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

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 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
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 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
out of gas control assembly. P2
is located on the feed tube to
the gas mixers.
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NOTE: The 60 / 60HE gas fuel systems are similar
but the 60 G fuel system does not have a CAT
(compressor intake air temp) sensor fitted.
In addition, the fuel system venturies have
different bores.
 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)
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 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.
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 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.
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 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.