Cooling Systems LEBW4978-08 PDF

APPLICATION AND INSTALLATION GUIDE
COOLING SYSTEMS
Contents
Cooling System Basics ............................................................... 2

Typical Cooling System.......................................................... 2
Heat Transfer ........................................................................ 2
Water Jacket .................................................................... 2
Aftercooler........................................................................ 3
Oil Cooler.......................................................................... 3
Basic System Configurations .................................................. 3
Separate Circuit Configuration ............................................ 3
Combined Circuit Configuration .......................................... 6
Air-to-Air Aftercooling........................................................ 7
Temperature Control ............................................................ 11
Inlet Controlled Cooling Systems ...................................... 12
Outlet Controlled Cooling System ..................................... 12
Selection of Inlet or Outlet Controlled Systems .................. 12
Pressure Control .................................................................. 13
System Pressure Control.................................................. 13
After Boil ........................................................................ 14
Expansion....................................................................... 14
Gas Engine Cooling System Configurations............................ 15
Standard Cooling System................................................. 15
Combined Heat and Power Cooling System (CHP) ............. 15
Low Energy Fuel Engine Cooling System ........................... 17
High Temperature Cooling System.................................... 17
Two-Stage Aftercooler Cooling Systems ........................... 18
Compressor Oil Coolers........................................................ 18
Special Cooling Systems ...................................................... 18
Cooling System Sizing .............................................................. 20
Cooling System Design Requirements ................................... 20
Heat Rejection................................................................. 20
Recoverable Heat ............................................................ 22
Heat Rejection Tolerances................................................ 22
Basic Operating Parameters.............................................. 22
Cooling System Sizing Procedure .......................................... 23
Coolant Calculation Constants.......................................... 24
Coolant Flow Calculation.................................................. 25
External Restriction and Pump Flows................................. 26
Types of Cooling Systems ........................................................ 30
Open System .................................................................. 30
Closed System................................................................ 30
Radiators............................................................................. 30
Radiator Performance Criteria ........................................... 31
Radiator Design Criteria and Considerations....................... 32
Radiator/Fan Performance ................................................ 34
Ambient Capability .......................................................... 35
Heat Exchangers.................................................................. 41
Shell and Tube Type........................................................ 41
Plate Type ...................................................................... 41
Design Criteria and Considerations.................................... 42
Heat Exchanger Sizing ..................................................... 43
Submerged Pipe Cooling....................................................... 44
Cooling Towers ................................................................... 45
Open Cooling Tower........................................................ 45
Closed Cooling Tower...................................................... 45
Cooling Tower Design Criteria .......................................... 47
Keel Coolers ........................................................................ 48
Jacket Water Aftercooled with Keel Cooler ...................... 48
Separate Circuit Aftercooled with Keel Coolers ................. 49
Separate Circuit Aftercooled with Keel Coolers
and Aftercooler Keel Cooler Bypass .................................. 50
Fabricated Keel Coolers.................................................... 51
Marine Gear Heat Rejection.............................................. 51
Design/Installation Considerations..................................... 54
Use of Keel Inserts to Improve Local Flow Velocity ............ 54
Direction of Flow through Keel Coolers.............................. 55
Bypass Filters.................................................................. 55
Strainers......................................................................... 56
Packaged Keel Coolers..................................................... 56
Location of Keel Coolers on the Hull.................................. 57
Pumps for Keel Cooler Circuits ......................................... 57
Venting and Piping of Keel Coolers ................................... 57
Corrosion Inhibitors.......................................................... 58
Box Coolers......................................................................... 58
Seawater Systems............................................................... 59
Jacket Water Aftercooled with Heat Exchanger ................ 59
Seawater Aftercooled ...................................................... 60
Separate Circuit Aftercooled with Heat Exchangers............ 61
Separate Circuit Aftercooled with Heat Exchangers
with Aftercooler Seawater Recirculation............................ 62
3600 Combined Circuit System........................................ 63
Sea Chest....................................................................... 65
Suction Line.................................................................... 65
Sea Valve ....................................................................... 65
Seawater Strainers .......................................................... 65
Priming........................................................................... 66
Seawater Pumps ............................................................. 66
Seawater Piping .............................................................. 67
Fresh Water Heat Exchangers........................................... 68
Marine Gear Oil Cooler..................................................... 68
Stern Tube Lubrication & Cooling ..................................... 69
Seawater Temperature .................................................... 69
Marine Growth................................................................ 69
Potential Problems........................................................... 69
Dissimilar Metal Combinations to Avoid............................. 70
The Protective Role of Zinc .............................................. 71
Contaminants.................................................................. 72
Electrochemical Series.......................................................... 73
Erosion ........................................................................... 73
Heat Recovery ......................................................................... 74
Heat Balance ....................................................................... 74
Heat Balance Calculation.................................................. 75
Standard Temperature Heat Recovery ................................... 76
Critical Design Criteria for Standard Temperature Heat
Recovery ........................................................................ 79
High Temperature Heat Recovery Circuits.............................. 79
High Temperature Solid Water System.............................. 79
High Temperature Water-Steam System ........................... 81
Water Quality and Treatment for Heat Recovery
Cooling Systems.................................................................. 82
Standard Cooling Systems ............................................... 82
High Temperature Cooling Systems .................................. 82
Make-up Water ............................................................... 83
Feed Water ..................................................................... 83
Engine Jacket Water........................................................ 83
Total Dissolved and Suspended Solids............................... 84
Measurement of TDS and Control..................................... 84
Cooling System Design Considerations ...................................... 87
Expansion Tanks.................................................................. 87
Full Flow and Partial (Remote) Flow Expansion Tanks......... 88
Maintaining Pump Suction Head with the Expansion Tank .. 88
Sizing Expansion Tanks.................................................... 93
Venting and Filling ........................................................... 93
System Pressures............................................................ 95
Auxiliary Expansion Tank ................................................. 96
Jacket Water Circuit Auxiliary Expansion Tank................... 96
Aftercooler Circuit Auxiliary Expansion Tank...................... 98
Sizing the Volume of Auxiliary Expansion Tanks ................ 98
Installation of Auxiliary Expansion Tank............................. 98
Pressurization of Systems Containing Auxiliary
Expansion Tanks - Afterboil.............................................. 98
Bladder Type Expansion Tanks ......................................... 98
Deaeration ...................................................................... 99
Low Velocity................................................................... 99
Hotwell............................................................................... 99
Interconnection of Engines.................................................. 101
Piping Supports ................................................................. 101
Jacket Water Heaters......................................................... 102
Preparations for Initial Startup............................................. 103
Serviceability and Isolation Valves....................................... 104
System Monitoring ........................................................ 104
Customer Connections................................................... 104
Mechanical Vent Valves................................................. 104
Watermakers, Domestic Water Heaters, Cabin Heaters......... 105
Watermaker Controls..................................................... 106
Interconnecting Engines ................................................. 109
When the Watermaker is Far from the Engine.................. 109
Cooling System Protective Devices................................. 109
Coolant Level Switches.................................................. 109
High Water Temperature Switches ................................. 109
Emergency Systems ...................................................... 109
Jacket Water Pump Connections.................................... 110
Auxiliary Seawater Pump ............................................... 111
Auxiliary Freshwater Pump Connections.......................... 111
Central Cooling Systems .................................................... 112
Advantages of a Central Cooling System......................... 112
Disadvantages of a Central Cooling System..................... 112
Suggestions for Design of a Successful Central Cooling
System......................................................................... 112
Cold Weather Considerations ......................................... 114
Extreme Cold Weather Considerations............................. 114
Coolant Considerations........................................................... 117
Coolant Function ............................................................... 117
Coolant Properties ............................................................. 117
Water........................................................................... 117
Supplemental Coolant Additives ..................................... 118
Glycol........................................................................... 118
Coolant Recommendations ................................................. 118
Coolant Testing............................................................. 118
SOSSM Coolant Analysis.............................................. 118
Boiler Type Coolants...................................................... 119
Reference Material ................................................................. 120
Media List ......................................................................... 120
Jacket Water Cooling Circuit Worksheet.............................. 122
Auxiliary Cooling Circuit Design Worksheet.......................... 125
Heat Exchanger Sizing Worksheet....................................... 128
Heat Exchanger Sizing Worksheet....................................... 128
Keel Cooler Sizing Worksheet ............................................. 129
Packaged Keel Cooler Sizing Worksheet .............................. 130
Auxiliary Expansion Tank Sizing .......................................... 131
Foreword
This section of the Application and Installation Guide generally describes Cooling
Systems for Cat engines listed on the cover of this section. Additional engine
systems, components and dynamics are addressed in other sections of this
Application and Installation Guide.
Engine-specific information and data is available from a variety of sources. Refer to
the Introduction section of this guide for additional references.
Systems and components described in this guide may not be available or applicable
for every engine.
Information contained in this publication may be considered confidential. Discretion is

recommended when distributing. Materials and specifications are subject to change
without notice.
CAT, CATERPILLAR, their respective logos, Caterpillar Yellow the Power Edge
trade dress as well as corporate and product identity used herein, are trademarks of
Caterpillar and may not be used without permission.
Cooling Systems Application and Installation Guide
Cooling Systems
All internal combustion engines produce heat as a byproduct of combustion and
friction. This heat can reach temperatures up to 1925C (3500F) and can have
catastrophic affects on engine components. Pistons, valves and cylinder heads
must be cooled to reduce the risk of detonation. Cylinder temperatures need to be
controlled so lubricating oil can maintain a protective film on the cylinder surfaces
and the lubricating oil should be cooled to ensure its integrity.
In addition to overheating, overcooling can have negative effects on the engine.
Overcooling can reduce engine performance and shorten the engines service life.
Cooling systems are used to manage engine heat. Cooling systems must be properly
designed, operated and maintained for proper engine operation and service life. This
guide describes and explains methods of managing engine heat for various engine
applications.
SECTION CONTENTS
Cooling System Basics .............. 2 Heat Recovery........................ 74
Typical Cooling System Heat Balance
Heat Transfer Standard Heat Recovery
System Configuration High Temperature Circuits
Temperature Control Water Quality & Treatment
Pressure Control Systems
Gas Engine Configurations Cooling System Design
Special Cooling Systems Considerations........................ 87
Cooling System Sizing............. 20 Expansion Tanks
Design Requirements Central Cooling Systems
Design Procedure Hotwell
Flow Calculations Coolant Considerations ......... 117
Types of Cooling Systems ....... 30 Function, Properties, and
Radiator Recommendations
Heat Exchanger Reference Material................ 120
Submerged Pipe Media List
Cooling Tower Heat Exchanger, Keel Cooler &
Keel & Box Coolers Auxiliary Expansion Tank Sizing
Worksheets
Seawater Systems
Jacket Water Circuit & Auxiliary
Electrochemical Series
Circuit Design Worksheets
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All rights reserved. Page 1
Application and Installation Guide Cooling Systems
Cooling System Basics

Typical Cooling System When the engine is cold, the
Figure 1 shows the basic components temperature regulators bypass the
of a common engine cooling system. radiator and direct the coolant back
The basic components are the coolant, to the water pump. As the temperature
water pump, engine oil cooler, coolant of the bypass coolant flow becomes
temperature regulators, radiator fan and warmer, the temperature regulators
the radiator. In many instances, heat begin to open and permit some of
exchangers and other similar devices the coolant to flow to the radiator.
are used instead of radiators. For this The regulator opens to maintain the
discussion, radiator will be used to correct engine temperature. The amount
describe all such devices. that the regulator opens and the percent
of coolant flow to the radiator depends
Typical Cooling System on the load on the engine, and the
outside air temperature.
The fan pushes or pulls air through
the radiator and around the tubes that
extend from the top to the bottom of
the radiator. When the hot coolant goes
through the tubes in the radiator, the
flow of air around the tubes lowers the
temperature of the coolant. The coolant
then flows back through the water
pump.
Coolant expands as it is heated.
Figure 1 Expansion tanks are used on some
applications to contain the increased
In operation, the water pump pushes volume.
coolant through the engine oil cooler
and into the cylinder block. The coolant Heat Transfer
then flows through the cylinder block There are three common components
and into the cylinder head(s) where it used to transfer heat from the engine.
flows to the hot areas of the cylinder Jacket Water
head(s). Additional components that Oil Cooler
will transfer heat to the coolant are
Aftercooler
aftercoolers, water-cooled exhaust
The components are used in various
manifolds, water-cooled turbochargers,
combinations and have specific design
water-cooled shields and oil coolers.
criteria that must be met to ensure
After flowing through the cylinder
proper cooling of the engine.
head(s), the coolant goes into the
coolant temperature regulator housing. Water Jacket
The water jacket in an internal
combustion engine is a series of cavities
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Page 2 All rights reserved.
and passages that carry coolant cool internal engine parts, which cannot
throughout the engine. Heat is be directly cooled by the water jacket
transferred from the engine to the coolant. Heat is transferred to the
coolant and carried away to a radiator lubricating oil as it passes around engine
or similar device where the heat can components such as bearings and
be dissipated. pistons. Oil cooler is used to dissipate
The jacket water, or coolant, also heat from the oil to maintain optimum
flows through the cylinder head to temperatures for proper lubrication.
remove more heat. In gas engines, Coolant is circulated through the oil
the combustion chamber and spark cooler to absorb the heat from the
plug bosses are cooled by jacket water lubricating oil.
flowing through the cylinder head. Note: If excessive oil temperatures are
Carefully sized passages in the cylinder permitted during operation, oil life will
head aid in regulating water flow and be shortened and engine damage
help to maintain uniform temperature can occur.
throughout the block.
Depending on the basic system
Water jacket coolant is often circulated configuration, the oil cooler may be
through aftercoolers and oil coolers to part of the jacket water circuit or the
collect heat and carry it away from aftercooler circuit.
the engine.
Aftercooler
Basic System Configurations
Cat engines offer different cooling
Intake air temperature increases when
system configurations and options to
compressed by the turbocharger. On a
fulfill the specific requirements of any
diesel engine, an aftercooler is used to
application.
reduce the air temperature for better
combustion. In a gas engine, the Three basic cooling system
reduced air temperature increases configurations are used.
power density and detonation margin. Separate Circuit
Coolant is circulated through the Combined Circuit (also
aftercooler to absorb the heat from known as single circuit)
the compressed intake air. Air-to-Air Aftercooling
Aftercooler fouling is a threat to All three of the configurations are
optimum aftercooler performance. If designed to supply regulated nominal
dirt or oil accumulates in the aftercooler jacket water temperature to the block
core, heat transfer to the coolant is and regulated oil to the bearings.
reduced and the air temperature will Separate Circuit Configuration
rise. This can raise piston temperature The separate circuit cooling system
and lower engine horsepower. configuration, also called the standard
Oil Cooler cooling system for gas engines, cools
The lubrication system of a modern the engine jacket on one circuit and the
engine does more than reduce friction aftercooler on another circuit. The oil
between moving parts; it is also used to cooler is part of the aftercooler circuit
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on 3600/G3600 engines, and part of temperature circuit, must be

the jacket water circuit on 3500/G3500 cooled to nominal jacket water
and smaller engines. temperature and the other half,
The separate circuit system is used on the low temperature circuit, must
all gas engines and is recommended for be cooled to nominal aftercooler
high ambient temperature diesel engine water temperature.
installations to reduce the external The jacket water circuit and the
cooling package size. aftercooler circuit both require a
Note: All pressure and temperature minimum expansion volume to contain
values in this publication are gauge the increased volume. This is typically
values unless otherwise specified. provided by separate expansion tanks;
however, some applications may allow
Advantages of the separate circuit
the use of a single expansion tank
include:
for the jacket water circuit that is
The total radiator surface area may connected via shunt and vent lines
be 20% less at 45C (110F) to the aftercooler circuit. Refer to the
ambient and up to 30% less at section on Expansion Tanks for
higher ambient temperatures, different types of expansion tanks,
when compared to a combined sizing guidelines and information about
circuit. factory provided expansion tanks. Vent
Nominal water temperature to the lines are required on both circuits to
aftercooler is maintained while return to the expansion tank and
rejecting heat from the cylinder eliminate air traps in the circuit. Refer
block and heads at higher to the section on Venting and Filling
temperatures. for recommended vent line sizes and
The total external flow is venting locations. Refer to Figure 2
approximately twice the external and Figure 3 for typical separate
flow of the single circuit system. circuit schematics.
Half of the flow, the high
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Separate Circuit Cooling System - Inlet Controlled

(with full flow expansion tanks)
Turbo Jacket Water
Heat Exchanger
Raw Water
Out
Engine Jacket B
A C
Temperature Raw Water

Jacket Water Full Flow Regulator In
Pump Expansion Tank
Raw Water
Out
Oil Cooler
Mixer
Box
Aftercooler
B Raw Water
A C In
Temperature AC-OC Circuit

AC-OC Pump Full Flow Regulator Heat Exchanger
Expansion Tank
Figure 2
Separate Circuit Cooling System - Outlet Controlled

Turbo Temperature
Regulator
A C
Engine Jacket B
Jacket Water Full Flow

Pump Expansion Tank Jacket Water
Temperature Radiator
Regulator
Oil Cooler
A C
Mixer B
Box
Aftercooler
AC-OC Circuit
AC-OC Pump Full Flow Radiator
Expansion Tank
Figure 3
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Combined Circuit Configuration a portion of the high temperature outlet

The combined circuit configuration is water to maintain nominal jacket water
often referred to as the single circuit temperature to the cylinder block. The
two pump system. It is typically used block is a closed circuit contained on
for diesel engine applications where the engine; therefore, only the water
a single radiator or heat exchanger returning to the aftercooler pump
is applied. requires a cooling source. This results
The aftercooler circuit is externally in a relatively simple coolant piping
regulated to nominal temperature (fluid installation. Refer to Figure 4 and
inlet temperature control). The system Figure 5 for typical combined
uses the aftercooler outlet water to cool circuit schematics.
Combined Circuit Cooling System - Inlet Controlled

Turbo
Engine Jacket B
A C
Temperature
Jacket Water Regulator
Pump
Raw Water
Out
Oil Cooler
Mixer
Box
Aftercooler
B Raw Water
A C In
Temperature Heat Exchanger

AC-OC Pump Full Flow Regulator
Expansion Tank
Figure 4
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Combined Circuit Cooling System - Outlet Controlled

Turbo Temperature
Regulator
A C
Engine Jacket B
Jacket Water
Pump Temperature
Regulator
Oil Cooler
A C
Mixer B
Box
Aftercooler
Radiator
Temperature
AC-OC Pump Full Flow Regulator
Expansion Tank
Figure 5
Air-to-Air Aftercooling radiator is an air-to-air heat exchanger,

Air-to-Air Aftercooled (ATAAC) systems known as a charge air cooler (CAC).
can be applied to some turbocharged The CAC is used for the aftercooler
and aftercooled engines in order to circuit. The heated charge air from the
improve fuel consumption, reduce turbocharger is ducted to the CAC,
emissions to meet government which is positioned in series or in parallel
regulations and in some cases permit with the conventional engine radiator.
increased horsepower. The success of The engine fan moves cooling air
this cooling system configuration is through the CAC and reduces the
dependent on the reduction of engine charge air temperature. The air is then
intake air manifold temperature. The ducted to the engine intake manifold.
intake manifold temperature (IMT) Air ducting or piping must be fabricated
affects the pressure and temperature in to direct air from the turbocharger to the
the cylinder and hence the combustion CAC and return it to the engine.
efficiency. For this effect, the IMT is The ATAAC design must be able
monitored by the ECM and makes to meet the IMT requirements of the
adjustments to injection to maximize engine. In some cases, depending on
performance and meet emission customer selectable parameters and
requirements. engine model, electronic engines may
This configuration uses a dual-core derate at elevated inlet manifold
radiator and fan. One section of this temperatures. Refer to product specific
2011 Caterpillar
documentation for further information. the turbochargers to turn in reverse

IMTs that are excessively cold also while the engine is not running and
affects the combustion of the engine. It could harm the turbo bearings. In these
may be required in arctic type conditions types of applications it is recommended
to minimize fan speed by utilizing a to have oil accumulators on the
variable speed fan or to allow bypass turbochargers to provide oil to the
of the charged air cooler to prevent bearings in these conditions.
overcooling of the charged air. A Design of the aftercooler core and
thermostat control should be used when related piping are critical to prevent
the flow is diverted so that the flow can corrosion of the core, water entry into
be diverted back to the cooler when the the engine and excessive pressure drop
charge air needs cooling. Normally the of the intake air across the aftercooler
thermostat setting is around 30C circuit. A schematic for a typical
(90F). As is the case with the SCAC ATAAC system is shown in Figure 6.
systems, the ATAAC system may
For engine only sales in which the
require the combustion air to be heated
customer will design/build his own
in extreme artic conditions. Most diesel
ATAAC system for use with the
engines need to have IMT of +10C
Cat engine:
(50F) before they will start easily. This
varies greatly depending on engine The customer designed ATAAC system
compression ratio and design. Low load should be designed to (1) accept the
operation in cold ambient temperatures particular engines boost level and (2) the
will cause engine slobbering on diesel resulting forces acting on the customer
engines and incomplete combustion if designed piping system due to included
the IMT is less than +10C (50F). bends or pipe size decreases. The forces
For additional information, see Form acting on the ATAAC system due to
SEBU5338-01 Cold Weather Operation the engines rated boost levels can be
and Extreme Cold Weather extreme. If the customer designed
Considerations section in this guide. piping is not properly restrained and
supported, movement relative to
Another parameter that needs to be
the engine could occur causing a
considered to properly apply an ATAAC
displacement of the hose connecting
is the pressure drop between the turbo
the engine to the customer ATAAC
and the manifold. This maximum drop
piping. No customer designed piping
includes not only the ATAAC core, but
or portion of the customer designed
also the piping associated with it. The
ATAAC system can be supported by
maximum pressure drop for a given
the engine, engine piping, or engine
engine is available in TMI.
brackets. (Refer to LEXH6521)
For ATAAC engines with air shutoffs
On G3400 low emission engines, a
and large charge air coolers, it is
temperature control valve is required
possible that if the air shutoffs are
to maintain a constant air temperature
active while running near full load
of 43C (110F) to the engine. The
(emergency shutdown) that the
control valve modulates to bypass air
charged air in the system can cause
around the aftercooler core. Some of
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the air flows directly from the ATAAC Critical Design Criteria
turbocharger into the carburetor. The piping and heat exchanger core
On engines without a postlube system, must be sized so the total pressure
both diesel and gas, a gas (CO2)-over-oil drop from the compressor outlet to
accumulator is available and the inlet manifold meets TMI specs.
recommended to provide oil pressure to (For Petroleum products refer to TMI
the turbocharger bearings after engine systems data. (Refer to LEXH6521)
shutdown. This is required because the Install 1/4 in pipe-threaded test fittings
pressurized air trapped in the aftercooler in the piping at the compressor outlets
after shutdown will flow out through and carburetor inlet, so both the
the turbocharger and cause it to spin. pressure and temperature at these
Since the engine is shutdown, there is points can be monitored. Measurements
no engine supplied oil pressure to the at these points are required to determine
turbocharger bearings. The accumulator if the installation meets the design
provides a reserve of pressurized oil requirements.
directed to the turbocharger for
lubrication.
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Typical Air-to-Air Aftercooling System for Gas Engine
Figure 6
1. Actuator with Valve Positioner 4. Turbocharger

2. Air Cleaner 5. Cooling Unit
3. Carburetor
2011 Caterpillar
Because large amounts of water can be break loose, pass into the engine
condensed from the air, the aftercooler and cause serious engine damage.
core must be made from a corrosion Caution: The ATAAC engine
resistant material such as brass (not to configuration cannot be used with
be used with gas containing H2S), low gas pressure arrangements. This
aluminum, or stainless steel. The piping combination creates a rather large
to and from the aftercooler core must volume of combustible air and gas
also be a corrosion resistant material, mixture that flows through the
possibly aluminized steel or aluminum. aftercooler core. If this mixture is
Provisions to remove the condensed ignited, damage may result to the
water from the aftercooler core and aftercooler core.
piping must be included in the design.
With humid air and ambient Temperature Control
temperatures above freezing, a The function of the temperature
significant amount of water will be regulator is to control minimum
condensed in the aftercooler core. This operating temperatures of the engine
water can be easily drained if the intake cooling system. All cooling systems
air enters the bottom of the core on one must have a method of maintaining
side and exits high on the opposite side. minimum operating temperature. If
A valve to automatically drain the minimum-operating temperature is
condensed water should be plumbed not maintained, severe maintenance
into the bottom side of the core, problems may result.
opposite the entrance of the intake air. Factory supplied temperature regulators
The drain valve should not be allowed are provided with most applications for
to freeze in cold temperatures. Cat engines. The regulators may be
Install a condensate trap in the intake assembled with the factory packaged
piping close to the engine intake cooling system or shipped loose to be
manifold. Condensate traps are connected with the customers cooling
designed to quickly change airflow system.
direction, usually by a minimum of The factory supplied temperature
180, and throw the heavier water regulator is only capable of controlling
droplets onto a wall of the trap. The the minimum temperature of the cooling
collected water then drains through a circuit. It cannot control the maximum
float valve. The condensate trap must temperature of the cooling circuit.
be sized and designed so that its Maximum temperature must be
pressure drop is not excessive; the total controlled by the correct sizing of
system resistance from the turbocharger the radiator, heat exchanger or
outlet to the inlet manifold cannot be similar device.
more than 38 mm Hg (1.5 in Hg). There are two basic methods of
Caution: After fabrication, the piping thermostatic control of minimum
and cooler core must be cleaned operating temperature in cooling
thoroughly of weld slag, debris or systems; inlet controlled and outlet
anything left in the piping that could controlled.
2011 Caterpillar
Inlet Controlled Cooling Systems (CHP) systems will be inlet controlled

Inlet controlled cooling systems provide for both heat exchanger and radiator
a constant temperature to the inlet of applications.
the jacket water circuit, aftercooler, To understand which control method is
and/or oil cooler. An example is shown the better choice for the system under
in Figure 2. This design is used to consideration, the following items
minimize overcooling when very cold should be considered.
or thermally large cooling sources are
A shunt line is required on inlet
involved. The sensing bulb of the
controlled systems that do not
thermostat is placed in the inlet flow
use a full flow expansion tank.
to the expansion tank. The thermostat
This is to prevent the possibility
then balances the hot water directly
of pump cavitation by providing a
from the engine with cool water from
positive head on the suction side
a heat exchanging device such as a
of the pump. Outlet controlled
radiator or heat exchanger.
systems generally do not have
Outlet Controlled Cooling System this requirement as full head
Outlet controlled cooling systems pressure is not restricted by the
provide a constant outlet temperature temperature regulator and a shunt
from the engine by regulating the flow line is not required.
between the bypass and cooling Full engine outlet pressure is
circuits. This is illustrated in Figure 3. present at all times on the heat
Usually applied with radiator-cooled exchanging device for the inlet
systems, the sensing bulb of the controlled system. This can be a
thermostat is placed in the outlet concern with a radiator, since the
flow from the engine. If the outlet outlet pressures are in the same
temperature becomes too high, more range as the structural capability
water is allowed to flow to the cooling of some solder tube radiators.
system. If the water is too cool, the Outlet controlled systems tend to
water is directed through the bypass isolate the cooler from the
and is recirculated to the engine without pressure during bypass operation.
being cooled. Unless specified Nuisance high temperature
otherwise, all Cat radiator cooled shutdowns can be experienced
systems use an outlet regulated cooling with an inlet controlled system
system. if the system flow is inadequate.
Selection of Inlet or Outlet This is true even if there is
Controlled Systems adequate cooling capacity in
There are certain applications that are the system. The inlet controlled
better suited for either inlet controlled system provides a fixed
or outlet controlled systems. In general, temperature coolant to the engine
inlet controlled systems work well with independent of the amount of
heat exchangers and outlet controlled flow. If the flow is low, the
systems work best with radiators. temperature rise across the engine
However, Combined Heat and Power will be high. If the temperature rise
2011 Caterpillar
is higher than the maximum Full open flow is the term used when
allowable outlet temperature, the the coolant has reached the full open
engine monitoring system will temperature of the regulator and coolant
shut the engine down. An outlet- flow is directed to the radiator or heat
controlled system would not have exchanger instead of bypassing to the
this problem since it will reduce engine. The engine monitoring system
the bypass flow and increase provides warnings and shutdown for
cooler flow. The temperature rise high water temperature on cooling
across the engine may be higher systems.
than desired for a short period until The selection of expansion tanks for
the system stabilizes but the inlet and outlet controlled systems is
engine will continue to operate. discussed and illustrated in the section
Thermal shock is caused when the on Expansion Tanks.
temperature regulator tries to open
and close to maintain temperature Pressure Control
on an outlet control system. System Pressure Control
Thermal shock of the engine is a The cooling system and its components
potential problem with an outlet must meet both maximum and
controlled system because the minimum pressure design limits. The
coolant must pass through the minimum pressure at any location in the
engine before the temperature cooling system shall not fall below the
regulator detects the coolant vapor pressure of the coolant to prevent
temperature. If cool return boiling. However, Pressure in the
temperature of coolant is possible, system shall not fall below the pressure
the inlet controlled system will that would cause a non-rigid component
prevent the thermal shock to the to collapse. A minimum pressure/head is
engine components. An outlet also required at the pump inlet to avoid
controlled system with a full flow cavitation, minimizing metal erosion and
expansion tank will also prevent noise. Similarly, the pressure at any
this problem. point in the cooling system shall not
The deficiencies of both inlet and outlet exceed the maximum pressure for the
controlled systems can be overcome local components, I.e. a radiator.
with proper system design; specifically,
The purpose of an engine cooling
a full flow expansion tank. Engine side
system is to maintain an appropriate
system pressures are usually the highest
coolant operating temperature for the
at full bypass. System pressures are
engine over a wide range of operating
lowest when nearly equal flow is in
and ambient conditions without failure
bypass and the cooler flow. System
in its lifespan. Overheating of the engine
pressures at full open flow are near
occurs when coolant boils and increases
maximum and should match external
the risk of permanent engine damage.
resistance targets. The external pressure
While the engine is running, heat is
drops of both systems are identical at
transferred from the engine to the
full open flow condition.
coolant by means of forced convection
2011 Caterpillar
and occasionally by means of nucleate Tables: 110C steam forms at 20.47

boiling at very high heat fluxes where PSIA. 20.47 + 7 = 27.47 - 14.7 =
discrete vapor bubbles form on the wall 12.77 PSIG. Therefore, a 15 PSI cap is
and detach. When the local heat flux is used. By using a 15 PSI cap: 15 PSI +
above the critical heat flux, nucleate 14.7 PSI = 29.7 PSI - 20.47 PSI =
boiling becomes film boiling, in which a 9.33 PSI boiling safety margin.
blanket of vapor over the metal surface Glycol based coolant with a boiling point
interferes with heat transfer and causes higher than water can also mitigate
damage on interior surfaces. some after boil.
After Boil The selection of a pressure cap rating
After boil can occur after an engine hot should not only take into account the
shut-down, when coolant flow ceases, expected max temperature of the
local hot spots begin boiling, and cooling system, but also recognize the
without adequate pressure control affect of altitude on boiling point.
steam is created. Use of a pressure cap Increased pressure is needed to maintain
with an integral relief or a separate relief boiling point safety margin at higher
valve is necessary to increase the boiling altitudes. (See Figure 51) Therefore,
point. For a standard system with jacket extra cap rating margin should be added
water outlet temperature up to 99C the to compensate for the engine installation
relief pressure is set above atmospheric altitude.
(typically 4 to 7 psi gauge), allowing the Cooling system component pressures
cooling system to pressurize thus raising such as the radiator must be limited to
the boiling point. This also helps the maximum pressure specified by the
mitigate pump cavitation problems radiator manufacturer. If internal
which can lead to reduced flow in the pressures exceed the specified limit, the
cooling system. The relief valve protects oval tubes can balloon causing distortion
components from a catastrophic failure of the fins, and reduced heat transfer
by releasing pressure. The typical 4 to performance. Pressures inside a
7 psi gauge pressure cap rating is component can be decreased by
recommended for engines with increasing hydraulic resistance upstream
maximum jacket water outlet of the component, or by decreasing
temperature of 99C. hydraulic resistance downstream of the
For Low Energy Fuel Engine Cooling component, or by decreasing pump
System engines operating with landfill output pressure. Therefore mounting the
gas and High Temperature Cooling thermostat upstream of the radiator
System / Solid Water System, in which (outlet controlled) can reduce pressures
elevated jacket water outlet inside the radiator, because the
temperatures 110-127C (230-260F) thermostat is often the most significant
are used, typically 15-21 psi gauge single source of resistance in the
pressure is needed. For Example: Low system.
Energy Fuel Engine Cooling System
Expansion
engines with max operating water
As mentioned in the Temperature
temperature of 110C. From the Steam
Control section, the expansion tank can
2011 Caterpillar
be utilized to mitigate various impacts Inlet controlled systems must be

from different cooling system selection, maintained within 4C (9F) of
such as outlet vs. inlet temperature rated SCAC temperature within any
control, pump cavitation avoidance, and given 5 minute time span. It is important
coolant pressurization, aeration, filling that temperature changes do not occur
and after boil relief. External mechanical more quickly than approximately 1C
only vent valves that must be manually per second. Fluctuations in the SCAC
opened are not acceptable for the inlet water temperature will adversely
continuous venting requirement. Extra affect engine performance and
expansion volume may be required for emissions.
cooling systems with higher than 99 G3300 & G3400
degree C operating temperatures to
All Cat G3300 & G3400 engines are
provide larger after-boil relief margin. equipped with the oil cooler and jacket
See the sections on Expansion Tanks water connected in series. If the engine
and Venting for details.
is aftercooled, it is equipped with a
Gas Engine Cooling System SCAC and pump; however, the
thermostat must be supplied by
Configurations
the customer.
Standard Cooling System
Combined Heat and Power Cooling
G3600 System (CHP)
The standard G3600 cooling system
G3600
utilizes the separate circuit cooling
In applications where the heat energy
system configuration, cooling the engine
from various engine components is used
jacket on one circuit and aftercooler and
to provide hot water for domestic and
oil cooler on the other. The aftercooler
industrial end users, the aftercooler, oil
and oil cooler are connected in parallel.
cooler and engine jacket are all cooled
This system is available with the option
with the same water source. Typically,
of an inlet controlled system or outlet
the water in these applications is from
controlled system.
the local utility. This water is known
G3500 as district water and is untreated.
All Cat G3500 Engines come standard The engine block should be cooled by
with the oil cooler and jacket water treated water only, so for these CHP
combined. If the engine is turbocharged, applications, the jacket water circuit
it utilizes a separate circuit aftercooler is designed as a closed circuit to control
(SCAC) pump and thermostat to the quality of the coolant used in the
maintain the incoming water at the engine jacket.
required minimum temperature. The jacket water circuit is inlet
G3500B, G3500C, and G3500E series controlled with factory mounted
engines utilize a two-stage aftercooler temperature regulators, an engine
in order to improve engine performance mounted pump, expansion tank
and reduce emissions. and heat exchanger. The district water
recovers the jacket water heat load
2011 Caterpillar
from the heat exchanger. The external be combined with jacket water for
system relies on district water pressure greater heat recovery.
to flow water through the circuit. With high temperature cooling, the oil
The aftercooler and oil cooler can cooler is separate from the jacket water
tolerate higher amounts of contaminants circuit. The aftercooler circuit and the
than the jacket water circuit, permitting oil cooler circuit can be ordered either
district water to be used to cool them combined or separate. In the combined
directly. system (2-circuit), the auxiliary pump
The aftercooler/oil cooler circuit requires circulates water in series through the
a customer provided booster pump and aftercooler and the oil cooler. This
does not require a temperature system is most often used when the
regulator. The automatic derating oil cooler heat cannot be effectively
system on the engine starts to derate recovered. If the oil cooler heat is
the engine when the aftercooler water recoverable, separate aftercooler and
inlet temperature exceeds the maximum oil cooler circuits (3-circuit) are available.
temperature limit. With a 3-circuit system, an auxiliary
This type of open system requires that pump supplies the aftercooler circuit
permanent strainers must be installed while a new pump supplies the oil
to prevent debris from clogging water cooler. This new pump is mounted in
passages in the aftercooler an oil the location normally used by the
cooler circuits. jacket water pump. In both cases, the
For additional design guidelines to be minimum oil temperature is controlled
followed for the CHP cooling system, by a thermostat in contact with the oil.
refer to the section on Design Criteria There are no engine mounted jacket
for Standard Temperature Systems in water thermostats. They are to be
the section on Heat Recovery. supplied by the customer. In sizing the
thermostats, jacket water pump, and
G3500 heat recovery/rejection equipment for
The ability to produce steam or high cogeneration systems, there are several
temperature water is a necessity for considerations to keep in mind.
some co-generation installations. See
the Heat Recovery Section for more The jacket water outlet
discussion. Attachment groups allow temperature must be maintained
the G3500 engines to perform either within preset limits.
task. With these attachments, the When sizing the pump, the
engines have a higher maximum jacket water flow should be kept
outlet temperature for the jacket between the maximum and
water. A customer supplied water minimum as indicated on the
pump maintains the appropriate water block resistance curves found
flow. The water leaving the engine in the technical information
can be flashed to steam in an external and performance books.
boiler or used in the liquid phase.
Heat recovery from the exhaust can
2011 Caterpillar
If the system results in a combined through the factory by way of a Design-

static and dynamic head above the to Order (DTO) process.
engines capabilities, then a heat High Temperature Cooling System
exchanger must be used to isolate The ability to produce low pressure
the engine from the systems high steam or high temperature water is
static and dynamic heads. a necessity for some cogeneration
Low Energy Fuel Engine Cooling applications. The High Temperature
System Cooling System is designed to provide
Engines operating with landfill gas, a higher outlet temperature on the
digester gas or any other low energy jacket water circuit. The aftercooler/oil
fuel or corrosive gas need to maintain cooler system is similar to that of the
higher cooling circuit operating Standard Cooling System can be inlet
temperatures for long engine and oil life. controlled or outlet controlled.
This helps to prevent condensation of A customer-supplied pump and
acids formed during combustion in the temperature regulating system is
oil. On the Low Energy Fuel Engine required to maintain flow through
cooling system, the jacket water circuit the jacket water circuit and the water
and the aftercooler-oil cooler circuit are leaving the engine can be flashed to
both outlet controlled with factory steam in an external boiler or used in the
supplied temperature regulators. Engine liquid phase. Steam formation inside the
mounted pumps supply water for both engine jacket is not allowed at any time
the jacket water circuit and the and the control system will shut the
aftercooler-oil cooler circuit. engine down if there is any drop in
The expansion volume for both jacket coolant pressure which leads to steam
water and the aftercooler-oil cooler formation. The operating pressure in the
circuit should be provided and is system should be maintained above the
typically provided in the radiator tanks. minimum specification to prevent water
This cooling system must be pressurized from vaporizing to steam inside the
to prevent steam formation at this high engine which causes serious damage
operating temperatures and appropriate to engine components. (See Pressure
expansion tank cap or radiator cap Control) If the system results in a
should be used to maintain system combined static and dynamic head
pressure. (See Pressure Control) above the engines capabilities, then a
heat exchanger must be used to isolate
Note: The low energy fuel engine
the engine from the systems high static
arrangements can be ordered with high
and dynamic heads. In sizing the jacket
temperature cooling for heat recovery
water pump, heat exchangers and other
by way of a Design-to Order (DTO)
cogeneration equipment, adhere to
process.
limits specified in the Technical
Note: The preceding text has described Information Appendix. The design
standard product. If an application guidelines for the high temperature
requires special features or a unique cooling system are given in the Heat
cooling system configuration, order Recovery section. This section also
2011 Caterpillar
discusses several other recommended Special Cooling Systems

configurations for heat recovery circuits. The systems discussed so far are
Two-Stage Aftercooler Cooling the various production configurations
Systems offered. If an application requires
The two-stage aftercooler, currently special features or a unique cooling
offered for some gas engines, is system configuration, order through
intended to provide high temperature Caterpillar using the Design-to-Order
heat recovery for Electric Power (DTO) process.
Generation (EPG) applications and
reduce overall radiator sizing for Gas
Compression applications. There are
two coolant stages on the two-stage
aftercooler; the first stage uses high
temperature coolant to cool the charge
air to an intermediate temperature and
the second stage cools the air down to
engine rating requirements. The two-
stage aftercooler can allow much higher
coolant inlet pressure to both stages
than the single stage aftercooler.
There are various cooling systems
available for use with the two-stage
aftercooler. These are offered in the Gas
Engine Price List. Contact Caterpillar for
more details on these cooling systems.
Compressor Oil Coolers

A compressor oil cooler (or other
external heat load) should be connected
into the aftercooler circuit after the
water has left the aftercooler. The
return line back into the circuit should
be placed before the thermostat.
The additional heat load into to the
aftercooler circuit needs to be included
when sizing the radiator. The flow to
the aftercooler is critical in gas engines.
If the inlet manifold air is not properly
cooled by the aftercooler, there is a
higher risk of detonation. See Figure 7
for a typical G3600 system configure-
ation and Figure 8 for a typical G3500
or smaller system configuration.
2011 Caterpillar
G3600 Separate Circuit Cooling System

with External Heat Load
Bypass Line (if needed)

Mixer Temperature
Box Regulator
Compressor Oil
Engine Oil Cooler
Cooler
Aftercooler
AC-DC
Circuit
Radiator
AC-DC
Pump
Figure 7
G3500 and Smaller Separate Circuit Cooling System

with External Heat Load
Bypass Line (if needed)

Temperature
Regulator
Compressor
Aftercooler
Oil Cooler
AC-DC
Circuit
Radiator
AC-DC
Pump
Figure 8
2011 Caterpillar
Cooling System Sizing

Cooling System Design QTotal (Btu/min) =
Requirements BSFC (BTU/(BHP - hr)) X Power Output (bhp) X
The primary purpose of the engine 0.01666 (hr/min)
cooling system is to reject heat from the
Some technical data sheets list the Heat
jacket water coolant and auxiliary circuit
Input with the Heat Balance Data under
if equipped, at greatest engine load,
the name Fuel Input or LHV Input.
highest ambient temperature, and
altitude. This section will outline the Work Output (W)
proper methods to be used for cooling The work output is the shaft power
system sizing. created from the engine. It is the power
that the engine generates from the fuel
Heat Rejection and is the total of the flywheel power
Before a cooling system can be and any driven equipment. Driven
designed, the designer must understand equipment includes alternators,
how much heat is being rejected equipment driven off the accessory
through each of the cooling circuits. drives and equipment on the front stub
This information is available in the shaft such as a radiator fan. The power
Technical Marketing Information (TMI), used internal to the engine is included in
and on the Engine technical data sheets the heat load values. These include the
available for each engine model. The jacket water pump, aftercooler pump,
following guide will help the designer in friction and gear train loads.
interpreting and applying the heat
Work Output is expressed in bkW
rejection data.
or bhp. To convert between units of
The heat balance: The heat input into horsepower and kW, use the factor:
the engine equals the sum of the heat 1hp = 0.7457 kW. To convert bhp
and work outputs. This equation is to Btu/min, use the factor:
typically applied with all factors either 1hp = 42.42 Btu/min.
in kW or Btu/min units.
Total Exhaust Heat (QExh)
Q Total = W + Q Exh + QSur + Q JW + QOC + Q AC The total exhaust heat is the total heat
Where: available in the exhaust when it is
Total Heat Input (QTotal) cooled from the stack temperature
The Total Heat Input, or total fuel down to standard conditions of 25C
consumed by the engine, is calculated (77F). Values shown are lower heating
by multiplying the Brake Specific Fuel values and do not include the heat of
Consumption (BSFC) and the Power vaporization. The exact exhaust
Output bkW (bhp). The resulting temperature varies from engine to
formula reads as follows: engine depending on rating and
respiration.
QTotal (kW) =
Heat Loss to the Surroundings (QSur)
BSFC (MJ/bkWhr) x Power Output (bkW) Some of the heat that is rejected from
3.6 (MJ/kWh) the engines surface is lost to the
2011 Caterpillar
surrounding environment. This is due to The aftercooler temperature listed on

convective and radiation effects. Heat the engine technical data sheet is the
loss to the surroundings is commonly water supply temperature to the
listed on the tech data sheet as Heat aftercooler.
Rejection to Atmosphere. The air fuel ratio and inlet manifold
Jacket Water Heat (QJW) temperature are key parameters for gas
Jacket Water Heat is the total amount engine combustion performance. For
of heat dissipated from the engine equivalent performance, a gas engine
jacket water cooling system. Cat must deliver the same amount of air
engines are designed to operate with at altitude as is provided at rated
a jacket water temperature (coolant) conditions. Therefore, at altitude,
differential typically less than 11C the turbocharger of a given engine
(20F), measured across the engine configuration works harder and delivers
under full load. However, this differential higher temperature boost air than at
will vary according to engine model standard conditions, and to cool the
and type. boost air to the same inlet manifold
Oil Cooler Heat (QOC) temperature, the aftercooler at altitude
The amount of heat transferred from must reject more heat than at standard
the lubricating oil to the cooling system. conditions.
Most of the heat in the oil comes from An aftercooler heat rejection factor
oil that is sprayed on the bottom side is used to quantify the additional
of the pistons. aftercooler heat rejection at altitude. A
The oil cooler is often cooled with the table of factors for various combinations
engine jacket water; therefore, the oil of altitude and ambient temperature is
cooler heat rejection may not be stated typically provided with a gas engine
separately in the engine technical data. technical data sheet.
However, for the sake of completeness, Failure to consider these factors for
the oil cooler heat rejection may be gas engines will result in an undersized
stated separately as well as being cooling system and excessive inlet
included with the jacket water total. manifold temperatures which will likely
The heat balance equation is a quick cause the engine to detonate and result
and reliable way to verify whether or in engine shutdown or failure.
not the oil cooler heat rejection is Diesel engines operate at high levels
included in the jacket water heat of excess air, so the turbocharger can
rejection figure. provide roughly the same amount of
Aftercooler Heat Rejection (QAC) work at altitude, deliver a lower mass
The aftercooler heat rejection is the airflow, and still have sufficient excess
amount of heat imparted by the air to provide equivalent engine
turbocharger on the boost air that must performance. Therefore, aftercooler
be rejected via the engine aftercooler. heat rejection factors are not applicable
Aftercooler heat rejection is given for to diesel engines (they are assumed
standard conditions of 25C (77F) to be 1.0).
and150 m (500 ft) altitude.
2011 Caterpillar
More important to diesel engine ratings Where:

is the aftercooler supply temperature. Q = Heat rejection in kW (Btu/min)
Diesel emission levels are impacted where one kW = 56.86 btu/min.
by inlet manifold temperature and Cp = Specific heat of exhaust gas:
an emission certified rating carries [kJ/kg/C (Btu/lb/F)]
with it a separate circuit aftercooler
inlet temperature requirement. 1.163 (0.277) TA standard
gas engines
Recoverable Heat 1.121 (0.267) TA low gas
Recoverable heat in the exhaust is not a emission engines
separate component of the heat balance
equation, but is the customary number 1.186 (0.280) NA gas engines
used in heat recovery calculations. It See TMI diesel engines
represents the heat available when M = Exhaust mass flow, kg/min
cooling the exhaust from the stack (lb/min)
temperature to a given reference T1 = Exhaust from engine, C (F)
temperature. The recoverable heat
T2 = Exhaust out of heat recovery
figures included in the Engine technical
silencer, C (F)
data sheets are based on 177C
(350F) for English units and 120C Note: Exhaust gas flow is the flow at
(250F) for metric units. The different standard pressure and exhaust stack
reference temperatures are based on the temperature.
differing standards in North America and Heat Rejection Tolerances
Europe. In every calculation using engine data,
If exhaust temperature other than there is a tolerance band or a deviation
177C (350F) is desired, the from the norm. Heat balance tolerances
recoverable heat can be approximated must be applied when sizing cooling
by the following formula. system components. The tolerances
Q = Cp x M x (T1 T2) recommended by Caterpillar may vary
depending on the engine model and
Note: The actual formula used to
are noted on the engine technical
calculate TMI data is more complex and
data sheets.
requires data not available in published
sources. Basic Operating Parameters
All engine cooling circuits are designated
by the maximum permissible inlet or
outlet temperature to that circuit. In
addition, each engine cooling system
component has static and dynamic
pressure limitations that must be
observed in order to preserve the
integrity of the cooling system. These
temperature and pressure limits can
be found in TMI.
2011 Caterpillar
Cooling System Sizing restriction vs. flow curve is

Procedure provided so the external pump
The following is a step-by-step can be sized properly. If a module
procedure for design and sizing of mounted expansion tank or
cooling systems for Cat engines. temperature regulator is used,
correct for its internal restriction.
Obtain heat rejection data for
Add an additional external circuit
specific engine model and rating.
system tolerance to the heat
This information is available from
rejection to account for system
the engine technical data sheet.
fouling or degradation. Depending
For cooling system design, use
on the type cooling system and
the maximum heat rejection
operating conditions, this tolerance
(nominal + tolerance) values.
should be on the order of 1% to
Find the appropriate density
10%.
and specific heat values for the
With the heat rejection, flow rate,
specific coolant formulation.
and a temperature (either the
Table 1 provides these values for
water supply temperature or exit
standard atmospheric conditions.
temperature) and a maximum
These values can be used for
restriction, a cooling system can
cooling system calculations even
be designed.
at higher temperatures.
Once the system is designed,
Select a coolant flow rate for the
recheck the external system
circuit based on the allowable
restriction against the restriction
temperature rise and the minimum
vs. flow curve for the engine.
and maximum flow rates for the
Do not extrapolate. The operating
circuit. For some models, these
point needs to be on the restriction
limits are stated explicitly and the
vs. flow curve for the system to
flow rate is calculated. For others,
be acceptable. Excessively high
these limits are essentially built
restriction will result in inadequate
into the external restriction vs.
coolant flow. Cooling system
coolant flow curve. When a
design changes will be needed
temperature rise is not provided
to correct the problem. Low
for an engine, simply select a
restriction will result in too much
coolant flow rate near the middle
flow, which can cause internal
of the external restriction vs. flow
wearing. Low restriction can be
curve.
addressed by inserting an orifice
Once the design coolant flow is
in the cooling system.
obtained, determine the allowable
The worksheets provided on Page 125
resistance for the circuit using the
and Page 122 provide step by step
external restriction vs. coolant
instructions for calculating the heat
flow curve provided for the engine
rejection, flow rate, and maximum
configuration. In cases where the
restriction that an external heat sink
pump is not supplied with the
(radiator, heat exchanger, or other
engine, an internal system
2011 Caterpillar
cooling device) must operate to for a show the density multiplied by the
successful installation. specific heat capacity; this is a good
indicator of the heat absorption capacity
Coolant Calculation Constants
of the coolant. Since heat absorption
Table 1 shows the density and specific
capacity of coolant vary, it is important
heat capacities needed in the coolant
to use the correct coolant properties in
flow calculation for commonly used
cooling system calculations.
coolants. The values in the last column
Coolant Density & Specific Heat Values

Specific Heat
Density Specific Heat x Density
Coolant kW min/kg C
kg/L (lb/gal) kW min/L C (Btu/gal F)
(Btu/lb F)
Pure Water 0.98 (8.1) 0.071 (1.00) 0.0696 (8.1)
50% Ethylene-Glycol /
1.03 (8.6) 0.060 (0.85) 0.0618 (7.31)
50% Water
50% Propylene-Glycol /
1.01 (8.4) 0.065 (0.92) 0.0657 (7.728)
50% Water
Table 1
2011 Caterpillar
Coolant Flow Calculation

The coolant flow required for each
circuit to transfer the heat load from the
engine components to the heat
exchangers or radiators can be
calculated using the following equation:
Heat Rejection (kW)
Flow (L/min) =
T(C) x Density (kg/L) x Spec. Heat (kW-min/kgC)
Heat Rejection (Btu/min)

Flow (gpm) =
T(F) x Density (lb/gal) x Spec. Heat (Btu/lbF)
Where T is the temperature rise of the circuit:

T = Outlet Temperature Inlet Temperature (for the particular circuit).
Depending on the engine model, the

temperature rise, T, may be given in
the form of maximum top tank and
bottom tank temperatures or directly
as a temperature rise limit.
Example:
A diesel 3412C TA with engine speed
@ 1800 rpm has:
Maximum top tank temperature
of 99C (210F)
Maximum bottom tank
temperature of 88C (190F)
Engine coolant heat rejection of
508 kW (28,890 Btu/min)
Flow 508
= = 747 L/min
(L/min) (99-88) x 1.03 x 0.06
Flow 28,890
= = 198 gpm
(gpm) (210-190) x 8.6 x0.85
2011 Caterpillar
External Restriction and Pump Flows flow velocities in tubes and pipes for a
After determining the required coolant given volume of flow. It is important to
flow rate, pump performance observe the water velocity guidelines
establishes maximum allowable external to help insure proper operation of the
resistance. Piping and heat transfer cooling system and to extend its life.
equipment resist water flow, causing an Excessive velocities lead to erosive
external pressure head which opposes tube wear.
the engine-driven pump. The water flow Suppliers of other components such as
is reduced as the external resistance strainers and heat transfer equipment
increases. The total system resistance can provide the required data on their
must be minimized in order to ensure components.
adequate flow. A cooling system with It is always necessary to evaluate the
excessive external heads will require design and installation of cooling
pumps with additional pressure circuits. An installation audit tests the
capacity. operation and effectiveness of the
The following items will affect the flow completed system to ensure proper
resistance: performance and life.
Size and length of pipe Both TMI and the Engine technical data
Quantity, size and type of fittings sheets contain pump curves that show
and valves used coolant flow versus external system
Coolant flow rate head for the various engine-mounted
Heat transfer devices pumps in metric and English units. An
When designing an engine cooling example of a pump curve is shown in
system, the pressure drop (resistance) Figure 9. The data is shown in both
in the external cooling system can be tabular and graphical form.
calculated by totaling the pressure drop Figure 9 illustrates a maximum external
in each of the systems components. head allowable equal to 10.7 meters
The Piping System Basic Information (35 ft) of water. Maximum external
Application and Installation Guide can resistance must not be exceeded in the
be used to determine pressure drop cooling circuit added by the customer,
through pipe fittings and valves. The in order to maintain the minimum
guide can also be used to determine water flow for proper cooling.
2011 Caterpillar
Example of Jacket Water System Performance
Figure 9
2011 Caterpillar
Cooling System Design Sketch
Figure 10
Pipe Size Restriction per Elbow Restriction per Valve Total System
Straight Length
(Inch) (Equivalent Length) (Equivalent Length) (Effective Straight)
m (ft)
m (ft) m (ft) m (ft)
4 32 (105) 3.35 (11) 0.76 (2.5) 53.6 (176)
5 32 (105) 4.27 (14) 0.90 (3.0) 59.4 (195)
6 32 (105) 4.88 (16) 1.07 (3.5) 65.0 (214)
8 32 (105) 6.40 (21) 1.37 (4.5) 73.1 (240)
Table 2a
Equivalent Length Restriction/100 ft @ Total Restriction

Pipe Size (Inch)
m (ft) 1325 L/min (350 gpm) m H2O (ft H2O)
4 53.6 (176) 12.40 6.64 (21.8)

5 59.4 (195) 4.19 2.49 (8.17)
6 65.0 (214) 1.70 1.10 (3.60)
8 73.1 (240) 0.43 0.31 (1.03)
Table 2b
2011 Caterpillar
Example Restriction Calculation: straight length values for components

A G3516 Gas engine running at in this system.
1200 rpm requires a 1325 L/min Effective straight length =
(350 gpm) flow to provide cooling. Straight Length + 6 x Effective Elbow + 2 x Effective Valve
Figure 10 shows a cooling system
Effective straight length using
designed for this application.
6 inch pipe =
This example is comprised of two gate
32m + 29.28m + 2.14m = 63.42m
valves, six 90 elbows and 32 m
(105 ft) of pipe connected between (105 ft + 96 ft + 7 ft = 208 ft)
the engine and a remote-mounted Using the information in the Piping
radiator. System Basic Information Application
To calculate the restriction, the effective and Installation Guide, with the
straight length of the system previously found equivalent length, the
components shown in Figure 10 must total restriction can be calculated as:
be determined. To aid calculation, non- (Restriction/100 ft) x Equivalent Length
straight components such as elbows
and valves should be converted to Table 2b shows the restriction for
effective straight length values. various pipe diameters.
Table 2a shows example effective
2011 Caterpillar
Types of Cooling Systems

There is a myriad of different types disassembled and cleaned, allowing
of cooling systems. No one system is them to be used in an open system.
correct for every location, size and
Closed System
application of Cat engine. It is important
Closed systems include cooling towers
to work with our experienced engineers
(with heat exchanger), radiators, heat
and/or the local dealer when designing
exchangers and evaporative coolers.
the best cooling system for each
application. This section discusses some In the closed system, proper coolant
of the more common types of cooling treatment can virtually eliminate scale
systems. formation and corrosion. The coolant
does not come into direct contact with
There are two basic types of cooling
the air but is cooled by a process of
systems, open and closed.
heat transfer to a cooler medium,
Open System usually air or water. The amount of
Open systems include cooling towers coolant in the engine closed system is
(without heat exchanger), spray ponds relatively small and confined, and can
and bodies of water. Open systems are be economically treated.
not recommended. Closed systems are normally designed
In the open system, the cooling water is to operate under pressure. Slight system
exposed directly to the air and is cooled pressure minimizes pump cavitation
by evaporation and water-to-air heat (voids in water) even at high altitude,
transfer. About 75% of the total heat is and increases pump efficiency.
removed by evaporation, and 25% by
convective heat transfer. The continued Radiators
process of evaporation means that any Radiator cooling is the most common
scale-forming salts present in the water type of closed cooling system,
will gradually be concentrated, and the providing a self-contained system that
water may pick up further contaminants is both simple and practical for most
from the air. These impurities can result installations. Figure 10 shows a
in the buildup of scale on the walls of schematic of a typical radiator design.
the cooling water passages in the Cooling of the engine parts is
engine, decreasing the cooling system accomplished by keeping the coolant
efficiency, and increasing the possibility circulating and in contact with the metal
of overheating. Open cooling systems surfaces to be cooled. The pump draws
are not recommended. The exceptions the coolant from the bottom of the
are when specific precautions have radiator, forces it through the jackets
been taken to accommodate an open and passages, and ejects it into a tank
system. For example, some engines can on top of the radiator. The coolant
be equipped with a cleanable aftercooler passes through a set of tubes in the
core and corrosion resistant piping. radiator core to the bottom of the
These aftercoolers are of a round radiator and again is circulated through
tube/plate fin design and can be the engine by the water pump, or
2011 Caterpillar
system cooling pump. A fan draws air cannot take place if the coolant level
over the outside of the tubes in the is allowed to become too low.
radiator and cools the coolant as it flows The top tank is used for filling,
downward. It should be noted that the expansion, and deaeration of engine
coolant is pumped through the radiator coolant. For cooling systems with
from the top down. The reason for this additional volume due to plumbing or
is that when the coolant is heated in the additional components, the expansion
jackets of the engine, it expands slightly tank may need to be enlarged to allow
and as a result becomes lighter and for the expansion of the additional
flows upward to the top of the radiator. volume of the system. The top tank is
As cooling then takes place in the fitted with a pressure cap. This cap
radiator tubes, the coolant contracts, allows coolant level to be checked and
becomes heavier and sinks to the replenished as necessary. The cap also
bottom. This desirable action, however, seals the cooling system and limits its
pressure with a spring-loaded disc valve.
Typical Radiator Design with Sample Coolant Flow
Figure 11
As previously mentioned, the cooling formation in the engine water jacket.

system is designed to operate under a (See Pressure Control)
slight pressure of 27.6 to 48.3 kPa (4 to Radiator Performance Criteria
7 psi) which keeps the coolant from Since many of the radiators used by
boiling or evaporating as the coolant equipment manufacturers will not be
temperature approaches the boiling designed by Caterpillar, a complete
point. This limit prevents steam
2011 Caterpillar
evaluation is required to prove the temperature as it flows across

capability of the system. the engine to the radiator. Typical
Caterpillar Application Engineering or ambient temperature rise for
EDS 50.5 Cooling System Field Test different radiator locations is
can provide specific information on found in Table 3.
methods and criteria used to evaluate
radiator performance criteria. Blower
Suction Fan
Fan
A cooling system test needs to be
performed in accordance with this Engine only, outside or in a 3C
None
large engine room (5.4F)
document when a Cat radiator
or expansion tank are not used.
Engine & generator outside 4C Not Recommended
or in a large engine room (7.2F) with generator
Radiator Design Criteria and
Considerations Engine & generator in
7C Not Recommended
The following factors must be enclosure with external
(12.6F) with generator
muffler
considered when designing and
installing a radiator cooling system. Engine & generator in
enclosure with internal
9C Not Recommended
(16.2F) with generator
Size the radiator to accommodate insulated muffler
a heat rejection rate approximately Table 3

10% greater than the engines
heat rejection at rated power. The Additional air temperature rise will
additional 10% will compensate come from components or
for possible variations from equipment located in the air intake
published or calculated heat flow that to the heat load. This
rejection rates, overload and additional heat load must be
system deterioration. calculated in order to increase the
Radiator sizing should be corrected estimated air to core rise shown in
to account for operating site Table 3. This additional heat load
altitude. Altitude above sea level could be due to lights, electrical
reduces the density of the air and equipment, hot surfaces, heaters,
its ability to cool the radiator. The etc. that are located in the
radiator must be oversized to engine room.
adjust for the maximum altitude The effects of antifreeze must be
at which the engine is to be considered when sizing a radiator.
operated. These factors are The ability to transfer heat
provided for all gas engines and diminishes when water is mixed
some diesel engines on the with ethylene glycol. The loss in
Engine technical data sheets. ambient capability due to
Ambient air temperature may not antifreeze is about 1C (1.8F)
be the same as the air temperature for each 10% glycol, up to 50%.
flowing across the radiator core. Fan noise should be considered
An engine equipped with an when selecting radiator location.
engine mounted radiator and Fan noise transmits through the air
blower fan will increase the air inlet as well as the outlet. Soft
2011 Caterpillar
flexible joints between the radiator demonstrates this problem for

and the ducting will reduce a radiator. Radiators must be
vibration and noise transmission. arranged so that engine exhaust
Position the radiator so prevailing gases and/or crankcase ventilation
winds do not act against the fan, gases are not drawn into the air
which can reduce the cooling air inlet of the radiator as shown in
flow volume and cause over- item C of Figure 12.
heating. One form of wind Backpressure or air flow restriction
protection is to shelter the radiator reduces radiator performance. If
from the wind with a baffle or radiator air flow is to be ducted,
wall located several feet from the consult TMI or your radiator
radiator exhaust. Another method manufacturer regarding the
is to duct the radiator discharge allowable backpressure. An engine
outside the wall and if needed, installation in an enclosed space
mount the air inlet vertically. Large requires that the inlet air flow rate
radius bends and turning vanes to the enclosed space include the
help to reduce excessive air flow combustion air requirements of the
restriction. engine, unless the air for the
It is important to make sure that engine is ducted directly to the
the hot radiator air discharge is engine from the outside.
not recirculated to the engine,
generator or radiator air inlet.
Item A and item B in Figure 12
2011 Caterpillar
Radiator Recirculation
Figure 12
Radiator/Fan Performance Temperature

Air density, flow restrictions, and speed Revised Coolant Temperature =
affect fan performance, which can Original Air Flow 0.7
possibly limit radiator ambient Original Coolant Temp X
Revised Air Flow
temperature capabilities. Performance
changes are estimated by the following
Revised Coolant Temperature =
relationships.
Original Fan Speed 0.7
Air Density Original Coolant Temp. X
Revised Fan Speed
Revised Static Pressure =
Revised Air Density
Original Static Pressure X Radiator Ambient 99C Revised Coolant Temp.
Original Air Density =
Temp. Capability Coolant Temperature
Revised Fan Horsepower =
Revised Air Density Radiator Ambient 210F Revised Coolant Temp.
Original Fan Horsepower X =
Original Air Density Temp. Capability Coolant Temperature
Speed
Revised Air Flow = Where:
Revised Fan Speed Coolant Temperature Differential =
Original Air Flow X
Original Fan Speed Coolant top tank temperature minus air
temperature to radiator.
Revised Static Pressure = Air Density = gm/cucm (lb/cucm)
Revised Fan Speed 2 Air Flow = cum/min (cfm)
Original Static Pressure X
Original Fan Speed
Coolant Temperature =
Revised Fan Horsepower = 5.5 Original Radiator
99C (210F) - -
2 Temperature
Revised Fan Speed 3
Original Fan Horsepower X
Original Fan Speed
2011 Caterpillar
Original Radiator Temperature = standard rule of thumb is to make the

Ambient Air Temperature to the inlet air ducts 1.5 times greater than air
Radiator outlet ducts.
Assumptions: Louvers are often used to protect the
Coolant Top Tank Temperature = engine and engine room from rain,
99F (210F) snow, and vandalism. Since louvers
restrict air flow, the radiator ducting
Inlet to Outlet Radiator Temperature
Change = 11.1C (20F) area must be increased a minimum of
25% when flat louvers are used. Total
Fan Horsepower = kW (hp) air flow restriction due to engine room
Fan Speed = rpm ventilation, duct work, etc. should be
Static Pressure = mm H2O (in H2O) limited to 12.7 mm (0.5 in.) of water.
Fan performance will suffer if this limit is
Ambient Capability
exceeded.
Ambient capability is a value expressing
how well the cooling system cools. The If movable louvers are used, specify
value, therefore, depends on the specific those which use mechanical force.
cooling configuration and the operating Pneumatic and electric-actuated louvers
conditions and can be found in the are satisfactory. Use of louvers which
price list. open from the discharge pressure of the
radiator fan are discouraged. Rain, ice,
Fan Speed and snow can render them inoperative
Fan speed affects the performance within a short period of time and cause
of a fan in respect to radiator ambient an unwanted engine shutdown due to
temperature capabilities. Revised air overheating.
horsepower can be calculated using
revised and original fan speed. Standby Ducting
Standby or emergency power units will
Steel bladed fans should not exceed
be loaded immediately and will require
the tip speed guidelines as the fan will
full air flow upon startup. Therefore,
produce excessive noise and could
louvers should be activated immediately
potentially fail. Recommended
on engine start-up.
maximum tip speeds are 3660 m/min
(12,000 ft/min) for low noise, and Emergency units are frequently
4575 m/min (15,000 ft/min) for exercised at no load. The full air flow
higher but acceptable noise. under these conditions may result
in maintenance problems from
The formula for calculating fan blade
overcooling, and therefore, the air flow
tip speed is:
across the radiator should be restricted
Fan diameter meters x x Fan rpm = Fan blade tip to allow for the proper cooling.
speed meters per minute
(Fan diameter feet x x Fan rpm = Fan blade tip speed Engine Mounted Radiator
feet per minute) If an engine-mounted radiator is used
and the generator set is installed in a
Ducting room, a blower fan can be used and a
Radiator ducting, when required, should radiator duct provided to the outside.
be larger than the radiator core. A
2011 Caterpillar
Ducts directing radiator air to the Remote Mounted Radiator

outside will reduce recirculation and high On installations where it is desirable or
room temperatures; refer to Figure 13. necessary to locate the radiator at some
Some generator set packages have, as distance from the engine, a remote
standard, radiator duct flanges available radiator can be used.
for installation ease. Remote systems impose added
The duct length is short and direct to restriction on coolant flow by the use
minimize backpressure, with total inlet of additional piping and fittings. An
and outlet restriction on the radiator fan auxiliary pump in series with the engine-
less than 12.7 mm (0.5 in) of water. mounted pump should not be used to
overcome this restriction. Consideration
Ducting to the Outside
should first be given to radiator design
and the use of larger piping. If that does
not provide an effective solution, then it
may be necessary to replace the engine
driven pump with an electric motor
driven pump that is sized to handle the
increased systems restrictions.
If the empty radiator is exposed to
extreme cold, initial flow of unprotected
coolant can freeze and block the core.
Antifreeze must be included in the
coolant treatment to assure
uninterrupted flow.
Figure 13 The radiator inlet tank loses its air
venting capability if it is located below
Restrictions the level of the engine regulator
If common window screening housing. When a radiator must be
is used, the size of the opening mounted lower than the engine, a
should be increased by 40%. separate expansion tank must be used.
Solid walls perpendicular to fan air In addition, remove the radiator cap
flow must not be closer than two and seal the opening. This prevents
fan diameters from the radiator. untrained personnel from causing
Avoid uneven loading of the fan problems.
caused by obstructions If an engine mounted expansion tank
or auxiliary coolers partially is used, it should include a radiator
obstructing air flow. fill cap. The radiator must be selected
Fatigue failure of fan blades with consideration to the inlet controlled
as well as air turbulence may guidelines. The core must also
occur when obstructions are too withstand full pump pressure. This will
close to the face of the fan. usually require a round tube radiator.
Maintain a minimum spacing equal If the core is vertical, water flow can
to 8% of the fan diameter. be reversed through the radiator. This
2011 Caterpillar
ensures gas or air is not trapped in the required. In some cases, the auxiliary
radiator inlet tank. expansion tank may be incorporated in
Preferred location is an elevation lower the radiator package itself as shown in
than the expansion tank, but higher Figure 16.
than the engine pump inlet. Radiators Radiator design operating pressure must
connected with straight piping and be increased by 6.9 kPa (1 psi) for every
mounted at engine outlet level minimize 610 mm (2 ft) the engine is above the
air traps, see Figure 14. Bleed valves or radiator. All elevated radiator cooling
automatic air release valves may still systems must be evaluated to assure
be required on the radiator unit itself. that system pressures are within
Dips in engine outlet piping trap air acceptable limits.
during the initial fill and during engine Additional precautions must be taken
operation and should be avoided. Vent with shunt type cooling systems. As
lines or automatic air-release valves the flow-through type expansion tank is
must be provided at each potential eliminated, a deaeration chamber must
trap, see Figure 15. be provided at the engine outlet. Vent
Radiators are sometimes located above lines from the deaeration device and
the engine outlet level. This situation is potential traps must be routed to the
most common in rooftop mounting as expansion tank. The tank must be the
shown in Figure 16, Figure 17 and highest point in the system, and a
Figure 18. Never locate remote mounted make-up line routed to the water pump
radiators more than 17.4 m (57 ft) inlet piping. The system, must meet
above the pump. At greater heights, the acceptance criteria. The shunt system
static resistance developed may cause shown in Figure 18 uses rooftop
leakage at the engine water pump seal. mounting, but is applicable for any
Static head is the maximum height the radiator location.
coolant is raised; refer to Figure 16. Vertical Remote
Note the use of an auxiliary expansion Vertical remote radiators should be
tank and appropriate vent lines. positioned so prevailing winds or
In Figure 17, the main (Cat) expansion structures do not impede fan air flow
tank provides the regulator mounting or cause the heated air to recirculate
location and deaeration function for the through the radiator core.
cooling system. The auxiliary expansion
Horizontal Remote
tank is the highest point in the system
Horizontal remote radiators nullify
and provides the fill location, coolant the effects of wind, but may require
level gauge, pressure cap, vent line protection from rain, snow and ice.
termination point, and expansion volume
2011 Caterpillar
Figure 14
Figure 15
2011 Caterpillar
Figure 16
Figure 17
2011 Caterpillar
Figure 18
2011 Caterpillar
Heat Exchangers is usually piped to flow through the shell

A heat exchanger can be used to cool side, so that the raw water flows
the engine when ventilation air is through the tubes. This permits the raw
limited, or when excessive static water side to be readily cleaned by
resistance on the engine must be mechanical means.
avoided. Heat exchangers are typically The direction of flow of the raw water
classified according to flow arrangement will affect the heat transfer from the
and type of construction. engines coolant. In a single-pass heat
Advantages to using a heat exchanger exchanger the raw water can flow in
are: that there is no fan noise, it reduces the same direction as the coolant
the air flow requirements, the parasitic (Parallel-flow) or it can flow in the
load will be less, and the fuel opposite direction as the coolant,
consumption will be improved. When (Counter-flow). A given heat exchanger
a source of water is readily available, can transfer more heat when connected
this is an effective method for for counter flow than it can when
cooling the engine. connected for parallel flow.
Some of the disadvantages are that
Heat Exchanger
a heat exchanger requires a separate
cooling source and a separate expansion (shell and tube type)
tank which means using an extra pump
and plumbing. Provisions for room
ventilation will also be required.
Shell and Tube Type
The most common type of heat
exchanger is the shell and tube type as
shown in Figure 19. In a shell and tube
heat exchanger, the engine coolant is
cooled by the transfer of heat to another
liquid at a lower temperature. The
design parameters available to the
shell and tube heat exchanger designer
include the diameter, length, number
of tubes, the number of raw or treated
water passes, the number and cutoff
Figure 19
height of shell side baffles. These heat
exchangers can have single-pass, or
Plate Type
multiple-pass flows. A single pass heat
Another common type of heat
exchanger has the cooling media pass
exchanger is the plate type heat
through the heat exchanger only once
exchanger as shown in Figure 20. The
before exiting. A multiple-pass heat
design parameters available to the plate
exchanger allows cooling media to pass
type heat exchanger designer include
through the heat exchanger multiple
the size and number of plates, the
times before exiting. The engine coolant
2011 Caterpillar
turbulator design and the number of raw The fouling factor relationship is:
or treated water passes. Tight baffling FF = [(1/UCoolant) (1/UClean Core)]
around the heat exchanger is critical Where:
to obtaining good heat transfer
performance. FF = Fouling factor, hr-m2-C/kJ (hr-
ft2-F/Btu)
Heat Exchanger UCoolant = Heat Transfer Coefficient
(plate and frame type) of core with coolant,
kJ/hr-m2-C (Btu/hr-ft2 F)
UClean Core = Heat Transfer
Coefficient of clean
core kJ/hr-m2-C
(Btu/hr-ft2 F)
Fouling Factor Chart for Water (hr-ft2-F/Btu)
Engine Coolant Temperature < 116C (240F)

Raw Water Temperature < 52C (125F)
Raw Water Velocity
Figure 20 Water Types

0.9 m/s >0.9 m/s
(3 ft/sec) (3 ft/sec)
Seawater 0.0005 0.0005
Design Criteria and Considerations Brackish Water 0.002 0.001

Many engine models have attachment Cooling Tower and Artificial Spray
0.001 0.001
Pond: Treated Makeup Spray Pond:
heat exchangers in the price list. Untreated
0.003 0.003
Consider the following factors when City or Well Water
0.001 0.001
(such as Great Lakes)
designing and installing a heat
River Water 0.003 0.003
exchanger cooling system.
Hard (over 15 grains/gal) 0.003 0.003
Size the heat exchanger to
accommodate a heat rejection rate Engine Jacket 0.001 0.001
approximately 10% greater than the Treated Boiler Feedwater 0.001 0.0005
engines heat rejection. The additional 2 2
Note: 1 hr-ft -F/Btu = 0.0545 hr-m -C/kJ
10% will compensate for possible
Table 4
variations from published or calculated
heat rejection rates and engine overload.
For the coolants listed in Table 4, fouling
The cooling capacities vary for different factors greater than 0.001 will result in
cooling mediums, and tend to reduce significant change in the heat transfer
heat transfer. A fouling factor is capacity. Use Table 5 to correct the
assumed during equipment sizing, which heat capacity of the heat exchanger
will affect the heat transfer of a heat given in TMI for fouling factor different
exchanger. Factors for common types from the base of 0.001. For coolants
of water can be found in Table 4. with fouling factors less than 0.001
the values have been left unchanged.
2011 Caterpillar
Caterpillar does not recommend is controlled by a temperature regulator;

designing for a fouling factor less additional controls add expense,
than 0.001. restriction and decrease reliability.
Since heat exchanger tubes can be Heat Exchanger Sizing
cleaned more easily than the Occasionally, special applications
surrounding shell (jacket), the raw exist which require an inboard heat
water should be passed through the exchanger size that is not available
tubes and the engine cooling water from Caterpillar. When these conditions
through the shell or jacket. exist, it is necessary to obtain a heat
exchanger from a supplier other than
Fouling Factor Chart Correction Factors Caterpillar. In order to expedite the
Engine Coolant Temperature < 116C (240F)
selection of a nonstandard heat
Raw Water Temperature < 52C (125F) exchanger, a Heat Exchanger Selection
Raw Water Velocity Worksheet is provided in this guide;
Water Types
refer to Page 128. Heat exchanger
0.9 m/s >0.9 m/s
(3 ft/sec) (3 ft/sec)
suppliers will provide information and
aid in selecting the proper size and
Seawater 1.0 1.0
material for the application.
Brackish Water 0.83 1.0 For a given jacket water flow rate,
Cooling Tower and Artificial Spray
Pond: Treated Makeup Spray Pond:
1.0 1.0 the performance of a heat exchanger
0.71 0.56
Untreated depends on both the cold water flow
City or Well Water (such as Great
1.0 1.0 rate and differential temperature. To
Lakes)
River Water 0.71 0.71
reduce tube erosion, the flow velocity
of the cold water through the tubes
Hard (over 15 grains/gal) 0.71 0.56
should not exceed 183 cm/s (6 fps).
Engine Jacket 1.0 1.0
At the same seawater flow rate, the
Treated Boiler Feedwater 1.0 1.0 flow resistance and the flow velocity
will be greater through a two-pass heat
Table 5
exchanger than through a single-pass
If solenoid valves are used to control heat exchanger. The heat exchanger
cooling water, position them upstream should be selected to accommodate the
of the heat exchanger. The drain for the cold water temperature and flow rate
heat exchanger is always open and the needed to keep the temperature
heat exchanger is relieved of pressure differential of the jacket water below
when inoperative. If solenoid valves are about 8.3C (15F) at maximum engine
installed on both sides, raw water could heat rejection. Thermostats must be
be trapped in the tubes if the solenoids retained in the jacket system to assure
fail to open. Water trapped during that the temperature of the jacket water
engine operation expands and could coolant returned to the engine is
rupture the exchanger. All solenoid approximately 79C (175F).
valves should include a manual bypass. Size heat exchangers to accommodate
Do not add temperature regulators in a heat rejection rate approximately 10%
raw water supplies. Engine jacket water greater than the tabulated engine heat
2011 Caterpillar
rejection. The additional capacity is the engine and can be used if the engine
intended to compensate for possible is located near a supply of relatively cool
variations from published or calculated water, preferably 29C (85F) or less.
heat rejection rates, overloads or engine In this system, the engine coolant water
malfunctions which might increase the is pumped through coils (or lengths of
heat rejection rate momentarily. It is not pipe) that are submerged in the nearby
intended to replace all factors which cool water. Figure 21 shows an
affect heat transfer, such as fouling example of a typical submerged pipe
factor and shell velocity. cooling system.
Pay particular attention to the shell side A concrete catch basin or tank should
pressure drop to ensure that the entire be placed in the source of the cooling
cooling system flow resistance does not water. This will help ensure a consistent
exceed the limitations of the engines volume of water around the coils and
freshwater pump. help keep mud and silt from burying the
coils. The pipes must be supported up,
Submerged Pipe Cooling off the bottom of the tank to ensure
Submerged Pipe Cooling is a simple, but maximum cooling efficiency.
yet effective way of rejecting heat from
Submerged Pipe Cooling System
Figure 21
Engine heat rejection and the A trial and error method can be used if
temperature of the cooling medium jacket water temperature is too high or
must be carefully considered in too low; by adding or removing pipe as
determining the correct amount of pipe necessary, the engine cooling water
to use. As a rule-of-thumb, 0.003 m2 temperature can be maximized.
(0.0353 ft2) of submerged pipe surface The system should be connected so
area is required for every 1.055 kJ/min that jacket water flows from the engine,
(1 Btu/min) of jacket water heat to the cooling coils, and to the
rejection that must be removed. expansion tank, before returning to
This rule-of-thumb is for raw water the water pump inlet.
temperatures up to 29C (85F).
2011 Caterpillar
Cooling Towers a cooling tower will cool. However,

Since radiators are often ineffective for in the practical application of a cooling
cooling Separate Circuit Aftercooling tower, the coolant temperature can only
(SCAC) water below 54C (130F), be maintained down to about 5.6C
an alternate source of water is needed (10F) above the wet-bulb temperature.
for low temperature cooling circuits of There are two types of cooling towers.
32C (90F) SCAC. In such cases, Open-Type
cooling towers are used when a large Closed-loop-Type or Evaporative
supply of cool water such as a river, Cooler
lake or cooling pond is not available or
not usable for environmental reasons. Open Cooling Tower
In open cooling systems using cooling
Though there are several types of
towers, the engine cooling water is
cooling towers, the basic method of
sprayed directly into the tower and is
heat transfer is the same. Air is brought
subjected to the inherent concentration
in direct contact with the cooling
of water contaminants of this system.
water. Cooling by cooling towers
Unless special provisions are made,
is accomplished in two ways.
such as a cleanable aftercooler and
Approximately 75% occurs by water
corrosion resistant plumbing, the use
evaporation, and about 25% by direct
of an open cooling system is not
heat transfer from the water spray to
recommended for Cat engines.
the passing air. Since the primary
mechanism for cooling the water is Closed Cooling Tower
through evaporation, the ability of the Figure 22 demonstrates how a heat
air flow to absorb moisture is critical to exchanger can be used to maintain a
the effectiveness of a cooling tower. It closed cooling system for the engine
is for this reason that the performance while using a cooling tower. In this
of a cooling tower depends on the system, raw water is circulated by an
relative humidity of the ambient air. auxiliary water pump driven from the
Relative humidity is a measure of the engine, or by an electric motor. The
airs ability to absorb moisture. When pump flows cool water from a basin at
the relative humidity is 100%, the the bottom to the cooling tower, forces
wet-bulb and dry-bulb temperatures it through the heat exchanger, and to
are equal and the air cannot absorb the distribution system at the top of
additional moisture. Therefore, there the tower. As the heated water passes
will be no evaporation and little cooling. through the tower, it cools and collects
However, when the relative humidity in the basin.
is less than 100%, the wet-bulb For the closed-loop cooling tower, the
temperature is less than the dry-bulb engine coolant can be circulated to the
temperature and the air can absorb cooler eliminating the heat exchanger
moisture by evaporation. at the engine; refer to Figure 23. The
The prevailing wet-bulb temperature is coolant in a closed-loop system can be
a key factor in the design of a cooling treated to prevent corrosion, eliminating
tower; it is the theoretical limit to which the need for corrosion resistant piping.
2011 Caterpillar
Closed Cooling Tower with Externally Mounted Heat Exchanger
Figure 22
Closed Loop Cooling Tower
Figure 23
2011 Caterpillar
Cooling Tower Design Criteria These impurities can result in the build-
As a rule, cooling towers are most up of scale on the cooling water
effective in areas with an ambient passages, decreasing the cooling
dry-bulb temperature above 37.8C system efficiency. As these salts and
(100F), and an average relative minerals build, they must be drained
humidity below 50%. and the tower water diluted with fresh
Cooling towers are very sensitive water. Solids such as dust may also
to approach temperatures (i.e. the accumulate in the tower water.
temperature between the wet bulb Filters or centrifugal separators can be
temperature and the desired coolant installed to reduce these contaminants.
temperature). To go from an approach If the tower water is used in the engine
temperature of 8.3C (15F) to an circuits such as the aftercooler, it should
approach temperature of 5.6C (10F), be treated with corrosion inhibitors to
the cooling tower size would have to be compatible with engine piping and
be increased by as much as 50%. components. Even with treated water,
Any approach temperature below a cleanable aftercooler core is required
2.8C (5F) becomes unrealistic. when used with cooling tower water.
As with radiators, cooling towers are Cooling towers installed in frigid
very sensitive to recirculation and the locations require additional design
presence of other upwind cooling requirements to prevent freezing.
towers; refer to Figure 24. Any
recirculation or ingestion of exhaust Tower Recirculation Due to Wind
from another cooling tower effectively
reduces the approach and wet-bulb
temperature of the incoming air. As
was demonstrated earlier, the approach
temperature has a significant effect on
cooling tower size. Therefore, factors
such as location of the towers, direction
of the prevailing winds, and height of
the towers (a taller tower will reduce
recirculation), should be taken into
consideration.
Figure 24
The continued process of evaporation
means that any scale-forming salts
present in the water will gradually be
concentrated; the water may pick up
further contaminants from the air.
2011 Caterpillar
Keel Coolers Jacket Water Aftercooled

A keel cooler is an outboard heat with Keel Cooler
exchanger which is either attached to, Jacket water aftercooling uses engine
or built as part of, the submerged part jacket water in the tube side of the
of a ships hull. They are typically used aftercooler and results in inlet manifold
in marine applications operating on temperatures lower than those obtained
inland waterways and rivers, where in non-aftercooled turbocharged
there is potential for encountering engines. The lower inlet manifold air
muddy or silt-laden cooling water. temperature allows a jacket water
The heated water from the engine is aftercooled engine to achieve a rating
circulated through the keel cooler by higher than either a naturally aspirated
an engine driven water pump. or a turbocharged-only engine. Jacket
Figure 25, Figure 26 and Figure 27 water aftercooled circuits are completely
represent three (3) typical keel cooler installed at the factory.
system configurations. Jacket water aftercooling, when feasible
Jacket Water Aftercooled for a particular application, represents
with Keel Cooler the simplest cooling system possible.
When coupled with the use of a keel
Separate Circuit Aftercooled with
cooler, it becomes even simpler, with
Keel Coolers
only one cooling circuit required per
Separate Circuit Aftercooled with
engine.
Keel Coolers (with Aftercooler Keel
Cooler Bypass)
Jacket Water Aftercooled Keel Cooler
Figure 25
1. Turbocharger 7. Keel Cooler
2. Aftercooler, Jacket Water Cooled 8. Bypass Filter
3. Jacket Water Outlet Connection 9. Duplex Full-Flow Strainer
4. Jacket Water Inlet Connection 10. Shut-Off Valve
5. Expansion Tank 11. Auxiliary Expansion Tank
6. Jacket Water Pump 12. Flexible Connection
2011 Caterpillar
Separate Circuit Aftercooled Caution must be used when using the

with Keel Coolers aftercooler keel cooler water circuit to
The use of keel coolers in the aftercooler cool an auxiliary piece of equipment
circuit allows a low temperature, fresh such as a marine transmission. The
water, closed circulating system to be auxiliary equipment cooler should be
used. All closed fresh water aftercooler connected to the water circuit after it
circuits require the installation of an leaves the engine aftercooler to avoid
expansion tank. Refer to the section of adding any heat to the water before it
auxiliary expansion tanks. The use of enters the aftercooler. The additional
an inlet manifold air temperature gauge, resistance of the auxiliary equipment
or alarm, can provide guidance for cooling circuit must be held to a
required cleaning of the system in minimum to avoid reducing the
order to maintain the desired engine flow of water to the aftercooler.
performance, and is strongly
recommended.
Separate Circuit Aftercooled Keel Coolers
Figure 26
1. Turbocharger 10. Bypass Filter

2. Aftercooler, Keel Cooled 11. Shut-Off Valve
3. Jacket Water Outlet Connection 12. Duplex Full-Flow Strainer
4. Jacket Water Inlet Connection 13. Keel Cooler for Aftercooler
5. Expansion Tank 14. Keel Cooler for Jacket Water
6. Jacket Water Pump 15. Expansion Tank for Aftercooler Circuit
7. Auxiliary Fresh Water Pump 16. Vent Line for Aftercooler Circuit
8. Auxiliary Fresh Water Inlet Connection 17. Auxiliary Expansion Tank
9. Aftercooler Outlet Connection 18. Flexible Connection
2011 Caterpillar
Separate Circuit Aftercooled with To minimize condensation during

Keel Coolers and Aftercooler Keel light engine load in separate circuit
Cooler Bypass aftercooled systems, it is desirable to
The separate circuit aftercooler cooling maintain the inlet manifold temperature
system must be designed with sufficient between 38C and 52C (100F and
capacity for the hottest water and the 125F). This may be achieved by
higher ambient air conditions for recirculating the aftercooler cooling
operation in climates where both air and water back to the auxiliary water pump
seawater temperatures run to extremes. inlet until the desired temperature is
This results in a cooler with excess reached. Cool water should then be
capacity in cold seawater and warm mixed with the recirculated water
air conditions. This can result in to maintain the temperature. The
condensation in the engines intake temperature of the water to the
system, especially during prolonged aftercooler can be controlled by
light engine load. using a thermostatically controlled
three-way valve.
Separate Circuit Aftercooled Aftercooler Keel Cooler Bypass
Figure 27
1. Turbocharger 8. Auxiliary Fresh Water Inlet 15. Expansion Tank for

2. Aftercooler, Keel Cooled Connection Aftercooler Circuit
3. Jacket Water Outlet 9. Aftercooler Outlet 16. Vent Line for Aftercooler
Connection Connection Circuit
4. Jacket Water Inlet 10. Bypass Filter 17. Bypass Valve,
Connection 11. Shut-Off Valve Thermostatically Controlled
5. Expansion Tank 12. Duplex Full-Flow Strainer 18. Auxiliary Expansion Tank
6. Jacket Water Pump 13. Keel Cooler for Aftercooler 19. Flexible Connection
7. Auxiliary Fresh Water Pump 14. Keel Cooler for Jacket Water
2011 Caterpillar
Fabricated Keel Coolers raw water film varies with the velocity
Fabricated keel coolers may be made of water flow past the cooler due to
of pipe, tubing, channel, I-beams, angle vessel speed. Surface corrosion factors
or other available shapes. The choice are based on treated fresh water and
of materials used is dependent on the polluted river water. Miscellaneous
waters in which the vessel will operate. factors become so predominant in the
These materials must be compatible resultant heat transfer rate that the type
with materials used in the vessels hull of material used and thickness of metal
in order to prevent galvanic corrosion. become minor considerations.
Sizing of Fabricated Keel Coolers Normal deterioration of the coolers
Engine water temperature maximum inner and outer surfaces in the form
limits are controlled by size of the keel of rust, scale and pitting progressively
cooler. Heat transfer rates through any reduce a keel coolers effectiveness over
cooler depend mainly on cooling water a period of years. Protective coatings
temperature, cooling water flow and and marine growths will also reduce the
heat transfer surface area. A cooler rate of heat transfer. It can take four to
may have to operate at its maximum five years before deterioration stabilizes
capacity at zero hull speed, as in the in keel coolers. It must be designed
case of an auxiliary generating set, considerably oversized when new.
operating while the vessel is in port. Because of the severe deterioration of
The minimum area calculated includes heat transfer characteristics associated
a fouling factor. Materials used in cooler with structural steel coolers, adequate
construction, condition of waters in cooler size sometimes becomes
which the vessel will operate and impractical. This is particularly true
service life expectancy will influence where seawater temperatures are over
the size selection of a new cooler. 30C (85F). In these high seawater
The keel cooler sizing worksheet temperature regions, the use of
on Page 129 and the keel cooler area packaged keel coolers, or box coolers,
recommendations contained in made of corrosion-resistant materials is
Figure 28, Figure 29 and Figure 30 suggested. These coolers can provide
apply only to keel coolers made of more heat exchange surface area in a
structural steel (channel, angle, half given volume on, or within the hull, than
pipe, etc.) welded to the ships shell the coolers made of structural steel.
plating. These recommendations take Marine Gear Heat Rejection
into account the thermal resistance to Marine gears, or transmissions, whether
heat transfer of the steel plate, the offered by Caterpillar or provided by a
internal and external water films, and marine gear manufacturer or supplier,
the internal and external surface will all generate heat. Typical marine
corrosion factors. The coefficient of gears are 95% to 97% efficient, with
heat transfer of the fresh water film the 3% to 5% efficiency loss (or power
flowing inside the cooler is based upon loss factor) representing the amount
a flow velocity of 0.9 m/sec (3 ft/sec). of heat being rejected to the marine
The coefficient of heat transfer for the gear oil.
2011 Caterpillar
While the actual marine gear efficiency Where:

can be provided by the gear H marine gear = Heat rejection
manufacturer based on the specific of the marine gear oil
application, a good rule for cooler sizing P engine = Power generated in the
is to use 95% efficiency with a 5% engine and transmitted through the
power loss factor. marine gear
Maximum heat rejection to the marine F power loss = A factor relating the
gear cooling system is equal to the heat generated in the marine gear oil
transmitted power from the engine to the marine gear efficiency
multiplied by the power loss factor.
The following conversion factors are
H marine gear = P engine x F power loss
tabulated below.
31.63 x kW = Btu/min
42.41 x hp = Btu/min
Aftercooler Water Keel Cooler Area Requirements
Figure 28
2011 Caterpillar
Jacket Water Keel Cooler Area Requirements
Figure 29
Marine Gear Keel Cooler Area Requirements

35C (95F) Max. Water to Transmission Heat Exchanger
Figure 30
2011 Caterpillar
Design/Installation Considerations practice in sizing the connecting

Water Velocity Inside the Cooler piping.
If water flow through the keel cooler Determine the cross-sectional area
is too fast, the cooler can be damaged. of one keel cooler passage. This
Water velocity over 2.5 m/sec (8 ft/sec) is best done by consulting the
will erode internal components, manufacturer or an engineering
particularly near manifold entrances reference on shapes of structural
and exits, elbows and other channel, pipes, angles and other
discontinuities in the water flow. flow details.
If the water flows through the keel Use a good conversion factor table
coolers too slowly, cooler efficiency to convert the most likely water
will be reduced. Water velocity less flow to units of m3/min (ft3/min).
than 0.6 m/sec (2 ft/sec) will allow Use a good conversion factor table
rust particles, sand and other to convert cross-sectional area of
particulate matter to settle out of the one keel cooler passage to units of
water and into the cooler. This tends m2 (ft2).
to choke off the flow and degrade Divide the most likely water flow
the transfer of heat. by the cross-sectional area of one
Use the following procedure to keel cooler passage.
determine the proper flow pattern The result will be the average
through the keel cooler. velocity through the keel cooler
flow passages. If the average
Determine the maximum and
velocity through the keel cooler
minimum expected water flow
flow passages is greater than
through the keel cooler. This can
2.5 m/sec (8 ft/sec), arrange the
be determined from the engines
water flow in parallel, so it passes
water pump performance data.
through two or more of the keel
Subtract the minimum expected
cooler passages per pass through
water flow from the maximum
the keel cooler. If the average
expected water flow.
velocity through the keel cooler
Multiply the resultant difference flow passages is less than 0.6
(between the min and max flow) m/sec (2 ft/sec), use a keel cooler
by 2/3. Add 2/3 the resultant passage with a smaller cross
difference (from the prior step) to section.
the minimum flow*. This is the
most likely water flow. Use this Use of Keel Inserts to Improve Local
figure to determine how to Flow Velocity
distribute the water flow through It is economically desirable to use steel
the keel cooler passages. channels for keel cooler passages
* For design purposes, this is which are large in cross-sectional area.
the most likely water flow Unfortunately, this design produces
through the keel cooler. This water flow that is too slow for effective
is dependent on the use of good heat transfer. Keel cooler inserts are
used in these coolers to cause localized
2011 Caterpillar
high water velocity or turbulence within Direction of Flow through Keel

the keel cooler passage. Coolers
An effective design for keel cooler Engine coolant should flow through the
inserts is a ladder-like device, inserted keel cooler from the rear of the vessel
into the full length of the keel cooler toward the front of the vessel. This is
passages. Typical inserts should have counter-flow to the seawater and will
the following design features: significantly increase the effectiveness
of the heat transfer. This is rarely
The inserts must be made of the
practical to implement completely since
same metal alloy as the hull and
the flow must be divided through the
keel cooler to protect against
various flow passages in the keel cooler.
galvanic corrosion.
If the flow is divided through too many
The rails of this ladder shape
passages, the velocity becomes
should be made of 6 mm (1/4 in)
too slow to maintain turbulent flow
diameter rod.
conditions. This will reduce heat
The rungs of this ladder shape transfer. The best compromise is to
should be made from flat bar that manifold the coolant in such a way
has approximately the same that the flow, in the largest practical
shape, but 70% of, the cross number of flow passages, is from rear
sectional area of the to the fore end of the vessel.
keel cooler flow passages
The flat bar cross pieces must not Bypass Filters
restrict flow through the keel Welded structural steel keel or skin
cooler flow passages, but simply cooler systems require the installation
redirect the flow to avoid laminar of strainers between the cooler and the
flow due to too slow an average pump inlet. Material, such as weld slag
velocity. and corrosion products, must be
Insert the ladder into the keel cooler removed from the system to prevent
flow passages and weld on the end wear and plugging of cooling system
fittings (inlet and outlet manifolds). components. Use a continuous bypass
filter to remove smaller particles and
sediment. The element size of the
continuous bypass filter should be
20 to 50 microns (0.000787 to
0.000197 inches). Do not exceed
19 L/min (5 gal/min) water flow
through the bypass and filter.
2011 Caterpillar
Strainers Typical Packaged Keel Cooler

Full-flow strainers are desirable.
The strainer screens should be sized
no larger than 1.6 mm (.063 in) mesh
for use in closed freshwater circuits.
The strainer connections should be no
smaller than the recommended line size.
The use of a differential pressure gauge
across the duplex strainers will indicate
the pressure drop, and enables the
operator to determine when the
strainers need servicing.
The pressure drop across a strainer Figure 31
at the maximum water flow must be
considered part of the systems external Packaged keel coolers are purchased
resistance. Suppliers can help in the as prefabricated units and mounted
proper selection of strainers and furnish to the outside of a ships hull.
the values of pressure drop versus flow Manufacturers offer keel coolers in
rate. The strainer should be selected to many configurations. They are generally
impose no more than 3 ft (1 m) water made of copper-nickel alloys and are
restriction to flow under clean strainer initially toxic to marine growth. This is
conditions. one of their more important advantages.
Another important advantage of
Packaged Keel Coolers packaged keel coolers is their
Although the channel type keel cooling compactness and lightweight when
system discussed so far provides compared to fabricated keel coolers.
advantages over seawater cooling Some packaged keel coolers are able
by eliminating silt/sand build-up and to cool an engine with less than 20%
protecting against corrosion, their bulk of the heat transfer surface of an
size and location can reduce a vessels analogous fabricated keel cooler.
capacity and increase its drag. They are
also prone to seaweed fouling. A more Sizing of Packaged Keel Coolers
compact and streamlined keel cooler Manufacturers of packaged keel coolers
can be provided with a packaged type publish sizing guides which help users
keel cooler as shown in Figure 31. determine the proper cooler size for
specific conditions. Caterpillar does not
offer guidance outside of manufacturers
guidelines, other than providing the
worksheet on Page 130 for the
collection of appropriate keel cooler
sizing data. This data can then be used
by the keel cooler manufacturer to
determine the proper keel cooler.
2011 Caterpillar
Location of Keel Coolers on the Hull Additional considerations for keel cooler
Keel coolers can be mounted almost mounting:
anywhere on a ships hull, providing the Seawater must flow over the
flexibility to match a coolers installation entire length of the unit.
to the hull design and operating Cooler must be parallel to the
conditions of most ships. For example; skeg or keel.
on shallow draft riverboats, the coolers When mounted on the side of the
may be mounted on the side of the hull hull, the cooler must be positioned
or on the skeg. On towboats, they may below the lowest water line to
be mounted near the propeller, in order avoid aerated surface water.
to take advantage of the slipstream
On fast vessels, keel coolers
during heavy towing operations. On
should be located as far aft
fast vessels, they are usually recessed
as possible to avoid aeration.
along side the keel.
Keel coolers should not be located
Mount the keel cooler in a well- directly above propellers, in any
protected area on the hull. This is known high vibration area, or near
particularly true of packaged keel any raw water suction or
coolers which are manufactured of discharge ports.
lighter gauge material than fabricated
keel coolers. Pumps for Keel Cooler Circuits
Ordinarily, the engine water pump will
To achieve the greatest possible heat
satisfactorily circulate the engine jacket
transfer, mount separate keel coolers
water through the keel cooler, if the
for the aftercooler low on the hull and
water lines to and from the cooler are
forward of other keel coolers. As with
relatively short, of adequate size, with
jacket water routing, the aftercooler
minimum bends and if the keel cooler
coolant should flow through the keel
restriction is low. If the total external
cooler from the rear of the vessel
flow resistance cannot be held within
toward the front of the vessel. This
the jacket water pumps capacity, then
arrangement assures maximum heat
the engine driven pump may need to be
transfer with the vessel moving
replaced with a suitably sized electric
forward or motionless.
motor driven pump.
Although the area immediately forward
of the propeller is a region of high water Venting and Piping of Keel Coolers
velocity and high enough on the hull to Locate the cooler and its through-hull
be protected from grounding damage, connections so the length of water
one must consider the effects on the piping will be kept to a minimum and
keel cooler from the propeller. During the cooler will be well vented. Extend
backing maneuvers, the propeller will water piping downward from the engine
create a sandblasting effect by casting to the keel cooler, without high points.
sand and debris toward the cooler. It is very difficult to purge trapped air
from the high points of some keel
coolers. The air must be bled off
during initial fill or when the system is
2011 Caterpillar
completely drained. Vent plugs must used in marine applications. As seen

be designed into the keel coolers in Figure 32, box coolers are mounted
where they rise toward the bow and inside a vessels sea chest. This location
stern, and any other high points where provides excellent protection from
air may be trapped. mechanical damage, but does negate
the benefit that vessel speed through
Corrosion Inhibitors
the water provides for keel cooler
A suitable corrosion inhibitor, carefully
installations. However, box coolers, like
maintained, will minimize internal
keel coolers, eliminate the need for the
corrosive effects. See the section on
raw water system associated with the
Cooling System Protection.
use of inboard heat exchangers.
Box Coolers
Box coolers represent another type of
packaged cooler that is sometimes
Typical Box Cooler
Figure 32
2011 Caterpillar
Seawater Systems Separate Circuit Aftercooled with

Due to its obvious proximity and Heat Exchangers (with Aftercooler
excellent heat transfer capabilities, Seawater Recirculation)
seawater is commonly used as a Jacket Water Aftercooled with
cooling medium in marine and Heat Exchanger
offshore applications. Heat exchangers can be mounted on
Seawater cooling systems, similar to the engine or remote from the engine.
other types of cooling systems, have Engine-mounted heat exchangers
many special design considerations that require the least amount of pipe fitting
must be taken into account in order to since the jacket water connections to
ensure satisfactory engine operation the heat exchanger are provided by
and service life. the factory.
Typical seawater cooling system Remote-mounted heat exchangers
configurations are represented in Figure require connecting the jacket water
33, Figure 34, Figure 35 and Figure 36. inlet and outlet at the engine to the
Jacket Water Aftercooled shell side of the exchanger. As shown
with Heat Exchanger in Figure 33, an engine driven seawater
Seawater Aftercooled pump is used to circulate the cooling
Separate Circuit Aftercooled with water through the heat exchanger.
Heat Exchangers
Jacket Water Aftercooled with Heat Exchanger
Figure 33
1. Turbocharger 6. Jacket Water Pump 11. Duplex Full-Flow Strainer
2. Aftercooler, Jacket Water Cooled 7. Auxiliary Seawater Pump 12. Heat Exchanger
3. Jacket Water Outlet Connection 8. Seawater Inlet Connection 13. Shut-Off Valve
4. Jacket Water Inlet Connection 9. Seawater Outlet Connection 14. Seawater Intake
5. Expansion Tank 10. Pressure Cap
2011 Caterpillar
Seawater Aftercooled inlet manifold air temperatures lower

Engines equipped with seawater than those resulting from jacket water
aftercoolers use untreated water in the or separate circuit fresh water
tube side of the aftercooler. Seawater aftercooling. This lower inlet manifold air
refers not only to salt water but also temperature permits ratings of seawater
includes river water, lake water or any aftercooled engines that exceed those
source of untreated water. Use of of jacket water aftercooled engines.
seawater for aftercooling achieves
Seawater Aftercooled
Figure 34
1. Turbocharger 7. Auxiliary Seawater Pump 12. Heat Exchanger

2. Aftercooler, Seawater Cooled 8. Auxiliary Seawater Inlet 13. Shut-Off Valve
3. Jacket Water Outlet Connection Connection 14. Seawater Intake
4. Jacket Water Inlet Connection 9. Aftercooler Outlet Connection 15. Seawater Discharge
5. Expansion Tank 10. Pressure Cap
6. Jacket Water Pump 11. Duplex Full-Flow Strainer
2011 Caterpillar
Separate Circuit Aftercooled with aftercooler circuit requires the use of

Heat Exchangers a seawater pump in addition to the
A heat exchanger will also provide freshwater pump used to circulate
cooling for fresh aftercooler water if the water through the aftercooler. An
seawater temperatures are cold enough expansion tank is also required for
to provide adequate cooling. The use of the aftercooler circuit.
an inboard heat exchanger for the
Figure 35
1. Turbocharger 8. Auxiliary Fresh Water Inlet 15. CustomerProvided Seawater

2. Aftercooler, Heat Exchanger Connection Pump
Cooler 9. Aftercooler Outlet Connection 16. Seawater Intake
3. Jacket Water Outlet Connection 10. Pressure Cap 17. Seawater Discharge
4. Jacket Water Inlet Connection 11. Shut-Off Valve 18. Expansion Tank for Aftercooler
5. Expansion Tank 12. Duplex Full-Flow Strainer Circuit
6. Jacket Water Pump 13. Heat Exchanger for Aftercooler 19. Vent Line for Aftercooler Circuit
7. Auxiliary Fresh Water Pump 14. Heat Exchanger for Jacket Water
2011 Caterpillar
Separate Circuit Aftercooled with air temperatures are relatively warm

Heat Exchangers with Aftercooler with high moisture content.
Seawater Recirculation The thermostatic valve used should not
The separate circuit aftercooler cooling allow the temperature of the water to
system must be designed with sufficient the aftercooler to exceed 30C (85F).
capacity for the hottest water and the The heat exchanger and marine
higher ambient air conditions for transmission oil cooler used must be
operation in climates where both air sized for this maximum temperature.
and seawater temperatures run to A thermostatically controlled 3-way
extremes. This results in a cooler with valve that is equipped with a remote
excess capacity in cold seawater and sensor to monitor the inlet manifold air
warm air conditions. This can result in temperature can be used. Adjust the
condensation in the engines intake remote sensor to insure that the
system, especially during prolonged thermostatic valve does not permit
light engine load. Extremely cold recirculation when the inlet manifold
seawater in the aftercooler can also temperature reaches 49C (120F).
cause condensation when engine inlet

(with Aftercooler Seawater Recirculation)
Figure 36
1. Turbocharger 7. Auxiliary Seawater Pump 12. Heat Exchanger

2. Aftercooler, Seawater Cooled 8. Auxiliary Seawater Inlet 13. Shut-Off Valve
3. Jacket Water Outlet Connection Connection 14. Seawater Intake
4. Jacket Water Inlet Connection 9. Aftercooler Outlet Connection 15. Seawater Discharge
5. Expansion Tank 10. Pressure Cap 16. Bypass Valve Thermostatically-
6. Jacket Water Pump 11. Duplex Full-Flow Strainer Controlled
2011 Caterpillar
It is important that water be recirculated 3600 Combined Circuit System

rather than be throttled to reduce flow. Figure 38 is a typical combined circuit
It is essential that unrestricted water seawater cooling system designed for
flow through the aftercooler be 3600 marine applications. The fresh
maintained regardless of temperature water circuit is cooled with seawater
conditions. Thermostatic valve plumbing having a maximum temperature of
must be sized to have internal diameters 32C (90F). Since the lubricating oil
as large, or larger, than the inlet and air aftercooler are cooled directly
connection of the auxiliary pump. Use by water from the fresh water cooling
an air intake manifold temperature alarm circuit, only one fresh water heat
set for 52 to 57C (125 to 135F) exchanger is required. The aftercooler
maximum to warn of a system and oil cooler systems are an integral
malfunction. part of the basic engine design; nothing
In situations where condensation can be is required from the shipyard to pipe
a problem, a corrosion-resistant water these systems. The arrangement
trap can be attached to the intake reduces the seawater piping system
manifold(s) of the engine; refer to and lowers the cost of expensive
Figure 37. copper-nickel alloy piping, fittings,
and valves. The result is less wear,
Condensate Valve Group corrosion problems, and maintenance.
Figure 37
2011 Caterpillar
Typical Seawater Cooling System
Figure 38
2011 Caterpillar
Sea Chest Sea Valve

The sea chest serves the following Where practical, all sea valves should
functions: be flanged gate or globe type. Lug type
butterfly valves may also be used.
Provides a low restriction
Angle valves can be used where the
connection for the seawater
installation of gate, globe or butterfly
inlet plumbing.
valves are impractical.
Provides a connection point for
the sea cock. The sea cock is a Sea valves should be controllable from
seawater shutoff valve that is a deck above the sea chest. Fit all
installed between the seawater valves with open/close indicators.
inlet and the seawater inlet The recommended materials for sea
plumbing. chest or overboard discharge valves are
Provides a way to separate air cast steel, bronze or nodular iron. Cast
from the seawater required for iron and malleable iron valves are not
cooling. Sea chests must have recommended. The valve seat, disk,
vent connections to allow air, and stem must be made from corrosion
forced under the hull during resistant material such as monel alloys.
maneuvering, to be purged before Seawater Strainers
it is able to reach the centrifugal Strainers are required in order to protect
seawater pump. the seawater pump, aftercooler, heat
Suction Line exchanger and other cooling system
The installation, size and material of the components from foreign material in the
seawater suction lines are extremely seawater. The foreign material can plug
important. and/or coat heat transfer surfaces,
The seawater suction lines should be causing overheating of the engine and
below the vessel water line as much as shortened life of components. If the
possible and designed without air traps. foreign material is abrasive, it will erode
pump impellers and soft metal parts,
Install a water pressure actuated check reducing their effectiveness.
valve downstream of the strainer and as
close to it as possible. The function of Seawater strainers should be installed
the check valve is to prevent water from below the water line and as close to the
draining out of the pump inlet while the seawater inlet or sea chest as possible.
pump is not operating and during The strainers should also be installed
cleaning of the strainer. Install a vent adjacent to the sea cock and before the
valve between the strainer and the first component of the cooling system.
check valve to allow venting of trapped The strainer must be installed so it can
air after cleaning the strainer and be easily cleaned, even in the worst
opening the sea cock. If the pump is weather conditions.
above the vessel water line, install a Although simplex strainers will
piping loop above the pump inlet elbow adequately protect the engine, they
to trap enough water to keep the pump require the seawater flow to be shutoff
and priming chamber filled. during servicing. Duplex strainers can be
cleaned without interrupting seawater
2011 Caterpillar
flow or engine power and greater safety Priming

will result. It is strongly recommended All seawater pumps (self priming,
to use a serviceable strainer in order to centrifugal and water ring pumps)
allow frequent cleaning. MUST be filled with water prior to initial
Appropriately sized strainers will impose start up to ensure that the pump primes
no more than 9 kPa (3 ft H2O) restriction and also to avoid damaging the
to flow at full seawater flow conditions. mechanical seal and impeller. Once
Suppliers can help in the proper initial priming has taken place, there is
selection of strainer size by providing no need to re-fill the pump unless the
the flow restriction of each size of system has been fully drained.
strainer at varying water flow
Seawater Pumps
conditions.
Two centrifugal seawater pumps are
Strainer media of 2.0 mm (0.079 in) typically required for marine propulsion
diameter hole size or less is required. applications; one is engine driven and
Strainer media of 1.6 mm (0.0625 in) one electrically driven.
diameter hole size is recommended in
The engine driven seawater pump is not
applications where sea grass and/or
self-priming, so it must be located below
other debris are present, or cases when
the light water line of the ship or a
plugging of engine cooling components
priming arrangement must be provided.
persists with the use of 2.0 mm
The engine power required to drive the
diameter media.
Caterpillar supplied pump is shown in
Schools of small fish, ice chips and TMI.
floating debris such as plastic bags and
The electrically driven seawater pump
plant material can plug a clean strainer
capacity is determined by the type of
in a few seconds. When this happens,
cooler used, heat to be dissipated, and
the differential pressure across the
the seawater inlet temperature. The
strainer will rise. This is an indication
heat to be dissipated in the main engine
that the strainer should be cleaned. A
fresh water heat exchanger is listed on
differential pressure switch will provide
the engine technical data sheets.
early warning of strainer plugging and
resultant loss of engine cooling. In time, In many seawater systems, the pump
high engine water temperature alarms supplying cooling water to the main
will also warn of a loss of seawater engine heat exchanger also supplies
flow, but the differential pressure sensor cooling water to auxiliary heat
will give early warning and the precise exchangers, such as the reduction gear
location of the problem. Even with a oil cooler. In these arrangements, the
differential pressure sensor, best capacity of the seawater pump must
practice is to clean the strainer be increased to allow for the additional
frequently in order to ensure optimum requirements.
engine performance and reduce stress Start and stop control of the electric
on the cooling system components. motor driven pump should be with a
pressure switch installed in the common
discharge line from the pumps. The
2011 Caterpillar
switch starts the pump at 35 kPa (5 psi) Caution: A goose neck may be
and stops at 245 kPa (35 psi). The necessary with these pumps to keep
pipes connecting to the individual water in the pump for priming. The
pumps must be at least equal to the goose necks are made entirely of
pump suction diameter, to minimize corrosion resistant metals, with no
the restrictions in the suction piping. elastometric components.
The suggested materials for seawater Centrifugal Seawater Pumps
pumps are shown in Table 6. Centrifugal seawater pumps must be
installed with their inlet below the boats
Suggested Material for Seawater light waterline. Air allowed to enter
Pumps centrifugal seawater pumps will likely
Component Material/Type result in loss of prime and probable
Casing Bronze engine damage due to loss of cooling.
Do not start an engine equipped with a
Impeller Bronze centrifugal pump unless the pump and
Shaft Monel priming chamber are full of water.
Seal Type Mechanical Seawater Piping
Table 6 Flow restriction in the seawater suction
piping will result in abnormally high
Caterpillar offers three types of engine temperatures which can lead to
seawater pumps. unscheduled shutdowns and, in severe
Rubber Impeller cases, reduced engine life. To minimize
Water Ring flow restriction, pipes and hoses should
be at least as large as the seawater
Centrifugal
pump suction opening.
Rubber Impeller Seawater Pumps If the distance to the through-hull fitting
Rubber impeller seawater pumps are or sea chest is large or if many pipe
characterized by excellent priming elbows or bends in the hose are used,
characteristics, though they often suffer the pipe or hose size should be one size
relatively short life in abrasive waters. larger than the seawater pump opening
Water Ring Seawater Pumps (suction connection). In no case should
Their priming characteristics are less the seawater pressure, measured at the
than rubber impellers, but can lift up seawater pump suction, be less than
to 1.5 m (5 ft). 24 kPa (3.5 psi) vacuum.
Piping System Materials
An excellent material for piping carrying
seawater is of the copper- nickel
alloys; CuNi 90/10 UNS C70600 is
recommended. The cost of such piping
makes its use unusual for all but the
most critical systems.
2011 Caterpillar
The material of all the seawater piping A plate and frame type heat exchanger
should be the same, whenever practical. can be substituted for the shell and tube
If parts of the seawater piping, made of type. If installed, the suggested
different metals, make contact with materials for the plate and frame heat
each other, one of the metals will exchanger are shown in Table 8.
corrode, sometimes very rapidly.
The materials will corrode according to Suggested Material for Plate & Frame
their position in the electromotive series. Type Heat Exchangers
See electromotive series chart in section Component Material/Type
of Useful Tables to Designers of Frame Mild Steel, Painted
Cooling Systems.
Titanium or
Black iron pipe is often used in seawater Seawater Plates
Aluminum Brass
service (replacement should be planned
every two or three years). If it is Fresh Water
Stainless Steel
necessary to use pipe or other cooling Plates
system components of more than one Seawater
Steel, Coated
material, avoid letting the dissimilar Nozzles
metals touch, even by mutual contact Fresh Water
with an electrically conductive third Steel, Coated
Nozzles
material.
Gaskets Nitrile
Corrosion will be much more severe if a
flow of electrons is able to pass freely Table 8
from one of the metals to the other.
Classification societies may require a
Fresh Water Heat Exchangers spray shroud around the plates to
Caterpillar supplies both shell and tube prevent liquid spray on equipment or
and plate and frame type coolers for the personnel if a gasket fails.
fresh water heat exchanger. The engine technical data sheets include
The suggested materials for the shell heat rejection to the seawater for the
and tube type heat exchangers are various propulsion engine ratings. Add
shown in Table 7. a safety margin of 10% to the total
heat rejection to allow for heat
Suggested Material for Shell & Tube exchanger fouling.
Type Heat Exchangers Marine Gear Oil Cooler
Component Material/Type Reduction gear lube oil coolers normally
Shell Steel use seawater taken directly from the
Heads Iron engine seawater circulating system.
The water flow required is obtained
Tubes 90/10 CuNi
from the gear manufacturer.
Tube Sheets 90/10 CuNi
Baffles Steel
Table 7
2011 Caterpillar
Stern Tube Lubrication & Cooling darkness and abundance of suspended

It is good practice to divert a small food particles combine to create prime
portion of the engines seawater to growth conditions for sponges,
lubricate and cool the stern tube and barnacles and like creatures. Strainers
stuffing box (sometimes called the are no protection against creatures that
packing gland) before discharging it are microscopic in size during their
overboard. Generally, 4-12 L/min infant stages of life.
(1-3 gal/min) are adequate. Periodic operation in fresh water will
The engines seawater strainer and the exterminate salt-water life in the cooling
flow of water from the stuffing box end system. Likewise, periodic operation in
of the stern tube will tend to keep sand salt-water will exterminate fresh water
and other abrasive material out of the life. However, the cooling system
stern tube. piping and passages must be cleaned
Avoid using excessive quantities of to remove the deceased organisms.
the engines flow of seawater, as this Heat exchangers must be periodically
practice tends to increase the seawater disassembled to remove marine growth
system restriction, making the engine in the heads and tubes.
more likely to overheat. Periodic chemical treatment combats
Seawater Temperature marine growth. Chemical type and
In some instances, the seawater concentration must be carefully
temperature may be too low for the controlled to prevent deterioration
fresh water heat exchanger. It can be of the seawater cooling system
raised by installing a locally or remote components. Contact a knowledgeable
controlled three-way valve just inboard chemical supplier. Continuous low-
of the overboard discharge valve. The concentration chemical treatment via
valve bypass feeds warmed discharge either bulk chemical or self-generating
water directly back to the common electrical processes is offered by
suction pipe of the seawater various manufacturers.
circulating pumps. High water temperature alarms,
Note: Pressure drop across the valve seawater pump pressure switches and
would normally be about 35 kPa (5 psi), other instrumentation can be used and
and must be included in the seawater are highly recommended to warn of
pump total dynamic head requirements. the gradual loss of seawater flow.
Marine Growth Potential Problems

Marine plants and animals will enter Non-reinforced Seawater Pump
seawater systems and take up Suction Hose
residence in the piping and passages of The vacuum inside the Seawater Pump
the heat exchanger. Many forms of sea Suction Hose can become quite high.
life are very comfortable within engine If the hose is not internally reinforced,
cooling system piping and will grow to a atmospheric pressure will collapse it.
size that will threaten adequate cooling That will severely impede the flow of
system flow. The lack of predators, seawater with potentially dangerous
2011 Caterpillar
results. Use a hose which is sufficiently Corrosion

strong to resist collapse due to high Galvanic Corrosion in Seawater
suction vacuum. When two dissimilar metals are
Internal Hose Deterioration electrically connected and both
Some hose will shred internally, submerged in saltwater, they form a
releasing bits of rubber which can plug battery and an electrochemical reaction
cooling passages. It is good practice to takes place. In this process, one metal is
use good quality hoses. If users are eaten away. The rate of deterioration is
unsure of their hoses quality, it is good proportional to a number of factors:
practice to examine hoses internally at The differential potential
least once during their life. Replace between the two metals on the
them with good quality hose every electrochemical series (see Useful
three years. Tables to Designers of Cooling
Achieving and Maintaining Seawater Systems).
Pump Prime The relative areas of the two
Pump speeds and suction pressures metals: If there is a small area of
must fall within certain limits for the more noble metal relative to
seawater pumps to achieve prime the less noble metal, the
(start pumping water). The priming deterioration will be slow and
characteristics of Cat seawater pumps relatively minor. If there is a large
are available from the factory. area of the more noble metal such
as copper sheathing on a wooden
Seawater Discharge through Exhaust
hull, and a much smaller area of
System
the less noble metal, such as iron
Wet exhaust systems use seawater,
nails holding the copper sheathing
after it has passed through the various
to the wood, the wasting away of
heat exchangers and coolers, to cool
the iron nails will be violent
the hot exhaust gases. After seawater
and rapid.
is injected into the hot exhaust gas
Stray electrical currents will
(generally immediately downstream
accelerate the electrochemical
of the engines turbocharger), the
reaction. Proper grounding and
temperature of the gas is reduced
isolation from all electrical sources
enough to allow use of sections of
is required.
rubber hose, fiberglass-reinforced plastic
pipe or other similar materials to be used Dissimilar Metal Combinations to
as exhaust pipe. It is critical that nothing Avoid
interfere with the flow of seawater Bronze Propeller on Steel Shaft
which cools the exhaust gas. Anytime Mill Scale on Hull Plate (Internal
the engine is operating, the flow of or External)
seawater must be present. Aluminum Fairwaters Fastened to
a Steel Hull
Steel Bolts in Bronze Plates
2011 Caterpillar
Bronze Unions and Elbows Used converting to fresh water system. For
With Galvanized Pipe seawater cooled systems, zincs should
Bronze Sea Cocks on Iron only be installed on the discharge of the
Drain Pipes pump. Zincs installed on the inlet side of
Brass Bilge Pumps on Boats With the pump after the strainer could result
Steel Frames in pump damage.
Brass, Bronze, or Copper When electrical contact is made through
Fasteners in Steel Frames the fastening studs, it is desirable to put
Stainless Steel Pennants on Steel galvanized or brass bushings in the
Mooring Chains holes in the zincs so that contact will
Bronze or Brass Rudder Posts With be maintained as the zincs corrode.
Steel Rudders Zinc anode rods should be initially
Bronze Rudders With Steel inspected after the first 50 hours of
Stopper-Chains operation. The condition of the zinc
Steel Skegs (Rudder Shoes) rod will determine how often the zinc
Fastened With Bronze or Brass rods should be inspected for possible
Leg Screws replacement. As zinc rods work, a
Steel and Brass Parts in the Same white, crust-like deposit of zinc oxides
Pump and salts form on the surface. This is
Many of the combinations above follow normal. If it does not form and the zincs
this basic rule: remain clean and like new, they are not
protecting the structure. This would
Do not put iron or steel close to or
indicate that the zinc anodes are either
connected with alloys of copper in
not connected electrically to the less
salt water.
noble metal or the anode is not located
The Protective Role of Zinc in the right location to protect the less
If alloys of copper (bronze, brass), iron noble components. This should be
(steel), and zinc are all connected corrected immediately as the less
together and submerged in salt water, noble metal will quickly be eaten
the zinc will be eaten away, protecting away be corrosion.
the iron (steel). It is necessary to have Zinc anodes are available in two types,
a metallic electrical connection to the threaded and press fit. The press fit type
metals to be protected. This is usually is where the zinc anode is pressed into
easy to accomplish on a steel hull. It is the threaded plug. The threaded type is
more difficult on a fiberglass hull, since where the zinc anode is threaded into
special electrical connection may be the threaded plug that is inserted into
required unless the zincs are connected the desired plumbing location. Caterpillar
directly to one of the metals, preferably recommends using the threaded type.
the copper alloy. The press fit type can fail prematurely
Note: The zinc must never be painted and fall out of the threaded plug. Then
or its protective quality will be lost. the desired protection to the system
Zincs are not necessary for keel cooled will not be provided. Zinc anodes are
systems and should be removed when made in two types of material. Type 1
2011 Caterpillar
contains zinc and cadmium. This is the Pressure taps should be installed before
most common standard type of anode. and after the seawater heat exchanger
Type 2 contains almost pure zinc. This to allow for flow measurement.
is the standard for under ground mining
Contaminants
applications. Caterpillar recommends
Flow rates should not exceed 2 meters
using only the Type 2 threaded anodes
per second if the seawater contains
as the anode will last longer, and the
sand or debris to prevent erosion.
cadmium is a hazardous material to
the environment. Inspect the zinc plugs Contaminants in the cooling system
within 24 hours of filling the piping with can cause component failure quickly
seawater. If no significant corrosion if the zinc anodes are not properly
is noted, inspect them again after 50 installed and maintained. Dissimilar
operating hours. Inspect them again in metals are common on tubes and
7 days of seawater submersion. If no piping from the manufacturer due to
significant deterioration is noted, the machinery forming the material or
inspect them again in 60 to 90 days. from fabrication and installation of the
Thereafter, inspect on a regular basis plumbing system. This can leave small
determined by the life of the zinc particles of metal on the formed metal
anodes and replace them when and can cause pitting of the formed
necessary. Time after submersion is a piece if not protected. Even with
critical factor since corrosion continues washing and cleaning some of these
when the engine is not running. particles remain on the surfaced of the
desired component. This is common
Seawater flow rate is critical to system
for many materials and the effect is
component life. A protective film is
accelerated when seawater is present in
produced on the surface of copper
the system. This is why it is very critical
nickel if fresh clean oxygenated
to properly maintain the zinc anodes as
seawater continuously flows at a
they are the protection for the entire
minimum rate of 1 meter/second. Too
seawater cooling system. Without their
little or too much flow rate can cause
protection failure can happen in a
component failure. The system should
matter of hours.
not be left idle or stagnant (without
circulation flow) when ever possible.
If the system is to be shut down for
more than a few hours then the system
should be drained and blown dry with
compressed air. Localized pitting of
components can occur quickly if salt
water is left uncirculated in the
plumbing. A minimum flow rate of
1 m/sec should be maintained even if
the engine is not running. Flow rates
greater than 3.5 meters per second can
cause the protective film to be eroded.
2011 Caterpillar
General Corrosion
Electrochemical Series A protective film is produced on the
The following series of elements is
surface of copper-nickel if fresh
listed in order of highest reactivity or
clean oxygenated seawater
corrosiveness to lowest, as they relate
continuously flows at a minimum
to cooling system components.
rate of 1 meter/second. If long
Corroded End Least Noble
stagnant conditions are expected,
Magnesium
Magnesium Alloys blow-drying the system is
Zinc recommended.
Beryllim Flow rates greater than 3.5 meters per
Aluminum Alloys
second can cause the protective film to
Cadmium
Mild Steel or Iron be eroded.
Cast Iron Polluted water containing sulfides is
Low Alloy Steel especially corrosive to copper alloys
Austanitic Cast Iron
Aluminum Bronze
and should be avoided.
Naval Brass Erosion
Yellow Brass Flow rates should not exceed 2 meters
Red Brass
18-8 Stainless Steel (Active) per second if the seawater contains
18-8-3 Stainless Steel (Active) sand or debris.
Lead-Tin Solders Pressure taps should be installed before
Lead
and after the seawater heat exchanger
70-30 Copper Nickel
Tin to allow for flow measurement.
Brasses
Copper
Bronzes
Copper-Nickel Alloys
Monel
Admiralty Brass, Aluminum Brass
Manganese Bronze
Silicon Bronze
Tin Bronze
Silver Solder
Nickel (Passive)
Chromium-Iron (Passive)
18-8 Stainless Steel (Passive)
18-8-3 Stainless Steel (Passive)
Silver
Ni-Cr-Mo Alloy 8
Titanium
Ni-Cr-Mo Alloy C
Gold
Platinum
Graphite
Protected End Most Noble
2011 Caterpillar
Heat Recovery
Heat recovery refers to the capture water, water and steam, and ebullient
and utilization of heat energy which steam systems.
is normally wasted. This process, Heat Balance
increasingly common today, improves The typical heat balance for a Cat
total system efficiency and return on engine is shown in Figure 39. Heat
investment. rejection values for the following
Reciprocating engines convert about components are provided for all engines
30-42% of their input fuel energy into in the Technical Data Manual or
mechanical power. Another 20-40% Specification Sheets.
is rejected to the jacket water, 30-40% Jacket Water Heat Rejection
to exhaust, and 5-7% is radiated to the
Oil Cooler Heat Rejection
environment.
Aftercooler Heat Rejection
The heat rejected by the jacket water
Exhaust Heat Rejection
can be totally recovered and 50-70%
Exhaust Heat Recoverable
of the exhaust energy is economically
recoverable. Total heat recovery results
Typical Heat Balance for Cat Engines
in approximately 80% efficiency.
Heat recovery design best suited for
any installation depends on many
considerations, both technical and
economic. The chief function of any
design is to cool the engine. The engine
must be cooled even when heat
demand is low, but power is still
required.
There are two heat recovery methods:
standard temperature and high
temperature. Standard temperature
heat recovery systems recover heat
from coolant at up to 99C (210F)
outlet temperature. High temperature
heat recovery systems recover heat
Figure 39
from coolant at up to 127C (260F)
outlet temperature. High temperature
systems are further divided into solid
2011 Caterpillar
Heat Balance Calculation

Typical heat balance calculations are illustrated in the following example. The values
used in the example are for illustration purposes and should not be used for design.
Refer to the published heat rejection data for the specific engine for design
calculations.
2011 Caterpillar
Standard Temperature Heat bypass line are retained. The engine

Recovery system is independent from the load
Heat recovery of a standard engine may process loop, which allows operation
amount to nothing more than utilizing with antifreeze and coolant conditioner.
heat transferred from the engine This relieves concern for problems
radiator. This air is usually 38-65C associated with using process water
(100-150F). The recovered heat is to cool the engine.
quite suitable for preheating boiler When normal process load is insufficient
combustion air, space heating or drying to absorb enough heat, load balancing
grain and lumber. The system cost is thermostatic valves limit jacket water
minimal and overall efficiency will inlet temperature by directing coolant
increase to approximately 60%. through a secondary cooling source
A more versatile method of recovering (load balancing heat exchanger).
heat from a standard temperature Note: The load balancing heat
system uses a heat exchanger to exchanger must be incorporated in
transfer rejected engine heat to a the engine loop, not the load loop.
secondary circuit, usually process The load balancing condenser may be
water. An example system is illustrated either a heat exchanger or radiator. Heat
in Figure 40. There are many transfer through the load balancer is
advantages inherent with this design. usually cyclical. If a radiator is used, it
The standard engine jacket water pump, must be designed to withstand thermal
thermostatic configuration, and water shocks developed from cyclic loading.
Standard Temperature Water System
Figure 40
2011 Caterpillar
A second variation on the standard expansion tank may be utilized.

temperature system includes an exhaust Generally, boiler water is used as a
heat recovery device in the system in medium in the load loop. Boiler water
series, parallel, or as a separate water or is pumped through the jacket water
steam circuit. Consult the manufacturer heat exchanger and exhaust heat
for design details for the unit in recovery device in series where it is
question. Figure 41 shows a muffler heated to the desired temperature.
included in series with the engine As shown, water flow through the
system. Note the engine loop is still expansion tank provides deaeration.
separate from the load loop. The engine
Standard Temperature Water System with Muffler In Series
Figure 41
2011 Caterpillar
A third variation on the standard components. The disadvantages to this

temperature system is to incorporate system are the engine cooling system is
the exhaust heat recovery device into modified, and the design of the system
the engine cooling loop, Figure 42. To becomes more critical to successful
ensure coolant flow through the muffler, engine operation.
the engine thermostats and the bypass Caution: Any heat recovery system
line must be removed and an external where the process water circulates in
warm-up thermostat is added. (The the engine is not recommended.
added external resistance of the heat Experience has shown that, in most
recovery device may exceed the cases, the user cannot economically
allowable resistance available from the treat the quantity of process water to
engine mounted pump.) An auxiliary the level required to avoid maintenance
circulation pump may be required. The problems with the engine.
advantages of this system are that the
obtainable process water temperature is
usually higher and there are fewer
Standard Temperature Water System with Exhaust Heat Recovery Device

Incorporated
Figure 42
2011 Caterpillar
Critical Design Criteria for Standard coolant temperature falls below

Temperature Heat Recovery 94C (194F) to avoid steam
The purpose of the following discussion pockets forming inside the engine.
is to call attention to certain basic If the engine thermostats are
criteria necessary for proper operation removed, an external warm-up
of a heat recovery system. In no way thermostat is required.
should this be considered an all-inclusive To keep external head within
list. Contact a consulting engineer for allowable limits for the engine-
specific requirements. mounted pump, locate heat
The system must provide recovery mufflers and heat
adequate coolant flow through the exchangers as near the engine as
engine so the engine coolant possible. While static head on the
temperature differential (outlet jacket water pump is limited to
minus inlet) does not exceed 172 kPa (25 psi) static head
11.1C (20F). greater than 35 kPa (5 psi)
The expansion tank must be the requires the expansion tank to be
highest point in both the engine vented to air, i.e., no pressure cap.
and load loop cooling systems.
The pressure cap on the expansion High Temperature Heat
tank should be rated for a pressure Recovery Circuits
higher than the inlet pressure To ensure proper cooling in all types of
requirements of the jacket water high temperature systems, the engine oil
pump. cooler and aftercooler require a cooling
Use only coolant or treated water water circuit separate from the engine
in the engine cooling circuit. jacket water. A thermostat in the oil
Incorporate deaeration circuit and system bypasses the oil cooler to
air vents to eliminate air traps and control lubricating oil minimum
locks. temperatures and prevent overcooling.
If the coolant in the oil cooler circuit can
A load balancing thermostatic
be below 10C (50F), an external
valve must be used to direct
control valve is recommended to allow
coolant through a secondary
the oil to reach operating temperature,
cooling source to limit jacket water
prevent oil gelling, and ensure oil flow
inlet temperature.
through the oil cooler.
Coolant must continually flow
through the exhaust heat High Temperature Solid Water
recovery device when the engine System
is operating to avoid thermal shock This system functions similar to a
on hot muffler surfaces. This may standard temperature water system
be accomplished using a low except elevated jacket water
water flow shutdown device. temperatures 99-127C (210-260F)
After engine shutdown, the are used. The standard thermostat and
coolant must continue to flow bypass are removed and replaced by an
through the engine until the external control. A pressure cap or static
2011 Caterpillar
head must be provided in the engine Water pumps must be suitable for
coolant circuit to assure a pressure of use with elevated temperatures
27.6-48.3 kPa (4-7 psig) above the and pressures.
pressure at which steam forms. (See The engine oil cooler requires a
Pressure Control) cooling circuit separate from the
The source of this pressure may be engine jacket water.
a static head imposed by an elevated The load balancing heat exchanger
expansion tank or controlled air pressure must be incorporated in the engine
in the expansion tank. For 127C loop, not the load loop. The load
(260F) water, the pressure at the balancing condenser may be either
engine should be approximately a heat exchanger or radiator. Heat
172 kPa (25 psig). Maximum system transfer through the load balancer
pressure allowed on the engine water is usually cyclical. Thus, if a
jacket is 276 kPa (40 psig). This is radiator is used, it must be
measured by taking the total of designed to withstand thermal
circulating differential pressure, system shocks developed from cyclic
pressure, and static resistance on the loading.
system. The standard jacket water For multiple units that share
pump is removed and must be replaced a single steam separator, all
by one with high temperature and circulating pumps must run when
pressure capabilities. any one engine operates. This
Critical Design Criteria for High practice prevents a severe thermal
Temperature Solid Water shock if a unit is started later.
High temperature solid water systems High jacket water temperatures
include the same basic requirements as will result in after-boil if there
a standard temperature system, but the is a hot shutdown. Add an
following points must also be additional 10% of system volume
considered. to the normal expansion tank
sizing guidelines to provide
A high temperature system
expansion volume (25% total for
requires a pressure control valve
high temperature solid water
for the engine coolant circuit.
systems).
2011 Caterpillar
High Temperature Water-Steam System
Figure 43
High Temperature Water-Steam consuming steam, the pressure in the

System steam line will increase. Once pressure
The high temperature water-steam reaches 90 kPa (13 psig), the excess
system provides solid water to cool the steam valve will open to transfer engine
engine, but then flashes it to steam to heat to the waste cooling device (load
be used for loads requiring low-pressure balancing condenser). The excess steam
steam, 96 kPa (14 psig). A circulation valve must be located downstream from
pump forces water through the cylinder the pressure control valve to function
block to the steam separator. In the properly.
steam separator, some of the water Critical Design Criteria for High
flashes to steam and the water returns Temperature Water-Steam
to the engine. High temperature water-steam systems
The pressures shown in Figure 43 are include the same basic requirements as
representative values. The relief valve a standard temperature system and a
pressure 103 kPa (15 psig) is set by high temperature solid water system,
boiler codes qualifying low-pressure but there are also the following
steam. Pressure in the separator is additional points which are important
controlled by the pressure control valve. to consider:
When the pressure builds to 96 kPa
There are no elevation or static
(14 psig), the control valve will allow
resistance requirements for the
steam to flow. The actual steam
steam separator other than what
pressure in the load line is a function
suction head is required for the
of load requirements. If the load is not
circulation pump. Thus, this
2011 Caterpillar
system may be used in locations be downstream of the pressure

with limited overhead clearance. control valve.
The maximum temperature at the A warm-up thermostat is not
engine outlet must not exceed required since the pressure control
130C (266F). Inlet pressure to valve does not allow any heat
the pump must be maintained (steam) to exit the system until
within limits to prevent cavitation the engine has warmed up and the
at the high temperatures. separator has reached system
A pressure switch is required pressure.
at the jacket water inlet to the
engine in order to monitor absolute Water Quality and Treatment
pressure. for Heat Recovery Cooling
A low water flow shutdown Systems
device is required on high Standard Cooling Systems
temperature cooling engines. The coolant recommendations outlined
This is accomplished by using previously for typical diesel and gas
a differential pressure gauge engine applications apply here.
across the engine water jacket.
When the water flow rate slows High Temperature Cooling Systems
or stops the lack of a pressure The engine cooling water in a low-
drop across the engine block will pressure steam or high temperature
shutdown the engine. Since an water system can be circulated within
electric motor driven pump is the engine water jacket at temperatures
used, it is important to insure the above 100C (212F). As a result,
pump is operating while the engine there is a potential for steam to form in
is running. The pump should both of these applications. Since several
continue running approximately localized areas of the engine jacket
five minutes after the engine is water system can have very high
stopped to cool the engine. heat flux rates and narrow water flow
Use only treated water in the passages, the engine water chemistry
cooling circuit. Continuous water will have the same requirements as
chemistry monitoring with a close tolerance steam boiler.
automatic boiler blow-down Note: The coolant specifications in this
devices are recommended. guide and in the Cat operators manual
A low water level shutdown have been written for ethylene glycol
on the steam separator device is systems with temperatures less than
required. A low water level 100C (210F). This is not applicable
pre-alarm is also recommended. for low-pressure steam and high
Low water level could cause temperature heat recovery systems.
engine overheating and serious Minerals in the water can precipitate
damage. during the heating process and form
The excess steam valve cannot be deposits within the cooling system of
in the steam separator and must the engine. These deposits can restrict
2011 Caterpillar
the heat transfer and water circulation, jacket water should not exceed the
resulting in engine failure. To prevent following maximum concentrations:
these deposits from forming in the Silica concentration:
cooling system, the following engine 150 ppm as SiO2
jacket water (boiler water) quality
guidelines are recommended. Total alkalinity:
700 ppm as calcium CaCO3
Make-up Water
Make up water is added to a low- Specific conductance:
pressure steam system to replace 3500 micro mho per cm
steam and blowdown losses. It should Total suspended solids:
not exceed the following maximum 10 ppm
concentrations:
These stringent guidelines are based on
Iron: 0.1 ppm established limits of the American Boiler
Copper: 0.05 ppm Manufacturers Association (ABMA)
Total Hardness: 0.3 ppm as CaCO3 and recommendations of the ASME
The make-up water can be treated to Research Committee on Water in
reduce, or remove, the impurities from Thermal Power Systems.
the water. In general, the water is In addition to the above chemistry,
treated when one or more of the feed Caterpillar recommends the engine
water impurities are too high to be jacket water (boiler water) be treated
tolerated by the system. There are with chemicals:
many types of water treatment. An oxygen scavenger to remove
Softening, evaporation, deaeration oxygen from the feed water with
and ion exchange are typical methods sufficient reserve in the engine
used to treat makeup water for a jacket water (boiler water) to
particular system. remove all oxygen from the water.
Feed Water Maintain 200 to 400 ppm as
Feed water is a mixture of returning CaCO3 equivalent of hydroxide
condensate and make-up water that alkalinity in the engine jacket
enters the engine jacket water loop water (boiler water). The reserve
to replace steam that has left the loop. alkalinity prevents corrosion and
Water treatment chemicals that are causes precipitation of iron and
added to the system are usually mixed silica in a form that can be
with the feed water as it enters the removed by blow-down.
engine jacket water system. A blend of dispersants to
adequately condition and suspend
Engine Jacket Water the precipitated solids in the
Engine jacket water (boiler water) is water. The dispersants keep the
a mixture of feed water and resident solids suspended until they are
water. It is the water circulated within removed during blow-down.
the water jacket of the engine to cool
Appropriate treatment of the
the engine and recover heat. Engine
steam to provide condensate
2011 Caterpillar
returning to the engine that meets separator. This may be done once per
the engine jacket water (boiler hour, once per shift, or some other
water) specifications. interval, depending on the
Total Dissolved and Suspended circumstances.
Solids Because blow-down is only performed
Depending on the make-up water periodically, significant dilution is needed
source and quality of treatment, the to ensure that the engine jacket water
feed water will contain some dissolved (boiler water) conductivity does not
and suspended solids. On a low- exceed the maximum before the
pressure steam system, the steam operator returns to blow-down the
will leave the engine; however, the engine again. Note that the conductivity
minerals and chemicals will remain. can exceed targeted maximum or even
This results in a concentrating of the absolute maximum if the operator
Total Dissolved Solids (TDS). does not blow-down the boiler at
Engine water jacket scale forms when the appointed time, or if the engine
the concentration of solids reaches a steaming rate increases between
critical point. This depends on the type blow-down operations. If the absolute
of contaminants in the feed water, maximum is exceeded, scaling will
engine operating temperature, and occur. Because small amounts of scale
other factors. wastes energy and can lead to engine
damage, it is very important to stay
Measurement of TDS and Control below the absolute maximum.
TDS can be measured by parts per Conversely, the steam production
million, ppm (grains/gal), or by rate may decrease, and as a result,
conductivity (micro mhos/cm). The Cat the operator would blow-down the
level for TDS is given in micro mhos/cm engine sooner than necessary.
because conductivity is easier to Therefore, Caterpillar recommends
measure with commercial continuous continuous monitoring of TDS and
monitoring equipment or hand-held automatic blow-down controls.
equipment. There is a direct relationship
between ppm and conductance, Conductivity runs high for ELC
2680 ppm = 3500 micro mhos/cm. carboxylated type coolants (as
compared to traditional coolant
To avoid exceeding the maximum inhibitors), usually 4000 micro mhos/cm
allowable conductivity, it is necessary despite low dissolved solids.
to drain off some of the engine jacket
water (boiler water) periodically. This is A less common method of monitoring
referred to as boiler blow-down. As this TDS is to measure chlorides in both
occurs, new feed water is added to the engine jacket water and the make-
dilute the water in the engine water up water by a titration process. Since
jacket, thereby reducing its conductivity. chlorides are not reduced by chemical
treatment, the operator can determine
Historically, operators have performed the number of concentrations that have
blow-down manually by periodically occurred in the engine jacket water
opening a valve to drain the steam by comparing the ratio of the two
2011 Caterpillar
values. Based on known values of Low-pressure steam engines will have

the make-up water, the operator can special requirements if the unit does
calculate the acceptable number of not run continuously. Any low-pressure
concentrations that can occur before steam engine that is shut down
blow-down is required. frequently can be prone to deposits
Alkalinity even with a good water treatment
Alkalinity is required in high temperature program. Once the engine is shut down,
water and a low pressure steam system the dispersants in the feed water can
to prevent corrosion. Alkalinity holds no longer keep the solids in suspension.
silica in solution and causes iron to They will settle to the low parts of the
precipitate in a form removable by blow- system, which is usually the engine.
down. Too much alkalinity can result in These solids will collect and harden to
a high pH and cause caustic cracking form scales and can result in engine
and caustic attack to external engine failure. For turbocharged and aftercooled
compartments. (TA) ebullient and all ebullient engines
that do not run continuously, a
Total Alkalinity circulating pump of 100 kg water/kg
Total alkalinity is usually measured on of steam (100 lb water/lb of steam)
site by a titration with methyl orange capacity is recommended. The
and is frequently referred to as M circulating pump should be operated
alkalinity. Many coolant analysis even while the engine is shutdown
companies refer to the pH of coolant to keep the solids in suspension. High
water as its alkalinity. Because of the output TA engines can benefit from
wide variation in local make-up water the addition of a circulating pump to
and commercial treatments, there is no prevent hot spots and reduce deposits.
direct correlation between total alkalinity The above water chemistry limits are
and pH. Generally, in high temperature stringent, but not excessive when
water and low pressure steam systems, considering that deposits formed
the pH will be in a range of 10.0 to within the engine are cumulative.
11.5 pH. Co-generation and heat recovery
Reserve of Hydroxide Alkalinity equipment is intended to last 20 years
To prevent corrosion and scale deposits, or longer.
a reserve of hydroxide (OH) alkalinity To maintain the performance and value
is required. The OH alkalinity is not of equipment, it is important to eliminate
easily measured in the field, but can be scale deposits within the engine. Once
calculated. A P alkalinity is measured a deposit is formed, it is very difficult
with phenolphthalein indicator in a and may be economically impractical
sulfuric acid titration. Once P value to remove.
is determined, the following formula
is used to calculate OH alkalinity.
OH Alkalinity =
2 x P Alkalinity - M Alkalinity
2011 Caterpillar
Note: Scale formation is cumulative. Operators who adhere to these

The most successful method of guidelines are likely to have years of
preventing scale problems is to avoid deposit-free and scale-free performance
the conditions that allow scale to form. from their Cat engines.
These guidelines are based on Since water chemistry and water
established limits of the American treatment are very regional items and
Boiler Manufacturers Association vary considerably around the world,
(ABMA) and suggested guidelines the engine owner has the ultimate
by the ASME Research Committee responsibility for the engine cooling
on Water in Thermal Power Systems. water treatment.
2011 Caterpillar
Cooling System Design Considerations

Expansion Tanks additional added static pressure
An expansion tank is an integral part of provided by the auxiliary
an engines cooling system. The primary expansion tank may make the
function of an expansion tank is to system pressure exceed the
allow for the thermal expansion of the allowable limits for the engine or
coolant. However, the expansion tank design operating point for the
of a well-designed cooling system will engine-mounted expansion tank.
perform all of the following functions. The auxiliary expansion tank adds
Provide expansion volume to more cost and may make the
prevent coolant loss when engine mounted expansion tank
the coolant expands due to redundant. Those installations may
temperature change. be more successfully designed
with a remote expansion tank
Vent gases in the coolant and
instead of the engine mounted
prevent hot spots due to trapped
expansion tank.
gas in the coolant system reducing
the ability of the coolant to cool Engine-mounted expansion tanks
the hot surfaces in the engine, to are normally rated for a maximum
reduce corrosion and to prevent pressure of 96 kPa (14 psi); this
loss of coolant due to pressure limit will prohibit using
displacement by gases. the engine mounted expansion
tank for many high temperature
Provide a positive head on the
system designs.
system pump to prevent
cavitation. The size of the expansion tank
should be at least 15% of the total
Provide a place to fill the system
system coolant volume. This
and maintain its corrosion
provides for expansion plus
inhibiting chemical additives.
reserve.
Provide a place to monitor the
Depending on location, the tank
system coolant level; an alarm
must be vented to the atmosphere
switch located in the expansion
or incorporate a pressure cap to
tank will give early warning of
assure system ressure and prevent
coolant loss, or a sight glass can
boiling of the coolant.
be used for visual inspection.
The tank must provide deaeration
In order to perform these functions,
and can be the means of filling a
the expansion tank must meet the
system.
following guidelines.
Factory supplied engine mounted
The expansion tank must be the radiators and most aftermarket-
highest point in the system. If the supplied engine mounted radiators
engine-mounted expansion tank have the expansion tank functions
is not the highest point of the listed above as an integral part of
system, an auxiliary expansion the top tank design. Therefore, the
tank will be required. The
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user has no control over the not cause coolant aeration at the low
function of the expansion tank. coolant mark.
However, many engines can have
Partial (Remote) Flow
custom cooling systems and/or
A partial or remote flow expansion tank
remote radiators that have a
is simply a tank mounted preferably at
separate customer specified
the highest point of the cooling system;
expansion tank.
refer to Figure 16, Figure 18 and Figure
Full Flow and Partial (Remote) Flow 44. Its function is to contain the
Expansion Tanks expansion volume of the coolant as it
There are two types of expansion tanks, heats up, provide a positive head to the
full flow and partial flow. Partial flow inlet of the pump and provide a filling
tanks are also called remote flow tanks and venting location from the system.
or shunt tanks. In this type of an expansion tank, very
Full Flow little flow takes place through the tank
Since all flow circulated by the cooling itself. The shunt line provides the make-
system passes through it, a full flow up for the system and any flow leaving
expansion tank performs several the system through the vent lines.
functions; refer to Figure 14, Figure 15, Maintaining Pump Suction Head with
Figure 17 and Figure 46. It provides a the Expansion Tank
large area for the flow to settle and de- An important function of the expansion
aerate the circulated coolant. It also tank is to maintain positive pressure on
provides a positive suction head the suction side of the circulating pump
pressure at the pump inlet without to prevent cavitation. This function can
requiring a shunt line. Since full flow be difficult to understand since the
expansion tanks perform the deaeration method depends on whether the system
function, they require greater volume. is inlet controlled or outlet controlled.
This type of a tank must be well
Inlet Controlled Systems
designed and constructed to withstand
Inlet controlled systems have the
the full system pressure which is
thermostat positioned between the
exerted on the tank.
cooling device and the suction side of
A full flow expansion tank requires the circulating pump. The thermostat
careful attention to design to prevent provides a restriction on the pump
the tank from causing coolant aeration suction which can result in pump
at high flow. A full flow expansion tank cavitation. To prevent the negative
might require a volume several times pressure and pump cavitation a shunt
that of a remote tank to prevent line is connected between the bottom
aeration. Generally, a full flow tank of the expansion tank and the pump
should be sized to limit the fluid change suction side as shown in Figure 44.
rate to an absolute maximum of 50 The height elevation of the expansion
times per minute at the low-level mark. tank provides static resistance on the
Fluid change rates of 30 times per pump to raise the suction pressure
minute or less and proper baffling will and prevent cavitation. The shunt line
help insure that the expansion tank will should be a minimum of 25.4 mm
2011 Caterpillar
(1 in.) diameter. The diameter of the pressure because of vent and deaeration
shunt line is important. The area of flow. For a full flow or engine mounted
the shunt line must be at least four expansion tank, the tank is located in
times the combined area of the total the suction line to the pump and no
vent lines connected to the tank. This shunt line is needed. Refer to Figure 45.
will minimize any reduction of the static
Inlet Controlled System with Partial Flow Expansion Tank and Deaeration
Circuit
Figure 44
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Example of an Inlet Controlled System with Full-Flow Expansion Tank
Figure 45
Outlet Controlled Systems minimum pressure loss. This means the

Outlet controlled systems differ from expansion tank may be connected to
inlet controlled systems in the routing the outlet tank or anywhere in the return
of the expansion tank connection. line to the pump. Refer to Figure 46,
On an outlet controlled system, the Figure 47 and Figure 48. Do not
expansion tank connection is called the connect the fill line to the inlet tank.
fill line. Since there is no thermostat There will not be sufficient resistance
located between the radiator outlet tank for the deaeration circuit to function
and the suction of the pump, the fill line properly. Also, there will not be
does not need to be plumbed back to sufficient resistance on the pump
the inlet of the pump. The relative size suction which may force coolant to
of the return line of the radiator provides overflow the pressure cap.
2011 Caterpillar
Outlet Controlled with Vertical Radiator Core
Figure 46
Outlet Controlled with Vertical Cross-Flow Radiator
Figure 47
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Outlet Controlled with Horizontal Radiator
Figure 48
Expansion Rate of Coolant
Figure 49
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Sizing Expansion Tanks The system volume for jacket water

As discussed earlier, the primary and standard aftercooler-oil cooler
function of an expansion tank is to systems is given in the section System
allow for thermal expansion of the Volume. The minimum reserve capacity
coolant. Coolant expansion is a function is determined from Table 9.
of the coolant temperature from coldest
ambient temperature to warmest
Total External Circuit Vol. Min. Reserve Capacity
operating temperature. In addition to (% of Engine Coolant Vol.) (% of Total System Vol.)
the thermal expansion, there should also
50 10
be volume for after-boil and sufficient
reserve to allow operation with small 60 9
leaks until they can be repaired. 70 8
The required expansion volume for the 80 7
jacket water circuit can be calculated 90 6
based on the coolant temperature
100 5
change and type of coolant. The
expansion rate for the different type Table 9
of recommended coolants is shown
in Figure 49. The minimum tank
expansion volume for the jacket water Therefore the minimum acceptable
on standard cooling systems is 15%. expansion tank volume is:
Higher temperature systems (higher Minimum Tank Volume =
than 100C or 212F) will need a larger (Expansion Rate x System Volume) + Minimum Reserve
volume to adsorb after-boil that may Capacity =
occur on hot shutdown, see section on
Expansion Volume + Minimum Reserve Capacity
High Temperature Solid Water Systems
in the Heat Recovery section for more Venting and Filling
information. Closed accumulator-type The filler cap is usually located on
tanks are not recommended since they the expansion tank. To accept the
cannot be designed to actively deaerate maximum fill rate of the system, the line
the coolant. connecting the expansion tank with the
A separate expansion tank is typically pump suction must be sized correctly.
required for the aftercooler-oil cooler The minimum guidelines for filling rate
cooling circuit of a separate circuit are 19.0 L/min (5 gal/min). Air trapped
cooling system to eliminate the in high points of the cooling system
possibility of coolant exchange during the initial fill is difficult to purge
between the high temperature jacket and requires venting. For best system
water system and this circuit. The operation, vent lines must be connected
maximum expansion required for from the highest points of the system
this circuit is 8%. This is due to the to the expansion tank. Vent lines must
lower coolant temperatures and enter the expansion tank below normal
system volume of the aftercooler-oil water level, have a continuous upward
cooler circuit. slope, and contain no air traps. A
minimum vent line size should be
2011 Caterpillar
6.3 mm (0.25 in.) inside diameter points of the engine to the expansion
tubing. Use of a smaller size will clog tank to allow a proper fill.
and may not provide adequate venting Air can be trapped in the cooling system
ability. Too large a vent tube may at initial fill, and after filling, it is possible
introduce a circuit that could contribute for gases to be formed by evaporation
either to subcooling or overheating, and of coolant at hot surface locations or
can cause the system thermostats to combustion gases to leak into the
loose their ability to control the system cooling circuit. This air and gas must
to the desired temperature. Vent line be vented from the system, or system
sizing depends on the volume of the deterioration and water pump cavitation
system to vented and the length of will result. Refer to the Coolant (DEAC)
the vent line. For engine size of 3400 Change section of the C175
or C32 size or below, the 6.3 mm Operation and Maintenance Manual
(0.25 in) diameter is sufficient unless (SEBU8100) for additional details on the
the vent line is long or system volume, venting procedure during coolant drain
due to remote mounted components, and fill.
is much larger than normal. For 3500
Entrained gases require deaeration
series engines or systems with volumes
capabilities to be built into the system.
above 75 gallons, the vent size should
Deaeration may be accomplished with
be increased to 9 mm (3/8 in) as a
a centrifugal deaeration gas separator by
minimum. For C175/3600 series
venting the gases back to the expansion
engines or system volumes above
tank as shown in Figure 18. If a
150 gallons, a 13 mm (1/2 in) diameter
centrifugal deaeration gas separator is
vent line minimum size should be used.
not used, separation of gas from a liquid
These are rule of thumb values; the total
medium requires a low coolant velocity
system design should be engineered
of 61 cm/sec (2 ft/sec) with a diverted
based on the system pressure, pressure
flow to the expansion tank, where the
drops due to length of vent lines,
relatively static velocity in the tank
system volume and expected vent flow
allows the gases to be separated. When
rates. For large system designs, it is
using low coolant velocity de-aeration,
best to design the vent line oversized.
the tank or low coolant velocity area
This allows the use of an orifice in the
should be built with an area for the
vent line that can be reduced in size if
water and gases to separate and collect
the vent line provides excessive flow
with a vent to return the gases to the
and loss of temperature control.
system expansion tank. Therefore, in
Caution: To allow for expansion, the the areas where deaeration must take
full level in the expansion tank must place, the water velocity should be
not exceed half the volume of the tank. held below this limit by increasing
Failure to provide adequate expansion the diameter of the water pipe.
volume may result in a boil over. The Refer to Figure 50.
constant full level in the expansion tank
must be above all piping. The full level
in the expansion tank must not exceed
half the volume of the tank. Vent high
2011 Caterpillar
boiling point. Figure 51 and Figure 52

show the effects of system pressure
on the boiling point of water and 50%
ethylene glycol mixture at various
altitudes.
Water Boiling Point Change with

Change in Cooling System Pressure
Figure 50
The deaeration line is usually connected Figure 51

to the radiator inlet tank. Most radiator
inlet tanks have sufficient cross- Glycol Mixture Boiling Point Change
sectional area to meet this velocity with Change in Cooling System
requirement. Full-flow expansion tanks Pressure
must be designed with sufficient cross-
sectional area to slow the velocity of the
water. They must have internal baffles
designed to separate the gases from
the coolant.
System Pressures
Depending on the altitude of engine site
and system operating temperatures,
pressurizing the system will help to Figure 52
prevent the coolant from boiling under
adverse conditions. Slight system Expansion tanks supplied by Caterpillar
pressures also minimize pump have a suitable pressure cap to maintain
cavitation, even at high altitudes, correct system pressures for normal
and increase pump efficiencies. applications as discussed in the section
For each 7 kPa (1 psi) of increase in Attachment Expansion Tank. When a
system pressure, the boiling point of factory expansion tank is not used, the
pure water is raised about 2C (3.5F). following three methods can be used
Elevations above 3048 m (10,000 ft) to ensure the right system pressure.
require higher rated pressure caps to Use a pressure cap on the
avoid boiling. auxiliary expansion tank.
Ethylene and propylene glycol solutions Providing the pressure with a
raise the boiling point. However, alcohol water column by locating the
or other volatile antifreezes lower the auxiliary expansion tank at an
2011 Caterpillar
elevation above the pump. A Auxiliary Expansion Tank

pressure cap may be required The function of the engine mounted
if the system temperature in the expansion tank was covered earlier
auxiliary expansion tank and is applicable for the engines jacket
is near the boiling point. water circuit. Caterpillar does not
A combination of an elevated provide expansion tanks for the engines
auxiliary expansion tank with auxiliary water circuit (the aftercooler
a pressure cap 1 m of water = circuit). It can provide adequate
9.8 kPa (1 ft = 0.43 psi) expansion volume for only a modest
Static head is the maximum height the amount of jacket water.
coolant is raised. Large static heads are Jacket Water Circuit Auxiliary
encountered when radiators are located Expansion Tank
one or more floors above the engine. An auxiliary expansion tank is needed
Excessive static head can cause engine when additional expansion volume is
mounted pump seal leakage. Refer to required in the cooling system. This
Figure 16 for maximum height. generally occurs when remote
Dynamic head is the sum of the static mounted heat exchangers are used.
pressure head plus the pump rise at The auxiliary tank can consist of a
operating condition. Excessive dynamic simple tank as shown in Figure 53.
head can cause leakage at gasket joints These tanks are typically fabricated
downstream of the coolant pumps. The by the engine installer and internal
combination of static and dynamic head baffles are not required.
must meet the pressure criteria specified
The engine-mounted components of the
in TMI. Components in the external
cooling system will adequately separate
cooling system, particularly radiators,
gases from the coolant. However, the
must meet operating pressure levels.
gases, once separated, must be allowed
When static and dynamic pressure
to rise by a continuous upward sloped
exceed acceptable limits, isolate the
standpipe or vent to the auxiliary
engine side by providing a heat
expansion tank. Additional air vent
exchanger or hot well; refer to
piping may be required if the auxiliary
Figure 53 and Figure 54.
expansion tank is not located directly
above the engine mounted expansion
tank.
2011 Caterpillar
Auxiliary Expansion Tank for Engine Jacket Water
Figure 53
Auxiliary Expansion Tank for Separate Circuit Aftercooler Fresh Water
Figure 54
2011 Caterpillar
Aftercooler Circuit Auxiliary Install a vent line from the tapped

Expansion Tank hole in the aftercooler to the aftercooler
All closed, fresh water aftercooler circuit expansion tank. A 6 mm
circuits require an expansion tank. (0.25 in.) vent line is adequate. The
The tank provides coolant expansion vent line should enter the tank below
volume, allows system venting and the low water level and be sloped
provides a positive pressure on the upwards from the engine to the tank.
inlet side of the circulating pump. The If possible, water lines connecting to
expansion tank should be the highest the aftercooler circuit should be level
point in the aftercooler water circuit with or below the connecting points
as shown in Figure 54. Also, refer to on the engine. If the water lines must
the Mechanical Vent Valves section. run above the connection points on the
This tank is a simple reservoir with the engine, it will be necessary to vent the
connecting pipe placed as close to the high points in the external system. Air
pump inlet as possible. The tank is traps in the external system piping
usually fabricated by the engine installer. should be avoided.
Sizing the Volume of Auxiliary Pressurization of Systems Containing
Expansion Tanks Auxiliary Expansion Tanks - Afterboil
The minimum volume of the auxiliary Generally, pressure caps are not
tank should include the total jacket required or desirable on auxiliary
water system expansion volume expansion tanks. This is to allow free
required, plus the volume for the water venting and refilling, when required.
to the low water level in the tank. An exception exists in the situation
The worksheet on Page 131, Auxiliary of high performance engines, which
Expansion Tank Sizing, can be used are prone to be stopped immediately
to determine the minimum volume after periods of extended use. In this
required. circumstance, a phenomenon known
Note: Auxiliary jacket water expansion as afterboil can occur.
tanks are not always required. Afterboil is the boiling (change of liquid
Installation of Auxiliary Expansion to vapor) of the coolant, caused by hot
Tank engine components which have lost
Use flexible mountings and connections coolant flow and pressure when the
when installing an auxiliary expansion engine is hastily shut off. This can result
tank. Separately support and isolate the in sudden loss of coolant out the vents
auxiliary tank to protect it from engine- and fill openings of the expansion tank.
mounted tank vibration. This can be dangerous to personnel in
the area.
All closed separate circuit aftercooler
circuits require installation of a vent line. Bladder Type Expansion Tanks
A tapped hole is provided at the high Bladder type expansion tanks are
point in the engine mounted aftercooler commonly used in high temperature
circuit for this purpose. cooling applications when space
restrictions and height limitations
are involved. These expansion tanks
2011 Caterpillar
eliminate the need to have the and connecting piping. A baffle divides
expansion tank at the highest point the tank into a hot and a cold side, but
in the cooling circuit. is open sufficiently to assure full engine
flow. Baffles are also used where water
Deaeration
enters the tank to minimize aeration as
Air or gas trapped in the cooling system
shown in Figure 56. The baffle shall
often results in coolant foaming.
have sufficient openings to allow the
Foaming promotes pitting, particularly
flow of water between the hot and cold
around water pump impellers, which
sides of the tank. The flow will be the
will affect its performance. Pitting and
difference in flow rates between the
corrosion increase significantly when
engine-driven and remote pumps.
exhaust gases introduce bubbles and
foam into the cooling system. If the hotwell does not have sufficient
volume, the pumps will draw in air
Low Velocity during operation. The hotwell tank
To assure venting of gas entrained in must be large enough to accept the
the jacket water system, it is necessary full volume of the remote radiator and
to reduce the water flow to 0.3-0.6 the interconnecting piping, plus some
m/sec (1-2 ft/sec) in the top tank of the reasonable amount to prevent air
radiator. This can be accomplished with ingestion by the pumps. Generally,
baffles or a dog house built into the 110% of the radiator and piping
tank. A dog house is a fabricated volume is adequate.
chamber within the radiator top
The tank bottom must be above
tank water inlet.
the engine coolant outlet level. The
Hotwell recommended minimum is 0.6 m (2 ft).
Hotwell systems are used when static The auxiliary pump flow must exceed
or dynamic head exceeds acceptable the engine water pump demand. The
limits or when a boost pump imposes recommended minimum is 120% of the
excessive dynamic head. Refer to nominal engine demand at rated speed.
Figure 55. Acceptable venting and deaeration of
A hotwell tank accommodates total the engine and external circuit must
drain back of the remote cooling device also be provided.
2011 Caterpillar
Hotwell System
Figure 55
Hotwell Tank The hotwell must be vented by some

means to atmosphere to reduce the
overall system pressure and allow the
remote system to drain properly back
to the hotwell.
Hotwells must be engineered to have
proper venting and system pressures
evaluated to provide correct system
operation. In some cases, it may be
Figure 56 necessary to have multiple hotwells
to control the system pressures when
large elevation differences are present.
2011 Caterpillar
Interconnection of Engines temperature and pressure of the cooling

Central cooling systems utilize a single system. Clamp-type flexible connections
external circuit supplying coolant to are not recommended for the high
several engines. Although separate temperature circuits on G3600 Engines.
cooling systems for each engine is Bolted flange-type connections should
preferable, use of a single radiator be used for all jacket water circuits and
or heat exchanger system is possible. any other circuit running more than
Practical experience has shown that 65C (150F). Material compatibility
only identical engines at the same must also be evaluated. The internal
loads and speeds can be successfully surface must be compatible with the
combined in a joint cooling system. coolant used and the liner material must
A failure on one engine can adversely be compatible with potential coolant
affect all engines. For this reason, contaminants, such as lube oil and
interconnected engines should have system cleaning solutions. The outer
isolating valves. Check valves are cover must be compatible with
required on the output line of each environmental conditions such as
engine to prevent recirculation through temperature extremes, ozone, grease,
an engine that is shutdown with the oil and paint. Factory-provided flexible
thermostats opened. connections are available for most pipe
The cooling system for mixed engines sizes; refer to the Price List for available
with mixed speeds and loads are options.
very difficult to design and are rarely Piping Supports
successful. They must meet required
All piping to and from the engine must
criteria, such as water flow,
be suitably supported by means of
temperatures and pressures, for each
brackets and clamps.
engine while operating in all possible
combinations with other units. Piping must not overhang excessively
from the pump inlet, mixer box
Flexible Connections outlet, temperature regulators
Use flexible connections for all and expansion tanks.
connections to the engine (rubber hoses
The weight of the piping combined
are not recommended). The positions of with the water in the pipes can place
flexible connections are important. Shut
a considerable load on engine
off valves should be located to allow components; especially when the
replacement of flexible connections
engine is vibrating during operation.
without draining the entire cooling
system. Orient the flexible connection Piping should be supported adequately
to take the maximum advantage of the on installations where the radiators or
flexibility. When selecting connections, heat exchangers are roof-mounted or
normal thermal expansion and the piping is routed through the roof.
maximum expected movement must be
considered. Flexible connections should
be rated for conditions well above the
anticipated maximum operating
2011 Caterpillar
Jacket Water Heaters Physical location and exposure to the

Jacket water heaters are recommended elements can affect sizing. Contact
for faster and easier starting in ambient Caterpillar for special voltages, three
air temperatures below 21C (70F). phase current and special heaters for
All automatic starting installations ambient temperatures lower than listed.
should include jacket water heaters. The For customer-installed systems, the
heaters should maintain engine jacket following guidelines should be
water at approximately 32C (90F) considered.
at minimum ambient room temperature. Mount the heater as low as
Jacket water heater sizing information possible; refer to Figure 57.
for each engine is available in the TIA. The cold water inlet to the heater
Model-specific heater availability is should be from the lowest possible
included in the Price List. point in the engine cooling system.
Heater sizing is based on wind velocity Avoid cold water loops; this is any
of 0 km/h (0 mph) around the engine. situation where cold water must
When a 24 km/h (15 mph) wind is rise to enter the heater. Refer to
present, the heater requirement doubles. Figure 57, location A.
Factory provided jacket water heaters Join the hot water side of the
are available for these specifications. heater near the top of the engine
The normal time required for cooling system, but below the
temperature to stabilize is 10 hours temperature regulators.
for large engines. Wattage requirements Use the same pipe size (or larger)
for shorter periods are inversely as the heater connections.
proportional to the 10-hour requirement.
2011 Caterpillar
Pipe Routing with Jacket Water Heater
Figure 57
Caution: Do not create hot water loops. Caterpillar for 100 mm, 127 mm
Hot water line should enter the engine and 152 mm (4 in, 5 in, and 6 in) pipe
in either a horizontal or slightly inclined sizes and all have 1.6 mm (1/16 in)
plane, eliminating the possibility of mesh size.
forming a steam pocket; refer to Caution: Temporary strainers are
Figure 57. intended to be temporary. If left in the
system indefinitely, they can collapse,
Preparations for Initial Startup causing a great deal of damage to the
Before the initial start up of any engine
engine.
installation, all pipe, water passages
and radiators, heat exchangers or Rust inhibitors can be in the form of
other equipment external to the engine ethylene or propylene glycol if operating
must be cleaned, the cooling system temperatures are expected to go below
should be filled with rust inhibitors, and freezing, or in the form of coolant
coolant flow should be verified. These conditioner. The coolant conditioners
precautions apply to an initial start up as or rust inhibitors should be compatible
well as the first start up after significant with the antifreeze used in the engine,
modifications are made to the external refer to the documents listed under
cooling circuit. Reference Material at the end of this
section for more information.
Temporary strainers should be installed
in all pipes between the engine and If an engine is expected to be stored for
external equipment prior to start up and long periods without operating or before
removed after commissioning to catch commissioning, special treatment in the
contamination that may remain after form of Vapor Corrosion Inhibitor (VCI)
cleaning. Strainers are available from is required for the cooling system to
2011 Caterpillar
prevent rust formation. Long-term the design and construction of the

preservation treatments for cooling cooling system. If the ports are installed
systems can be provided by the factory, later, ensure the pipes are cleaned of
refer to the Price List for more drill chips and weld slag after the
information. pressure ports are installed. Install
sample ports and fittings before the
Serviceability and Isolation cooling system is filled. The preferred
Valves sizes for the ports on the customer side
Access to the heat exchangers is are 1/8 in or 1/4 in NPT and 9/16 in
required for cleaning or removal of the O-ring ports. These port adapters are
tube-bundle assemblies or plates. Engine available as standard Cat parts; refer to
water pumps must be easy to remove. the G3600 Price List for part numbers.
Remote water temperature regulators The recommended locations for
should be accessible and have measurements and available
appropriate isolation valves to allow measurement ports are shown in
servicing of engine and temperature Figure 58.
regulators without draining the entire Self-sealing probe adapters are available
system. Apply similar guidelines to in several sizes of male pipe threads
radiators, heat recovery units, and straight threads for g-ring ports.
deaeration units, jacket water heaters The adapters use a rubber seal allowing
and other components requiring service temperature and pressure to be
or replacement. measured without leakage. Probe
System Monitoring diameters up to 3.2 mm (0.125 in) may
Provide locations to measure pressure be used. The straight threaded adapters
and temperature differentials across are used on the engines with available
major system components. This allows ports. Pipe threaded adapters are more
accurate set-up and performance easily incorporated in the customer
documentation of the cooling system supplied system. The adapters are an
during the commissioning procedure. excellent alternative to permanently
Future system problems or component installed thermometers, thermocouples
deterioration (such as fouling) are easier or pressure gauges. They are not
to identify if basic data is available. It subject to breakage, fatigue failures
also provides information for relating and gauge-to-gauge reading variations.
field conditions to original factory tests. Customer Connections
Temperature and pressure measurement The customer connection points for all
locations should give accurate reading configurations explained in the Basic
of fluid stream conditions. Preferred System Configurations Section are
locations are in straight lengths of shown in the Engine Installation
piping reasonably close to each Drawings.
system component. Avoid pressure
Mechanical Vent Valves
measurements in bends, piping
The ideal system is to have all high
transition pieces or turbulent regions.
points vented to the expansion tank.
Plan to install monitoring ports during
However, when modifying existing
2011 Caterpillar
installations, venting all of the high and the use of mechanical vent valves
points may not be possible. Mechanical should be minimized.
vent valves can be added to these For G3500 turbocharged engines,
high points to vent air and gases that a vent line is connected to the turbo
accumulate. The disadvantages of charger to ensure that there are no air
mechanical vent valves are the fact that pockets in the turbochargers cooling
they are usually manually operated and passages; refer to Figure 58. This vent
can leak coolant or allow air to enter the line must be connected to the expansion
system during shutdown. There are also tank used for the jacket water cooling
automatic vent valves, but they can be circuit. If an aftermarket expansion tank
troublesome. In some areas, coolant is used, the customer will be responsible
may be considered a hazardous liquid for connecting the vent line to the
expansion tank. (See Pressure Control)
Watercooled Turbocharger Venting
Figure 58
Watermakers, Domestic Water of approximately 15% of the fuel

Heaters, Cabin Heaters input energy.
Watermakers, domestic water heaters Certain aspects of the engine cooling
and cabin heaters can put normally- system must be thoroughly understood
wasted jacket water heat to work. to avoid misapplication. For example, an
This has the potential for recovery engine will only produce significant
2011 Caterpillar
amounts of waste heat if there is a entrained air/gases to collect. Trapped

significant load on the engine. Many air/gases will displace the water
engines in marine service are lightly required to carry engine heat to the
loaded for large parts of their life and watermakers, domestic water heaters,
are poor choices for installation of and cabin heaters and interfere with
watermakers, domestic water heaters, proper operation. Trapped air/gases
and cabin heaters. When an engine is can be vented by installing small,
lightly loaded, almost all of the engines approximately 3 mm (0.125 in.), inside
jacket water flow goes through a diameter-vent lines. The vent lines
bypass line, from the thermostat should carry air/gases from the high
housing to the jacket water pump points in the domestic water heater
inlet, to maintain a constant high flow and its associated piping to a higher
through the engines cooling passages. point in the engine jacket water cooling
Watermakers, domestic water heaters circuit; this is normally an installer-
and cabin heaters can overcool an supplied auxiliary expansion tank.
engine. If the watermaker, domestic See the engine general dimension
water heater, or cabin heater extracts drawing for the connection locations
too much heat from the flow of jacket of points on the engine where water
water, the engines water temperature for this purpose should be extracted
sensors/thermostats will sense the and returned. However, please note
engine cooling jacket is operating at that not all engine cooling system
a dangerously low temperature. It will designs have connections for
attempt to correct the condition by watermakers.
reducing the external flow of cooling
Watermaker Controls
water. If there are automatic controls
The watermaker controls may be
on the watermaker, domestic water
manually operated valves or
heater, or cabin heater, it may shut
thermostatically controlled valves.
off having sensed insufficient flow for
continued operation. This leads to a Any failure of the watermaker control
troublesome condition of repetitive system, such as electrical or air, must
starting and stopping of the shut off jacket water flow to the
watermaker, domestic water heater, watermaker and return the flow
or cabin heater. Automatic control of to the engine heat exchanger.
these devices has proven troublesome The thermostat valve, shown in
and is not recommended. Consider the Figure 60, would have a temperature
use of auxiliary water heaters so during setting that will not interfere with the
periods of light engine load, adequate engine thermostats. This valve should
amounts of heat can be sent to the begin to divert water flow to the engine
watermaker, domestic water heater, heat exchanger at no more than 88C
or cabin heater. (190F) and be fully diverting at 96C
Cooling water piping to and from the (205F). For safety, the bypass valve(s)
watermakers, domestic water heaters, in the engine heat exchanger circuit
and cabin heaters must not allow should contain 6.35 mm (0.25 in.)
orifices so there will be a slight water
2011 Caterpillar
flow in case all valves are inadvertently engine cooler. If the watermaker cannot
left closed. This orifice is then required handle the full heat rejection of the
to assure water flow to actuate an engine and/or cannot handle the full
alarm system. The slight water flow water flow of the engine, the automatic
from the orifice will also reduce the system must be used.
possibility of thermal shock on the
Manual Control Watermaker Circuit
Figure 59
2011 Caterpillar
Automatic Control Watermaker Circuit
Figure 60
Typical Mixing Tank
Figure 61
2011 Caterpillar
Interconnecting Engines shutdown capability. The boats pilot

Several problems arise from has the option to continue operation
interconnection of several engines: of a distressed engine to provide a short
unequal water flow, one failure shuts duration of engine power to escape a
down all engines and excessive more present danger.
external head pressures are just a few.
Coolant Level Switches
For these reasons, separate connection
Coolant level switches are devices
of one engine per watermaker is
which can give early warning of coolant
recommended. It is the customers
loss. They generally consist of a sealed
responsibility to provide a system that
single pole-double throw switch,
is compatible with the engine cooling
actuated by a float which rides on the
system in all modes of operation.
surface of the coolant in the expansion
When the Watermaker is Far from tank. It is good design practice to locate
the Engine the coolant level switch in the highest
When the watermaker is a long part of the cooling system; this will
distance from the engine or where the provide the earliest warning of a drop
watermaker requires a constant water in coolant level. High water temperature
flow, a mixing tank and circulating switches will not give warning of
pump is required. Do not use a coolant loss; their temperature sensing
circulating pump by itself, because portion works best when surrounded
the circulating pump head pressure will by liquid water rather than steam.
damage the engine thermostats in the
High Water Temperature Switches
event they are closed. Although the
High water temperature switches are
mixing tank is not supplied by
devices which continuously monitor the
Caterpillar, it can be used with either
temperature of some fluid, generally
of the suggested circuits. An auxiliary
coolant, and actuate switch contacts
electrical heater may be installed as
when the fluid temperature goes above
shown in Figure 61.
some preset limit. In the case of jacket
Cooling System Protective Devices water coolant, the set point is usually
A common problem associated with between 96 and 102C (205 and
properly installed cooling systems is loss 215F), depending on the engine,
of coolant, generally due to breaking a cooling system type, and whether alarm
water hose or overheating, which can of impending problems or actuation of
have many causes. As with many engine shutdown systems is desired.
engine safety devices, the decision Switches can be set for either condition.
to automatically shut down the engine,
Emergency Systems
or to continue operation risking total
Many marine applications require the
engine destruction, is for the careful
capability to connect emergency
consideration of the owner. In
cooling water pumps into the engines
conditions where an entire boat and
cooling system. Cat engines can be
the lives of those on board are at stake,
provided with these optional
it may be appropriate to use a safety
connections when necessary. This is
system which does not have automatic
a specific requirement of marine
2011 Caterpillar
classification societies for seagoing Jacket Water Pump Connections

single propulsion engine applications. The optional Cat emergency jacket
The requirement applies to both the water connections, available
engine jacket water and auxiliary (sea for the large vee engines, meet the
or fresh) water systems. The purpose requirements of the engine and the
of the emergency systems is to ensure marine classification societies. Use
cooling if either the jacket water or of these connections permits the
auxiliary (sea or fresh) water pump emergency system to utilize the normal
should fail. The customer-supplied jacket water as the coolant and to
emergency pumps should provide flow bypass the engine-mounted jacket
equal to the failed pump to permit water pump. The system includes a
operation at full, continuous power with blanking plate or valve to direct
the emergency systems. For pump flow jacket water to the emergency
requirements of engine-mounted pumps, system and flanged connection points
refer to TMI or consult a Cat dealer. If on the engine for the emergency system
reduced power operation is piping. Figure 62 is a schematic diagram
acceptable, reduced flows can be of the system properly connected.
utilized. Use flexible connectors at the The customer-supplied emergency
engine to protect the piping and engine. water pump should provide flow
equal to the failed pump.
Emergency Jacket Water Pump Connections

(Location of Jacket Water Pump May Vary)
Figure 62
The use of seawater in the engine jacket the lowest engine power level
water system is not recommended. If commensurate with the sea state.
seawater must be used in the jacket On reaching port, the jacket water
water system to ensure the safety of system must be thoroughly flushed
the ship in an emergency situation, use and cleaned.
2011 Caterpillar
Auxiliary Seawater Pump as indicated in the Figure 63. The flow

required for the emergency separate
Connections
keel cooled aftercooler pump should
All emergency seawater cooling
equal the failed pump. The use of
connections are to be provided by
seawater in the separate keel cooled
the installer and connected as indicated
aftercooler circuit is not recommended.
in Figure 63, illustrating emergency
The engine- mounted pump and lines
auxiliary pump connections. The
are of ferrous material and have low
emergency seawater pump should
corrosion resistance in seawater. If
provide flow equal to the failed pump.
seawater must be used in an emergency
Auxiliary Freshwater Pump to ensure the safety of the ship,
Connections thoroughly flush the system as
All emergency connections for separate mentioned in the jacket water section,
keel cooled aftercooler circuits are to be and inspect the parts for corrosion
provided by the installer, and connected damage and deposits.
Emergency Auxiliary Pump Connections
Figure 63
2011 Caterpillar
Central Cooling Systems in such a system due to the

A central cooling system is defined as number of potential modes of
one which cools multiple engines and operation.
which combines many individual cooling For example: with a system
system components (heat exchangers containing three engines, one heat
and pumps) into a large central one. exchanger, and two pumps, there
However, there are both advantages will be 162 possible combinations
and disadvantages to a central cooling or modes of operation.
system that must be considered when Suggestions for Design of a
making that determination. Successful Central Cooling System
A typical marine central cooling system Flow Control: There are upper and
diagram is shown in Figure 64. lower limits to the allowable flow
Advantages of a Central Cooling through an engine. The system
System must be able to throttle the
A central cooling system will flow through each engine
reduce the extent of the seawater independently.
piping system and thereby reduce Temperature Control: The heat
wear, corrosion, and maintenance. exchanger must be capable of
The reduced extent of the delivering the proper amount
seawater system will also of cooling, proportional to
significantly reduce the amount of engine load.
shipyard labor required to install Load Control: The amount of
such a system. external water flow through a Cat
The smaller number of Engine is directly proportional to
components will reduce the cost the engines load. The greater the
of cost procurement, inventory, load, the greater the amount of
and support with repair units. cooling required and the more
Larger components are generally water the engines internal cooling
more robust and can be expected circuitry will discharge for cooling.
to last longer. At light loads, the engines
temperature controls will bypass
Disadvantages of a Central Cooling the external portion of the engine
System cooling system, recirculating
A disadvantage of a central virtually all of the coolant. If the
cooling system involves the water pressure presented to an
additional electrical loads engine by a central cooling system
required for the additional is too high, the proper operation of
circulating pumps, and the the engines temperature controls
somewhat higher capital and may be overridden, and the engine
installation cost associated will suffer over or under cooling
with them. problems. It is very difficult to
Another disadvantage is the adequately balance and control
difficulty in diagnosing problems the flow through several engines,
2011 Caterpillar
all of which might be operating The ring main is the water source
at widely varying loads.Keep each for each engines independent
engines jacket water system cooling system. The temperature
independent of all others, using and pressure of the water in the
a separate jacket water heat ring main do not need precise
exchanger at each engine. The control. Each engine should have
load control problems are not an engine-driven, auxiliary (not
economically solvable. The water jacket water) water pump. This
pressure on an engine jacket water pump will draw water from the
inlet cannot be allowed to exceed ring main and return it back to the
an engines published pressure ring main, downstream.
limits. Economic factors may Pressure Control Valve: A valve
encourage many designers to use must be installed to balance the
higher pressures, but this must be system if one or more of the
discouraged, as higher pressures heat exchangers are shut off.
will significantly reduce water In response to pressure differences
pump seal life. across the exchangers, the valve
Ring Main: Provide a ring main of will open or close and try to
freshwater, circulated by at least maintain the pressure at its
two, parallel water pumps. A third original setting. As a result,
water pump should be kept in the water flowing through the
reserve to maintain operation remaining heat exchangers will
when either of the other pumps remain unchanged, and the
requires maintenance. Each pump temperature relationships will
should be identical for ease of remain constant.
parts inventory and maintenance.
2011 Caterpillar
Typical Marine Central Cooling System
Figure 64
Cold Weather Considerations considered on engines that must start

Form SEBU5338-01 Cold Weather when no AC power is available.
Operation, contains information on Engine enclosures or engine room
operation, lubrication, and maintenance enclosures are recommended to
in cold weather conditions. retain engine heat.
Methods of retaining engine heat are Extreme Cold Weather
discussed below. Considerations
Commercially available radiator Extreme conditions require additional
shutters should be considered. Fan air protection as shown in Figure 65. This
flow across the engine increases heat protection is commercially available.
lost to radiation. Particularly at light The radiator should be in a separate
load, shutters minimize this heat loss room from the engine. Absence of the
and raise the engine temperature. radiator air flow will ensure the engine
Commercially available diesel fuel fired environment is kept at a warmer
jacket water heaters should be temperature in cold weather.
2011 Caterpillar
Extreme Cold Weather Protection
Figure 65
In warm temperatures, the weather The house should be as airtight as

enclosure is either removed or opened. possible. This includes an air barrier
Radiator cooling air is drawn in through under the engine oil pan, as illustrated.
a roof door in the radiator room during To minimize air changes in the engine
winter operation. Normally, radiator room, combustion air can be ducted to
discharge air is utilized for rig heating. the air cleaner from outside, as shown.
If emissions regulations allow An air source valve is included so the
them, two-speed radiator fans are engine can be started and idled on the
recommended because they offer warmer air in the engine room. The
several advantages for utilization of engine should be operated on outside
engine heat. First, lower fan speed air. Otherwise, a vacuum may be
reduces air flow and consequently caused in the engine room, depending
increases air temperature rise of the upon how airtight the engine room is.
radiator air flow utilized for rig heating. Air cleaner adapters are available to
Second, radiator fan horsepower is connect ducting.
considerably reduced. Heavy duty air cleaners can be utilized
Sensors for the two-speed motor and for protecting the engine from air
shutters have to be protected from cleaner plugging due to ice fogs,
being affected by the cold air coming if they occur.
through the roof door. The roof door Crankcase breather fumes should be
area is sized to accommodate only the piped out of the engine room to
low fan speed air requirements. The minimize oily deposits. In extremely
opening is adjustable. The enclosure cold weather, the fumes may have to
door will have to be opened by hand be discharged into the engine room
for summertime operation. due to breather outlet freezing. Fumes
should be discharged as remotely as
possible from engine air cleaner inlets.
2011 Caterpillar
An alternative sometimes used is to a resultant increase in fuel usage. Jacket

discharge the fumes under the power water heaters are readily available, but
module base where it is generally oil heaters are not. Oil is difficult to heat
warmer. without circulation. Thus, immersion-
Lube oil and jacket water heaters should type oil heaters are generally not
be provided. They are required for cold recommended as they lead to coking
startup after a rig move. (Power is of the oil. Unitized oil and water heaters
supplied by a small cold start generator are commercially available which
set.) They also can be used to maintain overcome the problem. They employ
the temperature of an engine that is not oil and water circulating pumps for
running. On many rigs all engines are proper system operation.
generally run at all times, as there is no Exhaust piping should be so arranged
reliable way to keep the engine ready that exhaust will NOT be drawn into
for service at a moments notice, with the radiator or combustion air inlet.
2011 Caterpillar
Coolant Considerations
While the quality of fuels and lubricating Cat Commercial Diesel Engine
oils is of primary concern to engine Fluids Recommendations
operators, the quality of the engine Cat Gas Engine Lubricant, Fuel,
coolant is just as important. With and Coolant Recommendations
over 50% of all engine failures related 3600 Diesel Engine Fluids
to poor cooling system maintenance, Recommendations for Lubricants,
proper coolant selection and Fuels, and Coolants
maintenance are vital to successful Coolant and Your Engine
engine service life. Media numbers for these publications
Coolant Function are available at the end of this guide.
The engines cooling system, as we Water
have discussed throughout this section, Water is used in the coolant mixture
is designed to meet specific guidelines, because it is the most efficient, best-
driven by the specific project application known and universally available heat
requirements. The proper transfer agent. However, each water
coolant/antifreeze will provide the source contains contaminant levels to
following functions: various degrees. At operating
Adequate heat transfer temperatures of diesel and natural gas
Compatibility with the cooling engines, these contaminants form acids
systems components such as or scale deposits that can reduce
hoses, seals, and piping cooling system service life.
Protection from water pump Prime consideration in closed cooling
cavitation systems is to ensure no corrosion or
Protection from other cavitation scale forms at any point. Therefore,
erosion Caterpillar recommends using distilled or
Protection from freezing deionized water. If distilled or deionized
and from boiling water is not available, use water that
meets Caterpillars published minimum
Protection from the build-up of
acceptable water requirements.
corrosion, sludge, and scale
Note: Do not use the following types
Coolant Properties of water:
Coolant/antifreeze is normally composed Salt water/seawater
of three elements: water, glycol, and Hard water
additives.
Softened water that has been
Note: Each of these elements must conditioned with salt.
meet specific guidelines.
Note: Never use water alone as a
Additional information on coolant coolant. Supplemental Coolant Additives
properties and their effect on engines (SCA) are required because water is
is available in the following Caterpillar corrosive at engine operating
service publications. temperatures. When additional
2011 Caterpillar
protection against boiling or freezing Cat ELC, as it provides extended coolant

is required, both glycol and SCA service life, corrosion protection,
are required. extended water pump seal service life,
and extended radiator service life. In
Supplemental Coolant Additives
addition, Cat ELC requires less ongoing
SCAs help to protect the metal surfaces
coolant maintenance than conventional
of the cooling system and help prevent:
coolants such as Cat DEAC.
Corrosion
The Cat ELC anticorrosion package
Formation of mineral deposits
is totally different from conventional
Rust coolants. Cat ELC is an ethylene glycol
Scale based coolant that contains organic acid
Pitting and erosion from cavitation corrosion inhibitors, and antifoaming
of the cylinder liner agents.
Foaming of the coolant Note: Cat NGEC is recommended
Note: Over-treatment should be avoided for all Cat natural gas engines.
because this can cause cooling system Caterpillar does not recommend Cat ELC
problems. Do not add SCA or Extender for use in natural gas engines.
(for Cat ELC) unless testing shows
additive depletion. Coolant Testing
The coolant should be maintained
Glycol throughout the life of the application.
Glycol in the coolant provides protection Testing the engine coolant is important
against the following conditions: to ensure that the engine is protected
Boiling from internal cavitation, corrosion,
Freezing boiling and freezing.
Water pump cavitation SOSSM Coolant Analysis
(ATAAC equipped engines) Coolant analysis can be performed at
For optimum performance in most your Cat dealership. Caterpillar SOSSM
applications, Caterpillar recommends a coolant analysis is an excellent way to
1:1 mixture of an approved water/glycol monitor the condition of your coolant
solution. and your cooling system.
Note: Refer to the engine specific The SOSSM coolant analysis is a two
Operation and Maintenance Manuals level program. The Level 1 analysis tests
for exceptions. the properties of the coolant including
glycol concentration, additive level,
Coolant Recommendations pH, conductivity, hardness, visual
The Caterpillar line of coolants
appearance and odor. The Level 2
includes Cat DEAC (Diesel Engine
analysis is a comprehensive chemical
Antifreeze/Coolant), Cat ELC (Extended
evaluation of the coolant that includes
Life Coolant), and Cat NGEC (Natural
a full Level 1 analysis, and also checks
Gas Engine Coolant).
the overall condition of the inside
While both Cat DEAC and Cat ELC are of the cooling system by identifying
acceptable for use in Cat diesel engines, the source of metal corrosion, scaling,
Caterpillar recommends the
2011 Caterpillar
and contaminants. Contact your Cat Overtreatment should also be avoided

dealer for complete information and since this can cause problems as well;
assistance on the SOSSM coolant do not add treatment unless testing
analysis program. shows additive depletion. Caterpillar
also has specifications covering
Boiler Type Coolants
contaminants such as chlorides,
If boiler type coolants are used, certain
sulfates, hard water minerals, as well
additives known to the system operator
as dissolved gases. These must be
must be kept at corrosion arresting
checked by analytical methods since
levels. These all should be checked
they can destroy a system even if
at dealer recommended intervals, such
corrosion inhibitor additives are in
as every 250 hours or six months
correct proportions.
(depending on application), otherwise
problems may occur.
2011 Caterpillar
Reference Material
Media List PEHJ0067
The following information is provided Data Sheet, Cat ELC (Extended Life
as an additional reference to subjects Coolant) (Worldwide)
discussed in this manual. PEHJ0068
The following publications are available Data Sheet, Cat Advanced Efficiency
for order through your Cat dealer. Engine Oil Filter
Note: The information that is contained PEHJ0072
in the listed publications is subject to Data Sheet, Cat DEO (SAE 10W-30
change without notice. and SAE 15W-40) (Brazil)
Note: Refer to this publication, the PEHJ0082
respective product data sheet, and Data Sheet, Cat Fuel/Water
to the appropriate Operation and Separators and Prime Time Priming
Maintenance Manual for product Pumps
application recommendations. PEHJ0091
AECQ1042 Data Sheet, Cat DEO (SAE 10W-30
Caterpillar Product Line Brochure and SAE 15W-40) (Egypt and Saudi
GECJ0001 Arabia)
Cat Shop Supplies and Tools (catalog) PEHJ0093
PECP9067 Data Sheet, Cat DEO (SAE 30 and
One Safe Source (catalog) SAE 40) (For use in 3600 Series
diesel engines and for use in older
PEDP7036
precombustion chamber diesel
SOSSM Fluid Analysis
engines. Do NOT use in direct
PEDP9131 injected 3500 Series and smaller
Fluid Contamination The Silent Thief diesel engines.)
PEEP5027 PEHP6028
Label ELC Radiator Label Data Sheet, Cat Ultra High Efficiency
PEHJ008 Air Filters
Data Sheet, Cat Arctic DEO (SAE PEHP7032
0W-30) (Canada and United States) Data Sheet, Radial Seal Air Filters
PEHJ0021 PEHP7045
Data Sheet, Cat DEO (SAE 10W-30 Data Sheet, Fuel Contamination
and SAE 15W-40) (Worldwide Control for 3500 Series Cat Engines
Except North America, Egypt,
PEHP7046
Saudi Arabia, and Brazil)
Data Sheet, Fuel Contamination
PEHJ0059 Control
Data Sheet, Cat DEO (SAE 10W-30
PEHP7052
and SAE 15W-40) (North
Making the Most of SOSSM Services
America - Canada, Mexico,
and United States) PEHP7057
SOSSM Coolant Analysis
2011 Caterpillar
PEHP7062 LEKQ7235
Data Sheet, Cat DEO SYN (SAE 5W- Engine Data Sheet 50.5 Cooling
40) System Field Test
PEHP7076 REHS1063
Understanding SOSSM Services Special Instruction Know Your
Tests Track-Type Tractor Cooling System
PEHP7077 SEBD0970
Data Sheet, Cat Turbine Pre- Coolant and Your Engine
Cleaners SEBU6250
PEHP9013 Cat Machine Fluids Recommendations
Data Sheet, Air Filter Service SEBU6251
Indicator Cat Commercial Diesel Engine Fluids
PEHP9554 Recommendations
Data Sheet, Cat DEAC (Diesel Engine SEBU6400
Antifreeze/Coolant) (Concentrate) Cat Gas Engine Lubricant, Fuel, and
PEPP5027 Coolant Recommendations
Label ELC Radiator Label SEBU7003
PELJ0176 3600 Diesel Engine Fluids
Cat ELC (Extended Life Coolant) Recommendations for Lubricants,
223-9116 Dilution Test Kit Fuels, and Coolants
PELJ0179 SENR9620
Cat Engine Crankcase Fluid-1 Improving Fuel System Durability
Specifications (CAT ECF-1) WECAP
(All International Markets) Web Engineering Cataloging and
PEWJ0074 Procuring website
Cat Filter and Fluid Application Guide LEXH6521
Air to Air Aftercooling system Guide.
2011 Caterpillar
Jacket Water Cooling Circuit Worksheet

Sheet 1 of 3
Engine Model: _________________________ Compression Ratio: ____________

Engine rpm: _________ Water Temperature to Aftercooler: _______ C or F
Feature Code: ________________ Rating: ________________
Site Conditions: ________________________________________________________
________________________________________________________________________
1. Heat Rejection
Determine the cooling system configuration, obtain the heat rejection data for the specific
engine model and rating and add the appropriate tolerance.
* Possible configurations: JW only, Combined JW + OC, Combined JW + AC, Combined
JW + OC + AC.
Jacket Water Heat Rejection: ___________ kW or Btu/min
Jacket Water Heat Rejection x 1.10 tolerance = Heat Rejection with Tolerance
________________x 1.10 tolerance = ______________ kW or Btu/min
Oil Cooler Heat Rejection: ______________ kW or Btu/min (if applicable)
Oil Cooler Heat Rejection x 1.20 tolerance = Heat Rejection with Tolerance
_______________________ x 1.20 tolerance = ______________ kW or Btu/min
Aftercooler Heat Rejection: _____________ kW or Btu/min (if applicable)
Aftercooler Heat Rejection x (ACHRF) x 1.05 tolerance = Heat Rejection with Tolerance
________________________ x ________ x 1.05 tolerance = _____________ kW or Btu/min
Add the kW or Btu/min values of the jacket water, oil cooler and aftercooler
circuits:
Total Heat Rejection with Tolerance = ___________ kW or Btu/min
*Note: The system configuration is defined on the performance data sheets. For diesel
engines, the oil cooler heat rejection is typically included with the jacket water heat load. To
check if a circuit load is included, use the following equation to calculate the energy balance.
For example, if the JW heat rejection contains the oil cooler heat, the oil heat rejection must
be zero for the equation to balance.
Energy Balance Equation:

QTotal = W + QExh + QSur + QJW + QOC + QAC
2011 Caterpillar

Sheet 2 of 3
2. Coolant Flow Rate

Calculate the coolant flow rate using the temperature rise, heat rejection and coolant
properties. Density and Specific Heat can be found in Table 1 on Page 24 of the Cooling
Systems Application & Installation Guide.
Note: If a temperature rise value is not provided for the engine, the coolant flow must
be selected from the external restriction vs. coolant flow curve for the engine rather
than calculated. Select a flow rate near the midpoint of the curve.
Recommended Temperature Rise (T): ____________ C or F

Density of Coolant: ____________ kg/L or lbm/gal
Specific Heat of Coolant: ____________ kW-min/kg C or Btu/lbm F
Heat Rejection
= Cooling Circuit Flow Rate
T x Density x Specific Heat
= _______________ (Lpm or gpm)

x x
Cooling Circuit Flow Rate = ___________ Lpm or gpm
2011 Caterpillar

Sheet 3 of 3
3. Allowable External Restriction

From the graph of External Restriction vs. Coolant Flow for the Jacket Water Circuit,
find the maximum allowable restriction for the flow calculated in step 2.
Maximum Allowable External

Restriction for Jacket Water
Cooling Circuit: ____________________ m H2O or ft H2O
4. Jacket Water Circuit Sizing (Radiator, Heat Exchanger or other cooling device)
Add an additional external circuit system tolerance to the Total Heat Rejection with
Tolerance value calculated in step 1 to account for system fouling or degradation.
This additional tolerance should be 1% to 10%, depending on the cooling system
used and operating conditions.
Total Heat Rejection with Tolerance x (1.01 to 1.10) = Jacket Water Circuit Heat Rejection
_____________________________ x 1.______ =________________ kW or Btu/min
Jacket Water Circuit Heat Rejection: ____________________ kW or Btu/min
5. Recheck Cooling System Pressure Drop

After selecting a cooling system, calculate the pressure drop of the system and compare
it to the external restriction vs. flow curve to determine if the flow rate changed from the
assumed value. If the value changed, recheck the cooling system at the new value to
assure the system is sized correctly. As long as the operating point is on the given pump
curve for the engine and rating, it is an acceptable operating point for the engine. Do not
extrapolate the curve as this operating point will not be acceptable for the engine.
2011 Caterpillar
Auxiliary Cooling Circuit Design Worksheet

Sheet 1 of 3
Engine Model: _________________________ Compression Ratio: ____________

Engine rpm: __________ Water Temperature to Aftercooler: ______ C or F
Feature Code: ________________ Rating: ________________
Site Conditions: ________________________________________________________
________________________________________________________________________
1. Aftercooler Heat Rejection Factor

Published aftercooler heat rejection data is for the standard conditions of 25C (77F)
and 500 ft (152.4 m). Use the aftercooler heat rejection factor table provided with the
engine technical performance data sheet to determine the aftercooler heat rejection factor
for the site conditions. (For diesel engines, the aftercooler heat rejection factor is 1.0.)
Aftercooler Heat Rejection Factor (ACHRF): __________
2. Heat Rejection of Cooling Circuit

Determine the cooling system configuration, obtain the heat rejection data for the specific
engine model and rating and add the appropriate tolerance. Possible configurations: SCAC
only, Combined SCAC + OC*.
Aftercooler Heat Rejection: ___________ Btu/min or kW
Aftercooler Heat Rejection x (ACHRF) x 1.05 tolerance = Heat Reduction with Tolerance
________________________ x _______ x 1.05 tolerance = ______________ kW or Btu/min
Oil Cooler Heat Rejection: ____________ kW or Btu/min

Oil Cooler Heat Rejection x 1.20 tolerance = Heat Reduction with Tolerance
_______________________ x 1.20 tolerance = ___________ kW or Btu/min
Add the kW or Btu/min values of the aftercooler and oil cooler circuits:
Total Heat Rejection with Tolerance = ___________ kW or Btu/min
*Note: Most engines have the oil cooler on the jacket water circuit and the heat load is
included in the jacket water value. For gas engines and 3600 engines, check the
performance data sheet to determine which circuit contains the oil cooler.
2011 Caterpillar

Sheet 2 of 3
3. Coolant Flow Rate

Calculate the coolant flow rate using the temperature rise, heat rejection and coolant
properties. Density and Specific Heat can be found in Table 1 on Page 24 of the Cooling
Systems Application & Installation Guide.
Note: If a temperature rise value is not provided for the engine, the coolant flow must
be selected from the external restriction vs. coolant flow curve for the engine rather
than calculated. Select a flow rate near the midpoint of the curve.
Recommended Temperature Rise (T): ____________ C or F

Density of Coolant: ____________ lbm/gal or kg/L
Specific Heat of Coolant: ____________ kW-min/kg C or Btu/lbm F
Heat Rejection
= Cooling Circuit Flow Rate
T x Density x Specific Heat
= _______________ (Lpm or gpm)

x x
Cooling Circuit Flow Rate: _______________________ Lpm or gpm
4. Allowable External Restriction

From the graph of External Restriction vs. Coolant Flow for the Auxiliary Circuit,
find the maximum allowable restriction for the flow calculated in step 3.
Maximum Allowable External

Restriction for Auxiliary Cooling
Circuit: ____________________ m H2O or ft H2O
2011 Caterpillar

Sheet 3 of 3
5. Auxiliary Cooling System Sizing (Radiator, Heat Exchanger or other cooling

device)
Add an additional external circuit system tolerance to the Total Heat Rejection with
Tolerance value calculated in step 2 to account for system fouling or degradation.
This additional tolerance should be 1% to 10%, depending on the cooling system
used and operating conditions.
Total Heat Rejection with Tolerance x (1.01 to 1.10) = Auxiliary Circuit Heat Rejection
_______________________________ x 1.______ =______________ kW or Btu/min
Auxiliary Circuit Heat Rejection: ____________________ kW or Btu/min
6. Recheck Cooling System Pressure Drop

After selecting a cooling system, calculate the pressure drop of the system and compare
it to the external restriction vs. flow curve to determine if the flow rate changed from the
assumed value. If the value changed, recheck the cooling system at the new value to assure
the system is sized correctly. As long as the operating point is on the given pump curve for
the engine, it is an acceptable operating point for the engine. Do not extrapolate the curve,
as this operating point will not be acceptable for the engine.
2011 Caterpillar
Heat Exchanger Sizing Worksheet

Sheet 1 of 1
2011 Caterpillar
Keel Cooler Sizing Worksheet

Sheet 1 of 1
2011 Caterpillar
Packaged Keel Cooler Sizing Worksheet

Sheet 1 of 1
2011 Caterpillar
Auxiliary Expansion Tank Sizing

Sheet 1 of 1
2011 Caterpillar
LEBW4978-08 2011 Caterpillar Printed in U.S.A.
All rights reserved.

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APPLICATION AND INSTALLATION GUIDE

Cooling System Basics ............................................................... 2

Information contained in this publication may be considered confidential. Discretion is

Cooling System Basics

on 3600/G3600 engines, and part of temperature circuit, must be

Separate Circuit Cooling System - Inlet Controlled

Temperature Raw Water

Temperature AC-OC Circuit

Separate Circuit Cooling System - Outlet Controlled

Jacket Water Full Flow

Combined Circuit Configuration a portion of the high temperature outlet

Combined Circuit Cooling System - Inlet Controlled

Temperature Heat Exchanger

Combined Circuit Cooling System - Outlet Controlled

Air-to-Air Aftercooling radiator is an air-to-air heat exchanger,

documentation for further information. the turbochargers to turn in reverse

Typical Air-to-Air Aftercooling System for Gas Engine

1. Actuator with Valve Positioner 4. Turbocharger

Inlet Controlled Cooling Systems (CHP) systems will be inlet controlled

and occasionally by means of nucleate Tables: 110C steam forms at 20.47

be utilized to mitigate various impacts Inlet controlled systems must be

If the system results in a combined through the factory by way of a Design-

discusses several other recommended Special Cooling Systems

Compressor Oil Coolers

G3600 Separate Circuit Cooling System

Bypass Line (if needed)

G3500 and Smaller Separate Circuit Cooling System

Bypass Line (if needed)

Cooling System Sizing

surrounding environment. This is due to The aftercooler temperature listed on

More important to diesel engine ratings Where:

Cooling System Sizing restriction vs. flow curve is

Coolant Density & Specific Heat Values

Coolant Flow Calculation

Heat Rejection (Btu/min)

Where T is the temperature rise of the circuit:

Depending on the engine model, the

Example of Jacket Water System Performance

Cooling System Design Sketch

Equivalent Length Restriction/100 ft @ Total Restriction

4 53.6 (176) 12.40 6.64 (21.8)

Example Restriction Calculation: straight length values for components

Types of Cooling Systems

Typical Radiator Design with Sample Coolant Flow

As previously mentioned, the cooling formation in the engine water jacket.

evaluation is required to prove the temperature as it flows across

a heat rejection rate approximately Table 3

flexible joints between the radiator demonstrates this problem for

Radiator/Fan Performance Temperature

Original Radiator Temperature = standard rule of thumb is to make the

Ducts directing radiator air to the Remote Mounted Radiator

Heat Exchangers is usually piped to flow through the shell

Fouling Factor Chart for Water (hr-ft2-F/Btu)

Engine Coolant Temperature < 116C (240F)

Raw Water Velocity

Figure 20 Water Types

Seawater 0.0005 0.0005

Design Criteria and Considerations Brackish Water 0.002 0.001

Caterpillar does not recommend is controlled by a temperature regulator;

Submerged Pipe Cooling System

Cooling Towers a cooling tower will cool. However,

Closed Cooling Tower with Externally Mounted Heat Exchanger

Closed Loop Cooling Tower