OCTANE RATING SYSTEMS

Transcription

1 OCTANE RATING SYSTEMS ELECTRONIC SYSTEMS DESIGN, INC PALATINE, ILLINOIS USA

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3 ASTM TEST METHODS TWO DIFFERENT ENGINES D-2699 RESEARCH METHOD D-2700 MOTOR METHOD OCTANE NUMBER IS (R + M) / 2 THREE WAYS TO FIND OCTANE NUMBER COMPRESSION RATIO BRACKETING FALLING LEVEL (DYNAMIC)

4 COMPRESSION RATIO METHOD MANUALLY ADJUST CYLINDER HEAD HEIGHT AND FUEL LEVEL TO FIND THE MAXIMUM KNOCK FOR THE UNKNOWN FUEL. THEN DO THE SAME FOR A KNOWN PRIMARY REFERENCE FUEL. REPEAT CALCULATE THE UNKNOWN OCTANE NUMBER FROM TABLES IN THE ASTM BOOK.

5 BRACKETING FIND THE PEAK KNOCK BY RAISING AND LOWERING THE FUEL BOWL LEVEL BY HAND DO THIS FOR THE SAMPLE PLUS TWO KNOWN PRIMARY REFERENCE FUELS REPEAT CALCULATE THE SAMPLE OCTANE NUMBER

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7 DYNAMIC METHOD WE CALL IT THE FALLING LEVEL METHOD THE FUEL BOWLS DO NOT HAVE A FLOAT. THE LEVEL IN THE BOWL GOES DOWN AS THE ENGINE BURNS THE FUEL. THEREFORE, THE ENGINE WILL GO FROM LOW KNOCK, TO PEAK KNOCK, AND BACK TO LOW KNOCK.

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10 ELECTRONIC SYSTEMS DESIGN LABORATORY SYSTEM FALLING LEVEL METHOD WITH COMPUTER MEASUREMENT 1. THREE OR FOUR ESD FUEL BOWLS ARE SUPPLIED (Sample bowl is cooled). ALL OTHER COMPONENTS ARE OFF THE SHELF STANDARD ELECTRICAL PARTS. 2. SYSTEM INCLUDES PROGRAMS FOR NETWORK COMMUNICATION, DATA STORAGE, AND STATISTICAL QUALITY CONTROL.

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15 Automated Lab System

16 Automated Lab System Ability to run 4 samples in one pass unattended. Ability to run two passes of 1 sample unattended (with 6 bowls, a pair of bowls can be filled for each of the fuels: sample, PRF 1 and PRF 2).

17 Automated Lab System Dump and Feed solenoids

18 Automated Lab System Stainless box with analog inputs & digital controls

19 ADVANTAGES OF FALLING LEVEL NO MOVING PARTS OPERATOR NOT IN THE LOOP COMPUTER CAN FIND A BETTER PEAK KNOCK HARDCOPY REPORT EACH TEST NO PENCIL IN THE LABORATORY RESULTS SENT DIRECTLY TO MAINFRAME COMPUTER SYSTEM (to LIMS system or )

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21 ELECTRONIC SYSTEMS DESIGN ON-LINE OCTANE RATING ASTM D-2885 compliant. Falling level method. Compares peak knock difference between product being blended and a proto (known octane) fuel.

22 FEATURES OF AN ON-LINE SYSTEM 1. Delta octane reported 2. Engine variables monitored (temperatures) 3. Unmanned operation after engine is set up. 4. Same engines as laboratory test equipment, but without the four fuel bowls and selector valve assembly.

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27 ESD ON-LINE SYSTEM BLENDING PROCEDURES 1. ENTER TYPE OF FUEL TO BE BLENDED 2. BATCH (BLEND) NUMBER 3. BLENDING TANK

28 COMPUTER TELLS OPERATOR TO SET UP ENGINE FOR BLEND STARTUP

29 COMPUTER PERFORMS FLUSH CYCLE AND FILLS ONE OF THE SIX BOWLS WITH PROTO FUEL. COMPUTER TELLS THE OPERATOR TO COMPUTER TELLS THE OPERATOR TO START THE ENGINE

30 OPERATOR STARTS THE ENGINE. THE SYSTEM STARTS A WARMUP CYCLE LASTING UP TO ONE HOUR (ASSUMING THE ENGINE IS NOT ALREADY WARMED UP).

31 QUALITY CONTROL CHECK (Optional) COMPUTER COMPARES THE PEAK KNOCK OF TWO KNOWN FUELS. COMPUTER DETERMINES IF THE ENGINE IS CORRECTLY RATING THESE FUELS. IF NOT, BLENDING IS NOT ALLOWED AND THE ENGINE MUST BE REPAIRED.

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33 BLENDING COMPUTER SELECTS FUEL FOR THE ENGINE FROM ONE OF THREE BOWLS. ONE FOR THE PROTO FUEL, AND TWO FOR PRODUCT. TWO PRODUCT BOWLS ALLOW PRODUCT TO BE TESTED IN ONE BOWL WHILE FRESH PRODUCT IS FILLING THE OTHER BOWL. PROTO FUEL BOWL ONLY NEEDS TO BE TOPPED UP, MEANING MUCH LESS PROTO USED. TANKS MAY LAST 3 TIMES LONGER.

34 WHEN A PRODUCT BOWL IS NOT BEING USED OR FILLED, THE INCOMING FUEL TO THAT BOWL IS DUMPED AND THE BYPASS VALVES ARE OPENED TO THE DRAIN SO THAT THE LATEST SAMPLE OF THE BLEND FUEL IS ALWAYS AVAILABLE.

35 EACH TIME THE PRODUCT FUEL IS TESTED, A DELTA (DIFFERENCE) OCTANE NUMBER IS CALCULATED AND THE NEW OCTANE VALUE IS SENT TO THE REFINERY BLEND COMPUTER (e.g. via 4-20ma, Modbus, TCP).

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38 OTHER ON-LINE FUNCTIONS ASTM System Checkout Proto Rating NEG Exchange Fuel Checkout Spread Calibration Reports and logs (alarms and events) Graphs for trend analysis

39 Alarms and warning conditions PROTO REPEATABILITY WARNING ============================= Excessive proto drift from previous proto pair (0.25 RON, 0.35 MON) LIST OF WARNING CONDITIONS =========================== Any Temperature out of operating range Rate of change of delta O.N. too large Out-of-Fuel warning, bowl X Delta Octane out of range (+1.0/-1.0, user defined) LIST OF TROUBLE ALARM CONDITIONS ================================= Coolant temp over 220 (also triggers shutdown) Oil pressure under 20 (also triggers shutdown) Product O.N. out of range No peak K.I. found after two attempts Oil pressure out of operating range Proto over 99 or under 20 Product over 99 Product under 10 Any abort out of blending screen (other than "User abandon") QC bowl became full during blending (triggers shutdown) Low Water Pressure (triggers shutdown)

40 NEWEST FEATURES 2006 Graphical analysis of octane & KI trends 2006 Temperature Control (mixture and intake air) for online systems 2006 Temperature inputs & control for lab systems 2007 Remote control of engine screens 2007 Graphical valve control Ability to test additional samples for lab system stem

41 NEWEST FEATURES 2008 Very Remote control of engine screens 2008 Seventh bowl (optional) for warmup for semi-automated lab systems Product bypass moved off bowl assembly.

42 Graphical trend of Delta O.N.

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44 Graphical Valve Control

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46 Troubleshooting

47 Exhaust problem and a solution Add a hose to allow you to see how high the water level gets!

48 Noise in knock signal or RTDs Radio suppressing spark plugs should be used (RD16 vs D16). Noise suppressing spark plug wires. A bad coil wire or contact which can arc and cause radio interference which shows up as high frequency noise on the screen or crazy temperature readings.

49 Solenoid leaks Does a bowl stay full? No? Is one product bowl knock curve much longer than the other? Is fuel getting into bowl 3? Then feed solenoid is leaking and letting fuel from another bowl in.

50 Fuel Fill Rates Too much pressure can overwhelm the drain line. Fast fill rates overfill the bowls (by the time the level sensor has detected a full, an extra ¼ of fuel has entered the bowl). Can cause problems with inconsistent knock k curves.

51 Printer problems Printer stops printing after the ink cartridge has been changed. Printer top cover not completely closed. New systems have menu option to restart the printer. Buy a new compatible printer: HP DeskJet 6940 or an HP OfficeJet 6000 (and assign it the same IP address as old printer).

52 Water level sensors Water level sensors work by detecting electrical current in the water. Type of water: ASTM says Type 4 water Water with Nalcool 3000 works best, (de-ionized water may be trouble). Needs some mineral deposits.

53 Cyclical wave on the knock signal A cyclical wave superimposed on the knock signal, of a consistent period, typically 10 seconds. This could be caused by a partially plugged cooling tower which causes the temperature to cycle or by a burnt spot on an exhaust valve which rotates at about 10 seconds per rotation.

54 Oil Pressure Shutdowns Oil Pressure shutdowns caused by? It s probably not the oil pressure but instead something that caused the engine to shut down. Low oil pressure Other Waukesha safety shutdowns ESD system safety shutdowns (water pressure, water level, coolant temp too high) will cause a relay to close killing engine. Thermal safety at the on/off switch Synchronous motor thermal overload Start switch failure?

55 THANK YOU FOR YOUR ATTENTION DO YOU HAVE ANY QUESTIONS?

56 FOR FURTHER DETAILS, PLEASE CONTACT Walter Wulczak Harry Rueckel, CEO ELECTRONIC SYSTEMS DESIGN, INC. 418 S. Vermont St. Palatine, Illinois Fax