conversion of a diesel generator to - kraft power...diesel engine load, a dual fuel engine will...

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Heinzmann Dual Fuel Solution

Conversion of a diesel generator to enable safe operation on a mixture

of diesel and natural gas fuel.

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When converting a diesel engine to a Dual Fuel engine as a retrofit solution, an additional gas system is installed on the engine to enable the engine to operate mainly in gas mode and to use the diesel fuel primarily as pilot injection.

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Due to physical limits, Kraft Power and Heinzmann highly recommend that the engine operation in Dual Fuel mode is limited to a maximum engine load of 80% The effective, final values are dependent on the engine, the engine condition, gas composition and other influence factors which have to be ascertained individually for every engine.

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In Dual Fuel mode, • Below 20% of diesel engine load, coking may occur and result in damage of the injectors; so below 20% diesel engine load, a dual fuel engine will operate completely on diesel. • Above 80% of diesel engine load, engine knocking and high temperatures can be experienced; so above 80% engine load, a dual fuel engine will operate completely on diesel.

One major effect in Dual Fuel mode is the increasing combustion temperature compared to normal diesel operation.

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The Heinzmann dual fuel solution monitors exhaust temperature and engine knock to help keep the engine operating within safe limits, avoiding engine damage possible from higher combustion temperatures of gaseous fuels.

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Project Scope

• Install Dungs Fuel Train • Install regulator • Install all fuel vent and safety lines • Install mixer body (1) between air cleaner and turbo • Remove Woodward actuator and speed controller • Install Heinzmann actuator and Pandaros Speed

controller • Install Heinzmann detonation (knock) Controller • Install Heinzmann Theseus Generator Controller

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Equipment: Kohler 600 REOZD mobile generator, manufactured in 2006. Under 2,000 total run hours prior to conversion to bi-fuel.

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Mitsubishi S6R Six Cylinder Diesel Engine.

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Original Woodward Pro-Act governor actuator will be replaced with an updated HEINZMANN actuator to improve performance. This is an optional component replacement.

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Original placement of battery charger; will be relocated to make space for new control panel.

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Air filter will be relocated to accommodate installation of gas fuel mixer.

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Original Kohler controller- will be optionally replaced with Heinzmann Theseus generator control

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Original Placement of Speed Pickup.

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Woodward Pro-Act speed controller – will be optionally replaced with Heinzmann Pandaros speed control for diesel operation.

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Charger has been relocated, and battery disconnect switch added to provide for choice of external shore power or onboard DC power supply.

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Mounting of Tone wheel and Hall-effect speed Sensor

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Mounting of Dungs Fuel Train – Zero pressure regulator and two gas shutoff valves.

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New Gas Piping

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Balance Lines for Gas Regulator.

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Vent Regulator- controls venting of unburned gas to evacuate gas from container.

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Drill and Tap Head Bolts for Knock Sensors on each cylinder head

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Knock Sensors Installed. Knock system is a critical safety device to protect the engine from detonation damage.

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Installation of Exhaust Temperature Sensor. Natural gas will increase exhaust temperatures and must be monitored to maintain temperature within safe limits.

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New Throttle Body and Mixer. Gas will be mixed into air flow between air cleaner and turbocharger.

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Stainless steel flexible fuel line from fuel train to throttle body.

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Mounting of New Stg 2040 Heinzmann speed control actuator to control diesel fuel flow.

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Mounting Brackets for Air Cleaner and Control Panel

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New Control Panel Installation

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Natural Gas Piping and Regulator

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External Fuel Connections

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Control Panel –includes Theseus generator controller. AC Power inverter added to allow for AC shore power.

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Heinzmann Pandaros digital speed controls for diesel and gas actuator control, with Ariadne knock protection control. System will reduce gas flow and load when detecting knock conditions.

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Control Panel User Interface

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Speed Governor 100% load off and 100% load on. Load response in diesel mode significantly faster with Heinzmann speed controls compared to original Woodward 2301.

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Natural Gas fuel control at 50% load (300kw). Gas actuator follows diesel actuator.

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Knock Detection at 50% load. Monitoring individual cylinders, if knock out of allowed range gas supply is reduced or shut off. If knock continues, engine will shut down.

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Thank You!

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