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CONTENTS
Cover .............................................................................................................. 1
Table of Content ............................................................................................. 2
Preface 3
Background4
The Problems of the Paper.5
The Purposes of the Paper..6
The Benefits of the Paper...6
The Definition of Cooling System.6
The Types of Cooling System7
The Parts which Cooled by Cooling System.15
The Disorders in Cooling System..16
The Maintenance of Cooling System.16
The Rules of Cooling System.17
The Design of Cooling System..18
The Detail of Calculation..19
References.. 37
PREFACE
Let us say praise be to God who has mercy and is blessing us and let's not forget the
great prophet beloved blessings on the Prophet Muhammad that have brought us from a
world of ignorance into a world of natural science as it is today, so that I can finish the task
with care and substantial report about the detention and propeller of the course lecturers Mr.
Dr. Semin Sanuri, S.T, M.T
The task of this report covers the aspects contained in the course of Machinery Basic
Design. Hopefully this report will help enhance the knowledge and experience to readers,
especially to students JTSP to be reading which can increase our knowledge.
I realize that in the preparation of this report is less than perfect, both in terms of the
preparation of the study, and writing. Hence my criticism and constructive suggestions,
particularly from the course lecturers Mr. Dr. Semin Sanuri, S.T, M.T in order to become a
reference in the provision of the author in order to better future.
Surabaya, April 15 20
3
A. Backgrounds
Although there is an abundance of free sea water available, marine diesel engines do
not use it directly to keep the hottest parts of the engine cool. This is because of the corrosion
which would be caused in the cooling water spaces, and the salts which would be deposited
on the cooling surfaces interfering with the heat flow.
Instead, the water circulated around the engine is fresh water ( or better still, distilled
water) which is then itself cooled using sea water. This fresh water is treated with chemicals
to keep it slightly alkaline ( to prevent corrosion) and to prevent scale formation. Of course, if
distilled water, which some ships can make from sea water using evaporators, is used then
there is a reduced risk of scale formation.
The cooling water pump which may be engine driven or be a separate electrically
driven pump pushes the water around the circuit. After passing through the engine, where it
removes the heat from the cylinder liners, cylinder heads, exhaust valves and sometimes the
turbochargers, it is cooled by seawater and then returns to the engine. The temperature of the
cooling water is closely controlled using a three way control valve. If the water is allowed to
get too cold then it will cause thermal shocking which may lead to component failure and will
also allow water and acids to condense on the cylinder bores washing away the lubricating
film and causing corrosion. If it gets too hot then it will not remove the heat effectively
causing excessive wear and there is a greater danger of scale formation. For this reason the
cooling water outlet temperature is usually maintained at about 78-82C. Because it is at a
higher temperature than the cooling water used for other purposes (known as the LT cooling),
the water for cooling the engine is known as the HT (High Temperature) cooling water.
Cooling can be achieved by using a dedicated cooler or by mixing in some of the
water from the LT cooling circuit. The LT cooling water is then cooled in the sea water
coolers. The temperature is controlled using cascade control which monitors both the inlet
4
and outlet temperatures from the engine. This allows a fast response to any change in
temperature due to a change in engine load.
To make up for any leaks in the system there is a header tank, which automatically
makes up any deficiency. Vents from the system are also led to this header tank to allow for
any expansion in the system and to get rid of any air (if you are familiar with a domestic
central heating system then you will see the similarities). The header tank is relatively small,
and usually placed high in the engine room. It is deliberately made to be manually
replenished, and is fitted with a low level alarm. This is so that any major leak would be
noticed immediately. Under normal conditions, the tank is checked once per watch, and if it
needs topping up, then the amount logged.
The system will also contain a heater which is to keep the cooling water hot
when the engine is stopped, or to allow the temperature to be raised to a suitable level prior to
starting. Some ships use a central cooling system, whereby the same cooling water is
circulated through the main engine(s) and the alternator engines. This system has the
advantage whereby the engines which are stopped are kept warm ready for immediate
starting by the engines which are running.
B. The Problems of the Paper
1. How cooling system works ?
2. How to calculate and design the cooling system ?
Engine mounted on a vessel designed to work with maximum efficiently and walk
for hours to walk ever. The loss of the most frequent and maximum energy from the engine is
in the form of thermal energy. to eliminate the excessive heat energy must use cooling media
(Cooler) in order to avoid functional disturbance or damage to the machine engine. For that,
the cooling water system installed on the ship.
b. The Components
1. Pump :
Sea water pump serves to suck seawater and pressing water into the system,
then circulated in order to perform cooling. In general, the motor vessel using
centrifugal type seawater pump, which is driven by means of pulleys (belt), so that
the pump shaft will rotate in the same direction. Motors of this type usually use
this type of piston pumps and pump installation should not be higher than the
water supply tank, but the pump must be lower than the water level in the tank, so
that sea water can get into the end of the suction pipe. There are two types of
pumps that can be used to circulate the cooling water which is kind of a piston or
plunger pumps and centrifugal pumps.
2. Impeller :
Impeller is sort of a hollow disc with curved blades in it and mounted on the
shaft, which is driven by an electric motor, steam engine or steam turbine or other
pengerak. Channels on the side of the impeller near the shaft is connected to the
suction channels, and a liquid (water), oil, etc.) into the rotating impeller through
the channel and for rotary motion of the impeller, the fluid will follow the rotary
motion of this and due to the centrifugal force that occurs , water came away from
the center, and into the space between the outer circumference of the impeller and
the pump house and headed to the outlet. A narrow part called the tongues in
determining the fluid pressure arising in the room out, because if the tongues have
worn it between the outer edge of the impeller with a house getting bigger, and the
7
liquid is pressurized will come back again into the suction channel through the
room worn earlier , Because based on the speed of the pump can not suck itself, so
that the pump should be placed under the surface of the water being pumped.
3. Oil Cooler
Lubricating oil is a medium that serves to cool the engine parts that rub against
and circulating in the lubrication system inside the motor. Points of heat exchange
using shell and tube type (shell and tube) for heat exchange with the water as a
cooling medium in which there is the copper pipes that fed the sea water as
coolant medium, while around pipes flowing lubricating oil cooled.
Cooling water channels typically use pipes made of steel, and galvanized part
in it. This pipe passed the cooling water, wherein the flow and speed in
accordance with the cross sectional area of the pipe to the cooling requirements.
1. Seachest
2. Valve
3. Filter
7. Thermometer
8. Main Engine
9. Exhaust Pipe
4. Pump
5. Safety Valve
6. Coolant Tank
c. The Advantages :
Maintenance easier
The initial cost is cheaper.
In the specifications for engine cooling system MAN & BW coolant is used to cool
the lubricating oil, jacket water, air conditioning rinse.
9
d. The Disadvantages :
Material requires corrosion resistant components.
Greater maintenance costs
If there is one component damage will cause other components disturbed function.
2. Indirect Cooling System
a. Definition
Indirect cooling system uses two cooling medium, which is used is fresh water
and sea water. Fresh water is used to cool the motor parts, while the sea water used to
cool fresh water, after the sea water directly pumped overboard and fresh water
circulates in a closed cycle. This cooling system has a higher efficiency and can cool
the motor parts evenly.
b. The Components
1. Expansion Tank
The water in the cooling system will expand when the temperature rises so
that there will be excess water, and excess water will be placed in the highest
place in the cooling water channel so that the pressure on the system always
remains and prevent pockets of steam / air in the cooling system.
2. Heat Exchanger
This tool serves to cool the fresh water that circulates in the cooling system. In
diesel motors used in ships, fresh water cooling devices usually shaped shell and
tube (shell and tube) with seawater as a coolant medium.
10
4. Cooling Plumbing
This pump serves to suck and swallow fresh water that circulates in the
cooling system. The pumps are typically used are centrifugal pumps.
11
Only one heat exchanger that is cooled by seawater and only one heat exchanger in
overhaul
The entire heat exchanger cooled by fresh water and materials used are cheaper.
Only slightly corrosive pipe installations
Reduced maintenance for refrigeration components
Extra utility tool
d.The Disadvantages
There are 3 sets of cooling water pump (seawater, freshwater low temperature, and
13
water pumps
The main cooling water pump may be attached to the propulsion plant. It is to
be ensured that the attached pump is of sufficient capacity for the cooling
water required by main engines and auxiliary equipment over the whole
14
Main and stand-by cooling water pumps are to be provided for each fresh
F. Detail of Calculation
1. Expansion Tank
The expansion tank should be equipped with an inspection hatch, a level gauge, a
low level alarm and necessary means for dosing of cooling water additives.
15
So, the
4. Transfer Pump
Time to transfer the cooling water from the drain tank is:
T = 20minutes
= 0.333333333 hour
After estimate the time to transfer the cooling, the capacity of pump can be
calculated by following formula:
Q = V/t = 3.06 m3/h
16
Head Static
Head static is the difference height of suction and discharge side. The suction side is
taken from drain tank, and the discharge side is the expansion tank.
b.
Hs = 7.309 m
Head Pressure
Head pressure is the difference pressure of suction and discharge side. The design
pressure of both side is same, so the head pressure is 0.
c.
Hp = 0 m
Head Velocity
Head velocity is the difference velocity of suction and discharge side.
d.
Hv = 0 m
Head Losses
Head losses is the sum of the losses at the suction side and the discharge side. It is
estimated that the losses at the suction side is 4 m, and the losses at discharge side is
e.
f.
H = 15.309 m
Q = 3.06 m3/h
Pump Selection
Equipment : Transfer Pump
Merk
: EVERGUSH
Type
: XA3226-42.2
Capacity
:7
m3/h
Head
: 17 m
Rotation
: 1450 rpm
Power
:3
HP
compensate a high flow resistance in the circuit with a smaller pressure drop over the
central cooler. The flow to the fresh water cooler must be calculated case by case
based on how the circuit is designed.
In case the fresh water central cooler is used for combined L T and HT water flows in
a parallel system the total flow can be calculated with the following formula:
Where:
q
qLT : Nominal LT pump capacity [m3/h]
Tout : HT water temperature after engine
Tin : HT water temperature after cooler
: Heat dissipated to HT water
So, the value of total fresh water flow is:
q
80
91
38
640
m3/h
oC
oC
kW
: 90.375 m3/h
be
dissipated.
So, the capacity of sea water pump is:
Q : 1,5 x Fresh Water Flow
: 135.56 m3/h
The pressure of pump is 1,4 bar. Then choose the pump.
Equipment No. : Sea Water Pump
Merk :
IRON PUMP
Type :
CN(X) 125/250
Capacity :
140
m3/h
Head :
17
m
Rotation :
1500 rpm
Power :
6.6
kW
18
7.
HT Stand By
Pump
Stand-by pumps should be of centrifugal type and electrically driven. Required
capacities and delivery pressures are stated in Technical data.
Wartsila 32 Project Guide 9.3.1. Stand By Pump, Page 99
The capacity of stand by pump is = 80 m3/h
The pressure of stand by pump is = 4 bar
Equipment No.
:
HT
Merk
: EVERGUSH
Type
: XA8040-437
Capacity
: 85
m3/h
Head
: 42
Rotation
: 1450 rpm
Power
: 50
Stand
By
Pump
HP
19
80
m3/h
The pressure of stand by pump is
bar
: EVERGUSH
Type
: XA8040-437
Capacity
: 85
m3/h
Head
: 42
Rotation
: 1450 rpm
Power
: 50
HP
9. Calculation of Preheater
It is recommended to heat the HT water to a temperature near the normal operating
temperature. The heating power determines the required time to heat up the engine
from cold condition. The minimum required heating power is 5 kW/cyl, which
makes it possible to warm up the engine from 20 C to 60...70 C in 10-15 hours. The
required heating power for shorter heating time can be estimated with the formula
below. About 2 kW/cyl is required to keep a hot engine warm.
Wartsila 32 Project Guide 9.3.12. Preheating, Page 102
The power of the preheater can be calculated by this following formula.
Where:
20
70
oC
25
oC
43.5
ton
m3
0.51
10
kW
m3
oC
TA / TB = 2.8
So, the value of LMTD is : LMTD = 43.71 C
After got the LMTD value, will gained the heating surface area.
A = H/(K-LMTD)
Where :
A = Heating surface area [m2]
H = Heating Coil Output (42,39 kW) = 36473.231 kcal/h
K = 1000 kcal/mhC
So, the heating surface area is:
A = 38.14 m2
After got the heating surface area, select the heat exchanger.
Merk =
Funke ViFlow CPS
21
The capacity of
the pump is:
Q = 0,4 x 8 = 3.2
m3/h
The pressure of the pump is:
P = 0.8
bar
So, the selection pump for preheater pump is:
Equipment
: Preheater Pump
Merk
: EVERGUSH
Type
: XA3213
Capacity
:4
m3/h
Head
:9
Rotation
: 1450 rpm
Power
:1
HP
12. Pipe's
Diameter
a.
Transfer
Pump's
Diameter
Q=
3.06 m3/h
0.00085
23
m3/s
v = 2.5
m/s
So, the pipe's diameter is:
A = Q / v = 0.000340
m2
A = x d/4
d
= ((4 x A) / 3,14)
= 0.021
m = 21 mm
The pipe is located in the machinery space, so the minimum wall thickness of main
pipe is at group N. The minimum thickness value of group N:
Pipe outside diameter (da) = from 20
Thickness
= 2.0
mm
mm
Germanischer Lloyd Chapter 2 Section 11, Piping Systems, Valves and Pumps, Table
11.5 and Table 11.6
The selected pipe based on DIN for main pipe:
Inside Diameter
Outside Diameter
= 23
= 25
mm
mm
Thickness
= 2,0 mm
DIN 2448 Carbon Steel Pipe's Catalog
b. Sea Water Pump's Pipe Diameter
Q = 135.56 m3/h
= 0.037656295
m3/s
v = 2.5
m/s
So, the pipe's diameter is:
A =Q/v
= 0.015063 m2
A = x d/4
d = ((4 x A) / 3,14)
= 0.139
=139 mm
The pipe is located in the machinery space, so the minimum wall thickness of main
pipe is at group N. The minimum thickness value of group N:
24
= from 133.0 mm
Thickness
= 3.6 mm
Germanischer Lloyd Chapter 2 Section 11, Piping Systems, Valves and Pumps, Table
11.5 and Table 11.6
The selected pipe based on DIN for main pipe:
Inside Diameter
= 159,05 mm
Outside Diameter
= 163,90 mm
Thickness
= 4,85 mm
DIN 2440 Galvanized Pipe Catalog
0.022222222 m3/s
v : 2.5
m/s
So, the pipe's diameter is:
A = Q / v : 0.008889 m2
A = x d/4
25
= ((4 x A) / 3,14)
= 0.106 m= 106
mm
The pipe is located in the machinery space, so the minimum wall thickness of main
pipe is at group N. The minimum thickness value of group N:
Pipe outside diameter (da)= from 88.9
mm
Thickness
= 2.9
mm
Germanischer Lloyd Chapter 2 Section 11, Piping Systems, Valves and Pumps, Table
11.5 and Table 11.6
The selected pipe based on DIN for main pipe:
Inside Diameter
Outside Diameter
= 110,7
= 114,3
mm
mm
Thickness
= 3,6 mm
DIN 2448 Carbon Steel Pipe's Catalog
SUMMARY
Volume of Expansion Tank = 0,75
m3
Volume of Drain Tank
= 1,02
m3
Transfer Pump Specification:
Merk
= EVERGUSH
Type
= XA3226-42.2
Capacity
=7
m3/h
Head
= 17
m
Sea Water Pump Specification:
Merk
= IRON PUMP
Type
= CN(X) 125/250
Capacity
= 140
m3/h
Head
= 17
bar
Main HT & Stand-by Pump HT Specification:
Merk
= EVERGUSH
Type
= XA8040-437
Capacity
= 85
m3/h
Head
= 42
m
Main LT & Stand-by Pump LT Specification:
Merk
= EVERGUSH
Type
= XA8040-437
Capacity
= 85
m3/h
Head
= 42
m
Separator Pre-Heater in Specification:
Merk
= Funke ViFlow CPS
Heat Exchange Area
= 38,14
m2
Preheater Pump Specification:
Merk
= EVERGUSH
Type
= XA3213
26
Capacity
=4
m3/h
Head
=9
m
Transfer Pump Pipes Specification:
Inside Diameter
= 23
mm
Outside Diameter
= 25
mm
Thickness
= 2,0
mm
Standard
= DIN 2448 Carbon Steel Pipes Catalogue
Sea Water Pump Pipes Specification:
Inside Diameter
= 159,05
mm
Outside Diameter
= 163,90
mm
Thickness
= 4,85
mm
Standard
= DIN 2440 Galvanized Pipes Catalogue
HT Main Pump & HT Stand-by Pump Pipes Specification:
Inside Diameter
= 110,7
mm
Outside Diameter
= 114,3
mm
Thickness
= 3,6
mm
Standard
= DIN 2448 Carbon Steel Pipes Catalogue
LT Main Pump & LT Stand-by Pump Pipes Specification:
Inside Diameter
= 110,7
mm
Outside Diameter
= 114,3
mm
Thickness
= 3,6
mm
Standard
= DIN 2448 Carbon Steel Pipes Catalogue
H. Conclusion
Indirect cooling system has two cooling stages . Freshwater cooling the main engines
and fresh water is cooled by sea water through the media heat exchanger ( Heat Exchanger ) .
Circulation of cool fresh water in the main engine and auxiliary pump fresh water in the fresh
water tank capacity in fresh water and then cooled by seawater entering through seachest and
assisted circulation by pumping sea water .
There are filters to filter sea water to prevent dirt into the seawater circulation
system .The heat exchange between sea water and fresh water occurs at medium heat
exchanger , type of heat exchanger is a shell and tube where fresh water flows through small
tubes in the media and seawater flows zig zag in the media caused by skating in that a shell
27
REFERENCES
Agha, F.P. (1978). "High-pressure paint gun injuries of hand: clinical and roentgen
aspects". NY State Journal of Medicine 78: 19551956.
Kent, James A. Riegel's Handbook of Industrial Chemistry (1983) Van Nostrand
Reinhold Company ISBN 0-442-20164-8 pp.492-493
Payne, F. William. User's Guide to Natural Gas Technologies. ISBN 0-585-19376-2.
P.V Lamarque: "The Design of Cooling Fins for Motor-Cycle Engines". Report of
the Automobile Research Committee, Institution of Automobile Engineers Magazine, March
28
1943 issue, and also in "The Institution of Automobile Engineers Proceedings, XXXVII,
Session 1942-43, pp 99-134 and 309-312.
Schrooten, L; De Vlieger, Ina; Int Panis, Luc; Chiffi, Cosimo; Pastori, Enrico (2009).
"Emissions of maritime transport: a reference system". Science of the Total Environment 408:
318323
http://www.brighthubengineering.com/marine-engines-machinery/41043-procedure-of-swpump-sea-chest-cleaning/
http://www.gl-group.com/infoServices/rules/pdfs/gl_vi-3-1_e.pdf
http://www.machineryspaces.com/cooling.html
http://www.marinediesels.info/Basics/cooling_the_engine.htm
http://www.wartsila.com/docs/default-source/product-files/engines-generating-sets/dual-fuelengines/wartsila-o-e-w-50df-pg.pdf?sfvrsn=3
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