Application

Engineering
Bulletin
Subject This AEB is for the following applications:
Generator-Drive HPI-TP & PT Fuel
System Installation Requirements

Automotive Industrial Marine

G-Drive Power Generation

Filtration Emissions Solution

Date: August 18, 2011 AEB Number 70.28


Engine Models included: QSX15 & QSK 23/45/60/78


Author: A.H.M. (Nur) Nuruzzaman Approver: per Procedure VPI-GAE-0001 Page 1 of 15


This AEB supersedes AEB 70.28
dated J uly 2, 2010

Introduction

The High Pressure Injection (or HPI ) fuel systems on QSX15/QSK23/45/60/78
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 requirements (e.g. fuel cooling) for the HPI-TP (QSX15) and HPI-PT
(QSK23/45/60/78) systems.

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 QSK23/45/60/78 engines have Cummins-supplied and plumbed 10 micron fuel
filters that must be used to protect the engine fuel system.
The QSX15 engine has a Cummins-supplied 25 micron fuel filter that 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) is recommended between either the main
tank and day tank or between the main tank and the engine.


AEB 70.28
Page 2 of 15

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 Designers 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 (QSK23/45/60/78 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 (QSK23/45/60/78) 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 (1.5 in Hg).
AEB 70.28
Page 3 of 15


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 QSK23/45/60/78 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.

AEB 70.28
Page 4 of 15

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 25 mm (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.

If the machine fuel tank is located so that the maximum fuel level is at or above the
level of the engine cylinder head gasket, fuel system with High Pressure Injection
(or HPI ) on QSX15/QSK23/45/60/78 can allow fuel to enter an engine cylinder by
flowing through the fuel lines and an injector after engine shutdown. If fuel enters
an engine cylinder, it can cause a hydraulic lock upon startup which can result in
severe engine damage. For overhead tank applications check valves must be
installed in the fuel supply and return lines to prevent filling a cylinder with fuel
during shutdown period. Tier 2 and Tier 3 QSX15 engines with HD (Heavy Duty) HPI
(High Pressure Injection) and overhead tanks must have additional protection
against fuel drainback. The fuel system must have a check valve in the fuel return
line and OEM-supplied shutoff valve in the fuel supply line. A quality electronic
solenoid valve is recommended for the inlet shutoff. For additional protection, a 50
micron filter element can be installed in the supply line between the solenoid valve
and the fuel tank. The filter will prevent large contaminants from getting to the
solenoid valve and IFSM.

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)
QSK23/45/60/78 = 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 15 cm (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)


AEB 70.28
Page 5 of 15

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.

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 1.5 m (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 1.5 m (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.

AEB 70.28
Page 6 of 15

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 (25 mm) 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.
AEB 70.28
Page 7 of 15

















































Fuel Tank
Drain Opening
25 mm
(1 in)
Breather
Sight
Glass
Fuel return
Fuel Supply
Min. Fuel level
Crank
Centerline
QSX15 =91cm (36in)
QSK23/45/60/78 =107cm (42in)
Fill Opening
Approved Flexible
Fuel Hose
Approved Flexible
Fuel Hose
All piping to be
Black Iron
Figure 1: Typical Fuel Tank below Fuel Inlet
Fuel Tank
Fuel
Return
Fuel Supply
Figure 2: Typical Fuel Tank above Fuel Inlet
Drain Opening
Fill Opening Breather
Sight
Glass
25mm
(1 in)
Crank
Centerline
2.1 m (84 in)
Max Fuel Level
Approved Flexible Fuel Hose
Approved Flexible
Fuel Hose
All piping to be
Black Iron
5% Expansion space
AEB 70.28
Page 8 of 15













































Fuel Tank
Fuel
Return
Fuel Supply
Figure 2B: Typical Fuel Tank above Fuel Inlet
(emergency start requirements)
Drain Opening
Fill Opening
Breather
Sight
Glass
Max Fuel
Level
Approved Flexible Fuel Hose
Approved
Flexible Fuel
Hose
All piping to be
Black Iron
5% Expansion space
25mm
(1 in)
152mm (6 in)
Minimum Fuel level
above pump inlet
Fuel Supply to engine
Fuel supply drop
tube with filter
screen 25 mm (1 in)
off bottom of tank
Fuel supply to Day Tank
Return fuel from engine

Breather
Drain Opening
Float switch to
control fuel level
in Day Tank
Baffle to permit
deaeration of fuel
Figure #3: Float Tank Requirements
Overflow return
to bulk tank
Fuel level
sight glass
AEB 70.28
Page 9 of 15

6. Fuel Line Plumbing (Supply and Return)

All rigid lines must be black iron pipe or steel tubing.
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 GPH (L/hr)
Flex Hose I.D. in (mm) Flex Hose I.D in (mm)
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)



AEB 70.28
Page 10 of 15


Table #1: Fuel Flow vs Fuel line size
(continued)
Line length 3m - 15m (10 - 50 ft)
Supply Return
Max Fuel Flow
rate GPH (L/hr)
Flex Hose I.D. in (mm) Flex Hose I.D in (mm)
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.






AEB 70.28
Page 11 of 15

Baffle
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 crank centerline specified for
the engine. The lowest level must not fall below the
specified lift height of the engine fuel pump. 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 15 cm (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
5% Expansion Space (minimum)
Fuel Supply Tank
Screened Vent
Cap (outside)
Construction, location, installation, venting,
piping, leak containment, and inspection must
comply with all applicable codes.
Approved
Day Tank
Fuel Supply
piping
Fuel Return
piping
All piping to be
Black Iron
Float
Switch
Screened fill cap
(outside)
Float switch operated
Siphon-break Solenoid
valve
Manual
shutoff
valve
Float switch
operated solenoid
valve
120 Mesh fuel strainer
Manual priming
ball valve-Self
closing
Approved flexible fuel hoses fromIron
pipe to Return and Supply fittings
Screened
vent cap
(outside)
Approved
Day Tank
Fuel Supply
piping
Fuel Return
piping
All piping to be
Black Iron
Float
Switch
Approved flexible fuel hoses fromIron
pipe to Return and Supply fittings
5% Expansion Space (minimum)
Fuel Supply Tank
Construction, location, installation, venting,
piping, leak containment, and inspection
must comply with all applicable codes.
Overflow pipe-One pipe
diameter larger than supply
Pump, Solenoid Valve and 120 mesh
Fuel Strainer
Auxiliary pump if required
Screened vents
Fill Cap
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
crank centerline specified for the engine. The lowest level must not fall
below the specified lift height of the engine fuel pump. 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 15 cm (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
Figure #5: Remote Fuel Supply Lower then Day Tank
Figure #4: Remote Fuel Supply higher then Day Tank
Baffle
AEB 70.28
Page 12 of 15

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 = 3.7inHg (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 QSK23/45/60/78 engines

















HPI-PT Fuel Pump and
Pressure Regulator
Assembly
Fuel Inlet
from filters
Fuel Outlet to
Electronic Fuel Control Valve
Max allowable restriction
with clean filters @
CompuCheck fitting
=4 in Hg (102 mm Hg)
Compucheck fitting on
the fuel pump
AEB 70.28
Page 13 of 15






















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)






Checking Fuel Inlet Restriction on
QSX15
Customer Fuel
Inlet Hose
IFSM
Allowable restriction @ IFSM
OEM Fuel Inlet Connection
=3 in Hg (76 mm Hg)
Customer Fuel Inlet
Connection
AEB 70.28
Page 14 of 15






















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.











Customer Fuel Return
Connection
Customer Fuel Inlet
Connection
Customer Fuel
Return Hose
IFSM
Allowable restriction @ IFSM
OEM Fuel Return Connection
with IFSM mounted filter
=6 in Hg (165 mm Hg)
Checking Fuel Return Restriction on QSX15
AEB 70.28
Page 15 of 15

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 24.07 Fuel cooling installation recommendations




Change Log
Date Author Description Page(s)
18Aug2011 A.H.M. (Nur)
Nuruzzaman
Updated Approver number in header.
Added information for overhead tank applications.
Added requirements on Tier2/Tier3 QSX15 fuel system
supply and return lines for drainback protection.
1
4
4
J uly 2, 2010 A.H.M. (Nur)
Nuruzzaman
Updated Introduction and Reference Documents. 1, 15
J uly 9, 2009 Emmanuel
Padilla
Updated format and moved images so they would
appear on page.
1, 6, 7
Nov. 4, 2004 Norm J ones Initial Release