Manual 2017Q4 OptiBlend System

OptiBlend System Operation and Installation Manual

eden
Innovations that work."

Eden Innovations India Pvt. Ltd.

S-2, Kushan apartment,
Friends colony,
Ambawadi, Ahmedabad-380015
Gujarat, India
+91 79-26420121
+91 9898069956
mdixit@edeninnovations.in
www.edeninnovations.in
Manual 2017Q4 OptiBlend System

Product Manual HY-7017

WARNING – FOLLOW INSTRUCTIONS

Read this entire manual and all other publications pertaining to the work to be
Performed before installing, operating, or servicing this equipment. Practice all plant
Safety instructions and precautions. Failure to follow instructions can cause
Personnel injury and/or property damage.

WARNING-OUT-OF-DATE PUBLICATION
This publication may have been revised or updated since this copy was produced. To verify that
you have the latest revision, be sure to check the Hythane website:

www.hythane.com

The revision level is shown at the bottom of the front cover after the publication number. The latest
version of most publications is available at:

www.hythane.com
If your publication is not there, please contact your customer service representative to get the
latest copy.

WARNING - OVERSPEED PROTECTION

The prime mover should be equipped with an over speed shutdown device to protect against
runaway or damage to the prime mover with possible personnel injury, loss of life, or
property damage.

The over speed shutdown device must be totally independent of the prime mover control system.
An over temperature or over pressure shutdown device may also me needed for safety, as
appropriate.
Manual 2017Q4 OptiBlend System

WARNING - PROPER USE

Any unauthorized modification to or use of this equipment outside its specified mechanical,
electrical, or other operating limits may cause personnel injury and/or property damage,
including damage to the equipment. Any such unauthorized modification: (i) constitute "misuse"
and/or "negligence" within the meaning of the product warranty thereby excluding warranty
coverage for any resulting damage, and (ii) invalidate product certifications or listings.

WARNING - DANGER OF DEATH OR PERSONNEL

INJURY

CAUTION - BATTERY CHARGING

To prevent damage to a control system that uses an alternator or battery-
charging device, make sure the charging device is turned off before
disconnecting the battery from the system.

CAUTION - ELECTROSTATIC DISCHARGE

Electronic controls contain static-sensitive parts. Observe the following

precautions to prevent damage to these parts.

o Discharge body static before handling the control (with power to the control

turned off, contact a grounded surface and maintain contact while handling

the control)

o Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around

Printed circuit boards.

o Do not touch the components or conductors on a printed circuit board with

Your hands or with conductive devices.

 Manual 2017Q4 OptiBlend System

IMPORTANT DEFINITIONS

 A WARNING indicates a potentially hazardous situation which, if not avoided,

could result in death or serious injury.
 A CAUTION indicates a potentially hazardous situation which, if not avoided, could
result in damage to equipment or property.
 A NOTE provides other helpful information that does not fall under the warning or
caution categories.

CAUTION - POSSIBLE DAMAGE TO EQUIPMENT

OR PROPERTY

PRODUCT MANUAL HY-

7017.............................................................................................1

CHAPTER 1.................................................................................................................5

GENERAL INFORMATION.....................................................................................................5

About this Manual........................................................................................................................................ 5

Safety Precautions........................................................................................................................................5

CHAPTER 2………………………………………………………………………………......6
SYSTEM FUNCTIONAL DESCRIPTION……………………………………………………….....6

Application………………………………………………………………………………………………....6
Manual 2017Q4 OptiBlend System

Theory of Operation………………………………………………………………………………………..6

Components.................................................................................................................................................. 8

Gas Train………………………………………………………………………………………………. 8

Power Transducer……………………………………………………………………………………... 9

Engine Vibration Sensor………………………………………………………………………………. 9

Programmable Logic Controller……………………………………………………………………..... 9

Control Panel…………………………………………………………………………………………..10

CHAPTER 3..............................................................................................................................11

INSTALLATION..............................................................................................................................11

Introduction.........................................................................................................................................11

Assemblies……………………………………………………………………………………………...11

Mixer Installation.....................................................................................................................................13

Gas Train Assembly and Installation...................................................................................................... 15

Fuel Hose and Reference Air Hose Installation………………………………………………………. .18

Control Panel Installation........................................................................................................................ 20

Sensor Installation...................................................................................................................22

Exhaust Gas Temperature Sensor……………………………………………………………………….22

Power Transducer.....................................................................................................................................23

Electronic Vibration Switch………………………………………………………………………….... 24

Wiring……………………………………………………………………………………………….......25

CHAPTER 4..............................................................................................................................26

VALIDATION AND OPERATION……………………………………………………………....26

Validation……………………………………………………………………………………………….26

Operation………………………………………………………………………………………………..26

CHAPTER 5…………………………………………………………………………………..27

SERVICE…………………………………………………………………………………………….....27

DIAGNOSTICS/TROUBLE SHOOTING……………………………………………………………..28
Manual 2017Q4 OptiBlend System

Chapter 1.
General Information
About this Manual
This manual will explain how to install and operate the OptiBlend dual fuel system for
stationary diesel engines.

Safety Precautions

All local codes should be followed when installing the OptiBlend System. All gas train
components should be installed and/or inspected by a licensed plumbing contractor certified
by Eden.
The work area should have adequate ventilation to prevent gas accumulation caused by
undetected leaks. Accumulation of natural gas can result in explosions that can damage or
destroy structures and cause injury or death. An appropriately rated fire extinguisher must be
kept readily accessible during all phases of installation. Adhere to all warnings found on the
equipment. All warnings and labels should be easily legible.
Do not install any component that appears to have been tampered with, subjected to high
temperatures or damaged in any way. Installation of a damaged component may result in gas
leaks, or improper operation of the OptiBlend System.
All OptiBlend System components must be used within the temperature and pressure ranges
specified in this manual or as otherwise directed by component labeling. Operation of
components outside of design temperature and pressure limits can result in fire, explosion,
and/or harm to personnel.
Manual 2017Q4 OptiBlend System

Chapter 2.
System Functional Description
Application
The OptiBlend System has been designed for constant engine speed applications with
isochronous governor control. The dual fuel kit can be used for continuous duty such as
prime power or stand-by applications.
The dual fuel kit is currently sized for applications as low as 150kW up to 2.5MW.
Hydrocarbon gases such as propane and butane cannot be used with the dual fuel kit. Pipeline
gas with a high concentration of methane and low overall concentration of heavier
hydrocarbon gasses are recommended. Lower quality gasses may produce reductions in
engine efficiency, and performance.

Theory of Operation
Diesel Fuel CI engines retrofitted with the dual fuel kit use natural gas as the primary fuel.
The advantages are both economical and environmental. Typically 50-70% of the diesel fuel
used can be safely displaced with natural gas. This greatly reduces the NOx formation due to
lower combustion temperature than diesel fuel. It addition due to the lower carbon content of
natural gas less CO2 is generated. A partial oxidation catalyst can also be added to the kit,
which will nearly eliminate HC and CO emissions.
The OptiBlend System is designed to allow for fuel switching during full or part load
conditions, without interruption of engine speed or power. The natural gas is fumigated to the
combustion chambers using the stock air intake system. When the diesel fuel is injected into
the chamber it acts as a pilot igniting the air-gas mixture. The fuel control valve adjusts the
natural gas to air ratio based on the kW load.
The gas fuel controller is a Programmable Logic Controller. The PLC has two alarm levels.
The first level will reduce the gas fumigated to the engine. The second level will disable gas
flow by de-energizing the gas solenoid. All alarm levels are programmed according to the
engine specifications, and OptiBlend System calibration. The following parameters are used
to determine if an alarm is set:
Exhaust Gas Temperature
Vibration Level
Generator Load Level
Generator Frequency
Knock (optional)
The knock detection is an optional upgrade to the OptiBlend system, Knock Detection
commissioning requires the support of Hythane Engineering.
Manual 2017Q4 OptiBlend System
Manual 2017Q4 OptiBlend System

Manual HY-7017
Components
Gas Train The gas train consists of a
manual gas ball valve, gas filter, gas lock off
solenoid, zero pressure regulator, gas
control valve, and mixer.
The gas filter protects the
gas train and engine from
particulate contaminants
that may be present in the gas
stream. The primary gas
pressure regulator is sized to
accept 1-5 psi gas pressure
supply.
The gas lock off solenoid is a
24V single stage solenoid, and
controlled by the PLC.
The zero pressure regulator
detects changes in engine
vacuum through the mixer to
maintain approximately
atmospheric pressure.
The fuel control valve has internal software with fault
detection, and position control.