LBNG QSK60G & QSK60G - High
Efficiency Series Gas Engines
Module 4 – Base Engine
Cummins Corporate Training
1
QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
QSK60G LBNG Engines
Learning Objective
To identify Key differences between the Industrial QSK60
diesel and gas engine and to identify components unique
to the gas range. Participants will also understand QSK
Gas engine terminology, layout and configuration.
Agenda
• Gas Engine Data.
• Gas Engine Layout.
• Engine Configuration.
• Differences between QSK Gas and QSK Diesel Engines
• Gas Component Familiarisation.
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
QSK - Gas Engine Data
METHANE INDEX
• Standard QSK60G - Operates on Natural Gas with a Minimum
Methane Index between 52 & 73 (dependant on model type).
• HE QSK60G - Operates on Natural Gas with a Minimum
Methane Index between 65 & 86 (dependant on model type).
IDLE SPEED
• 900 rpm for all engine models.
COMPRESSION
• QSK60G = 11.4 : 1 or 12 : 1 (dependant on model type).
• QSK60G HE = 11.4 : 1 (all models)
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
QSK60 Diesel / Gas
Design Change Details
Piston: Gas system:
Change to deep bowl Ferrous Cast Ductile Iron (FCD) Add inlet gas injection on each turbo
piston. Add Cummins type gas metering system
Combination of Q60 (Keystone type top ring) and Q19G Add gas line connections (for customer supplied off-
( Rectangular type 2nd) rings. engine fuel supply system).
Cylinder head:
Valve cover modifications for coil, Add coil Air handling:
Remove injector hardware and design to accept spark Turbochargers (Two HX82 or one ABB).
plug. Turbine out elbow
Remove injector rocker arm, replace with spacer ring Exhaust manifold sections (re-design for log manifold)
Stellite exhaust valves & seats with 20 deg seating Single aftercooler, two stage ( LTA & HT)
angle. Multi turbo, 30 deg sinlge turbo (exhaust valve seat Aftercooler coolant and air connections
modified for increased seat Throttle & throttle driver (Pre 2009 models)
area due to increased temp). Compressor inlet connections, Air filter, Air filter
Trib-alloy intake valves & seats with 30 deg seating angle. header box.
Modified valve stem seals ( wetter, more oil flow) Cast iron intake manifolds (Log type)
Modified valve guides (Hardening specification)
Provision for Knock sensor location Controls:
Different machining of cylinder head casting, for optimum CENSE or CM850 monitoring 16 exhaust
cooling and to add intake swirl. thermocouples / Thermistors
Free end: One CM700/harness/sensors
Left bank cam gear ( l only) with 24+1 pattern for engine Two CM558/harness/sensors
position sensing (EPS) Lambda sensor & KW transducer for closed -loop fuel
Access to cam gear for EPS sensor through gear housing control. (GCP1 engines only)
Diesel Fuel system: Two ignition modules/harnesses .
Remove diesel fuel system components
(fuel lines, filters, housings), CM550 and housing.
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
Key Feature Comparison –
QSK60 / QSK60 HE
QSK60G Gas Engine QSK60G HE Gas Engine
• Twin Holset HX 82 Turbo’s. • Single ABB TPS 52 Turbo.
• Standard Wax Bulb • Electronic Motor Control
Temperature Thermostats. Valves Regulate Temperature
To High Accuracy.
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
QSK60G V-16 Engine
• Base Engine design generally as QSK 60
diesel.
• Two Holset HX52 Turbochargers with water
cooled bearing housings.
• No Compressor by-pass valve required.
• Gas/Air Mixer is of simple basic design.
• On engine air filters (off engine optional).
• New Air Handling Pipework for Intake and
Exhaust (LOG type)
• Wax bulb thermostats fitted in thermostat
housing as diesel.
• Modified HT & LT cooling pipework.
• Single fuel control Assembly.
6 • Standard Otto Cycle Camshafts QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
QSK60G V-16
High Efficiency Engine
• Base Engine design as standard QSK 60G.
• Single ABB H/E Turbo with water cooled
bearing housing.
• Compressor by-pass valve (CM700 control).
• Special H/E Gas/Air Mixer.
• Off engine air filters
• New Air Handling Pipework for Intake and
Exhaust.
• Thermostats replaced by electronic control
valves.
• Modified HT & LT cooling pipework.
• Single fuel control Assembly.
• Miller Cycle Camshafts
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
Bank and
Cylinder Identification
Front 2
1 4
3 6
5 8 RIGHT - Bank
7 10
9 12
11 14
13 16
15
LEFT- Bank
Bank designation always refers to
REAR
engine when viewed from the ‘Rear’.
Cylinder numbering from the ‘Front’
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
QSK 60 G - Front View
4 2
1. Compressor outlet Pressure (Boost)
2. LT Coolant Temperature
3. LT Coolant Pressure
4.Throttle Position Actuator/ Sensor.
QSK 60 G - Left Bank View
1 2
3
12
XYZ 4
11 10 9 8 7 6 5
1.Compressor Inlet Temp, 2. Oxygen Sensor (when fitted), 3. Oil Rifle Pressure, 4. CM700 Speed
Sensor, 5. Engine Harness Interface Connections (X -Power Y -Auxiliary Z - User Interface ), 6.
Throttle Driver, 7. Crankcase Blowby Pressure (x2), 8. Oil Temperature Sensor, 9.CM558, 10. Oil
Level Switch , 11. Ignition Module, 12. HT Coolant Temperature.
QSK 60 G - Right Bank View
1 2
3
4
9 8 7 6 5
1. Gas Control Assembly (Fuel Inlet Pressure, Gas Mass Flow sensor, Fuel Control Valve, Fuel Outlet
Temperature & Pressure) 2. HT Coolant Pressure, 3. Intake Manifold Pressure, 4.
Intake Manifold Temperature, 5. Ignition Module, 6. Oil Pressure – Pre-Filter, 7.
Oil Pressure – Post-Filter, 8. CM558, 9. CENSE (CM530)
QSK 60 G - Top View
6 5 4 3 2
1. Fuel Inlet Pressure (FIP), 2. Fuel Outlet Temperature (FOT) , 3. Fuel Outlet Pressure (FOP), 4.
Exhaust Back Pressure Sensor, 5. Coil On Plug (on each cylinder), 6. Knock Sensor (on each cylinder,
refer to knock sensor position diagram), 7. Exhaust Port Temperature Sensor (on each cylinder).
QSK60G HE – Left-Bank View
8 x Exhaust
Thermocouples
CIT – Coolant Inlet
Temp (LT)
LCP – LT Coolant
Pressure
COT – Coolant
Outlet Temp (LT)
CCD CM558 CM850
Engine oil Level Switch.
E (Fitted & wired as part of
genset build). Oil fill & Dipstick
DT Dirty oil tank level Switch.
(Fitted & wired as part of DT
genset build). EPS – Engine OTS – Oil Temp Sensor
Position Sensor
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
QSK60G HE – Right-Bank View
HCP - HT coolant
8 x Exhaust pressure
Thermocouples
Compressor
By-Pass Valve
COP – Compressor
outlet pressure
MAP - Manifold
Absolute Pressure
IMT - Intake
FOP – Fuel outlet
Manifold Temp
pressure
FIT – Fuel inlet
Temperature CM850 CM558 CCD
FCV – Fuel Control
Valve
GMF – Gas Mass
Flow
FIP – Fuel inlet
Pressure
OAP – Oil pressure OIP – Oil pressure
after filters before filters
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
QSK Gas
Verses QSK Diesel
External components:
• Fuel system & controls
• Air handling - intake, after
cooling and delivery layout.
• Exhaust Layout
• Cylinder head design
• Cooling circuit modifications
Grey area
un-changed
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
QSK Gas
Verses QSK Diesel
Internal components:
• Piston
• Piston Rings
• Rocker arrangement
• Valves & Valve guides
• Camshaft drive gear
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
Camshafts &
Camshaft Drive Gears
One piece camshaft for valve
timing only. Requires special
tooling for support on removal
to prevent damage to shaft and
Camshaft bushings.
Use ‘Straight’ keys only. Use of ‘Offset’
keys is prohibited and will result in
timing and fuelling related problems.
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
Standard QSK60G
Exhaust Manifold
Multi section ‘LOG’ design for each
bank and Turbo
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
QSK60G HE
Exhaust Manifold
Special Assembly
Procedures are required
to ensure correct
alignment and fit.
Ref. Module 12 -
Component R & I.
Special H/E
Exhaust ‘Header”
section
Standard QSK60G
Exhaust Manifold
Sections & Bellows
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
Air/ Fuel System
• Std 60G:
- Single stage turbo charging – 3.5 Bar (50 psia) boost @
rated speed/load.
- Two Holset HX82 turbo’s, with water cooled bearing housing.
- Non-serviceable.
• 60G H/E:
- Single stage turbo charging – 3.5 Bar (50 psia) boost @ rated
speed/load.
- One ABB TPS52 turbo, with water cooled bearing housing.
- Non-serviceable.
Both have:
• Single aftercooler, two stage 12 pass (6 x HT and 6 x LTA loops).
• Single Woodward ProAct III throttle with driver module.
• Single Fuel Control Assembly.
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
Turbochargers –
Std QSK60 Gas
FEATURES:
Single-Stage Radial Turbine design.
Cast iron turbine and housing.
Aluminium compressor with cast iron housing
In-board Plain Bearings.
Engine sump oil lubrication
Water cooled bearing housing. Oil & Water
Connections
Cartridge Design, Balanced Sealed Unit.
(C.H.R.A. - Centre Housing Rotating Assembly).
2 X Holset
HX82 Series
Turbochargers
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
Gas / Air Mixer
– Std 60G
Air filter box Gas supply
pipe from
gas control
assembly
Gas feed to
each of the
two mixers
Air filter
Position
Mixing point
Mixer built into both outlets of the air filter box
- Simple two hole design.
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
QSK60G HE –
ABB Turbo Turbo mounting bolts
Air/Fuel inlet
from Mixer.
Exh.
Outlet to outlet
C/A cooler
Exh.
manifold
connection
Flywheel housing
ABB – TPS 52 saddle
O- ring seal
O- ring seal (Water)
(Oil supply)
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
ABB Turbo –
Speed Sensor
Arrangement
1) Located LHS/RHS of bearing
casing.
2) Output to CM700 Module.
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
QSK60G HE Mixer &
Fuel Control Assembly
Fuel Mixer
Transfer line
Fuel Control
assembly
High efficiency mixer design to: – Compressor
• maximize swirl by-pass connection
• minimize restriction to gas flow
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
Compressor By-pass
– HE Engines ONLY
Charge Air Cooler
Inlet Manifold
Connection
By-Pass Flow
Support Bracket
Direction
Vent Tube
back to mixer
Support
Bracket Valve
Support Bracket
Vent Tube
Fuel by-pass valve
( 33.0mm Woodward
Flo-Tech valve)
Fuel Mixer
29 Connection QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
Intake Manifold
New multi section ‘LOG’ design
Two cylinders serviced per section;
QSK60 - 4 sections
‘O’ ring seal between sections
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
Charge Air/Gas Flow –
Std QSK60G
New pipework layout
- charge air cooler to throttle and
cylinder.
- filter housing (including gas mixer)
to turbo’s.
- turbo’s to charge air cooler.
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
Charge Air/Gas Flow –
QSK60G H/E
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
Aftercooler
6 pass HT core 6 pass LTA core
Right Side - HT Loop, feed / return Left Side - LTA Loop, feed / return
Air &Gas Flow
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
Cylinder Head
Exhaust
Thermocouple
Detonation (Knock)
sensor
Design changes;
‘Dry’ Spark plug seat
Exhaust valve / seat angle 20° multi
turbo, 30 ° single turbo (Dry)
Intake valve / seat angle 30° (Dry)
Knock sensor location
Exhaust thermocouple location
4 Valves / Cylinder
Centrally located ‘dry’
spark plug seat
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
Cylinder Head –
Knock Sensor Locations
Engine Lifting
Knock Turbo Drain
brackets at four
Sensor position (Oil return)
locations
R2 R4 R6 R8 R10 R12 R14 R16
QSK 60G Front
L1 L3 L5 L7 L9 L11 L13 L15
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
Valve Gear & Camshaft
Design changes; Design changes;
Spacer replaces injector lever Diesel Camshaft with roller tappets
on intake & exhaust cams only
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
QSK60G & H/E Gas Pistons
FEATURES
• Mono block (one piece) design with
optimised combustion bowl.
• FCD Iron - High strength & durability.
- Low weight.
- High operating temp 550° C,
without material degradation.
• Nitride finish - Improved scuff resistance
INSTALATION
• No offset or piston cooling cut-outs in
skirt.
• ‘EX’ marking toward exhaust valve side of
head when factory assembled. Good MONO BLOCK DESIGN
practice to maintain orientation. FERRIOUS CAST DUCTILE IRON
( FCD )
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
QSK60G & H/E Gas Pistons
• Fitted with standard ring pack - two
compression rings and one oil scraper ring in
the crown.
• Two piston cooling nozzles per cylinder –
Mandatory - Remove nozzles before
attempting to remove piston.
2 x Piston Cooling
Nozzles per cylinder.
(inboard/outboard).
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
QSK60G - New
Thermostat Housing
Thermostat rating dependant LTA Thermostat Location (fitted
on emissions target; in standard 60G ONLY)
HT - 95° C (All models)
LTA - 40° C (0.7 TA Luft )
- 50° C (TA Luft/1g + )
HT Thermostat Locations
(fitted in standard 60G ONLY)
Improved one-piece housing design
60G - Incorporates 6 x HT & 1 x LTA Thermostats with easy access.
NOTE: QSK60G HE uses off-engine coolant temperature control, therefore no
on-engine thermostats fitted.
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
Engine Wiring Harness
• Aluminium main structure,
flexible plastic limbs.
• Inter connects all ECM’s and
sensors.
• All genset wiring in separate
harness.
• Must be removed prior to
major power cylinder work.
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
LBNG QSK60G & QSK60G - High
Efficiency Series Gas Engines
Module 4 – Base Engine
End
Cummins Corporate Training
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QSK60G / Base Engine / KDL / April 2010 / REV 1.01.
