W200

19
Cooling water system

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 W200

Cooling Water System .........................................................................................................................3

19.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
19.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
19.1.2 Preheating (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
19.1.2.1 Preheating, W200PH 1 version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
19.1.2.2 Preheating, PH2 and PHC versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
19.1.2.3 Preheating (option) version PHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

19.1.3 Different types of external cooling water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

19.1.3.1 Radiator system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
19.1.3.2 Tower system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
19.1.3.3 Raw water system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
19.1.3.4 Sea water system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

19.1.4 Piping complies with the following rules : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

19.1.5 De-aeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
19.1.6 Expansion tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
19.1.7 Drain tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

19.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
19.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
19.2.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
19.2.2.1 Recommandation before water draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
19.2.2.2 Draining of the group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

19.2.3 Recommendation before water filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

19.2.3.1 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

19.2.4 Mounting instructions of preheating pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

19.2.4.1 Pump casing position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
19.2.4.2 Electrical box position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

19.3 Monitoring of pressure and temperature parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

19.4 Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

19.4.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
19.4.2 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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 W200 Cooling Water System 19.

19. Cooling Water System

19.1 Description
19.1.1 General
The cooling water system consists of two cooling circuits : the low
temperature (LT) and the high temperature (HT) circuit.
The low temperature circuit water cools both the charge air and the
lubricating oil cooler in parallel.
The high temperature cooling water cools the cylinders (jacket wa-
ter), cylinder heads and the uninsulated part of the exhaust system
in the multiduct.

LT and HT circuit communicating

:
:
:
:

Fig. 19-1

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 19. Cooling Water System W200

The twin pump circulates both cooling water circuits.

The twin pump is a one shaft centrifugal pump with a double-sided
impeller, one side for the low temperature circuit and the other side
for the high temperature circuit.
Water pump for Ph1, Ph2 and PhC engines

Fig. 19-2

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 W200 Cooling Water System 19.

Water pump for PhD engines

HT in
HT out
LT in
LT out

Fig. 19-3

The temperatures of the cooling water are controlled by thermosta-

tic valve elements of wax type.
The thermostatic valves for both circuits are in same casting. The
cooling water control unit, is assembled on the rear side of the
engine.

19.1.2 Preheating (option)

To allow quick load application after starting, the cooling water sys-
tem can be fitted out with a preheating system. This system permits
to preheat the cooling water to a temperature as near to the
operating temperature as possible, or to a minimum of 50°C in the
HT circuit.
However the engine can be started without preheating until the
intake is over 5°C. Thanks to the cooling system design, at low
loads, the temperature is high enough to reduce ignition delay and
rough combustion and to prevent cold corrosion in the combustion
space.
The preheating set consists of a group of thermo-plunger of 12kW
output, set at 60°C and a circulation electropump.

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 19. Cooling Water System W200

19.1.2.1 Preheating, W200PH 1 version

10 kW preheater elements Thermostat Water circulating pump

From cylinder heads

B-bank

From cylinder heads

Preheater box A-bank

To cylinder
liners B-bank

Thermostat T441

To cylinder
liners A-bank

Non return valve Non return valve

Water circulating direction

Fig. 19-4

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 W200 Cooling Water System 19.

19.1.2.2 Preheating, PH2 and PHC versions

Fig. 19-5

Note : A kit is existing to remove the preheating module from the en-
gine. See ASI W200-02079.

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 19. Cooling Water System W200

19.1.2.3 Preheating (option) version PHD

WaWater circulating
ter circulating pump pump

Preheater element
preheater element

Fig. 19-6

19.1.3 Different types of external cooling water

The diesel engine installation depends on the auxiliary system in or-
der to function properly.
The environmental conditions must be considered at an early stage,
and it is of upmost importance that all auxilliary systems are consi-
dered and optimised for their intented purpose in the project design
stage.
The different types of external cooling systems are :
• Radiator
• Tower
• Raw water
• Sea water
19.1.3.1 Radiator system
The radiator cooler is often selected when the ambient temperature
is about +5°C to +35°C and when there is a shortage of raw water. In
cold weather applications (when the ambient temperature may be
below 0°C) the engine cooling system must be contain a solution to
avoid freezing and be design accordingly.
The radiator system consists of the following modular units :
• a radiator module
• an expansion tank
19.1.3.2 Tower system
The cooling tower is selected in situations when the ambient tempe-
rature is high and when a small supply or raw water can be arran-

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 W200 Cooling Water System 19.

ged. This system makes it possible to use treated fresh water in the
engine circuit while using untreated fresh water in the cooling tower
circuit. An advantage with using the cooling tower is that the coo-
lant can reach a temperature lower than the ambient temperature,
due to a forced evaporation of the water. Adding new water must
compensate for the evaporation losses.
The system consists of :
• cooling water
• expansion tank
• heat exchanger
• pump unit.
19.1.3.3 Raw water system
The raw water-cooled system is normally the most cost-effective so-
lution when raw water is available in sufficient quantities and quali-
ty.
The system consists of :
• a pump unit
• a heat exchanger
• an expansion tank.
The raw water used is taken from an intake reservoir, or direct from
the sea, lake or river.

19.1.3.4 Sea water system

As an option marine installation can be provided with an engine as-
sembled seawater cooler, seawater pump and expansion tank.

19.1.4 Piping complies with the following rules :

All tubes must be installed with a slope of 1 cm/m in order to facili-
tate fluid emptying or staining.
Low points are fitted with valves or drainplugs, both on fluid circuits
and gas circuits. Raw water exchangers are also inclined by 1 cm/m.
In case of frost, the bundle can be emptied by blowing through a
hole.
Circuit filling points must be indicated at the low points, and the
high parts must be fitted with manual or automatic degassing sys-
tems.If required by the water quality, circuits should be made of
rustproofed material - PVC or bronze -.
The connections between the installation and the generator set are
flexible, so as to absorb the vibrations and misalignments resulting
from relative motions or expansion.

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 19. Cooling Water System W200

19.1.5 De-aeration
The engine is provided with connections for continuous de-aeration
of the HT-circuit and the LT-circuit.

19.1.6 Expansion tank

The expansion tanks should compensate for volume changes in the
cooling water systems, serve as venting arrangement and provide
sufficient static pressure on the cooling water.
• Pressure from the expansion tank : minimum 0.5 bar at
crankshaft height
• Volume : approx. 10 % of the system cooling water column
The de-aeration pipe of each engine should be run to the tank sepa-
rately, continuously rising, and so that aeration of the water cannot
occur (the outlet should be below the water level).

19.1.7 Drain tank

It is recommended to provide a drain-tank in which the treated coo-
ling water can be stored when this has to be drained from the engine
or the system during maintenance and overhaul. A pump should be
provided to refill the water into the system.

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 W200 Cooling Water System 19.

19.2 Maintenance
19.2.1 General
The installation - including expansion, venting, preheating, pressu-
rising - should be carried out strictly according to the instructions of
the engine manufacturer to obtain correct and trouble free service.
The cooling water should be controlled according to the recommen-
dations in Chap. 02 to prevent corrosion and deposits. If risk of frost
occurs, drain all cooling water spaces. Avoid changing the cooling
water. Save the discharged water and use it again.

19.2.2 Cleaning
In completely closed systems the fouling will be minimal if the coo-
ling water is treated according to the instructions in chapter 02. De-
posits on cylinder liners, cylinder heads and cooler stacks should be
removed as they may disturb the heat transfer to the cooling water
and thus cause serious damage.
The deposits can be of the most various structures and consisten-
cies. In principle, they can be removed mechanically and/or chemi-
cally as described below. More detailed instructions for cleaning of
coolers are stated in Chap. 15.
a) Mechanical cleaning
A great deal of the deposits consists of loose sludge and solid parti-
cles, which can be brushed and rinsed off with water.
On places where the accessibility is good, e.g. cylinder liners, me-
chanical cleaning of considerably harder deposits is efficient.
In some cases it is advisable to combine chemical cleaning with a
subsequent mechanical cleaning as the deposits may have dissolved
during the chemical treatment without having come loose.
b) Chemical cleaning
Narrow water spaces (e.g. cylinder heads, coolers) can be cleaned
chemically. At times, degreasing of the water spaces may be neces-
sary if the deposits seem to be greasy (See Chap. 15).
Deposits consisting of primarily limestone can be easily removed
when treated with an acid solution. On the contrary, deposits con-
sisting of calcium sulphate and silicates may be hard to remove
chemically. The treatment may, however, have a certain dissolving
effect, which enables the deposits to be brushed off if there is only
access. On the market there are a lot of suitable agents on acid base
(contact your Wärtsilä representative).
The cleaning agents should contain additives (inhibitors) to prevent
corrosion of the metal surfaces. Always follow the manufacturer’s
instructions to obtain the best result.
After treatment, rinse carefully to remove cleaning agent residuals.
Brush surfaces, if possible. Rinse again with water and further with
a sodium carbonate solution (washing soda) of 5 % to neutralise
possible acid residuals.

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 19. Cooling Water System W200

19.2.2.1 Recommandation before water draining

• Switch off the engine, the CMR, and the electrical supply
of the preheating pump and heater elements.

Warning : During the handling, the genset must be stopped and locked.

19.2.2.2 Draining of the group

1 Before draining the group, wait until the water tempera-
ture is lower than 40°C.
2 Insulate the group (if the installation is equipped with
valves before and after the engine ) at the level of HT and LT water
pipes coming from external exchangers.
3 Open the different draining points : A drawing : items 1,
2, and 3 ; B drawing : items 4 and 5 ; the plug on the expansion ves-
sel, and the air cooler draining point, if the engine is not fitted with
insulation valves.
4 Provide a system able to recover the water and to pre-
vent the liquid from flowing into the sewer.
5 Drain the HT water thanks to the different draining
points represented on the C drawing : items 10 & 11 (main
draining points), on the D drawing : items 12 & 13 (secondary
draining points, engine inlet and outlet), on the D & E drawings :
items 14 & 15 (cylinder head lines secondary draining points) and
on the C drawing : item 16 (preheating water box draining).

Note : The draining points items 14 & 15 (fig. 10 and 11) have to be
opened only when a liners replacement is performed.

6 Drain the LT water thanks to the different draining points

shown on the F drawing , item 20 and on the G drawing , items 21 &
22.

Note : If necessary, change the cooling liquid after each draining.

7 After that, you can work on the engine without any risks
of water leakage into the oil sump.

19.2.3 Recommendation before water filling

• Be sure that you have respected the O&M manual
recommandations concerning the sealing fitting or part
remounting.
• Close the different draining points on the engine (items 11,
12, 13, 14, 15, 16, 21 and 22) except items 10 and 20.

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 W200 Cooling Water System 19.

19.2.3.1 Filling
1 The venting points must be opened, A drawing , items 1,
2, 3, 4, 5, the expansion tank too.
2 Fit the draining/filling points with connections at the
engine lower point or connect the existing tapping with HT and LT
water pipes, located between the insulation valve and the engine.
3 Start to fill-up the engine.
4 When water begins to flow out from the venting
points, close each venting screw as far as the liquid appears.
5 Close the connection cocks .
6 Open slowly the engine insulation valves.
7 If necessary, add water in the filling pipes and open the en-
gine venting points again.
8 Let the venting points opened, until water flows out.
Then, close the filling cocks, remove them from the connections
and close the venting points.
9 If necessary, add water in the expansion tank again,
and then close the expansion tank plug.

Note : It is important to check carefully the venting point item 5, fig.

19-8 (venting of the HT circuit water pump ).
During the preheating and engine starting, airlocks should not
appear.

10 Start the engine and check the water pressures. If they are
unsteady when the engine is stabilized, check the different ven-
ting points.

Warning : When engine water temperature is higher than 60°C, you have
to protect your arms and hands to prevent any burn during the
water circuit ventings, when the engine is running.

11 If necessary, add water in the expansion tank.

12 Check the five venting points again when the engine is
fully running.

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 19. Cooling Water System W200

Venting points with internal oil exchanger

1. HT water venting (manual drain cock)
2. LT water venting (manual drain cock)
3. LT water venting (manual drain cock)
4. Preheating water box venting (manual drain cock)
5. Water pump venting (manual drain cock)
A Drawing : A side view (view non contractual)
1 2 3

Fig.19-7

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 W200 Cooling Water System 19.

B Drawing : free end side view (view non contractual)

4 5

Fig. 19-8

HT draining points
10. HT draining point (engine lower point)
11. HT draining point (engine higher point)
12. HT draining point (inlet)
13. HT draining point (outlet)
15. HT B side cylinder draining point (when cylinder head removal)
16. HT draining point (preheating water box).
C Drawing : free end side view (view non contractual)

11

16
10

Fig. 19-9

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 19. Cooling Water System W200

D Drawing : B side view (view non contractual)

XX
15 12 13

Fig. 19-10

HT draining points (following)

14. HT A side cylinder draining point (when cylinder head removal).
E Drawing : A side view (view non contractual)

14

Fig. 19-11

LT draining points
20. LT draining point.

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 W200 Cooling Water System 19.

F Drawing : Free end side view (view non contractual)

20

Fig. 19-12

LT draining points (following)

21. LT draining point (engine inlet)
22. LT draining point (engine outlet).
G Drawing : B side view (view non contractual)
XX

21
22

Fig. 19-13

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 19. Cooling Water System W200

19.2.4 Mounting instructions of preheating pump

19.2.4.1 Pump casing position
When you change a preheating pump, you must check the pump po-
sition. For heating efficiency, the cooling water flows have to be
from top to bottom in the preheating element box. Then the arrows
printed on the preheating pump casing must indicated the bottom.

Note : Use Perfect Seal paste N°4 ref. MGE000084 for the casing
mounting.

Arrows printed on the preheating

pump casing

Fig. 19-14

19.2.4.2 Electrical box position

When the preheating pump casing is correctly installed, you must
check that the pump electrical box is not positioned down (see fig.
19-15). The position on top and on the side are both allowed. If
needed you can turn the pump motor by loosing the screws fixing
the motor to the casing. use the bottom packing for the wiring if the
electrical box is on the side (see fig. 19-16).

Electrical box below the pump

electrical motot

Fig. 19-15

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 W200 Cooling Water System 19.

Pump electrical box on the side

Screws that fix the pump motor to

the casing

Bottom packing for the wiring

Fig. 19-16

Warning : The electrical wiring screws must be checked regularly :

Replace the plain washer by lock washer
Remount the screws with Loctite N°184741220 (if the screws
are damaged, replace them).

Rotation control :
After wiring, you must check that the preheating pump rotates in
the good way (indicated on the pump motor). According to the
pump type and brand, you have two possibilties :
• Directly check the way with the indicator light on the
pump electrical box (see Fig. 19-17)
• Open the draining screw and check the rotor rotation (see
Fig. 19-17).
In all cases, after preheating system starting, check that the HT wa-
ter temperature is increasing in the engine.

Note : Before starting preheating system, check that the water circuit
and preheating systems are correctly vented (see chap. 19.2).

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 19. Cooling Water System W200

Indicator light Rotation way Draining screw

Fig. 19-17

19.3 Monitoring of pressure and temperature parameters

In order to control the pressures and the temperatures of the LT and
the HT cooling water circuits, there are thermometer and manome-
ter installed on the cooling water circuit, see chapter 23.
The thermometer and the manometer are connected with the
Engine Control Unit. Main engines are provided with alarm switches
for low and high pressure and temperature on the HT and LT cir-
cuits.

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 W200 Cooling Water System 19.

19.4 Water pump

19.4.1 Description
The twin water pump is a one shaft centrifugal pump with a double-sided
impeller : one side for the low temperature circuit and the other side for
the high temperature circuit.
The pump is driven by the gear mechanism at the free end of the engine.
The impeller, pump and bearing housings, LT suction pipe are machined
from raw casting in grey cast iron.
The shaft, in contact with the cooling liquid, is made of acid proof steel
without chrome plating. It is machined in as steel bar.
The shaft is mounted in two ball bearing (items 30 and 31) which are lu-
bricated by splash oil entering through the opening in the bearing hou-
sing.
The shaft seal (item 44) prevents the oil from leaking out and, at the same
time dirt and leak water from entering. The impeller is fastened to the
shaft.
The waterside of the pump is provided with a mechanical shaft seal.

19.4.2 Maintenance
You must check the pump at intervals according to the recommen-
dations in Chap. 04 or if water and oil leakage occurs, immediately.

Fig. 19-18

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