NAME-219

Marine Engines and Fuels

Lecture 8
Cooling systems of IC Engine

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 Engine Cooling

In a SI engine, cooling must be satisfactory to avoid pre-ignition and knock.

In a compression ignition engine, since a normal combustion is aided,
cooling must be sufficient to allow the parts to operate properly. In short,
cooling is a matter of equalization of internal temperature
to prevent local overheating as well as to remove sufficient heat energy to
maintain a practical overall working temperature.

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 Cooling Requirements
The cooling system is provided in the IC engine for the following reasons:

-The temperature of the burning gases in the engine cylinder reaches up to

1500 to 2000°C, which is above the melting point of the material of the
cylinder body and head of the engine. (Platinum, a metal which has one of
the highest melting points, melts at 1750 °C, iron at 1530°C and
aluminium at 657°C.) Therefore, if the heat is not dissipated, it would
result in the failure of the cylinder material.

-Due to very high temperatures, the film of the lubricating oil will get
oxidized, thus producing carbon deposits on the surface. This will result in
piston seizure.

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 Cooling Requirements

• Due to overheating, large temperature differences may lead to a distortion

of the engine components due to the thermal stresses set up. This makes it
necessary for, the temperature variation to be kept to a minimum.

• Higher temperatures also lower the volumetric efficiency of the engine.

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 Effect of Overcooling

-Thermal efficiency is decreased due to more loss of heat carried by the

coolant

-The vaporization of the fuel is less resulting in lower combustion efficiency

-Low temperature increases the viscosity of lubricant causing more loss due
to friction

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 Effect of Overcooling

• Evaporation of lubricating oil that lubricates the piston and

cylinder wall is the reason of undercooling. This will result in
metal to metal contact of the piston and cylinder (crack
formation).

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 Types of Cooling

There are mainly two types of cooling systems:

(a) Air cooled system (Direct air cooling system)

(b) Water cooled system (Indirect air cooling system)

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 Air Cooling System
Air cooled system is generally used in small
engines say up to 15-20 kW and in
aero plane engines. In this system fins or
extended surfaces are provided on the cylinder
walls, cylinder head, etc. Heat generated due to
combustion in the engine cylinder will be
conducted to the fins and when the air flows
over the fins, heat will be dissipated
to air.

The amount of heat dissipated to air depends

upon :
(a) Amount of air flowing through the fins.
(b) Fin surface area.
(c) Thermal conductivity of metal used for fins.

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 Advantage of Air Cooling System

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 Disadvantage of Air Cooling System

Disadvantages of air cooled engines

-Relatively large amount of power is used to drive the cooling fan.

-Engines give low power output.

-Cooling fins under certain conditions may vibrate and amplify the noise level.

-Cooling is not uniform.

-Engines are subjected to high working temperature.

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 Water Cooling System

Cooling water jackets are provided around the cylinder, cylinder head, valve seats
etc. The water when circulated through the jackets, it absorbs heat of combustion.
This hot water will then be cooling in the radiator partially by a fan and partially by
the flow developed by the forward motion of the vehicle. The cooled water is again
recirculate through the water jackets.

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 Water Cooling System
Antifreeze mixture
In western countries if the water used in the radiator freezes because of cold
climates, then ice formed has more volume and produces cracks in the cylinder
blocks, pipes, and radiator. So, to prevent freezing antifreeze mixtures or solutions
are added in the cooling water.

Normally following are used as antifreeze solutions:

(i) Methyl, ethyl and isopropyl alcohols
(ii) A solution of alcohol and water
(iii) Ethylene Glycol raises the boiling temperature substantially and hence more
heat dissipation
(iv) A solution of water and Ethylene Glycol
(v) Glycerin along with water, etc.
(vi) Chromates are used to prevents deposit

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 Water Cooling System
Component of water cooling system

Water cooling system mainly consists of:

-Radiator
-Thermostat valve
-Water pump
-Fan
-Water Jackets
-Antifreeze mixtures

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 Water Cooling System

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 Water Cooling System

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 Thermo-syphon cooling

This system works on the principle that water becomes light on heating. Hot water
being lighter rises up and the cold water being heavier goes down. In this system
the radiator is placed at a higher level than the engine for the easy flow of water
towards the engine. Heat is conducted to the water jackets from where it is taken
away due to convection by the circulating water. As the water jacket becomes hot,
it rises to the top of the radiator. Cold water from the radiator takes the place of
the rising hot water and in this way a circulation of water is set up. This helps to
keep the engine at working temperature.

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 Thermo-syphon cooling

Disadvantages of Thermo-
syphon system

-Rate of circulation is slow.

-Circulation commences only when

there is a marked difference in
temperature.

-Circulation stops as the level of water

falls below the top of the delivery pipe
of the radiator.

For these reasons this system has

become obsolete and is no more in use.

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 Thermo-syphon cooling

• Advantages of Thermo-syphon system

• Cheap as no water pump is required

• Reliable as there is no moving parts

• Circulation of water depends only on engine temperature. Hotter the engine greater
will be the circulation

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 Pump Circulation System

-This system is used in large number of

vehicles like car, buses, trucks and other
heavy vehicles. Here circulation of water
takes place with convection currents help
by a pump.

-The water or coolant is circulated through

jackets around the parts of the engine to be
cooled, and is kept in motion by a
centrifugal pump, driven from the engine
through V-belt.

Limitation
-Cooling is independent of temp.
-Engine is overcooled (when range of
temp.=75-90°C)
-Can be overcome by using thermostat
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 Radiator

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 Radiator

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 Radiator

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 Radiator

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 Fan
• The fan is generally mounted on the water pump pulley, although on some engines
it is attached directly to the crankshaft. It serves two purposes in the cooling system
of a engine.

• (a) It draws atmospheric air through the radiator and thus increases the efficiency
of the radiator in cooling hot water.

• (b) It throws fresh air over the outer surface of the engine, which takes away the
heat conducted by the engine parts and thus increases the efficiency of the entire
cooling system.

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 Thermostat Valve

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 Thermostat Valve

Bellow type thermostat valve which is generally used. It contains a bronze bellow
containing liquid alcohol. Bellow is connected to the butterfly valve disc through
the link.

When the temperature of water increases, the liquid alcohol evaporates and the
bellow expands and in turn opens the butterfly valve, and allows hot water to the
radiator, where it is cooled.

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 Water Pump

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 Water Pump

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 Water Jacket

Cooling water jackets are provided around the cylinder, cylinder head, valve seats
and any hot parts which are to be cooled. Heat generated in the engine cylinder,
conducted through the cylinder walls to the jackets. The water flowing through the
jackets absorbs this heat and gets hot. This hot water will then be cooled in the
radiator (Referred in Figure below)

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 Anti freeze Mixture

In western countries if the water used in the radiator freezes because of cold
climates, then ice formed has more volume and produces cracks in the cylinder
blocks, pipes, and radiator. So, to prevent freezing antifreeze mixtures or solutions
are added in the cooling water.

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 Anti freeze Mixture

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 Advantage of water Cooling

(a) Uniform cooling of cylinder, cylinder head and valves.

(b) Specific fuel consumption of engine improves by using water cooling

system.

(c) If we employ water cooling system, then engine need not be provided at
the front end of moving vehicle.

(d) Engine is less noisy as compared with air cooled engines, as it has water
for damping noise.

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 Disadvantage of water Cooling

(a) It depends upon the supply of water.

(b) The water pump which circulates water absorbs considerable power.

(c) If the water cooling system fails then it will result in severe damage of
engine.

(d) The water cooling system is costlier as it has more number of parts. Also it
requires more maintenance and care for its parts.

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 Difference between the air cooling system
and water cooling system
• Air Cooling System

• The design of this system is simple and less costly.

• Weight of the cooling system (per b.h.p. of the engine) is very less.
• The fuel consumption (per b.h.p. of the engine) is more.
• Its installation and maintenance are very easy and less costly.
• There is no danger of leakage or freezing of the coolant.
• It works smoothly and continuously. Moreover, it does not depend on any
coolant.
• Air cooling system is not suitable for multi cylinder engines.

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 Difference between the air cooling system
and water cooling system

• Water Cooling System

• The design of this system is complicated and more costly.

• Weight of the cooling system (per b.h.p. the engine) in much more.
• The fuel consumption (per b.h.p. the engine) is less.
• Its installation and main tenace in difficult and more costly.
• There is a danger of leakage or freezing of the coolant.
• If the system fails, it may cause serious damage to the engine within a
short time.
• This system can be employed in multi cylinder engines satisfactorily.

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 Cooling system in marine engine
 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

 The main engine is cooled by two separate but linked systems: an open system
(sea-to-sea) in which water is taken from and returned to the sea (seawater
cooling), and a closed system where freshwater is circulated around an engine
casing (freshwater cooling).

 Freshwater is used to cool machinery directly, whereas seawater is used to cool

freshwater passing through a heat exchanger. The particular feature of an engine
cooling system is continuous fluid flow. Fluid in motion causes abrasive corrosion
and erosion. To reduce the effects of turbulent flows, seawater systems incorporate
large diameter mild steel pipes, the ends of which open to the sea through sea
chests where gate valves are fitted.
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• A 500 hp diesel engine has thermal efficiency of 40%. It is
water cooled which takes 25% of the total heat input. If the
temperature rise of the water through cooling of the engine is
to be maximum 30°F, what should be the flow of water in
gallon/hr

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• Estimate the cfm of cooling air per hp if it takes 30%
of the fuel energy. Given that, thermal efficiency =
35%, Cp = 0.24 BTU/lb-°F, dT = 130°F, specific
volume of air = 13.7 cft/lb.

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 Reference

1. Combustion on CI Engines by Jagadeesha T, Assistant Professor, Department of Mechanical

Engineering, Adichunchanagiri Institute of Technology, Chikmagalur
2. INTERNAL COMBUSTION ENGINES by Fernando SalazarDepartment of Aerospace and Mechanical
Engineering, University of Notre Dame .
3. Introduction Diesel Engine and Fuel Injection System
4. Fundamentals and Designs of Various Types of Combustion Chambers for Diesel Engines lectures by Dr.
Avinash Kumar Agarwal Engine Research Laboratory, Department of Mechanical Engineering, Indian
Institute of Technology, Kanpur INDIA

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