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Gaseous Fuel System forOn-Road Diesel Engines
Technology Overview
Co-firing of diesel fuel and natural gas 50% ~ 75% natural gas use
No engine modifications required Compression ignition –no spark plugs No power loss / equivalent efficiencies Retrofit kit Easy to install
Technology Overview Continued…
Designed for severe on-road service Fail-safe design; system automatically defaults to
100% diesel mode Automatic switching of fuel modes Electronic monitoring of critical parameters Compatible with turbocharged and normally
aspirated diesel engines
Gaseous Fuel Advantages
Reduced operating costs Fuel flexibility
Vehicle can operate on 100% diesel fuel if required
Lower cost vs. spark-ignited gas engines Compatible with compressed natural gas (CNG)
or liquefied natural gas (LNG) fuel storagesystems
Compatible Diesel Engines
4-cycle Turbocharged Normally aspirated Mechanically fuel injected using in-line pump
or common fuel rail some rotary / distributor-type pumps not
compatible limited compatibility with electronic engines new kit under development that will be compatible
with most electronic diesel engines
Typical Applications
Buses Refuse haulers Delivery trucks Dump trucks Short-haul cargo
carriers (CNG) Long-haul cargo
carriers (LNG)
GFS Kit –Safe by Design
All high pressure gas components UL listedand/or CSA approved
Gas supplied to engine at atmospheric pressurereducing possibility of over-fueling
Gas concentration in engine combustion air isless than 3% by volumemixture is non-explosive / non-flammable until
compressed in the combustion chamber
CNG / LNG on-board fuel systems haveexcellent safety history worldwide
Natural Gas Overview
Pipeline quality natural gas composed primarily ofmethane (C1)
Odorless, colorless, formless gas Lower explosive limit (LEL) 5% by volume Upper explosive limit (UEL) 15% by volume Approximately 1000 Btu per cubic foot Approximately 37 MJ per cubic meter
Low energy density compared to diesel fuel
Comparison of Natural Gas andDiesel Fuel
1 gallon no. 2 diesel equivalent to 130 standardcubic feet of natural gas
1 liter of no. 2 diesel equivalent to 1 cubic meterof natural gas
1 gallon of liquid natural gas (LNG) equivalent to0.60 gallon no. 2 diesel
1 liter of liquid natural gas (LNG) equivalent to0.60 liter no. 2 diesel
Gas Ratio vs. Duty Cycle
Urban duty cycletypically yields 50%to 65% gas ratio
On-highway dutycycle typically yields65% to 75% gasratio
Mixed duty cycle willresult in variable gasratio
Estimating Gas StorageRequirements
Typical diesel fuelconsumption per dayor route
Estimated maximumgas substitution forduty cycle
Refuelingopportunities?
Gas Storage Calculation
Urban bus using 170 liters of diesel / day Fueled at yard –1 x day Estimated gas ratio of 60% 40% diesel = 68 liters / day (170 x .40) 60% natural gas = 102 cubic meters
CNG storage = 102 cubic meters LNG storage = 143 liters (102 liters x 1.4)
Fuel Cost Savings
Based on cost differential between CNG or LNGand diesel fuel
Large cost differential between diesel and CNGor LNG results in rapid ROI
High fuel consumption applications result inlarger savings Light-duty diesels may not generate
adequate savings due to low fuelconsumption
Calculating Fuel Cost Savings
Cost of diesel / unit Cost of CNG or LNG / equivalent energy unit Average daily diesel consumption before
conversion Average daily diesel consumption + average daily
CNG or LNG consumption after conversion Savings / day x operating days / year = savings
per year
Sample Saving Analysis
Assumptions:Urban bus duty cycleNormal daily diesel consumption of 170 litersDiesel cost of $1.00 / literCNG cost of $0.45 / cubic meter60% average gas substitution260 operating days / year
Savings Calculation
Average daily diesel fuel consumption of 170liters = $170 / day fuel cost
Average daily diesel fuel consumption afterconversion is 68 liters = $68.00 / day diesel cost based on 40% diesel use
Average daily CNG consumption after conversionis 102 cubic meters x 0.45 = $45.90 / day CNGcost based on 60% gas use
Daily savings = $170 –($68 + $45.90) = $56.10 Annual savings = $56.10 x 260 days = $14,586
GFS Kit ComponentsOn-Road CNG / LNG
Applications
GFS Conversion Kit
Kit Contents
Gas Train Diesel Fuel Controller Air-Gas Mixer Electronic Controller Wiring Harnesses Optional CNG Level Display System Status Indicators Installation Manual
Items not included
CNG Cylinder(s) LNG Tank(s) Mounting Brackets CNG / LNG Fill Valve Manual Isolation Valve High Pressure Tubing Mechanical Pressure Gauge
GFS Air-Gas Mixer
High efficiency design Integral gas power
valve Aerospace quality
materials andconstruction
No moving parts Mil-spec anodized
finish for long servicelife
Mixer Installation
Installed upstream ofturbo compressor inlet
Mixer kit includes humphoses and clamps
Air flow directionindicated on mixerbody
Available in 3”, 4”, 5”and 6”diameters(76.2mm, 101.6mm,127mm and 152.4mm)
Air-Gas Mixer with Hump HoseAdaptors
Air-Gas Mixer Markings
GFS Gas Train
High Pressure Regulator
UL Listed 38N5 Rated for 3600 psi /
24,840 KPa Pressure relief device Factory-set outlet
pressure Water jacket heated
to prevent ice crystalformation
Long service life
Gas Solenoid Valve
CSA Approved Rated for 3,600 psi /
24,840 KPa 2-way normally closed
design is fail-safe Weather-proof
electrical connection 12 Volt DC operation
Low Pressure Regulator
UL Listed 792G Rated for 312 psi /
2153 KPa inletpressure
Gas delivered atatmospheric pressure
Long service life Easily rebuilt in-field
Gas Train Installation
Installed adjacent toair-gas mixer
Flexible fuel hoseconnection to mixer
6mm compressionfitting included
Safely secured usingfour mounting lugs
Diesel Fuel Control Devices
Diesel Fuel Control Valve
Controls fuel pressureto injection pump orengine fuel rail
Fail-safe, 3-way valvedesign; 100% dieselflow when de-energized
DIN rated electricalconnection / 12 Volt DC
Inlet and outlet portsSAE spec for leak-tightinstallation
Installation of Diesel Fuel ControlValve
Installed upstream ofinjection pump / fuelrail inlet
Leak-tight tubefittings and banjoadaptors included inkit
Fuel hose assemblyrated for 250 psi /1725 KPa
Installed off-engineon chassis rail orbulkhead
Aneroid Control Valve
Used with aneroid-controlled injectionpumps
Controls engine boostpressure to injectionpump aneroid device
Fail-safe 3-way valvedesign
DIN rated electricalconnection / 12 Volt DC
Installation of Aneroid ControlValve
Installed upstream ofinjection pumpaneroid device
Leak-tight tubefittings and adaptorsincluded in kit
Tube assembly ratedfor 100 psi / 690 KPa
Installed off-engine onchassis rail orbulkhead
Electronic Control Unit
Electronic Control UnitComponents
Controller Gas Pressure
Transducer Exhaust temperature
thermocouple Wiring Harnesses Indicator Lamps Optional CNG level
indicator
Controller Functions
Engine exhaust gastemperaturemonitoring
CNG / LNG pressuremonitoring
System statusindicators
Display of CNG level Automatically switches
engine to diesel modeif fault detected
Installation of Electronic ControlUnit and Accessories
Control unit mountedinside cab / undervehicle dash
Gas pressuretransducer installed ingas train
Status lamps andoptional CNG levelindicator installed invehicle dash
12 Volt DC powered
Installation Requirements
8 to 10 man hours No special tools
required Some fabrication of
brackets may berequired
Commissioning can bedone on-road or usingchassis dynamometer
Off-Road Applications
Locomotives Earth Moving
Equipment Mobile Cranes Construction
Equipment Yard Tugs
Conversion Systems for Large DieselEngines
400 h.p. to >3,000 h.p. CNG / LNG compatible Sophisticated engine protection systems 50% ~ 80% natural gas use depending on engine
model and gas quality Technology proven on over 900 MW of power
generation applications
1317 Shotgun RoadWeston, Florida 33326
++(1) 954.693.9657 (ph)++(1) 954.472.1447 (fax)
www.gfs-corp.net