Cummins Launches 4000khp World's Largest Output Engine QSK95

On November 1, 2011, Cummins officially released the QSK95, the highest output high-speed diesel engine in the world today, at Seymour, Indiana, with a power of more than 4,000 hp (2,983 kW). With a displacement of 95 litres, the 16-cylinder QSK95 engine is the first of Cummins' new high-horsepower diesel and natural gas engine platforms. This new product line will be extended to 120 liters in the future, has a 20-cylinder QSK120, output power can exceed 5000 horsepower (3728 kilowatts).

The QSK95 sixteen-cylinder engine has a high power density and strong power, and is capable of super-high power that other 1800-rpm and 20-cylinder high-speed high-power engine types cannot match. At the same time, QSK95 is a more space-saving and cost-saving alternative to most medium-speed high-powered engines with speeds below 1200 rpm without degrading power.

For long-time, high-load passenger and cargo locomotives, multiple ship machines and oversized tonnage mining vehicles, the QSK95 offers a perfect power match, and customers can benefit from their long-term attendance and overhaul mileage.

As a generator set application, QSK95 has high reliability and good fuel economy. On offshore platforms, the QSK95 is a well-matched rig power module. The QSK95 is used to drive Cummins' latest C3000 series generator sets to provide industry-leading 3.5 megawatts of power output.

QSK95 strives to meet today's most stringent emission standards in a variety of applications, including the fourth phase of the US Environmental Protection Agency's EPA, which will be implemented in 2015, replacing the exhaust muffler with a market-proven Cummins selective catalytic reduction system. The standard.

The QSK95 is a milestone in the history of the development of large-scale high-speed diesel engines. Its power and durability surpass those of other products in its class and it is also enough to equip those larger, more costly medium-speed engines. QSK95 brings Cummins to the next level of power, which is what many customers are looking forward to. During the development of QSK95, Cummins collected opinions from hundreds of potential users and fully considered their needs for operation and installation.

Cummins has been specifically designed to make the QSK95 higher in attendance and reliability than other engines in its class, because these qualities are key to their success. The launch of QSK95 means the successful launch of Cummins' new high-power diesel and natural gas engine platform. This platform will continue to introduce new series of 12-cylinder, 16-cylinder, and 20-cylinder engines in the future. The natural gas engine product line is also not a derivative of diesel engines, but will be specific to gas-fired designs, and Cummins will announce more details on the natural gas product line in 2013.

During the development of the QSK95 product platform, four cylinder positions have been reserved for upgrading to QSK120 models with power exceeding 5,000 horsepower, again breaking the limits of high-speed diesel engine performance. The QSK120 will use the same structure and system design as the QSK95, giving full play to the platform's versatility.

Cummins invested a lot of manpower and material resources for the development of the QSk95 and the new high-powered platform: A total of 150 senior engineers participated in research and development throughout, and Cummins invested more than US$100 million in establishing a new production line and advanced experimental equipment at Seymour's plant.

Developing QSK95 models with analytically oriented design

The QSK95 development process uses the highest level of analytical tools, including advanced simulation combustion systems. These powerful analysis tools help us find the optimal solution through tens of thousands of combustion design methods before the actual production to achieve the best state of fuel economy, performance, emissions, and cylinder durability.

QSK95 has designed the internal structure of the engine with strong bearing capacity to ensure that the power cylinder can withstand the pressure at higher peaks, creating efficient and durable in-cylinder conditions for reducing emissions and improving fuel economy. One of the major achievements of the combustion-analysis-oriented approach is that QSK95 meets higher emission standards and does not discount any performance. This is undoubtedly a huge advantage compared to other high-speed engines that meet the fourth-stage standard.

Using proven performance systems

Although the QSK95 was produced on a completely new platform, this engine effectively utilized the advantages of Cummins' proven performance systems in its high-powered technology series.

Four turbocharger systems apply the QSK60's highly reliable air handling system directly to the QSK95. The four compact turbochargers provide excellent sudden load acceptance and transient response in a single-stage boost mode.

The modular common rail fuel system is further upgraded to a maximum pressure of 2200 Pa. The system ensures that not only can the fuel economy be further improved in various operating levels, but it can also be significantly improved in terms of noise reduction, stability and smoothness, and reduced smoke emissions.

Cummins' new NanoNetTM oil filter significantly improves fuel cleanliness, further enhancing the durability of modular common rail fuel systems. Taking into account the significant differences in oil quality in different regions of the world, this technology will be an important advantage for Cummins engines.

Strengthen structural strength

The new ductile iron cylinder body and the extended skirt ensure the structural strength of QSK95 with high performance, enhance the durability of adapting to multiple overhauls, and the built-in cylinder block reinforcement plate greatly contributes to the shock absorption. Monolithic forged steel pistons greatly enhance durability and create conditions for future remanufacturing. The three piston rings are made of top grade materials and the first air ring uses PVD coating technology. The cylinder liner on the reinforced cylinder block and the double-piston cooling nozzle act as a relay, which effectively reduces the temperature of the piston ring and enhances the durability.

The more powerful engine design process of QSK95 enhances the reliability of the engine during the warranty period, and also reduces the replacement of the engine overhaul, which significantly reduces the cost of the entire life cycle of the engine. The QSK95 has an amazing long overhaul cycle, with a maximum interval of up to 1.7 million gallons (6.4 million liters) or more in fuel consumption, without major repairs, and greatly improving attendance.

Meet the ultra-low emission limits

The Selective Catalytic Reduction Aftertreatment System (SCR), designed specifically for the QSK95, provides flexible installations to meet the requirements of Phase IV and higher emission standards. The design of the aftertreatment system also leaves room for increased technology to reduce particulate emissions to meet specific needs.

With load cycling, the Cummins SCR system can save 5% to 10% of fuel while significantly reducing CO2 emissions. The fuel savings achieved by the SCR technology is a further improvement in the performance of the high pressure fuel system, and the resulting operating cost savings exceed the increased cost of using a diesel emission treatment fluid (DEF).

The QSK95 uses a selective catalytic reduction system (SCR) instead of an exhaust gas recirculation system (EGR) to reduce nitrogen oxide emissions. Doing so can avoid the complex internal matching of the EGR system and the high-power engine, and there is no problem of applicability. Another advantage is that the engine heat sink is no longer needed, while saving installation costs and space.

Longer attendance and easier maintenance

The QSK95 enhances reliability in design and maximizes attendance time. The appearance of the engine is designed for easy access to cooling, oil and fuel system maintenance points, making after-sales maintenance services faster and more convenient. The minimum maintenance interval is greater than 500 hours. At the same time, if the ELIMINATORTM oil cleaning system is selected, the oil change interval can be greatly extended.

The entire engine is designed with no leakage as its goal. All important connection points such as the flywheel housing, flywheel, gear chamber, oil pan, and cylinder head are fitted with embedded plugs to ensure a tight fit. The special plug around the cylinder head ensures that debris in the air will not penetrate this important interface.

Four Cummins Electronic Control Modules (ECMs) provide powerful data processing and storage capabilities for monitoring and protecting engine systems. An electronic control module monitors a quarter of the engine, and four electronic control modules work together to easily observe data in the protective cover in front of the engine. The user-friendly operation interface makes all diagnostic work easy.

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