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InteliBifuel controllers

THE PRACTICAL DUAL FUEL CONTROL MANAGEMENT SOLUTION FOR DIESEL ENGINE APPLICATIONS

Benefits
Substantial Fuel Savings & Operational costs
 Substitute up to 70% of your diesel consumption with gas  Reduce your operational costs substantially

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


100% $900 000

Diesel

Gas

80% $600 000 60%

100%
40%

70%

$905 851

$300 000 20%

$38 430

0%

30%

$0

$271 755

Before

After

Before

After

Fuel consumption at nominal output

Fuel costs per year

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

FUEL
Normal 10 days extended run time run time without refueling due to with 70% gas substitution standard rate diesel tank

99Continuous operation 99Prime Power applications 99Standby power 99Peak shaving & Peak saving
2 COMAP INTELIBIFUEL THE PRACTICAL SOLUTION

Greener Energy
 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 bifuel.support@comap.cz).

Other important benefits and features


 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

Solution
How it works
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 bifuel.support@comap.cz for more information.

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: bifuel.support@comap.cz

COMAP INTELIBIFUEL THE PRACTICAL SOLUTION

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COMAP INTELIBIFUEL THE PRACTICAL SOLUTION

Key Elements of the system


InteliBifuel CU
 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 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.  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)

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.

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

COMAP INTELIBIFUEL THE PRACTICAL SOLUTION

InteliBifuel DENOX 2

InteliBifuel DENOX 20

 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

InteliBifuel DFM

Order codes
Package InteliBifuel 2 InteliBifuel CU InteliBifuel DENOX 2 InteliBifuel DFM Software and documentation Order code IBF-2

 Dual-Fuel Module interface unit for InteliBifuelCU controller with Speed governor and Dieselactuator  Gas throttle valve servo control loop  Diesel consumption measurement via currentloop

InteliBifuel 20 InteliBifuel CU InteliBifuel DENOX 20 InteliBifuel DFM Software and documentation

IBF-20

COMAP INTELIBIFUEL THE PRACTICAL SOLUTION

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 2months  Prime power operation  Natural gas

COMAP INTELIBIFUEL THE PRACTICAL SOLUTION

Romania | Oil & Gas Environment

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

COMAP INTELIBIFUEL THE PRACTICAL SOLUTION

Examples of converted high speed engines


Brand Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Cummins Cummins Cummins Cummins Deutz MAN Mercedes Mitsubishi Mitsubishi MTU MTU Perkins Perkins Perkins Perkins Perkins Perkins Perkins Perkins SCANIA Volvo Type 3300 series 3400 series 3500 series C15 series C18 series C27 series KTA series QSK series QST series VTA series TBD series D2842LE201 OM444LA/12183TB83 SR6-PTA S12R-PTA 18V2000 20V4000 2206D-13TAG3 2306C E14 TAG1A 2506C E15TAG3 2806C-E18TAG3 2806A-E18TAG2 3012TAG2A 4006-23TAG3A 4012-46TAG2 DC series TD series DG set Output 150 kW220 kW 200 kW650 kW 700 kW2000 kW 500 kW 400 kW500 kW 800 kW 400 kW1200 kW 1100 kW1800 kW 650 kW800 kW 500 kW600 kW all outputs 400 kW 440 kW 440 kW600 kW 1285 kW 1000 kW 2200 kW 400 kW 280 kW 450 kW 600 kW 560 kW 580 kW 600 kW 1200 kW 225 kW520 kW all outputs

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COMAP INTELIBIFUEL THE PRACTICAL SOLUTION

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 INTELIBIFUEL THE PRACTICAL SOLUTION

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Manufacturer

ComAp, spol. sr.o.


Kundratka 2359/17 180 00 Praha 8 Czech Republic Phone: + 420 246 012 111 Fax: + 420 266 316 647 info@comap.cz www.comap.cz
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