QSK 60G & 60G High Efficiency Series
Gas Engines
Module 5 – FUEL SYSTEM
Cummins Corporate Training
1
HE -60G/
HE -60G/
Fuel System
Cooling//BMG
BMG // 03
03 -- 07
07 // REV
REV 01.
01.
System Module - Fuel
Learning Objective
To give an introduction to the Gas Fuel System. At the end of this
section of the module you will be able to describe the operation of the
Fuel System and trace the gas flow path.
Agenda
• Gas Supply Components -
- Mounted ‘Off’ the Engine,
- Mounted ‘On’ the Engine.
• Fuel System Schematic.
• Main Fuel System Components.
2
Gas Supply Components
The natural gas supply system can be split into two parts;
components mounted external to the engine and those mounted on the
engine.
1) The components EXTERNAL to the engine:
Main shut-off valve (manual).
Gas filter.
Flow meter (optional).
Pressure reducer / regulator down to 150mBar.
High pressure discharge valve.
Twin Solinoid Gas Control Valve - Twin shut-off valves (for isolation &
safety, includes adjustable high and low pressure safety switches).
3
Gas Pressure Safety Blow
Gas Pressure Switch Off Valve
Regulator
IN OUT
Engine Connection
Manual Gas Safety Shut Double must be via approved
armored flexible gas
Gas Valve Filter Off Valve Solenoid Valve line
WARNING: Ensure ALL gas pipe work is Earthed! Clamp type Earth straps should
also be fitted onto flexible supply connection to engine.
Gas Supply Line as shown normally 80mm diameter up to 3.0Bar inlet pressure,
50mm diameter over 3.0 Bar.
Gas pressure regulator should be set for 150m bar at engine inlet ( Gas control
assembly Fuel inlet Pressure ).
4 Gas Supply System EXTERNAL to Engine - Supplied Loose
Hand Valve
Concentric disc soft sealing butterfly valve.
Install between flanges DIN/ISO 5211.
Pressure rating up to dP16Bar.
Tight seal with flow in either direction.
5
Filter
GF Type - general fine filter for all gasses
and air, 50 micron rating.
Body cast - Aluminium & Silicon (ALSi).
Flanges to DIN 2533.
Filter pad - removable polypropylene
fleece.
Can be fitted in horizontal and vertical
indoor pipes.
Maximum operating temp + 80º C.
Maximum pressure 2 or 4Bar.
Note: Direction of gas flow
6
Pressure Regulator
Pressure
Gas pressure regulator with high Control
level safety shut-off valve at Adjustment
200mBar, manual reset only.
Actuator Control
(Diaphragm) Spring
Pressure settings - 3 inlet options
determined by valve seat diameter: Pressure Breather
1) 1.25 - 1.8 Bar / 150mBar Equalisation Nozzle
2) 1.80 - 3.0 Bar / 150mBar Diaphragm
3) 3.00 - 4.0 Bar / 150mBar
SSV
Regulator output pressure range set Reset
by spring choice - orange supplied: Shaft
100 - 160mBar. Tap
Connection
P1 P2 (sense)
SSV pressure range set by colour-
coded spring - green supplied: 200 - SSV Control
800mBar above set regulator output Valve Seat.
Element
pressure. Blow-off Nozzle.
Tap Nozzle.
SSV Actuator
Differential between set and Casing
Spring
response pressure of the SSV SSV Adjustment
should be not less than 20mBar to
prevent sporadic tripping.
7
Regulator Installation & Operation
Blow-off & Regulator breather
To ensure that the device lines (run separately)
will respond properly in the
event of rapid load changes,
the regulator breather line Pressure Typical Regulator
should have the following Regulator Installation
dimensions: with SSV
Up to 3.0m long DN -15
TO ENGINE
Up to 5.0m long DN - 20
Tap Line
Over 5.0m long DN - 25
MAINS GAS SUPPLY
Tap lines should be
connected to a length of outlet
pipe where turbulence is low, SSV Tap Line 5 x DN
i.e. at a minimum distance of 5
times the pipe diameter SSV - Safety
Shut-off Valve
8
SSV Reset Procedure
• Slowly open the by-pass
valve to equalise the pressure
across the regulator.
• Remove the closing cover.
• Move the valve bar
downwards until the ball lock
shut-off re-engages. OPEN
• Ensure good ventilation, a
small quantity of gas can
escape when removing the
closing cover.
• Refit the closing cover and
seal. CLOSED
• Close the by-pass valve.
• Perform a leak test on the
closing cover.
• The SSV is again ready to
operate.
9
Safety Blow Off Valve
Sealing Cap
20…1000mBar
P1
0.28…14PSI Adjustment Device
Set Point Spring Breathing Plug
Safety Diaphragm
Cover
Diaphragm Disc
Intermediate Disc
Working Diaphragm
Controller Plate
Sealing Ring
P1 P2
Housing Spindle
10
Twin Solenoid Gas Control Valve
Vent Solenoid
Gas Control Valve - 24v dc solenoid
operated twin shut-off valves with vent
( for isolation and safety).
Normal shutdown shuts off supply via this
valve.
LP protection set at 80mBar (adjustable).
HP protection set at 180mBar (adjustable).
Valve operation can be checked by
listening to the sound of the valve operating
when switching the valve isolating switch on
the generator control panel. LP Safety HP Safety
switch switch
THE CONTROL VALVE THEN SUPPLIES THE GAS GAS CONTROL ASSEMBLY ON THE ENGINE
11
Valve Proving System – VPS504 maintenance
Valve Proving VPS Outlet The VPS requires regular
System Filter & O-Ring inspection and service.
Carry out a yearly inspection. If
operating in a harsh environment
carry out every six months.
Inspect gas connections and VPS
fittings. Test for leaks.
Replace Inlet and Outlet filters and
O-rings.
Filter servicing is vital as blocked
filters will cause the VPS to pass
the test, regardless of condition of
the DSSV valves.
Filter replacement Kit Cummins
VPS Inlet Filter Part No. 0504-0305
& O-Ring
NOTE: In some countries VPS servicing MUST be undertaken by a gas registered
technician. Follow local legislation & codes
12
Gas Supply Network
Gas Valve Proving System (VPS)
TEST/
Reset
Engine Mounted FSOV w/ Validation Module P2
Front View of Top View of
Validation Module Validation Module
13
Gas Control Valve DMV-D
Main Flow
Adjustment Cover
Electrical Blanking Plug
Connection
Solenoid V1 Solenoid Housing
Plunger V1 Solenoid V2
Plunger V2
Closing
Spring V1 Closing Spring V1
Housing
Valve V1 Valve V1
V1 V2
P1 P2
Strainer
Flange Double-Solenoid Valve,
fast opening.
14
Gas Supply Components
2) The supply components mounted ON the engine:
Gas Control Assembly (Mixture Control - FloTech valve).
Gas /Air Mixer (2 off).
Turbocharger (2x Holset HX82).
Charge Air / Gas Cooler.
Actuator / Driver (throttle) - (1 off).
CM558 Module (Control Module x 2) Fuel & Ignition control
( Left bank only controls mixture).
CM700 (Control Module 700 x 1) Throttle control / speed.
CM700 / CM 558 module functions will be covered in the control module
15
Gas Control Network
Gas Flow
QSK60G Multiple Turbocharger Models
16
Gas Control Network
Gas Flow
QSK60G Single Turbocharger Models
17
Gas Control Network
Gas Flow
QSK60G Single Turbocharger Models
18
‘QSK 60’ Engine Gas Circuit Schematic
Gas / Air mixture to - Charge Air / Fuel 2 x Mixers Air into
Cooler - Throttle Actuators - cylinders turbochargers
FIP = Fuel Inlet pressure Sensor.
FOP = Fuel Outlet pressure Sensor. FIP Gas control
FT = Fuel Temperature Sensor. assembly.
GMF Sensor.
Twin Solenoid Flow Calculation
Valve via CM 558
HP Safety Valve
Gas (200mBar)
Duty Cycle Valve
Supply Regulator (FloTech)
Train
Filter Filter Components Mounted on
the Engine
Isolation Valve FT FOP
Externally Mounted
( Hand Valve) Components
19
QSK 60G Gas Control Assembly (Duty Cycle)
Typical Value; T2 = Fuel System Temp AIR GAS MIXER
P1 = 1.15Bar abs. Compensation. INTAKE
P2 = 0.9Bar abs.
PRESSURE SENSORS P1 & P2
dP
FIP GAS mass FLOW DUTY CYCLE VALVE FOT
(P1) SENSOR (FloTech) (P2)
GAS TO
IN TURBO’S
VENTURI
FT
(T2)
5v
By-pass line
reduces
G.M.F 0v
turbulence and SENSOR
increases (Hot Wire) Mark Space Ratio
measurement GAS MIXER
resolution
All control signals to and from Left Bank CM558
20
QSK60 HE Fuel System FOT – Fuel Outlet
Temperature.
Mixer Housing
CAT –
Compressor Air
Temp (inlet).
FIT – Fuel Inlet
Temperature.
FCV – Fuel
Control Valve.
GMF – Gas
Mass Flow
Sensor.
FIP – Fuel Inlet
Pressure
Sensor.
21
22
(D) CM558 Plug B Pin xx - Sensed Gas Mass Flow Signal
(B) CM558 Plug B Pin xx - Sensor (–)
(A) CM558 Plug B Pin xx - Sensor (+24 v dc supply from CM558)
(C) Battery 24V (–)
GMF Pin-out
GMF
FIP
Gas Metering
Gas Control Network
QSV Gas Control Assembly Shown
FOP - Located on outlet pipe work to mixer
FCV
QSK60 Fuel System
Gas Mass Flow Sensor Duty GMF
• Low maintenance. Cycle
Valve
• Requires calibration on
replacement.
Duty Cycle Valve
(FloTech)
• Low maintenance.
• No calibration required on
replacement.
P1
Pressure Sensors Component position and location shown.
• P1 & P2 Fuel pressure in and NOTE: The 60 / 60HE gas fuel systems are similar
out of gas control assembly. P2 but the 60 G fuel system does not have a CAT
is located on the feed tube to (compressor intake air temp) sensor fitted.
the gas mixers. In addition, the fuel system venturies have
different bores.
23
Gas Control Assembly
- Cut-a-way example shown for clarity, as Fitted to QSV engines
Pressure
Gas Mass Flow Sensor Sensor ( P2)
(GMF)
Control ‘Butterfly’
Pressure
Duty Cycle Valve
Sensor ( P1)
(FloTech)
24
Gas Mixer
The mixer is part of the
air box outlet tube on
QSK60 engines. One air T A
U
box and mixer for each R I
B
turbo. One gas inlet hole O R
is positioned at either
side of each mixer.
GAS IN - 0.9 Bar abs.
OPERATING PRINCIPLE
25
QSK 60 Throttle Actuator
Gas / Air Flow
Turbocharger to Charge
Air Cooler Pipework
Throttle Actuator
( Woodward ProAct)
• From the two Gas mixers the fuel passes to two Holset Turbochargers.
• Fuel flows from the turbochargers and through the Charge Air Cooler.
• Fuel supplied to LB and RB Intake manifolds via the throttle actuators.
26
QSK60 H/E - Compressor by-pass
The compressor by pass valve is controlled via the CM558 module and is used to divert air/fuel
mixture back to the mixer intake. This butterfly valve is fitted on the QSK60 H/E model only and
acts much like a waste gate to match turbo performance to requirement over a wide speed range.
Boost is by-passed (reduced) at higher turbo rpm.
27
QSK 60G & 60G High Efficiency Series
Gas Engines
Module 5 – FUEL SYSTEM
End
Cummins Corporate Training
28
HE -60G/ Cooling / BMG / 03 - 07 / REV 01.
