Information from the Appli 0.2 ion Engineers at Waukesha Engine Division/Waukesha Power Systems “2. Air Elnnaoe/ Vacuum breaker Le From Load 8, Water roses Rogan Fioe Sco a Leer, jaa condensate Tank an Pere Mate Up War EBULLIENT COOLING SYSTEMS ‘An ebullient engine cooling system is designed for use in the production of steam in heating domestic hot water or for low pressure plant load steam requirements. This type of cooling system is accomplished by natural con- vection--without the use of a jacket water pump. Convec- tion, in this application, is defined as the transfer of heat by the circulation or movement of the heated parts of the liquid or gas. ‘The illustration shows a typical ebullient cooling system diagram, showing all the minimum components re- quired for proper operation of this type of system. ‘Note: This isa typical system diagram showing heat recovery ffom the jacket water and exhaust. Ebullient ‘exling can also be accomplished using the jacket water heat only, without exhaust heat recovery equipment, how- ever the steam rate to load ts substantially less with this system type. WAUKESHA POWER SYSTEMS: ‘Water is circulated through the cooling system by means of gravity head into the bottomrof the engine where the coolant absorbs the heat produced by the engine. This ‘begins a process of the formation of tiny steam bubbles within the coolant. This formation of bubbles in the coolant lowers the density ofthe fluld causing the coolant to rise toward the top of the engine to the engine ‘water outlet lange. The water temperature in this type of system is to be controlled at 250" F, maximum (15 PSIG) measured at the engine water outlet lange. The temperature difference between the inlet and outlet of the engine is normally 2-3" F. Coolant from the engine is then piped through an ex- ‘haust gas heat recovery unit where tt absorbs the latent ‘heat from the exhaust which is necessary to bring about the change of state of the coolant allowing tt to flash to steam within a steam separator ar heat recovery unit. “The steam is then used for same process, condensed back to its liquid form, returned to the condensate tank, pumped back into the heat recovery unit and then by ‘convection into the engine for the recirculation process tobegin again, FEBURARY 15, 1989MINIMUM SYSTEM COMPONENT REQUIREMENTS 1. Heat Recovery Unit: This device is designed to pro- ‘vide for recovery of the heat from the Jacket water and the exhaust. This recovered heat is converted nto low pressure steam at approximately 13-15 PSIG within the hheat recovery unt. 12. Safety Relief Valve: A pop-type safety valve sized to relieve the full steam capacity of the system and set at a pressure slightly above, but very close to, the system pressure (approximately 1 PSIG above the excess steam valve setting) 3. Back Pressure Steam Valve: An engine protective and pressure/t ‘control device which is an ad- Jjustable modulating type valve used to set and maintain ‘the outlet temperature and pressure at the engine water outlet flange. It must be mounted directly after the heat recovery unit outlet (as close as possible) in the steam load supply pipe. There may be no steam load ‘withdrawal before this vale. Ifthe system pressure should fall toa level which is lower than the back pres- sure valve setting, then the valve will gradually begin to close to protect the engine fram a sudden decrease in pressure which could result in an immediate flashing of the water to steam within the engine water Jackets. The valve is to be designed as a failed closed device; that is, if the valve malfunctions it will go to a closed position to prevent damage to the engine. ‘Note: If muiiple unts are to be gperated in parallal i. ‘system d common header should be used among allof the heat recovery uni cutlets using only one backpressure value atthe end of the steam header ‘4, Excess Steam Valve: A control device, an adjustable valve to waste dump/relieve any excess steam pressure should there not be sufficient steam load. This valve must be set at a pressure 1-2 PSIG higher than the back pressure valve. It is located in the system before the ‘steam condensing unit and will direct excess steam ‘which is not required by the system process to the steam. ‘condensing unit. ‘5. Excess Steam Condenser (waste heat dump): The ‘excess steam condenser converts any excess steam to wwater for recirculation in the system. It should have the capability to condense the entire quantity of steam ‘produced by the heat recovery untt. 6. Condensate Tank and Pump: The condensate tank sfores the returned condensate fram the process load and/or from the excess steam condenser. The conden- ‘sate pump is necessary to rectrculate the condensate ‘back into the engine jacket heat recovery loop. 7. Make-up Water Treatment Device: All systems ‘must be equipped with water treatment equipment. The consequences of using untreated water can be ‘Write for Waukesha Technical Data No. S- 7610 for water treatment recommendations of engine cooling systems. ‘WAUKESHA POWER SYSTEMS 8. Water Pressure Regulator / Flow Control Valve: ‘Water make-up systems require regulation of the pres- sure and flow to the condensate tank depending on. ‘steam system pressure requirements and water make up pressure and flow rates. 9. Blowdown Connections: Every low point in the sys- tem should have blowdawn valves for the removal of sdlids or soft sludge that accumulate due to water treat- ‘Surface blowdowns are also necessary analysis and treatment (Reference S-7610, Water Treat- tment Recommendations). 10, Engine Shutdown Device: An ebullient-cooled en- gine must be equipped with shutdown devices which Operate automatically when system temperature or pres- sure gets to a critical point which could be harmful to the engine and system ‘This device must ‘be set fo shut down the engine at a temperature/pres- sures lightly above the jacket water outlet limits. ‘Waukesha suggests using a rate of change device~a linear rate limiter-~set to sense the gradual changes in system operating pressure for engine shutdown limits. Consult Waukesha Application Engineering for recam- ‘mendations. 11. Water Level Alarm and Shutdown Devices: Low ‘water level or high water level cause damage to the sys- tem. A low water level alarm device should be supplied ‘to war against an impending condition of low water due to. lack of feedwater flow to the heat recovery unit A high water level alarm warns against a high level due to system overfill when make-up water is not required. 12. Air Eliminator / Vacuum Breaker: This device is ‘designed for discharging air from the jacket water sys- ‘tem and preventing any vacuum from occurring in the system. It should be thermostatically operated and pro- vide for reliable air elimination. ‘John Peffer, Waukesha Power Systems ‘John Peffer, BSME, ts an application engineer at ‘Waukesha Power Systems with over 10 years experience. “His specialty is cogeneration system design. WAUKESHA POWER SYSTEMS DRESSER INDUSTRIES, INC. WAUKESHA, WISCONSIN 53188 FEBURARY 15, 1989