The Winning Advantage

Yancoal has specified a newly engineered version of the Cummins QSK60.

One of Australia’s largest coal miners, Yancoal has specified a newlyengineered version of the Cummins QSK60 for major environmental and cost reduction benefits at its Moolarben mine in NSW.

The Cummins QSK60 'Advantage' engine has been engineered to deliver both lower total cost of ownership

and significantly reduced emissions the key factors behind Yancoal's decision to specify the engine as part

of the upgrade of its haul truck fleet for extended life.

With the 'Advantage' engine the single-stage QSK60 rated at 2500 hp Cummins has achieved a huge

particulate matter (PM) reduction of 63% through in-cylinder combustion technology with no after treatment.

This reduction is over the existing Tier 1 QSK60 engine. Additionally, a fuel economy benefit of up to 3%

dependent on duty cycle has been calculated as well as longer life-to-overhaul.

Yancoal is the first miner in NSW to put the QSK60 'Advantage' engine into service an engine developed specifically for Australian conditions by Cummins' high horsepower technical centre in the US and the Cummins engineering team in Australia.

At the end of January, the miner had three 'Advantage' engines powering Komatsu 830E haul trucks at its Moolarben mine, and will progressively upgrade the rest of its Komatsu 830E fleet 17 units when the QSK60 engines are ready for change out at 30,000 hours.

The 'Advantage' rebuild package So what precisely is the 'Advantage' engine? In simple terms, it is a rebuild upgrade for the QSK60 from Tier 1 to the latest generation Tier 2 platform with the addition of Tier 4 component technology.

The upgrade features Cummins' Tier 2 modular common rail fuel system (MCRS) as distinct from the HPI unit injection system on the Tier 1 engine. Importantly, the MCRS 'Advantage' solution utilises

the original factory cooling system package.?

Liam Whittaker, maintenance manager at Yancoal's Moolarben mine, has worked closely with Cummins

mining business manager Jason Linke and Komatsu regional service manager Andy Wiggan to develop a

plan to meet ambitious cost saving targets.

In fact, the joint customer-focused approach of Cummins and Komatsu and the major engineering

effort put in by both companies has been critical to meeting Yancoal requirements.

Even before the Cummins 'Advantage' engine came into being, extending life of the original QSK60 HPI

engines in the Komatsu 830E fleet at Moolarben was examined.

Extended engine life "The original life-to-overhaul target was 24,000 hours, but the decision was made to extend life to 30,000 hours a realistic engine life as long as the maintenance history is top notch," says Jason Linke.

Teardown of Moolarben's first 30,000-hour QSK60 HPI engine at Cummins' Master Rebuild Centre in

Brisbane proved this extended life was achievable.

The introduction of the MCRS 'Advantage' engine at Moolarben now sees further extension of targeted

life-to-overhaul, to 36,000 hours and with minimal mid-life change out of components.

While significant total cost of ownership benefits are calculated for the 'Advantage' engine, Liam Whittaker is quick to point out: "We are committed to the highest environmental standards across our operation, and the QSK60 'Advantage' engine is contributing to those standards with its reduced emissions."

The Moolarben mine, which has both open cut and underground operations, is producing 13 million tonnes per annum of ROM coal from its open cut operations. Cummins engines total 45, ranging from the 60-litre V16 QSK60 in the Komatsu haul trucks to the 3.3-litre four cylinder QSB used as pit pumps.

Liam Whittaker describes Cummins' service support as "excellent" support that is headed up by Cummins regional branch manager Phil Wright and mine site representative Ashley Waugh.

"Our own maintenance people take a lot of pride in their work," says Whittaker. He points out availability of the Komatsu 830E fleet is averaging 92% - "a terrific number for trucks that have done 25,000-plus hours".