Genforce | DFS Products

About GenForce® | DFS:

Dual Fuel system in generators will operate in the technology of simultaneous combustion of two fuels. Existing diesel injection considered as primary fuel, additional fuel such as gas (PNG / CNG / LPG) considered as secondary fuel system. In our case the primary fuel system is un disturbed to retain the same performance of existing generator.

GenForce DFS Technology:

GenForce DFS System for generators works by starting on Diesel fuel and then adding PNG until the mixture offers maximum efficiency. The generator can switch seamlessly between diesel-only and dual fuel operations, prevent- ing unwanted disruptions and downtime. The generator can also resume Operating with only diesel if the gas supply is not available

Another key benefit of the Dual Fuel System is that it can keep the engine power levels steady while using gas mode within the "continuous and "prime" ratings of the engine. If the opera- tion exceeds the set power limit, the engine automatically switches to 100% diesel mode, so there is no need to lower the engine rating. For applications with large load variations, our system allows for changing the gas substitu- tion rate based on a fuel vs. load map.

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Dual Fuel Technology :

Duel fuel technology, a well proven technology evolved in 1960s which is suited for diesel engines. In brief, Gas such as LPG/CNG/Hydrogen will be fed inside the combustion chamber along with air. Gas will combust along with diesel combustion during power stroke. Excess thermal energy produced by gas combustion will reduce the equivalent diesel quantity to maintain the same torque.

Dual fuel in genset consists of two systems as below

Gas induction system

Electronic control system

Our electronic control system, studies the diesel engine operating condition dynamically and will decide the gas injection to achieve the optimal substitution rate.

Gas induction system:

Gas from piped or storage (CNG), pressure will be reduced from the input pressure by pressure reducer to just above the atmospheric pressure, then metered quantity will be fed inside the inlet manifold depending on the load requirement. The quantity of fuel (metering) will be done by the electronic throttle placed just before the gas air mixture. To ensure the safety, a solenoid valve is placed just before the pressure reducer which opens only when required.

Gas air mixture carefully designed to create negative pressure to feed the gas inside the inlet manifold, without affecting the main air stream flow. A Zero pressure regulator used to maintain the constant outlet pressure irrespective of inlet manifold pressure variation

Electronic control system :

Standalone electronic control system used to meter the gas quantity. Sensors are used to identify the engine operating point, ECU decides the gas quantity and injected inside the inlet manifold through Electronic throttle body, which happens instantly and accurately. Various safety sensors like Manifold air temperature, Knock and Exhaust gas temperatures are used to ensure the engine safety. Since the retrofitment are with old engines, all the sensors are calibrated individually based on the engine’s present condition and safety parameters set accordingly. Fuel trim options are inbuilt in the ECU which will meter the gas quantity based on the sensor inputs.

ECU

The GenForce® | ECU

The GenForce® Dual Fuel System uses an advanced electronic control and monitoring system that tracks important engine and Dual Fuel System parameters and turns on or off gas mode based on programmed limits. If a tracked parameter goes beyond the acceptable limit, the controller switches the engine to 100% diesel mode and electronically records the fault for diagnostic purposes.

Advantages

GenForce® | DFS Advantages

It saves fuel costs by using cheaper fuels that is gas.
It reduces the environmental impact of flar- ing unwanted gases by using them as fuel, lowering emissions and carbon content (keeping the engine system and lubricants clean), and extending the Service Interval with cleaner or more efficient PNG.
It can extend runtime by switching between fuels when one runs low.
It can adapt to different situations by choos- ing the best fuel for the environment or the load.
It does not require Engines Modifications.
There is no power & efficiency loss.
Less refueling is required, which cuts down on the costs and risks of carrying & storing diesel fuel, especially to challenging places thereby enabling simplified logistics.
It has minimal hardware and extensive sensor & actuator controls, which make it easy to install, cost-effective, and highly effi- cient on dual fuel.
It can be used with other alternate fuels like CBM/Bio-Gas/Syn-Gas/Waste- Gas etc.

Protection:

GenForce® | DFS Protection:

Load-based governing using MAP, Knock & Lambda sensor. It is the pioneer controller for gas and diesel.

Safeties like EGT, Knock, Gas Pressure & Tem- perature & Coolant Temperature ensure safety. The system automatically switches to diesel mode if it detects any engine anomalies due to the above-mentioned safeties.

solution:

GenForce® | Unique Solution:

Certified Gas Train Components
ECU controlled gas quantity over the operation range
Proven Woodward USA ECU & Gas flow control unit
ECU & GFC unit – Certified for international standards
Can meet relevant regulation compliance (India DDF Regulation - on the anvil)
Built-in safety features – Knock & EGT based gas quantity control / cutoff
Consistent Best Performance and Reliability
Can provide DDF solution up to 5 MW

ECU & GFC unit:
- European Compliance
- Machinery Directive
- Pressure Equipment Directive
- ROHS Directive

ECU (70 pin) & GFC < 1250 KVA

ECU (112 pin) & GFC < 1250 KVA

Product

Dual Fuel System For all make of Generators

Dual Fuel system allows your diesel engine to use natural gas as its secondary fuel without modifying the engine or the diesel fuel system. DFS can be used for any make of genset upto 2000 KVA.

Dual Fuel Kit for Cummins Generators

Cummins Generators(Jackson Generators/Sudhir Generators)

Dual Fuel Kit for Kirloskar Green/KOEL Green Generators

Kirloskar Green/KOEL Green Generators

Dual Fuel Kit for Mahindra Powerol Diesel Generator

Mahindra Powerol Diesel Generator

About

Power With care

Power with Care is an initiative promoting responsible energy consumption and conservation. It aims to raise awareness about the environmental impact of energy usage and encourages individuals and businesses to adopt sustainable practices for a greener future.

Longer Life

More Saving

Low Maintainance

High Performance

We have installed a Dual Fuel conversion kit. This was done to reduce the emission and the running costs of the generator in addition to being in conformity with the pollution norms.
The DG Set and the Kit are running satisfactorily.

Aditya Urban Casa Apartment Owners Association

We have installed a Dual Fuel conversion kit. This was done to reduce the emission and the running costs of the generator in addition to being in conformity with the pollution norms.
The DG Set and the Kit are running satisfactorily.