Cummins And Sygnet Rail Technologies Introduce Drop-In Tier 4 Repower Capability

INDIANAPOLIS (Sept. 29, 2013) – Cummins Inc. (NYSE: CMI) today revealed a QSK95 Power Module with 4200-hp (3132 kW) output meeting U.S. Environmental Protection Agency (EPA) Tier 4 regulations for line-haul locomotives taking effect Jan. 1, 2015. The fully self-contained power module introduced at the Railway Interchange Show in Indianapolis represents the first repower package capable of bringing Tier 4 ultra-low emissions capability to heavy-haul locomotives. Cummins has announced that the first freight locomotive to be repowered with the QSK95 Power Module will enter service with the Indiana Rail Road Company by mid-2014, designated as CECX 1919.

The QSK95 Power Module is designed to replace the complete diesel-electric system and carbody of the base locomotive as a complete drop-in package. The fully enclosed unit features the QSK95 engine, alternator, cooling system and dynamic braking system, together with integral Selective Catalytic Reduction (SCR) exhaust aftertreatment specifically designed for locomotives. The clean combustion of the QSK95 works together with Cummins SCR aftertreatment to meet the stringent Tier 4 emissions levels.

The power module is the result of a design collaboration between Cummins and Sygnet Rail Technologies, LLC, to introduce the QSK95 engine with the benefit of more compact and efficient 1800 rpm high-speed operation. The power module interfaces with locomotive electronics using standard J1939 engine data bus integration, and features advanced controls for wheel slip functionality, idle limiting and remote operational reporting.

“By working together, Cummins and Sygnet Rail Technologies combine the latest in Tier 4 engine technology with a universal drop-in power module that is adaptable for many locomotives independent of original manufacturer, allowing for simpler and faster repowers,” said Ed Pence, Vice President and General Manager – Cummins High-Horsepower Engine Business.

“Cummins high-speed diesels are leading a transformation in locomotive prime mover capability –­ not only smaller, but powerful, clean and highly fuel-efficient – equipping the power module with the ability to outperform medium-speed engines,” added Pence.

Cummins latest-generation Modular Common Rail System (MCRS) enables the QSK95 to achieve high fuel efficiency even when operating at maximum-power output for long periods. With up to 2200-bar high-pressure fuel injection, the MCRS reduces noise, offers smooth idle stability and eliminates visible smoke across the entire operating range.

A quad-turbocharging system with one turbo for each 4-cylinder quadrant provides outstanding response to load demands, with tractive power delivered more rapidly across the entire rpm range to increase acceleration, boost gradient climbing ability and reduce journey times.

The 4200-hp (3132 kW) output of the QSK95 prime mover is the highest achieved from a 16-cylinder high-speed diesel, made possible by deep structural strength at the heart of the engine. When running at high engine-load factors, the QSK95 powers the locomotive with relaxed ease, operating well within its design capability.

High power density is enabled with a hardened power cylinder featuring the strongest, single-piece forged-steel piston available in the industry. This inherent robustness enables the engine to achieve over 20,000 hours on the track before rebuild, without the need for any major midlife intervention. The extra strength components of the QSK95 mean that there is less to replace, so that total life-cycle costs are lower.

A Simpler Approach For Tier 4
The QSK95 engine and SCR exhaust aftertreatment meet the EPA Tier 4 emissions regulations of 0.03 g/bhp-hr Particulate Matter (PM) and 1.3 g/bhp-hr of oxides of nitrogen (NOx) for line-haul locomotives with over 1006 hp (750 kW) output. Compared with current (Tier 3) regulations, this represents over 70 percent reduction.

Cummins takes a simpler approach to meeting these stringent levels by putting the main focus of emissions reduction in the exhaust stream, with the SCR aftertreatment removing the NOx. This leaves the engine combustion to focus on removing PM emissions, avoiding the need for any additional complexity on the engine.

“Cummins SCR exhaust aftertreatment is a passive, flow-through system working together with the clean-combustion QSK95 to meet the Tier 4 regulations. By using SCR, we are able to influence the engine combustion formula to optimize fuel efficiency,” commented Randy Nelson, Marketing Director – Cummins Rail Business.

“In fact, the only real difference with an SCR system compared to exhaust silencers is the requirement for small amounts of Diesel Exhaust Fluid (DEF) dosing to initiate the catalyst and remove the NOx. The fluid is easy to source, store and handle, with refilling aligned with the locomotive refueling,” added Nelson.

The SCR aftertreatment has been specifically developed by Cummins Emission Solutions (CES) for locomotive installations, with a space claim similar to that of exhaust silencers, and providing equivalent acoustic reduction. CES experience with SCR is unrivaled in the industry, and has been successfully applied to over 600,000 Cummins engines.

About Cummins Inc.
Cummins Inc., a global power leader, is a corporation of complementary business units that design, manufacture, distribute and service diesel and natural gas engines and related technologies, including fuel systems, controls, air handling, filtration, emission solutions and electrical power generation systems. Headquartered in Columbus, Indiana (USA), Cummins currently employs approximately 46,000 people worldwide and serves customers in approximately 190 countries and territories through a network of approximately 600 company-owned and independent distributor locations and approximately 6,500 dealer locations. Cummins earned $1.65 billion on sales of $17.3 billion in 2012. Press releases can be found on the Web at cummins.com or cumminsengines.com. Follow Cummins on Twitter at twitter.com/cumminsengines and on YouTube at youtube.com/cumminsengines.

About Sygnet Rail Technologies, LLC 
Sygnet Rail Technologies, LLC, is a worldwide supplier of innovative products and services for the rail industry that provides competitive advantage, quantifiable financial returns and environmental benefits. Sygnet Rail Technologies has been refurbishing locomotives for decades, managing projects all the way from complete disassembly through to onsite commissioning. Sygnet Rail Technologies’ revolutionary solutions such as the Power Module, Control System and Information Telematics bring the latest technology to organizations of any size, in any geography, with reduced effort, time and expense.