EcoCleanTM HSDI Fuel Additive Evaluation on Abellio ScotRail MTU 183TD & Cummins NT855 Engines Authors: O.J. Rumford-Warr (Fuelcare Ltd), W. Pang, M. Wheeler (Innospec Inc.), D. Keaveney, M. Goldie, M. Sarvar (Abellio ScotRail) Draft: PU002 Customer: Abellio ScotRail, Transport for Scotland Date: July 2019 EcoCleanTM HSDI Fuel Additive Evaluation on Abellio ScotRail MTU 183TD & Cummins NT855 Engines Participants Abellio are the parent company of ScotRail and provide transportation services across Scotland. ScotRail are a T.O.C. (Train Operating Company) that provides both diesel and electric services across Scotland. Fuelcare a UK company specialising in the distribution & dosing of fuel additives to the rail sector, including EcoCleanTM HSDI. Innospec Inc., is a global specialty chemical company, responsible for the development & manufacture of EcoCleanTM HSDI. EcoCleanTM HSDI Fuel Additive Evaluation on Abellio ScotRail MTU 183TD & Cummins NT855 Engines. This document, any 2 electronic file and the intellectual property rights relating to this project are the property of Abellio Group, Fuelcare Ltd & Innospec Inc. and shall not be used, reproduced or disclosed in whole or in part without their written consent. EcoCleanTM HSDI Fuel Additive Evaluation on Abellio ScotRail MTU 183TD & Cummins NT855 Engines Contents 1.0 Background 2.0 Executive Summary 3.0 Test Methodology 4.0 Results 5.0 Summary of Findings 6.0 References 7.0 Appendix EcoCleanTM HSDI Fuel Additive Evaluation on Abellio ScotRail MTU 183TD & Cummins NT855 Engines. This document, any 3 electronic file and the intellectual property rights relating to this project are the property of Abellio Group, Fuelcare Ltd & Innospec Inc. and shall not be used, reproduced or disclosed in whole or in part without their written consent. EcoCleanTM HSDI Fuel Additive Evaluation on Abellio ScotRail MTU 183TD & Cummins NT855 Engines 1.0 Background § Abellio Transport Group are committed to Greenhouse Gas reduction through reducing the energy consumption of its rail operation. § ScotRail has a franchise obligation, working in partnership with Transport for Scotland, to reduce Carbon emissions. § EcoClean™ HSDI fuel additive has long been known to ScotRail, and has been successfully evaluated by TransPennine Express & Govia Thameslink, the results of which were a deciding factor in choosing this product. § Innospec Inc. develop and manufacture EcoClean™ HSDI, a fuel additive for diesel, designed to return engine performance to a ‘like-new’ status. § EcoClean™ HSDI works by cleaning engine injectors & fuel systems. Whilst EcoClean™ technology is used heavily in the forecourt sector (commonly found in premium retail fuels) it is now available for fleet users. § Cleaner engines have various benefits to diesel fleet operators, most notably fuel economy improvements. § Fuelcare Ltd distribute EcoClean™ HSDI to the U.K. rail sector as part of a long-term commitment to Innospec Inc. § Abellio Group & ScotRail decided to evaluate EcoClean™ HSDI for potential use on their Class 43, 15x & 170 diesel units. § The Class 43, 15x & 170 diesel units feature MTU 4000, MTU 183TD & Cummins NT855 engines respectively. § Only the MTU 183TD & Cummins NT855 engines were selected for evaluation based on fleet diesel usage by engine, engine size and ease of evaluation. § The test was designed primarily to illustrate the fuel-saving benefits of EcoClean™ HSDI (and ancillary benefits of Torque & Power performance). § Cummins NT855 & MTU 183TD diesel rail engines nearing end of life were tested at Millbrook Leyland between January and June 2019 with EcoClean™ HSDI. § Millbrook Leyland is an independent, accredited engine testing facility. Data produced by Millbrook Leyland is available to supplement this document and its’ findings. § A test cell was made available with a dynamometer to illustrate any performance benefits from using EcoClean™ HSDI. § Test cycles were performed before the use of EcoClean™ HSDI, after 100 hours conditioning with EcoClean™ and finally after 200 hours conditioning with EcoClean™. § Whilst both trials achieved their aims, the Cummins NT855 began to exhibit low fuel pressure fluctuations between 100 and 200 hours as a result of fuel pump malfunction unconnected to EcoClean™ HSDI. Data was disregarded after 100 hours. EcoCleanTM HSDI Fuel Additive Evaluation on Abellio ScotRail MTU 183TD & Cummins NT855 Engines. This document, any 4 electronic file and the intellectual property rights relating to this project are the property of Abellio Group, Fuelcare Ltd & Innospec Inc. and shall not be used, reproduced or disclosed in whole or in part without their written consent. EcoCleanTM HSDI Fuel Additive Evaluation on Abellio ScotRail MTU 183TD & Cummins NT855 Engines 2.0 Executive Summary During the two engine tests, a wide range of data was collected. Torque, Power and Fuel Economy were deemed the most prudent measurements for building a use-case for EcoClean™ HSDI. Data available shows clear, unambiguous performance improvement as a result of the introduction of EcoClean™ HSDI into both engines. The MTU 183TD performance was analysed up to 200 hours and the Cummins NT855 to 100 hours, where unrelated fuel pump failure prematurely ended the test. As EcoClean™ HSDI is designed primarily to clean up fuel injectors, prior to the trial, fresh injectors were tested for measuring the potential of EcoClean™ HSDI. Key data points from this test indicate continued improvement even after the conclusion of the trial. Once dirty injectors were reinserted, no plateau in performance were reached at the end of each trial, so further benefits are likely. Benefits were highest at maximum & minimum load, where the engines spend most time in service. Throttle and engine speed were adjusted to match a modified ISO8178 ‘F’ duty cycle. ISO 8178 Cycle F is an independently recognised test procedure used to determine engine performance that matches real world, in-service locomotive behaviour. Using the ISO 8178 Cycle F weighting at the conclusion of the trial, the following benefits were identified: Corrected Torque Corrected Power Corrected BSFC/Fuel Economy MTU 183TD +21.70% +21.40% -3.41% Cummins NT855 +14.02% +12.42% -2.66% Weighted Average* +16.76% +17.60% -3.06% * Weighted based on ScotRail engine split by fuel consumption - 46% Cummins NT855, 53% MTU 183TD. Finally, when considering the real-world benefits of EcoClean™ HSDI, it is important to consider that fuel economy results are a direct result of a mixture of driving profile, engine power output, engine efficiency & transmission efficiency. Considering a fleet fuel usage of 67.3m litres of Gas Oil per year, the considered benefit to the ScotRail fleet from the use of this product would therefore be a 3.06% reduction in energy usage and 1 thus CO2e reduction, which currently would equate to 5,680 tonnes of CO2e per year. This consists of 5,610 tonnes of Carbon Dioxide (CO2), 6.03 tonnes of Methane (CH4) & 64.07 tonnes of Nitrous Oxide (N2O). Finally, based on current Gas Oil prices, an annual gross cost saving in fuels would be £1.25m. EcoCleanTM HSDI Fuel Additive Evaluation on Abellio ScotRail MTU 183TD & Cummins NT855 Engines. This document, any 5 electronic file and the intellectual property rights relating to this project are the property of Abellio Group, Fuelcare Ltd & Innospec Inc. and shall not be used, reproduced or disclosed in whole or in part without their written consent. EcoCleanTM HSDI Fuel Additive Evaluation on Abellio ScotRail MTU 183TD & Cummins NT855 Engines 3.0 Test Methodology • Prior to commencing the test programme, a batch of BS2869:A2 Gas Oil from Millbrook stock was set aside in IBC containers, intended for use through the whole programme. The batch was analysed, found to be free of Biodiesel and within normal specification. • Following delivery from Wabtec/LH Group, each engine was installed into Millbrook Leyland Test Bed 13. • Each engine was instrumented to monitor and record parameters for safe operation whilst in the test cell. Fig. 1 – MTU 183 TD Test Cell Installation. View of charge cooler, exhaust and coolant out connections. • Initial shakedown runs were carried out and approved by Innospec. • EcoClean™ HSDI was then blended into the stock Gas Oil at 1000ppm by volume. • The EcoClean™ HSDI test programme was conducted as shown in the table below. EcoCleanTM HSDI Fuel Additive Evaluation on Abellio ScotRail MTU 183TD & Cummins NT855 Engines. This document, any 6 electronic file and the intellectual property rights relating to this project are the property of Abellio Group, Fuelcare Ltd & Innospec Inc. and shall not be used, reproduced or disclosed in whole or in part without their written consent. EcoCleanTM HSDI Fuel Additive Evaluation on Abellio ScotRail MTU 183TD & Cummins NT855 Engines Gas Oil + EcoClean™ Test Description Number of Tests HSDI 1. Baseline Performance 3, 2, 2, 2 curves Power curves 100%, 75%, 50%, 25% Gas Oil 6 cycles Emissions ISO 8178 Cycle F (Clean Injectors) 2. Baseline Performance 3, 2, 2, 2 curves Power curves 100%, 75%, 50%, 25% Gas Oil 6 cycles Emissions ISO 8178 Cycle F (Dirty Injectors) 3. Fuel Trial Conditioning Gas Oil + EcoClean™ 0 -100 hours ISO 8178 Cycle F (Dirty Injectors) HSDI 4. Power Curves 100%, 75%, 50%, 25% Gas Oil + EcoClean™ 3, 2, 2, 2 curves Emissions ISO 8178 Cycle F (Dirty Injectors) HSDI 6 cycles 5. Fuel Trial Conditioning Gas Oil + EcoClean™ 100 - 200 hours ISO 8178 Cycle F (Dirty Injectors) HSDI 6. Power Curves 100%, 75%, 50%, 25% Gas Oil + EcoClean™ 3, 2, 2, 2 curves Emissions ISO 8178 Cycle F (Dirty Injectors) HSDI 6 cycles Table 1 – EcoClean™ HSDI Test Program • The conditioning phases of the fuel trial were conducted by cyclic repeats of three operating modes for speed, load and duration, based on ISO 8178 Cycle F. • Engine servicing during typically involved daily stops for oil level and hardware checks. • Oil consumption measurements were performed pre-trial and again during the initial stages of the trial to monitor engine health. No significant increases were noted during the trial. • During the conditioning tests (Table 1) data was recorded at the end of the mode for every cycle.