Remote Cooling

Applications
This session

Remote Cooling Packages

Engine Cooling Configurations
Heat Exchangers & Dearation
Static and Friction Head
Room Cooling and Ventilation

2
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
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
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 engines capability.
Add Room Ventilation.
Add Header/Deaeration Tank.
Add Pump for Roof pipework.

5
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
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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Remote Cooling Applications

So how do we make it work?

8
Engine Coolant System Types
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

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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
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 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

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Two-Pump Two Loop Systems
(Low Temperature Aftercooler)

12
Isolated Remote Radiator System

Aftercooler Core
Air

Aftercooler

Radiator Circuit Core

Remote Radiator
Engine

Jacket Water Core

Aftercooler

Air

Table
Table D
D Flange
Flange Auxiliary
Auxiliary coolant
coolant pump
pump

Remote
Remote Heat
Heat Exchanger
Exchanger 13
Layout with Heat Exchanger
Heat Exchanger
Complex System
Additional Pumps
Deaeration/Expansion Tanks
Control & Auxiliary Supply

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Heat Exchanger Types

Shell and tube

Plate

15
Heat Exchanger Installed on Genset

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

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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
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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

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Deaeration Tanks
Tank must always be Installed at highest point in the system.
Pressure Cap/Valve
A. Top tank to provide
Overflow Tube
recommended
Vent Hole
drawdown capacity.
Vent Line
Vent Line B Top Tank B. Expansion space
sized by depth of neck
A extension into tank.
Vent hole near top of
tank in side of neck.

Cooling System vent

connection Point(s)
Coolant Line from C. Tank Fill line 19 mm
engine/aftercooler
to remote
(3/4 in) minimum to
Thermostat Radiator provide positive head
Housing/Coolant out
C Remote to the pump suction.
Radiator
/Cooler

Coolant Line from remote

Coolant Pump Inlet Radiator to Coolant pump

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Deaeration Pipes & Tanks

21
Avoid Air Entrapment
Route fill line/make-up line upstream of water pump
Avoid air traps in piping/vent lines

22
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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Auxiliary Fan for Room Ventilation

Radiator

Air Inlet
Louvers

Cool Air Room Ventilation

Flow In Fan

Room
Room ventilation
ventilation fans
fans provide
provide the
the necessary
necessary vacuum
vacuum toto pull
pull air
air into
into the
the room
room andand across
across the
the genset.
genset.
ItIt is
is often beneficial to include an auxiliary fan in set mounted radiators as well to cool the room and
often beneficial to include an auxiliary fan in set mounted radiators as well to cool the room and
genset
genset afterafter the
the unit
unit has
has shutdown.
shutdown. TheThe hot
hot surfaces
surfaces ofof the
the machine
machine will will continue
continue to
to reject
reject heat
heat toto the
the
room and in most cases without a shutdown ventilation fan provision, the room
room and in most cases without a shutdown ventilation fan provision, the room temperature will rise temperature will rise
AFTER
AFTER the the unit
unit is
is off.
off.
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Ventilation System Design
Inlet Outlet
Recommended

Outlet
(for remote cooling only)

Not Acceptable
Inlet

Airflow is required through genset room for

Radiant heat from hot engine parts
Engine air intake
Alternator Cooling 25
Determining Airflow Requirements
a)
Determine heat rejection to ambient room (Q ) total

Include engine, alternator, muffler, exhaust piping, auxiliary

items. Key

b) Maximum allowable temperature rise Vroom= minimum forced ventilation

airflow (m3/min)
Qtotal = total heat emitted to room
(MJ/min)
c) Calculate cooling airflow required (Qroom)
Cp = specific heat
(1.01x10-3 MJ/kg/oC)
T = Generator set room
d) Calculate total room airflow requirement (Qroom) temperature rise (oC)
D = density of air (1.20 kg/m 3)

e) In case of need compensate for density changes due

to altitude
For every 305 meters increase air flow by 3%

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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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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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Any Questions?

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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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