G3600 Gas Engine Packaging Tips

Cooling Systems
G3600 Gas Engine Packaging Tips
Cooling System
• Application and Installation
Guide
– Blue Cover-non-current
guide
– B & W Cover-current guide
• Non-current guide is best for
G3600 engine packaging
– Some items have not yet
made it to the current A & I
Guide
• A & I Guide has the best
information to guide design
G3600 Gas Engine Packaging Tips
Cooling System
• Cooling System issues
– Temperature regulator placement
– Connecting vent lines
– Filling cooling systems
– Cooling system screens
– Fan drives
– Jacket water heater
 G3600 Standard Cooling System

• Cooling system design

– Jacket water
– Auxiliary water
• Outlet controlled Fill/

– Controls engine
coolant temperature
exiting the engine
• Remote expansion
tank Fill/
 Cooling System – Temperature Regulator

• Temperature regulator
– Cast housing with integral
coolant flow passages and
flanged connections
– Internal replaceable
elements sense temperature
and route coolant flow
accordingly
– Elements are rated for
• Opening temperature
• Fully open temperature
Cooling System – Temperature Regulator

• Coolant flow path

– While cold: All flow
through bypass [AB];
none to external loop
(regulator fully closed)
– While warming up: Flow
split through bypass and
into external loop [AB+C]
(regulator partially open)
– At operating temperature:
All flow to external loop
[AC]
(regulator fully open)
G3600 Cooling System – System Design

• Remote temperature regulator placement

– G3600 temperature regulators
are shipped loose for
site-specific installation
– Location should help achieve
the best control of temperature
and flow of the coolant
– Locate regulators close to
engine to minimize bypass
loop coolant volume
– Location should also consider
what provides easiest access
for service
 G3600 Cooling System – System Design

• Pump inlet piping design

– Straight length at the pump
inlet gives best flow to pump,
allow use of inlet screen
– Minimize bends and other
restrictions before pump inlet
to reduce chance of cavitation
– Minimize total circuit length to
reduce coolant volume,
shorten warm-up time
– Piping segments should be
short for easier handling
during servicing
G3600 Cooling System – System Design

Cooling screens
– Always use screens during commissioning to remove
debris left in system from fabrication and assembly
• Piping design is important
– Poor piping design and/or
construction can make
screen use impossible
• Mesh size
– Screens from sources other
than Caterpillar must use
1.59 mm (0.0625 in.) mesh
G3600 Cooling System – System Design

• Screen installed in jacket water pump inlet pipe

G3600 Cooling System – System Design

Field example: Poor regulator group placement

• Accessibility To Cooler

– Difficult to access for Eng Aux Out

service
– Unsafe-no work platform From Cooler
Bypass

• System operation
– This system has a long
bypass loop. Extra pipe
length means excessive
coolant volume, adds
time to warmup
G3600 Cooling System – System Design

Field example: Poor regulator group placement

• Accessibility
To Cooler
– Difficult to access for
service
JW Temp
Regulators
Eng Aux Out

– Unsafe-no work platform Bypass

From Cooler

• System operation Aux Temp

– Extra pipe length means Regulators

excessive coolant volume,

adds time to warmup
G3600 Cooling System – System Design

Field example: Poor regulator group

placement
• Accessibility
– Difficult to access for
service
– Unsafe-no work platform
• System operation
– Extra pipe length means
excessive coolant volume,
adds time to warmup
G3600 Cooling System – System Design

Field example: Poor regulator group

placement
• Good connection design
– Pipe segments are short for
easy handling
• Poor accessibility
– Regulator group is difficult to
service in tight location next to
cylinder head
– Requires removal of piping
to access regulator group
G3600 Cooling System – System Design

Field example: Good regulator placement, good inlet

design
• Accessibility/Serviceability
– Easy to service from the skid To Engine

– Short pipe segments are easy

to handle
• System operation
– Close to engine; does not add Eng Aux

unnecessary coolant volume

Out

for quicker warm-up To Cooler

– Straight spool piece into pump

– Minimal bends/restrictions
G3600 Cooling System – System Design

Field example: Good regulator placement, OK inlet

design
• Accessibility/Serviceability
– Easy to service from the skid
– Pipe segments a little heavy
• System operation
– Regulator close to engine;
requires less coolant volume
for quicker warm-up
– Straight length at pump inlet
is good, but a little short
G3600 Cooling System – System Design

Field example: Good regulator placement, good inlet

design
• Accessibility/Serviceability
– Easy access for service
from the skid
– One technician can handle
sections of piping
• System Operation
– Regulator close to engine
– Straight section of pipe
into pump inlet
 G3600 Cooling System – System Design

Field example: JW
circuit, part 1
• Good regulator group
placement
– Easy to service from
the skid
– Close to engine; does
not add unnecessary
volume for warm-up
• Short connecting pipes
– Easy for one
technician to handle
 G3600 Cooling System – System Design

Field example: JW circuit, part 2

• No straight spool piece at the
pump inlet for inlet screen
• Very sharp radius elbow at
pump inlet increases
minimum inlet pressure
– Increases chances of
cavitation
• No pressure tap at pump inlet
for performance
measurements
G3600 Cooling System – System Design

Field example: Aux circuit, part 1

• No straight spool for inlet screen
installation
– Difficult to install screen
for commissioning cleaning
• Short inlet pipe and sharp
elbow to pump inlet
– Increases chance for
pump cavitation
G3600 Cooling System – System Design

Field example: Aux circuit, part 2

• Pump inlet path poorly designed
– Sharp elbows leading to
pump inlet
– Radiator return tees into
pump inlet, adding to
restriction
• Regulator located
close to engine
– Minimzes system
coolant volume
G3600 Cooling System – System Design

Field example: Poor inlet piping design

• No straight spool at the
pump inlet for screen
• Sharp radius bends at
pump inlet increases
chances of cavitation
(especially in bypass
loop; see extra “tee”
connection)
 G3600 Cooling System – System Design

• Pump inlet piping design

– Piping to pump inlet must
align properly with pump
inlet flange
– Flexible connections are
recommended:
• To adapt to small
misalignments
• To allow for thermal growth in
external system piping and in
the engine itself
G3600 Cooling System – System Design

• Piping must align properly at connections

• Poor alignment:
– Places stress on
components
– Raises possibility of
leaking of flexible
connection
– Exerts force on
engine that can affect
driveline alignment
G3600 Cooling System – System Design

Field example: Piping misalignment

• Offset shown exceeds design
capability of flexible coupling
• Do not force into alignment!
– Forcing into place can cause
early weld failures elsewhere
in piping system
– Remove inlet pieces and
rework to achieve acceptable
alignment
G3600 Cooling System – System Design
Field example: Piping misalignment (alternate
view)
• Offset shown exceeds design capability of
flexible coupling
• Do not force into
alignment!
– Forcing into place can
cause early weld failures
elsewhere in piping system
– Remove inlet pieces and
rework to achieve
acceptable alignment
 G3600 Cooling System – System Design

Examples of flexible connection types

available…
G3600 Cooling System – System Design

Field example: Preferred type of flexible connection

• Connector shown has:
– Very good flexibility
– Connector construction
includes electrical ties,
providing electrical
continuity with cooler
– Uses bolted, flanged
connections; best
for coolant circuits with
operating temperatures
above 65°C (150°F)
G3600 Cooling System – System Design

• Example of good design

• Good placement of regulator
– Easy access for service
– Piping is easily managed
during servicing
• Pump inlet piping is straight
– Gives best pump inlet flow
– Allows use of screen
– Good pump inlet pressure check
 G3600 Cooling System – Radiator Fan Drive
• A properly designed fan drive
will not place excessive
bending loads on the engine
crankshaft
– Fan drive design must deliver
require fan power without
exceeding published side load
limits
– Fan drive design must also
account for vertical growth of
the engine as it warms up
• Fan drive components should
be placed to be easily
accessible for servicing
G3600 Cooling System – Radiator Fan Drive

• Fan drive using free end stub shaft (no support

bearings)
– Cat-supplied front stub shaft rated for 150 hp at 1000
rpm
– Allowable side load given in A&I Guide
NOTE: Dimensions shown
are from the center of the
front main bearing of the
engine crankshaft
– Exceeding the side loads
shown will lead to excessive
bending forces in the engine
crankshaft
G3600 Cooling System – Radiator Fan Drive

• Fan drive using single

support bearing
– Single bearing support
is not recommended
– Belt tension is transmitted
to crankshaft through the
bearing
• Fan drive using two support bearings
– Belt tension is not transferred to crankshaft and front stub shaft
– Bearings and lay shaft must be properly aligned to crankshaft
– Fan drive coupling must flex to allow for engine vertical growth
G3600 Cooling System – Radiator Fan Drive

Field example: Single bearing fan drive

– Single bearing acts as a fulcrum to impose belt tension
on the crankshaft
– No flexible coupling;
does not allow for
engine vertical growth
G3600 Cooling System – Radiator Fan Drive

Field example: Single bearing fan drive

• Damaged stub/damper adapter
• Operated less than 24 hours
• Failure caused by fan drive not
allowing for vertical engine growth
– Change in alignment due to growth
created side load at the support bearing
– Side load passed to front stub shaft
through support bearing
– Cyclic stress due to bending load
caused failure of stub shaft adapter
G3600 Cooling System – Radiator Fan Drive

Field example: Two-shaft fan drive

– Complex configuration uses two belt groups and two
shafts
– Lay shaft isolates stub shaft
from fan drive belt load
– Stub shaft drive end sensitive
to lay shaft belt adjustment
– This configuration works with
attention to belt load capability
and tension adjustment
• As installed, the fan drive belts
were not adequate for required
fan power, slipped above 900 rpm
• Engine overheated after 30 minutes
G3600 Cooling System – Radiator Fan Drive

• Field example: Two-bearing fan drive

– Two pillow block bearings accept all belt side loads
– Flexible coupling accommodates engine
vertical growth
– Fan drive shaft installation provides open
access for
service
(shaft guard
not shown)
G3600 Cooling System – Expansion Tanks

• Expansion tanks provide:

– Added volume for expansion of coolant due to temperature change
– Location for coolant fill/service, venting of entrained gas/air bubbles
– Positive static pressure on pump inlet to prevent cavitation
– System design examples from A&I Guide:
G3600 Cooling System – Expansion Tanks

• Expansion tanks:
– Must be the highest point in the cooling system
– Should provide at least 15% added volume
– May be full flow or partial flow
– May be part of radiator top tank
– Should include an automotive
style pressure cap
• Usually rated for 7 psi
• Use 14 psi rating for
installations above
4000 ft altitude
G3600 Cooling System – Expansion Tanks

Field example: Expansion tank installation

• Good design points
– Separate expansion tank
for each cooling circuit
– Tanks have pressure caps
• Poor design points
– Vent lines do not enter the
tank below coolant level
(bottom entry is best)
– Elevated tank location
not easily serviced
G3600 Cooling System – Expansion Tanks

Field example: Expansion tank installation

• Good system design
– Divided tank has section
for each cooling circuit;
divider welded into tank
– Pressure cap for each side
– Vent lines enter bottom
of tank under coolant level
– Platform offers easy and
safe access to tank for
service
G3600 Cooling System – Expansion Tanks

Field example: Expansion tank installation

• Good system design
– Divided tank has section
for each cooling circuit;
divider welded into tank
– Pressure cap for each side
– Vent lines enter bottom
of tank under coolant level
– Platform not provided;
access to tank for service
not as safe
G3600 Cooling System – Expansion Tanks

Field example: Expansion tank installation

• Poor system design
– Divided tank used, but may be too small for system
volume
– Pressure relief valves used
instead of pressure caps; not
an acceptable substitute
– Vent lines enter tank bottom
but do not provide continuous
upward slope for de-aeration;
hose loops act as gas traps
– Platform provides safe access
G3600 Cooling System – Vent Lines

Field example: Vent line construction

• Vent line on left has a trap built in (see loop at
connection)
– Trap prevents venting function
• Vent line on right is well built
– Both vent lines should be
constructed like the vent line
on the right
G3600 Cooling System – Vent Lines

Field example: Vent line construction

• Small rise in tubing for service
access to couplers forms a trap
– Prevents proper purging of air/gas
from liquid
• Vent line tubing may be too small to
allow proper movement of air/gas
G3600 Cooling System – Vent Lines

Field example: Vent line construction

• Shows proper continuous upward slope to
expansion tank
• Shows good support of
vent line along entire run
• Vent line appears to be
adequately sized for use
in a venting system
– Use at least 9.5mm
(0.375 in)
– Greater than 12.7mm
(0.5 in) may promote
coolant circulation in
the venting lines
 G3600 Gas Engine Packaging Tips
Cooling System
• Horizontal coolers
– Header away from
engine must be vented
to expansion tank
 G3600 Gas Engine Packaging Tips
Cooling System

• Pressure
check
locations
(in red)
C
– JW system E

– Aux system J A,
G

K B, H
G3600 Gas Engine Packaging Tips
Cooling System
• Taps for pressure checks
– Weldolet fittings shown here
in correct locations
– Install needle or ball valves
and pipe plugs to facilitate
servicing in the future
• Cat pressure probe adapter
– Adapter offers easy and quick access for checking
pressures and temperatures in the cooling circuit
– 5P2720, 5P2725, 5P3591 Adapters & 164-2192 Pressure Probe
G3600 Gas Engine Packaging Tips
Cooling System
Jacket Water and Engine Oil Heater
• Provides heating of coolant and oil to minimum
temperatures
required for cranking
• Lube oil heater circulates
oil to heat oil in the oil pan
– Cannot be used for
prelube or postlube
G3600 Gas Engine Packaging Tips
Cooling System
• Cat jacket water connection group provides correct
flow locations for best heater performance
• For other jacket water
heater circuit designs,
consult the A&I Guide
for guidelines to achieve
best results
G3600 Gas Engine Packaging Tips
Cooling System
Extra Slides
G3600 Cooling System – System Design

Good regulator group placement

• Temperature regulator placement
– Easy to service from the skid
– Close to engine; does not add unnecessary volume for
warm-up
 G3600 Gas Engine Packaging Tips
Cooling System
Poor pump inlet piping
• Sharp elbow at inlet
– Raises minimum pump
inlet pressure to prevent
cavitation
– No place to install cleaning
screen
– Turbulent flow prevents
accurate dynamic pressure
check
 G3600 Gas Engine Packaging Tips
Cooling System

Poor pump inlet piping

• Sharp elbow at inlet
– Raises minimum
pump inlet pressure
to prevent cavitation
– No place to install
cleaning screen
– Turbulent flow
prevents accurate
dynamic pressure
check
 G3600 Gas Engine Packaging Tips
Cooling System

Poor pump inlet piping

• Sharp elbow at inlet
– Raises minimum pump
inlet pressure to prevent
cavitation
– No place to install
cleaning screen
– Turbulent flow prevents
accurate dynamic
pressure check
 G3600 Gas Engine Packaging Tips
Cooling System

• Pump inlet spool too

short
– Longer than screen
– Cannot remove screen
• Insufficient clearance
– For coupling flex
– For engine growth
G3600 Gas Engine Packaging Tips
Cooling System
Conclusion
• Pay attention to the function of the system area
– Make sure that the design and construction enhances
function
• Pay attention to the ease and safety of service
during maintenance
• Weigh initial cost versus maintenance difficulty
costs
– Properly designed configuration will save money and
time in the long run