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QSV Diesel Engines

Module 4 - Operating

Cummins Corporate Training

QSV Diesel CUMMINS CORPORATION


Cummins Corporate Training

D / 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 (Industrial / Marine).
☛ Engine Starting.
☛ Engine Monitoring.
☛ Operating Parameters.
☛ Engine Shutdown.
☛ Engine Isolation Procedure.

QSV Diesel CUMMINS CORPORATION


Cummins Corporate Training

D / Operating / BMG / 01-01 / Rev. 03


2
Onan Power Command - Industrial Genset Control System

QSV Diesel CUMMINS CORPORATION


Cummins Corporate Training

D / Operating / BMG / 01-01 / Rev. 03


3
Marine Power Generation & Propulsion

PLC controller with LCD display

QSV Diesel CUMMINS CORPORATION


Cummins Corporate Training

D / Operating / BMG / 01-01 / Rev. 03


4
Engine Starting

• Check engine oil level.


• Check coolant level, pre-heated to
40º C and circulating.
• Check fuel level, valve open.
• Check all covers in place.
• Check engine control system on.
• Check pre-lube operated 0.5Bar.
• Check starting air 100psi min.
• Fuel control lever ‘Run’ position.
• Start engine from control panel.
• Check for oil pressure within 15
seconds.
• Idle 3-5 min. before load 40-60º C.

QSV Diesel CUMMINS CORPORATION


Cummins Corporate Training

D / Operating / BMG / 01-01 / Rev. 03


5
Engine Starting
After Extended Shutdown (+48 Hrs)

Follow normal starting procedure checks, then;


• Vent air from oil filter housing with pre-lube pump running.
• Check coolant level in header tank.
• Check that the control shaft system and injection pump racks
move freely.
• Bar the engine over two revolutions with the fuel control
lever in the stop position - check for coolant at cylinder
plugs.
• Prime the fuel system.
Every three to four weeks during extended shutdown;
• Turn crank to new position.

QSV Diesel CUMMINS CORPORATION


Cummins Corporate Training

D / Operating / BMG / 01-01 / Rev. 03


6
Engine Monitoring 1 of 2

Typical System Monitoring Devices


Cooling System Thermometers:
• Water temperature before central water cooler.
• Water temperature after central water cooler.
• HT Water circuit after engine.
• HT Water circuit after Turbocharger.
Cooling System Manometers:
• System pressure before central water cooler.
• System pressure after central 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.

QSV Diesel CUMMINS CORPORATION


Cummins Corporate Training

D / Operating / BMG / 01-01 / Rev. 03


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Engine Monitoring 2 of 2

Lubrication system.
• Lubricating oil temperature.
• Lubricating oil pressure.
Fuel System.
• Fuel oil pressure.
• Fuel temperature.
Air System.
• Charge air temperature
• Charge air pressure
Starting System.
• Starting air pressure.
Speed Probes.
• Turbocharger
• Engine

QSV Diesel CUMMINS CORPORATION


Cummins Corporate Training

D / Operating / BMG / 01-01 / Rev. 03


8
Operating Parameters

QSV ENGINE OPERATING PARAMETERS ( GENSET APPLICATIONS )


Engine Gauge Alarm / Shutdown Limits
Nominal Value Immediate
(Full speed, Shutdown
Meter / Measurement Range full load) Alarm
0 - 12.0Bar 4.2 - 5.0Bar 2.3Bar (low) 2Bar (low /low)
Lube oil pressure ( 0 - 174PSI ) (61 - 72.5 PSI) (33.5 PSI) (29 PSI)
Lube oil temperature
( after oil cooler) 0 - 80º C 60 - 70º C 78º C (high) 80º C (high/high)
Common water inlet
temperature 0 - 55º C 40 - 50º C - -
Common water outlet
temperature 0 - 65º C 55 - 65º C - -
Charge air pressure 0 - 3.0Bar 2.8Bar 2.9Bar
(after CAC) ( 0 - 43.5 PSI ) ( 41 PSI ) ( 42 PSI ) -
Charge air temperature
(after CAC) 0 - 70º C 45 - 60º C 70º C -
0 - 6.0Bar 5.0 - 6.0Bar 4.5Bar
Fuel oil pressure ( 87 PSI ) ( 72.5 - 87 PSI ) ( 65 PSI ) -
0 - 3.5Bar 3.0 - 3.5Bar 0.65Bar
L.T. water pressure ( 51 PSI ) ( 43.5 - 51 PSI ) ( 9.5 PSI ) -
L.T. water temperature
(before CAC) 0 - 60º C 40 - 58º C 60º C -
0 - 4.5Bar 4 - 4.5Bar 0.65Bar
H.T. water pressure ( 0 - 65 PSI ) (58 - 65 PSI) ( 9.5 PSI ) -
MAX 15.0Bar 11.0Bar 7.0Bar
Starting air pressure ( 218 PSI ) ( 160 PSI ) ( 102 PSI ) -

QSV Diesel CUMMINS CORPORATION


Cummins Corporate Training

D / Operating / BMG / 01-01 / Rev. 03


9
Normal Operating Supervision

• Regularly check thermometers, pressure gauges, exhaust pyrometers.


• Listen for unusual changes in engine noise.
• Check indicator for pressure drop over fuel filters, 1.5Bar max.
• Check indicator for pressure drop over oil filters. Filter Bypass valves
open if pressure drop exceeds 2 - 3Bar.
• Check coolant header tank level and for leakage from water pump “Tell
Tale”.
• Check the condensate drain from the charge air cooler is open and not
blocked.
• Check the quantity of leak fuel from the drain pipes.
• Drain water and sediment from the fuel tank and starting air receiver.
-End-

QSV Diesel CUMMINS CORPORATION


Cummins Corporate Training

D / Operating / BMG / 01-01 / Rev. 03


10
Engine Shutdown

• Run engine at no load or idle


for 3-5 minutes before
shutdown.
• Shutdown from control panel
(Key-switch or run/off/auto
switch as fitted)
Emergency shutdown
• Hit the emergency stop button
on the control panel.
or
• Move the fuel control lever to
the ‘STOP’ position.

QSV Diesel CUMMINS CORPORATION


Cummins Corporate Training

D / Operating / BMG / 01-01 / Rev. 03


11
Engine Isolation Procedure
• Shut down the engine and isolate fuel supply.
Stop position
• Move the Stop lever to the stop position and engage the
starter interlock (baring device).
• Isolate control system, first switch off the battery charger, if
fitted, then disconnect control battery.
• Isolate air compressor and drain system -
including engine actuator air receiver.
• Isolate the lubricating oil priming pump and oil make-up
system, if fitted.
• Isolate engine heaters and circulating pump, if fitted. Starter Interlock
• Tag the engine “OUT OF SERVICE ”.
NOTE: On Genset applications ensure the mains or HV
Engine Out
supply is isolated and locked out. Check if a permit to work
of Service
system is in operation.

QSV Diesel CUMMINS CORPORATION


Cummins Corporate Training

D / Operating / BMG / 01-01 / Rev. 03


12
Module 4 - Operating

Team Task
- End -
Cummins Corporate Training

QSV Diesel CUMMINS CORPORATION


Cummins Corporate Training

D / Operating / BMG / 01-01 / Rev. 03