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francis_mechanical,

You are in right path.


1. You have to find out what is cooling water requirements
for each engine. This give you water flow, inlet and outlet
temperature ranges. By multiplying by 26 you have got total
cooling water flow, which is you calculated to be 2,600 gpm, I
assume. We probably will have constant flow closed circuit
cooling water system.

2. From Crane reference table I can find out that for 2500
gpm: 7.17 fps for 12" X SCH40, and 5.93 fps for 14" X SCH40. I
think, for this type of application 12" pipe is minimum you
can use. Please note that 12" pipe STD (0.375") and SCH40
(0.406") doesn't much, so be careful! Corrosion Allowance for
this type of application will be around 1/16"-1/8".

3. So you probably will have 5 psi pressure drop across each


engine (please check this number from engine manufacturer),
so you will have about 10-15 psi differential pressure
between supply and return headers. You will have another 10
psi allowance for your Air Cooler (I think you can use Air
Cooler to cool water), and 10 psi pressure drop through all
piping. So we will need 35 psi total DP for your pump.
Probably three (3) pumps at 50% flow is a good idea as
mentioned above (two pumps running, one stand-by), so
your pump shall be able to deliver 1300 gpm @ 35 psi. Your
system will have 50 psig design @ 100C. Piping will be
uninsulated (except areas where human can hurt themselves
by touching high temp surface).

4. You will have supply and return header 12"xSTD and 26


branches going to and coming from engines. For 88 gpm flow
for each engine 2" pipe may be sufficient (Crane says 8.6 fps
for 90 gpm). I think you can use STD wall pipe, but many
specs use "extra strong" XS wall for small bore piping 2" and
below for corrosion allowance.

5. I recommend to use manual butterfly valves to adjust flow


on each branch going to each engine. These come flangeless
body and installed between two flanges. During start-up
these will be adjusted to have 88 gpm through them and
locked. It is simple and not expensive solution for constant
flow application. Of course you can install control valves with
flow meters on each line and control flow through it (I don't
think it will add any value, except cost).

6. You will have in the end supply and return header 3"-4" bypass line with by-pass valve. This line needed to control
differential pressure between supply and return header, and
will be helpful during start-up and adjusting flows to each of
26 engines.

7.Now, you can size Air Cooler, based on supply and return
temperature ranges, we can determine how big cooler do you
need. Use summer hottest air temperature for Air Cooler
sizing. 10 psi pressure drop should be maximum, but do not
go below 4 psi because you may have problem with flow
distribution. I think stainless steel tubes with extruded AL fins
are most cost efficient Air Cooler designs. You can choose
from number of suppliers who can built and supply complete
package with fans.

8. Once you have sizing of Air Cooler, and preliminary layout,


you can calculate internal volume of your system. You need
this to calculate an expansion tank, because your system is
closed system, and you need a space for expanding volume of
water. So you will need an expansion tank, which should have
internal volume of 200% - 300% of volume calculated
expansion volume of water. You expansion tank will be
installed close to suction side of the pumps.

9. If you have gone this far, now you can draw P&ID of the
system, have Line List, Equipment List, Valve List, PRV List
(you will need at least two, one for Air Cooler, one for
Expansion Tank), Instrument List (Pressure and Temperature
gauges), and start cost estimate of the system.

10. Anything else? You can try to get built a Pump Skid and
install all three pumps in a steel skid with all piping,
instrumentation, valves, expansion joints. This will reduce site
costs, because all of this can be built at fabrication shop for a
fraction of the cost of the on site costs. Of course you have to
have a space to bring in this skid into you location. You have
to have close attention to structural and foundation design
for this pump skid because of vibration issues you may have.
You may consider using glycol, if you need freeze protection
in case you system will be down (emergency, maintenance,
whatever reason) in winter. Please keep in mind there is
slight difference between properties of water and glycolwater solution.

Regards,
Curtis

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