GE Power & Water

Gas Engines Cooling Systems

Cooling System Guidelines for Waukesha* Gas Engines

1. The radiator or heat exchanger must be sized to maintain normal jacket water temperature out of the engine under
all site conditions. Normal jacket water outlet temperature is:
180°F (82°C) for non–heat recovery applications
220°F (105°C) for alternate fuel applications
210 – 235°F (99 – 113°C) for heat recovery applications
Consult the Engine Specification Sheet in the Technical Data Manual for operating temperatures of specific engine
models.
The engine power rating of intercooled engines is based on the maximum water inlet temperature to the
intercooler (auxiliary) water pump. Consult the Power Rating Chart or Technical Data Manual for power ratings at
various intercooler inlet water temperatures.
The radiator or heat exchanger must be sized for the site conditions. Remember that special consideration must be
given to altitude, high or low ambient temperature, and extremely dirty applications. Consult the Technical Data
Manual — Heat Balance subsection of the specific model for engine, intercooler, and oil cooler heat rejection.
2. The suggested minimum jacket water circuit return delta temperature into a warm engine is 30°F (16.6°C) less than
the designed jacket water outlet temperature with a maximum rate-of-change return temperature of 18°F (10°C)
per minute while between the minimum and maximum operating temperatures. See Waukesha Installation
Chapters form 1091, latest revision, for more information.
3. If a unit mounted radiator with a pusher fan is used, reduce the allowable ambient or increase the design
temperature by approximately 10°F (5.5°C). This is necessary because of the increase in air temperature as it flows
across the engine. If the driven equipment, such as a generator, radiates significant heat, then a further
temperature allowance must be made.
4. Coolant flow and allowable system resistance are based on the pump flow curves for the specific configuration to
which the engine is built. Consult the Technical Data Manual — Cooling Systems subsection for the specific model.
5. Heat rejection data are average values at standard conditions and will vary for individual engines and with site
operating and ambient conditions and with timing or air/fuel ratio change. An adequate reserve for this variation
and normal design fouling factors should be used when sizing the cooling system. Waukesha suggests a 15%
reserve.
6. Use antifreeze protection for applications where the engine or cooling system can be exposed to ambient
temperatures below 32°F (0°C) or boiling conditions are expected at the outlet. An adequate mixture of ethylene
glycol and water, or propylene glycol and water is recommended.
7. If antifreeze or significant levels of other water treatments are used, the cooling system heat rejection capacity
must be increased. Antifreeze solutions reduce the heat transfer capability of the cooling system by approximately
3% for each 10% by volume addition of antifreeze. As an example, if a 50/50 solution of ethylene glycol and water
is used instead of 100% water, the heat transfer capability of the radiator must be increased by about 15%. For this
example, if the capability of the radiator system is not increased there will be an approximate 10°F (5.5°C) decrease
in the allowable ambient temperature.
8. For information on water treatment for engine cooling systems refer to S7610-3 or its replacement.
9. Initial add and make-up water must be treated before use in a solid water system.

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Ref.
Cooling System Guidelines for Waukesha EN: 154438
S
Gas Engines DATE: 3/12
6699-7
GE Power & Water
Gas Engines Cooling Systems
10. The cooling system must be designed to properly pressurize the system and remove entrained air from the coolant.
This can be accomplished by proper use of vent lines, a static line, and an expansion tank. The diagram below
illustrates this:
Vent lines should be 1/4" (6.5 mm) diameter
EXPANSION TANK on systems with vent lines less than 10 ft. (3
VENT LINE m) long, or 1/2" (13 mm) diameter with a
1/4" (6.5 mm) orifice on systems with vent
lines more than 10 ft. (3 m) long. These vent
TRAPPED AIR lines are piped from high points in the
STATIC LINE cooling system to the expansion tank
below the coolant level but away from the
static line connection. The expansion tank
must be the highest component in the
cooling system. Trapped air can then flow
ENGINE to the expansion tank. This system also
COMPONENT
bleeds air out of the system during filling. It
must bleed air with the thermostat fully
opened or fully bypassing.
COOLING COMPONENT COM18

The static line is sized much larger than the vent lines to minimize flow velocity and pressure drop. The static line is
typically 1" (25 mm) diameter or larger for greater than 400 GPM (1500 l/min) systems, and 3/4" (19 mm) diameter or
larger for less than 400 GPM (1500 l/min) systems. This static line provides a static head pressure to the inlet of the
water pump equal to the height of the expansion tank plus the pressure of the expansion tank. Do not assume that
a pressure cap will pressurize the tank to the cap’s rating.
A pressure cap is required to prevent coolant evaporation losses and to prevent boiling in the system.
JACKET WATER TEMPERATURE RECOMMENDED SYSTEM PRESSURE CAP SETTING

Up to 210°F (99°C) 7 psig (48 kPa)

210 - 235°F (99 - 113°C) 8 psig (55 kPa)

The pressure cap must have a vacuum relief function to prevent a vacuum from forming in the tank during load
reduction or cool–down operation. Only a single pressure cap can be used in a cooling system and must be at the
highest point on the expansion tank.
11. The expansion tank must be sized for 6% expansion of the coolant. An additional 5% is recommended for coolant
makeup. With these volumes, an expansion tank should be sized to contain 11% of the total cooling system volume.
Separate expansion tanks must be used for separate auxiliary and jacket cooling circuits. A sight glass is
recommended for monitoring expansion tank level.
12. The expansion tank height and pressure must be sufficient to provide pressure at the water pump inlet to meet the
requirements on S9068 (or its replacement) for ATGL* engines and S7424-1 (or its replacement) for all other
Waukesha engines. Do not assume that a pressure cap will pressurize the tank to the cap’s rating.

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Ref.
Cooling System Guidelines for Waukesha EN: 154438
S
Gas Engines DATE: 3/12
6699-7
GE Power & Water
Gas Engines Cooling Systems
13. As an alternative, pressurized expansion tanks can be used for systems that require high pressure levels. These are
closed systems that do not allow air to enter the cooling system when the engine is cold and the coolant is at the
lowest volume. A pressurized expansion tank has a bladder and uses compressed air or nitrogen to maintain the
required pressure. This means that the pressure in the cooling system is not in the bladder. Air and other gases are
removed by a degassing tank with an automatic degasser. A pressurized expansion tank requires a relief valve to
prevent excessive pressures in case the system is overfilled with coolant.

220GL Bladder Style Pressurization System Schematic With Degassing Tank.

Refer to S-7424-1, latest revision, for more information regarding minimum water pump pressure requirements. To
safety and continuously meet this requirement, a bladder style pressurization system with degassing tank and relief
valve is strongly recommended. Waukesha Engine offers such a system, which includes an air compressor for the
pressure in the bladder, optionally for 220GL. The pressurization tank is to be connected near the inlet of the engine
circuits. The degassing tank is to be connected, as mentioned above for the expansion tank and pressure cap
system, to the highest points of the engine and its cooling system.
14. Bypass water filtration can remove debris from the cooling systems on any engine. Bypass water filtration sized to
remove 15 – 25 micron particles from 2% of the water flow is recommended for Waukesha engines. Consult a
water treatment company such as Perry Water Filter or equal for available filters.
Care must also be taken when welding external cooling system pipes together or when drilling and tapping a hole
anywhere in the water system. Ensure that the weld slag and chips are totally cleaned from the cooling system
before the engine is operated. Debris in the cooling system will cause erosion of water passages and water pump
seals.
15. Jacket water and auxiliary water pump static inlet pressure must not exceed pressures published in the
specifications section of the Technical Data Manual for the specific engine model.
16. For information on ebullient cooled systems refer to the Waukesha Cogeneration Handbook, Form 7030 (or its
replacement), and system manufacturers.
17. Consider thermosiphoning prevention in cooling system design. Thermal shock from thermosiphoning is often a
problem in engines subjected to frequent shutdowns (several times a week or daily) and engines with coolers
mounted above them. A shutoff valve in the return leg from the cooler will prevent thermosiphoning.
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Ref.
Cooling System Guidelines for Waukesha EN: 154438
S
Gas Engines DATE: 3/12
6699-7
GE Power & Water
Gas Engines Cooling Systems
18. Because of the unique twin-circuit water pump on the 220GL product line, it is necessary to install a balance line
between the LT (auxiliary) and HT (jacket) water circuits to avoid a pressure differential between the inlets of both
sides of the pump. The LT and HT inlet pressures should balance to within less than 0.3 bar (4.4 psi). This balance
line should be installed preferably within 2 meters (6.6') of the inlet locations to the engine and be a minimum DN25
(1") pipe. Failure to apply these guidelines could result in premature water pump failure and/or poor engine cooling
system performance.
NOTE: This requirement for a balance line between the LT and HT circuits only applies to 220GL engines delivered
with the gear-driven water pump. For engines shipped after January 2011 with the Auxiliary Module option code,
this balance line is included. If separate electric pumps are used for each circuit, a pressure balance between the
circuits is not necessary.

*Trademark of General Electric Company. All other trademarks are the property of their respective owners.

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Ref.
Cooling System Guidelines for Waukesha EN: 154438
S
Gas Engines DATE: 3/12
6699-7