Cooling System Process Description

1. Brief Process Description (Overall)

This cooling system will consist of several integrated cooling water loops. The system covering all
heat rejections needed in Low Temperature (LT) engine cooling system, High Temperature (HT)
engine cooling system, fuel oil cooler, pilot oil cooler, nozzle cooling system and lubricating oil
cooler. The simplified block flow diagram of cooling water for these integrated loops is as follows:

There are two main loops, HT loop and LT loop, the LT loop is integrated with the other systems
because of quiet low temperature of the cooling water can still be used to recover the heat from
lube oil system. There is no heat exchange integration for the HT loop because of the high
temperature makes it not feasible for further integration. The radiator is (air cooled type) used to
reject the heat from both HT loop and LT loop into the air.

In the LT loop, the water will be directed into engine LT cooling system, fuel oil cooler, pilot oil
cooler and nozzle cooling system. These systems are set to have same inlet and outlet
temperature. The combined outlet of these streams then will be directed into lube oil cooler and
after that may be sent back into radiator or recirculated into HT cooling system again depending
on the resulted (outlet) temperature.

2. Radiator

There are two radiators, one for each engine, to cool the HT and LT cooling water simultaneously.
Each radiator is sized for enough cooling duty to lower the 100 m 3/h HT cooling water from 90 0C
to 570C (3756 kW) and 141 m3/h LT cooling water from 420C to 340C (2364 kW). Those cooling
duty is the worst possible duty, the operating condition may be lower sometimes than these
specifications. This is because the cooling water flowrate that will be cooled by the radiator
depends on the actual outlet temperature of respective HT & LT system loop, as will be explained
in following engine HT cooling & LT cooling sections below.
 In the HT loop, the radiator supplies the cooling water into the engine HT cooling system. As for
the LT loop, the radiator supplies the water into engine LT cooling system, fuel oil cooler, pilot oil
cooler and engine nozzle cooling system.

3. Engine HT Cooling

From radiator, the HT cooling water is circulated into HT engine cooling system. This system is
within the MAN 9L 51/60 DF gas engine, consists of 1 st charge air cooler and engine jacket. The
water is supplied at 570C. The heat rejected in 1 st charge air cooler is 2880 kW resulting the water
temperature rise to 820C. After that the water immediately used for engine jacket to reject 876 kW
heat and the water temperature is risen to 900C.

The water then is can both recirculated into radiator, or recirculated back into the engine HT
cooling system via a three-way valve (01-PGB404KA101 or 02-PGB404KA101). The recirculation
will depend on the outlet water temperature from this system. If the water is still cool enough to be
reused without further cooling by radiator, the water will be recirculated again into the engine. But
if the water is not cool enough to be used again, the three-way valve will direct the water into
radiator for heat rejection.

The control system consists of 1 electronic Proportional-Integral (PI) controller, 1 electrically

activated three-way valve with linear characteristic and 1 temperature sensor located downstream
of the engine output. This control system is used to maintain the engine inlet water temperature
below 900C. If the temperature reach 90 0C, the controller gives signal to the three-way valve to
direct the water to the radiator for heat rejection. If recirculated into radiator, the water will be
cooled again down to 570C. This loop water circulation is performed by the engine driven HT
circulating pump.

There may be the case when the water temperature in this loop is below 60 0C. In that case, the
water will be preheated by electric preheater in engine jacket cooling system.

4. Engine LT Cooling

LT cooling water is supplied from radiator to the engine at 34 0C. The cooling water is used to
reject 1178 kW heat from 2 nd charge air cooler within the gas engine, resulting water temperature
rise to 420C. After that, the water is supplied into lube oil cooler.

After going through lube oil cooler, the cooling water can be directed into engine LT cooling
system again or be directed to radiator through three-way valve (01-PGB404KA106 or 02-
PGB404KA106). As well as engine HT cooling system, the direction will depend on the
temperature. If the water temperature is cool enough to be used again without further heat
rejection, the water will be redirected into engine LT cooling system. If not, the water will be
directed into the radiator for heat rejection.

The Control system of this loop consists of temperature Proportional-Integral controller, 1

electrically activated three-way valve with linear characteristic (as the actuator) and 1 temperature
sensing device located downstream of the three-way valve. The purpose is to keep the
temperature not exceed 420C. If the temperature reach 420C, the three-way valve will adjust the
opening to direct the cooling water to the radiator. The water is then cooled back again in radiator
to 340C before being recirculated into the LT loop.
5. Fuel Oil Cooler (01-MJN401KC001 and 02-MJN402KC001)

This section is integration between cooling system and fuel oil system. This cooler has main
function of cool down the recycled feed fuel oil from the engine to daily tank. The fuel from the
engine has 900C temperature, and needs to be cooled down to 600C. The cooling duty is 129 kW.

The water will be supplied to this cooler from main LT loop by 01-MJG407KP001 or 02-
MJG408KP001 pumps. The water supply to this cooler is set as the flow needed to provide this
cooling duty (129 kW) if the inlet and outlet temperature are the same as engine LT cooling
system (340C to 420C). Based on this, the water needed is 13.4 m 3/hr. After that, the water is
mixed with the LT engine cooling water to being sent down to lube oil cooler.

6. Pilot Oil Cooler (01-MJN403KC001 and 02-MJN404KC001)

As fuel oil cooler, this section is also integration between cooling system and fuel oil system. This
cooler has main function of cool down the recycled pilot fuel oil from the engine to fuel main
storage tank. The fuel from the engine has 90 0C temperature, and needs to be cooled down to
600C. The cooling duty is 3.15 kW.

The water will be supplied by the same pump as the fuel oil cooler. The water supply to this
cooler is as well set as the flow needed to provide this cooling duty (3.15 kW) if the inlet and
outlet temperature are the same as engine LT cooling system (34 0C to 420C). Based on this, the
water needed is 0.33 m3/hr. After that, the water is also mixed with the LT engine cooling water to
being sent down to lube oil cooler.

7. Engine Nozzle Cooling System

This system is located within the engine scope. The nozzles of the fuel injection valves need to
be cooled by freshwater circulation, therefore a nozzle cooling water system is required. As the
two coolers before, this system also use LT cooling water circulation. The LT cooling water is not
directly used to contact/cool the nozzles. The actual cooling of the nozzles uses separated
freshwater loop that is within the engine scope, and the LT is used to cool this freshwater. The
MAN 9L51/60 DF gas engine has already specified that 20 kW heat will be rejected from this
system. The water supply is the amount needed to recover 20 kW when the inlet and outlet
temperature of this system is the same as LT engine cooling system has (34 0C to 420C). The
needed cooling water supply to this system becomes 2.1 m 3/h. After this system, the water will be
sent down to lube oil cooler.

8. Lube Oil Cooler (01-MAV302KC001 and 02-MAV303KC001)

This cooler uses cooling water from four combined source: engine LT cooling system, fuel oil
cooler, pilot oil cooler and engine nozzle cooling system. The main function of this cooler is to
cool down 194 m3/h lube oil from 640C to 550C. The cooling duty is 1066 kW. To fulfill this, the
water supplied from those 4 sources at 42 0C is sufficient and this temperature will rise to 47 0C.
Then the cooling water will either be directed into the radiator or recirculated again into the engine
LT cooling system by the three-way valve. As explained in LT cooling system section before, the
direction will depend on the temperature of water outlet stream from lube oil cooler.

9. Expansion Tank
There are four expansion tanks, two HT expansion tanks and two LT expansion tanks. The
function of these tanks is to lower the pressure of recycled water from the engine drain, and to
store the makeup water. The HT tanks will store the makeup water for HT loop, and LT tanks for
LT loop. The makeup water will be fed in HT & LT engine inlet stream respectively.