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QSV 81/91 Series Gas Engines

Module 6 - Operating

Cummins Corporate Training

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Operating / BMG / 01 - 01 / REV .03.
Operating Module

Learning Objectives
To familiarise the operator with the procedures for safe
operation of the engine.

Agenda
• Control Systems - Powergen.
• Engine Starting.
• Engine Monitoring.
• Operating Parameters.
• Engine Shutdown.
• Engine Isolation Procedure.

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Operating / BMG / 01 - 01 / REV .03.
2
Onan Power Command Control
• Power Command Control
(PCC) - Std Diesel Genset
controller. Full function, inc.
AVR & speed control.
• Power Command Supervisor
(PCS ) - Std Gas Genset engine
controller. Reduced function,
inc. AVR but No speed control
(MCM700 function). Speed
bias signal for sync only.
• Both systems provide full PCC & PCS Genset Control Systems
Genset monitoring Similar looks and functions

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Operating / BMG / 01 - 01 / REV .03.
3
Engine Starting
• Check engine oil level.
• Check coolant; level, pre-heated, circulating (50/55ºC).
• Check fuel pressure (150Mb) at engine inlet (gauge).
• Check all covers and guards are in place.
• Check manual gas valve switch is on, toggle system
key switch ‘off’ 5-8 seconds to reset control.
• Check engine is pre-lubricated to 0.5Bar.
• Check starting air 150psi (10Bar). Vent Cycle - At first
• Start engine from external customer run/stop switch. start, the engine will
Note: PCS switch position; vent without gas for 12
RUN = idle only, no changeover. AUTO = normal op. seconds of crank, then
• Check for oil pressure within 15 seconds. rest for 5 seconds before
proceeding to crank for
• Engine start control is automated by the PLC, it will
12 seconds with gas on.
ensure pre-lube taken place & idle engine below 50º C
• MCM 700 controls venting and start attempts.

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Operating / BMG / 01 - 01 / REV .03.
4
Engine Starting
After Extended Shutdown (+48 Hrs)
Follow normal starting procedure checks, then;
• Check control battery - 24/26 V(below 18v system shuts down).
• Verify that all sensors are functioning properly prior to engine
start (using the Cummins service tool or HMI on Genset).
• Vent air from oil filter housing with pre-lube pump running.
• Check coolant level in header tank.
• Bar the engine over two revolutions - check for coolant in
cylinders to prevent hydraulic lock, remove spark plugs if in
doubt (no cylinder plugs fitted on QSV 81/91).
Every three to four weeks during extended shutdown;
• Turn crank to new position.

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Operating / BMG / 01 - 01 / REV .03.
5
Engine Monitoring (1 of 2)

Typical System Monitoring Devices


Cooling System Thermometers:
• Water temperature before dual water cooler.
• Water temperature after dual water cooler.
• HT Water circuit after engine.
• HT Water circuit after Turbocharger.
Cooling System Manometers:
• System pressure before dual water cooler.
• System pressure after dual water cooler.
• HT Pressure after pump (Flow to engine and turbo).
• LT Pressure after pump (Flow to LOC / CAC).
Exhaust system Pyrometers:
• Cylinder Exhaust Temperature.
NOTE: QSV Gas cooling systems only have separate LT / HT coolers, as req’d for CHP.

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Operating / BMG / 01 - 01 / REV .03.
6
Engine Monitoring (2 of 2)

Lubrication system.
• Lubricating oil temperature.
• Lubricating oil pressure.
Air & Fuel System.
• Gas pressure at inlet.
• Charge air temperature (Ambient).
• Fuel pressure before throttle actuator (Boost).
• Fuel pressure and temperature after throttle actuator.
Starting System.
• Starting air pressure.
• Speed Probes.
• Engine.
USE CUMMINS SERVICE TOOL FOR MONITORING OR HMI ON
GENSETS

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Operating / BMG / 01 - 01 / REV .03.
7
Operating Parameters
QSV GAS ENGINE OPERATING PARAMETERS (GENSET APPLICATIONS)

Nominal Value Controlled Immediate


(Full speed, full load) Alarm Shutdown Shutdown
Meter / Measurement
4.2 - 5.0 Bar 3.6 Bar 3.1 Bar (low) 2.6 Bar (low/low)
Lube oil pressure (61.0 -72.5 PSI) (falling) (44.5 PSI) (37.0 PSI)
(51.5 PSI)
o o o
Lube oil temperature 95 C 107 C 113º C (high) 116 C (high/high)
(after oil cooler) (rising)
H.T. water temperature
(Engine outlet) 85 - 95º C 104o C 113º C 115o C
H.T. water pressure 4 - 4.5 Bar 1.7 Bar 1.5 Bar 1.2 Bar
(58.0 - 65.0PSI) (24.5 PSI) (22 PSI) (17.5 PSI)
L.T. water temperature
o o
(Engine outlet) 40 - 45º C 70 C 72º C 74 C
3.0 - 3.5 Bar 1.5 Bar 1.24 Bar 1.0 Bar
L.T. water pressure (43.5 - 51 PSI) (21.7 PSI) (18.2 PSI) (14.7 PSI)
Charge air pressure 2.2 Bar > 4.2 Bar
(after CAC) (33.0 PSI) (62 PSI) N/A N/A
Charge air temperature
(after CAC) 45 - 60o C 82o C 85º C 88o C

Fuel pressure (gas) 150mBar < 80mBar N/A < 70 / > 180mBar
11.0 Bar < 7.0 Bar
Starting air pressure (160 PSI) (102 PSI) N/A N/A
Individual cylinder
exhaust gas temperature 555º C 666º C 682º C 693º C

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Operating / BMG / 01 - 01 / REV .03.
8
Normal Operating Supervision
• Regularly check thermometers, pressure gauges, exhaust
pyrometers plus, monitor for constant gas pressure at inlet.
• Listen for unusual changes in engine noise and vibrations most
evident at the exhaust stack.
• Check indicator for pressure drop over oil filters. Filter by-pass
valves open if pressure drop exceeds 2 - 3Bar.
• Check coolant header tank level and for leakage from water
pump “Tell Tale”.
• Drain water and sediment from the starting air receiver.
• Control load increases to steps of 25 - 30% and decreases to
steps of 15 - 20% .
• Do not idle a Gas engine for prolonged periods.

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Operating / BMG / 01 - 01 / REV .03.
9
Engine Shutdown
• Set external Run/Stop switch to stop or
shutdown from control panel Run/Off/Auto
switch as fitted to PCS.
• The controller will run engine at no load or
idle for 3-5 minutes before shutdown.
Emergency shutdown
• Hit the emergency stop button on the control
panel or building installation.
or
• Disable the manual gas valve
NOTES:
1) Remember a fuel control lever is not fitted to
the QSV Gas series engines.
QSV Diesel Only
2) Reset system after E-STOP shutdown by
cycling system key, switch-off for 8-10secs.

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Operating / BMG / 01 - 01 / REV .03.
10
Engine Isolation Procedure
• Shut-down engine and isolate manual gas valve at panel.
• Shut-off the fuel supply valve from facility (1/4 turn
valve) and engage the starter interlock (baring device).
• Isolate control system and switch-off the battery charger,
if fitted, then disconnect control battery.
• Isolate air compressor and drain system. Starter Interlock
• Isolate the lubricating oil priming pump and oil
make-up system if fitted.
• Isolate engine heaters and circulating pump if fitted.
• Tag the engine “OUT OF SERVICE ”. Engine Out
NOTE: On Genset applications ensure the mains or HV of Service
supply is isolated and locked out. Check if a permit to
work system is in operation.

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Operating / BMG / 01 - 01 / REV .03.
11
Module 6 - Operating

End
Cummins Corporate Training

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Operating / BMG / 01 - 01 / REV .03.

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