QSV 81/91 Gas Engines

Module 5 - Systems
Cooling

Cummins, Inc Training

QSV Gas CUMMINS, INC

CUMMINS, INC TRAINING
Total Gas / Systems - Cooling / KDL / 08 - 02 / REV 2.5
 System Module - Cooling
Learning Objective
At the end of this section of the module you will be able to describe
the operation of the cooling system and trace the coolant flow path.

Agenda
• The Cooling System; Features, Block Diagram.
• Water Pump.
• Cooling Water Control Unit.
• Head & Multi-duct.
• Pre-Heater Assembly.
• System Schematic - Dual Cooler Systems.
• Cooling System Flow Path.

QSV Gas CUMMINS, INC

CUMMINS, INC TRAINING
Total Gas / Systems -Cooling / KDL / 08 - 02 / REV 2.5
 Cooling System Features
• Water Pump Drive
- Provision for power take-off from rear of pump.

• After-cooling
- Two-stage (HT / LT) with by-pass on all QSV Gas engines.

• Central Cooler Configuration

- Combined LT / HT or separate systems option.

• Cooling Water Control Unit

- 2 x HT & 2 x LT Thermostats (LT 42 - 54º C, HT 83 - 95º C
& 94 - 104° C).
• Block Heaters
- 2 x 6KW mounted in free-end block casting.

QSV Gas CUMMINS, INC

CUMMINS, INC TRAINING
Total Gas / Systems -Cooling / KDL / 08 - 02 / REV 2.5
 QSV 81/91 Engines - Simplified Cooling System
Block Diagram
Cooling Water Control Unit
High Temp Water Circuit

HT
CC

LT
CC Low Temp Water Circuit

Note: TC: Turbocharger Dual Circuit Water Pump

HT thermostat option of 94
- 104°C modulating range
for use with CHP systems
& 16Bar engines.
LOC: Lube Oil Cooler
Thermostatic Valve
CAC: Charge Air Cooler
CC: Central Cooler Communicating Circuit Plug

QSV Gas CUMMINS, INC

CUMMINS, INC TRAINING
Total Gas / Systems -Cooling / KDL / 08 - 02 / REV 2.5
 Dual Cooler System

Communicating
circuit plug
FITTED IN
FREE-END
HOUSING

KEY
- Non return valve OPTIONS

- Pump 1 - Electric LT Pump

2 - Electric HT Pump
- Heater elements 3 - Water Heaters

QSV Gas CUMMINS, INC

CUMMINS, INC TRAINING
Total Gas / Systems -Cooling / KDL / 08 - 02 / REV 2.5
 Dual Loop Water Pump
LT out HT out

Oil return channel to

free-end housing and
pan

Oil supply channel

HT in Impeller Seal Detail

- Spacer

- Impeller Seal
LT in - Shaft Mechanical Seal Position
- Ball / Roller Bearing
“Kolmex” Pump Shown

QSV Gas CUMMINS, INC

CUMMINS, INC TRAINING
Total Gas / Systems -Cooling / KDL / 08 - 02 / REV 2.5
 The Dual Loop Water Pump

LT Circuit “Gilkes” Pump Shown

HT Circuit

‘Tell -Tale’ Drilling

QSV Gas CUMMINS, INC

CUMMINS, INC TRAINING
Total Gas / Systems -Cooling / KDL / 08 - 02 / REV 2.5
 Drive Gear Attachment

Oil Pump Ringfader

shown here

Ringfeder shown here

(Tapered Rings)
Used on both water
and oil pump drive
gears.

QSV Gas CUMMINS, INC

CUMMINS, INC TRAINING
Total Gas / Systems -Cooling / KDL / 08 - 02 / REV 2.5
 Cooling Water Control Unit
2 x HT Thermostats

HT
HT IN Radiator / Cooler
OUT Connections

2 x LT Thermostats

LT
LT
IN Radiator / Cooler
OUT
Connections

DUAL COOLER OPTION

QSV Gas CUMMINS, INC

CUMMINS, INC TRAINING
Total Gas / Systems -Cooling / KDL / 08 - 02 / REV 2.5
 Thermostatic Control Valve
COLD HOT

To HT / LT Pump To Cooler / Radiators

(Return to LT Pump Circuit)

10

QSV Gas CUMMINS, INC

CUMMINS, INC TRAINING
Total Gas / Systems -Cooling / KDL / 08 - 02 / REV 2.5
 Cylinder Head Cooling

Coolant to
Multi-duct

Water Cooled
Flame Plate
Coolant from
Liner Cavity
11

QSV Gas CUMMINS, INC

CUMMINS, INC TRAINING
Total Gas / Systems -Cooling / KDL / 08 - 02 / REV 2.5
 Multi-duct Cooling Flow
To vent line / header tank.
(via turbo bearing housing
on ‘V’ engines ).

HT Return to Block / CW Control Unit

12

QSV Gas CUMMINS, INC

CUMMINS, INC TRAINING
Total Gas / Systems -Cooling / KDL / 08 - 02 / REV 2.5
 Coolant Supply - QSV Turbochargers
Coolant Vent Line / Header Tank

QSV 81/91 - 4 x Holset HX 82 Series

- Water Return
Line

- Water Supply
Line

13

QSV Gas CUMMINS, INC

CUMMINS, INC TRAINING
Total Gas / Systems -Cooling / KDL / 08 - 02 / REV 2.5
 Pre-Heater Assembly - Optional

2 x 6 kW 220v Heaters
installed here,
thermostat control 40 -
50° C (AMOT Switch)

Location of Industrial ‘V’ Engine Heater elements

14

QSV Gas CUMMINS, INC

CUMMINS, INC TRAINING
Total Gas / Systems -Cooling / KDL / 08 - 02 / REV 2.5
Cooling System Flow QSV 81/91 “V” Engines

HT to Block &
Cylinder Liners

2 Feed Pipes

HT from Pump
LT through Block to LOM
LT from Pump at Flywheel-End

15

QSV Gas CUMMINS, INC

CUMMINS, INC TRAINING
Total Gas / Systems -Cooling / KDL / 08 - 02 / REV 2.5
Cooling System Flow QSV 81/91 “V” Engines
HT return from
Block / Head to CWCU
Main Oil Gallery

To Cylinder Head
and Multi-duct

Piston Cooling

LT from LOM LT to LOM

to CWCU from CAC

16

QSV Gas CUMMINS, INC

CUMMINS, INC TRAINING
Total Gas / Systems -Cooling / KDL / 08 - 02 / REV 2.5
 Block / Liner Drain Point

‘V’ engine - A & B-bank

17

QSV Gas CUMMINS, INC

CUMMINS, INC TRAINING
Total Gas / Systems -Cooling / KDL / 08 - 02 / REV 2.5
 Typical Header Tank Installation
Static Head Fill Header tanks fitted with 15psi vacuum break
Engine pumps require 0.5Bar Point (1Bar) pressure caps and level gauge including
(@ 95°C/203°) or 1.5Bar LT Header OFF HT Header OFF WARNING and SHUTDOWN switches.
(@110°/230°F) standing Tank Tank
pressure at pump inlet to ensure
adequate priming and operation.
ON ON
HT - Vent Connection
Header tank height required is LT - Vent Connection
5.18m (17 ft.) and 14.6m (48 ft.)
respectively. Min 50 mm dia. Flexible Flexible
Note: High temperature systems pipe- work connection connection
are typically fitted with closed recommended for to engine to engine
pressurised circuits utilising a header connections.
bladder or nitrogen pressure COOLER
vessel in place of header tanks. CONNECTIONS

HT
HT HT IN
OUT Important: The block
Install flanged LT must also be drained
LT
LT strainer sock here IN
OUT separately.
if necessary after
installation - run
OPEN for 12 hours
before removal.
CLOSE
To flatbed radiators
or heat exchangers
HT

LT
OPEN

Coolant Flow System Drain

Valves. CLOSE
Flexible Braided Hoses or Rubber Coupling to engine.

18

QSV Gas CUMMINS, INC

CUMMINS, INC TRAINING
Total Gas / Systems -Cooling / KDL / 08 - 02 / REV 2.5
Engine Coolant Tank & Make-up - CHP System

Pressure
Accumulator

Pump
Pump Isolator Control
Switch Switchbox

Automatic Make-
up Pump.

Electric Top-up
Pump (manual)

Engine Coolant Coolant Supply &

Storage Tank. Feed Pipes

19

QSV Gas CUMMINS, INC

CUMMINS, INC TRAINING
Total Gas / Systems -Cooling / KDL / 08 - 02 / REV 2.5
 Genset Off-Engine Coolant Pumps
and Pressure Accumulators

LT pressure
accumulator tanks.

Electric coolant
circulation pump for HT HT pressure
circuit. There will be a accumulator
similar pump for the LT tanks (one per
circuit. engine).

20

QSV Gas CUMMINS, INC

CUMMINS, INC TRAINING
Total Gas / Systems -Cooling / KDL / 08 - 02 / REV 2.5
Cooling System Flow QSV 81/91 “V” Engines
19 15 14
15
20

14
16
13

9
24

23
13
22

8
21
7
12

11

10 6

25

18 2 3

5
26
4
21

QSV Gas 17
CUMMINS, INC
CUMMINS, INC TRAINING
Total Gas / Systems -Cooling / KDL / 08 - 02 / REV 2.5
 Module 5 - Cooling

End
Cummins, Inc Training

QSV Gas CUMMINS, INC

CUMMINS, INC TRAINING
Total Gas / Systems - Cooling / KDL / 08 - 02 / REV 2.5