InteliBifuel Controllers Brochure 2012-08 CPBECIBC

InteliBifuel controllersTHE PRACTICAL DUAL FUEL CONTROL MANAGEMENT SOLUTION FOR DIESEL ENGINE APPLICATIONS

Substitute up to 70 % of your diesel consumption with gas Reduce your operational costs substantially

Fuel costs per year

0%

20%

40%

60%

80%

100%

100% 70%

30%

Before After

Fuel consumption at nominal output

Case study of CAT 3512B, 1500 kVA, 1500 RPM

$0

$300000

$600000

$900000

$905851

$38430

$271755

Before After

Diesel Gas

Substantial Fuel Savings & Operational costs

Extended Run Times without refueling

Manufacturing & production factories On shore/off shore drilling rigs and operations Data centers Shopping complexes Municipal systems Wastewater treatment Financial institutions Healthcare facilities Other critical installations

9Continuous operation 9Prime Power applications 9Standby power 9Peak shaving & Peak saving

Benefits

10 days extended run time without refueling due to

70% gas substitution rate

Normal run time

with standard

diesel tank

FUEL

2 COMAP INTELIBIFUEL THE PRACTICAL SOLUTION

Greener Energy

Other important benefits and features

ComAp Bi-fuel is a more environmentally friendly solution for Diesel engines

Emission reductions possible: Reduction of CO2 5% to 20% Reduction of NOx 30% to 40% Reduction of SOx 70% to 100% Reduction of Particulate emissions (PM) up to 50%

Together with the option of the fitment of a catalytic convertor, significant reduction of CO can also be expected (please enquire at [email protected]).

Fuel flexibility Maintenance savings longer oil life and increased periods between required maintenance intervals No de-rating of engine power output or performance ideal for transient loads Fully automatic and dynamic solution which will safety maximize the substituted gas All engine parameters are kept withing the limits specified by the engine manufacturer: Engine boost air and exhaust temperatures measurement, monitoring/protection Minimum & Maximum Gas pressure measurement, monitoring/protection Comprehensive Knocking detection system Frequency sensors fitted to every cylinder (InteliBifuel 20) Diesel portion mapping and measurement Actual Load measurement Minimum Load gas protection

Smooth transition between diesel and bi-fuel modes at any time Non intrusive solution no change of any engine partsrequired

Gas/diesel ratio display Full history files recording Remote monitoring, control and configuration via PC or viainternet

COMAP INTELIBIFUEL THE PRACTICAL SOLUTION 3

Solution

The Bi-fuel principle is based on adding gas to the engine (this can be also perceived as an addition of an alternative energy e.g. the gas).

Generator engines are typically governed and therefore must maintain the same RPM at all times, when an alternative energy (the gas) is introduced to the governed engine there is simply less energy (orpower) required to be delivered by the engines diesel governor. This allows InteliBifuel to control precisely the amount of gas being introduced to the engine and in doing so enable lower quantities of diesel to be used to provide the power. The diesel engine principal does not change the engine is still dieseling and the diesel fuel is required to provide 30% of the engine power, parts lubrication, cooling and as an ignition source for thegas.

ComAps quality and fully automated InteliBifuel solution ensures that all key engine safety parameters are met at all times. Should any engine parameter move towards a maximum limit, the amount of gas will automatically decrease and adjust itself and should any of the engine manufactures parameters be exceeded for any reason, gas is immediately stopped and the engine continues to operate on 100% diesel without any interruption of the power supply. By this principle InteliBifuel achieves the highest possible gas/dieselratio.

On the next page is an example of ComAp InteliBifuel system used in paralleling gensets application. However, InteliBifuel can be configured for various applications: pumps, frac trucks, heavy mining trucks, locomotives, ships, etc. Please contact [email protected] for more information.

How it works

Frequently asked questions

1. How much diesel can be replaced?Depending on the type of engine typical gas/diesel ratios after conversion are up to 70%gas/30%diesel. There are additional factors which can also affect gas/diesel ratios such as: engine condition, ambient weather conditions at the site, site load variability, and gas quality etc. 2. Is my engine suitable?Yes. Any 4 stroke diesel engine is generally suitable.3. Will Bi-fuel affect engine performance?No, the engine performance will remain the same as before the conversion. The engine can still operate up to full or maximum load at any time; itshould be noted that the best gas/diesel ratios are normally achieved at around 80% of nominal engine power, which is usual for a continuous operation. When the engine needs to operate above 80% of nominal engine the ComAp InteliBifuel automatically decreases the amount of gas. Also the engines response to load steps and transient loads or changes will remain exactly the same as before theconversion.

4. Does ComAp InteliBifuel system interfere with the existing control system on my engine?

No, InteliBifuel does not interfere with the existing engine control system nor does it control the engine in any way or stop the engine at any time. InteliBifuel is mainly concerned with the precise control of thegas and protection of the engine when operating in Bi-fuel mode. Gas is only introduced to the engine once the engine has already started and is running on 100% diesel.5. What warranty or guarantee is provided

byComAp?ComAp has a standard two year warranty for allComAp products.6. What types of gases can be used?ComAp InteliBifuel will safely maximize the use of any available combustible gas, i.e. natural gas, well gas, bio gas, landfill gas, propane gas, coal gas, CNG, LNG. ComAp provides a free gas suitability feedback service where you can send any gas analysis to: [email protected]


MAINS

LOAD

GEN-SET

GEN-SET

INTERNE

T

REMOTE

CONTR

OL ROOM

GEN-SET

InteliBifue

l CU

J1939

InteliBifu

el CU

J1939

InteliBifue

l CU

J1939

InteliBifue

l

DENOX 2

0

InteliBifue

l

DENOX 2

0

InteliBifuel

DENOX 20

InteliCom

pactNT MIN

T

InteliCom

pactNT MIN

T

InteliCom

pactNT MIN

T

MainsCom

pactNT

IL-NT GPR

S

IL-NT GP

RS

IL-NT GPR

S

IL-NT GPR

S GAS T

HROTTLEVALV

E

SHUTOFF

VALVES

GAS THR

OTTLE

VALVE

SHUTOF

F VALVES

GAS THR

OTTLE

VALVE

SHUTOF

F VALVE

S

FLYWHEE

L

CAMSHA

FT

BOOST A

IR

TEMPER

ATURE

SENSOR

EXHAUS

T TEMPE

RATURE

SENSOR

AIR FILT

ER

AIR

GAS

TURBO C

HARGER

KNOCKIN

G

SENSOR

EXHAUS

T

GAS TRA

IN

GAS TRA

IN

GAS TRA

IN

GAS INLE

T

GAS INLE

T

GAS INL

ET


Key Elements of the system

The InteliBifuel CU is the highly flexible main control unit of the ComAp fully featured InteliBifuel solution. This sophisticated Bi-fuel (dual fuel) controller has outstanding monitoring, protection and control features including allocation for J1939 protocol and/or sensors that may be used in order to convert any type of diesel engine to Bifuel operation.

The InteliBifuel CU protects the engine during Bifuel operation by controlling the gas throttle valve and gas shut off safety solenoid valves preventing the engine from exceeding any critical safety parameters.

This advanced controller is designed to communicate through both standard and proprietary CAN J1939 communication protocols to a wide range of EFI engines including: Caterpillar, Cummins, Detroit Diesel, Deutz, GM, Isuzu, Iveco, John Deere, MAN, MTU, Perkins, Scania, Sisu, Volvo Penta and others.

Benefits:

Integrated solution with hardwired safetyfunctions Full communication support of engines with ECU access to information from ECU via Modbus

Event driven History recording, easy backtracking and problem solving

Slave panels available economical solution for remote control

Integrated clutch control less wiring andcomponents

Many types of communication Perfect price/performance ratio Built-in PLC-integrated control of technology

Features

14 binary inputs, 14 binary outputs, 8 analog inputs RS232/Modem/Modbus/Internet communication Engine measurement from sensors or via J1939 Input/output and J1939 configuration Bifuel running hour meter Sealed membrane panel to IP65 Operating temperature: -20 to +70 C regular unit -40 to +70 C low temperature unit

3 level password protection InteliBifuel controller meets several forcing counter standards (EN, UL, CSA, NFPA)

Configurable PLC functions

Logical functions: AND, OR, XOR, RS Comparators with delay or with hysteresis Analog switch from two inputs to one output Mathematical functions: ADD, SUB, MAX, MIN, AVG

Linear interpolation, Moving average PID loops with analog or binary outputs Counters, Timers, Delay functions History and protection forcing Ramp Up/Down, Inc/Dec, Jump

Extension module and remote display possibilities

up to 1 I-AOUT8 (Analog Outputs ExtensionModule)

up to 4 IGS-PTM (Input/Output Module) up to 4 IS-AIN8 (Analogue Input Module) up to 3 IS-BIN16/8 (Binary Input/Output Module) up to 4 IGL-RA15 (Remote Annunciator) up to 2 I-RD-CAN (Remote Display with CANBusInterface)

InteliBifuel CU


Key Elements of the system

InteliBifuel DENOX 2 InteliBifuel DENOX 20

InteliBifuel DFM

Anti knocking device Field proven solution of knocking detection Integration with InteliBifuel CU controller via Analog and Binary outputs

Parameters for adjustment accessible via DenEdit software

2 monitoring channels Each channel can be configured for single cylinder monitoring or for the monitoring of neighbouring cylinder

Suitable for all inline engines up to a maximum of 6 cylinders

Anti knocking device Field proven solution of knocking detection Integration with InteliBifuel CU controller via Analog and Binary outputs

Parameters for adjustment accessible via DenEdit software

Up to 20 monitoring channels Each channel can be configured for single cylinder monitoring up to 20 cylinders

Suitable for engine up 20 cylinders

Dual-Fuel Module interface unit for InteliBifuelCU controller with Speed governor and Dieselactuator

Gas throttle valve servo control loop Diesel consumption measurement via currentloop

Package Order code

InteliBifuel 2InteliBifuel CUInteliBifuel DENOX 2 InteliBifuel DFMSoftware and documentation

IBF-2

InteliBifuel 20InteliBifuel CUInteliBifuel DENOX 20InteliBifuel DFMSoftware and documentation

IBF-20

Order codes


References

Mexico | Simply Integrated Solution

Ottomotores Largest genset packager in Mexico Ottomotores offers Bi-fuel range of gensets with ComAp InteliBiFuel as standard product

Multiple projects carried out in 2012 with following engines: Perkins 2806, 2206; Cummins QSK60-G6, QST30-G4

Nigeria | Short Payback Period

Dangote Pasta Caterpillar 3512B 1200 kW gensets Short payback period less than 2 months

Prime power operation Natural gas


Russia | Extreme Climatic Conditions

Severo-Khosedayuskoe Energocentrum

Cummins KTA50 gensets Cummins QSK60 gensets

Prime power operation Natural Gas Extreme conditions Siberia

Romania | Oil & Gas Environment

Eneria Romania Caterpillar 3512B 1200 kW gensets Remote location oil platform, Black sea

Prime power operation Natural gas


Examples of converted high speed engines


Brand Type DG set Output

Caterpillar 3300 series 150 kW 220 kW



Caterpillar C15 series 500 kW

Caterpillar C18 series 400 kW 500 kW

Caterpillar C27 series 800 kW

Cummins KTA series 400 kW 1200 kW

Cummins QSK series 1100 kW 1800 kW

Cummins QST series 650 kW 800 kW

Cummins VTA series 500 kW 600 kW

Deutz TBD series all outputs

MAN D2842LE201 400 kW

Mercedes OM444LA/12183TB83 440 kW

Mitsubishi SR6-PTA 440 kW 600 kW

Mitsubishi S12R-PTA 1285 kW

MTU 18V2000 1000 kW

MTU 20V4000 2200 kW

Perkins 2206D-13TAG3 400 kW

Perkins 2306C E14 TAG1A 280 kW

Perkins 2506C E15TAG3 450 kW

Perkins 2806C-E18TAG3 600 kW

Perkins 2806A-E18TAG2 560 kW

Perkins 3012TAG2A 580 kW

Perkins 4006-23TAG3A 600 kW

Perkins 4012-46TAG2 1200 kW

SCANIA DC series 225 kW 520 kW

Volvo TD series all outputs

About ComAp


ComAp is a dynamic international company with a solid reputation for delivering innovative electronic solutions to the power generation, industrial engine and equipment markets. By providing customers with state-of-the-art products, ComAp has built aname for delivering excellent reliability and goodvalue.

Excellent and reliable product solutions

ComAp specializes in creating electronic control and management solutions for use in the power generation industries and drive power markets. Our portfolio of products, software and accessories is designed to support emergency power, standby power generation and engine driven applications all over the world. We also work closely with our customers todevelop unique customized and turn key solutions for ordinary and extraordinary applications delivering high standards of excellence on every project.

Professional partnerships

ComAps extensive global distributor network means that our products are locally available in almost 100 countries, spanning every continent in the world. Through our professional and highly dedicated global distributor network wecan satisfy customers needs, however challenging. People make the difference

ComAps key strengths are flexibility, experience, knowledge and enthusiasm. This blend of values defines our personality and gives you the assurance of a truly honest and positive relationship. By supporting our people, investing in their development and encouraging creativity, our teams work hard to find new opportunities, technologies and solutions that enable us to successfully help our customers solve their problems effectively.

At ComAp, we believe passionately in the importance of continuously developing new technology along with forward thinking software and hardware to maintain the enviable position as worldwide leader in communication and control forpower generation and drive powerapplications.

ComAp, spol. s r. o.

Kundratka2359/1718000Praha8CzechRepublic

Phone:+420246012111Fax:+420266316647

[email protected]

Manufacturer

Local Distributor / Partner

Customer satisfaction is our mission. We continuously develop the best people to succeed in our mission.

ComAp. Features and specification are subject to change without prior notice 2012-08/CPBECIBC

InteliBifuel Controllers Brochure 2012-08 CPBECIBC

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