Getting up to speed on Cummins' natural gas turbochargers – part 1

Holset ® turbocharger

Cummins’ technological leadership in developing Holset® turbochargers for diesel power solutions is well documented, but some people may be surprised to learn about Cummins’ leadership in designing turbochargers for low emission natural gas engines. While investment in cleaner technologies seems to be a relatively recent trend for many, Cummins Turbo Technologies (CTT) has been designing and manufacturing natural gas Holset turbos for decades. In addition to our years of experience with >19-liter large commercial engines, the growth in the on-highway market has pushed technology and driven improvement in our technology offerings. 

In this two-part series, we’ll highlight four key elements that contribute to the success of Cummins’ natural gas turbochargers.                                               

1. Cummins has responded to a shift in technology

In order to reduce emissions, the on-highway natural gas market moved from lean-burn to stoichiometric combustion engines. Stoichiometric combustion recipes drive high exhaust temperatures and therefore generate severe thermal duty cycles. Holset turbochargers are able to meet these requirements through more compact turbocharging solutions tailored to emissions requirements.

Today, Cummins is dedicated to satisfying increasing natural gas turbocharger demands, especially in regions where infrastructure is growing. The attractive total cost of ownership in China has resulted in increased infrastructure growth and caused a surge in the demand for natural gas fueled on-highway freight vehicles. India is also starting to see natural gas infrastructure develop backed by sustained efforts of the government, which is fueling demand for natural gas engine technologies. Demand in Europe, North America, and other regions will also grow over the next decade due to low NOx and lower greenhouse gas emission regulations being introduced. 

To cope with the differences in mechanical turbocharger design for natural gas applications, Cummins has conducted significant work to develop capable analytical tools for simulative assessments of vibration and thermal fatigue. The advances in Thermo-Mechanical Fatigue (TMF) analysis have made iterative design optimization easier and enables CTT to select robust designs prior to committing to costly production tooling, which also eases the reliance on expensive engine endurance test work.

2. Natural gas air handling technologies designed to meet a multitude of challenges

Engine requirements have evolved as emission norms have changed over the last decade, but Cummins has remained at the technological forefront by introducing turbocharger technologies that meet the challenging demands posed by the natural gas market. In addition to helping address emission challenges, Cummins has invested design efforts into natural gas developments to be a leader in fuel consumption, reliability and durability. Inherently, turbochargers used for natural gas engines have notably different performance attributes compared with their diesel counterparts. Cummins has designed very specific turbocharger aerodynamic characteristics that enable high-performance for stoichiometric natural gas engines, while simultaneously evolving other key features of the turbocharger to meet robustness and reliability targets over the service life of the engine. 

Stay tuned for the second part of this series that explains the other benefits of Cummins’ natural gas turbochargers. In the meantime, you can stay connected with Cummins and learn more about the exciting developments we’re making in the natural gas space by signing up for our newsletter.

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Cummins Inc.

Cummins is a global power leader that designs, manufactures, sells and services diesel and alternative fuel engines from 2.8 to 95 liters, diesel and alternative-fueled electrical generator sets from 2.5 to 3,500 kW, as well as related components and technology. Cummins serves its customers through its network of 600 company-owned and independent distributor facilities and more than 7,200 dealer locations in over 190 countries and territories.

Getting up to speed on Cummins' Natural Gas Turbochargers – Part II

This is Part II of our article exploring Cummins’ natural gas turbochargers. To read part I, click here.

Cummins’ broad portfolio of technology leading power solutions also includes turbochargers designed and manufactured by Cummins Turbo Technologies to power low emission natural gas engines for the medium- and heavy-duty engine markets. This is the second part of our series that will highlight two other key elements that contribute to the success of Cummins’ natural gas turbochargers. 

1. A turbocharger with benefits 

With original equipment manufacturers continuously pushing for natural gas engines to meet diesel engine performance levels, designing the turbos with finely tuned turbine and compressor aerodynamic traits is essential. This needs to be supplemented by robust material selections to handle aggressive exhaust gas constituents, the application of exhaust gas control technologies plus the ability to survive extreme thermal duty cycles.

Engineers use the enhanced simulation techniques developed by Cummins for thermal fatigue evaluation and turbocharger thermal analysis, to better evaluate a design’s capability to meet these strict engine duty cycles. Cummins’ knowledge of a turbocharger’s duty cycle within natural gas applications has resulted in a more resilient and cost-effective product.  

“The growth of Holset natural gas turbos in the last five years is a testament to Cummins’ advances in technologies that address the aggressive thermal and duty cycle environments of the natural gas market,” said Matt Franklin, Director - Product Management and Marketing at Cummins Turbo Technologies. “Cummins is uniquely positioned to support our customers as markets change and help them successfully transition to newer technologies. We are excited to invest in and expand the portfolio of natural gas turbochargers for our customers.” 

2. Holset Turbochargers: Helping Cummins arrive at Destination Zero 

Holset natural gas turbochargers are paving the way for Cummins’ path to zero emissions. The natural gas product portfolio will help Cummins achieve its environmental goals, which include lowering emissions from newly sold products by 25% by 2030 and a goal of carbon neutrality by 2050 – all of which are aligned with the Paris Climate Agreement.

Cummins is equally committed to helping our customers achieve CO2 reductions. Holset natural gas turbochargers are available now to meet the emission reduction goals of customers and end markets with additional upgrades coming in 2024.

Did you enjoy this series? If so, you can stay connected with Cummins and learn more about the exciting developments we’re making in the natural gas space by signing up for our newsletter. Click here to subscribe now!

Cummins Office Building

Cummins Inc.

Cummins is a global power leader that designs, manufactures, sells and services diesel and alternative fuel engines from 2.8 to 95 liters, diesel and alternative-fueled electrical generator sets from 2.5 to 3,500 kW, as well as related components and technology. Cummins serves its customers through its network of 600 company-owned and independent distributor facilities and more than 7,200 dealer locations in over 190 countries and territories.

It’s time for the next generation in HE300 Variable Geometry Turbocharger technology

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Holset® turbochargers are synonymous with turbomachinery and air handling excellence across the globe. Engineered and manufactured by Cummins Turbo Technologies (CTT), Holset turbochargers have set the standard for turbocharger technology and design in the mid-range and heavy-duty diesel engine market for more than six decades.

The latest Series 300 Variable Geometry Turbocharger (VGT), which launches in 2024, will deliver performance enhancements as well as significant efficiency and reliability upgrades to the current HE300VG turbocharger.

Designed for diesel engines ranging from six to nine liters for the on- and off-highway commercial vehicle market, the 300 Series VGT is typically found on mid-range engine applications like trucks (pick-up/cab chassis), buses, front-end loaders and excavators. The 300 Series VGT, along with other critical elements found on a diesel powertrain, will likely play a critical role in helping customers’ meet future emission standards in Europe and the U.S. 

VGT Mechanism

The upcoming HE300 VGT offers further enhancements by introducing a new compressor and turbine stage to achieve higher turbocharger efficiency compared to its predecessor. This was possible with CTT’s latest and best practice wheel design. It also features a new rotor system which provides a more stable rotor platform that can support new aero enhancements. A new free-rotating multi-clearance shroud provides significant performance gains - specifically at lower flows that add value through improved engine down speeding and fuel economy.

Always at the forefront of technology, Cummins’ Holset brand continually develops innovative solutions to deliver reliable turbochargers that offer best-in-class performance and exceed customers’ expectations. “CTT’s variable geometry turbo architecture will offer improved performance while maintaining reliability and durability,” said Arun Ramachandran, General Manager – America. "Its advanced design helps achieve improved fuel economy and meet emission regulations without compromising performance, which is critical to ensuring our customers continue to be competitive in the mid-range market.”  

Stay connected with Cummins and learn more about the exciting developments we’re making to the 300 VGT by signing up for our newsletter. Subscribe below! 

Cummins Office Building

Cummins Inc.

Cummins is a global power leader that designs, manufactures, sells and services diesel and alternative fuel engines from 2.8 to 95 liters, diesel and alternative-fueled electrical generator sets from 2.5 to 3,500 kW, as well as related components and technology. Cummins serves its customers through its network of 600 company-owned and independent distributor facilities and more than 7,200 dealer locations in over 190 countries and territories.

Cummins introduces the Advanced Series 150 Holset Wastegate (WG) Turbocharger

Cummins introduces the Advanced Series 150 Holset Wastegate (WG) Turbocharger

For more than 60 years, Cummins has been powering their customers’ success with class leading air handling technologies. That legacy continues with the introduction of the next generation Series 150 Holset Wastegate (WG) turbocharger from Cummins Turbo Technologies (CTT). 

Engineered by Cummins Turbo Technologies and manufactured in Wuxi, China, the advanced Series 150 turbocharger will initially be available to the light-duty truck market in China in the second quarter of 2021.

Featuring the latest wastegate technology, the Series 150 caters to typical truck applications for the on-highway light-duty commercial vehicle market with engines ranging from 2.8L to 3.8L. This turbocharger has a standard pneumatic wastegate mechanism and can be easily integrated with electric wastegates.

The new turbocharger better supports low end torque requirements and offers improved fuel economy benefits at duty cycle zones for typical 4.5-6 Ton gross vehicle weight (GVW) applications.

The Series 150 turbocharger has achieved improved performance versus its predecessor and offers the following technological advancements:

  • Improved next generation turbine wheel design to provide superior performance.
  • Improved low end torque, which can support 350-380Nm at 1000rpm.
  • Higher turbo efficiency up to ~2% points at duty cycle.
  • Non-Map width enhanced compressor stage, which provides higher low flow performance and can meet engine altitude flow criteria.
  • The capability to integrate with an electronic wastegate actuator. 
  • The ability to work with exhaust throttle valve (ETV) architecture.

“In addition to improved turbo efficiency and fuel economy, these advancements also offer improved drivability, better altitude margin and can help in meeting more stringent emission regulations,” said Brett W Fathauer, Executive Director - Research & Engineering at Cummins Turbo Technologies. “We believe the pneumatic wastegate design found in the Series 150 will cater to light-duty commercial vehicle customers in India and China where compact turbochargers are becoming increasingly desirable and useful in powering our customers’ success.”

The Series 150 light-duty turbocharger offered by Cummins is the latest product development that will expand on the Company’s current market-leading position in the design and manufacture of turbochargers for the commercial diesel engine market.

Want to learn more about CTT’s products and technical innovation? Sign up for our quarterly newsletter below.

Cummins Office Building

Cummins Inc.

Cummins is a global power leader that designs, manufactures, sells and services diesel and alternative fuel engines from 2.8 to 95 liters, diesel and alternative-fueled electrical generator sets from 2.5 to 3,500 kW, as well as related components and technology. Cummins serves its customers through its network of 600 company-owned and independent distributor facilities and more than 7,200 dealer locations in over 190 countries and territories.

Cummins introduces new compressor stage to Series 800 Holset Turbocharger

Cummins Holset Turbo HE800

Cummins Turbo Technologies (CTT) offers advanced improvements to the Series 800 Holset Turbocharger with an all-new compressor stage. The Series 800 Holset Turbocharger from CTT offers a world class product for its global customers that focuses on delivering performance and uptime in high-horsepower industrial markets.

Already a key component of CTT’s product catalogue, the Series 800 Turbocharger takes a leap forward and has been revitalized to deliver significant improvements in performance, flow range, temperature capability and seal robustness. The Series 800 turbocharger is designed for engines ranging from15L to 28L, but can be paired with two or four additional turbochargers for engines ranging from 28L up to 100L.

The Series 800 turbocharger has achieved its best-in-class results by introducing technological advancements like:

  • High Pressure Ratio Compressor 
  • Extended flow range 
  • Thin wall stainless steel compressor cover
  • Lead free bearings option
  • High temperature capable turbine housing option 
  • Improved seal and joint robustness

For the very first time we are introducing the High-Pressure Ratio Compressor (HPRC) technology on Series 800 Turbocharger. This product architecture increases flow range capability by up to 25% and is optimized for pressure ratios of up to 6.5:1. These capabilities have allowed our customers to uprate engines by 20-40% without the need to move to a 2-stage architecture. We have also enabled additional altitude capability for many applications. The HPRC offering also improves our product efficiency. These gains enable air handling architectures which have resulted in 5-7% BSFC improvements for existing applications during engine simulation work. 

The new Series 800 Holset Turbocharger is available with a thin walled stainless-steel compressor cover, enabling us to increase capability without adding to our weight or space claim. We also offer lead free bearings, high temperature capable turbine housings and have increased robustness of our joints and seals.

At Cummins, our continued investment in research and development enables us to engineer new solutions for this market. We are currently in development of an integrated electronic wastegate for optimal flow control as well as focusing on turbine stage efficiency improvement.  

“We are excited to be offering new innovative technologies to increase the capability of the HE800 product line without needing additional space claim. We have been able to leverage our technical engineering expertise and advanced simulation analysis to provide critical air-handling features such as higher-pressure ratios and improved efficiencies while offering more product robustness.” commented Brett Fathauer, Executive Director – Engineering and Research. 
The performance results of the upgraded Series 800 Turbocharger have been met with enthusiasm from off-highway customers who describe the Holset product as "class leading.”

The team at CTT has used the latest design practices to ensure this new product is superior to competition and drives value for customers. The upgraded Series 800 Turbocharger is available now and caters to a wide range of off-highway customer applications including power generation, agricultural, mining, oil & gas, rail, construction and marine. 

"At CTT, we continuously work to improve our products for on- and off-highway customers. The new Series 800 turbo is a class-leading product which exceeds performance expectations and provides excellent value for our customers around the globe," commented Matt Franklin, Director - Product Management and Marketing at Cummins Turbo Technologies.

Learn more and stay up to date on our latest advancements by signing up for our quarterly newsletter and email updates
 

Cummins Office Building

Cummins Inc.

Cummins is a global power leader that designs, manufactures, sells and services diesel and alternative fuel engines from 2.8 to 95 liters, diesel and alternative-fueled electrical generator sets from 2.5 to 3,500 kW, as well as related components and technology. Cummins serves its customers through its network of 600 company-owned and independent distributor facilities and more than 7,200 dealer locations in over 190 countries and territories.

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