Cooling Water System 1

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Cooling Water System - 1
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PIPING DOWNLOADS
RSS FEED Most of the all process industry requires the cooling
tower for certain application depends
upon industry and uses size of cooling tower may varry.
Web hosting Linux For bigger and huge capacity
cooling tower high capital investment and high
operation of cost involve. To select proper
Grab New Articles cooling tower and execution and maintenance
understand the cooling tower and its piping
via E-mail is very important in this chapter we will study
consideration of piping routing and layout of
cooling water piping.
Just Enter your email
address: The cooling water systems which are commonly used in
practice according to the availability of the water are
listed below:
Subscribe Once — through or open cooling water system.
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Re circulating or closed cooling water system.
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Google Translate My Page Combination of Once * through and re circulating or

mixed cooling water system.
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Select Language Types of Cooling Water Systems
Gadgets powered by Google z Open System
In the open cooling water system, all the required

quantity of cooling water is withdrawn from the source
(sea, river, lake or well water) for entire plant cooling
duties. In this system, the water is drawn directly from
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the upstream side of the river, pumped through the
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Facebook social plugin condensers and then discharged to the down ward side
of the river at temperature 5 to 100c in excess of the
inlet temperature. The temperature of the discharged
water should be kept within safe limits to prevent harm
to fishes. The limit of discharge water temperature is
specified by the Fisheries Board. The arrangement of
the open system is
shown in the figure 4.1.
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Saw Something in search

engine & not able to find The position of inlet and outlet should be chosen in such
here. Search your query in a way that there should not be any re circulation of hot
the search box given above & water, which impairs the efficiency of the cooling water
surely you would find the users. Therefore, the distance between the inlet and
required article. Need
discharge points should be as large as one km or more.
something else, just mail me
This type of cooling water system can be used only
at ankit@pipingguide.net. If
when required quantity of water is available throughout
your looking for downloading
handbooks then visit Piping the year.
Books Downloads
(www.pipingdownloads.blog
complete articles related to

download material only. Plants on tidal waters (using water from the tides or
sea) have a special problem in the construction of the
cooling water system and in avoiding recirculation of the
cooling water from the outlet back to the intake. In
DAILY CRUDE many plants, the intakes and outlets are separated by
OIL PRICE!! as much as 3 kilometres.
Crude Oil Price by OIL-PRICE.NET ©
Price Cha In tidal waters, the water flows in one direction for
some time and in another direction for some time,
04:51 - $ 112.29 0.11 0
therefore it requires special arrangements for the
Range Open 52 Wk change in flow direction. Stations taking water from
0.00 - 0.00 0.00 68.01 - river or tidal sources usually have the ends of both
section and discharge pipes submerged below the
lowest recorded tidal level. The water circulation system
Piping Articles will operate at all times and at all states of tide if the
distance between the lowest level and highest point of
PIPE LINES the circulation water system does not exceed 10 metres.
PIPELINE RISERS
FLANGES z Closed System
PIPE WORK
VALVES The re circulating or closed cooling water systems
SIZING OF PIPELINES operate in a closed loop with fresh water make-up
PE Pipes and which constitutes only a small fraction of the cooling
Dimensions
water circulation.
PRESSURE VESSEL
DESIGN & CODES
NPSH - Net Positive
Closed systems are of two types- Water or Air-cooled
Suction Head type. Water cooling type employ cooling towers or
“m” & “y” Factors in cooling ponds. Air cooling type employ direct dry type
calculations for cooling tower system or indirect air cooling system.
Gaskets in Heat
Exchanger Equipment When enough quantity of water is not available for
Designing cooling requirements from rivers, the closed type
Pump Suction system is universally adopted.
Strainers
PIPING & TUBE In the closed system, the hot water coming out of the
SPECIFICATIONS
cooling water users is cooled either by sparging in the
AIR-COOLED HEAT
pond or passing through the cooling tower instead of
EXCHANGERS
discharging to the downward flow of the river.
PIPELINE PIGGING
AN INTRODUCTION TO
PIPELINE PIGGING - 1 The quantity of water required is from the river during
AN INTRODUCTION TO flood period or when sufficient water is available with
PIPELINE PIGGING – 2 required purity and same water is used again and again
ASME Boiler & for condenser by passing through the cooling towers.
Pressure Vessel Code – Such arrangement of cooling system is shown in figure
(Digital Version) 4.2.
CRITERIA FOR
SELECTION OF
VALVES FOR PIPING
NETWORK
(2)
Basics of Pipe Stress -
(1)
Standards of Pipes and
Fittings
B31.11 Slurry
Transportation Piping
Systems
B31.8 Gas
Transmission and
Distribution Piping
Systems
B31.5 Refrigeration
Piping and Heat
Transfer Components
B31.4 Pipeline
Transportation
Systems for liquid
hydrocarbons and
other liquids
B31.3 Process Piping With this system of cooling, an external source of water
B31.1 Power Pping is needed to replace tower evaporation and carry over
DESIGN LOADS - varies between 2 to 5% of that circulated, depending
PIPING upon the design of the tower.
DESIGN OF PIPING -
CSA Z662 z Mixed System
DESIGN OF PIPING -
B31.8 A combination of the once-through and re-circulating or
DESIGN OF PIPING - mixed cooling water system is sometimes employed to
B31.3
carry-out process cooling via the closed cooling water,
DESIGN OF PIPING –
which in turn is cooled by a open cooling water circuit in
B31.1
a suitable heat-exchanger. The arrangement of system
PIPING SYMBOLS
is shown in figure 4.3 (a).
Piping &
Instrumentation
Diagram
Standards of Pipes and
Fittings
General Guidelines for
Equipment and Piping
Location, Spacing,
Distances and
Clearances
PIPING CODES &
STANDARDS
PIPING DESIGN
FOULING
PIPELINE
CONSTRUCTION
Process Articles
Engineer’s Perspective
on Using Equivalent
Lengths of Valves and
Fittings in Pipeline
Pressure Drop
Calculations
McCabe-Thiele method
OIL INDUSTRY
CONVERSIONS
Jacketed Vessel
Design - 1
Jacketed Vessel
Design - 2
What is Heat Pipe?
Common mistakes in
process
design/simulation
CRITERIA FOR
SELECTION OF
VALVES FOR PIPING
NETWORK
Fabricated Tees & The main advantage in this system is the flexibility of
Area Reinforcement & operation it gives to the process side which is on the
Flexible Analysis closed loop.
MATERIAL
SELECTION - PIPING Another type of mixed system uses river water as well
SHELL & TUBE HEAT as the cooling tower simultaneously. This system
EXCHANGER: overcomes the difficulty of re-circulation and meets the
CORRECTED LIMITED
requirements of the Fisheries Board on a fairly small
LMTD
river. The arrangement of system is shown in figure 4.3
GAS COMPRESSOR
(b).
PERFORMANCE
ORIFICE SIZING FOR
FLUID FLOW
PARTIAL VOLUMES OF
TANKS
SIZING OF LIQUID-
VAPOR SEPARATORS
FORCE ON A PIPE
BEND
GAS PIPE FLOW:
FLOW RATE
CALCULATION FOR
INCLINED PIPELINE
GAS PIPE FLOW:
FLOW RATE
CALCULATION FOR
HORIZONTAL
PIPELINE
NATURAL GAS: Z-
FACTOR & VISCOSITY A part of the water from the cooling water users is
FOR GIVEN SPECIFIC discharged directly into the down stream of the river,
GRAVITY
NATURAL GAS Z
FACTOR & VISCOSITY

FOR GIVEN and part of the water is pumped to the cooling tower,
COMPOSITION where it is further cooled and then discharged to the
LIQUID PIPE FLOW: downward side of the river. In this way the water
PIPE DIAMETER discharged to the river is maintained at a suitable
CALCULATION temperature and re-circulation troubles are eliminated.
LIQUID PIPE FLOW: The advantages of this system are: -
FLOW RATE
CALCULATION (i) The size of the cooling towers can be reduced where
LIQUID PIPE FLOW: the site area is limited.
PRESSURE DROP
CALCULATION
(ii) The quantity of cooling water required is reduced as
LIQUID PIPE FLOW:
PIPE LENGTH
re-circulation is eliminated.
CALCULATION
REYNOLDS NUMBER (iii) The turbine plant efficiency is increased.
AND FRICTION
FACTORS (iv) This system should be adopted only when there is a
possibility of recirculation
and it is necessary to meet the requirements of
PDMS Articles frsheries board.
PDMS -
REPRESENTATION Engine cooling
The Database Listing
Form After the above discussion on cooling water systems
Positioning Radial and cooling system principles, we now come to the
Nozzles specifics of cooling of engines. The necessity of cooling:
PDMS SYNTAX'S Part of the heat developed during the combustion in
PDMS PSEUDO engines flows from the gases to the cylinder walls,
ATTRIBUTES raising their temperature. If, with an un-cooled piston,
PDMS Creating & the wall temperature is allowed to rise above a certain
Deleting Elements limit, about 300 0F, the oil that lubricates the piston
PDMS Orientation begins to evaporate rapidly, and both piston and
Commands
cylinder may be injured. Warping of valves and pistons
PDMS Positioning
takes place. The proper cooling of the engine is
Commands (Piping)
absolutely necessary
PDMS Positioning
Commands (General)
to extend the life of the plant. At the same time high
PDMS QUERY local temperatures in certain parts of the engine, such
COMMANDS as the cylinder head and piston, may cause excessive
SETTING PDMS stresses and cracking of these parts. Additional heat is
ATTRIBUTES developed through friction between various rubbing
PDMS SYNTAX surfaces, chiefly between the piston and piston rings
EXAMPLES and the cylinder walls. With oil-cooled pistons the limit
STRUCTURE, for a safe cylinder wall temperature is considerably
EQUIPMENT & OTHERS higher.
Remaining Commands
of PDMS The heat generated in an engine cylinder by the
PDMS COMMANDS: combustion of the fuel varies from about 6,000 to
PIPING COMMANDS 10,000 Btu per hp-hr. Tests show that from 25 to 35
percent of this heat in water-cooled and about 15 to 25
TO GET COMPLETE
DOWNLOAD MATERIAL IN
ONE GO, VISIT Piping Book percent in air-cooled engines finds its way into the
Downloads. cylinder walls and must be carried away. If some means
were not provided for the removal of this heat, the
temperature of the metal would begin to approach that
Download Section of the combustion gases as they leave the engine
cylinder, or about 800 to 1200 0F. Therefore, this heat
E-Books removal, or cooling, problem is so vital that, if not taken
HYSYS: An care of properly, it can cause more engine trouble than
introduction to any other phase of engine operation. The exit
Chemical Engineering temperature of the cooling water must also be
simulation controlled. If it is too low, lubricating oil will not spread
Fundamentals of pipe - properly and wearing of piston and cylinder takes place.
--benedict If it is too high, the lubricating oil burns. Therefore, the
Plastics for Corrosion maximum exit temperature of the water is limited to 70
Inhibition (Springer 0C. Constant cooling water flow rate rises the exit water
Series in Materials
temperature with the increase in load or vice versa,
Science
when inlet water temperature is constant. Therefore, a
Experimental Methods
control on the flow of the cooling water is necessary
in Kinetic Studies, 2nd
Edition according to the load conditions on the plant.
Gas exploration Hand
book Heat Transfer
Design Of Piping
Systems-Mw.kellog The three means of heat transfer conduction,
Petroleum convection, and radiation are used in cooling engine
Engineering: Principles cylinders. Conduction plays an important part in
and Practice
carrying the heat through the metal walls and the thin
Relative Permeability
layers of stagnant gas and water in contact with the
of Petroleum
Reservoirs
walls; the rest of the heat is exchanged partly by
Integration of radiation but chiefly by convection.
Alternative Sources of
Energy by Felix A. The heat flow between the two fluids separated by a
Farret metal wall can be best explained using the figure 4.4.
Small Scale Biomass The temperature ta of the gas at a point in the interior
Gasifiers for Heat and of the cylinder gradually falls to the value tb at the
Power A Global Review surface of the inert gas film. The thermal resistance of
by Hubert E. Stassen this film is very great and a great temperature head, tb -
Thermal Biomass tc, is required for conduction. The temperature head
Conversion and required to cause heat flow through the metal wall is tc-
Utilization Biomass
td The temperature head required for conduction
Information System by
A. Bridgwater through the outside film is td - te. Its value is
Bioenergy Realizing comparatively small if the cooling fluid is water and
the Potential by Dr. large if it is air. Finally, the temperature of the cooling
Semida Silveira liquid drops to tf at some distance away from the wall.
Bioenergy Options for
a Cleaner Environment
in Developed and
Developing Countries
by Ralph E.H. Sims
Concise Encyclopedia
f Bi
Technology by Ashok
Pandey
Synthesis of
Transportation Fuels
from Biomass
Chemistry , Catalysts
and Engineering by
G.W. Huber
A Geographic
Perspective on the
Current Biomass
Resource Availability
by A. Milbrandt
Specification for
Welding Procedue and
Perfornance
Qualificaito by
American Welding
Society
Wrought Stainless
Steel Butt-Welding
Fittings by The heat flow per unit area of surface in contact with
Manufacturers hot gases on one side and the cooling medium on the
Standardization
other side thus depends upon the inside film coefficient
Society
h1, the conductivity k of the metal, thickness L of the
Jeffersons Welding
Encyclopedia 18E by
cylinder wall, on the outside film coefficient h2 between
Robert L Obrien - the metal and cooling medium, and the difference
password: between the gas temperature and the cooling-medium
www.Chipollo.Info temperature.
Elements of Propulsion
By Jack D. Mattingly The value of the outside-film coefficient depends in the
Caesar II Coade first place on whether the outside surface of the cylinder
Presentation is cooled directly by air or by liquid. The value of Fit is
Flow of Fluids Through rather small if the cylinder is cooled by air and
Valves, Fittings, and considerably higher when it is cooled by water.
Pipe
Tube Turns,
For reference the thermal conductivity k of metals is
INC., «Piping
Engineering
given in Table — 1. However, the coefficient of
Basic Of Piping
conductivity k affects the heat flow to every small
Drawings extent, much less than the film coefficient hi and h2.
Equipment & Piping
Layout Table - 4.1 gives also the specific heats and coefficients
Pipe Hanger Design of linear expansion of metals used for pistons, cylinders,
Piping Drawing & Plot and other engine parts. The temperature t2 of the
Plan inside surface of the cylinder wall is not constant during
Practical guide to a cycle but fluctuates following the variation of the gas
ASME B31.3", by temperature. The temperature of the inner surface goes
Woods and Bagley
HYSYS: An
introduction to
Chemical Engineering
simulation
Piping Guide Zone

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Towers and Columns
Gas Turbines
Piping for Steam
Distribution
Cooling Water System - 2
Cooling Water System - 1 up to tmax during combustion, and drops to tmin toward the end of
► 2009 (135) the suction stroke. However, these fluctuations are not great: for
a two stroke oil engine at full load the fluctuation above the
► 2008 (6)
average value, tmax - t2 is about 25 0F and that below it, t2 - tmax is
► 2007 (1) about 15 0F. In a four- stroke engine the downward fluctuation
will be about the same as the upward one owing to cooling
during the suction stroke. This gives a temperature range of
about 50 0F. The temperature fluctuation does not penetrate
deeply; 3/8 in from the surface the range of fluctuation is less
than 1 0F.
Heat Flow
When the rotary speed of an engine increases, the

duration in seconds of all events of each cycle
decreases. However, the increased piston speed creates
a greater turbulence, slightly increasing the heat flow,
and as a result the percentage of heat of the fuel
rejected to the jacket increases slightly with the engine
speed.
Tests have shown that the percentage of jacket loss is

nearly independent of the engine load and decreases
slightly with an increase in the cylinder diameter.
Water Circulation
Quantity - The quantity of water that must be circulated depends
upon the initial temperature and the desired temperature rise of
the water. The initial temperature depends upon the
atmospheric conditions, either directly, as in marine engines, or
indirectly, if a re-cooling system is used and the water is re-
circulated over and over. In order to avoid excessive heat
stresses, the temperature difference between the incoming and

outgoing water should be about 20 0F in small and medium
sized engines and slightly less in large engines. The
temperature of the outgoing water was usually not allowed to go
above 140 0F. For engines with a closed system a maximum
temperature of 160 to 180 0F was allowed. In automotive
engines the cooling water often reaches the boiling point, about
212 0F, without damage to the engine, but thermostats are
usually set for 180 0F. The results of investigations of cooling by
evaporation discussed below with jacket water temperatures
from 215 to 250 0F, will probably change the above limits.
If an engine is cooled by untreated water, which always contains

dissolved salts and other foreign matter, the temperature should
be kept low enough to prevent the precipitation of impurities and
the formation of scale. If an engine uses salt water in the
cylinder jackets, the temperature of the outgoing water should
not exceed 110 to 115 0F.
The water is usually circulated through the lubricating oil cooler,

through the cylinder jackets, then to the cylinder heads; after
this, in large engines, a branch line leads water to the exhaust
valve cages. Pistons are usually cooled from a separate pipeline.
The quantity of water G that must be circulated, gallons per
hour, is
Where Q = the amount of heat rejected to the cooling

water, Btu per hr
t1 = the temperature of the incoming cooling water,

degrees F
t2 = the temperature of the outgoing water.
For average conditions, the heat flow to the water

jacket, in unsupercharged engines, is about 2600 Btu
per hp-hr for large engines, increasing to about 3000
and to 3500 Btu per hp-hr for small and less efficient
engines. In a supercharged engine the total heat flow,
Btu per hr, is about the same as in an engine with
natural aspiration of the same dimensions and speed.
However, since a supercharged engine develops from
35 to 50 percent more power, the specific heat flow, or
heat flow referred to I hp-hr. is correspondingly smaller,
about 1850 to 2300 Btu per hp-hr. The heat flow to
lubricating oil coolers, where these are used, is about
100 to 200 Btu per hp-hi, depending upon the
amount of oil circulated and friction losses in the

bearings.
Excessive water circulation resulting in low final water

temperature is not desirable, since it will increase the
fuel consumption and decrease the useful power.
A low cooling water temperature increases the viscosity

of the lubricating oil and, consequently, the piston
friction. The difference between friction loss at high and
low jacket temperature may amount to as much as 8
percent of the power, if the piston is large and heavy,
and drops to about 4 per cent, if the piston has small
bearing area and weight.
Temperatures
Formerly it was considered good practice to operate all engines
so as to maintain a moderate outlet water temperature of some
120 to 1400F and not over 160 or at the most 180 0F, when
using an enclosed cooling system. The object in using low water
temperatures was mainly to reduce the formation of scale in the
cylinder jackets. Scale is particularly dangerous in horizontal
engines.
The dew point of the water vapour in the exhaust gases

depends upon the pressure and hydrogen content of the
fuel. A considerable condensation of water is bound to
occur on the cylinder walls. The water causes corrosion,
which seems to be one of the main causes of cylinder
wear.
Numerous tests conducted since 1937 and careful

observation of a number of
installations have shown that permitting the water
temperature to rise above the boiling temperature, to
about 220 to 250 0F, gives very important and far
reaching advantages:
1. It eliminates the condensation of the water vapour

contained in the products of combustion, thereby
(a) preventing, or at least reducing materially, the

washing off of the lubricating oil film from the cylinder
and piston ring surfaces and prevents the formation of
sulphuric acid from sulphuric dioxide, often contained in
the products of combustion; these two factors reduce
the wear of the cylinder, piston rings, and valves
considerably under certain conditions down to one
eighth of the usual amount;
(b) eliminating crankcase condensation and sludging of

the lubricating oil.
2. It lowers the viscosity of the cylinder lubricating oil;

this reduces the mechanical losses and raises the
mechanical efficiency of the engine, thereby permitting
a lower fuel consumption per horsepower hour.
3. It reduces the amount of water which must be

circulated, because part of the water is evaporated in
the jackets and the cooling effect of each pound of
evaporated water is about 970 Btu per lb, instead of the
10 to 20 Btu per lb absorbed by the water due to
temperature difference; this fact reduces the fuel
consumption still further.
4. It increase the temperature difference between the

cooling water and the air to which the heat is rejected
and, if a radiator is used, a considerably smaller
radiator surface and a smaller fan will do, and fuel will
thus be saved.
5. At a full load, the total fuel saving may reach 10

percent. Quite naturally, with an increase of the jacket
temperature, the heat absorbed by the jacket from the
gases in the cylinder decreases because of a smaller
temperature difference, for a typical engine. The heat
not transferred to the jacket water increases the heat
carried away by the
exhaust gases and raises their temperature.
The use of higher jacket temperatures, up to 250 0F,

does not require a change in the construction of the
engine or in the lubricating-oil specifications. However,
it is desirable to have wide water passages and to
eliminate possible vapor pockets.
Other Liquids
The use of ethylene glycol, or Prestone, which at atmospheric

pressure has a boiling temperature of 387 0F, instead of water,
gives the same advantages, except No. 3, if the jacket
temperature is maintained at the same level. The specific heat
of Prestone is 0.675 Btu per lb at 212 0F and about 0.775 Btu
per lb at the boiling temperature.
The pistons of big double-acting engines are sometimes

cooled by circulating oil instead of water through them.
Pistons of high-speed single acting engines are
sometimes cooled by a jet of oil directed toward the
underside of the piston top.
Construction Features of Engine Parts

Requiring Cooling
z Cylinders
In some small and medium sized engines the water

jacket is cast together with the cylinder. In many
automotive and in all larger engines the cylinder is
formed by a cast-iron liner inserted into a cast iron
jacket.
The water space between the cylinder proper or liner

and the water jacket is made such as to obtain a fair
velocity of water circulation, at least 5 ft per mm in
stationary engines and up to 60 ft per mm in
automotive engines.
z Cylinder Heads
In a four stroke engine the heat carried away by the

water that cools the head comes from two places: from
the bottom plate, which forms the upper wall of the
combustion space, and from the exhaust passage and
exhaust valve, if the latter is not water cooled.
In cylinder heads good cooling is obtained by (1)

eliminating air and steam pockets, (2) maintaining, as
far as possible, uniform water velocities in all parts of
the water space, and (3) avoiding narrow water
passages that are apt to become close due to formation
of scale and thus disturb proper circulation. Exhaust
valves- need cooling only in large engines. With the use
of heat resisting steels or special cast iron for valve
heads, even large engines are built with uncooled
exhaust valves but then have water cooled valve cages
or valve seats.
z Trunk Pistons
Dissipate heat to the cylinder walls and to the

lubricating oil quite satisfactory and some engine
builders therefore dispense with special cooling with
pistons up to 22 in. in diameter. However, most engines
from 6 in up have oil cooled pistons.
Pistons of many small and medium sized diesel engines

at present are cooled by lubricating oil delivered in
comparatively large quantities through the rifle bored
connecting rods. In some engines the oil is admitted to
one side of an enclosed space under the piston crown
and discharged on the opposite side and allowed to flow
down into the oil sump. In other engines the oil is
discharged in the form of a jet from the top of the
connecting rod and impinges on cooling ribs on the
inside of the piston crown.
z Barrel Pistons
With the improved design of the water circulating

system some large engines now use water for piston
cooling. However, the majority uses oil. Piston rods in
cross head engines are cooled by water or oil that is
admitted through the cross head to the pistons.
There are two possible cooling mediums available for

engine either water or air-cooling. Air-cooling is
reserved for small engines which do not develop large
amounts of power. Only engines designed and properly
equipped for air cooling can be used as such they
generally incorporate ducting and finned flywheels to
promote a rapid flow of air around the hot spots of the
block. In areas of heavy water pollution, the simple air-
cooled engine has big advantage in turns of ease of
maintenance and lack of corrosion. The vast majority of
engines nowadays are water cooled using heat
exchanges or keel cooling. There can be two types of
cooling water circuits.
z Direct or Raw Water Cooling
The ultimate short term money saver is the direct

cooling system which takes raw water directly out of the
sea or river, circulates it around the engine block, and
finally discharges back to the source. There are,
however, many drawbacks to this system. It is not
possible to use a standard thermostat to allow the
engine to run at its correct temperature, of around 80 —
85 0c as this will eventually cause severe blockages to

the water passages from impurities building up on the
walls.
The usual recommended workship temperature for a

direct cooled engine is around 54 0c which causes some
sluding of the oil as it can never achieve its optimum
working temperature; the result of which is increased
engine wear. But the most important point is that
corrosion products from the hot raw water will
continually attack the engine internals as it is
impossible to add inhibitors to the water. The engine
cooling system
must also be drained during the winter months to
prevent damage from freezing as antifreeze cannot be
added.
Indirect or fresh water cooling : None of the above

mentioned problems occur with indirectly cooled
engines which have a separate freshwater supply within
the engine block in the manner for which the engine
was designed. This means that antifreeze and corrosion
inhibitors can be added to the freshwater supply
preventing the problems which beset the raw water
cooled engines. They can also use a standard
thermostat and run at their correct designed
temperature for maximum efficiency and long life. The
modest extra cost is therefore well worth considering.
Additional equipment required for indirect cooling
includes a heat exchanger (often combined with the
water cooled manifold ) and an engine oil cooler if
required.
z Circulation
Two methods of water circulation are in use gravity

circulation and forced circulation. Gravity circulation,
also called thermo siphon circulation, is based on the
fact that when water is heated its density decreases and
it tends to rise, the colder particles sinking to take the
place of the rising, warmer ones. Circulation is obtained
if the water is heated at one point and cooled at
another. Gravity circulation is used only in small
engines - seldom in those of more than 30 hp. Figure
4.5 Shows the gravity a circulation arrangement for a
small horizontal engine.
Water heated in the cylinder jacket flows to a tank

where it is cooled by radiation and convection, gradually
descends to the bottom and flows back to the engine. In
an automotive engine to obtain proper water circulation
the connections between the engine jacket and the
radiator must present small resistance to the water flow
and be wide, short and have as few bends as possible.
Even under favorable conditions circulation is slow,
especially when the temperature difference is small, as
at light loads. At heavy loads the jacket heat may
exceed the heat dissipated by the radiator and the
water in the jacket is apt to boil.
This system is used only is smaller engines where

simplicity is of importance. Most engines have forced
circulation by pumps, of either the centrifugal or the
plunger type. The advantage of the forced circulation is
the ease of controlling the jacket water temperature.
This may be accomplished either by regulating the
opening of the valve between the pump and the engine
or by regulating the water discharge valve of individual
cylinders.
Evaporative Cooling
If the water in the cylinder jacket is allowed to boil, 1 lb

of evaporated water will absorb heat equal to the latent
heat of vaporisation, or about 970 Btu. This is from 24
to 48 times more than the heat carried away by 1 lb of
circulating water with a temperature rise of 20 to 40 0F.
Neither pump nor radiator being required, this system
has the advantage of simplicity and is used for small
stationary and tractor engines. The water jacket is
made large at the top, forming a so called hopper. The
quantity of water in the hopper must be sufficient to run

the engine for several hours without the addition of
water. The evaporative system is not advisable if the
water contains impurities which form scale on the
cylinder walls.
The re cooling of water for continuous use can be

effected by one of the following means
1) direct evaporation;
2) heat exchangers with secondary water circulation;
3) radiators with atmospheric air as a coolant.
By the first method, called an open cooling system, the

water from the jacket is discharged either into a cooling
pond or to the top of a cooling tower and is cooled by
the latent heat of evaporation of the part carried away
by the air. The advantage of this system is its simplicity
and the small expenditure of power needed for
circulation of the water. Its big drawback is a gradual
contamination of the water by salts. As pure water
evaporates, leaving salts behind, and make-up water is
added, with salts of its own, the salt concentration
gradually increases. When it reaches a certain limit, all
water must be drained and fresh water added into the
system. However, even if this is done regularly, a
certain amount of sediment is deposited in the engine
jackets and forms scale, which eventually may cause
cracks, usually in the cylinder head. At the same time,
this system requires low jacket temperatures, with the
ensuing drawbacks mentioned before.
A closed system normally uses distilled or treated soft

water. However, raw water is also occasionally used
because the original small mineral content in the raw
water is not increased and therefore little scale is
deposited . The cooling water from the engine is passed
through a heat exchanger where it is cooled and then
led back to the jacket. The heat exchanger may be
either simply a coil in the basin of a cooling tower or a
shell and tube exchanger. In the latter the jacket water
passes through the tubes and the cooling medium
through the shell. In oil pipe line pumping stations, the
pumped oil is used as a coolant. A closed system
permits the use of any jacket temperature up to the
highest desirable; if the amount circulated is large
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z Cooling Water System - 2 (this site)
z
enough,
PIPINGthe temperature
CODES difference
& STANDARDS (this site)
between the incoming and outgoing water can be kept
low, 10 to 20 0F.
The drawbacks of the closed system are a slightly

greater power requirement for the two pumps and a
higher initial cost. However, the elimination of scale and
the advantages of higher jacket temperatures are so
important that the use of the closed system has become
almost universal.
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Cooling Water System 1

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PIPING GUIDE: Cooling Water System - 1 Page 1 of 18

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Thursday, January 14, 2010

Subscribe Once — through or open cooling water system.

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FACTOR & VISCOSITY

Piping Guide Zone

When the rotary speed of an engine increases, the

Tests have shown that the percentage of jacket loss is

stresses, the temperature difference between the incoming and

If an engine is cooled by untreated water, which always contains

The water is usually circulated through the lubricating oil cooler,

Where Q = the amount of heat rejected to the cooling

t1 = the temperature of the incoming cooling water,

t2 = the temperature of the outgoing water.

For average conditions, the heat flow to the water

amount of oil circulated and friction losses in the

Excessive water circulation resulting in low final water

A low cooling water temperature increases the viscosity

The dew point of the water vapour in the exhaust gases

Numerous tests conducted since 1937 and careful

1. It eliminates the condensation of the water vapour

(a) preventing, or at least reducing materially, the

eighth of the usual amount;

(b) eliminating crankcase condensation and sludging of

2. It lowers the viscosity of the cylinder lubricating oil;

3. It reduces the amount of water which must be

4. It increase the temperature difference between the

5. At a full load, the total fuel saving may reach 10

The use of higher jacket temperatures, up to 250 0F,

The use of ethylene glycol, or Prestone, which at atmospheric

The pistons of big double-acting engines are sometimes

Construction Features of Engine Parts

In some small and medium sized engines the water

The water space between the cylinder proper or liner

In a four stroke engine the heat carried away by the

In cylinder heads good cooling is obtained by (1)

Dissipate heat to the cylinder walls and to the

Pistons of many small and medium sized diesel engines

With the improved design of the water circulating

There are two possible cooling mediums available for

z Direct or Raw Water Cooling

The ultimate short term money saver is the direct

85 0c as this will eventually cause severe blockages to

The usual recommended workship temperature for a

Indirect or fresh water cooling : None of the above

Two methods of water circulation are in use gravity

Water heated in the cylinder jacket flows to a tank

This system is used only is smaller engines where

If the water in the cylinder jacket is allowed to boil, 1 lb

quantity of water in the hopper must be sufficient to run

The re cooling of water for continuous use can be

2) heat exchangers with secondary water circulation;

3) radiators with atmospheric air as a coolant.

By the first method, called an open cooling system, the

A closed system normally uses distilled or treated soft

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The drawbacks of the closed system are a slightly

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