Mech.

Installation – Ventilation/Cooling

1 10/20/2018 ALBERTO.MARVAO@CUMMINS.COM
Covered Topics
▪ Energy Balance ▪ Coolant Sensors
▪ Ventilation System Design ▪ Sizing
▪ Remote Cooling – Ventilation
– Piping
▪ Engine Cooling Systems
▪ Layout Remote Cooling
▪ Radiators
▪ Dearation
▪ Heat Exchangers
▪ Pipes
▪ Pumps

2 Application Engineering Training – CPG - SAE Kent

 Basic Principles: Energy Balance

Jacket Water Exhaust Heat & Air

After Cooler 30% Energy Output Radiated Heat 5%
25% Energy Output
Radiated Heat 5%
Energy Output
Energy Output

Discharge Air Intake Air

92 to 94% 100%

Fuel 100% Electrical 35%

Energy Input Energy Output

Note: Conceptual diagram and values

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 Ventilation System Design
Acceptable Acceptable

Outlet

Outlet
Inlet

Inlet

Inlet
Not Acceptable Not Acceptable

Outlet
Outlet

Inlet

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 Ventilation System Design
Inlet Outlet

Outlet
Recommended
(for remote cooling only)
Not Acceptable
Inlet

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 Remote Cooling
▪ Heat Exchanger + Coolant Pump
▪ Engine Coolant Pump

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 Engine Coolant System Types Overview
▪ One Pump/One Loop (1P/1L)
▪ One Pump/Two Loop (1P/2L)
▪ Two Pump/Two Loop (2P/2L)
▪ Charge Air Cooling
▪ Fuel Cooling

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 Layout – without external pump
▪ Simple System
▪ Control
▪ Auxiliary Supply
▪ Short Distances
▪ Back Pressure
▪ Maintenance (Coolant Quality)
▪ Maintenance (System Capacity)

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 Layout with external pump

▪ Complexity System
▪ Control
▪ Auxiliary Supply
▪ Pumps
▪ Heat Exchanger
▪ Expansion Tanks
▪ Maintenance

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 Radiators
▪ Vertical
– Single Core
– Double Core
• Back to Back
• Side Mounted

▪ Horizontal
– Single Core
▪ Mechanically Driven (Fan)
▪ Electrical Driven (Fan)

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 Dearation
▪ Expansion Volume
▪ Vent gases (preventing hot spots)
▪ Positive Head Pump (prev. cavitation)
▪ Fill
▪ Monitor Level
▪ Highest Point of the system Engine

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 Heat Exchangers
▪ Shell and Tube

▪ Plate

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 Pipe Types

▪ Copper
▪ Galvanized Steel (*)
▪ Plastic
▪ Stainless Steel
▪ Black Iron
▪ Fittings
– Welded
– Flanged
– Threaded
– Press

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 Pumps

Centrifugal Pumps
Single Impeller
Up 90 meters-30m3/h

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 Coolant Sensors

Switch
Capacitive

(+) Operates different voltages (+) Operates different voltages

(+) Performance turbulent conditions (-) Performance turbulent conditions
(+) Operating Temperatures (-) Operating Temperatures
(-) Demanding maintenance -> Applicable to Spill Tanks
-> Applicable to Expansion Tanks

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 Control

▪ Auxiliaries Supply
– Voltage/Frequency
– Starting System (direct, soft start, star/delta)
– Pumps
– Electrical Motor Radiator
▪ Fault Sensing
– Level Sensors (Float Tanks)
– Differential Circuit Breakers (Pumps and Electrical Driven Fans)
– Thermal Protection (Pumps and Electrical Driven Fans)
– Auxiliary contacts Protection devices

▪ Logic
– Starting Stopping of the System
– Available Inputs/Outputs on the PCC
– Logic for redundant systems
– DMC ?
– Remote Monitoring

16 Application Engineering Training – CPG - SAE Kent

 Specifying Airflow Requirements
a) Determine heat rejection to ambient room (Qtotal)
i. Include engine, alternator, muffler, exhaust piping, auxiliary items.
b) Spec max. allowable temperature rise
i. ∆𝑇𝑚𝑎𝑥 = 𝑀𝑎𝑥. 𝑅𝑜𝑜𝑚𝑇𝑒𝑚𝑝. −𝑀𝑎𝑥. 𝐴𝑚𝑏𝑖𝑒𝑛𝑡𝑇𝑒𝑚𝑝.
c) Calculate cooling airflow required (Qroom)
𝑄𝑡𝑜𝑡𝑎𝑙
i. 𝑄𝑟𝑜𝑜𝑚 =
𝐶𝑝 ×∆𝑇𝑚𝑎𝑥 ×𝑑

d) Calculate total room airflow requirement (Qroom)

i. 𝑄𝑡𝑜𝑡𝑎𝑙 = 𝑄𝑟𝑜𝑜𝑚 + 𝑄𝑐𝑜𝑚𝑏𝑢𝑠𝑡𝑖𝑜𝑛
e) In case of need compensate for density changes due to altitude
i. For every 305 meters increase air flow by 3%
f) Compare to radiator airflow (when applicable)

Qroom= minimum forced ventilation airflow (m3/min)

Qtotal= total heat emitted to room (MJ/min)
Cp=specific heat (1.01x10-3 MJ/kg/oC)
∆T=Generator set room temperature rise (oC)
d=density of air (1.20 kg/m3)

17 Application Engineering Training – CPG - SAE Kent

 Sizing Remote Cooling System
Using just the Coolant Pump of the engine:

Procedure to calculate/check the cross section piping

– Retrieve data from the engine data sheet:
• Coolant Flow
• Maximum Coolant Head Static Pressure ft(m) piping
• Maximum Coolant Friction Head psi (kPa) piping
– Calculate the total length of the vertical pipes in the system
– Calculate the total length of the straight pipes in the system
– Calculate equivalent length of all the fittings and valves
– Calculate the sum of equivalent length of all the fittings and valves with total length of the
straight pipes in the system
– Compare the results obtained to check if they are inside the specified limits

18 Application Engineering Training – CPG - SAE Kent

 Sizing Remote Cooling System
Using heat exchanger and external pump:
Procedure to calculate/check the cross section piping
and spec the pump:
– Retrieve data from the radiator data sheet:
• Coolant Flow
• Pressure Loss
– Retrieve data from the heat exchanger data sheet:
• Coolant Flow
• Pressure Loss
– Spec cross section of the pipe (estimate)
– Calculate the total length of the vertical pipes in the system
– Calculate the total length of the straight pipes in the system
– Calculate equivalent length of all the fittings and valves
– Calculate the sum of equivalent length of all the fittings and valves with total length of the
straight pipes in the system
– Sum all the pressure losses of the system (radiator, exchanger, piping, fittings, etc)
– Spec the pump according to the results

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 Sizing Remote Cooling System

▪ Dearation
– Determine the total capacity of cooling system/loop
– Sizing the dearation tanks accordingly to 15% of the capacity of the loop

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 Cooling

QUESTIONS ?

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 Quiz
1. “The quantity of air that goes in the engine room is of the same quantity of
air that is expelled by the engine room air outlet ..” Comment the statement
if it is false
2. Using the Genset as reference what is the best position for the air inlet and
outlet to be located?
3. As a rule of thumb what would be the size of an genset room air inlet ?
4. What are the two components that differentiate most the two layouts for
remote cooling covered ?
5. What factors can determine the use of remote cooling ?
6. What factors can determine the use of remote cooling with other devices,
like heat exchangers, external pumps, etc ?
7. What factor can influence the use of vertical radiators or horizontal radiators
8. What does dearation mean?
9. What materials can be used for coolant piping?
10. Why capacitive sensors are better for certain applications?

22 Application Engineering Training – CPG - SAE Kent

 Exercise
▪ Find total room airflow requirement for 2 x C1400D5
(KTA50G3,P7LVB, remote radiator application, prime duty)
▪ Assumptions:
– Max ambient temperature of 110°F/40°C
– Maximum Engine room temperature 45°C
– Heat rejection from each muffler 7000kJ/min
– Heat rejection from exhaust piping 1000 kJ/min
– Heat rejection from water pipes and other sources 200kJ/min
– Air Density = 1,1kg/m3, cp=0.001MJ/kg. °C
– Genset total heat radiated to room 8 MJ/min

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