GE Power & Water

Distributed Power Cooling Systems

Application of VGF* Engines at Elevated Jacket Water Temperatures

Jacket water outlet temperatures between 210°F and 235°F (99°C and 113°C) are considered to be “elevated” jacket water
temperatures for the VGF family of engines. The maximum allowable jacket water outlet temperature for VGF engines is
235°F (113°C). Engine cooling is accomplished by a closed-loop system equipped with one or more water pumps, where
solid water (non-ebullient) coolant is circulated through the engine under specific pressures.
Below are the guidelines and requirements for operating a VGF engine at elevated jacket water temperatures. It is important
for a customer to become completely familiar with each of the documents listed below prior to packaging a VGF engine
using elevated jacket water temperature.
1. CUSTOMER SUPPLIED COMPONENTS
The customer must supply several components for the elevated jacket water temperature engines. This allows the customer
to select components which meet the exact requirements of their specific cooling system. The customer supplied
components required for an elevated jacket water engine are as follows:
a) Electric motor driven jacket water pump(s),
b) Electric motor driven auxiliary water pump(s),
c) Jacket water temperature control device (e.g., thermostats),
d) Auxiliary water temperature control device (e.g., thermostats).
It should also be noted that the oil cooler is shipped loose on the F18 and H24 elevated jacket water engine models.
Reference installation drawing L8070-53 (or latest version) for further details.
2. ENGINE LUBRICATION OIL REQUIREMENTS
Elevated jacket water temperatures place an added thermal stress on an engine’s lube oil. Proper lube oil selection and oil
change intervals are necessary for these applications. The following document contains the appropriate engine lubrication
oil requirements when operating at elevated jacket water temperatures:
Waukesha Lube Oil Recommendations, S1015-28 (or latest revision); found in the General Tech Data Book under the “Fuels &
Lubrication” tab.
3. COOLING WATER TREATMENT REQUIREMENTS
Cooling water quality is one of the most overlooked factors in an engine installation. Poor water quality can cause scaling,
corrosion, and sediment buildup within the entire cooling system. This leads to heat transfer problems which typically result
in failed parts. The following document contains information necessary for maintaining proper cooling water quality when
operating at elevated jacket water temperatures:
Water Treatment for Engine Cooling Systems, S7610-2 (or latest revision); found in General Tech Data Book under the
“Cooling Systems” tab.
4. COOLING SYSTEM REQUIREMENTS
Specific cooling system design requirements must be met when operating at elevated jacket water temperatures. Failure to
meet these requirements can result in cavitation, coolant flashing to steam, engine overheating, and failed parts. The
documents and requirements listed below should be fully understood prior to designing the cooling system of an elevated
jacket water engine.
a) Alarm & Shutdown Devices and Setpoints: To protect an engine from overheating, the customer is required to
install an alarm and shutdown device to monitor the following criteria: 1) jacket water outlet temperature, 2) low
water level, and 3) loss of water circulation. A coolant pressure rate-of-change device is recommended to protect
an engine from sudden loss of coolant. The following documents address alarm and shutdown criteria as well as
the coolant pressure rate-of-change shutdown device:
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Ref.
Application of VGF Engines EN: 156543
S
at Elevated Jacket Water Temperatures DATE: 10/13
7790-1
GE Power & Water
Distributed Power Cooling Systems
1) Alarm & Shutdown Setpoints, S8382 (or latest revision); found in General Tech Data Book under the “Control
Systems” tab,
2) Coolant Rate of Change Shutdown Control, PSA-1211M; reference Waukesha Power Systems Price Book,
Engomatic Control System Model 1105.
b) Coolant Flow and Circuit Restrictions: Table 1 and Table 2 below depict the minimum and maximum flows and
restrictions for VGF jacket water circuits and auxiliary water circuits. Note: The restriction data below reflects jacket
water and auxiliary water circuits without thermostats, as these devices are supplied by the customer.

TABLE 1. VGF Jacket Water Flows and Restrictions (without thermostats).

JACKET WATER
CIRCUIT RESTRICTION JACKET WATER
MINIMUM JW COOLANT (PSI) AT MINIMUM MAXIMUM JW COOLANT CIRCUIT RESTRICTION
ENGINE FLOW (GPM) JW COOLANT FLOW FLOW (GPM) (PSI) AT MAXIMUM
MODEL 1500 / 1800 RPM 1500 / 1800 RPM ALL RPM’S JW COOLANT FLOW
F18 104 / 130 1.6 / 2.5 225 7.5
H24 104 / 130 1.6 / 2.5 225 7.5
L36 184 / 218 2.3 / 3.2 475 15.1
P48 231 / 280 3.6 / 5.3 475 15.1

TABLE 2. VGF Auxiliary Water Flows and Restrictions (intercooler in series with oil cooler; without thermostats);
applies to intercooler water inlet temperatures 130°F (54°C) or less.
AUXILIARY WATER
CIRCUIT RESTRICTION AUXILIARY WATER
MINIMUM AUX COOLANT (PSI) AT MINIMUM MAXIMUM AUX COOLANT CIRCUIT RESTRICTION
ENGINE FLOW (GPM) AUX FLOW FLOW (GPM) (PSI) AT MAXIMUM AUX COOLANT
MODEL 1500 / 1800 RPM 1500 / 1800 RPM ALL RPM’S FLOW
F18 25 / 35 1.2 / 2.4 70 9.6
H24 25 / 35 1.2 / 2.4 70 9.6
L36 52 / 62 4.6 / 6.5 105 18.6
P48 71 / 87 8.5 / 12.8 105 18.6

NOTES:
1. liters per minute = gpm x 3.785
2. kPa = psi x 6.894

c) Cooling System Pressures: To maintain proper cooling system performance, the following cooling system static
pressures must be maintained:
1) Pressure at engine jacket water inlet connection flange:
a) Minimum: 45 psia (310 kPa).
b) Maximum: 75 psia (517 kPa).
2) Pressure at intercooler water inlet connection flange:
a) Maximum: 90 psia (621 kPa).
These minimum and maximum pressures are achieved through proper sizing of external restrictions (heat exchangers,
piping, thermostats, etc.) combined with proper expansion tank design. For information on expansion tank design, including
pressure cap rating selection, reference the latest revisions of Cooling Systems, Chapter 4 of the Waukesha Installation
Manual (Form 1091), and Cooling System Guidelines for Waukesha Engines, S6699-7 (or latest version).

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Ref.
Application of VGF Engines EN: 156543
S
at Elevated Jacket Water Temperatures DATE: 10/13
7790-1
GE Power & Water
Distributed Power Cooling Systems
Note: In addition to meeting the above system pressure requirements, the expansion tanks are also required to meet the
net positive suction head (NPSH) requirements of the customer-supplied water pumps. The customer is advised to consult
with their pump manufacturer regarding net positive suction head requirements.

d) Cooling System Design and Layout: Elevated jacket water cooling systems can be relatively complex cooling
systems, incorporating exhaust heat recovery units, waste dump heat exchangers, multiple water pumps and
multiple temperature controls. In addition, the high jacket water temperatures encountered in these systems will
cause the coolant to flash to steam unless maintained at proper pressure levels. Thus, the complexity of the system,
combined with the potential for the coolant to flash to steam, dictates that special measures be taken to assure
proper cooling system performance. The documents listed below contain information vital to the proper design of
elevated jacket water cooling systems:
1) Cooling Systems, Waukesha Installation Manual, Form 1091 (or latest revision),
2) Cooling System Guidelines for Waukesha Engines, S6699-7 (or latest revision); found in General Tech Data Book
under the “Cooling Systems” tab,
3) Elevated Temperature Cooling Systems, WPS 7/90; found in the General Tech Data Book under the “Application
Notes” tab.
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 Manual, Form 1091, (or
latest revision), for more information.
Figures 1 and 2 depict typical elevated temperature cooling system layouts using a water-to-water heat exchanger for
isolation of the jacket water coolant circuit and recovery of engine heat for use in a process thermal requirement. A waste
dump heat exchanger can be included in the process loop to allow continued engine operation during periods when there is
little or no process thermal requirement. The waste dump heat exchanger can be a remote fan-cooled radiator, a cooling
tower, or some other type of heat exchanger device. As is typical of the VGF engine family, the auxiliary water circuit
(intercooler and lube oil cooler) require a separate source of cooling water, as aux water temperatures are significantly less
than jacket water temperatures.
Figure 2 is similar to Figure 1, with the addition of a heat recovery silencer. Note that in either schematic, the process loop
requires its own circulating water pump. The exhaust gas temperature exiting the heat recovery silencer should be kept to a
minimum of 100°F (55°C) above the engine jacket water outlet temperature to prevent condensation within the silencer.
Figures 1 and 2 are generic high temperature cooling systems, and do not depict all valving, air bleeds, orifices, balance
lines, bypasses, etc. Reference Cooling Systems, Waukesha Installation Manual, Form 1091 (or latest revision), for complete
cooling system component details.

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Ref.
Application of VGF Engines EN: 156543
S
at Elevated Jacket Water Temperatures DATE: 10/13
7790-1
GE Power & Water
Distributed Power Cooling Systems

PRESSURE CAP RATING

(MINIMUM)
8 PSIG @ 235° F

Page 4 of 5

Ref.
Application of VGF Engines EN: 156543
S
at Elevated Jacket Water Temperatures DATE: 10/13
7790-1
GE Power & Water
Distributed Power Cooling Systems

PRESSURE CAP RATING

(MINIMUM)
8 PSIG @ 235° F

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

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Ref.
Application of VGF Engines EN: 156543
S
at Elevated Jacket Water Temperatures DATE: 10/13
7790-1