Diesel testing unit for optimal asset performance

HYDAC recently completed a diesel testing unit for a technology and project development company focused on improving the reliability, efficiency, and sustainability of assets, products, and processes to transform commercial performance.

HYDAC Australia Project Engineer Kent Paulsen commented that the diesel testing unit is used to test diesel fuel injectors at a power plant. Features of the unit include a full range of sensors connected to a HMG 4000 data logging device, with the HMG 4000 programmed to convert the flow rate (L/min) measured by the EVS flow turbines to mass flow rate (kg/s) and an ability to achieve over 30 bar of pressure for a diesel system.

Full range of sensors connected to a HMG 4000

The HMG 4000 is a hand-held portable measuring and data logging device. HYDAC developed it for values measured in relation to hydraulic systems, such as pressure, temperature, flow rate and position.

“The customer was quite specific in terms of what data they wanted logged,” said Paulsen. “The testing unit monitors the supply pressure, flow, and temperature of the diesel going into the furnace. Then it monitors the return pressure, flow, and temperature as well. Additionally, we included a temperature transducer in the drain line. In total we had eight transducers all feeding back to the HMG 4000.”

He points out that normal analog sensors with 4–20 mA HSI output and HYDAC proprietary sensors/protocols were used.

“You can basically connect the HSI sensor to the HMG 4000 and you don’t need to program the parameters. It automatically recognises what kind of sensor it is and the sensing range, which makes life very easy on the ground,” he said. “We used one of those and then ran about eight sensors that all went back to the HMG 4000, which displayed all eight sensors at one time on a screen, with real-time information.”

Conversion of flow rate to mass flow rate

The HMG was also programmed to convert the flow rate (L/min) measured by the EVS flow turbines to mass flow rate (kg/s).

“This is very helpful to the end user or engineer who works in kilograms of diesel: they don’t measure in litres but in kilograms,” said Paulsen. “And the furnace will use their units of measurement in kilograms per second of diesel when it burns. That information on the HMG 4000 is much more useful to have as it eliminates the requirement of doing conversions later.”

Paulsen adds that the user can add any complex conversions or formulas to the HMG 4000 to aid in data logging.

“You can take two different sensors and the HMG 4000 can work out what the differential flow rate is between those two sensors,” he said.

Operation of a diesel fuel injector

Diesel fuel injectors have two different functions: the first is to vapourise the diesel as it goes into the furnace for combustion, and the second is to ensure the diesel gets circulated through the injector to provide cooling.

“A power plant is run off a diesel furnace using the vapourised diesel supplied via the injectors,” he said. “A spin is imparted onto the diesel — like a centrifugal force — that gets it rotating quickly. This vapourises the diesel, making for perfect combustion conditions.

“Additionally, the injectors sit in the furnace and get hot as combustion occurs. The second function of the diesel testing unit was to provide cooling liquid that is circulated through the nozzle to prevent failure due to overheating.”

Collaborative approach

The group has extensive experience in the industry of power generation and manufacturing across the Asia-Pacific. Paulsen said the project started when HYDAC received “an enquiry along with a schematic” from the specialist engineering company in 2021.

“The customer had a good idea of what it wanted to execute and what it wanted from us,” he said. “We quoted in October and received the first order for a unit at the beginning of November.”

Thereafter HYDAC commenced the design phase with a schematic and general arrangement for approval.

“The customer wanted additional back pressure valves in addition to other similar products for inclusion in the system. We had to undertake quite a few revisions, but this helped fine tune exactly what the customer wanted.

Paulsen emphasised that a collaborative approach “really works” because the customer can precisely convey what they want, enabling HYDAC to precisely meet its requirement.

“By the beginning of December 2021, we commenced procurement and fabricating, and the unit was assembled in February 2022: now that’s teamwork that gets the job done,” he concluded.

Image: ©stock.adobe.com/au/Alexey Seafarer