Dual Fuel Systems
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Dual fuel engines are a type of engine that can operate using a mixture of two different fuels, diesel and natural gas. In this system, a small amount of diesel acts as an ignition source, while natural gas replaces a significant proportion of diesel in the combustion process. This results in a reduction in environmental impact, as the engine emits fewer pollutants. The gas is inserted into the engine through a Venturi-based system, which includes a gas train and air-gas mixer that operates at atmospheric pressure.
The proportion of gas is controlled through a state-of-the-art logic controller that includes all safety features such as audio/visual alarms and tripping for safe operation. The controller system constantly monitors and adjusts the amount of gas being injected into the engine, ensuring optimal performance and efficiency. The advanced technology of the logic controller allows for precise control of the fuel mixture, resulting in a cleaner and more sustainable energy source.
Upcharge energy solutions provides SITC (supply installation testing commisiong ) of dual fuel kits with Cylinder based gas bank/cascade system for one stop solution with no dependency on citygas distributors , pipeline infrastructure or any tedious long waiting times.
Coupled with our after sales service this is the only truly independent dual fuel system in existence
Typically 4-6 hours per Diesel Generator. Our system is designed as a stand-alone external solution, necessitating only a single modification to the Diesel Generator’s air inlet. This enables installation with minimal equipment downtime.
No, the dual fuel kit does not affect the power generation capacity of the Diesel Generator. The engine would be able to generate the same power as before. There would be no difference in the working of the Diesel Generator.
The required gas supply pressure ranges from 1 bar to 4 bar. If gas is available at any other pressure, you can let us know and we’ll provide you with an appropriate solution. We can also provide solutions for other forms of gas such as LPG, Bio Gas, LNG.
Gas consumption varies based on the load and DG capacity. As a reference, the maximum gas flow for a converted 500 kVA generator would be 80 SCM/hr, and for a converted 1010 kVA generator, it would be 150 SCM/hr. The gas flow will vary according to the load of the engine.
No certification is needed for Dual Fuel Kits. The dual fuel technology is well-proven and safe as per guidelines from the Ministry of Environment and Forest, NGT, CAQM, and SPCB. Additionally, Upcharge will provide you with a Commissioning Report for the Dual Fuel Kit, which you can submit to your state pollution control board as proof of compliance with DG emission standards.
Dual fuel technology has been effectively used worldwide for over 40 years, originally developed for oil rigs to utilize flared gas in DG sets, reducing diesel consumption. It has been adopted in India since 2008, coinciding with the availability of gas.
Upcharge’s Dual Fuel kit, with a successful track record of 5 years, includes several mechanisms to mitigate failure risks:
In case of any system fault, the engine seamlessly switches to 100% diesel operation without halting. We receive notifications of such incidents, and our service team is dispatched within 48 hours for investigation and necessary action.
The installation of Upcharge’s Dual Fuel Kit involves minimal modification. It primarily consists of fitting our Air Mixer before the turbocharger, which is then connected to the gas train and the fuel control valve. Our dual fuel diesel-to-gas conversion technology is designed as a retrofit solution. It’s a plug-and-play model, ensuring there’s no need to alter the engine’s original design or any critical engine parameters.
The key aspect to ensure the safety of a DG set post-conversion to dual fuel control here is to effectively control the real-time injection of gas in the DG, based on the operating parameters of the DG. This is achieved through a gas governor, which is a position-control-based fuel control valve, responding within approximately 10-15 milliseconds. It operates in a closed-loop, controlled by a PLC-based system.
Moreover, there is continuous monitoring of several critical DG parameters, such as DG Load, Exhaust Temperature, and DG Vibrations, using various sensors installed on the DG set. These readings are fed back to the PLC system in real-time. The system then dynamically adjusts the gas injection quantity in a closed-loop manner, considering these parameters through the gas governor. This ensures safe and efficient operation at all times.
The Energas Dual Fuel Kit is compatible with high-speed diesel engines (1500 RPM). Our bifuel technology has been successfully installed in over 200 kits across various reputable diesel generator brands. These include Cummins, Volvo Penta, Kirloskar, Perkins, Mitsubishi, Caterpillar, MTU, and Baudouin, covering a range from 62.5 KVA to 3000 KVA.
However, it’s important to note that converting small-capacity diesel generators (under 62.5 kVA) is not feasible with our kit due to the lack of turbocharging mechanisms in these engines.