The Problem of Fuel Recirculation in Diesel Generators Part 2

Next, we will continue to introduce the issue of fuel recirculation in diesel generators.

Design solution:

The heated "reflux" fuel can be adequately treated (cooled) to prevent recirculation to the engine and prevent engine derating or shutdown. The following are potential solutions for maintaining acceptable fuel temperatures:

Solution 1:

Most generator set manufacturers equip their large units with fuel coolers installed on radiators. The design of the fuel cooler should be able to cool it before the engine return oil returns to the metering tank. If the performance of the fuel cooler installed on the radiator can take away enough heat from the fuel to prevent it from reaching a critical high level, then the designer of EPSS can accept this solution. However, it is not yet clear whether engine manufacturers must consider specific application conditions when selecting fuel coolers, such as the specified EPSS operating time, local ambient temperature, or the size of the day tank that receives the return fuel (i.e., any residual heat in the return fuel has a lower dissipation efficiency in smaller day tanks than in larger day tanks).

It is also important to understand that the EPSS device utilizing remote cooling components (remote radiators) will lack the traditional "fuel cooler installed on the radiator", so there should be detailed specifications on how to handle any returned fuel before returning to the day tank. Bottom line: The designer of EPSS should review the heat dissipation capacity of the fuel cooler (if any) installed on the engine and confirm its suitability, as it is related to the application at hand.

Solution 2:

In some cases, it is feasible to design the engine's return oil directly (if the pump installed on the engine can overcome pipeline limitations) or through the return oil tank to return to the large capacity fuel tank. The return fuel tank is designed to receive return fuel from the engine. When equipped with a pump, it can guide the hot fuel to a large capacity storage tank, where the hot fuel can dissipate with the larger capacity fuel. The disadvantage of this solution is that there is no benefit of returning fuel, and the fuel supply day tank may need to be designed with a larger capacity to allow for the minimum required operating time. In addition, a larger refueling pump is required (size should exceed the maximum fuel consumption of the engine, not the maximum fuel consumption).

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