How does the fuel delivery system work for hydrogen ICE, hydrogen fuel cell and natural gas vehicles?

Semi truck getting fuel

What is the fuel delivery system?

The fuel delivery system is one of the most critical components in a vehicle and is the heart of a vehicle's power generation process. The fuel delivery system serves a similar function to a fuel tank in diesel-powered vehicles.

However, the fuel delivery system is specifically designed to handle gaseous fuels like hydrogen and natural gas, both of which are stored at high pressures. 

This article explores key details of fuel delivery systems for hydrogen internal combustion engines (ICE), hydrogen fuel cell vehicles and natural gas vehicles.

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Fuel delivery system in hydrogen internal combustion (ICE) and hydrogen fuel cell engines

Storage tank

Hydrogen-powered vehicles such as transportation trucks are equipped with a specialized fuel delivery system that is engineered to handle the high-energy content and low density of hydrogen fuel. Central to this system is the storage tank, a cylindrical vessel made from carbon fiber. This storage tank is designed to hold hydrogen safely at high pressures that can reach up to 700 bar or 10,000 psi. This pressure refers to how tightly the hydrogen is squeezed inside the tank. So, the higher the pressure, the harder it is to keep it stored! This tank must therefore be able to endure the open road and the refueling process while maintaining its structural integrity.

On-tank valve 

The on-tank valve is another key component of the hydrogen fuel delivery system. It uses an electrical solenoid to regulate the flow of hydrogen to the engine or fuel cell injection system. It is also a vital component during the refueling process, ensuring that hydrogen can be refilled quickly and safely. This feature is especially important for on-highway commercial trucks that operate on tight schedules and may need to refuel at different stations along their route.

Important safety devices are also integrated into the on-tank valve, which help mitigate the potential risks associated with hydrogen fuel and its storage. The thermal pressure relief device (TPRD) is a temperature-sensitive valve that safely vents the fuel to the atmosphere when activated. This helps to avoid explosion or fire, ensuring the safety of the vehicle, its cargo and the driver. Additionally, the on-tank valve has multiple mechanical valves that can refuel the system or prevent fuel flow out of the tanks which enables the safe troubleshooting and servicing of the fuel delivery system.

High-pressure regulator

The high-pressure regulator of the fuel delivery system works on conditioning the hydrogen. It reduces the pressure of the fuel to a level that is suitable for energy generation at the fuel cell stack or engine. This is typically up to 20 bar for fuel cells and 50 bar for hydrogen ICE. Depressurizing hydrogen is not only a matter of safety but the accuracy of delivery pressure allows the engine to operate efficiently and effectively. For example, in a hydrogen ICE-powered vehicle, the regulator must consistently provide the correct delivery pressure to ensure accurate fueling regardless of application demands and driving conditions.

Fuel delivery system in natural gas engines 

Natural gas vehicles are increasingly popular for transportation, particularly in delivery trucks that operate in urban areas with frequent stop-and-go traffic. A fuel delivery system for natural gas has the same components but also a few distinct characteristics compared to the fuel delivery system for hydrogen vehicles. 

Storage tank

The storage pressure for natural gas is lower than that of hydrogen. However, the fuel delivery system still needs to be capable of storing and handling high-pressure gas. Typically, natural gas is stored in the fuel delivery system at pressures up to three hundred bar or 4000 psi. 

On-tank valve

The type of on-tank valve used in natural gas fuel delivery systems is different than those used in fuel delivery systems for hydrogen vehicles. In natural gas vehicles, mechanically operated on-tank valves are commonly used, whereas electronically controlled valves are found in the fuel delivery systems for hydrogen vehicles. Like hydrogen on-tank valves, natural gas valves may still possess integrated features such as TPRDs and bleed valves for safety and serviceability purposes. 

High-Pressure Regulator

Like hydrogen fuel delivery systems, a high-pressure regulator is used with natural gas to reduce the fuel supply pressure to an appropriate level for delivery to the engine – typically 4 to 10 bar. Since most natural gas on-tank valves are mechanical devices, the high-pressure regulator may also be integrated with a shut-off valve which is an electronically controlled valve that stops the flow of fuel to the engine when the vehicle is shut-off.

Considerations for fuel delivery systems in natural gas engines vs hydrogen ICE and hydrogen fuel cell engines

Natural gas fuel delivery systems are well-established in the market today. However, hydrogen fuel delivery systems are a new technology with greater complexity. There are a few considerations to keep in mind when it comes to choosing the fuel delivery system for hydrogen internal combustion engines (ICE) and hydrogen fuel cell engines. 

  • Sealing techniques: Hydrogen molecules are smaller than natural gas and therefore, more difficult to seal. Selecting the right sealing mechanisms and choosing materials with low porosity (fewer voids in the material) will help ensure a robust seal. Elastomeric seals (rubber-like polymers) have lower porosity which helps ensure a more robust seal.
  • Material selection: Hydrogen can cause embrittlement. Embrittlement is when metals become brittle over time as they absorb hydrogen. Therefore, proper material selection is critical. Stainless steel and anodized aluminum are good materials for hydrogen. Appropriate polymer selection for sealing is also important to prevent material degradation.
  • Material coating: Because hydrogen is a gaseous fuel, it does not provide lubrication for internally moving components in the way that diesel fuel would. Special materials and coatings between moving components can be used to minimize wear from two materials sliding against one another.
  • Testing: Hydrogen fuel delivery systems are subject to rigorous certification testing dictated by many global standards (e.g. – ECE R134, EC79, HGV 3.1, etc.). Depending on the market you are looking to serve, understanding the regulatory norms and identifying capable test partners to validate those norms is critical.

The transition to a more sustainable transportation industry is an exciting process. The fuel delivery system is a key component of this journey moving away from traditional, carbon-intensive fossil fuels. Whether for a hydrogen internal combustion engine, a hydrogen fuel cell vehicle, or a natural gas engine, the fuel delivery system stands as a testament to cutting-edge engineering. Cummins is ready to partner with manufacturers and fleets and help them take advantage of these new fuel technologies. Contact us here or at your local Cummins sales office today to learn more.

Accelera™ by Cummins works on the development of new technologies in fuel cells. Accelera, a business segment of Cummins, is both a components supplier and integrator, focused on batteries, hydrogen fuel cells, e-axles, traction drive and electrolyzers. For more information on the diverse Accelera portfolio of zero-emission solutions please visit accelerazero.com.

Cummins Office Building

Cummins Inc.

Cummins, a global power technology leader, is a corporation of complementary business segments that design, manufacture, distribute and service a broad portfolio of power solutions. The company’s products range from internal combustion, electric and hybrid integrated power solutions and components including filtration, aftertreatment, turbochargers, fuel systems, controls systems, air handling systems, automated transmissions, electric power generation systems, microgrid controls, batteries, electrolyzers and fuel cell products.

Why you should become a Cummins Home and Small Business dealer

Cummins dealer smiling next to home generator

For more than 100 years, Cummins Inc. has been dedicated to making people’s lives better by powering a more prosperous world. As a company, we seek to be customer-driven, innovative, responsible, and trustworthy so that we can truly make a difference now and in the future.

But exactly what does Cummins do? At a high level, we create power solutions. You’ll find Cummins products and solutions for on- and off-highway engines, turbochargers, electronics, fuel systems, generators and power systems, and more. We’re not in this on our own, though. With a broad network of Cummins-authorized dealers in the home and small business power solution space, we count on our independent dealers and their local relationships. If you’re interested in becoming a Cummins-authorized dealer, keep reading to find out the benefits and how to get started.

Does Cummins make Home Generators and Small Business generators?

Yes, Cummins offers generators that are sufficient for residential homes and small businesses, including:

  • 13-20 kW air cooled emergency standby generators
  • 25-150 kW liquid cooled emergency standby generators
  • 9,500-watt portable, dual fuel heavy duty generators
  • 2,500-4,500-watt portable, lightweight inverter generators
  • 300-1,000-watt portable lithium battery powered power stations

In the midst of severe weather, increased blackouts, and aging power grids, generators are becoming more and more important. Consider this: 83% of power outages were the result of weather-related incidents from 2000 to 2021.

When these outages occur during extreme temperatures, generators are critical to keeping homes and businesses comfortable, safe, and operational. Families won’t have to worry about losing their heat or everything inside their refrigerators. Businesses won’t have to worry about the potential financial impact that comes with an outage—which can be as much as $12,500 a day for a small business. 

All of these reasons are likely why search terms like “Cummins generator dealers near me” are so popular on Google and other search engines. Local people are consistently looking for the right generator solution. Cummins-authorized dealers can help ensure they have the power they need, no matter what.

What are the benefits of being a Cummins Generator Dealer for Home and Small Business?

Of course, if you’re thinking about becoming a Cummins-authorized dealer, the fact that there’s a market isn’t the only perk. Here are eight more reasons why you should become a Cummins-authorized Home and Small Business generator dealer.

  1. You’ll be backed by the Cummins brand, a name that’s synonymous with support, reliability, and sustainability. Cummins generators are quality, trustworthy equipment that you and your customers can count on.
  2. You will receive state-of-the-start training. Cummins provides courses and the certification path required to become a Cummins-authorized partner and product expert. Our technical training and certifications provide knowledge on Cummins home generator service like installation, maintenance, and repair.
  3. You can connect to a robust network of Cummins resources. Our dealers have access to a world-class set of tools, including training, a dedicated account executive, an online portal, sales and training certifications, and so much more.
  4. You’ll receive “preferred parts” pricing. By becoming an authorized dealer, you’ll get the best parts pricing around so you can maximize your profits. You can also pass these savings on to your customers to ensure your pricing is competitive.
  5. You can capitalize on marketing support. Cummins regularly invests in brand-building and lead generating campaigns to drive customers to our dealers. 
  6. You have access to warranty claim submission. Warranties don’t have to be a hassle for you or your customers. As an authorized-service dealer, you can submit warranty claims on behalf of your customer to improve customer satisfaction and loyalty. 
  7. You can join the ChannelOne Partner Rewards Program. This competitive rewards program helps you maximize your earning power.
  8. You can list your company on the Cummins Parts & Service Locator. The Cummins service locator makes it easy for local customers to connect with your business, and it increases your overall brand visibility.

How to become a Cummins Dealer: It’s easier than you think

Stop missing out on all of the local online traffic searching for “Cummins authorized dealer near me,” and bring great products to your community! It takes just four simple steps to get started.

  1. Complete the online “Become a Dealer” interest form. A regional Cummins Account Executive will contact you to start the discussion.
  2. Share additional information about your business, your experience, and why you’re interested in becoming a Cummins dealer.
  3. Fill out and return the necessary paperwork to be processed by the Cummins team.
  4. Complete your required product training and become a Cummins Home and Small Business Dealer.

At Cummins, our company is dedicated to providing great products and services to customers throughout the world. If you’re ready to join our world-class network, get started now.

Cummins Office Building

Cummins Inc.

Cummins, a global power technology leader, is a corporation of complementary business segments that design, manufacture, distribute and service a broad portfolio of power solutions. The company’s products range from internal combustion, electric and hybrid integrated power solutions and components including filtration, aftertreatment, turbochargers, fuel systems, controls systems, air handling systems, automated transmissions, electric power generation systems, microgrid controls, batteries, electrolyzers and fuel cell products.

How do I calculate what size generator I need?

Customers talking to Cummins dealer

There are several great reasons why you might be considering a standby generator for your home or small business. In the event of a power outage (caused by severe weather, for example), having a standby generator helps ensure ongoing safety and comfort. And in the case of a business, the ability to reduce downtime and maintain operations is a significant advantage.

Standby generators—also known as permanent or whole-house generators—offer reliable and efficient backup power solutions for a wide range of applications. If you’re currently exploring your options, we imagine you have a few concerns. You’re probably looking for a generator that’s sold and serviced by a reputable company, and want to determine the right generator capacity for your needs.

In this article, we’re going to help you answer a key question: “What size generator do I need to run my house or small business in the event of a power outage?” Keep reading for an overview of how to find the perfect Cummins Inc. standby generator for your needs.

What is the rule for generator sizing?

When it comes to understanding generator sizing, one important rule to keep in mind is that the generator needs to be able to power everything requiring electricity, but it also needs to have additional capacity to account for various appliances’ starting wattage. Otherwise, you might find yourself in a situation where your generator simply won’t cut it, potentially leaving your home or small business without the power it needs.

Next, we’ll cover a basic framework for calculating your power needs.

How to Calculate Standby Generator Size

Here’s a simple, three-step process for assessing your needs and priorities, understanding generator sizes, and finding what size generator is going to work best. 

Let’s take a look at what this process looks like.

Step 1: Understanding Generator Sizes

Here’s a basic formula for how to calculate standby generator size:

  1. First, create a list of everything in your home or small business that would need to be powered by the generator in case of an emergency. This should include anything that requires electricity and isn’t something you would want to go without should you lose power. It’s important to not only consider running wattage, but starting wattage as well—since most appliances will require a few seconds’ worth of extra wattage to get started. There are several online sources for determining appliances’ wattage requirements.
  2. Add together each item’s running watts. When in doubt, err on the side of overestimating wattage requirements since it’s much better to have a little more power available than is needed as opposed to having to adapt to a generator that lacks sufficient power.
  3. Then, to roughly account for starting wattage, add the single-highest starting watts figure to the total.
  4. To ensure a margin of safety—and to account for potential future needs—you should multiply that figure by at least 1.25. The resulting number is the minimum generator capacity you should consider.

You can also use our home generator sizing calculator to estimate your power needs.

Step 2: Assessing Your Needs

It’s important to understand your priorities. While getting the right size and type of generator that fits your budget are important, it’s also important to consider how you intend to use the generator.

  • Will it need to be capable of maintaining enough power for your home or small business in case of an emergency?
  • Do you envision having a permanently-installed generator, or is portability important?

How you answer these questions should help provide context for the next step: exploring generator sizing and zeroing in on the perfect product for your needs.

Step 3: Finding the Right Generator

In addition to the generator size calculator, our online buyer’s guide to home generators is a great starting point for exploring your options. Cummins offers three main types of standby generators suited for a home or small business:

  • Permanently-installed 13-20 kW air-cooled home standby generators that can be powered up when needed. 
  • Permanently-installed 25-150 kW liquid-cooled home standby generators that can be powered up when needed. 
  • Heavy-duty, gasoline- or propane-powered 9,500-watt dual fuel portable generators that can provide backup power for a home or small business. 

Cummins: Reliable and Affordable Standby Power Solutions

At Cummins, we build versatile, high-quality standby generators for homes and small businesses. Don’t let their quietness fool you—they’re powerful and reliable. 

When you’re ready to explore your options, you can reach out to request an on-site assessment. One of our authorized dealers will help you assess your needs, evaluate different generator types and capacities, and understand how much a generator might cost to have installed.

Cummins Office Building

Cummins Inc.

Cummins, a global power technology leader, is a corporation of complementary business segments that design, manufacture, distribute and service a broad portfolio of power solutions. The company’s products range from internal combustion, electric and hybrid integrated power solutions and components including filtration, aftertreatment, turbochargers, fuel systems, controls systems, air handling systems, automated transmissions, electric power generation systems, microgrid controls, batteries, electrolyzers and fuel cell products.

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