GFS EVO-SP dual fuel retrofit complete solution

GFS EVO-SP Dual Fuel System: Complete Guide for Natural Gas Transformation of Diesel Generator Sets

Against the backdrop of increasing electricity costs and environmental pressures, many users with backup or regularly operating diesel generator sets are seeking more economical and cleaner alternative fuel solutions. EVO-SP ™ The system emerged - it allows for the transformation of existing fixed diesel engines into natural gas diesel dual fuel (NG+D) operation, achieving a 50% to 70% diesel substitution rate without changing the original engine hardware, while maintaining diesel engine level load response, power output, and operational stability. This article will provide a detailed analysis of the technical architecture, installation process, core control logic, safety protection mechanism, and maintenance points of EVO-SP system from the perspective of engineering practice, providing a complete technical reference for power plant operators and on-site engineers.

System Overview: Why Choose EVO-SP Dual Fuel Transformation

The EVO-SP system consists of a series of proprietary and patent pending technologies specifically designed for fixed diesel generator sets (emergency power supply, peak shaving power station, islanded power supply, etc.). It achieves dual fuel operation through external additional components, without making any changes to the engine's cylinders, pistons, injectors, or cylinder heads, fully retaining the original pure diesel fuel system.

Core advantages:

Significant reduction in fuel costs (replacing some diesel with cheap natural gas)

Extend emergency operation time (dual fuel mode runs longer with the same fuel storage capacity)

Reduce carbon and particulate emissions to enhance sustainability

When natural gas supply is interrupted or abnormal, seamlessly switch back to 100% diesel mode without affecting power generation output

This system is suitable for scenarios using pipeline natural gas, with an intake pressure of only 3-7 PSI (approximately 0.2~0.5 bar), eliminating the need for high-pressure compressed natural gas (CNG) equipment and reducing on-site supporting requirements.

Hardware components and installation process

2.1 Main hardware components

The EVO-SP system consists of the following core components:

Electronic Control Unit (ECU)

32-bit microcontroller, integrated with USB and CAN communication, compatible with J1939 protocol. It monitors key parameters of the engine and generator in real-time, such as mass air flow rate, power generation, diesel flow rate, etc., and dynamically optimizes the gas substitution rate at a frequency of 50 times per second.

Touch screen control panel

12.1-inch TFT XGA LCD, IP65 protection level, installed in a NEMA 4X stainless steel housing, equipped with an external emergency stop button. It can display real-time data and historical records, support parameter configuration and diagnosis.

Air gas mixer and throttle body

Using a low resistance fixed geometry mixer, combined with an electronic throttle body, low-pressure natural gas is introduced into the intake duct. The mixer has a diameter of 6 inches and is made of 6061-T6 aluminum alloy. The gas interface is 1.5 inches JIC.

Dual module gas valve

DN65 caliber, 24~28 VDC power supply, switch time<1 second, in compliance with EN 161 Class A Group 2 standard, protection level IP54. Adopting dual redundancy, normally closed DC solenoid valve, and providing manual shut-off valve.

Safety Sensor Kit

Combustible gas detector

flame detector

Vibration (knock) sensor

Exhaust temperature sensor

Boost pressure/temperature sensor

Gas/diesel flow meters, etc

2.2 Key points of installation and construction

The EVO-SP system is completely externally installed and does not require entry into the engine interior. All components can be completed using pre configured wiring harnesses and military grade quick connectors with conventional tools. The typical installation time is 6-8 hours.

Step Overview:

Determine the installation position of the mixer on the intake pipe, usually located after the intercooler and before the intake manifold.

Install gas valve assembly (including dual solenoid valves, manual shut-off valves, pressure switches).

Arrange the gas pipeline from the natural gas source to the mixer, ensuring that the pressure is regulated to 3-7 PSI.

Install the ECU host and its wiring harness, and connect various sensors (which can use the J1939 CAN bus of the original engine to obtain diesel flow, speed, and other data).

Install touch screen panel and remote emergency stop button.

Connect a 24V DC power supply (subject to load surge protection requirements).

Perform leak testing and functional verification, and complete fuel mapping calibration.

Engineering Tip: The original engine retains pure diesel capability and can be switched back to diesel mode for testing or emergency power supply at any time during installation, without interrupting user power supply tasks.

Control strategy: dynamic substitution rate and real-time protection

3.1 Real time fuel mapping and optimization

Traditional dual fuel systems often use a fixed substitution rate, which is prone to misfire or detonation under high load or transient conditions. EVO-SP's ECU utilizes Dynamic Setpoint Protection ™） Technology has fundamentally solved this problem.