NPS Driven Builds Robust Stage V Engine for Inland Shipping

NPS Driven is launching the Stage V version of the John Deere 6135 diesel engine, developed and certified in-house, under its own name. NPS Driven offers the Stage V version for inland shipping under the NPS 6135 brand.The NPS 6135 (6 cylinders, 13.5 liters) is available in power outputs ranging from 272 to 559 kW for driving bow thrusters, cargo pumps, generators, and smaller inland vessels. As the holder of the Stage V certificate according to the regulations, NPS Driven is also the manufacturer of the engine. “As the producer of the NPS 6135, we fully guarantee the proper functioning of the engine and the emission system,” says Peter van der Heijden, director of NPS Driven.

The MPAT-FB emission system used by NPS Driven was developed in collaboration with its subsidiary Xeamos, which specializes in emissions systems for the maritime sector. “Technically, building the Stage V emission system wasn’t that difficult,” says Van der Heijden. “However, the numerous rules required to demonstrate and ensure proper functioning made the certification process complicated. We had to show that emissions remained within the standards even after 10,000 operating hours.” To mathematically demonstrate this (through extrapolation), the pilot engine and emission system had to complete 2,500 operating hours on the test bench.
“We also had to prove that the emission system of the engine is tamper-proof,” says Van der Heijden. “We thoroughly tested all our sensors and software. If NOx emissions unexpectedly rise, our software must warn the user and store the data indelibly in the engine control unit (ECU). The legislator can then read this data at any time. We performed a test on the test bench using a diluted AdBlue mixture. The emission system must detect this.”

Robust Emission System 

NPS Driven has built a robust emission system. The particulate filter and SCR catalyst are housed in a thick-walled welded steel casing, and there is no need for a separate exhaust silencer. “Stage V engines based on truck engines often use thin-walled casings. Our system is designed for the expected long lifespan of this engine,” says Van der Heijden. “The system is also simple to maintain. Our sensors are neatly positioned on the outside, making them easily accessible. Other Stage V engines often place their sensors deep inside the system, making them difficult to reach. You can easily remove the particulate filter through a hatch to clean it from ash residues. This is rarely needed because the filter has a large volume and includes a regeneration burner that ensures the required temperature for burning the soot when backpressure exceeds a certain level. This prevents problems, especially when the engine runs at idle for long periods and only occasionally needs to deliver high power, such as with a bow thruster. The engine is then briefly heavily loaded, and the soot filter does not burn clean because of the exhaust gas heat. Without this unique regeneration burner, a Stage V engine may fail to reach the required revs or even shut down due to excessive backpressure at the crucial moment. Often, significant damage to the particulate filter has already occurred, leading to increased costs.

Particulate Filter (DPF)

The particulate filter’s removable filter blocks require cleaning every 3,000 operating hours. The system gives a warning when this is necessary. The blocks, which have become sticky due to dirt and oil particles, are dried in an oven by NPS Driven, after which the dust particles are blown out. “If you do it carefully, you can use them for another 3,000 hours,” says Van der Heijden. “You can reuse the blocks multiple times. After cleaning, they are sealed again with special gasket tape and placed back into the housing, ensuring no exhaust gas leaks around the blocks.”

ISO Certification 

NPS Driven has been ISO certified for several years, ensuring the quality procedures required for being a manufacturer of Stage V engines. “Since Dieselgate, emission legislation for diesel engines has been significantly tightened,” says Van der Heijden. “Certification bodies have the right to test the emissions of any Stage V engine on a ship and read the software to check for tampering.”

Technical Specifications 

The NPS 6135 is equipped with electronic unit injectors (EUI), a water-cooled exhaust manifold, electronic engine control (ECU), keel cooling or a heat exchanger, and replaceable cylinder liners.

Dolpower

Dolpower, a John Deere dealer in Zwijndrecht, supplies the NPS 6135 engine in the Netherlands and Belgium. NPS Driven is also active in large parts of Europe. “We are a distributor for, among others, John Deere and DAF Paccar in the Benelux, Germany, and France. Our NPS 6135 13.5-liter Stage V engine is further distributed through suppliers in Italy, Croatia, and Denmark,” states Van der Heijden.