Cooling Systems

Global Application Engineer Certification

Training

April 28/29, 2021

Internal Use Only
Meet Your Speakers:
Cummins Presenter Guest Speaker Cummins Panelist

Nibal Kiwan Ahmad Adam Shen Yoon

Sales Application Engineer Customer Order Management Senior Sales Application
Global Technical Advisor Director / PSBU SCLT Member Engineer
AME Based in UAE / Global Responsibility North America
Cummins Inc. PSBU Cummins Inc.

For general product or application information,

contact Sales Application Engineering (SAE)

Africa-Middle East: sae.ame@cummins.com

Asia Pacific: sae.apac@cummins.com India: sae.india@cummins.com
China: sae.china@cummins.com North America: sae.na@cummins.com
Europe: sae.europe@cummins.com South America: saesouthamerica@cummins.com
Europe GDriveAE@Cummins.com
Internal Use Only 2
Contents

1. Cooling configurations
2. Radiator Performance & LAT
3. Engine Driven cooling systems
4. Remote Cooling Applications
5. Deaeration

3
3
Ice Breaker - 1

What is the objective of a cooling system in a generator set?

a) Safely carry emitted heat outside of the building or enclosure

b) Keep the engine as cold as possible since this will maintain the engine inner
components
c) Run the engine as hot as possible since this burns the fuel more efficiently
d) Maintain the engine temperature within certain limits Min/Max

Internal Use Only 4

Cooling Configurations

 Two types of installations...

1. Open genset for installation inside a room
2. Containerized genset for outdoor installations

 Two types of cooling packages…

1. Set-mounted radiator
2. Remote cooling system

5
5
Cooling Configurations

Several factors go into deciding the cooling package…

 Accessibility to the installation
• Road access, offloading & cranage
• Installed in room or packaged in a container
• Radiator on roof – Interconnecting pipe & head of water?
 Noise from cooling package
• Neighbourhood & Local Authority requirements
• Placement of cooling system
 Ambient conditions
• Temperature, Altitude, Wind, Saline or Dust
 Environment (Tropical, Arctic, coastal, Desert)

6
6
Basic Principles

35% Energy Output

Fuel Energy Engine Alternator Electrical Energy

100 % Energy Input

How do we deal with

25% Energy Output this heat?
Heat removed by radiator

7
 Cooling Capability Ratings

o Cummins rates systems

based on Limiting Ambient
Temperature LAT

o Provides ‘system level’ data

Air on core temp to customer instead of
60deg C ‘component level’
LAT
50deg C o Less complicated for facility
designers

o Generator design effects

radiators capability

o Room/Container restriction
effects LAT

o Coolant density affects LAT

8
LAT Cooling Capability
Calculate the LAT for the LTC and HTC as follows…
1. Using blocked open ‘stats, monitor the HTC engine outlet coolant temperature and the
LTC engine inlet coolant temperature at various load levels
2. Equation for LAT LTC
•

 =

   
     @
     ℎ −
  
      +      
3. Equation for LAT HTC = (maximum allowable HTC engine outlet temp @ LAT from
engine datasheet – stabilized HTC outlet temperature from test) + recorded ambient
temperature from test
•
 ! =

    !     @
     ℎ −
   !      +      
4. Record the two stabilized values at each load level to obtain a cooling load profile

9
9
Genset Standard Cooling Systems

10
Genset Standard Cooling Systems

11
Genset Standard Cooling Systems

12
Engine Driven Systems

13
Non-aftercooled units (turbo charged only):
• 1 liquid to air core [Jacket Water]
• NT855 (watchout for cooling system type) or X3.3
• Turbo charged

Air To Air:
• 1 liquid to air core [Jacket Water]
• 1 air to air core - Compressed intake air to external air flowing
across radiator
• 6CTAA8.3, KTAA19- Turbo charged Air to Air or QSK23

Low Temperature Aftercooler:

• 2 liquid to air cores [Jacket Water & LTA Coolant]
• KTA50, QSK60
• Turbo charged Aftercooled
14
Jacket Water Cooling

15
Air to Air Cooled Engines
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 Does not allow for remote cooling

capability

o Length of piping affects transient

performance, pressure loss over pipe

16
Air to Air Cooled Engines
ATA Set Mounted Radiator
Expansion/ Make-up/
Deaeration Tank

Charge Air Out

Jacket Water In

Jacket Water Out

Charge Air In

17
Low Temperature Aftercooled Engines

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 27-50 deg C

o Found on larger engines, remote

cooling possible

o Much better transient performance

18
 Low Temperature Aftercooled Engines
Coolant flow to low
Jacket Water Circuit & LTA Circuit temperature aftercooler
radiator

Low temperature
aftercooler pump.

19
 1P2L Vs. 2P2L Considerations
QSK60 Intake Flow

1 Pump/2 Loop LTA System – These engines have combined

engine cooling circuit plus two separate radiator circuits

2 Pump/2 Loop LTA System – These have two separate

engine and radiator circuits.

20
 1P2L Air to Water LTA
HT & LTA System use same pump
(Illustrating Hot Engine valve positions)
Thermostat Housing
Engine/Aftercooler

Jacket Water
Aftercooler

Aftercooler
Air Flow
Rear

Fan
Target Intake Manifold
of Temperature
Engine

Vent Line
Aftercooler

P
Bypass
Jacket Water
Engine/Aftercooler
Aftercooler Cool Pump
Aftercooler Hot

21
 2P2L Air to Water LTA
HT & LTA System Separated (2 pumps)
(Illustrating Hot Engine valve positions)

Aftercooler Bypass
Pump

Jacket Water
Aftercooler

Aftercooler
Air Flow
Rear

Fan
of Target Intake Manifold
Engine Temperature

Vent Line
Aftercooler

Main
Coolant Engine
Pump
Outlet
Jacket Water Temperature
Sensor
Aftercooler Cool
Aftercooler Hot

22
Ice Breaker - 2

Which of one the below statements is correct:

a) Charge Air Cooler pipes are relatively smaller than Low
Temperature Aftercooler coolant pipes
b) Air Cooled Gensets are cheaper because they have single core
radiator only
c) Aftercooler radiator core is installed in front of Jacket Water core

Internal Use Only 23

Remote Cooling Systems

24
Remote Cooling Applications
Outside Engine Room

 Extend Pipework and install

Radiator outside.
 Check Static & Friction Head
are within engine pump
capability.
 Add Room Ventilation
 Simple installation

25
Remote Cooling Applications
On the 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.

26
Remote Cooling Applications
On the Building Chiller

 Extend Pipework to nearest Chiller Feed.

 Add Heat Exchanger by engine to prevent mixing.
 Add Room Ventilation.
 Add Header/Deaeration Tank.

27
 Static Head & Friction Head
Primary concerns
 Static head = " ×  × ℎ
 Friction head
 Pipe size, # bends
Friction
 Other components
 Radiator restriction
Head
Static
 If either exceeded, then an
isolated cooling system would be Head,
required. possibly
 This example illustrates a High.
relatively low Friction Head

28
 Low Static Head & High Friction Head

High Friction
Head

Low
This example illustrates a relatively low Friction Head Static
Head 29
 Remote Cooling Considerations

 Engine pump capability (static & friction head)

 Type, size & location of heat exchanger (if required).
 Location, size and weight of interconnecting pipe.
 Noise from remote cooling package.
 Deaeration of engine, pipework & radiator.

30
Exercise # 2
 Calculate the pressure friction and static head of the following
installation (C2000 D5)
 Assume 90º standard elbows Pd=40kPa
1
 Material used » Commercial Steel
Radiator

2 Pd=10kPa
HT
4.5m Ø=127mm
5m
Ø=76.2mm
2 LT
9

Engine

15m
31
Exercise # 2

Height difference between engine centerline to radiator = 4.5 m

Static Head = " ×  × ℎ = 1029 × 9.81 × 4.5 = 45.425 kPa

32
Exercise # 2
Jacket Water Diameter 67 = 0.127 m Total Length of the Pipes = 34 m
After Cooler Diameter 67 = 0.076 m Number of 90º bends =5
89
Jacket Water Flow Rate = 25.2 L/s = 0.0252
:
89
After Cooler Flow Rate = 6.9 L/s = 0.0069
:

Equivalent length of 90º bends for JW = 4 m per bend

Equivalent length of 90º bends for AC = 2.3 m per bend

Overall length of JW pipe = 34 + (4 × 5) = 54 m

Overall length of AC pipe = 34 + (2.3 × 5) = 45.5 m

33
34
34
Exercise # 2
> × ? × @A CDEF ×D.DEGE ×D.CEH
;<= = B
= D.DDC
= 260,101

> × ? × @A CDEF ×D.DDLF ×D.CEH

;K= = = = 118,697
B D.DDC

Above > 4000 so, fully turbulent

Z<= = 2 m/s ZK= = 1.51 m/s

<= = 0.016, K= = 0.017

> × ?_ × ` × K CDEF × E_ ×D.DCL ×Ga

∆^<= = = = 14 kPa
E × @A E × D.CEH

> × ?_ × ` × K CDEF × C.GC_ ×D.DCH ×aG.G

∆^K= = E × @A
= E × D.DHLE
= 11.9 kPa

35
Exercise # 2
 ^     

= ^     + ^      

Total ∆^<= = 14 + 40 = 54 kPa > 48 kPa

Total ∆^K= = 11.9 + 10 = 21.9 kPa < 35 kPa

36
Heat Exchanger

Aftercooler Core
Air

Aftercooler

Radiator Circuit Core

Remote Radiator
Engine

Jacket Water Core

Aftercooler

Air

Table D Flange Auxiliary coolant pump

Remote Heat Exchanger

37
Heat Exchanger Types

Shell and U tube

• Plate
Shell and Fixed tube 38
Application – QSK78

39
 Deaeration Systems
 Allows air that is entrained in the coolant to escape
 For both set mounted & remote cooling systems
 Effects of air in coolant:
 Accelerated erosion of water passages
 Weakens structural integrity and shortens usable life of system
 Reduces the amount of heat that can be carried by the coolant
 Reduces efficiency and capability
 Higher expansion rate than pure coolant
 Can cause loss of coolant
 Rarely, can impact the coolant pump’s priming setup
 Can cause engine damage 40
Ice Breaker - 3

What are the main sources of Air in Coolant system

a) Incorrect system venting
b) Defective/worn seals or gaskets
c) Improper or careless filling of the cooling system
d) All of the Above

Internal Use Only 41

 Deaeration Tanks
 Commonly included within the top of the radiator
 Must always be at the highest point in the system
 Systems should include:
 Pressure Cap – To prevent air from pressurizing above tank limits
 Fill Cap/Port – System may be topped-up from this highest point
(note the engine must always be bottom filled)
 Sight glass – Coolant levels are determined here
 Low level alarm – Linked to engine shutdown
 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
42
Examples of Deaeration Tanks

43
Examples of bad Installation

44
 Deaeration Tanks & Drawdown Capacity
 The cooling system must be designed so when a cold system is completely
filled, there is at least 6% additional capacity to allow for coolant thermal
expansion.
 Drawdown Capacity is the amount of coolant lost from the system before
air is drawn into the engine coolant pump.
 Overall capacity on remote rads should be ~17% (min 15%) of the total
cooling system capacity
 On std set mounted radiators, drawdown capacity is usually ~10% to 11%
 System Drawdown Capacity must be greater than or equal to 11% of the total full cooling
system volume.
 Drawdown Capacity is in addition to the deaeration tank expansion space.

45
 Cooling System Venting
 Provides continuous removal of air during genset operation.
 High points in the engine cooling jacket must be vented to the
deaeration tank.
 Vent connections to the tank should be made above the maximum
coolant level.
 If venting to the deaeration tank is not possible, atmospheric vents may
be an alternative.
• Atmospheric vents will lose coolant during genset operation
• Drawdown capacity should be increased from 11% to 14% in this type of application to
account for coolant loss

46 46
47
48
 Summary
 Make sure the LAT is specified for the System Level.

 Remote radiators – needs to meet all the systems requirements (static and friction
heads, auxiliary ventilation, etc.).

 Only Clean Filtered water should be used (never river water).

 Coolant must be checked once a year or 3000 hours to monitor

sulfate <1500 ppm, chloride <200 ppm.

 Recommended coolant mix is 50/50 Antifreeze/Water (ethylene or propylene

glycol), Remote Cooling System should be filled from the lowest point, thereby
reducing the risk of air entrapment.

49
Summary - Key Considerations

Typical parameters that AE should consider:

Dimension Fuel Consumption Customer Service

General
Ambient Temperature Performance Power Output

50
 Additional Resources
Cummins White Papers
 Ambient temperature vs. air on core (AOC) temperature - White
Paper (PT-9007)
T030: Liquid-Cooled Generator Set Application Manual
 Chapter 6: Mechanical Design > 6.3, 6.4 Engine Cooling
PowerSuite – GenCalc Options
 Remote Radiator Ventilation
 Remote Cooling

51
52
52
APPENDIX

53
Standard 2P 2L Radiator System

Air

LTA Core
Aftercooler

Jacket Water Core

LTA Core
Engine

Jacket Water Core

Aftercooler

Air

Usual Core Arrangement

for smaller engines.

Usual HHP Core

arrangement. LTA core
must be first in airflow.
54
1P2L Vs. 2P2L Considerations

Caution
Consider the following…
 In a 2P2L system, the HT
water carries most heat.
 In 1P2L system the LTA water
carries the most heat to
radiator.
 Therefore, on a 1P2L engine,
its critical the water flow is
correct and balanced. There is
very little room for error.

55
Measuring Cooling System Restriction and Coolant
Flow Rate

Define minimum flow rate

 Check pressure drop across engine P1 – P2 meets stated value.
 Subtract from total Water Pump pressure rise across P1 – P5.
 External circuit resistance measured across P2>P3, P3>P4 & P4>P5.

56
56
Cooling System
Cummins always recommends EG
Premix

57
Exercise # 3
 If you had to source a heat exchanger, what information you
should provide to the supplier?
 We are using river water at 15C for the heat exchange.
Calculate the amount of raw water required at maximum river
water temperature of 20C.
 Model: C2000 D5

f Q − Heat Rejection kW For fresh water @ 15℃

V= Cr − Specific Heat Capacity ij
g = 4.187
g × ∆ × " ∆T − Temperature difference (℃) ℃ · i
s9 i
V − Flow Rate ( )
t " = 1000 l


58
Exercise # 3
Heat rejected to Jacket Water = 460 kW
Heat rejected to Aftercooler = 405 kW

For Jacket Water

f 460 l

V= = = 0.02197 = 21.97
g × ∆ × " 4.187 × 5 × 1000  

For Aftercooler

f 405 l

V= = = 0.01934 = 19.34
g × ∆ × " 4.187 × 5 × 1000  
59
Exercise #4
D2

 Size the deaeration tank D2

Radiator
for the new system with heat 1 300L
exchanger.
4
Ø=127mm 5
D1

9
Engine

15

60
Exercise # 4
Total Circuit Length ( )= 34 m
Pipe Diameter () = 0.127 m

Total Pipe Volume

u × E ×
V= = 0.43 l
4

Total System Volume = Total Pipe Volume + Radiator Volume = 0.43 + 0.3 = 0.73 l

De−Aeration Tank Volume = 0.17 × Total System Volume = 0.73 × 0.17 = 0.124 l

61