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Westport Launches Westport HPDI 2.0′

December 10, 2013 in CNG, Companies, LNG, New Products, NGVs by Rich Piellisch  |  No Comments

High Pressure Direct Injection Said Suitable to Wider Range of Engines
As Full Diesel Performance Is Maintained with 90 of Diesel Fuel Displaced

Westport Innovations has unveiled its next generation of high pressure direct injection technology, called “Westport HPDI 2.0.” Unlike the initial HPDI product available only with the Cummins ISX-based 15-liter engine for heavy duty trucks, the new system is aimed at a wider range of powerplants, from 10- to 100-liter displacement, for both vehicle and off-road markets.

Westport HPDI 2.0 allows high pressure direct injection technology for natural gas to be applied to a wide range of engines serving multiple markets.

Westport HPDI 2.0 allows high pressure direct injection technology for natural gas to be applied to a wide range of engines serving multiple markets.

In what amounts to a strong rebuttal of criticism from advocates of dedicated-natural gas spark ignition (SI) engines, Westport says that the improved HPDI technology, which employs a small amount of diesel as a pilot fuel, maintains the fundamental efficiency and performance of industry-prevalent diesel engines – “but with diesel substitution of over 90%.”

“The increased performance in torque and related power in Westport HPDI, combined with the best fuel economy and related emissions profile and the fully integrated engineered Westport HPDI 2.0 products, will give OEMs and their customers the ultimate natural gas engine and vehicle performance and reliability, and strong economic value particularly in high fuel use applications,” Westport says.

First availability will be in late 2014.

Cost Parity with Spark Engines

HPDI 2.0 includes “a new generation of proprietary fuel tank, fuel pump, and system controls that can match the vehicle range, performance, and driveability of diesel.” Some component improvements will be applicable to existing first-generation HPDI vehicles from Kenworth and Peterbilt.

First-generation Westport HPDI systems have been delivered on more than 1,200 Peterbilt and Kenworth trucks since initial wide-scale introduction in 2010, Westport says.

First-generation Westport HPDI systems have been delivered on more than 1,200 Peterbilt and Kenworth trucks since initial wide-scale introduction in 2010, Westport says.

Westport says it’s working on seven OEM applications “with engine sizes ranging from trucks to trains.” Among those OEMs, says engine fuel systems business VP Brad Douville, are Caterpillar-EMD, Volvo, and China’s Weichai.

And although Westport says that HPDI 2.0 is compatible with compressed natural gas fuel, all of the pending OEM applications will employ liquefied natural gas systems, Douville says. Long-haul truck customers of the OEM partners have “invariably” wanted LNG, he told F&F.

“Ultimately, the customer will decide which form of natural gas they wish to carry,” states the HPDI 2.0 announcement.

“Where performance, emissions and efficiency matter, HPDI 2.0 offers benefits that will be irresistible to fleet customers shifting to natural gas in their operations,” Westport CEO David Demers says in the release.

‘Simplicity, Performance and a Reduction in Overall System Costs’

“As the potential for natural gas is now apparent in all global vehicle and off-road markets, HPDI 2.0 will allow OEMs to introduce high performance, fully integrated products that match state of the art diesel performance, but can be produced without expensive and challenging investments in facilities, product development, and testing,” Demers said.

“Westport HPDI 2.0 has been designed for simplicity, performance and a reduction in overall system costs,” states the company’s Tuesday announcement. Westport (Toronto:WPT or NASDAQ:WPRT) is promising “a vertically integrated natural gas solution with breakthrough price, performance, and fuel economy.”

“For the first time, Westport expects OEM Westport HPDI vehicles to be competitively priced with SI-based systems.”

Commonality in the HPDI 2.0 nozzle actuators and precision needles allows Westport to economically tackle diverse markets with different size injectors matching the target engines’ injector sockets, Douville says. A proprietary dual common rail fuel injector features a unique concentric dual-needle design with electro-hydraulic actuation and control.

Those “tricky parts,” he says, “are where the commonality exists.”

Maintaining a Position in Heavy Over-the-Road Trucks

The second-generation HPDI product will allow Westport to maintain a presence in large engines for trucks, as sales of the Cummins ISX-based 15-liter engine with first-generation HPDI technology were discontinued last month (F&F, November 6). Westport has its hand in large spark ignition engines with the 8.9-liter Cummins Westport ISL G and the 11.9-liter ISX12 G, but the new 15-liter spark engine from Cummins will be from Cummins alone.

Westport describes HPDI 2.0 as “a complete architecture, offering OEMs flexibility to differentiate their natural gas product lines easily while also maintaining maximum commonality with their conventional diesel fueled products.

“We think it’s the future of natural gas,” the firm says.

Tugs and trains? They’re both potential markets for the Westport HPDI 2.0 high pressure direct injection fuel system allowing diesel cycle engines to run primarily on natural gas.

Tugs and trains? They’re both potential markets for the Westport HPDI 2.0 high pressure direct injection fuel system allowing diesel cycle engines to run primarily on natural gas.

Westport has supplied the following extensive background on HPDI 2.0:

  • Westport HPDI 2.0 is said to be the only natural gas technology capable of delivering performance and fuel economy equivalent to that of current high performance diesel-fueled engines, but with diesel substitution of over 90%.
  • Diesel engines have dominated commercial vehicle and heavy-duty off-road applications for decades, despite higher initial costs for diesel engines compared to gasoline engines, and the recent volatility and higher prices for diesel fuel. Energy efficiency, engine durability, high torque, low maintenance, and industry familiarity with the diesel engine mean that overall life-cycle cost of operation have kept the diesel engine a mainstay in commercial vehicles.
  • Westport HPDI will allow diesel customers to switch to natural gas, which is much cheaper than diesel fuel in most parts of the world, without sacrificing performance or energy efficiency.
  • The compression ratio of an engine with Westport HPDI is the same as the diesel engine on which it is based, which results in fewer changes to engine components and preservation of the fuel economy benefits associated with high compression.
  • Westport’s proprietary, patented HPDI technology utilizes the same Diesel thermodynamic cycle used by diesel fuel. This Diesel cycle is inherently more efficient than the Otto thermodynamic cycle used SI gasoline and natural gas engines.

“With the development of Westport HPDI 2.0 we have captured many significant new proprietary technologies that will extend the reach of our HPDI patent portfolio for the next 20 years,” Westport says. “HPDI 2.0 is protected by global patents,” the firm adds, noting that it’s filed 42 patent applications for inventions related to its HPDI since 2007.

Westport is predicting faster payback on customers’ natural gas vehicle investment behind “optimization of combustion and higher efficiency.” Besides a mew lines of LNG fuel pumps, HPDI 2.0 includes a proprietary on-engine gas fuel conditioning module and redesigned electronic controls allowing “the same responsiveness and fast torque achievement as diesel engines.”

Better LNG Tanks and Tank Mounts Too

“Got brakes?” the company asks. “By using the same high compression ratio as diesel engines, Westport HPDI engines deliver engine braking power equivalent to that of diesel engines.”

Westport HPDI 2.0 LNG fuel tanks range from 70 to 150 U.S. gallons and up to 20,000 gallons for off road applications. Both behind-the-cab gantry and frame-rail packages will be available.

“Overall,” Westport says, “HPDI 2.0 will provide a compelling combination of diesel-like power, torque, fuel efficiency, and engine braking performance in a natural gas engine – making it ideal for almost all commercial freight applications.”


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Westport, VP Gord Exel, 604-718-8384; [email protected]; www.westport.com

Westport (UK), VP Brad Douville, +44-784-190-9126; [email protected]


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Source: Westport Innovations with Fleets & Fuels follow-up

 

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