Breathing new technology into (old) power equipment

ComAp Systems Saudi Arabia is a systems integrator providing a complete solution in power energy and fully automated systems alongside electrical & electronic control packages for the independent power generation market throughout the Middle East, Gulf area, Yemen and Sudan.

Besides the development of custom designed power energy management packages ComAp Systems also offers cost effective alternatives for upgrading control systems or converting diesel engines to bi-fuel operation to increase their performance and economize fuel usage. Both solutions utilize the latest state-of-the-art technology for generator or CHP power applications and bring significant benefits in terms of improved usability, cost saving and increased performance.

This article looks at two effective ways to give existing generator driven and CHP applications a new lease of life by upgrading the control systems and bi-fuel engine conversion.

Upgrading an existing generator or CHP control system
Maintaining old generator and power equipment can bring significant problems, particularly when faced with major repairs or the unavailability of discontinued spare parts. One option is to ‘patch-up’ and hope for the best, another is to replace the entire system with new equipment, a path chosen by many unaware of how easy and cost effective it is to simply convert and upgrade their existing equipment.

Upgrading an existing control panel can bring major benefits, not just updating what is already there, but also completely transforming what it can do – delivering new capability and improved performance.

The scope of any conversion project is determined by the age and make of the equipment, and most importantly what is needed from the equipment in the future. Almost anything is possible – from upgrading with new modular electronic controllers to the complete replacement of existing control panels, each conversion is designed to work in complete harmony with the existing generator and engine.

A typical control system conversion brings old and new technology together in perfect harmony with sophisticated electronic control equipment providing the interface with the existing parts of the system. This introduces state-of-the-art capabilities like remote communication (internet and mobile phone) or event logging for easy troubleshooting. It also provides operators the ability to increase system flexibility, improve serviceability and access a wider range of PC software tools for simpler monitoring and management.

Key features of ComAp Systems control system conversion:
• Cost-effective alternative to replacing the whole system
• Conversions incorporate state-of-the-art technology
• Improved serviceability and future availability of parts
• Offers improved capabilities such as remote communication
• Flexibility of use – make better use of what you already have
• Reduce business interruption

Conversion of diesel engines to bi-fuel operation
Bi-fuel conversion modifies an original diesel engine so that the engine operates on diesel and gas simultaneously. This means that the engine uses two fuels (gas and diesel oil) at the same time. Natural gas is intended as the main fuel and diesel oil is used for the ignition of the gas/air mixture inside the cylinder (a portion of diesel oil is injected at the end of the compression stroke, thereby maintaining the original diesel operation principle) and eliminating the need to make any modifications to the engine.

Bi-fuel conversion kits are available for both slow/middle speed and high speed engines, targeting all diesel and heavy fuel engines above 200kW. Slow/middle speed engines with a speed below 1000rpm and output above 500kW generally substitute around 70-90% natural gas for diesel or HFO. High speed engines operating between 1200 –1800rpm substitute around 50-80% natural gas for diesel.

The choice of an appropriate conversion kit depends particularly on the engine speed and consequent suction/exhaust valve overlap (i.e. opening of suction and exhaust valves at the same time). Slow/Middle speed engines normally feature a large valve overlap when the pure air is flushing (cleaning) and cooling the cylinder. After bi-fuel conversion, it is necessary to continue cylinder flushing/cooling by pure air so the gas flow into the cylinder during the valve overlap is interrupted to avoid the presence of gas in the hot exhaust manifold (this would cause a potentially dangerous situation and result in substantial fuel losses). Therefore, each cylinder is equipped with the patented gas admission valve with variable gas injection timing controlled by a ComAp electronic control system called INCON.

Slow & medium speed engine conversion kits include: Engine control unit (InteliSysNT Bi-fuel), Injection control system (INCON), Gas admission valve, Knocking detector (DENOX) and Bi-fuel governor (ECON-2S).

In contrast, high speed engines have only a small valve overlap, so it is possible to install just a central mixer(s) before the turbocharger(s) for the continuous flow of gas/air mixture. Gas injection is controlled by a throttle operated by the ComAp electronic control system InteliDrive BF according to the required engine output and speed.

High speed engine conversion kits include: Bi-fuel controller (InteliDrive BF), Gas throttle valve, Knocking detector (DENOX) and gas/air blender.

In both engine types there is no reduction in engine power or efficiency and the transition between diesel and bi-fuel operation is always smooth and efficient.

Maintenance costs after conversion will not be increased at all. Substantial parts of the engine remain unchanged, new mechanical parts are of heavy-duty design (e.g. service interval for the gas admission valve is 6000 running hours), and electronic control systems are fully automatic. Moreover, the gas operation means less carbonization of combustion chambers and turbocharger, so that the interval for de-carbonization and overhauling of the engine is prolonged.

Key features of ComAp Systems bi-fuel conversion:
• Affordable diesel engines combined with inexpensive natural gas
• Economic solutions for slow-speed and high-speed engines
• Flexible use of fuel gives guaranteed power output
• Efficient and safe operation with lower emissions
• Longer engine life and reduced maintenance costs makes it the perfect investment

This simple conversion requires no engine modification and delivers a short return on investment through a substantial reduction in operation costs and cheaper electricity production.

ComAp Systems Saudi Arabia
ComAp Systems provides a complete package of power energy management services that have used across the gulf region including important public buildings, production sites and major civil engineering projects. The full range of services cover both power energy and fully automated solutions:

Power energy automated solutions:
• Local control systems
• Paralleling systems
• Automatic transfer systems
• Power management systems

Fully automated solutions:
• System control & data acquisition
• PLC operated systems
• Radio telemetry systems
• Motor control centers
• Direct digital control systems

ComAp Systems also offers specialised process visualization solutions that help simplify and extend user functionality such as the (p)Control SCADA control, which supports all ComAp controllers such as InteliSysNT, InteliGenNT or InteliMainsNT. The system fills the gap between ComAp ‘standard’ software packages and the use of an expensive graphical power station control system. The package provides a complete visual overview with various charts, trends, alarm list and history files. From this single point of control users, can stop and start the generator, make mode changes and reset the system as well as make parameter changes and valve, breaker and auxiliary commands.

(p) Control brings together the functionality for plant monitoring and control of a variety of ComAp software products such as WinEdit/ MultiEdit (GenConfig/InteliMonitor), WinScope or Supervisor in one package, without the typically high costs of customized software solutions.

ComAp Systems has undertaken a number of high profile installations for a number of major hospitals across the Kingdom of Saudi Arabia at sites in Riyadh and Jeddah cities, which include the National Guard hospitals, Shumaisi hospital and the King Faisal Hospital.
• National Guard Hospitals - Riyadh and Jeddah Cities – Al Sawyeh Co was commissioned to renew a total of 220 MCC panels and 35 DPB’s at the hospital.
• Shumaisi Hospital - Riyadh – At this 1000-bed hospital, Saudi ATS specified InteliSysNT to control and manage four MTU diesel powered generators providing 2000MVA/400V/1400 kWA with synchronizing via iCB-MTU CAN and encompassing InteliLite AMF 25 3200A 4P draw out with by-pass.
• King Faisal Hospital - Riyadh – KFSH is a specialist 894-bed hospital that now uses two InteliSysNT to control a pair of CAT powered diesel generators.

If you would like to talk to ComAp Systems about power energy management services or discuss the possibilities of a control system upgrade to an existing generator or find out more about bi-fuel conversion contact Qaraqi Mohammed on Tel: +966-1-4995603 or Email: info@comapsystems.com for expert advice on power control applications.

Contact details:
ComAp Systems, Qaraqi Mohammed, Riyadh 11393, P.O.Box 365185, Saudi Arabia
T: +966-1-4995603, F: +966-1-4995607, E: info@comapsystems.com, www.comapsystems.com/sa.