Gas Engine

Fuel Systems
 Gas Engine Fuel Systems

• Functions
– Receives fuel from source
– Mixes fuel and air
– Controls flow of mix to cylinders
• Systems
– High pressure
– Low pressure
• Types
– Carbureted
– Aftermarket Air / Fuel Ratio Control
– Factory Air / Fuel Ratio Control (G3500B, G3500C, G3600)
Carbureted Fuel Systems:
G3500 – G3300
• Gas shut-off valve
• Gas pressure regulator
• Load adjustment valve
• Carburetor
Gas Shut-Off Valve

• Provides positive
shut-off of fuel supply
• Located at fuel supply
connection

gas shut-off valve

 Gas Pressure Regulator balance
line
• Maintains a fixed pressure
difference between
carburetor air supply and fuel
supply
• Does not regulate fuel supply
pressure

gas pressure
regulator
 Gas Pressure Regulator

Balance Fuel Out to

Line Carburetor

Fuel In
Regulator Balance Line
 Carburetor
carburetor
• Mixes volume of fuel
per volume of air mixture
adjustment
• Effective for a limited air
range of LHV's valve
• Requires a constant fuel
supply pressure

mixed fuel

fuel
 Mixture Adjustment Valve

• Adjusts air/fuel ratio

at full load
• Located on or
near carburetor
mixture
adjustment
valve
 Throttle

• Throttle: a moveable plate

in the air / fuel passage
• Plate position is controlled
by governor to regulate flow
of mixture to the intake
manifold and ultimately to
cylinders
• Plate position has direct
relationship to power and
speed of engine
Impco Carburetor
Deltec Carburetor
 High Pressure Gas Fuel System
• Carburetor (mixer)
located after turbocharger
• Higher fuel supply
pressure is required to
mix fuel with high
pressure air from turbo
• Shorter fuel path means
better transient response
• Turbo works less,
aftercooler heat rejection
is lower

high pressure gas

fuel system layout
High Pressure Gas Fuel System
 Low Pressure Gas Fuel System
• Carburetor (mixer) located
before turbocharger
• Higher fuel supply pressure is
not required
• Fuel path from mixer to
cylinders is longer; transient
response suffers
• Turbo must boost air AND fuel;
heat rejection is higher
• Consequences/benefits:
– Aftercooler is exposed to fuel low pressure gas
– Lower fuel pressure meets fuel system layout
building codes
Low Pressure Gas Fuel System
 G3500 Mixer Mixer G3400
Throttle
Body
Naturally
Aspirated

low pressure gas fuel system

Fuel System Requirements
Gas Supply Pressure

psi kPa

G3300

Low Pressure Gas 1.5 – 5 10 – 69

High Pressure Gas 12 – 25 83 – 172

G3400

Low Pressure Gas 1.5 – 5 10 – 69

High Pressure Gas 20 – 25 138 – 172

G3500

Low Pressure Gas 1.5 – 5 10 – 69

Naturally Aspirated 2 - 10 14 - 69

High Pressure Gas

Low Emission (8:1) 35 - 40 241 – 276

Low Emission (11:1) 30 – 40 207 – 276

Stoichiometric TA 25 – 30 172 - 207

 Fuel Supply

• Fuel pressure fluctuation

– High: 1 Psi
– Low: 0.25 Psi
• Fuel filters are required
– Caterpillar filters remove 99% of debris down to 1 micron in diameter
– Change filter when pressure drop across it reaches 5 psi
– Coalescing filter required for gas with any suspected liquids
• Fuel line sizing
– Line to regulator - no smaller than regulator inlet
– Must provide required flow AND pressure
– Account for pressure drop across gas lines to the engine
 Air/Fuel Ratio Control
air/fuel
ratio
• Active electronic control monitors control
engine operating parameters to
maintain desired air/fuel ratio as
conditions change
• Effective for a limited range of
LHV’s
• Standard on G3500B and
G3500C
• Available as optional equipment
on G3500LE and G3400LE
• May be customer-supplied from
aftermarket source
 Air/Fuel Ratio Control
air/fuel
ratio
• Simple feedback design control
uses oxygen sensor in
exhaust
– Excess exhaust oxygen is
an indicator of in-cylinder
air/fuel ratio
• Oxygen sensor signal
controls valve that
adjusts fuel supply
pressure to the
carburetor
– Changes in fuel supply
pressure alter the air/fuel
mixing capabilities of the
carburetor
• Required for 3-way (non-
selective) catalyst to
maintain balance in
exhaust makeup
Optional Fuel Systems

• Vaporized propane
• Low energy biogas
– Landfill gas
– Digester gas
• Dual gas fuel systems
Dual Gas Fuel System

• Provides backup fuel system to allow operation in

the event of failure of the primary fuel system
• Engine configuration must be compatible for
operation on either fuel
• Availability of dual gas systems from the factory
depends on the engine family and fuel types;
please consult the Application Support Center
(ASC) for help
 Dual Gas Fuel System

Dual Gas Regulators for High Pressure Gas TA or NA

secondary fuel
regulator &
load adjustment
primary fuel valve
regulator (high energy fuel)
(low energy
fuel)
Dual Gas Fuel System

High Pressure/Low Pressure System

(G3500 only)
 Dual Gas Fuel System

• Fuel switching equipment must be provided by the

customer / installer
• Ignition timing changes for different fuel must be
accommodated
• Engine ratings must be determined for both fuels
 Cat G3516B

• Electronic fuel control valve

– Controlled by ECM
– Measures mass flow
• Air/fuel ratio control
– Closed loop, O2 sensor
– Adjusts for changes in
ambient conditions, including
atmospheric pressure,
temperature, and humidity
 Cat G3516B

Air In

Fuel In

Electronic Fuel
Control Valve

ECM
G3600 Fuel System

• Ultra-lean combustion system

– Gas admission valve for main fuel supply
– Enriched precombustion chamber ignition
• Air/fuel ratio control using in-cylinder feedback
– Combustion probe measures actual burn time
• Integrated control manages air flow (choke), turbo
boost (wastegate), and fuel supply (fuel valve) to
maintain very
low emissions and fuel consumption
Fuel System Components

• From fuel inlet to fuel manifold:

Fuel System Components

• From fuel manifold to cylinder:

Fuel System Components

• From fuel manifold to main combustion chamber:

Fuel System Components

• From fuel manifold to main combustion chamber:

Combustion Probe

• Detects flame front arrival

– Ionization of air/fuel in cylinder
• ECM computes the time
elapsed from spark to
detection for each cylinder
• Primary feedback for air/fuel
ratio adjustments when
engine is in advertised
load/speed range
Fuel System Considerations

• Fuel pressure provided to the regulator must meet

specifications
– (see chart or price list description)
• Gas pressure regulators require fuel temperatures
between 150°F (65°C) to -20°F (-29°C)
• Fuel filtration and removal of liquids are required to
avoid potential engine damage
Reserve Slides
Rich Burn vs. Lean Burn