3. remote cooling applications

1. Remote Cooling
Applications

2. This session…
 Remote Cooling Packages
 Engine Cooling Configurations
 Heat Exchangers & Dearation
 Static and Friction Head
 Room Cooling and Ventilation
2

3. Optional Engine Cooling
Remote Radiator in Engine room
 Extend Pipework and add Radiator in outside wall
 Check Static & Friction Head are within engine pump capability.
 Simple installation.
3

4. Optional Engine Cooling
Remote Radiator Outside Engine Room
 Extend Pipework and install Radiator outside.
 Check Static & Friction Head are within engine pump capability.
 Add Room Ventilation
 Simple installation
4

5. Optional Engine Cooling
Remote Radiator Outside on Roof
 Extend Pipework and install Radiator on roof.
 Add Heat Exchanger by engine to maintain Static & Friction Head
within engine’s capability.
 Add Room Ventilation.
 Add Header/Deaeration Tank.
 Add Pump for Roof pipework.
5

6. Optional Engine Cooling
Use Building Chiller System
 Extend Pipework to nearest Chiller Feed.
 Add Heat Exchanger by engine to prevent mixing.
 Add Room Ventilation.
 Add Header/Deaeration Tank.
6

7. Optional Engine Cooling
Use Cooling Tower or River/Lake Water
 Extend Pipework to the Cooling Tower or the Water Sauce.
 Add Heat Exchanger by engine to prevent mixing.
 Add Room Ventilation.
 Add Header/Deaeration Tank.
 Add Pump for external feed.
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8. Remote Cooling Applications
So how do we make it work?
8

9.  Charge Air Cooling
 One Pump/One Loop (1P/1L)
 One Pump/Two Loop (1P/2L)
 Two Pump/Two Loop (2P/2L)
And do not forget..
 Fuel Cooling
Engine Coolant System Types
9

10. Charge Air Cooled Engines
Jacket Water Circuit & ATA Circuit
o Removes heat from compressed
air before combustion
o Most efficient way of removing this
heat – used widely
o Excellent steady state performance -
Can be found up to the QST30-G4
o Length of piping affects transient
performance, pressure loss over pipe
o Does not allow for
remote cooling
capability 10

11. 11
Two-Pump Two Loop Systems
(Low Temperature Aftercooler)
o Alternative method to remove
heat from compressed air
before combustion
o Aftercooler found on side of
engine, filled with coolant
o Aftercooler chilled by LTA core on
radiator – typically 27 deg C
o Found on larger engines, remote
cooling possible
o Much better transient performance

12. Two-Pump Two Loop Systems
(Low Temperature Aftercooler)
12

13. Isolated Remote Radiator System
Aftercooler
Engine
Air
Air
AftercoolerCoreJacketWaterCore
RadiatorCircuitCore
RemoteRadiator
Aftercooler
Table D Flange
Remote Heat Exchanger
Auxiliary coolant pump
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14. 14
 Heat Exchanger
 Complex System
 Additional Pumps
 Deaeration/Expansion Tanks
 Control & Auxiliary Supply
Layout with Heat Exchanger

15. 15
Heat Exchanger Types
• Shell and tube
• Plate

16. Heat Exchanger Installed on Genset
16

17.  Primary concerns:
– Static head
– Friction head
• Pipe size, # bends
• Other components
• Radiator restriction
 If either exceeded, isolated
cooling system required
 Note other system features
– Isolation, fittings.
– multi-loop systems
Static
Head
Friction
Head
Static Head and Friction Head
17

18. Static Head and Friction Head
 Calculate pump pressure requirements
– Pressure drop across remote radiator
– Pressure drop due to coolant pipes
 Compare engine pump friction head limitations
– If out of spec: weigh cost of increasing pipe size vs adding auxiliary
pump
 Determine remote radiator coolant static head
 Compare to engine static head limitations
– If out of spec: design for isolated system
18

19. Deaeration Tanks
 Allows air in coolant to escape.
 Allows for expansion of coolant.
 Allows additional coolant
volume for system drawdown
 Applies to set mounted and
remotely cooled systems
Engine
19

20. Deaeration Tanks
Tank must always be Installed at highest point in the system.
Top Tank
Remote
Radiator
/Cooler
Coolant Line from remote
Radiator to Coolant pump
Coolant Line from
engine/aftercooler
to remote
Radiator
Vent Line
Pressure Cap/Valve
A
B
C
Thermostat
Housing/Coolant out
Coolant Pump Inlet
Cooling System vent
connection Point(s)
A. Top tank to provide
recommended
drawdown capacity.
B.Expansion space
sized by depth of
neck extension into
tank. Vent hole near
top of tank in side of
neck.
C.Tank Fill line 19 mm
(3/4 in) minimum to
provide positive head
to the pump suction.
Overflow Tube
Vent Hole
Vent Line
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21. Deaeration Pipes & Tanks
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22. Avoid Air Entrapment
 Route fill line/make-up line upstream of water pump
 Avoid air traps in piping/vent lines
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23. Deaeration Tanks
 Should hold minimum of 11% of total coolant volume
for system drawdown
 Thermal expansion volume = at least 6% of total
system volume
 Most 2P2L systems utilize a common tank
(exception being some stationary natural gas units)
– Mixing of LT and HT coolant streams is acceptable because of
minimal volume being transferred to LT through make-up fill line
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24. Auxiliary Fan for Room Ventilation
Cool Air
Flow In
Radiator
Air Inlet
Louvers
Room Ventilation
Fan
Room ventilation fans provide the necessary vacuum to pull air into the room and across the genset.
It is often beneficial to include an auxiliary fan in set mounted radiators as well to cool the room and
genset after the unit has shutdown. The hot surfaces of the machine will continue to reject heat to
the room and in most cases without a shutdown ventilation fan provision, the room temperature will
rise AFTER the unit is off.
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25. Ventilation System Design
Outlet
Inlet
Recommended
(for remote cooling only)
Not Acceptable
OutletInlet
 Airflow is required through genset room for…
 Radiant heat from hot engine parts
 Engine air intake
 Alternator Cooling 25

26. 26
a) Determine heat rejection to ambient room (Qtotal)
• Include engine, alternator, muffler, exhaust piping, auxiliary
items.
b) Maximum allowable temperature rise
• ∆𝑇 𝑚𝑎𝑥 = 𝑀𝑎𝑥. 𝑅𝑜𝑜𝑚𝑇𝑒𝑚𝑝. −𝑀𝑎𝑥. 𝐴𝑚𝑏𝑖𝑒𝑛𝑡𝑇𝑒𝑚𝑝.
c) Calculate cooling airflow required (Qroom)
• 𝑉𝑟𝑜𝑜𝑚 =
𝑄 𝑡𝑜𝑡𝑎𝑙
𝐶 𝑝×∆𝑇 𝑚𝑎𝑥×𝑑
d) Calculate total room airflow requirement (Qroom)
• 𝑉𝑡𝑜𝑡𝑎𝑙 = 𝑉𝑟𝑜𝑜𝑚 + 𝑉𝑐𝑜𝑚𝑏𝑢𝑠𝑡𝑖𝑜𝑛
e) In case of need compensate for density changes due
to altitude
• For every 305 meters increase air flow by 3%
Key
Vroom= minimum forced ventilation
airflow (m3/min)
Qtotal = total heat emitted to room
(MJ/min)
Cp = specific heat
(1.01x10-3 MJ/kg/oC)
∆T = Generator set room
temperature rise (oC)
D = density of air (1.20 kg/m3)
Determining Airflow Requirements

27. Cold Weather Climates
 Motorized Louvers
closed while genset is
off.
 Recirculation dampers
to warm room quickly
 Room heaters
– Anti-condensation
– Space heaters
– Lube/Fuel Oil heaters
– Battery heater
– Control panel heaters
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28. CPG Additional features
 55 degC radiators for specific applications.
 Two speed radiator fans for noise reduction.
 Tin Core radiators suited for saline environments
 Special design fins for sandy or dusty conditions
 Vertical and horizontal (flat-bed) remote radiators
 Remote Heat Exchangers
 Fuel coolers
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29. 29
Any Questions?

30. Cooling System Capability Ratings
 Limiting Ambient Temperature is measured via a combination of test
and simulation of the genset and cooling package.
– Reflects actual operating conditions
 Air on Core Temperature is measured with only the radiator itself.
– Does not reflect operating conditions
– Genset blocks a sizeable portion of the airflow
– Does not account for the temperature rise across the genset.
– Can also be misleading, as a customer may not check where the temperature is
measured and plan for a higher than capable ambient
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