1. INGAS - Integrated GAS Powertrain 24 months Meeting, 27-28 October, 2010 Project number: 218447 27-28 October 2010 Project number: 218447 27-28 October 2010 Fiat 1.4L CNG performance - Presentation contents Engine tests at bench : 1 st phase with base engine Engine characterization with CR 9.8 (full load + Willans) Engine improvements : CR = 11:0 + Turbo matching Engine tests at bench : 2 nd phase with new hardware Engine characterization with CR 11 + VGT (full load + Willans)

2. INGAS - Integrated GAS Powertrain 24 months Meeting, 27-28 October, 2010 Project number: 218447 27-28 October 2010 Project number: 218447 27-28 October 2010 Engine tests at bench : 1 st phase with base engine Engine tests at bench : 1 st phase with base engine Compression ratio : 9,8:1 Turbocharger : IHI 150 CV

3. INGAS - Integrated GAS Powertrain 24 months Meeting, 27-28 October, 2010 Project number: 218447 27-28 October 2010 Project number: 218447 27-28 October 2010 Engine tests at bench : 1 st phase with base engine Engine tests at bench : 1 st phase with base engine Partial load characterisation Willans lines

4. INGAS - Integrated GAS Powertrain 24 months Meeting, 27-28 October, 2010 Project number: 218447 27-28 October 2010 Project number: 218447 27-28 October 2010 Engine tests at bench : 1 st phase with base engine Engine tests at bench : 1 st phase with base engine Full load characterisation Constraints : max temperature inlet turbine = 950 °C max cylinder pressure (Pcyl max + 3  ) = 105 bars Max torque : IFP : 226 N.m @ 2500 rpm CRF : 218 N.M @ 2040 rpm Max power : IFP : 90 kW @ 5000 rpm CRF : 94 kW @ 5000 rpm

5. INGAS - Integrated GAS Powertrain 24 months Meeting, 27-28 October, 2010 Project number: 218447 27-28 October 2010 Project number: 218447 27-28 October 2010 Engine improvements : CR = 11:0 + Turbo matching Turbo matching : Simulation of 4 turbocharger configurations : Pressure loss models :

6. INGAS - Integrated GAS Powertrain 24 months Meeting, 27-28 October, 2010 Project number: 218447 27-28 October 2010 Project number: 218447 27-28 October 2010 Turbo matching Compressor IHI RHF3 BRL315 04 (Base TC) 2000 rpm 4750 rpm Compressor C224(38) 60 Trim 0.38 A/R > 3000 rpm Compressor C224(46) 55 Trim 0.46 A/R Compressor C224 (44) 60 Trim 0.44 AR (associated with VGT) 1 2 3 4

7. INGAS - Integrated GAS Powertrain 24 months Meeting, 27-28 October, 2010 Project number: 218447 27-28 October 2010 Project number: 218447 27-28 October 2010 Turbo matching VGT turbocharger simulation : 60 % 30 % 40 % 80% 100 % Target Allowed max. BMEP taking into account surge line ? VGT is the best competitor to improve the full load engine performances. VGT offers the potential to improve the low speed engine performance, in spite of the surge line of the compressor from 1000 to 1500 rpm For engine speed higher that 2500 rpm, the VGT turbine also offers an higher efficiency than a fixed geometry turbine with an opened waste gate.

8. INGAS - Integrated GAS Powertrain 24 months Meeting, 27-28 October, 2010 Project number: 218447 27-28 October 2010 Project number: 218447 27-28 October 2010 Engine tests at bench : 2 nd phase with new hardware Compression ratio : 11:1 Turbocharger : VGT Garrett GT1444

9. INGAS - Integrated GAS Powertrain 24 months Meeting, 27-28 October, 2010 Project number: 218447 27-28 October 2010 Project number: 218447 27-28 October 2010 Partial load characterisation Willans lines Engine tests at bench : 2 nd phase with new hardware

10. INGAS - Integrated GAS Powertrain 24 months Meeting, 27-28 October, 2010 Project number: 218447 27-28 October 2010 Project number: 218447 27-28 October 2010 Engine tests at bench : 2 nd phase with new hardware CR 9.8CR11 + VGT WMEP (bar) WSFC (g/kW.h) WMEP (bar) WSFC (g/kW.h) 1000 rpm1.78212.92.18209.8 2000 rpm2.05196.41.98208.6 3500 rpm2.29196.62.22202.9 5500 rpm2.43210.42.59213.9 Differences observed at partial load could be due to : New compression ratio New turbine permeability New engine parts (piston rings, crankshaft bearings, …)

11. INGAS - Integrated GAS Powertrain 24 months Meeting, 27-28 October, 2010 Project number: 218447 27-28 October 2010 Project number: 218447 27-28 October 2010 Full load characterisation : Torque Constraints : max temperature inlet turbine = 850 °C max cylinder pressure (Pcyl max + 3  ) = 105 bars Engine tests at bench : 2 nd phase with new hardware Max torque : IFP CR 9.8:1 : 226 N.m @ 2500 rpm IFP CR 11:1 + TGV 227 N.m @ 2250 rpm (limited by Tin turb = 850 °C) Max torque at lower rev

12. INGAS - Integrated GAS Powertrain 24 months Meeting, 27-28 October, 2010 Project number: 218447 27-28 October 2010 Project number: 218447 27-28 October 2010 Full load characterisation : Power Constraints : max temperature inlet turbine = 850 °C max cylinder pressure (Pcyl max + 3  ) = 105 bars Engine tests at bench : 2 nd phase with new hardware Max power : IFP CR 9.8:1 : 90 kW @ 5000 rpm IFP CR 11:1 + TGV ( =1) 76 kW @ 4500 rpm !!  strongly limited by Tin turb 850 °C, not WOT IFP CR 11:1 + TGV ( opti) 92 kW @ 5000 rpm limited by Tin turb = 850 °C

13. INGAS - Integrated GAS Powertrain 24 months Meeting, 27-28 October, 2010 Project number: 218447 27-28 October 2010 Project number: 218447 27-28 October 2010 Full load characterisation : Thermomechanical constraints Engine tests at bench : 2 nd phase with new hardware Turbine inlet temperature Pcyl4 + 3  Performation limitation due to turbine inlet inlet temperature

14. INGAS - Integrated GAS Powertrain 24 months Meeting, 27-28 October, 2010 Project number: 218447 27-28 October 2010 Project number: 218447 27-28 October 2010 Full load characterisation : Turbochargers duty zones Engine tests at bench : 2 nd phase with new hardware IHI 150 CVVGT Garrett GT1444 Compressor of Garrett TC presents better efficiency than IHI one In return, surge limit is dramatically reduced

15. INGAS - Integrated GAS Powertrain 24 months Meeting, 27-28 October, 2010 Project number: 218447 27-28 October 2010 Project number: 218447 27-28 October 2010 New hardware configuration (VGT + CR 11:0) offers similar performances regarding maximum torque and power. No improvement was obtained because the lower maximum turbine inlet temperature (850°C vs. 950°C) reduces maximum torque engine speed (VGT effect) does not reduce the fuel consumption because the turbine is undersized GT 1444 compressor works with a better efficiency … … but the safety margin regarding surge is not sufficient with the GT1444 Conclusions