Pressurizing of high-pressure fuel system forsingle cylinder test cell

Sammanfattning: This master thesis covers the development of a high-pressure fuel system for compression ignitedfuels such as diesel and diesel-like fuels that will be deployed into a single cylinder test cell at AVLMTC Södertälje, Sweden. The test cell is used by AVL to conduct research and testing of new fuelsfor their customers and this new fuel system will widen the span of fuels able to be tested by theequipment.This thesis focuses on pumping and pressurizing of the fuel, ensuring that all ingoing materialsare non-corrosive in this environment and compatible with the necessary fuels and lastly a safetyanalysis of the system with respect to operator and process safety. Other aspects of the projectsuch as mass flow measurements and fuel conditioning is covered in a sister thesis Mass flowrate measurement of compression ignition fuels in high-pressure stand-alone pump unit for singlecylinder test cell written by C. Aksoy [1].The goal of this thesis project was to deliver a finished manufactured fuel system and if the timeallowed for it, also validate its performance and finally installing and incorporating it into the singlecylinder test cell. The development process started with the writing of a product specificationoutlining the requirements and request on the product in a specification of requirements matrix andrelate these to product properties of the system using a quality function deployment (QFD) matrix.This document was then used as a base for further advancement in developing concepts to solveeach product property and weighing these concepts against each other using Pugh’s matrices. Thechosen concepts were then further developed, a flow chart for the system was developed as well asfuel lines and other supporting components were analyzed and chosen.In the end the high-pressure fuel pump from Scania’s XPI fuel system were chosen as well asa pressure transducer in the HP1000 series from ESI. Within the time frame of this thesis, theproject did not end up getting finished to the degree planned, but due to time constraints werehalted before starting manufacturing of the system. Some minor component choices remained aswell as documentation such as drawings and finalizing the physical layout of the system remained.All information regarding the remaining work needed to finalize the project and deploying thesystem in the test cell were outlined and with more time, the fuel system should fulfill its purposeof allowing testing and research of compression ignited fuel to be possible in the test cell.