PROJECT UIDE OCUMENT Subject QSK50-DPM Power … Power Module Overview (Technical Package) PGD 31.01...

QSK50-DPM Power Module Overview (Technical Package) PGD 31.01 Total Document Pages: 12

Cummins Confidential

PROJECT GUIDE DOCUMENT

Subject QSK50-DPM Power Module Overview

This PGD is for the following applications: PGD Number 31.01 Automotive Industrial Marine G-Drive Genset Date: November 13, 2015 Filtration Emissions Solution Engine Models included: QSK50-DPM Author: Christian Lobo Approver per Procedure VPI-CCE-9695

CHANGE LOG

Date Author Description Page(s)

Nov 13, 2015 Christian Lobo - Revised fuel filter part number - Updated AEB numbers to CEB

All

Jun 15, 2015 Christian Lobo - Added statement regarding ground strap requirements

10-11

Mar 17, 2015 Christian Lobo - Revised statement on Alternator Alignment

- Added engine driven radiator option information

- Added information on Dual Fuel system

4, 6, 10

Aug 26, 2014 Christian Lobo - Added information on Mounting Requirements PGD.

10

Jul 24, 2014 Christian Lobo - Added information on cooling system - Included information on PCC3300

genset controller. - Added lifting, alignment, and

mounting guidelines.

4, 6-9

Aug 13, 2013 Arvind Chandrasekaran - Original Publication. All

QSK50-DPM Power Module Overview (Technical Package) PGD 31.01 Page 1 of 12


QSK50-DPM Power Module Overview

_________________________________________________________________________________________

PURPOSE This document details out the mechanical and electrical features of the Cummins QSK50 Drilling Power Module (DPM). The QSK50 engine used in the module is a 16-cylinder engine with a 50 liter displacement. When coupled to a two-bearing 6-pole alternator, the engine-alternator (“power module”) will generate 60 Hz electrical power at 1200 rpm. The engine has been certified to meet U.S. EPA Non-road Source Emissions Standards, 40 CFR 89, Tier 2, but may be used in North America under the U.S. EPA TPEM Tier 4 interim (Transitional Program for Equipment Manufacturers) provision as detailed out under EPA 40 CFR 1039.625 and California Emissions Requirements under 13 CCR 2423(d). The TPEM program is an Equipment Manufacturer provision. Equipment manufacturers are responsible for compliance and must be familiar with all the requirements of the program. Refer to AEB 191.33 - Non-road Tier 4 U.S. EPA Emission Regulations and EPA TPEM Program for High Horsepower Engine for further details.

INTRODUCTION The QSK50-DPM has been designed for use in oil and gas land drilling operations wherein up to 3-6 DPMs may be paralleled to each other to supply all the necessary AC power to the drilling rig and associated rig equipment. The purpose of a drilling rig is to create a near-cylindrical hole in the ground to gain access to underground formations that will yield oil or natural gas. This is accomplished by turning the drill pipe and consequently the drill bit either via a rotary table or a top drive assembly. The rotary table or the top drive is the primary consumer of electrical power on a rig. However, additional systems such as the draw works (for hoisting the drill pipe out of the hole) and the mud pumps (for keeping the hole clear while drilling and cooling the drill bit) are key components of the operation that will also draw AC power from the main electrical bus. Auxiliary support functions such as lighting will account for the remaining small portion of the applied load on the system.

Figure 1. QSK50-DPM Genset

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QSK50-DPM Package Overview (Technical Package) PGD 31.01 Page 2 of 12


SYSTEM OVERVIEW The QSK50-DPM uses a G3 rated QSK50 engine that has been developed for prime power applications at 1200 rpm. Both AvK and Kato branded open coupled alternators are offered on the unit. The alternators are sized appropriately for continuous operation at varying loads typically seen in land drilling applications where maximum power is required for short periods of time during initial start-up or sudden overloads. Table 1 provides a summary of the power module rating offered on this product.

Frequency Voltage Speed Engine Power Alternator Rating

60 Hz 347/600 V 1200 rpm 1480 HP (1104 kWm) 1750 kVA (1225 kWe) @ 0.7 pf

Table 1. QSK50-DPM Rating

The product is accessible through the Central Product Information File (CPIF), Cummins Online Specifications (COLS), and Cummins Quickserve Online (QSOL). The configuration number for this product is D0Y3002GX03 and the COLS price spec is PRIC07167.

DISCUSSION

1. Base Engine The fuel rating available for the QSK50 engine is shown in Table 2. Additional information on engine performance is available on the engine datasheet published on GCE.

FR Option Rated Speed Rated Power Certification

FR60039 1200 rpm 1480 HP EPA T4i (TPEM)

Table 2. QSK50 Engine Rating

Refer CEB00070 QSK50 Tier 2 MCRS Mechanical Product Information for more detailed information on the features of the base engine sub-systems.

2. Alternator Both AvK and Kato alternator models are offered on the QSK50-DPM. The alternators are two bearing alternators that are open coupled to the engine flywheel via a torsionally flexible rubber coupling. Hard stops are provided on the alternator mounting to prevent axial movement of the alternator and subsequent thrust loading of the engine during high axial load conditions. Table 3 provides a summary of the alternator ratings offered on the QSK50-DPM. Additional alternator performance information is available on the datasheets published on GCE.

Table 3. Alternator Ratings



The stator windings have six resistance temperature detectors (RTDs) embedded within the windings (2 per phase) for temperature monitoring. The alternator enclosures are rated for ingress protection code IP23 classification and have built-in air filters. Anti-condensation heaters are provided within the housing to prevent water condensation during long periods of downtime. Refer to the alternator wiring diagrams published in PGD 21.01 Kato 6P6-3300 Alternator Wiring Diagram and PGD 21.02 AVK DSG86 L1-6 Alternator Wiring Diagram for the heater characteristic and wiring connections. Certain controls options do not include an automatic voltage regulator (AVR) with the QSK50-DPM. The OEM is responsible for having an AVR in place that will provide the required DC current to the built-in exciter stator assembly. This DC current passing through the coils on the exciter stator will generate a magnetic field with different polarity in each of the coils. As the exciter rotor spins at 1200 rpm, AC voltage is generated in the exciter rotor, which will be rectified back to DC through the rectifier diodes to feed the main field (main rotor) of the alternator. The OEM can also add a separate supplemental exciter such as a permanent magnet rotating (PMG) exciter which functions as a pilot exciter providing power to the AVR’s power supply. The PMG is an AC generator that uses permanent magnets in the rotor instead of electromagnets to provide the magnetic field. For more information on this topic, reference the Power Module Control System section in this document. Figure 2 shows the schematic of a typical excitation system.

Figure 2. Alternator excitation system

3. Cooling System The QSK50 engine has a 2-pump, 2-loop system that requires both an engine coolant loop radiator and a low temperature aftercooling (LTA) radiator. The engine coolant loop includes the oil cooler, engine block, jacket water thermostats, and water pump. The aftercooler loop contains the LTA thermostat, water pump, and aftercoolers. The two loops have separate radiator cores, but share a common top tank. Figure 3 shows the coolant flow schematic for the two loops.

AC OUT

EXCITER FIELD(STATOR)

SHAFT

EXCITER ARMATURE

(ROTOR)

AVR

MAIN FIELD (ROTOR)

MAIN ARMATURE (STATOR)

ENGINE

PMG ARMATURE(STATOR)

PMG FIELD(ROTOR)

RECTIFIER

AC

DC

DC

DCAC

AC

SENSING

https://gce.cummins.com/ice/ice_main/ice_coe/qsk50_dpm/project-guide-documents.html




Figure 3. 2-pump, 2-loop Coolant Flow

The COE offers a remote and an engine driven radiator option (Figure 4). Both options contain three (3) cores: LTA circuit, jacket water circuit, and fuel cooler circuit.

Drive Type Speed Fan Config. Discharge Direction

Coolant Capacity

Core Arrangement

Rating

480 V electric motor (50 hp)

Constant Blower Vertical 117 gal Side by side 50 deg C

VFD controllable

Engine Constant Blower Horizontal 102 gal Stacked 50 deg C

Table 4. COE Radiator Options for QSK50-DPM

Figure 4. QSK50-DPM cooling system with plumbing

If the OEM is interested in providing the radiator, he is responsible for sizing an appropriate cooling system that meets the system requirements for cooling. Refer to the engine datasheet on GCE for heat rejection data and performance criteria. The system must be designed to meet the installation recommendations outlined in the following AEBs:

AEB 24.18 LDI/MR/HD/HHP Cooling System Design - Installation Requirements AEB 24.26 Two-Pump, Two-Loop Cooling System Installation Requirements and

Recommendations




Refer to the package installation drawings on GCE for more detailed information on the coolant inlet and outlet connections.

4. Air Intake System The QSK50-DPM has four AH19481 air filters located at the rear of the module above the flywheel housing. The air filters are rated for a heavy-duty application environments. Table 5 provides additional details on the filters specification.

Table 5. Air Filters Specification

Figure 5. QSK50-DPM Air Intake Details

The air intake system has been designed to meet the performance and engine installation requirements outlined in AEB 24.21 Industrial Installation Requirements - Air Intake System for Off-highway Applications. However, the OEM must take measures to ensure that the final power module installation on the oil field base skid and/or enclosure does not negatively impact the performance of the intake air system.




Over-speed engine shutdown protection is provided by guillotine style air intake shut-off valves that are mounted on the intake manifolds of the engine. The valves will close automatically if the engine overspeeds, but can also be activated manually from the control panel emergency stop (e-stop) switch. The e-stop circuit is also brought out to the customer interface connector on the genset controller that allows the OEM to provide additional E-stop switches at other locations on the rig.

5. Exhaust System QSK50 engines have single stage turbocharging with each cylinder bank having a Holset HX83 turbocharger mounted on the exhaust manifold. Each of the turbo exhaust connections has a 90° elbow with a bolted flange connection. The elbows also come with a 1/8 NPT pyrometer feature. Please review the installation drawing on GCE for detailed information on location and interface points. Refer AEB 24.14 High Horsepower Inlet/Exhaust Restriction Guide for additional details and guidelines on sizing exhaust plumbing for the QSK50 engine.

6. Lubrication System The Fleetguard LF9050 Venturi Combo lube filters combines the full flow filter media with the bypass media in a common filter and is mounted on the left side of the engine near the flywheel housing end. 6.1 Rolling pre-lubrication The QSK50-DPM achieves pre-lubrication prior to engine startup by utilizing the rolling pre-lube feature integrated within the engine control module (ECM) to help distribute oil throughout the engine lubrication system. The pre-lubrication process assures oil pressure in the main rifle and oil availability to all friction surfaces in the engine at startup, thus reducing engine wear. It also reduces the risk of starting the engine without oil in the engine sump or dry oil filters. Pre-lubrication by use of the rolling pre-lube feature is acceptable only if the engine oil has been warmed to the temperature prescribed for starting (–10°F). The ECM monitors an oil pressure switch mounted in the left bank cam oil rifle at the rear of the engine and disables fueling until engine oil pressure increases to 4 psi (28 kPa). If oil pressure is not detected after 10 seconds, fueling will be reinstated thereby allowing the engine to start.

7. Fuel System The fuel delivery system used on the QSK50 engine is the Cummins Modular Common Rail System (MCRS) that utilizes a high pressure fuel pump to supply fuel to the injectors at the required pressure and timing. A two stage fuel filtration system is used to improve the filtering efficiency of the system. Stage 1 filtration (suction side) utilizes a triplex Fleetguard Sea Pro™ 5 FH23471 with 7 micron FS19841 filters while Stage 2 filtration (pressure side) is achieved by using 3 micron Fleetguard FF5644 filters. Figure 6 shows the layout of the fuel filtration system used on the QSK50-DPM. The Stage 1 filters must be mounted by OEM on the base skid, while the Stage 2 filters are mounted to the base rails next to the fuel pump. Refer PGD 70.02 QSK50-DPM Fuel System for additional guidelines and installation recommendations. 7.1 Dual Fuel The COE offers a Dual Fuel solution for the QSK50-DPM MS. For more information on this system, reference PGD 72.01 - QSK50-DPM Dual Fuel System and PGD 05.01 – QSK50-DPM Dual Fuel Data Sheet.








Figure 6. QSK50-DPM Fuel Filters

8. Power Module Control System

The QSK50 engine uses three CM2150 control modules (ECM) to provide advanced engine control and an enhanced electronic feature set. The modules are mounted on the engine left bank near the pan rail. The COE offers PowerCommand® 1302 and 3300 genset controllers as options. 8.1 PowerCommand 1302 The Cummins PowerCommand® 1302 (PCC) genset controller mounted to the power module provides full engine monitoring capability and protection in addition to start and stop functionality. It monitors engine temperature, oil pressure and speed. In the event of a fault, the fault type is indicated and on critical faults, the power module automatically shuts down. Gauges, control buttons, and display screen are located on the control panel as shown in Figure 7.

FUEL DRAIN FUEL PUMP

STAGE 2 FILTRATION (3 micron)

STAGE 1 FILTRATION (7 micron)

FUEL SUPPLY



Figure 7. PCC 1302 Genset Controller

The control system generates two categories of fault signals- warning and shutdown. Warning signals indicate imminent or non-critical faults for the engine, while shutdown faults indicate that the engine will shut down. The system operated on customer supplied 24 VDC power. History data is stored in non-volatile memory and is not deleted when power is lost. Refer to PGD 20.02 QSK50-DPM Genset Wiring Diagram (PCC1302) and PGD 141.01 QSK50-DPM PowerCommand® 1.2 Control System for additional details on the features offered on the PCC 1302 genset controller. 8.2 PowerCommand 3300 The PowerCommand® 3300 genset control provides paralleling capabilities to QSK50-DPMs (Figure 7). This controller is compatible with shunt or PMG excitation style alternators and includes integrated digital voltage regulation (AVR). PCC3300 controllers can provide full authority engine communications and control with the ECM. Similar to the PCC1302, this controller has the ability to monitor engine and alternator functions and contains start and stop functionality. For additional details, refer to PGD 20.03 QSK50-DPM Genset Wiring Diagram (PCC3300) and PGD 141.02 QSK50-DPM PowerCommand® 3.3 Control System located in GCE.









Figure 8. PCC3300 Paralleling Capabilities Schematic

9. Cranking System

An Ingersoll-Rand ST650 air starter or dual Prestolite MS7 electric starters are offered as options on the power module. The starters are mounted on the right bank lower quadrant of the flywheel housing. Table 6 provides additional details for the starter models offered on the QSK50-DPM.

Ingersoll-Rand ST650

Prestolite MS7

Quantity 1 2

Power supply Air Electric

Motor length 412.6 mm (16.24 in) 383 mm (15.1 in)

Inlet port size 1 1/2 NPT N/A

Supply pressure (nominal)

90-120 psi N/A

Voltage N/A 24 V

Table 6: Cranking Motor Specifications



Figure 9: Ingersoll-Rand ST650 (left) and Prestolite MS7 (right) Starters

Refer PGD 100.02 QSK50-DPM Starting System for additional details on the power module’s cranking system. INSTALLATION GUIDELINES AND RECOMMENDATIONS 1. Lifting Arrangements For lifting arrangements guidelines and recommendations, please refer to PGD 200.02 QSK50-DPM Power Module Lifting Requirements. 2. Alternator Alignment Misalignment between the alternator and the engine can introduce unnecessary and excessive vibrations to the system which can lead to coupling wear and failures. The alternator and engine must be aligned after installation on the oilfield base skid (or master skid) and upon commissioning of the QSK50-DPM unit. Transportation and loading procedures should be carried out with care to help prevent misalignment. For more information on QSK50-DPM alignment, reference the Service document 237-210-008 in QSOL. 3. Mounting Arrangements The QSK50-DPM is mounted on a steel frame (base rails) intended for installation on an oil field skid. These base rails use an isolated three-point mounting system. Refer to PGD 171.02 QSK50-DPM Mounting Requirements for more information. 4. Grounding Requirements The QSK50-DPM contains grounding provisions in the form of a ground strap located at the rear of the equipment (Figure 10Error! Reference source not found.). This ground strap is intended to ground the equipment to the oil field base skid (or master skid) to which the QSK50-DPM is mounted. Grounding (earthing) must be confirmed before starting the power module.






https://qsol.cummins.com/qs3/pubsys2/xml/en/procedures/237/237-210-008.html?q=237-210-008



Figure 10: QSK50-DPM Ground Strap Location and Details



REFERENCES Application Engineering Bulletins (AEB) CEB00070 QSK50 Tier 2 MCRS Mechanical Product Information

AEB 24.14 High Horsepower Inlet/Exhaust Restriction Guide

AEB 24.18 LDI/MR/HD/HHP Cooling System Design - Installation Requirements

AEB 24.21 Industrial Installation Requirements - Air Intake System for Off-highway Applications

AEB 24.26 Two-Pump, Two-Loop Cooling System Installation Requirements and Recommendations

AEB 191.33 Non-road Tier 4 U.S. EPA Emission Regulations and EPA TPEM Program for High Horsepower Engine Project Guide Documents (PGD) PGD 02.04 Kato 6P6-3300 Alternator Data Sheet

PGD 02.05 AVK DSG86 L1-6 Alternator Data Sheet

PGD 05.01 QSK50-DPM Dual Fuel Data Sheet

PGD 11.03 Kato 6P6-33000 Alternator Installation Drawing

PGD 12.02 QSK50-DPM with Kato 6P6-3300 Installation Drawing

PGD 20.02 QSK50-DPM Genset Wiring Diagram (PCC1302)

PGD 20.03 QSK50-DPM Genset Wiring Diagram (PCC3300)

PGD 21.01 Kato 6P6-3300 Alternator Wiring Diagram

PGD 21.02 AVK DSG86 L1-6 Alternator Wiring Diagram

PGD 31.01 QSK50-DPM Power Module Overview

PGD 70.02 QSK50-DPM Fuel System

PGD 72.01 QSK50-DPM Dual Fuel System

PGD 100.02 QSK50-DPM Starting System

PGD 130.02 QSK50-DPM Engine Coolant Heater Kit

PGD 141.01 QSK50-DPM PowerCommand 1.2 Control System

PGD 141.02 QSK50-DPM PowerCommand 3.3 Control System

PGD 171.02 QSK50-DPM Mounting Requirements

PGD 192.02 ARCUSAFLEX Torsional Coupling Details

PGD 200.02 QSK50-DPM Power Module Lifting Requirements

PGD 210.01 DPM Commissioning Requirements Worksheet



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