Dual-Fuel Engine Load Estimation for Drift-Compensated Fuel Substitution
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Solution Overview
Problem
Existing dual fuel engine systems face challenges in achieving precise and robust control to meet Tier 4 emissions regulations while maximizing the use of less-expensive gas fuel and minimizing diesel fuel, particularly in applications like oil and gas production, where interfacing with OEM and gas controllers is complex and costly.
Innovation Solution
A dual fuel engine system with a control system that includes a controller to measure and estimate engine parameters, determine adjusted load estimates, and compensate for drift, allowing for precise control of fuel substitution and parasitic loads, using sensors and actuators to optimize the use of both diesel and gas fuels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a dual fuel engine system is implemented to meet Tier 4 emissions regulations, then emissions compliance is improved, but control system complexity increases
Solution Approach 1:
The patent combines the OEM machine control system, base engine control system, and gas control system into an integrated dual fuel control architecture. The controller receives inputs from multiple sensors (fuel flow, load, speed, temperature) and coordinates control of both diesel and gas fuel injection systems, achieving emissions compliance through unified management rather than separate independent systems.
Solution Approach 2:
The control system implements continuous feedback loops by monitoring fuel flow rates, engine load, engine speed, and temperature parameters. The controller adjusts fuel substitution ratios based on real-time comparisons between actual performance and target emissions requirements, enabling dynamic optimization of the dual fuel mixture to meet Tier 4 regulations while adapting to changing operating conditions.
2Loss of energy
If fuel substitution control is optimized to maximize gas fuel use, then operating cost is reduced, but measurement and control precision requirements increase
Solution Approach 1:
The patent replaces mechanical fuel flow measurement systems with electronic sensors and digital control. Electronic fuel flow sensors provide precise measurement of both diesel and gas fuel rates, enabling the controller to accurately calculate and adjust the fuel substitution ratio. This electronic substitution allows for maximization of gas fuel usage (reducing operating cost) while maintaining the measurement precision required for optimal control.
3Manufacturing precision
If drift compensation is implemented in the fuel system, then fuel delivery accuracy is improved, but system complexity increases
Solution Approach 1:
The control system performs preliminary drift compensation by continuously monitoring fuel flow rates and comparing actual delivery against commanded delivery. The controller calculates drift deviations and applies correction factors to subsequent fuel injection commands, preventing accumulation of errors. This preliminary action approach maintains fuel delivery accuracy without requiring complex mechanical adjustment mechanisms.
Solution Approach 2:
The dual fuel control system implements self-service drift compensation through its inherent feedback capability. The controller autonomously detects fuel system drift by comparing sensor measurements with control commands, and automatically adjusts fuel injection parameters to compensate. This self-correcting mechanism improves fuel delivery accuracy without adding separate complex drift compensation hardware.
Data Source
AI summary
A method of controlling a dual fuel engine configured to receive a first fuel and a second fuel includes operating the engine using the first fuel, measuring a current load of the engine, sending a first signal to a first fuel system to deliver an amount of the first fuel to the engine, and determining at least one first operating parameter associated with the engine. The method also includes determining an engine load estimate based on the first signal and the at least one first operating parameter, comparing the engine load estimate to the measured load, and based on the comparison, determining, an adjusted engine load estimate to compensate for a drift in the first fuel system.