DUAL FUEL CONVERSION SYSTEMS

HUEGLI
TECH
SWITZERLAND
DUAL FUEL CONVERSION FOR HIGH SPEED DIESEL ENGINES

HUEGLI TECH offers an innovative retrofit technology to con- This kit is an inexpensive method to get an existing high
vert high speed diesel engines to operate reliably and effici- speed diesel engine running on dual fuel and significantly
ently in dual fuel mode, i.e. typically with 25% diesel fuel and reducing fuel costs while retaining the full output power and
75% natural gas, or other gaseous fuel. flexibility of the original engine.

No internal modifications to the diesel engine are required; The larger the engine and the higher the annual running
the standard compression ratio and pistons etc. are retained. hours, the shorter the payback period will be.

Note: Our system dynamically controls both fuels simultane- Return of Investment: Can often be less than 6 Months
ously, allowing better response to load changes than a pure
gas engine, whilst maximising cost savings in steady-state
conditions. The Benefits
• Save money with cheaper fuel
HUEGLI TECH has developped a comprehensive range of key
components, allowing each system to be tailored to meet in- • Simple conversion is cost effective
dividual customer requirements. • Low pressure gas compatible

The system automatically compensates for variations in gas • 100% power with diesel or dual fuel
quality and availability and will continue to function as a pure • Fast response time
diesel engine if the gas supply is interrupted. This allows for
• Improved dynamic performance
maximum utilisation ofthe most cost-effective gaseous fuels
and tarriffs. • Running clean gas can extend service intervals

Virtually unlimited Applications e.g

• Gensets converted to use associated gas at oil wells

• Biogas generators on farms turn waste into electricity

• Biofuel/natural gas CHP applications (where the liquid fuel

is cheaper but may be subject to shortages until the supply
infrastructure improves)

2
TARGET - OPERATING PRINCIPLE

Target Dynamic Performance

The development target was to combine simplicity with high The HT-SG105 and the HT-SG100 control the fast responding
tech components to safely operate the engine at an opti- electric actuators
mised diesel fuel/gas ratio of at least 25%/75%, and to main- in such a way to optimise economy in steady state and dy-
tain the same power output and response to load changes namic performance during load steps.
as the original diesel engine.
Protection and Safety
Operating Principle The system protects the engine against harmful situations.
The HT-SG105 Dual Fuel Module sets the amount of injected Each cylinder exhaust temperature is monitored individu-
diesel fuel via the diesel actuator (with positional feedback ally. If the temperature should exceed the set (safe) limit,
sensor) linked to the fuel pump. Simultaneously, the HT- the DFC-2000 control reduces the gas portion, and increases
SG100 also regulates the amount of gas into the special air/ the diesel fuel portion.
gas blender by means of a throttle body. The air/gas mixture All combustion engines are susceptable to harmful kno-
then passes through the turbo charger, through the inter- cking (Detonation), but gas-fuelled engines, running hotter,
cooler and into the engine. The requested engine speed are more prone than liquid fuelled ones. We strongly recom-
is controlled by the governor,which measures the engine mend the use of an anti-knocking control system. Multiple
speed at the engine ring gear via a speed sensor. Both, iso- knock sensors continually monitor engine vibrations, and
chronous or droop mode are possible. the Antiknock Controller uses these inputs to ensure that
the engine can be run close to, but still within the knocking
threshold.
As an option, and as an additional protection against over-
speed, etc, one or two solenoid-operated air intake shutoff
valves can be supplied.

HUEGLI
TECH
SWITZERLAND

3
QUALITY

Whilst looking to minimise the conversion costs, no compromise was made regarding quality. All components are of top
quality and offer utmost reliability, at an affordable price!

Fuel Economy Savings

A Dual Fuel conversion is a perfect investment for power To determine approximate cost savings you will need to be
users who are looking to upgrade their current system to al- aware of your present fuel cost. The fuel replacement per-
ternative fuel technology, without revamping their entire sys- centage and replacement cost with natural gas is in the ratio
tem. As a retrofit technology, the HT-SG105 system provides of approx: 25 / 75, but also can be lower. Be sure to apply any
an economically attractive alternative to buying costly new losses of efficiency and always estimate on the safe side.
generators. Ask a HUEGLI TECH representative to help you in determining
With the ability to utilise both fuels, the engine will never your projected annual cost savings including fuel and main-
be down due to a lack of adequate gas fuel supply. Another
tenance.
distinct advantage of dual fuel is the decreased engine wear
When considering the cost of natural gas, also bear in mind
that comes with the use of cleaner fuel. Due to a reduction
that many suppliers are willing to give better rates if they are
of carbon soot build-up and cleaner lube oil, longer intervals
able to interrupt your fuel supply. A dual fuel engine, which
between service maintenance can be expected, sometimes
doubled. This means a longer economic life for the engine can continue to run on diesel alone if the gas is interrupted,
and a better overall return on your investment. allows the operator to take full advantage of these tarriffs
without compomising system availability.

The Benefits

Cost per hour vs Genset Power

! Uninterrupted power supply around the clock save
Cost/h (USD)
cost for production and investment!
160

140
The below comparison is based on average fuel and
120
Diesel 100% gas costs. An automatic calculation table is available
100
Dualfuel 70/30%
in Excel which allows calculating with any fuel cost.
80
Costsaving

60
60 USD/hour Please contact us so we can provide more informa-
40
tion to you.
20

0
0 150 250 350 450 650 1000 1450
Genset Power (kVA)

Cost per Year

Cost/Year (USD) (at 14 hours operating a day)

$800'000

$700'000

$600'000

Diesel 100%
$500'000
Dualfuel 70/30%
$400'000 Costsaving
300'000
$300'000 USD/Year

$200'000

$100'000

$0
0 150 250 350 450 650 1000 1450
Genset Power (kVA)

4
CONFIGURATION EXAMPLES

Overview Inline Engine 1 Mixer 1 Turbo

Note:
The Diesel Actuator has to be selected engine specific it will be either an integral or ecternal type !
The Gas Street has to be selected according the gas pressure supplied from the main line incoming to the building !
HUEGLI
TECH
SWITZERLAND

5
CONFIGURATION EXAMPLES

Overview V-Engine Single Mixer 2 Turbo

Overview V-Engine 2 Mixer 2 Turbo

Note:
The Diesel Actuator has to be selected engine specific it will be either an integral or ecternal type !
The Gas Street has to be selected according the gas pressure supplied from the main line incoming to the building !

6
Overview V-Engine 2 Mixer 4 Turbo

Overview V-Engine 4 Mixer 4 Turbo

HUEGLI
TECH
SWITZERLAND

7
THE INDIVIDUAL COMPONENTS

HT-DST4602
HT-DST4602 AMF and PARALLEL genset controller.
HT-DST4602 is a highly configurable gen-set controller designed to handle
a broad range of critical and complex parallel applications, including mul-
tiple Mains and CHP systems. It includes an internal load sharing unit that
allows simple implementation of Multiple Prime Mover applications. PLC
functions (including PID blocks) are available in this unit.
A split version with a separate display and base box is also available.

DFC-2000
DFC-2000 Temperature Control Module monitors the exhaust temperatures
and controls the Y-Flap and signals to the DFM if diesel fuel needs
to be increased to cool the combustion chamber.

Denox antiknocking control

Denox antiknocking control. Each individual cylinder is monitored and
protected against knocking.

HT-SG100
HT-SG100 is an isochronous speed governor tailored to communicate with
the HT-SG105 or HT-TPD100.
Features such as dual gain, switchable engine configuration, start smoke
limitation and overspeed etc. make this governor an ideal choice for dual
fuel applications.

HT-SG105
HT-SG105, Dual Fuel Control module takes control of the Gas actuator in-
dependantly. The unit is fitted with a load anticipation feature that simulta-
neously adjusts the supply of the Gas Fuel to reduce load transients to an
absolute minimum, often achieving better transient performance than the
original diesel engine.

HT-TPD100
HT-TPD100 is a dual actuator driver with balancing function. This unit can
also be used together with diesel engines that have two fuel pumps, such as
the Cummins QST 30 or some 8 and 12 cyl. Komatsu engines.

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Y-Flap
Y-Flap, a unique device that works with the DFC-2000 to control the gas flow
to the individual cylinder banks! This provides accurately balanced cylinder
bank temperatures.

ITB Actuator
ITB series actuators are designed for precise efficient metering of gas flow.
The actuator is mounted directly to the DF-5 mixer and features a proporti-
onal electromagnetically driven throttle plate. Two internal return springs
make this a normally-closed fail-safe design.

DF-5 Air Gas Mixer

DF-5 is a simple but effective air gas mixer designed specifically for dual-
fuel systems. It can be adapted to fit a wide range of induction system dia-
meters and the internal gas inlet tube can be optimised on-site.

Actuator Variouse Variouse actuators are available for the diesel fuel pump. We also offer inte-
gral as external solutions including position feedback.

HUEGLI
TECH
SWITZERLAND

9
TYPICAL APPLICATION

Project: CAT 3306

Custom specified conversion on a brand new CAT 3306 with CNG. Fuel ratio:
20% Diesel 80% Gas at 100% load. The engine was converted in our factory
in Switzerland. Test conditions: Ambient temperature: 28°C, humidity:40% re-
lative, resistive load bank.

Project: Volvo 1613G

Conversion made in Indonesia. Due to Air to Air cooled system it was pos-
sible reducing the diesel fuel down to 10% and 90% of natural gas at 100%
load. Final adjustment set to 30% diesel 70% gas. Ambient temperature 40°C.

Project: Cummins KTA 38

Conversion made in Jakarta. Ratio 30% Diesel 70% Gas. Cylinder Tempera-
ture balance within 1 to 3 degrees C° via Y-Flap. Ambient temperature 35-
38°C high humidity.

Project: Cummins KTA 50

Conversion made in Pakistan through R.A. Engineering. Fuel Ratio 30% Diesel
70 % Gas at 100% power.

Project: CAT 3412

Conversion made in USA. Fuel Ratio 30% Diesel 70% Gas.

10
SOME REFERENCES

Pakistan Cummins NTA 855, KTA 19, 38 and 50, all engines operating with 30% Diesel 70
% Gas. Total sets converted, 15 pcs.

Germany MAN 2840 1 pcs, engine operating with Bio Gas at 18 % Diesel, 82 % Gas.

Indonesia Volvo TD 710 6 Cylinder, 1 pcs. 30% Diesel 70 % Gas.

China Jinan 12 Cylinder 190, 1 pcs. Engine is operating with 20 % Diesel 80 % Gas.

Egypt CAT 3406 1pcs, engine operating at 28% Diesel, 72 % Gas.

China Jinan 12 Cylinder 190, 10 pcs. Engine is operating with 20 % Diesel 80 % Gas.

China Jinan 12 Cylinder 3012, 3 pcs. Engine is operating with 20 % Diesel 80 % Gas.

China Jinan 12 Cylinder 190, 100 pcs. Engine is operating with 20 % Diesel 80 % Gas.

China Application: Hydraulic Drill sets, world wide first time 3 engines parallel to
hydraulic in dual fuel mode.

USA CAT 3406 and Mitsubishi 6 Cylinder operating at 25% Diesel and 75% Gas.

Iran KTA-19 operating at 30% Diesel 70% Gas.

Indonesia KTA-38 operating at 35% Diesel 65% Gas.

Korea KTA-38 at 35% Diesel 65% Gas, all new HT-TECHNOLOGY

HUEGLI
TECH
SWITZERLAND

11
 used by qualified personnel and in compliance with the applicable regulations in force in order to avoid
Catalogue descriptions and details, such as technical and operational data, drawings, diagrams and
instructions, etc., do not have any contractual value. In addition, products should be installed and
The products described in this publication are subject to be revised or improved at any moment.

*due to pre-existing agreements not all products are available in every country
damages and safety hazards.

Local Distributor / Partner: HUEGLI TECH are active

directly or through agents in:

EUROPE
AUSTRIA, BALTIC STATES,
BELGIUM, DENMARK, EIRE,
FAEROE ISLAND, FINNLAND,
FRANCE, GERMANY, GREECE,
GREENLAND, ICELAND, ITALY,
MOLDAVIA, NETHERLANDS,
NORWAY, POLAND, RUMANIA,
RUSSIA, SPAIN, SWEDEN,
SWITZERLAND, UNITED
KINGDOM, TURKEY.
HUEGLI TECH © Features and specifications are subject to change without prior notice
FAR EAST AND AUSTRALIA
AUSTRALIA , BANGLADESH,
CAMBODIA, CHINA, HONG KONG,
INDIA, INDONESIA, JAPAN,
KOREA, LAOS MIANMAR,
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PHILIPPINES, SINGAPORE,
HUEGLI TAIWAN, THAILAND, VIETNAM.

TECH MIDDLE EAST AND AFRICA

SWITZERLAND
ALGERIA, EGYPT, IRAN, IRAQ,
DualFuel_BR_EN_03.2015

HUEGLI TECH AG (LTD) Solution Provider for: ISRAEL, LEBANON, SYRIA AND
Murgenthalstrasse 30 • Gas Management Systems NIGERIA, PAKISTAN, SAUDI
4900 Langenthal Switzerland • Dual Fuel Conversion Systems
Phone: +41 62 916 50 30 • Governing Systems
ARABIA, TUNESIA, UNITED
Fax: +41 62 916 50 35 • Automation Systems ARAB EMIRATES.
• Engine Protection
e-mail: sales@huegli-tech.com • Starting Solutions
www.huegli-tech.com • Battery Care
NORTH AMERICA
• Oil Treatment and Recycling USA, CANADA.
• Thermostatic Control Valves