Improvement to Pipeline Compressor Engine Reliability Through Retrofit Micro-Pilot Ignition System

Abstract

This report documents a 3-year research program conducted by the Engines & Energy Conversion Laboratory (EECL) at Colorado State University (CSU) to develop micropilot ignition systems for existing pipeline compressor engines. Research activities for the overall program were conducted with the understanding that the efforts are to result in a commercial product to capture and disseminate the efficiency and environmental benefits of this new technology. An extensive state-of-art review was conducted to leverage the existing body of knowledge of micropilot ignition with respect to retrofit applications. Additionally, commercially-available fuel injection products were identified and applied to the program where appropriate. This approach will minimize the overall time-to-market requirements, while meeting performance and cost criteria. The objective for Phase I was to demonstrate the feasibility of micropilot ignition for large bore, slow speed engines operating at low compression ratios under laboratory conditions at the EECL. The primary elements of Micropilot Phase I were to develop a single-cylinder test chamber to study the injection of pilot fuel into a combustion cylinder and to develop, install and test a multi-cylinder micropilot ignition system for a 4-cylinder, natural gas test engine. In all, there were twelve (12) tasks defined and executed to support these two (2) primarily elements in a stepwise fashion. Task-specific approaches and results are documented in this report. The four-cylinder prototype data was encouraging for the micro-pilot ignition technology when compared to spark ignition. The objective for Phase II was to further develop and optimize the micropilot ignition system at the EECL for large bore, slow speed engines operating at low compression ratios. The primary elements of Micropilot Phase II were to evaluate the results for the 4-cylinder system prototype developed for Phase I, then optimize this system and prepare the technology for the field demonstration phase in Year 3. In all, there were twelve (12) tasks defined and executed to support objectives in a stepwise fashion. The optimized four-cylinder system data demonstrated significant progress compared to Phase I results, as well as traditional spark ignition systems. These laboratory results were enhanced, then verified via a field demonstration project during Phase III of the Micropilot Ignition program. An Implementation Team of qualified engine retrofit service providers was assembled to install the retrofit micropilot ignition system on an engine operated by El Paso Pipeline Group at a compressor station near Window Rock, Arizona. Testing of this demonstration unit showed that the same benefits identified by laboratory testing at CSU, i.e., reduced fuel consumption and exhaust emissions (NOx, THC, CO, and CH2O). Commercialization of the retrofit micropilot ignition technology is awaiting a ''market pull'', which is expected to materialize as the results of the field demonstration become known and accepted. The Implementation Team, comprised of Woodward Governor Company, Enginuity LLC, Hoerbiger Corporation of America, and DigiCon Inc., has direct experience with the technology development and implementation, and stands ready to promote and commercialize the retrofit micropilot ignition system