What is a generator remote cooling system?

What is a remote cooling system?

It is known as a remote cooling or radiator system when the complete cooling system or some of its partial components (radiator, heat exchangers, etc.) are located outside of the engine generating set. Remote radiators are utilized in various scenarios where a traditional unit-mounted radiator is impractical, such as heat recovery or for other technical reasons. Recent years have seen an increase in the number of businesses that recognize the necessity for backup power in manufacturing operations, large buildings, etc. Using the byproducts of power production for a number of purposes is one method for maximizing the return on their power unit investment.

While many generator sets have an enginemounted radiator, it is rather typical for bigger sets, particularly those situated inside, to use a remote radiator system. Typically, engine-driven generator systems use a unit-mounted radiator to transfer engine heat to the coolant. When building a generator in a physically limited space or in the engine room, where it is hard to supply sufficient cooling airflow, remote radiators are most usually employed. As engines become larger and installations become more complex, the vertical core and close-coupled fan layout may no longer be the optimal solution.

If a close- ounted unit would simply not perform and where the unique circumstances may necessitate many various radiator layouts, remote-mounted radiators greatly boost installation flexibility. In contrast to generator sets, which are shipped with the radiator already attached to the base, a remote radiator system requires final assembly of the cooling system to be completed on-site. Only a competent professional should carry out the operation since it demands specialized knowledge on sizing, pipe dimensions, radiator types and sizes, mounting, loading, etc.

When installing a remote cooling system, the following considerations must be made:

Pipe lengths and the engine manufacturer's specifications for coolant flow will decide the diameter of the coolant piping. To prevent engine vibration from entering the piping system, flexible pipe portions should be utilized at engine connections.

Choosing a Radiator Radiators exist in single- and split-core types. Split cores permit the cooling of two systems simultaneously.

If the generator set engine is single-core, it either employs a non-cooled turbocharger or is naturally aspirated.

Turbo aftercoolers with a split core are a common component of larger generator sets and those that commonly require remote radiator systems. To cool the coolant in aftercoolers that utilize air/water heat exchangers, the radiator must contain an extra core.

To regulate the flow of coolant to a radiator adjacent to the engine, the engine maker incorporates a pump. A remote radiator system may require an additional pump to ensure sufficient coolant flow, as it will be placed a considerable distance from the engine. For radiators positioned above the engine, such as on the roof, the installation must consider both the flow requirement and the pump's required height.

Ventilation - Although installing the radiator far from the generator will divert a large portion of the needed airflow, the system designer still needs to account for the ventilation needs to control combustion and radiated heat.

Expansion Tank: The main purpose of the expansion tank is to facilitate the coolant's thermal expansion. Furthermore, the position, proportions, and dimensions of the expansion tanks are critical. For systems with a remote expansion tank, a deaeration chamber near to the engine outlet with vent lines leading to the expansion tank is required. As the entire flow of coolant does not pass through the expansion tank, it is unlikely that entrained air or gas will escape the flow. A slowing zone must be inserted into the flow path to create that option. The expansion tank must be located at the highest point within the overall cooling system.

CONSIDERATION FOR CHARGE AIR COOLER SIZE

Size considerations for charge air coolers comprise the following:

rejection of heat\sCooler temperatures while the charge is on and off.

The maximum temperature that can be put into the intake manifold of the engine.

The absolute lowest allowable intake manifold temperature

Depending on the type of charge air cooler, additional components, such as a fan or a heat exchanger, may need to be designed or selected.

CONSIDERATIONS FOR SIZE

There are numerous additional factors to consider when determining the size of the radiator and its accessories. A radiator in a remote location may need to be raised higher than usual. Yet, if the configuration's installation height exceeds the maximum height specified by the engine manufacturer, engine performance may be compromised and engine parts may be physically damaged. To mitigate the effects of altitude, a heat exchanger, a hot/cold well system, or a combination of the two is required. This enables the use of a radiator at a greater elevation than the engine, but at the expense of increasing the total cost of the system.