Application

Engineering
Bulletin
Subject This AEB is for the following applications:
Generator-Drive HPI-TP & PT Fuel
System Installation Requirements Automotive Industrial Power Generation
Author: Norm Jones
Date 4/10/01 Page 1 of 14 AEB Number 70.28
Engine Models included: QSX15 & QSK45/60
Fuel Systems included: HPI-TP & PT

Introduction
The QSX15 and the QSK45/60 are now a part of the Generator-Drive engine product line. The new
“High Pressure Injection” (or “HPI”) fuel systems on these new engines offer a number of advantages
(including injection timing control) over the Cummins PT fuel system. This bulletin is intended to be a
refresher of the basic requirements for the generator set and installation Designer to follow when
designing the fuel supply and fuel return systems that connect to the engine. This document will also
highlight a few new requirements (e.g. fuel cooling) for the HPI-TP (QSX15) and HPI-PT (QSK45/60)
systems.

NOTE: The HPI fuel systems are new and involve significantly higher fuel flows
than previous Cummins systems, but the fundamentals of a good fuel system
design/installation are not new.

The Designer will need access to Engine Data Sheets and other important documents referenced
throughout this bulletin to complete the system design.

1. Fuel Type and Quality

• The fuel delivered to the engine must satisfy the recommended properties listed in Cummins
Service Bulletin 3379001 (Fuels for Cummins Engines). This bulletin also provides guidelines
on filtration, microbial contamination, and fuel additives.

2. Filtration

• The Cummins-supplied and plumbed 10 micron fuel filter(s) must be used to protect the
engine fuel system.
• A customer-supplied fuel filter/strainer/water separator of 100-120 mesh or equivalent
(approx. 150 microns nominal) must be fitted between either the main tank and day tank or
between the main tank and the engine.

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Discussion:
Cummins filters are designed to provide the necessary protection to fuel system components while
offering an appropriate service life.

The customer-supplied filter should not require servicing at shorter intervals than the Cummins-
supplied filters (see applicable engine Operation and Maintenance Manual). The added restriction
caused by the addition of a customer-supplied filter must be accounted for during the design phase
when determining the total fuel system inlet restriction (if fitted to the inlet plumbing of the engine).

3. System Restriction

• Fuel restriction imposed on the engine by customer-supplied plumbing must not exceed the
limits stated on the Engine Data Sheet at the stated flows.

Discussion:
Engine performance and fuel system durability will be compromised if the restriction limits are not
adhered to. Fuel flow rates for the HPI-TP and HPI-PT are significantly higher than that of the
traditional Cummins PT system. The Designer must take care to account for these higher flow rates.
The fuel flow is stated in the Fuel System section on the Engine Data Sheet as:
• “Maximum Fuel Flow to Injection Pump”
• “Maximum Return Fuel Flow” or “Maximum Drain Flow”

NOTES:
1. Unlike the traditional Cummins PT system, the maximum fuel flows of the HPI-TP and HPI-
PT fuel systems occur at low load where fuel flow requirements for the injector timing chamber
is greatest.

2. Also see Table #1 in Section 6 “ Fuel Line Plumbing” for minimum recommended line sizes,
but it is still the Designer’s responsibility to insure that systems restrictions are acceptable.

a. Fuel Inlet Restriction Limit

Fuel inlet restriction must not exceed the limits stated in the Fuel System section on the Engine Data
Sheets as:
• “Maximum Restriction at OEM Inlet Connection” (QSX15 Engine Data Sheet)
• “Maximum Restriction at PT Fuel Injection Pump” (QSK45/60 Engine Data Sheet)

NOTES:
1. The HPI-TP (QSX15) inlet restriction limit is referenced to the point on the engine where the
customer-supplied plumbing is connected, and therefore, is a true restriction limit for customer-
supplied plumbing.

2. HPI-PT (QSK45/60) inlet restriction limit is referenced to a point downstream of the Cummins-
supplied fuel filters. The net available restriction for customer-supplied plumbing is actually
the Engine Data Sheet limit less the restriction contribution of the Cummins-supplied filters
(1.5in Hg).

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b. Fuel Return Restriction (or Pressure) Limit
Fuel return drain restriction (also know as “injector return”) between the engine injector return line
connection and the fuel tank must not exceed the limit stated in the Fuel System section on the Engine
Data Sheet as:

• “Maximum Allowable Head on Injector Return Line (Consisting of Friction Head and Static
Head)”.

NOTE: See the “Fuel Tank Design and Location” section for more on the effects
of tank location on injector return line restriction.

c. Pressurizing the Fuel Inlet and Return

Cummins does not recommend the use of customer-supplied circulating pumps to pressurize the fuel
supply or return system. The system Designer must make every effort to locate a fuel tank near
enough to the engine so that the restriction limits discussed above are not exceeded.

4. Fuel Temperature

• Fuel Inlet Temperature must not exceed the “Maximum Fuel Inlet Temperature” limit stated
on the Engine Data Sheet.

• A fuel cooler is required on QSX15 and QSK45/60 engines and must be installed in fuel
return line.

• Fuel heaters are required if ambient temperature is expected to be below the fuel cloud point.

Discussion:
The Designer can find the “Heat Rejected to Fuel” and “Maximum Return Fuel Flow” on the Engine
Data Sheet. There are specialty suppliers for fuel coolers that offer capable products (both for radiator-
mounted and remote applications). It is also common for the jacket water cooling system supplier to
be able to offer a suitable product. Industrial Application Engineering Bulletin AEB 24.07 is an
available reference document on the subject of fuel cooling.

5. Fuel Tank Design and Location

• The fuel supply tank and day tank construction, size, location, installation, venting, piping,
testing and inspection must comply with all applicable codes.

• The fuel return connection at the fuel tank must be designed and located to promote removal
of entrained air and be located as far as possible from the fuel supply (to engine) connection
point in the tank.

• The fuel tank must be properly vented.

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• The fuel tank must have a drain port for removing water and sediment.

• The fuel tank must allow for a minimum of 5% expansion space (via fill neck design) to allow
for fuel expansion.

• The engine fuel supply line connection must be located as far as possible from the return fuel
connection. The pick up point in the tank must be at least 25mm (1 in) above the bottom of
the tank.

• The fuel tank must be made of steel (with suitable protective coating) or aluminum.
Galvanized steel or other zinc-bearing materials must not be used.

• The fuel tank must be located as near as possible to the engine it supplies to provide the
shortest and most direct path for fuel supply and return.

• Maximum allowable height of fuel above crank centerline to prevent hydraulic lock is 2.1m
(7 Ft.) Note: Fuel friction head must be accounted for in addition to line restrictions. (See sample
calculation in Section 7)

• Maximum lift capability of fuel from below crank centerline.

• QSX15 = 91 cm (36 in)
• QSK45/60 = 107 cm (42 in)
Note: Fuel friction head must be accounted for in addition to line restrictions.

• Applications where the engines are used in gensets that are to be paralleled or that must
satisfy specific emergency start-time requirements must have a fuel tank located such that
the lowest possible fuel level is not less than 15cm (6 in) above the fuel pump inlet. This will
prevent air from accumulating in the fuel supply line when the engine is not in use.
(See Figure 2B)

Discussion:

A fuel supply system includes one or more storage tanks sized to support an acceptable refueling
interval (typically 1 to 5 days). The demands of a relatively long refueling interval must be balanced
against concerns about the storage of large quantities of fuel and the potential for microbial growth.
In the U.S., the National Fire Protection Association (NFPA) 110 standard describes tank sizes for
emergency systems. Also, NFPA 37 defines on-site fuel supply requirements.

a. Local Codes
Many installation sites are subject to regulations concerning the design, size, location, installation of
the main fuel storage tank as well as float tanks/day tanks. The fuel tanks used must conform to all
applicable codes.

b. Fuel Return Connection

Return fuel from the engine contains significant amounts of entrained air that must be removed in the
tank before the air is pulled into the engine supply line. The location and the design of the fuel return
connection can promote air removal from the fuel.

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There are 2 possible alternatives for the design of the return connection arrangement for HPI-TP and
HPI-PT fuel systems:

1. Preferred “Above Fuel Level” Method (traditional Cummins PT Method):

The fuel tank return connection is designed such that the fuel is returned above the
maximum fuel level in the tank. This method has proven effective for removing entrained
air. A baffle is recommended to further improve the removal of entrained air. (Figure 3)

NOTE: This method is acceptable for all tank sizes, but especially important for tanks
where fuel return and fuel supply connections are 1.5m (5 Ft.) or less distance from
each other (e.g. day tanks).

2. Alternate “Below Fuel Level” Method (traditional B/C Series engine Method):
The fuel tank return connection is designed with a drop tube, which delivers the return fuel
to near the bottom of the tank (below the lowest possible fuel level).
Note: This method is acceptable for large tank sizes (e.g. subbase tanks) where the fuel
return and fuel supply connections are more than 1.5m (5 Ft.) apart.

c. Tank Vent or Breather

The tank should be vented adequately to prevent system pressurization. As stated earlier, the HPI fuel
systems operate with higher fuel flow rates than previous systems and the return fuel contains
significant amounts for entrained air that must be removed. The vent must be designed such that
debris and water cannot enter the tank. Follow the requirements of the applicable local codes with
regard to where and how the vent is plumbed to the atmosphere.

d. Tank Water and Sediment Drain

The fuel tank must have a drain port for conveniently removing water and sediment from the bottom of
the tank. A valve is much more practical than a pipe plug.

e. Tank Fill Neck and Expansion Space

The fuel tank must allow for a minimum of 5% expansion space (via fill neck design) to allow for fuel
expansion. The fill neck must extend into the tank as shown in Figure #1 & #2.

f. Engine Fuel Supply Connection

The engine fuel supply line connection must be located as far as possible from the return fuel
connection. The pick up point in the tank must be at least 1 in (25mm) above the bottom of the tank.
The pick up tube must be well supported inside the tank to withstand vibration (cracks will allow air to
be pulled into the engine).

g. Tank material
The fuel tank must be made of steel or aluminum with a protective coating proven to be suitable with
diesel fuel. Galvanized steel or other zinc-bearing materials must not be used. The zinc reacts with
diesel fuel to form a substance that can damage the fuel system.

h. Sight Glass (optional)

If a sight glass is fitted to the tank, it must be made of unbreakable material and/or protected with
guards to prevent damage. Also, it must be fitted with shut-off valves on each end of the tube. It is
recommended that these valves be closed except when checking fuel level.

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 Figure 1: Typical Fuel Tank below Fuel Inlet
All piping to be
Black Iron Approved Flexible
Fuel Hose

Fuel return Crank

Centerline
Fill Opening
Breather QSX15 = 91 cm (36")
QSK45/60 = 107 cm (42")
Fuel Supply
Approved Flexible
Sight
Fuel Tank Fuel Hose
Glass Min. Fuel level

25mm
Drain Opening
(1 in)

Figure 2: Typical Fuel Tank above Fuel Inlet

Breather Fill Opening
5% Expansion space
Max Fuel Level
Sight
Glass Fuel Tank
Fuel
Return 2.1m (84 in)
25mm
Drain Opening
(1 in)

Approved Flexible Crank

Fuel Hose Centerline
All piping to be Fuel Supply
Black Iron
Approved Flexible Fuel Hose

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 Figure 2B: Typical Fuel Tank above Fuel Inlet
(emergency start requirements)

Fill Opening Max Fuel Approved

Fuel Flexible Fuel
Level
Return Hose
Breather
5% Expansion space

Sight 25mm
Glass (1 in) 152mm(6 in)
Fuel Tank
Minimum Fuel level
above pump inlet
Drain Opening

All piping to be Fuel Supply

Black Iron
Approved Flexible Fuel Hose

Figure #3: Float Tank Requirements

Fuel supply to Day Tank
Fuel Supply to engine
Return fuel from engine Breather
Overflow return
Baffle to permit to bulk tank
deaeration of fuel

Float switch to
control fuel level
Fuel level in Day Tank
sight glass
Fuel supply drop
tube with filter
screen 25mm (1 in)
off bottom of tank

Drain Opening

6. Fuel Line Plumbing (Supply and Return)

• All rigid lines must be black iron pipe or steel tubing.

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• All flexible lines must be diesel fuel compatible and rated for 1720 kPa [250 PSI] working
pressure, vacuum of 250 mm Hg [10" Hg] and an operating temperature range of at least-40°°
C to 120°° C [-40°° F to 250°° F]. (Ref. SAE J30R7)

• Flexible lines must be used to connect the rigid fuel lines to the engine.

• All plumbing must be well supported and allow for thermal expansion, vibration and other
component motion.

• Fuel shut-off valves are not permitted in the return line.

• Separate return lines must be provided for each engine in a multiple-engine installation.
Also, the return lines must not be plumbed with the return or supply fuel of any other
equipment.

• All fuel lines must be adequately flushed before they are connected to the engine.

Discussion:
Fuel line plumbing is required to supply fuel to the engine and to return fuel from the engine. Black
iron pipe or steel tubing are required for rigid plumbing. If black iron pipe is used, a thread sealant
must be used in place of Teflon tape.

Copper lines are not recommended because of their susceptibility to fatigue cracking. The copper can
also react with diesel fuel to form a “gummy” substance.

The Designer must develop a plumbing layout that avoids loops and high spots where air can
accumulate in the lines. Ideally, all lines should run “uphill” toward the tank to allow air to vent to the
tank when the engine is not running.

The following table summarizes the minimum recommended fuel line sizes for a given range of flow
rates. Note: Programs such as Cummins Advisor, Toolbox, or other acceptable calculations are
recommended to determine required line size for a specific application.

Table #1: Fuel Flow vs Fuel line size

Line length < 3m (10 Ft.)
Supply Return
Max Fuel Flow rate Flex Hose I.D. in (mm) Flex Hose I.D in (mm)
GPH (L/hr)
Less than 80 (303) No. 8 0.500 (12.7) No. 8 0.500 (12.7)
81-100 (304-378) No. 10 0.625 (15.9) No. 8 0.500 (12.7)
101-160 (379-604) No. 10 0.625 (15.9) No. 10 0.625 (15.9)
161-230 (605-869) No. 12 0.750 (19.1) No. 10 0.625 (15.9)
231-310 (870-1170) No. 12 0.750 (19.1) No. 12 0.750 (19.1)
311-410 (1171- 1550) No. 16 1.00 (25.4) No. 12 0.750 (19.1)
411-610 (1550-2309) No. 20 1.25 (31.8) No. 16 1.00 (25.4)
611-920 (2309-3480) No. 24 1.50 (38.1) No. 20 1.25 (31.8)

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 Table #1: Fuel Flow vs Fuel line size
(continued)
Line length 3m - 15m. (10 - 50 Ft.)
Supply Return
Max Fuel Flow rate Flex Hose I.D. in (mm) Flex Hose I.D in (mm)
GPH (L/hr)
Less than 80 (303) No. 10 0.625 (15.9) No. 8 0.500 (12.7)
81-100 (304-378) No. 10 0.625 (15.9) No. 10 0.625 (15.9)
101-160 (379-604) No. 12 0.750 (19.1) No. 10 0.625 (15.9)
161-230 (605-869) No. 12 0.750 (19.1) No. 12 0.750 (19.1)
231-310 (870-1170) No. 16 1.00 (25.4) No. 12 0.750 (19.1)
311-410 (1171- 1550) No. 20 1.25 (31.8) No. 16 1.00 (25.4)
411-610 (1550-2309) No. 24 1.50 (38.1) No. 20 1.25 (31.8)
611-920 (2309-3480) No. 24 1.50 (38.1) No. 24 1.50 (38.1)

Bulk Storage/Make-up Tanks (Figures #4 & #5)

• Must include valves to control and shut off make-up flow

• Must include equipment to prevent Day Tank Overfilling
• Must include fuel filters in transfer lines
• Transfer piping must not be capable of siphoning fuel from Day Tank

Bulk Storage or Make-Up Tanks are sized to support the acceptable refueling interval.

Typically Bulk Storage or Make-Up tanks are located remote from the engine.

When Bulk Storage Tanks are located such that their fuel levels are higher than the fuel level in the
Day Tank(s), gravity can be used to transfer fuel to the Day Tank(s). One or more valves is required to
control and shut off this make-up flow. The installation must include a method of preventing
overfilling of the Day Tank(s).

When Bulk Storage Tanks are located such that their fuel levels are lower than the fuel level in the Day
Tank(s), a transfer pump must be utilized to move fuel to the Day Tank(s). A check valve should be
provided to ensure fuel in the transfer line does not drain back to the Bulk Fuel Storage tank.

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 Figure #4: Remote Fuel Supply higher then Day Tank
Note: The fuel supply, day tank or other reservoir must be Float switch operated
Screened fill cap
arranged so that the highest fuel level does not exceed the Screened Vent Siphon-break Solenoid
(outside)
maximum height above the crank centerline specified for Cap (outside) valve
the engine. The lowest level must not fall below the 5% Expansion Space (minimum)
specified lift height of the engine fuel pump. Applications Screened
where the engines are used in gensets that are to be Manual priming vent cap
paralleled or that must satisfy specific emergency start- Fuel Supply Tank ball valve-Self (outside)
closing
time requirements must have a fuel tank located such that Construction, location, installation, venting,
the lowest possible fuel level is not less than 15 cm(6 in) piping, leak containment, and inspection must
above the fuel pump inlet. This will prevent air from comply with all applicable codes.
accumulating in the fuel supply line when the engine is not
in use. See Figure #2B 120 Mesh fuel strainer
Float switch
Approved flexible fuel hoses from Iron operated solenoid
pipe to Return and Supply fittings All piping to be valve
Black Iron Manual
Float shutoff
Switch valve
Fuel Supply
piping

Baffle
Fuel Return
piping
Approved
Day Tank

Figure #5: Remote Fuel Supply Lower then Day Tank

Screened vents
Fill Cap
Approved flexible fuel hoses from Iron
pipe to Return and Supply fittings All piping to be Pump, Solenoid Valve and 120 mesh
Black Iron Fuel Strainer
Float
Switch
Fuel Supply
piping

Baffle
Fuel Return
piping
Approved
Day Tank

Overflow pipe-One pipe

diameter larger than supply
Note: The fuel supply, day tank or other reservoir must be arranged so
that the highest fuel level does not exceed the maximum height above the
Auxiliary pump if required
crank centerline specified for the engine. The lowest level must not fall
below the specified lift height of the engine fuel pump. Applications 5% Expansion Space (minimum)
where the engines are used in gensets that are to be paralleled or that must
satisfy specific emergency start-time requirements must have a fuel tank Fuel Supply Tank
located such that the lowest possible fuel level is not less than 15 cm (6
Construction, location, installation, venting,
in) above the fuel pump inlet. This will prevent air from accumulating in piping, leak containment, and inspection
the fuel supply line when the engine is not in use. See Figure #2B must comply with all applicable codes.

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7. Testing

Static Head Pressure Calculation

Many questions arise concerning an engine's drain line restriction and overhead fuel height limits. The
two questions are related and thus were combined under a common heading on the Engine Data Sheet:
"Maximum Allowable Head on Injector Return Line”, consisting of Friction Head and Static Head.

This means that Friction Head + Static Head = Maximum Allowable Head.

Example:
Maximum Allowable Head on Injector Return Line" = 6.5 in. Hg (165 mm Hg)

Fuel return line is routed 5ft. (1.5 m) above injectors.

5ft. Fuel x 12 in. X 1in. Hg = 3.7in.Hg (94 mm Hg)
Ft. 16.3in. Fuel

The fuel drain line restriction must then be less than:

6.5 in. Hg (165 mm Hg) - 3.7 in. Hg (94 mm Hg) = 2.8 in. H (71 mm Hg)

Fuel Line Restriction Measurement

When: At engine commissioning/Installation review

Whenever engine performance appears to be degraded due to restriction

Checking Fuel Inlet Restriction on QSK45/60 engines

HPI-PT Fuel Pump and

Pressure Regulator Fuel Outlet to
Assembly ‘Electronic Fuel Control Valve’

Max allowable restriction

with clean filters @
CompuCheck fitting
= 4 in Hg (102 mm Hg)

Compucheck fitting on Fuel Inlet

the fuel pump from filters

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Checking Fuel Inlet Restriction Allowable restriction @ IFSM
OEM Fuel Inlet Connection
on QSX15 = 3 in Hg (76 mm Hg)

IFSM
Customer Fuel
Inlet Hose

Customer Fuel Inlet

Connection

Operate the engine at the data sheet recommended loads and speeds when taking the measurements.
Several minutes of operation may be required to purge air and other accumulated vapors from the
system and for the readings to stabilize.

Checking Return Fuel

Restriction on QSK45/60

Compucheck fitting located

@ front of engine by Engine Data Plate

Max allowable fuel return restriction

@ Compucheck fitting
= 9 in Hg (228 mm Hg)

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 Checking Fuel Return Restriction on QSX15
Customer Fuel Return
Connection

Allowable restriction @ IFSM

OEM Fuel Return Connection
IFSM with IFSM mounted filter
= 6 in Hg (165 mm Hg)

Customer Fuel Inlet Customer Fuel

Connection Return Hose

Fuel Quality Measurement

• At engine commissioning
• Whenever changing fuel suppliers
• Whenever fuel suppliers indicate fuel quality may change
• Whenever changing fuel type
• Whenever engine performance appears to be degraded due to fuel quality

Contact your local Cummins Distributor for assistance with fuel quality testing.

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Reference and Related Documents
The following documents contain additional information that may be useful when installing or
operating a fuel system:

Bulletin No. Description

3379001 Fuels for Cummins Engines
3382409 Construction, Mining, Logging, Agriculture and Stationary Power Installation
recommendations Fuel Systems
NFPA 30 Flammable and Combustible Liquids Code
NFPA 70 National Electric Code
NFPA 99 Health Care Facilities Code
NFPA 101 Life Safety Code
NFPA 110 Emergency and Standby Power Systems
AEB 70.23 Fuel System Installation Requirements for Emergency Generator Sets
AEB 74.10 10 Micron Fuel Filter
AEB 24.07 Fuel cooling installation recommendations
AEB 70.26 Fuel temperature effect on engine power for Mid-range Industrial and Power-
gen engines.

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