.5319.5319.5
319.75319.75319.75319.75319.75
320320320320320
320.25320.25320.25320.25320.25
320.5320.5320.5320.5320.5
320.75320.75320.75320.75320.75
321321321321321
321.25321.25321.25321.25321.25
321.5321.5321.5321.5321.5
321.75321.75321.75321.75321.75
322322322322322
322.25322.25322.25322.25322.25
322.5322.5322.5322.5322.5
322.75322.75322.75322.75322.75
323323323323323
323.25323.25323.25323.25323.25
323.5323.5323.5323.5323.5
323.75323.75323.75323.75323.75
324324324324324
324.25324.25324.25324.25324.25
324.5324.5324.5324.5324.5
324.75324.75324.75324.75324.75
325325325325325
325.25325.25325.25325.25325.25
325.5325.5325.5325.5325.5
325.75325.75325.75325.75325.75
326326326326326
326.25326.25326.25326.25326.25
326.5326.5326.5326.5326.5
326.75326.75326.75326.75326.75
327327327327327
327.25327.25327.25327.25327.25
327.5327.5327.5327.5327.5
327.75327.75327.75327.75327.75
328328328328328
328.25328.25328.25328.25328.25
328.5328.5328.5328.5328.5
328.75328.75328.75328.75328.75
329329329329329
329.25329.25329.25329.25329.25
329.5329.5329.5329.5329.5
329.75329.75329.75329.75329.75
330330330330330
330.25330.25330.25330.25330.25
330.5330.5330.5330.5330.5
330.75330.75330.75330.75330.75
331331331331331
331.25331.25331.25331.25331.25
331.5331.5331.5331.5331.5
331.75331.75331.75331.75331.75
332332332332332
332.25332.25332.25332.25332.25
332.5332.5332.5332.5332.5
332.75332.75332.75332.75332.75
333333333333333
333.25333.25333.25333.25333.25
333.5333.5333.5333.5333.5
333.75333.75333.75333.75333.75
334334334334334
334.25334.25334.25334.25334.25
334.5334.5334.5334.5334.5
334.75334.75334.75334.75334.75
335335335335335
335.25335.25335.25335.25335.25
335.5335.5335.5335.5335.5
335.75335.75335.75335.75335.75
336336336336336
336.25336.25336.25336.25336.25
336.5336.5336.5336.5336.5
336.75336.75336.75336.75336.75
337337337337337
337.25337.25337.25337.25337.25
337.5337.5337.5337.5337.5
337.75337.75337.75337.75337.75
338338338338338
338.25338.25338.25338.25338.25
338.5338.5338.5338.5338.5
338.75338.75338.75338.75338.75
339339339339339
339.25339.25339.25339.25339.25
339.5339.5339.5339.5339.5
339.75339.75339.75339.75339.75
340340340340340
340.25340.25340.25340.25340.25
340.5340.5340.5340.5340.5
340.75340.75340.75340.75340.75
341341341341341
341.25341.25341.25341.25341.25
341.5341.5341.5341.5341.5
341.75341.75341.75341.75341.75
342342342342342
342.25342.25342.25342.25342.25
342.5342.5342.5342.5342.5
342.75342.75342.75342.75342.75
343343343343343
343.25343.25343.25343.25343.25
343.5343.5343.5343.5343.5
343.75343.75343.75343.75343.75
344344344344344
344.25344.25344.25344.25344.25
344.5344.5344.5344.5344.5
344.75344.75344.75344.75344.75
345345345345345
345.25345.25345.25345.25345.25
345.5345.5345.5345.5345.5
345.75345.75345.75345.75345.75
346346346346346
346.25346.25346.25346.25346.25
346.5346.5346.5346.5346.5
346.75346.75346.75346.75346.75
347347347347347
347.25347.25347.25347.25347.25
347.5347.5347.5347.5347.5
347.75347.75347.75347.75347.75
348348348348348
348.25348.25348.25348.25348.25
348.5348.5348.5348.5348.5
348.75348.75348.75348.75348.75
349349349349349
349.25349.25349.25349.25349.25
349.5349.5349.5349.5349.5
349.75349.75349.75349.75349.75
350350350350350
350.25350.25350.25350.25350.25
350.5350.5350.5350.5350.5
350.75350.75350.75350.75350.75
351351351351351
351.25351.25351.25351.25351.25
351.5351.5351.5351.5351.5
351.75351.75351.75351.75351.75
352352352352352
352.25352.25352.25352.25352.25
352.5352.5352.5352.5352.5
352.75352.75352.75352.75352.75
353353353353353
353.25353.25353.25353.25353.25
353.5353.5353.5353.5353.5
353.75353.75353.75353.75353.75
354354354354354
354.25354.25354.25354.25354.25
354.5354.5354.5354.5354.5
354.75354.75354.75354.75354.75
355355355355355
355.25355.25355.25355.25355.25
355.5355.5355.5355.5355.5
355.75355.75355.75355.75355.75
356356356356356
356.25356.25356.25356.25356.25
356.5356.5356.5356.5356.5
356.75356.75356.75356.75356.75
357357357357357
357.25357.25357.25357.25357.25
357.5357.5357.5357.5357.5
357.75357.75357.75357.75357.75
358358358358358
358.25358.25358.25358.25358.25
358.5358.5358.5358.5358.5
358.75358.75358.75358.75358.75
359359359359359
359.25359.25359.25359.25359.25
359.5359.5359.5359.5359.5
359.75359.75359.75359.75359.75
360360360360360
Fx
Fy
Combustion Force
Compression Force
Suction Force
Crank Angle (deg)
Force (lb)
Working Model Simulation of TLA Power Piston and Compressor Piston Forces on Crankshaft Bearings
90200
0
0
-12.743
90200
0
0
322.235
90930
0
0
658.011
91700
0
0
994.748
92490
0
0
1332.472
93270
0
0
1671.167
94040
0
0
2011.076
94900
0
0
2351.948
95720
0
0
2694.065
96580
0
0
3037.423
97470
0
0
98330
0
0
3727.603
20500
99240
0
0
21460
100200
0
0
22390
101100
0
0
23370
102000
0
0
24340
103000
0
0
5475.951
25320
103900
0
0
26360
104900
0
0
27370
105900
0
0
106900
0
0
29520
108000
0
0
7260.842
30580
109000
0
0
31650
110000
0
0
32720
111000
0
0
33830
112100
0
0
8715.235
34950
113100
0
0
9083.19
36090
114200
0
0
37240
115300
0
0
9822.449
38340
116400
0
0
10200
39510
117500
0
0
40660
118600
0
0
41790
119600
0
0
11320
42950
120700
0
0
121800
0
0
45310
123000
0
0
46450
124000
0
0
12840
47610
125100
0
0
13220
48770
126200
0
0
49940
127300
0
0
51060
128300
0
0
52230
129400
0
0
53360
130500
0
0
54420
131400
0
0
55580
132500
0
0
56710
133600
0
0
57780
134500
0
0
58870
135500
0
0
59940
136500
0
0
60970
137400
0
0
61980
138300
0
0
62990
139300
0
0
18690
140100
0
0
141000
0
0
141900
0
0
142700
0
0
143500
0
0
144200
0
0
144900
0
0
21430
145700
0
0
21830
146300
0
0
147000
0
0
147600
0
0
148100
0
0
148700
0
0
149200
0
0
149700
0
0
150100
0
0
24900
150500
0
0
150900
0
0
25650
151200
0
0
151500
0
0
151800
0
0
152000
0
0
152200
0
0
152300
0
0
152400
0
0
152400
0
0
152400
0
0
152400
0
0
152400
0
0
152300
0
0
152100
0
0
152000
0
0
30630
151800
0
0
151500
0
0
151200
0
0
150900
0
0
150600
0
0
150200
0
0
149800
0
0
149400
0
0
148900
0
0
148400
0
0
77770
147800
0
0
147300
0
0
146700
0
0
146100
0
0
145400
0
0
144800
0
0
144100
0
0
143400
0
0
142700
0
0
141900
0
0
141100
0
0
36830
140300
0
0
139500
0
0
138700
0
0
137900
0
0
137000
0
0
38080
136100
0
0
135300
0
0
38560
134400
0
0
133500
0
0
132600
0
0
131700
0
0
130800
0
0
129800
0
0
128900
0
0
63020
127900
0
0
126900
0
0
126000
0
0
125100
0
0
40990
124100
0
0
123100
0
0
122200
0
0
121200
0
0
120200
0
0
119300
0
0
55790
118300
0
0
117400
0
0
116400
0
0
115500
0
0
42950
114500
0
0
113600
0
0
112600
0
0
111700
0
0
43680
110700
0
0
49600
109800
0
0
108900
0
0
108000
0
0
44400
107100
0
0
106200
0
0
105300
0
0
104400
0
0
103500
0
0
102600
0
0
101800
0
0
43270
100800
0
0
45750
100000
0
0
99140
0
0
46080
41560
98310
0
0
46250
97490
0
0
96670
0
0
39950
95850
0
0
46730
95010
0
0
94220
0
0
93450
0
0
47210
92650
0
0
91840
0
0
91060
0
0
90290
0
0
89520
0
0
47990
88770
0
0
88020
0
0
87270
0
0
86550
0
0
48590
85820
0
0
85120
0
0
84410
0
0
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