Closed Cooling Water Systems for Internal Combustion Engines and

GP 03-03-06 January 2008

Reciprocating Compressors

Closed Cooling Water Systems for

Internal Combustion Engines and
Reciprocating Compressors
GP 03-03-06

Scope
[I] This Global Practice (GP) covers the design and installation of closed cooling water systems for
internal combustion engines, integral gas engine compressors, and reciprocating compressors. It does not
apply to compressor intercooling and aftercooling facilities.

Refining/Chemicals, Upstream,
For Company Use Only Version 1.2.0
Downstream Imperial Oil

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Copyright Waiver
ExxonMobil Development Company and ExxonMobil Pipeline Company hereby license the use of ExxonMobil Engineering Practices System (EMEPS) Global Practices (GPs) for
use by any ExxonMobil division, subsidiary, or more-than-50%-owned affiliate. The GPs may be downloaded and modified as necessary for project and affiliate use. Written
permission from ExxonMobil Development Company or ExxonMobil Pipeline Company is not required. However, any modified GPs must be renumbered to a project-specific or
affiliate-specific number to distinguish them from the GPs on the EMEPS web site. ExxonMobil operated joint ventures may utilize GPs to create project-specific or location-specific
specifications. It is the responsibility of individual affiliate or joint venture to ensure that the use of GPs and their derivatives is limited to joint venture related business and not
disclosed or used outside the JV without appropriate EM management approval.
 Closed Cooling Water Systems for Internal Combustion Engines and
GP 03-03-06 January 2008
Reciprocating Compressors

Table of Contents

1. Required References ............................................................................................ 3

1.1. Global Practices–ExxonMobil Engineering Practices ................................... 3
1.2. ASTM–American Society for Testing and Materials ..................................... 3
1.3. TEMA–Tubular Exchanger Manufacturers Association ................................ 3
2. Materials................................................................................................................. 3

3. Design .................................................................................................................... 4
3.1. Cooling System ............................................................................................ 4
3.2. Coolers ......................................................................................................... 5
3.3. Cooling Water Reservoir .............................................................................. 6
3.4. Circulating Pumps ........................................................................................ 6
Record of Change ......................................................................................................... 7

Attachment: Purpose Code Definitions...................................................................... 8

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 Closed Cooling Water Systems for Internal Combustion Engines and
GP 03-03-06 January 2008
Reciprocating Compressors

1. Required References
This Section lists the Practices, codes, standards, specifications, and publications that shall be used with
this document. Unless otherwise specified herein, use the latest edition.

1.1. Global Practices–ExxonMobil Engineering Practices

GP 06-01-01 TEMA Type Shell-and-Tube Heat Exchangers
GP 06-04-01 Air-Cooled Heat Exchangers
GP 06-05-01 Plate and Frame Heat Exchangers

1.2. ASTM–American Society for Testing and Materials

ASTM B 111/B 111M Standard Specification for Copper and Copper-Alloy Seamless
Condenser Tubes and Ferrule Stock
ASTM B 169/B 169M Standard Specification for Aluminum Bronze Sheet, Strip, and Rolled
Bar
ASTM B 171/B 171M Standard Specification for Copper-Alloy Plate and Sheet for Pressure
Vessels, Condensers, and Heat Exchangers
ASTM B 584 Standard Specification for Copper Alloy Sand Castings for General
Applications

1.3. TEMA–Tubular Exchanger Manufacturers Association

TEMA 1 Standards of the Tubular Exchanger Manufacturers Association

2. Materials
1) [*] [R] Materials for shell and tube coolers shall be as follows:
a) If fresh water cooling is specified, then components shall be of carbon steel.
b) If salt or brackish water cooling is specified, then components shall be of the materials shown in
Table 1.
2) [R] Materials for air-cooled heat exchangers shall be as follows:
a) Headers shall be of carbon steel.
b) Tubes shall be of carbon steel, with aluminum fins.
3) [R] Cooling water system piping shall be carbon steel, Schedule 40 minimum wall thickness.
4) [R] Materials of system components shall be suitable for the cooling water treatment.
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 Closed Cooling Water Systems for Internal Combustion Engines and
GP 03-03-06 January 2008
Reciprocating Compressors

Table 1: Materials for Salt or Brackish Water Cooling

Channels and Covers Tubesheets Tubes

Shell
Materials Specification Material Specification Material Specification
Carbon Steel Acid ASTM B 584 Naval ASTM B 171/B Inhibited ASTM B
Resisting Alloy C92200 brass 171M Alloy Admiralty 111/B 111M
Bronze C46400 Alloy C44300
or C44400, or
ASTM B
Aluminum C44500
169/B 169M
Bronze
Alloy C61400

3. Design
3.1. Cooling System
1) [C] One or two engine installations shall be furnished with a complete manufacturer's standard
cooling system for each engine.
2) [*] [R] [M] Installations for reciprocating compressors and three or more engines, when specified,
shall have the system shown in Figure 1. The system shall be capable of providing the following:
a) Cooling water for reciprocating compressor cylinder jackets
b) Cooling water for engine cylinder jackets
c) Cooling water for oil coolers
d) Water for cooling compressor packing boxes, or in the case of refrigeration service, water to
warm the packing
3) [R] Capacity of system: The system shall be designed to meet the following operating conditions:
a) For engines, the inlet water temperature to cylinder jackets shall be maintained at 145°F to 155°F
(63°C to 68°C).
b) For reciprocating compressors, the inlet water temperature to cylinder jackets shall be maintained
at about 10°F (6°C) above the maximum specified suction temperature.
c) The water temperature rise shall be no more than 15°F (8°C) through the cylinder jackets.
4) Working and test pressures: The system shall be designed for, not less than, 100 psig (650 kPa)
working pressure, and a hydrostatic test pressure of 150 psig (975 kPa).
5) [R] Vapor phase cooling systems are not permitted.

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 Closed Cooling Water Systems for Internal Combustion Engines and
GP 03-03-06 January 2008
Reciprocating Compressors

Figure 1: Closed Cooling Water Systems for Reciprocating Compressor and

Multiple Engine Installations
Treated Water
Make Up

Vent
Atmospheric
Reservoir

HCV HCV
XXX XXX
Heater
FG If Required Lxx Lxx
HCV FG LA HA
XXX XXX XXX
Air Cooled or
TiXX Shell and Tube
D FG
XXX TiXX Engine Combustion
D Cylinder Jacket
HCV Txxx Cooler(1)
XXX HA
TiXX
D
FG
XXX Txxx Plant Cooling
C Water Inlet and Return
Reciprocating
Compressor
TiXX Air Cooled or Shell
Other D and Tube Compressor
Engines Cylinder Jacket Cooler(1)
and
Compressors
Plant Cooling
Water Inlet and
Txxx Return
HA Tixx Pxxx
D 1
Txxx
TiXX TiXX C
D D Circulating
Pump and
Spare
Pxxx
1
HCV HCV Plant
XXX XXX Txx Cooling
Oil Cooler Oil Cooler D Water

Outlet Air Cooled or Outlet Pxx Pxx

Shell and Tube LA L(Cl)
Air Cooled or
Shell and Tube Inlet
Auto Drain
Start

NOTE:
(1) Some combinations of engines and compressors may require separate cooling systems for engine and compressor
cylinders in order to maintain the required cylinder water inlet temperatures.

3.2. Coolers
1) [M] [R] Shell and tube coolers shall be per the following minimum requirements:
a) Design and construction per GP 06-01-01.
b) Tube diameter 5/ 8 in. OD (16 mm).
c) Tube wall thickness 0.049 in. (1.24 mm).
d) Tube bundles shall be removable.
2) [M] [R] Plate and frame coolers shall be per the following minimum requirement:
Design and construction per GP 06-05-01.
3) [M] [R] Air cooled heat exchangers shall be per the following minimum requirements:
a) Design and construction per GP 06-04-01.

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 Closed Cooling Water Systems for Internal Combustion Engines and
GP 03-03-06 January 2008
Reciprocating Compressors

b) Tube diameter 3/ 4 in. OD (19 mm).

c) Tube wall thickness 0.083 in. (2.1 mm).

3.3. Cooling Water Reservoir

1) [O] Location of cooling water reservoir: The system reservoir shall be located above the highest
point in the system.
2) [O] The working capacity of the reservoir shall be at least equal to the normal capacity of the pump
per minute.
3) [O] A gauge glass shall be provided for the reservoir and shall be of sufficient length to cover the
following:
a) Working range of the reservoir
b) Normal expansion and contraction within the system
c) The rundown from the system when all engines are idle
4) [O] A reservoir vent shall be provided, and shall have a diameter of not less than 1/ 2 the diameter of
the pump suction line.
5) [O] A continuous slope shall be provided from the reservoir down to the suction connection of the
pump.

3.4. Circulating Pumps

1) [R] Two pumps shall be provided. The main pump shall be motor driven; the spare pump shall be
steam turbine driven if a secondary selective electric system is not provided.
2) [O] [R] The spare pump shall start automatically on loss of pressure in the discharge line of the main
pump.
3) [R] Both pumps shall have mechanical seals.

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 Closed Cooling Water Systems for Internal Combustion Engines and
GP 03-03-06 January 2008
Reciprocating Compressors

Record of Change
Version 1.0.0 Date: 07/01
Location Action Description
Initial Publish.

Version 1.0.0 Date: 09/03

Global Practice version number and format updated to comply with new
process; however, original publish date remains, and no content was
modified.

Version 1.1.0 Date: 06/05

General From this version onward, revision bars in the right margin will be used
to identify technical changes from the last version of the GP.
Section 1 and Modification Updated reference mnemonic to ASTM B 111/B 111M.
Table 1

Version 1.2.0 Date: 01/08

Table 1 Modification Changed references from API documents to GPs.
Figure 1 Modification Added text allowing option for plate and frame exchangers.
Section 3.2 Modification Changed references to GP documents.
Section 3.2, Addition Added minimum requirement for plate and frame exchangers.
Item (2)
All Global Modifications To standardize the format of the Global Practices and to meet other
Practices requirements, the following changes have been implemented:
"For ExxonMobil Use Only" has been replaced with "For Company Use
Only."
A copyright waiver has been added in the first page Footer.
The definition of asterisks in the Scope has been deleted. The asterisk is
now defined in the Purpose Code attachment and is used within brackets
as other Purpose Codes.
Multiple paragraphs within a Section have been numbered.
The standard text for Required References has been modified.
The standard text for Additional Requirements has been modified.
The [S] Purpose Code has been modified.
The following Purpose Codes have been added:
[*] for additional information or decision required of Owner's
Engineer.
[A] for approval requirements before beginning work or finalizing
design.

Version 1.2.0 Date: 08/09

Upstream previously used Version 1.1.0 but now accepts Version 1.2.0.

RFCH, UPST, DIOL For Company Use Only Version 1.2.0

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 Closed Cooling Water Systems for Internal Combustion Engines and
GP 03-03-06 January 2008
Reciprocating Compressors

Attachment: Purpose Code Definitions

Code Description
* Assigned to paragraphs that require the Owner's Engineer to provide additional information or
make a decision.
A Assigned to paragraphs that require approval from the Owner's Engineer before the work may
proceed or the design is finalized.
C Assigned to paragraphs whose primary purpose is reduced costs. Reduced cost in this context
refers to initial investment cost and does not include life cycle cost considerations. Life cycle
cost considerations are captured under reliability, maintainability, or operability purpose codes.
E Assigned to paragraphs whose primary purpose is driven by environmental considerations.
Environmental considerations typically include specifications intended to protect against
emissions/leakage to the air, water, and/or soil. Deviations from the specifications contained
in such paragraphs require formal review and approval according to local environmental
policy.
I Assigned to paragraphs that provide only clarifying information, such as Scope statements,
definitions of terms, etc.
M Assigned to paragraphs whose primary purpose is to provide for maintainability of equipment
or systems. Maintainability provisions are those that facilitate the performance of maintenance
on equipment/systems either during downtimes or during onstream operations.
O Assigned to paragraphs whose primary purpose is to assure operability of equipment or
systems. Operability is the ability of the equipment/system to perform satisfactorily even
though conditions are off-design, such as during start-ups, process swings, subcomponent
malfunction, etc.
R Assigned to paragraphs whose primary purpose is to improve or assure the reliability of
equipment or systems. Reliability is a measure of the ability of equipment/systems to operate
without malfunction or failure between planned maintenance interventions.
S Assigned to paragraphs containing specifications/guidance where the primary purpose is the
avoidance of incidents impacting personnel safety, operational safety, and the public in general
and/or involving responses to emergency situations. Any deviation from the specifications
contained in such designated paragraphs requires formal review and approval according to
local safety policy.
Personnel Safety: Refers to incident-related personnel injuries or illness, e.g., burns, cuts,
abrasions, inhalation of or exposure to dangerous substances, etc., that
could result in medical treatment, restricted work, lost-time incidents, or
fatalities.
Operational Refers to the prevention and control of process releases, fires, and/or
Safety: explosions that could result in damage to equipment, process disruption,
or personnel injury or illness.

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