The ECI Economizer system is offered in three standard models with each model covering an approximate range of engine generator power.

System 1: 150 to 300 KW Single Turbo

System 2: 300 to 1000 KW Dual Turbo

System 3: 1000 to 2000 KW Dual Turbo

(Smaller and larger conversion systems are also available)

The Economizer utilizes electronic controls that monitor engine operation and automatically detect when gas operation is allowed, controlling the amount of gas the engine can operate with. The computer control utilizes closed loop tuning to maintain maximum fuel replacement while protecting critical engine parameters measured through industrial sensors. When all parameters are in proper levels, low pressure natural gas is delivered through a air/fuel diffuser to the intake air. Gas travels in the intake manifold to the combustion chambers, where it mixes with a small amount of diesel “pilot fuel” to facilitate combustion.

System information touch screen

Installation of the hardware usually takes a couple days. The site needs a gas supply line with at least 2 PSI of available gas pressure ( higher pressures allow for smaller control devices). The supply needs to be routed to the engine area. Voltage for powering the control system is typically 24 volts DC. The conversion system takes it from there to supply the diesel engine with a clean regulated gas supply that controls the fuel delivery to the engine and blends the fuel with the air. Sensors to measure critical engine functions like speed, load, boost pressure, water temperature, governor position and gas pressure. Wire harnesses to connect the sensors to the Electronic Control Unit and finally the Controller itself. The controller program is custom tailored to match the details of the engine/governor design. Fuel tables are developed for each engine family on site if necessary by performing a fairly simple load test. During the testing the fuel table numbers are generated and programmed into the control system. For engines already having been converted only testing and confirmation of proper operation is necessary.

A standard laptop PC equipped with optional software may be connected to the ECU to conveniently view data at a remote location and download information for long term storage and further analysis.

SYSTEM HARDWARE LIST:

While reducing equipment cost is an important goal, no short cuts are taken with respect to quality. Only top quality products are utilized in the conversion system. From the touch screen information panel to the gold plated electrical connectors, there is quality around every corner.

Economics: An ECI conversion is a sound investment for power users who are looking to upgrade their current system to alternative fuel technology, without revamping their entire system. As a retrofit technology, the ECI system provides an economically attractive alternative to buying costly new generators.

With the ability to operate both fuels, the engine will never be down due to a lack of adequate gas fuel supply. Another distinct advantage of dual fuel is the decreased engine wear that comes with the use of cleaner fuel. Due to a reduction of carbon soot buildup and cleaner lube oil, longer intervals between service maintenance can be expected, sometimes doubled. This means a longer economic life for the engine and a better overall return on your investment.

To determine approximate cost savings you will need to determine your present fuel cost, your fuel replacement percentage and replacement cost with natural gas. Be sure to apply any losses of efficiency and always estimate on the safe side. Ask a ECI representative to help you in determining your annual cost savings including fuel and maintenance.

When considering the cost of natural gas also consider your contract options with you gas supplier. Many suppliers are willing to give better rates if they are able to interrupt your fuel supply. An interruptible rate is exactly why the Dual Fuel system is a desirable option.

Information about Knock: Combustion knock is where the already ignited, burning air fuel mix in the combustion chamber starts to auto-ignite from the increasing pressures and high temperatures. It causes high pressure spikes and can cause engine damage. Knock is the reason many engines can not run full power at a minimized pilot fuel setting. Each engine family has its own differences. Different fuel timing, compression ratio and Turbocharger configurations affecting air fuel ratio, boost pressures and temperatures. The ambient temperature affects the combustion and so does the content of the gas. All of these factors come into play and make it somewhat difficult to predict exactly what power limit will be reached with minimized pilot fuel and what amount of pilot fuel will be required at full power. The Economizer system is designed to replace as much diesel fuel as is possible without running into the combustion knock limit. To accomplish this the controller is programmed to meter gas fuel into the engine based on its fuel map. The map is a curve fit to the capacity of the engine. On larger engines knock detection is used to protect the engine in case the fuel gas content changes and replacement levels need adjusting.

Additional Products: Also being developed at ECI is the Economizer II. A similar system designed for larger engine generators. Large engines can also be converted with a similar concept but due to their size require special considerations. Large engine applications usually require site by site design engineering.

EMD conversion systems (Electro Motive Division) of General Motors is a two stroke cycle diesel that ECI has exclusively developed a conversion system for. Full power with high fuel replacements are its bench marks. This is a high end system initially designed for the locomotive industry.

Caterpillar 6 1/4 bore, 399 and 398 engines for drill rig power. Applying special pistons, after cooling modifications and fuel linkages allow higher substitutions and extremely good response to load changes.

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