Method for reducing carbon/coke in fuel injectors in dual fuel applications

A method of reducing carbonaceous deposits on a fuel injector is provided in which a first fuel composition is supplied to the fuel injector in a dual fuel engine, the first fuel composition comprising natural gas fuel and a first percentage of diesel fuel; and a second fuel composition is supplied to the fuel injector in a dual fuel engine, the second fuel composition comprising a second percentage of diesel fuel that is greater than the first percentage of diesel fuel to cause cavitation to occur within the fuel injector, thereby reducing carbonaceous deposits.

CROSS REFERENCE TO RELATED APPLICATION

This application is a national stage filing of PCT International Application Serial No. PCT/US2014/049182, filed Jul. 31, 2014, the disclosure of which is hereby expressly incorporated by reference herein in its entirety.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to reduction of carbon/coke deposits from fuel injectors, and more particularly to a method for reducing carbonaceous deposits in fuel injectors in dual fuel engine applications.

BACKGROUND OF THE DISCLOSURE

The introduction of fuel into the cylinders of an internal combustion engine is most commonly achieved using fuel injectors. A commonly used injector is a closed-nozzle injector which includes a nozzle assembly having a spring-biased needle valve element positioned adjacent the injector nozzle for allowing fuel to be injected into the cylinder of an internal combustion engine. The needle valve element moves to allow fuel to pass through the injector nozzle and out the injector orifices or spray holes, thus marking the beginning of the fuel injection event. Fuel injector designs may include reduced nozzle orifice diameters and increased injection pressures to provide increased engine power density and reduced emissions. However, over time, the power resulting from such modern injector orifice and/or spray-hole geometries may degrade as a result of formations of carbonaceous deposits (also called carbon build up or coking) on fuel injector nozzles.

Increased fuel injector nozzle deposit formation occurs when the temperature at the nozzle tip rises. As is known in the art, when zinc levels reach a critical concentration in the fuel, significant coking occurs within a relatively short period. Internal and external deposits on fuel injector nozzles can negatively impact engine behavior as well as produce increased acoustic and pollutant emissions in diesel engines with direct injection. A variety of studies involving direct injection diesel engines show a deterioration of combustion and mixture formation as a direct result of carbonaceous deposits accumulating on the injector nozzle. Moreover, the deposits can also cause an increase in fuel consumption and a reduction in the power output of direct injection diesel engines.

Prior art attempts to mitigate injector nozzle coking have included running the engine with zinc-free fuel to partially reverse the nozzle coking deposition. Chemical mechanisms such as oxidation may also be employed to destroy the organic compounds present in the carbonaceous particles. Moreover, evaporation and desorption may be utilized to reduce the gaseous fraction dissolved in the deposits, however in both approaches an additional step of abrasion is necessary to cause the required breaking-off force to facilitate removal of the carbonaceous deposit layer. Detergent additives to the diesel fuel may also be effective at removing carbon deposits from fuel injector nozzles; however these additives can be expensive and difficult to dispense accurately.

SUMMARY OF THE DISCLOSURE

The various aspects of the present disclosure may be achieved by providing a method for reducing carbonaceous deposits from common rail fuel injectors in dual fuel applications by causing cavitation to occur and abrade off the deposits from the fuel injector nozzle. In one embodiment of the disclosure a method for reducing carbonaceous deposits from common rail fuel injectors in dual fuel applications is disclosed wherein a first fuel composition comprising natural gas fuel and a first percentage of diesel fuel is provided to a fuel injector in what is called the substitution rate of natural gas to diesel fuel. Normal operation of a dual fuel engine would be with a higher substitution rate of natural gas to diesel fuel for economy. This embodiment further includes providing a second fuel composition to the fuel injector comprising a second percentage of diesel fuel that is greater than the first percentage of diesel fuel to cause the diesel fuel to experience cavitation or high flow turbulence to occur within the fuel injector, thereby scavenging off and thus reducing carbonaceous deposits.

According to one aspect of this embodiment, the method further includes a prognostic approach to determine when diesel injection nozzles are sufficiently coked to initiate a scavenging process. One such method provides for a scavenging cycle which occurs when the second fuel composition is provided for a first predetermined time period. When the first time period ends the first fuel composition is once again provided. In a variant of this aspect the second percentage of diesel fuel is at least 50% of the second composition. In a variant of this aspect the cavitation or high flow turbulence reduces carbonaceous deposits adjacent a spray hole of the fuel injector. In another aspect the second percentage of diesel fuel is greater than 95% of the second composition. According to another aspect of the disclosure the second composition is provided for a first determined time period in response to at least one operational parameter satisfying a first condition. In a variant of this aspect at least one operational parameter includes at least one of engine run time, engine load, engine speed, and engine operating temperature. In a variant of this variant the first condition is at least one of engine run time in excess of a predetermined threshold run time, engine load in excess of a predetermined threshold load, engine speed in excess of a predetermined threshold speed, and engine operating temperature in excess of a predetermined threshold operating temperature. According to another variant of this aspect the at least one operational parameter includes at least one of a quantity of natural gas fuel used, a fuel filter restriction percentage, a fuel injector tip temperature, a fuel injector drain fuel temperature, an in-cylinder pressure, and an in-cylinder exhaust gas temperature. In a variant of this variant the first condition further includes at least one of a quantity of natural gas fuel used in excess of a predetermined threshold usage quantity, a fuel filter restriction percentage in excess of a predetermined threshold restriction percentage, a fuel injector tip temperature in excess of a predetermined threshold tip temperature, a fuel injector drain fuel temperature in excess of a predetermined threshold drain fuel temperature, an in-cylinder pressure below a predetermined threshold pressure, and an in-cylinder exhaust gas temperature in excess of a predetermined threshold gas temperature. In this aspect the in-cylinder pressure includes a pressure in a cylinder of a dual fuel engine during a combustion event. Additionally, in this aspect the in-cylinder exhaust gas temperature includes an exhaust gas temperature in the cylinder of a dual fuel engine after the exhaust stroke.

According to another aspect of the disclosure an engine torque output is monitored concurrent with providing the second composition for the first time period. A variant of this aspect includes providing the second composition and then providing the first composition in response to the engine torque output exceeding a predetermined threshold torque output. In another variant, providing the second composition for a first time period includes periodically providing the second composition for the first time period according to a predetermined schedule.

According to another embodiment of the present disclosure a method is provided comprising commanding a fuel supply assembly to provide a first fuel composition to a fuel injector in a dual fuel engine, the first composition comprising natural gas fuel and a first percentage of diesel fuel. This embodiment further includes monitoring an operational parameter of the dual fuel engine and commanding the fuel supply assembly to provide a second fuel composition to the fuel injector for a first time period in response to the operational parameter satisfying a first condition. The second composition comprises an injector cavitation or high flow turbulence diesel fuel threshold value. In this embodiment the second composition includes a percentage of diesel fuel that is greater than or equal to the injector cavitation or high flow turbulence diesel fuel threshold value.

According to one aspect of this embodiment, commanding the fuel supply assembly to provide a second composition further includes commanding the fuel supply assembly to adjust a fuel injector pressure and a fuel flow rate of the second composition. In a variant of this aspect the cavitation reduces carbonaceous deposits adjacent a spray hole of the fuel injector. In another variant the operational parameter is engine run time and the first condition is engine run time in excess of a predetermined threshold run time. In another aspect of the disclosure, commanding the fuel supply assembly to provide a second composition further comprises at least one of determining the first time period in response to the monitored operational parameter and determining the second percentage of diesel fuel in response to the monitored operational parameter. In a variant of this aspect the operational parameter includes at least one of engine load, engine speed, and engine operating temperature. In a variant of this variant the first condition includes at least one of engine load in excess of a predetermined threshold load, engine speed in excess of a predetermined threshold speed, and engine operating temperature in excess of a predetermined threshold operating temperature. In another variant commanding the fuel supply assembly to provide the second composition includes applying an algorithm to determine the second percentage of diesel fuel.

According to another aspect of this embodiment, the method determines a carbon build up factor in response to the operational parameter satisfying a first condition, and determines the first time period based on the carbon build up factor. In a variant of this aspect the operational parameter is engine run time weighted by at least one of a plurality of weight factors and the method further comprises determining a carbon build up factor based on the operational parameter. In this variant the plurality of weight factors includes at least one of engine speed, engine load, and the percentage of natural gas fuel in the first composition. Additionally, in this variant a magnitude of the engine speed weight factor increases as the engine speed increases, a magnitude of the engine load weight factor increases as the engine load increases, and a magnitude of the natural gas fuel weight factor increases as the percentage of natural gas fuel in the first composition increases. According to yet another aspect of this embodiment, the operational parameter includes at least one of quantity of natural gas fuel used, fuel filter restriction percentage, fuel injector tip temperature, fuel injector drain fuel temperature, in-cylinder pressure, and in-cylinder exhaust gas temperature. In a variant of this aspect the first condition further includes at least one of quantity of natural gas fuel used in excess of a predetermined threshold usage quantity, fuel filter restriction percentage in excess of a predetermined threshold restriction percentage, fuel injector tip temperature in excess of a predetermined threshold tip temperature, fuel injector drain fuel temperature in excess of a predetermined threshold drain fuel temperature, in-cylinder pressure below a predetermined threshold pressure, and in-cylinder exhaust gas temperature in excess of a predetermined threshold gas temperature. In this variant the in-cylinder pressure includes a pressure in a cylinder of a dual fuel engine during a combustion event. Additionally, in this variant the in-cylinder exhaust gas temperature includes an exhaust gas temperature in the cylinder of a dual fuel engine after the exhaust stroke. In yet another aspect of this embodiment, commanding the fuel supply assembly to provide the second composition includes applying an algorithm to determine at least one of the second percentage of diesel fuel, the first time period, and a carbon build up factor.

According to yet another embodiment of the present disclosure an apparatus is provided comprising a controller including a first interface configured to provide control signals to a fuel supply assembly for providing a dual fuel composition including a diesel percentage to a dual fuel engine, a second interface configured to receive parameter signals corresponding to an operational parameter of the dual fuel engine, and logic configured to monitor the parameter signals and to generate the control signals to cause an increase in the diesel percentage of the dual fuel composition in response to the operational parameter satisfying a condition, thereby causing cavitation to occur in a fuel injector. According to one aspect of this embodiment, the operational parameter is engine torque output and the condition is engine torque output below a predetermined threshold torque output. In a variant of this aspect the logic is further configured to generate control signals to cause an increase in the diesel percentage of the dual fuel composition in response to the engine torque output below a predetermined threshold torque output. In another aspect of this embodiment, the logic is further configured to generate control signals to cause an increase in the diesel percentage of the dual fuel composition for a first time period in response to the operational parameter satisfying the condition. In yet another aspect, the logic is further configured to generate control signals to periodically cause an increase in the diesel percentage of the dual fuel composition for a first time period according to at least one of, a predetermined schedule, an algorithm, and a carbon build up factor.

DETAILED DESCRIPTION OF EMBODIMENTS

The embodiments disclosed herein are not intended to be exhaustive or to limit the disclosure to the precise forms disclosed in the following detailed description. Rather, the embodiments were chosen and described so that others skilled in the art may utilize their teachings.

FIG. 1is a conceptual block diagram of a system100according to the present disclosure. System100generally includes a controller126, a fuel supply assembly116, dual fuel supply line118, fuel injector130, and dual fuel engine132. Controller126includes fuel supply assembly interface128, fuel injector interface124, engine interface122, timer134, memory136, and logic120. Controller126sends fuel injector control signals110to fuel injector130through interface124, sends fuel supply assembly control signals114to fuel supply assembly116through interface128, and receives operational parameter signals112from engine132through interface122.

When system100is operating, logic120configured within controller126provides commands and generates control signals110and114as is further described below. Under certain circumstances, logic120causes controller126to send fuel supply assembly control signal114through interface128to cause fuel supply assembly116to provide a first composition of fuel to fuel injector130via dual fuel supply line128. The first composition includes natural gas fuel and a first percentage of diesel fuel and is provided to dual fuel engine132via fuel injector130. During engine operation, logic120causes controller126to send fuel injector control signals110through interface124to cause fuel injector130to provide injections of the dual fuel composition to dual fuel engine132. Also during engine operation, dual fuel engine132generates a variety of different operational parameter signals112(as is further described below), which are received by controller126at interface122. According to the various methods of the present disclosure, controller126causes fuel supply assembly116to provide a different dual fuel composition in response to one or more operational parameter signals112indicating that the corresponding one or more operational parameters of engine132satisfy a certain condition.

In each of the embodiments described below, if an operational parameter signal112satisfies a first condition, logic120causes controller126to command fuel supply assembly116to provide a second composition of fuel including a greater percentage of diesel fuel than the first percentage of diesel fuel in the first composition. Logic120may also cause controller126to apply an algorithm to determine the second percentage of diesel fuel in response to one or more monitored operational parameter signals112satisfying a certain condition. The second composition includes a specific second percentage of diesel fuel calculated by the algorithm. The operational parameter signals112received through interface122are provided as inputs to the algorithm. Thus, controller126applies the algorithm and determines the second percentage of diesel fuel in response to one or more monitored operational parameter signals112satisfying a certain condition. The increased diesel percentage causes cavitation to occur in fuel injector130thereby reducing carbonaceous deposits on the fuel injector nozzle. In at least one of the embodiments described below (e.g. method200B), controller126may also apply the algorithm to determine an estimated percentage of fuel injector carbonaceous deposit accumulation. The second composition is provided for a first time period that may be determined in a variety of different ways. For example, as is further described below, in one embodiment the time period, which may be measured by timer134, may be of a predetermined duration according to a schedule stored in memory136. Additionally, in at least one of the embodiments described below (e.g. method500) logic120may apply the algorithm to determine the first time period.

Engine interface122may comprise a plurality of electronic components configured to receive analogue or digital inputs from a plurality of sensors coupled to dual fuel engine132. Engine interface122may, for example, convert an analog voltage value to a corresponding digital signal that may be received by controller126such that commands may be provided in response to the value assigned to the digital signal. Likewise fuel injector interface124and fuel supply assembly interface128may also comprise a plurality of electronic components configured to provide voltage and/or current values to cause fuel injector130to inject fuel and fuel supply assembly116to supply fuel.

FIG. 2AandFIG. 2Bare example methods200A and method200B according to the present disclosure for reducing carbonaceous deposits from a fuel injector nozzle. While this description refers to one fuel injector, it should be understood that typically multiple fuel injectors (e.g., one for each cylinder) are operated simultaneously. RegardingFIG. 2A and 2B, as indicated by block210in both embodiments, during normal operation a first composition of fuel is provided to fuel injector130of dual fuel engine132. The first composition may comprise natural gas fuel and a first percentage of diesel fuel. An example dual fuel composition may be more than 50% natural gas and less than 50% diesel fuel. As indicated above, over time, use of such a fuel composition may result in carbon/coke deposits in fuel injector nozzle. During engine operation a variety of operational parameter signals112of dual fuel engine132may be monitored. Alternatively, upon providing the first composition, a time delay may be implemented to postpone monitoring of operational parameter signal112until after a desired time period of providing the first composition has lapsed. Operational parameter signal112may include one or more of a plurality of engine operating parameter signals such as engine run time, engine load, engine speed, or engine operating temperature. Additionally, in one aspect of method200A and method200B operational parameter signal112may further include engine operating parameter signals such as total quantity of natural gas fuel used, fuel filter restriction, fuel injector tip temperature, fuel injector drain fuel temperature, in-cylinder pressure, and in-cylinder exhaust gas temperature.

Controller126receives parameter signals112corresponding to the operational parameter signal being monitored while the first composition is provided to fuel injector130. Controller126may be further configured to subject the parameter signals112to a test or condition to determine whether the condition is satisfied. Such conditions may include whether engine run time exceeds a predetermined threshold run time, whether engine load exceeds a predetermined threshold load, whether engine speed exceeds a predetermined threshold speed, and whether engine operating temperature exceeds a predetermined threshold operating temperature. Similarly, in other aspects of method200A and method200B the test or condition may further include, for example, whether total quantity of natural gas fuel used exceeds a predetermined threshold usage quantity, whether fuel filter restriction exceeds a predetermined threshold restriction, whether fuel injector tip temperature exceeds a predetermined threshold tip temperature, whether fuel injector drain fuel temperature exceeds a predetermined threshold drain fuel temperature, whether in-cylinder pressure falls below a predetermined threshold pressure, and whether in-cylinder exhaust gas temperature exceeds a predetermined threshold gas temperature.

With regard to engine run time as the operational parameter, it may be measured from a first combustion event within a cylinder of dual fuel engine132by a timer, such as timer134. In this example, the engine run time operational parameter may be monitored by controller126reading data output by timer134to determine total engine run time that has elapsed since the occurrence of the first combustion event within the cylinder of dual fuel engine132. In one aspect of method200A and200B, operational parameter signal112provides notification that a first combustion event has occurred and logic120causes timer134to begin measuring engine run time.

In one aspect of method200B, engine run time may be weighted by a weight factor configured to estimate carbon build up (which may also be referred to as a carbon build up factor). Exemplary weight factors may be based on engine speed and/or engine load and logic120may be configured to determine the weight factors to be applied. In this aspect, both engine load and engine speed are received by controller126as parameter signals112generated by corresponding engine speed and engine load sensors coupled to dual fuel engine132. In one example according to this aspect, logic120applies a weight factor that is proportional to engine speed, such that when engine speed increases the weight factor also increases. Likewise, in another example, logic120applies a weight factor that is proportional to engine load, such that when engine load increases the weight factor also increases. In the preceding examples, as engine run time elapses and the weight factors are applied, any increase or decrease in engine speed and engine load are provided as real time inputs to the algorithm disclosed above to determine an estimated carbonaceous deposit accumulation. For example, if dual fuel engine132runs for a certain period of time at a relatively high engine load or engine speed, under high natural gas substitution relative to diesel fuel operation, one would anticipate that the amount of carbon build up on the nozzle of fuel injector130would be higher; whereas, if dual fuel engine132runs for a certain period of time at a relatively low engine load or engine speed or under low natural gas substitution relative to diesel fuel operation, one would anticipate that the amount of coke buildup on the nozzle of fuel injector130would be lower. Actual weight factors to determine the precise build up rates of nozzle coke deposits would be empirically measured under a wide variety of engine speeds, loads and substitution rates, among other factors.

In another aspect of method200B, engine run time may be weighted by a weight factor based on a substitution or dual fuel ratio of the first composition. In this aspect, logic120applies a weight factor that is proportional to the ratio of natural gas fuel and diesel fuel in the first composition such that, for example, when the percentage of natural gas fuel in the first composition increases the weight factor also increases. As indicated in the preceding example, as engine run time elapses and the dual fuel ratio weight factor is applied, any increase or decrease in the percentage of natural gas fuel in the first composition is provided as a real-time input to the algorithm to determine an estimated carbonaceous deposit accumulation on the nozzle of fuel injector130.

As disclosed above, operational parameter signals112of dual fuel engine132are received by controller126and subjected to a test or condition to determine if the parameter signals satisfy a first condition (block212A and212B). However, in the various aspects of method200B, logic120may cause controller126to apply an algorithm to determine an estimated carbon build up factor in response to the monitored operational parameter satisfying a condition (block214B). Fuel injector carbonaceous deposit propensity and formation rate may be determined based on monitoring data corresponding to a plurality of engine operating conditions. Data points associated with certain individual operational parameter signals112may correspond to a specific percentage of carbonaceous deposit accumulation on fuel injector130. Alternatively, data points associated with a plurality of operational parameter signals112may be provided as inputs to the algorithm to determine an estimated carbon build up factor, a second percentage of diesel fuel, and a first time period.

Referring again to method200A and method200B, the test applied by controller126occurs at block212, wherein the method determines whether monitored operational parameter signal112satisfies a first condition. If operational parameter signal112does not satisfy the first condition, then the method returns to block210, the first composition is further used, and parameter signals112are further monitored. In method200A, if operational parameter signal112satisfies the first condition, then the method proceeds to block214A. In method200B, if operational parameter signal112satisfies the first condition, then the method applies and the algorithm at block214B and advances to block216B. At block214A and216B, a second composition is provided to fuel injector130. As described above with regard toFIG. 1, logic120causes controller126to send fuel supply assembly control signal114through interface128to cause fuel supply assembly116to provide a second composition to fuel injector130via dual fuel supply line128. The second composition includes natural gas and a second percentage of diesel fuel that is greater than the first percentage of diesel fuel provided at block210A and210B. The second composition may be further described as comprising an injector cavitation diesel fuel threshold value, wherein the threshold value is a second percentage of diesel fuel that is sufficiently greater than the first percentage of diesel fuel to cause cavitation to occur within fuel injector130. The higher percentage of diesel fuel in the second composition causes a series of bubbles and voids within the dual fuel mixture such that upon introduction into fuel injector130, cavitation occurs. The high pressures and fuel flow rate of the dual fuel composition entering fuel injector130contributes to the formation of these bubbles and voids and the manner in which the cavitation collides with walls of the injector nozzle such that abrasion and breaking off of carbonaceous deposits occurs. The carbonaceous deposits which are scavenged from the fuel injector nozzle exit fuel injector130during an injection event. To induce cavitation and thereby cause a reduction in the carbonaceous deposits from the injector nozzle, the second percentage of diesel fuel within the second composition should range from at least 50% of the second composition to greater than 95% of the second composition. In one embodiment of the present disclosure, the second composition comprises 100% diesel fuel.

In method200A, the second composition is only provided to fuel injector130for a certain time period, the duration of which may be determined in various ways as is described below. Whereas in method200B the time period is determined in response to the monitored operational parameter signal112satisfying a first condition, wherein the parameter signal data value corresponds to a carbon build up factor and the first time period is based on the carbon buildup factor. As indicated by block216A and218B, the second composition is supplied to fuel injector130until the time period expires. When the time period expires, the method returns to block210A or210B and the first composition is once again supplied to fuel injector130. With regard to method200A and200B, in either embodiment, method200runs in a continuous loop for the entire duration of engine operation. In another aspect of either embodiment, method200is activated according to a predefined schedule. In yet another aspect of either embodiment, method200is activated manually by an operator.

One of ordinary skill in the art of dual fuel engine control systems would be able to implement various designs to monitor any of the variety of additional engine operating parameter signals112and to determine whether the monitored signals satisfy a corresponding condition. For example, with regard to fuel injector tip temperature as the monitored operational parameter signal112, it may be measured by a thermocouple disposed within fuel injector130and affixed on an interior wall of the injector tip. As indicated above, multiple fuel injectors are operated simultaneously in dual fuel engine132. Therefore, when measuring injector nozzle tip temperature, a plurality of thermocouples (e.g. one for each cylinder) providing a plurality of temperature data values are in electrical communication with controller126via operational parameter signal112. As disclosed above, in method200A and200B controller126may be configured to subject the parameter signals112to a test or condition to determine whether a condition is satisfied. When parameter signals112correspond to injector tip temperature of fuel injector130, the condition is whether fuel injector tip temperature exceeds a predetermined threshold tip temperature. As is understood by those skilled in the art, elevated injector tip temperatures will provide an indication of carbonaceous deposit build up on the nozzle of fuel injector130.

In another example, if exhaust gas temperature is the monitored operational parameter, it may be measured by an exhaust gas temperature sensor disposed within an exhaust manifold and affixed adjacent the exhaust valve of a cylinder within dual fuel engine132. Dual fuel engine132includes a plurality of cylinders, each of which accommodates a reciprocating piston defining a combustion chamber therein. During operation of engine132, as part of the engine cycle, the pistons rise from bottom dead center (BDC) to top dead center (TDC) as they complete an intake stroke, a compression stroke, an expansion stroke, and an exhaust stroke. During the exhaust stroke, the rise from BDC to TDC discharges exhaust gas from the combustion chamber, through the exhaust valves, and into the exhaust manifold. The temperature sensor affixed adjacent the exhaust valve provides a temperature of the exhaust gas immediately after the gas exists the combustion chamber of the cylinder. This temperature value provided by the sensor is thus indicative of the in-cylinder exhaust gas temperature corresponding to a particular engine cylinder and a particular fuel injector130. As disclosed, controller126may be configured to subject the parameter signals112to a test or condition to determine whether a condition is satisfied. When parameter signals112correspond to the exhaust gas temperature of a particular cylinder, the condition is whether in-cylinder exhaust gas temperature exceeds a predetermined threshold gas temperature. As is understood by those skilled in the art, elevated in-cylinder exhaust gas temperatures will provide an indication of carbonaceous deposit build up on the nozzle of fuel injector130providing fuel to a particular cylinder.

As noted above, one of ordinary skill in the art of dual fuel engine control systems would be able to implement various designs to monitor additional engine operating parameter signals112, such as: total quantity of natural gas fuel used (e.g. monitor signal output from fuel quantity sensors); fuel injector drain fuel temperature (e.g. monitor signal output from temperature sensors); fuel filter restriction (e.g. monitor signal output from fuel flow sensors); and in-cylinder pressure (e.g. monitor signal output from pressure sensors). Likewise, one of ordinary skill in the art would be able to implement a basic comparator circuit to determine whether the current value of the monitored parameter signals exceeds or has fallen below a predetermined threshold value and thus satisfies a corresponding first condition. Additionally, when sensing in-cylinder pressures below a predetermined threshold pressure, the monitored parameter signal112should correspond to a pressure value obtained during a combustion event within a cylinder of dual fuel engine132. Low in-cylinder combustion pressure (e.g. below a predetermined threshold pressure) indicates low fuel quantity during an injection event which correlates to higher carbon build up on the nozzle of fuel injector130. Therefore, monitoring parameter signal112corresponding to in-cylinder pressure during a combustion event enables controller126to command fuel supply assembly116to provide the second fuel composition in response to the in-cylinder pressure falling below a threshold pressure.

FIG. 3is another example method300according to the present disclosure for reducing carbonaceous deposits from a fuel injector nozzle. Method300comprises substantially the same steps as method200. As indicated by block310a first composition is provided to fuel injector130of dual fuel engine132, wherein the first composition comprises natural gas fuel and a first percentage of diesel fuel. In method300, engine torque output of dual fuel engine132is monitored as the operational parameter of interest. As is understood by those skilled in the art, engine torque may be measured directly by an engine torque meter or a substitute such as an alternator output on a generator, or a pressure measurement on a hydraulic fracturing rig. Engine torque may also be inferred from a variety of different sensed signals such as a combination of engine speed, throttle position, intake manifold temperature and pressure, turbine speed, calculated fuel rate of diesel and engine fuel, to infer the engine torque (through calculations). The engine torque of dual fuel engine132is received and monitored as the first composition is provided to fuel injector130. As indicated above, the accumulation of carbonaceous deposits on fuel injector nozzles in dual fuel engine132results in a gradual reduction in engine torque or power output. A decline in engine torque as well as increased pollutant emissions are typical responses to injector nozzle deposit formation. Thus, method300monitors the engine torque of dual fuel engine132and responds when engine power output degrades below a threshold value. This step is accomplished at block312, in which torque is compared to a threshold. If torque remains above the threshold, then the first composition is further provided to fuel injector130and torque is further monitored. If torque falls below the threshold, then method300advances to block314.

At block314a second composition is provided to fuel injector130of dual fuel engine132. The second composition includes natural gas fuel and a second percentage of diesel fuel that is greater than the first percentage of diesel fuel. Controller126may continue monitoring engine torque concurrent with providing the second composition to fuel injector130to determine whether engine torque exceeds a predetermined torque output (i.e., satisfies a second condition). In other words, fuel supply assembly116supplies the second, high diesel composition for a period of time corresponding to the time required for the cavitation from the second composition to cause engine torque to recover to a value above the predetermined torque output. Thus, as indicated by block316, controller126may command fuel supply assembly116to switch back to the first composition in response to engine torque exceeding a predetermined threshold torque output.

FIG. 4is an example method400according to the present disclosure for reducing carbonaceous deposits from a fuel injector nozzle. As indicated by block410, a first composition including natural gas fuel and a first percentage of diesel fuel is provided to fuel injector130of dual fuel engine132. During engine operation a predetermined schedule is monitored. The predetermined schedule may be stored in memory136and may include a plurality of time intervals for providing a second composition including natural gas fuel and a second percentage of diesel fuel that is greater than the first percentage of diesel fuel. For example, logic120may be configured to access the predetermined scheduled stored in memory136to determine, as indicated by block412, the appropriate time to provide the second composition. If it is not time to provide the second composition according to the predetermined schedule then the method returns to block410, the first composition is further used, and the predetermined schedule is further monitored. If logic120accesses the schedule and determines it is time to provide the second composition, then the method proceeds to block414. At block414, controller126may command fuel supply assembly116to provide the second composition for a required time period as defined in the predetermined schedule. In one aspect of method400, timer134may be configured to function as a real-time clock providing current time as measured in seconds, minutes, hours, days or additional units of time as defined in the predetermined schedule. As indicated by block416, controller126may monitor the current time output by timer134and compare the current time to time values in the predetermined schedule stored in memory136. The second composition is provided for a predefined duration until timer134indicates that current time is equal to a time value in the predetermined schedule (i.e., the required time period has expired). The method then returns to block410.

As an example of the foregoing, the predetermined schedule may define that the second composition be provided based on a fixed time interval. For example, logic120may cause controller126to provide the second composition every72hours for10minute durations, every144hours for20minute durations, or any other variation of a fixed time interval and corresponding duration as defined in the predetermined schedule. At block416, controller126may command fuel supply assembly116to switch back to the first composition in response to the expiration of the time period or duration for providing the second percentage of diesel. Thus, in method400, controller126periodically causes an increase in the diesel percentage of the dual fuel composition for a certain time period according to a predetermined schedule of a fixed or intermittent interval.

FIG. 5depicts another example method500according to the present disclosure for reducing carbonaceous deposits from a fuel injector nozzle. At block510a first composition comprising natural gas fuel and a first percentage of diesel fuel is provided to fuel injector130of dual fuel engine132. As described above, during engine operation one or more operational parameter signals112of dual fuel engine132may be monitored. At block512, method500determines whether monitored operational parameter signal112satisfies a first condition. If parameter signal112does not satisfy the first condition, then the method returns to block510, the first composition is further used, and parameter signal512is further monitored. If parameter signal112satisfies the first condition then method500advances to block514. At block514, method500determines a first time period to provide a second composition in response to monitored operational parameter signal112satisfying the condition. As described below in further detail, method500may determine the first time period based on a predetermined scheduled stored in memory136or by applying the algorithm to determine a first time period based on an estimated carbon build factor determined from data values associated with the monitored operational parameter signals112. Additionally, at block514controller126commands fuel supply assembly116to provide a second composition comprising natural gas fuel and a second percentage of diesel fuel that is greater than the first percentage of diesel fuel. The second composition is provided to dual fuel engine132for the duration of the first time period determined at block514. At block516, while the second composition is provided, controller126further commands fuel supply assembly116and fuel injector130to adjust the fuel injector pressure and fuel flow rate of the second composition. While cavitation occurs in response to increasing the diesel percentage in a dual fuel composition, adjustments to fuel injector pressure and fuel flow rate of the second composition, provide additional methods to refine the degree of cavitation occurrence within fuel injector130. For example, under conditions of high diesel fueling and high injection pressure, cavitation and flow turbulence are more likely to occur in the spray holes and nozzle internal flow passages which will thus promote scavenging of the carbon/coke deposits on the nozzle of fuel injector130. Alternatively, lower flow and pressure conditions will inhibit the cavitation and flow turbulence and thus inhibit scavenging of the nozzle carbon/coke deposits. A variety of scavenging rates can be mapped as a function of fuel injector pressure and fuel flow rate and thus used to define a scavenging cycle time sufficient to remove the carbon/coke deposits on the nozzle of fuel injector130. As indicated by block518, the second composition is supplied to fuel injector130until the time period determined above expires. When the time period expires, method500returns to block510and the first composition is once again supplied to fuel injector130.

In one aspect of method500the monitored operational parameter signal112corresponds to engine run time and the first condition is engine run time exceeding a predetermined threshold run time. When engine run time exceeds the threshold, method500provides the second composition for a time period as defined, for example, in a predetermined schedule stored in memory136. For example, if the predetermined threshold run time is set to six hours and engine run time exceeds six hours then controller126will command fuel supply assembly116to provide the second composition for a first time period of, for example,30minutes. While the second composition is provided, controller126monitors timer134to determine whether the required30minute time period has expired (block518). If the time period has not expired then the second composition continues to be provided. When the time period expires, the method returns to block510and the first composition is once again provided.

In another aspect of method500the monitored operational parameter signal112corresponds to, for example, in-cylinder exhaust gas temperature and the first condition is exhaust gas temperature exceeding a predetermined threshold gas temperature. When in-cylinder exhaust gas temperature exceeds the threshold, method500provides the second composition for a first time period (block514). During this step controller126applies an algorithm to determine a carbon build up factor in response to the monitored operational parameter satisfying a first condition. The data value of the in-cylinder exhaust gas temperature is provided as an input to the algorithm. As disclosed above, data points associated with certain operational parameter signals112may correspond to a percentage of carbonaceous deposit accumulation on fuel injector130. In this aspect of method500, the time period determined at block514is based on the carbon build up factor and hence will be sufficient to reduce carbon build up on the nozzle of fuel injector130. Thus, in method500the algorithm may be applied to determine a first time period in response to the exhaust gas temperature parameter signal satisfying a condition, wherein the data value or the parameter signal corresponds to a percentage of carbonaceous deposit accumulation on the nozzle of fuel injector130.

As indicated above, data points associated with operational parameter signal112may correspond to a carbon build up factor. For example, as indicated in the preceding example, in-cylinder exhaust gas temperature in excess of a predetermined threshold gas temperature may result in a 15% carbonaceous deposit formation on the fuel injector nozzle, and in response, controller126may provide the second composition for a minimum required time period as determined by the algorithm. Additionally, data points associated with operational parameter signal112which indicate a predicted amount of carbonaceous deposit formation may further correspond to a variety of time periods defined in the pre-determined schedule stored in memory136. The pre-determined schedule may be comprised of a look-up table or data array which defines various time periods for providing the second composition in response to a particular parameter signal having a particular data value.