Cummins unveils the world’s most powerful high-speed diesel

Posted: November 2, 2011 in Uncategorized

QSK95 is the start of a new high-horsepower diesel and gas platform covering 12, 16 and 20 cylinders.

The new 4000 hp QSK95 is the highest horsepower diesel engine ever developed by Cummins.

With an output of 4000 hp and more, Cummins’ new QSK95 is the world’s most powerful high-speed diesel engine.

The 95-litre 16-cylinder QSK95 is the first engine to be introduced in a new high-horsepower diesel and gas platform from Cummins.

The new product line will eventually extend up to the 120-litre 20-cylinder QSK120, capable of over 5000 hp.

Designed to provide exceptional strength and high power density, the 16-cylinder QSK95 exceeds the power output of other large 1800 rpm high-speed engines which have  20 cylinders.

Compared with much larger medium-speed engines operating below 1200 rpm, the QSK95 offers a far more compact and cost-effective solution to achieve the same power output.

The QSK95 is ideally suited for high-hour, high-load applications such as ultra-class mine haul trucks, many types of marine vessels, and passenger and freight locomotives.

It will also power the new C3000-series genset from Cummins Power Generation, providing a class-leading 3.5 MW high-speed output, while for offshore oil and gas platforms, the QSK95 will be available as a ready-to-install drilling power module.

For all applications, the QSK95 is ready to meet the world’s most stringent emissions standards, including US EPA Tier 4 to take effect in 2015, using proven Selective Catalytic Reduction (SCR) aftertreatment designed by Cummins to replace the exhaust muffler.

“Our new QSK95 represents a landmark in the evolution of the large high-speed diesel engine, designed with the power and durability to surpass all other high-speed engines while also challenging much larger and higher capital cost medium-speed engines,” says Mark Levett, Cummins Vice President and General Manager – High-Horsepower Business.

“The QSK95 moves Cummins into a significantly higher power class, and we know that many of our customers have been eagerly anticipating us making that move. During the development of the QSK95, we engaged with hundreds of potential users to ensure that we fully reflected their operational and installation needs.

“That’s why we purpose-designed the QSK95 to set standards of uptime availability and in-service reliability higher than those of any other engine.

“The QSK95 is just the start of a new high-horsepower platform for both diesel and gas, covering 12, 16 and 20 cylinders. The gas engines will not be just a derivative of the diesel engines, but specifically designed for gas. We will release more details about our gas product line during 2013,” says Levett.

The QSK95 is pre-engineered to add four cylinders and will achieve over 5000 hp with the QSK120 engine, moving the boundaries of high-speed diesel performance even further ahead. The QSK120 will utilise the same architecture and systems as the QSK95, providing the advantage of platform commonality.

QSK95 will power the new C3000-series generator set from Cummins Power Generation, providing a class-leading 3.5 MW high-speed output.

Cummins has committed major resources to the new QSK95 and the high-horsepower platform, with 150 engineers working on the project.

The QSK95 has been developed using highly advanced combustion modeling. Jim Trueblood, Vice President – Cummins High-Horsepower Engineering, explains: “We evaluated thousands of possible combustion  designs until we arrived at the optimum formula for fuel efficiency, performance, emissions control and power cylinder durability before cutting any metal for the QSK95.

“The QSK95 is designed with immense strength at the heart of the engine, enabling the power cylinder to achieve higher levels of peak cylinder pressure. This gives a higher threshold in-cylinder to focus on emissions reduction and improve fuel efficiency.

“A key achievement of our combustion analysis-led work is that the QSK95 makes no performance compromise to meet very low emissions standards – an advantage that few, if any, other large high-speed or medium-speed engines will be able to claim for Tier 4 emissions,” saysTrueblood.

While the QSK95 is an all-new platform, the engine has been able to take advantage of proven performance systems from within Cummins high-horsepower technology portfolio.

A quad-turbocharger system brings highly reliable air-handling direct from the QSK60 engine to the QSK95. The four compact turbochargers – one for each bank of four cylinders – provide outstanding step-load acceptance and transient response with the simplicity of single-stage operation.

The Modular Common Rail System (MCRS) is upgraded to a next-generation design with up to 2200 bar (32,000 psi) high-pressure fuel injection. MCRS achieves high fuel efficiency, reduces noise, offers smooth idle stability and eliminates visible smoke across the operating range.

Cummins’ new NanoNetfuel filtration gives superior fuel cleanliness and enhances the durability of the MCRS system – an important advantage for engines required to operate anywhere in the world with varying fuel quality.

A new ductile iron block and an extended block skirt ensure the highest possible structural strength for the QSK95, improving its capability for multiple overhauls. An internal stiffening bedplate minimises vibration.

A single-piece forged-steel piston provides exceptional durability and reuse capability at rebuild. All three piston rings use premium materials, with the top ring Plasma Vapor Deposition (PVD)-coated. The hardened power cylinder features midstop cylinder liners and  dual piston cooling nozzles, contributing to reduced piston ring temperatures and increased wear resistance.

The QSK95 will provide long life-to-overhaul, capable of achieving 1.7 million US gallons (6.46 million litres) and above of fuel consumed before overhaul, with the significant advantage of no mid-life intervention required.

The QSK95 is configured to provide faster and easier servicing procedures. Service intervals are a minimum 500 hours, with the option of much-extended oil change intervals using the Eliminator oil purification system, mounted on the engine.

The goal of a leak-free engine is achieved by premium ‘press-in-place’ seals on all critical joints, such as flywheel housing, gear housing and oil pan-to-cylinder block. A special perimeter seal to the cylinder head guarantees that airborne debris cannot penetrate this important sealing interface.

Four standardised Cummins Electronic Control Modules (ECMs) provide the processing power and memory to monitor, control and protect the engine systems. One ECM monitors each engine quadrant, with all four ECMs grouped together for easy access at the front of the engine in a protected cover.

Designed to provide exceptional strength and high power density, the 16-cylinder QSK95 exceeds the power output of other large high-speed engines which have 20 cylinders.