LARGE

ENGINES
Delivering excellence to the global
large engine industry
LARGE ENGINES

Contents
3 Ricardo delivers solutions to
address the issues that matter
to your clients
4 Ricardo plc
6 W
 orld class analysis:
experience counts
7 Driven by analysis:
reducing cost of ownership
8 Ricardo Software
9 Industry specific expertise
10 Case studies and capabilities
22 Ricardo Knowledge
23 A
 dvanced Technology
Development
24 Strategic Consulting
25 Global test facilities
26 Ricardo’s corporate strategy
27 Ricardo’s global locations
28 Contact details
 LARGE ENGINES

Ricardo delivers solutions to

address the issues that matter
to your clients

Reducing cost Emission solutions

of ownership From EPA Tier 4 and IMO to local air quality, we deliver
optimised solutions that balance the functionality of
Our large engine design, development and application strategies combustion, fuelling and control, and after-treatment
reduce lifetime costs according to the needs of your specific markets systems
and clients

Fuel adaptation In-field performance

We offer the adaptation to a full range of fuels from Our resolution of in-field issues delivers short term
gas through to heavy fuel oil, for clean sheet engine containment, root cause confirmation and permanent
designs, manufacturer conversions and operator refits corrective fixes for engine components and systems,
supported by development of installed performance

Ricardo has the expertise and technology to address the key

challenges facing your industry
Legislative
Performance
compliance

Time to market Fuel efficiency

Product lifetime Packaging

Product Durability and

strategy reliability

Manufacturing Serviceability &

feasibility maintainability
Capital cost
$/kW

Delivering Excellence Through Innovation & Technology 3

LARGE ENGINES

Ricardo plc
Large engine innovation and world class technology

Who do we work for? How do we deliver value?

We work for the world’s leading large engine • By delivering innovative technical solutions that give
manufacturers, their suppliers, and their clients in the you a competitive edge
power generation, rail, marine and industrial sectors.
Our clients include: Caterpillar, General Electric, Hyundai • By enabling you to get products to market more quickly
Heavy Industries and Aggreko. • By fixing problems that are costing you money
• By taking full responsibility for projects that you do not
What do we do? have capacity to deliver
We deliver bespoke engineering solutions that enable our • By the transfer of our knowledge to your engineers -
clients to meet their business aspirations. increasing their value and enabling you to develop your
in-house capabilities.

We are active in
all areas of large Through life 1 Business
7
support
engine design and and product
strategy
development
across the full
product life cycle • Base engine and components
Field
trials
• Fuel and control systems
• Emission treatment systems
2
• Combustion and air systems
6
Research and
• Analysis software advanced
• Waste heat recovery systems engineering
• Application and installation
• CHP audit and certification
• Health and usage monitoring systems
• Root cause failure analysis and mitigation
Test, • Alternative fuels
development
and
• Maintenance optimisation 3
validation
Target setting
5 and engine
specification

Concept and
detail design 4

4 Ricardo plc
 LARGE ENGINES

Delivering Excellence Through Innovation & Technology 5

LARGE ENGINES

World class analysis: experience counts

Fully integrated designs from concept to production

Ricardo analysis Cylinder head design

Optimising large engines Complexity simplified
• Starting from an experience based design concept, Ricardo utilises • Cylinder heads are the most complex engineering component within a
analysis-led design to drive fast tracked development and optimisation large engine
of clean sheet and upgrade designs for critical components
• Ricardo’s highly experienced analysis team has an unmatched track
• E mbedded analysis tools, processes and the extensive experience of record of producing cylinder heads for large engine applications that
Ricardo engineers provide a faster time to market with robust high provide target performance levels and robust durability right out of the
performance designs box

• F ront loaded concept analysis combined with rapid iterative loops allow • Use of an extensive toolset of analysis software developed by Ricardo,
for optimised design development from initial concept through to specifically to aid development of critical engine components, provides
production targeted analysis with built in experience.

• A
 llows you to provide market leading performance levels coupled to
class leading reliability.
Development of coolant
flow performance
Ricardo analysis through multi-domain
process for cylinder CHT analysis allows in-
head development depth understanding
of the engine thermal
behaviours

Design of efficiently
cooled valve seats - critical
for high output large
engine performance
Poor cooling and design
may result in significant
valve and seat wear

Cycled thermo-structural analysis provides prediction

of design robustness
Control of thermal and mechanical loads developed
using knowledge from analysis results

6 Ricardo plc
 LARGE ENGINES

Driven by analysis: reducing cost of

ownership
Robust designs, emissions solutions, flexibility and speed of response for
resolution of development and field issues

Combustion system Combustion

development performance
optimised
• The extensive use of 3D CFD combustion system analysis within Ricardo with Ricardo
enables development of cutting edge performance for your engines analysis
experience
• Development of gas, Diesel or HFO can be tailored using rapid analysis
to provide market leading efficiency within the technological boundaries
of your products

• A clear understanding of the events within the combustion chamber

allow tuning of the design to extract maximum performance and
minimum emissions.

Resolving issues and building reliability

Ricardo’s experience in the development of high performance large Case Study
engines provides a wealth of experience for resolution of the common Piston system development
issues affecting reliability. Use of targeted analysis coupled with great • Utilising piston and ring pack software and Ricardo analytical expertise
experience provides the benefits of engineering out the root cause rather for development of piston systems provides an optimised solution for
than treating the symptoms. friction and wear with minimum oil consumption.

Case Study
Valve and seat recession
• Significant increase in service life of valves and seats suffering from
severe wear and recession issues provided by detailed analysis of valve
and seat misalignment and surface interaction.

Calculated wear
load due to firing

Delivering Excellence Through Innovation & Technology 7

LARGE ENGINES

Ricardo Software
A suite of products focused on powertrain and driveline solutions

WAVE: a comprehensive engine FEARCE: a finite element (FE) pre- and

system simulation software designed post-processing environment written
for 1D analysis specifically to support engine and
vehicle analysis
VECTIS: a CFD code developed
specifically to address fluid flow PISDYN: an advanced simulation
simulations in the vehicle and engine package for the design and analysis of
industries piston assemblies
VALDYN: a multi-body dynamic RINGPAK: a simulation tool used for
simulation tool specifically developed the design and analysis of a piston
for valvetrain and drive system analysis ring pack
ENGDYN: a dedicated engine analysis SABR: a simulation package which
code developed to aid the design and has been specifically developed
analysis of the crank train and engine for transmission shaft and bearing
structure analysis

8 Ricardo plc
 LARGE ENGINES

Industry specific expertise

We support from clean sheet to end application in all market sectors

Clean energy and power Rail

generation Over sixty years of rail engine experience in delivering client solutions for
a more efficient and cleaner future
• Independent, objective and practical advice tailored to the needs of
Ricardo’s expertise in systems integration allows our clients to exploit
rail sector clients
new power generation opportunities to meet future energy needs
• Expertise with in-depth sector knowledge and thinking from multiple
• Extensive experience in developing conventional power systems for
transportation sectors
lower cost solutions
• Access to world leading
• A proven track record in delivering high reliability, low cost of energy
experts in engine,
solutions for renewable energy clients
transmission and
• Combined with our expertise in conventional and renewable energy,
control technology
Ricardo can optimise
and systems
power systems and
• Multi-modal
deliver smart energy
transportation
solutions
expertise.
• Alternative and low cost
fuels.

Marine Off-highway and industrial

A global capability in advanced propulsion systems and enabling
technologies
machines
• One-stop shop for marine engineering support Advanced solutions for a more efficient, cost-effective and cleaner future
• Cost savings built-in from the concept stage through access to deep • Maximising machine efficiency and productivity
technical expertise and use of advanced CAE tools • Emissions reduction and legislative compliance for all markets at
• World-renowned expertise in HFO, MDO and gas engine design and lowest cost
development, with SCR free solutions • Reducing the cost of ownership of your equipment
• Innovative and imaginative engineering solutions for all types of large • Machine localisation in new markets.
commercial vessel.

Delivering Excellence Through Innovation & Technology 9

LARGE ENGINES

Case studies
and capabilities

Icon key
Reducing cost of ownership

Emission solutions

Fuel adaptation

Field issue resolution

10 Ricardo plc
 LARGE ENGINES

High speed gas engine High speed generator set

cylinder head design uprate with heavy fuel oil
operation

Ricardo role
• C
 oncept and definitive design of a new cylinder head for GE’s J624 Ricardo role
gas power generation engine. • R
 icardo has assisted Aggreko in developing high efficiency, robust
solutions to provide low total energy cost per kilowatt hour and
Situation and objective the ability to operate on widely available supplies of low cost fuel,
• E ngine uprate to class-leading levels of performance necessitated including marine grade HFO.
a new cylinder head to provide robustness against significant
increases in BMEP and cylinder pressure. Ricardo conducted a Situation and objective
detailed concept design phase supported by significant analytical • E xtensive engineering programme integrating Ricardo design,
input. Following selection of concept the definitive and detail design engineering and development with Aggreko operations and
was completed, supported by further detailed analysis, and the manufacturing to deliver the genset upgrade. The upgrade path
drawings were released into the GE system. needed to be feasible as a part scheduled engine rebuild and needed
to be packaged in a standard 20ft container maintaining compatibility
Results and benefits with fuel handling systems and the existing cabling, transformers and
• S ignificant reduction in cylinder head temperature magnitude switchgear.
and thermal gradient driven by optimised cooling, confirmed by
measurement Results and benefits
• Improvement in predicted low cycle fatigue lifetime compared with • D
 elivery of upgrade path for the existing fleet of 4,500 Cummins
baseline design KTA50G3 powered Aggreko diesel generator sets
• M
 ajor reduction in flame face deformation, resulting in improved
- Diesel solution upgrade producing 14 percent more power at 12
valve seat roundness and leading to significant reduction in valve/
seat mechanical wear prediction. percent lower cost per MW
- Development of solution delivering a low cost, high speed engine
capable of operation on heavy fuel oil.

Delivering Excellence Through Innovation & Technology 11

LARGE ENGINES

Medium speed gas engine Ricardo strategic consulting

development concept book for a 1MW
engine

Ricardo role
Ricardo role
• R
 icardo has assisted HHI with the engine development programme
to deliver gas variants of the H32/40 series power generation and • Ricardo clarified client requirements and product planning
assumptions, so that the client developed the right 1MW engine for
marine propulsion family of engines.
future global markets.

Situation and objective

Situation and objective
• T he 26 month engineering programme covered from concept
design phase through detailed design to engine development • The client was planning to develop a new, large diesel engine, initially
testing including performance and durability development support. optimised for gensets but with potential for other applications
The Ricardo and HHI engineering team worked together to deliver including large construction equipment and marine
the new engine design integrating new gas specific components • The client wanted to better understand the global market potential
with existing diesel variant components in a short development and competition for engines in the 1MW sector with quantitative
timeline. market analysis and insight, so the end user’s needs and expectations
could be understood and harnessed in the new engine.
Results and benefits
• R
 apid delivery of H35/40 gas variant delivering high BMEP and high Results and benefits
efficiency levels demonstrated on engine test. • A detailed market analysis by application, displacement and
geographical region supported by competitor benchmarking enabled
a technical scope to be developed focusing on hitting the optimal
market position
• This project provided the basis for a complete specification within the
engine concept book.

12 Ricardo plc
 LARGE ENGINES

Full engine design and

development

Ricardo role
• R
 icardo is assisting many of the world’s large engine producers in
the development of new high and medium speed engines, ranging
from architecture definition to full, turnkey design and development
programmes.

Situation and objective

• T he creation of new large engines and the major upgrade of existing
engines is a substantial investment, demanding a robust strategy for
rapid delivery of engines to market that are competitive at launch
and through product lifecycle. Expert support to pre- programme
market analysis and product strategy definition, through design
and analysis, to test, validation and in-field support, is invaluable to
product success.

Results and benefits

• F aster delivery to market of bespoke engines, developed to address
the issues that matter to your clients and markets.

Locomotive engine Situation and objective

• Initially increasing the performance, fuel efficiency and reliability
development and market of CNR’s sixteen cylinder 240 railway locomotive engine, this
collaboration extended to the very successful upgrade of CNR’s

expansion product through a series of projects over a period of thirty years. The
cooperation included technology and knowledge transfer through
on-site working, and most recently has explored the development
of CNR’s future large engine products.

Results and benefits

Ricardo role • E ngine performance, efficiency and reliability enhancement
delivered into the market through a long term partnership, together
• R
 icardo has assisted CNR (Dalian) over a thirty year period in the
with development of future product strategy.
design and development of the CNR 240 Z locomotive engine, and
in market analysis to assess future product strategy.

Delivering Excellence Through Innovation & Technology 13

 LARGE ENGINES

Submarine propulsion Engine development for

test facilities submarine application

Ricardo role
Ricardo role
The Australian Government under the SEA 1000 Future Submarines
programme are seeking to procure a new class of conventionally • Re-design of vital components and systems
powered (non-nuclear) submarine to replace the Collins class. • Performance simulation and turbo matching
In order to reduce the risks inherent in the production of the • Performance testing under submarine operating conditions.
propulsion and energy management system for the new submarine
it is intended that a land-based development and testing Situation and objective
facility be constructed. The facility is known as the Submarine
• Re-engineering of air- and exhaust systems including performance
Propulsion, Energy, Support and Integration facility (SPESIFy).
analysis and development to meet special operating requirements
The Australian Defence Material Organisation (DMO) commissioned • Engine testing under submarine operating
Babcock Pty Ltd to undertake a study into the options for SPESIFy conditions (high back pressure).
which is to support all phases of the submarine programme
through design, construction and operational life. Results and benefits
Ricardo was engaged by Babcock as subject matter experts to support • Targets met through the use of:
the study due to their extensive experience of diesel propulsion
- Understanding of special technical requirements
system R&D testing using land based facilities including those for the
development of surface warship and submarine propulsion systems. - Close contact with the client and key suppliers at all stages
- Early use of advanced performance simulation techniques
Situation and objective • Prototype design delivered within the agreed time frame.
The scope of the study included:
• The identification of candidate equipment for the diesel,
power system, energy storage and air independent
propulsion systems for the new submarine
• Provision of data on the equipment including
technology and system readiness levels
• Association of potential risks and mitigation efforts through
the development of a matrix of prospective test methods
• Identification and assessment of candidate
options for the SPESIFy facility.

Results and benefits

The study identified three alternative suitable options for SPESIFy with
associated costs, timescales and related technology de-risking potential.
This will enable the Australian Government to make an informed decision
on the nature and benefits to be realised from land based testing facilities
which, in turn, will enable Australia to significantly enhance its existing
submarine expertise.
© Crown copyright

14 Ricardo plc
 LARGE ENGINES

Medium speed gas engine Independent assessment of

uprate locomotive fuel economy

Ricardo role
• R
 icardo supported Caterpillar in further development of the GCM34
family of gas fired engines through the addition of a 20 cylinder
variant and increasing cylinder power from 420 kW to 500 kW
combined with increased engine efficiency.

Situation and objective

• T he V20 development programme was undertaken by Ricardo and
Caterpillar to deliver the V20 variant to a tight development timeline
• R
 icardo supported the definition of design changes to the major
engine components to ensure a durable design was delivered and
provided definition of performance systems including air path and
combustion system analysis and design.

Results and benefits

• Initial test results from 8 cylinder test engine have shown power
targets and efficiency improvements targets have been successfully
achieved.

Ricardo role
• Building upon a recent Ricardo study for the UK Government, into
potential technology improvements to improve diesel fuel efficiency
on the rail network of Great Britain, GE Transportation commissioned
back-to-back tests to demonstrate the fuel-efficiency credentials of the
Class 70 against the Class 66 locomotive
• To ensure that the tests were carried out according to a robust
methodology and in an accurate and thoroughly objective manner,
GE contracted Ricardo to oversee the work and to validate the test and
analysis approach taken as well as the results generated.

Situation and objective

• As a part of its study carried out for the Department for Transport,
Ricardo assessed a range of technology packages that could be
applied to the Class 66 locomotive which currently represents the
backbone of the UK’s rail freight fleet
• GE Transportation expressed interest in the results of the study because

Main engine calibration its Class 70 locomotive fitted with its four-stroke PowerHaul® engine
not only incorporates many of the features recommended by Ricardo
but it also complies with EU Stage IIIa emissions regulations
(7.4 g/kW.hr NOx). 

Results and benefits

• Main engine calibration and rating development • Fuel savings of 18 percent for GE’s state-of-the-art Class 70 locomotive
• Completion of first process led to other in comparison with the Class 66 currently used for 87 percent of rail
engine programmes with Ricardo freight movements in Great Britain
• Provided calibration par files for three ratings to meet • Additional fuel savings would be possible using the Class 70’s Auto
a range of performance and emissions targets Engine Stop/Start (AESS) feature and Auxiliary Power Unit (APU) in duty
• Test data provision to successfully sign off to Perkins specification involving extended stationary periods
• Transient performance assessment and • Builds upon a recent study for the UK Government into potential
calibration mapping data provided. technology improvements to improve diesel fuel efficiency on the rail
network of Great Britain
• Ricardo contracted by GE to oversee and validate back- to-back
locomotive fuel efficiency tests.

Delivering Excellence Through Innovation & Technology 15

LARGE ENGINES

Review of firing order Rapid robustness

options and assessment of development using
impact on vibration and Ricardo “7-Phase” problem
durability resolution process to solve
multiple issues

Ricardo role
• Ricardo supported the client through application of a novel analysis
technique to define the optimal firing order for a new engine family Ricardo role
with intended variants L6-L9 and V10-V20. • Ricardo set up a task force to address a wide range of issues on a
development engine of a new variant.  Project successfully identified
Situation and objective corrective actions required to address the robustness and reliability
• All potential firing orders for a new engine family with intended concerns to allow the development to proceed.
variants L6–L9 and V10–V20 required vee angle needed to be tested
rapidly and an optimal order defined with favourable vibration and Situation and objective
durability characteristics to reduce technical risk before the project • Client was experiencing more than 50 robustness and reliability issues
could progress during installation of a new engine variant relating to vibration, internal
• For each configuration, an initial screening of all even firing orders engine failures, fluid leakages and electrical/sensors
(consecutive and non-consecutive) was required to establish the • Client required a full team of on-site engineering support to propose
torsional vibrations at crank nose and flywheel corrective actions that could be implemented within a three-month
• For key variants in the family, further analysis was needed using 1-D timeframe.
VALDYN and ENGDYN software to identify:
-- Main & Big End bearing specific loads Results and benefits
-- Main & Big End bearing minimum oil film thickness • Ricardo “7 phase” problem resolution process used to assess and
recommend actions with respect to the initial 50 issues
-- Crankshaft durability safety factors across operating range
• Three issues remained unresolved after the three-month timeframe. All
-- Internal and external moments. other issues resolved to client’s satisfaction
• Further expertise provided to support in-depth development
Results and benefits programmes to resolve remaining issues.
• For each engine variant, a recommended firing order was identified
with the required flywheel size, flywheel fluctuation and system natural
frequency
• For key engine variants, a detailed study was made to optimise the
trade-off between vibration and durability
• The client was given clear design recommendations for successful
engine development.

16 Ricardo plc
 LARGE ENGINES

Technical and commercial Supporting the development

assessment of the of a new dual fuel system for
introduction of alternative high speed engines
fuels on a rail network
Ricardo role
• Ricardo has supported the development of a new dual fuel control
Ricardo role system providing both test facilities and control system engineering
• Assisting Canadian National to assess the implications of using expertise.
liquified natural gas as fuel in place of distillate Diesel
Situation and objective
Situation and objective • Definition of requirements for and implementation and advanced
testing of a control system for dual fuel capability applied to high-
• Ricardo reviewed the options for storage, transport and distribution of
the LNG, including the locomotive tender along with available engine speed engines – Diesel fuel to be substituted with CNG.
conversion technologies
• Particular attention was paid to identifying “Red Flag” issues which
Results and benefits
could affect reliability or safety • Baseline performance of the demonstrator engine completed on
Diesel. Will act as accurate foundation for future work
Results and benefits • Established tolerance of OEM’s control strategy to substitution with
• Significant benefits, particularly in reduced emissions were identified, CNG and identified key channels and error codes to enable integration
especially when annual fuel consumption is measured in millions of of new dual fuel control system
gallons • Control system specification documents updated with benefit of
experience from automotive and commercial vehicle programmes
• Development phase of control strategy with direct application onto
engine in progress. Supported by Ricardo control system engineers

Delivering Excellence Through Innovation & Technology 17

LARGE ENGINES

170mm bore IMO III/EPA Simulation model of a

Tier 4 marine emissions marine propulsion system
upgrade programme to develop vessels with
without SCR or DPF improved fuel economy and
NOx emissions
Ricardo role
• Ricardo implemented a new combustion system and emissions control Ricardo role
system within the existing marine engine architecture.  Combustion
• Ricardo has supported a client with the foundations to carry out in-
system used Ricardo intellectual property already in production for
house simulation of new propulsion systems to support strategic goal
<150mm bore engines.
for lower fuel consumption and NOx emissions.
Situation and objective Situation and objective
• Client required an updated engine offering for the marine market to
• Development of new hybrid marine propulsion system variants for
meet IMO III and EPA Tier 4 marine emissions standards, without the
tugs, supply vessels, ferries etc. to satisfy customer and legislative
use of SCR to minimise fluid logistics
demands
• Project represented the first large-engine application of Ricardo’s low
soot Twin Vortex Combustion System (TVCS) and cooled EGR for NOx • Creation of flexible vessel simulation model to predict the impact
reduction. of different powertrain architectures (Diesel and Diesel-electric) and
power management strategies on fuel consumption and emissions
Results and benefits and to assist in dimensioning of components.
• Design, application and implementation of new TVCS combustion
system with 2200bar HPCR FIE, air handling (intake, exhaust and turbo)
Results and benefits
and modular EGR systems (current engine didn’t have EGR) • Open source Matlab-Simulink simulation model of current vessel with
Diesel mechanical propulsion system developed and tested
• Development and implementation of EGR system control strategy
-- Design & development of new 220bar-rated cylinder head • Diesel-electric model developed with modular approach, adding in
new sub-systems: Power Management System (PMS), e-machines
-- Support for performance and emissions testing and development
(generators & motors) and electric power converters
and supplier liaison to demonstrate successful achievement of
programme targets • Optimal running pattern (PMS logic and set-up) judged on fuel
• Maintained current engine power density and ratings with stringent consumption and emissions
IMO III & EPA Tier 4 marine emissions regulations • Benefits of model:
• New 220bar-capable cylinder head designed
-- Baseline model validated with test data
• Intelligent modular EGR system designed with ‘EGR extended life’
control strategy to minimise EGR cooler fouling and increase system -- Modular approach to model building provides flexible platform for
reliability and lifetime further development
• Single stage high pressure ratio turbocharging incorporated to -- Model identifies the size of components to meet a defined duty
minimise system complexity, cost and package. cycle
-- Power Management System (Controller) optimises the system
performance based on selected criteria (e.g. fuel economy)

18 Ricardo plc
 LARGE ENGINES

New ECU and engine control High speed powergen SCR

software for High Speed module development for
Diesel engine flexible retrofit application
across multiple engine
platforms
Ricardo role
• Ricardo has defined the new ECU hardware specification and is
developing the engine control software for a global OEM’s new engine
family.
Ricardo role
Situation and objective • Ricardo designed and developed an emissions reduction module with
• Development of new engine family for application in power the capability to be retrofitted to multiple existing engine platforms.
generation, marine, locomotive and other areas, with V12 to V24
variants having dual fuel and natural gas options Situation and objective
• System and HW specification, safety analysis and concept design, SW • Production of SCR retrofit application for in-service gensets targeting
process and tools definition, HiL and SW specification required. conversion efficiency up to 90% and highly optimised package with
high cost focus.
Results and benefits
• Cost effective ECU HW architecture selected with expansion options Results and benefits
for engine variants • Concept design and selection, production development and system
calibration over 18 months
• Processes and tools defined for development in accordance with
IEC61508 • Bespoke package solution at competitive cost point

• SW framework defined with clean structure to enable both existing -- Vanadium catalyst without DOC
and new control functions to be developed and integrated -- Low cost fabricated assembly
• Specifications developed in sufficient detail to enable direct software -- 3D CFD to optimise urea mixing and backpressure
coding and validation. -- Calibration of urea dosing (Ricardo’s process)
-- Steady-state calibration and load ramps
-- Durability and ageing compensation.

Delivering Excellence Through Innovation & Technology 19

LARGE ENGINES

Design of Medium-Speed Identification of technology

piston for 250bar operation upgrade path to achieve
with both durability and lowest total cost of
friction optimised by Ricardo ownership for power gen
analysis toolset sector

Ricardo role Ricardo role

• Ricardo have designed and developed a new piston for a global OEM • Ricardo have developed the TSO (Total Systems Optimisation) toolset
to allow the use of low cost supplier base.  Technical knowledge which provides decision makers with a focused blend of the technical
transfer to client will allow future independent development of benefits and the commercial data
component.
• The decision maker can quickly run different usage scenarios over the
lifetime of the capital equipment and the toolset will instantly calculate
Situation and objective and compare key parameters for all possible technical packages.
• Design of large-engine application with high load factors and long
overhaul intervals, diesel, HFO and gas operation with 250bar peak Situation and objective
firing pressure with minimised friction for good BSFC, good skirt profile
• Decision makers need to be confident that they can see the full
and ring specification, and with lube oil consumption and blow-by
technical advantages of an upgrade (reliability, improved fuel
under control
economy) at the same time as the commercial aspects. Understanding
• Commercial objective to bring piston design and manufacture under the sensitivity for a range of scenarios is also required.
control of engine OEM customer using local manufacturing suppliers
Results and benefits
Results and benefits • Quantification of benefits of improvement options
• Piston design that offers commercial and technical benefits over
existing component • Optimised investment profile calculated to take account of availability
of new technologies and maximum implementation rate
• Commercial benefits:
-- Production cost reduced • Different usage scenarios and profiles can be run with instant
recalculation of output data including through life costs
-- Time-to-market advantages due to significantly reduced prototype
development lead times • Other built in functionality includes; identification of the optimum
• Technical benefits: solutions against user defined parameters (e.g. threshold investment
level), a full audit trail and fully customisable dashboard screen.
-- Greater potential for OEM-specific piston development to gain
competitive advantage, e.g. combustion/emission development or
fuel/lube consumption development.

20 Ricardo plc
 LARGE ENGINES

Ricardo research into split Atlas II single cylinder

cycle engines is producing research engine
results that point to a large
engine with 60% and higher
efficiency • Able to test engine concepts ranging from 150-200 mm bore with a
stroke of up to 280 mm, and a maximum cylinder pressure of up to 300
bar
• Provides a highly flexible, multi-fuel capable development tool for
500kW – 5MW high speed engines to support faster delivery of
Ricardo role products faster to market and at considerably reduced cost
• Successive research programmes have developed the concept of a • Testing for combustion, emissions and performance development,
split cycle engine which will have significantly lower through life and component development and functional validation, and durability sign
operating costs. off

Situation and objective • Offered as a product and as test time at Ricardo’s UK large engine
development facility
• Thermal efficiency of conventional reciprocating large engines has
stagnated at 42-45% with potential cost effective improvements
mapped out that will provide +1% per decade
• A revised technical approach is required that will provide a game-
changing improvement in efficiency, supported by a robust
commercial model
• Ricardo’s knowledge of split-cycle engines focused over 5 years of
development can produce an engine with significantly lower through
life and operating costs.

Results and benefits

• The Iso-Power project demonstrated a 3MW prototype split cycle
recuperated combustion engine with isothermal compression, using
water injection to achieve thermal efficiency in excess of 60%
• Next phases of analytical and experimental work were carried out to
explore use of LN2 to deliver isothermal compression as LN2 is very
cheap and widely available. Simulated capability of concept at >60%
thermal efficiency
• Current project focused on gas transfer/combustion in a cryogenic
isothermal compression, split-cycle engine. Includes high efficiency
recuperator, valve actuation development and combustion in a single
cylinder engine
• On completion of the current phase in late 2015, the performance
of the five sub-systems of the split cycle engine will have been
successfully demonstrated.

Delivering Excellence Through Innovation & Technology 21

LARGE ENGINES

RICARDOKNOWLEDGE
Technical Assistance, Training and Information Services

Ricardo Knowledge is a specialist team, on hand to listen to your

diverse and complex requests, giving you access to over 2000
independent knowledge holders in the field of transportation
and power system expertise.
Join the major OEMs and Tier 1 suppliers already using Ricardo Knowledge to support and sustain
their future strategies.

Technical Assistance
Training
Information Services
Choose your package
Insight Classic Digital
• Annual meeting with Ricardo specialist • Dedicated account manager • Dedicated account manager
• 5% off Information Services • 25+ hours of Technical Assistance • Ricardo Knowledge online client portal
• One place on a scheduled training • Annual meeting with Ricardo specialist • 50+ hours of Technical Assistance
course of your choice • One place on two scheduled training • Annual meeting with Ricardo specialist
courses of your choice • Two places on two scheduled training
• Discount on further scheduled training courses of your choice
courses • Discount on further scheduled training
• 10% off Information Services courses
• 15% off Information Services

£5k £20k+

Contact
Glen Hall
Manager, Ricardo Knowledge
Tel: +44 (0)1273 794469
Visit www.ricardo.com/knowledge
Email: [email protected]

22 Ricardo plc
 LARGE ENGINES

ADVANCED TECHNOLOGY DEVELOPMENT

Strategy, Risk Mitigation & Demonstration

Accelerating your technology development via three tailored

offerings
Ricardo ATD will accelerate your technology development with an agile, passionate
and creative team focused in three key offerings. Ricardo is your unrivalled engineering
partner, from small start-ups to global brands.
Ricardo ATD applies our outstanding independent market and technical knowledge, tools,
techniques and experience to any point in your development cycle working either as an extension
to your team or delivering a turnkey programme, minimising your risks and disruption and
maximising fast returns, quality and value.

ADVANCED TECHNOLOGY DEVELOPMENT Technology Readiness Level (TRL)

Strategy, Risk Mitigation & Demonstrators
1 2 3 4 5 6 7 8 9
Ricardo Main Programmes Support Zone
Ricardo ATD Support Zone

• Roadmapping
• Market analysis
• Technology assessment
Technology Strategy • Risk identification
• Intellectual property
• Sourcing external funding
• Training & development
Technology Risk Mitigation • Knowledge network

• Simulation & systems integration

• Concept specifications
• Rig-based testing
Technology Demonstration • Lab & field demonstrators

TRL1: New idea TRL6: Demonstration in appropriate environment shows it is worth taking forwards

TRL3: Concept validated via simulation and individual hardware test TRL9: In use with customers

Delivering Excellence Through Innovation & Technology 23

LARGE ENGINES

Award Winning Strategic Consulting

Your Trusted Partner in the Global Large Engines Industry

World Class Strategic Support Proven Programme Delivery Superior Engineering Expertise
For management and development 100 year history of success Design and development support –
of successful automotive businesses executing projects for Major OEM, ranging from individual components to
in all markets Tier 1 and Niche sectors whole vehicle programmes

Ricardo offers a unique combination of strategic and technical consulting

Ricardo Strategic Consulting is the global management consulting subsidiary of Ricardo plc and is
a natural extension of Ricardo’s high value-added engineering services in the large engines sector.
The large engines industry is among the most sophisticated industry. We bring to each client a deep, detailed industry,
and demanding users of consulting services. Today’s clients product and technical knowledge that other management
need broader and deeper capabilities that traditional consulting firms simply lack.
management consultancies often struggle to provide. We bring industry expertise to our clients that is unparalleled
Ricardo’s unique advantage is the coupling of management in our sector. As a Ricardo client, you always receive practical,
consulting and technical capabilities, allowing us to address implementable solutions expressed in clear language.
strategic issues with product implications in great detail.
Ricardo is therefore very different from the traditional
management consulting firms working in the large engines

24 Ricardo plc
 LARGE ENGINES

Global test facilities

From turnkey engineering responsibility to a ‘test’ only service
Multi cylinder engine test Comprehensive measurement
Suitable for engines of up to 4MW, and up to 8MW by arrangement. • Cylinder pressure
• Fuel, fluid and air flow
Single cylinder engine test • Oil consumption and quality
Suitable for power cylinders of up to 300kW, and up to 750kW by • Regulated gaseous emissions (CO/ CO2 /O2 /THC /NOx)
arrangement. • Unregulated gaseous emissions (on- and off-line)
• On-site chemical analysis (oil, fuel, wear metals, PM analysis)
Fuel types • TLA wear measurement
Diesel; marine diesel oil; heavy fuel oil; natural gas. • Vibration survey and analysis

Remote access to test bed systems Chemistry

Global Test Environment (GTE) is a Ricardo developed technology that Full chemical capability. On- and off-line techniques (GC, MS, FTIR, TGA).
allows a remote user with no more than a web browser and the internet, to Specialists in particle sizing (facilities incl. SMPS, MOUDI and Aerosizer).
view the testbeds in real-time and potentially control these remotely.
Specialist instrumentation services
Mechanical development • Temperature measurement
Comprehensive mechanical development capability on components or • Strain gauge installation
sub-systems. Component motoring (incl. engine simulator), tilt rigs (loaded • Photo-stress coating
and unloaded), torsional vibration, bending and fatigue, coolant and • Turbocharger speed indication
lubrication flow, hot gas rig, block testing, FIE • Custom built instrumentation and electro-mechanical mechanisms
• Instrumentation for crack detection and propagation
In-field tests • Fuel system instrumentation
Ricardo will support test, measurement and field issue resolution anywhere • Displacement
in the world

Delivering Excellence Through Innovation & Technology 25

LARGE ENGINES

Ricardo’s corporate strategy

Ricardo is a global world-class, multi-industry consultancy for engineering,
technology, project innovation and strategy.  With a century of delivering
excellence, we employ approximately 2000 professional consultants,
engineers and staff world-wide

MARKET SECTOR
Marine
GLOBAL ENGINEERING
DELIVERY CAPABILITY Clean Energy & Power Generation
Project Management Rail
Research & Development Defence
Mechanical Engineering
Agricultural & Industrial Vehicles
Electrical & Electronics
Commercial Vehicles
Computer Aided Engineering
Test & Development Motorcycles & Personal Transportation
Emissions Analysis & Management High Performance Vehicles & Motorsport
Policy & Strategy Development Passenger Car
Economic Evaluation
Government
Data Management

Engines
United Kingdom

United States

Germany

Czech Republic

China

India

Japan

Korea

Malaysia

Russia

Italy

GEOGRAPHY
Driveline & Transmission Systems
Vehicle Systems
Hybrid & Electric Systems
Intelligent Transportation Systems
Performance Products
Strategic Consulting
Environmental Consulting (Ricardo-AEA)
Software
PRODUCT/SERVICE

Our people are committed to providing excellence through quality Guided by our corporate values of respect, integrity, creativity and
engineering solutions focused on high efficiency, low emission, class- innovation and passion we enable our clients to achieve sustainable
leading product innovation and robust strategic implementation. growth and commercial success.

Our client list includes the world’s major transportation Original Equipment
Manufacturers (OEMs), supply chain organisations, energy companies,
financial institutions and governments.

26 Ricardo plc
 LARGE ENGINES

Ricardo’s global locations

Local project delivery, globally

Ricardo
Deutschland Ricardo
Schwäbisch Gmünd (HQ) Russia
Aachen Technical Centre Moscow
Schechingen Technical Centre
Ricardo UK
Shoreham Technical Centre Ricardo
Ricardo US Midlands Technical Centre Prague
Chicago Technical Centre Cambridge Technical Centre Czech Republic Ricardo
Detroit Technical Centre Ricardo-AEA Korea
Santa Clara Technical Centre Ricardo Seoul
Italy
Turin Ricardo
India Ricardo
Delhi Ricardo Japan
China Yokohama
Shanghai

Ricardo
With offices and technical centres around the world we can support projects Asia
Malaysia
locally and work closely with our clients wherever they are in the world.

Ricardo UK Ricardo UK Ricardo UK Ricardo - AEA Ricardo – AEA

Shoreham Technical Centre Midlands Technical Centre Cambridge Technical Centre Glengarnock Harwell

Ricardo - AEA Ricardo – AEA Ricardo US Ricardo US Ricardo US

London Cardiff Detroit Technical Centre Chicago Technical Centre Santa Clara Technical Centre

Ricardo Germany Ricardo Czech Republic Ricardo Italy Ricardo China Ricardo India
Schwäbisch Gmünd Prague Turin Shanghai Delhi

Ricardo Japan Ricardo in Korea Ricardo in Malaysia Ricardo in Russia

Yokohama Seoul Kuala Lumpur Moscow

Delivering Excellence Through Innovation & Technology 27

 V.9 —9/4/2015
Contact
Simon Brewster Dr. Ioannis Vlaskos
Head of Large Engines Global Market Sector Director - Marine
E-mail: [email protected] Director - Large Engines & Gas Engines
Tel: +44 (0)1273 794814 E-mail: [email protected]
Mob: +44 (0)7850 200096 Tel: +49 (0)7171 9821 - 519
Fax: +49 (0)1761 9821 - 400

Jörg Ruwe
Project Director
E-mail: [email protected]
Tel: +1 (0) 630 468 - 0003
Fax: +1 (0) 630 789 - 0127

Or your local office, details from www.ricardo.com/contacts

Sector focus
Ricardo delivers excellence in a number of market
sectors:
Passenger Cars
Commercial Vehicles
Agricultural & Industrial Vehicles
Motorcycles & Personal Transportation
High Performance Vehicles & Motorsport
Clean Energy & Power Generation
Marine
Rail
Defence
Government

The information provided in this brochure contains merely general descriptions or

characteristics of performance which in case of actual use do not always apply as described
or which may change as a result of further development of the products. An obligation to
provide the respective characteristics shall only exist if expressly agreed in the terms of
contract. Availability and technical specifications are subject to change without notice.