The Wärtsilä 18V46 engine, like other large marine engines, uses an efficient and robust

cooling system to dissipate the heat generated during combustion and maintain optimal
operational temperatures. One of the critical components of this system is the cooling tower,
which plays a significant role in managing the heat transfer process, especially in the context of
large engines operating in marine and industrial environments.

Cooling Tower Overview

The cooling tower is a key part of the engine cooling system that removes heat from the
engine's freshwater cooling circuit by transferring this heat to the surrounding environment,
typically using seawater or river water as a heat exchange medium. In the context of the
Wärtsilä 18V46 engine, the cooling tower serves to cool the freshwater coolant that circulates
within the engine's cooling system, as well as potentially cool other systems like the lubrication
oil and charge air.

Cooling Tower Functionality

1. Heat Transfer Process:

o The cooling tower operates by utilizing evaporative cooling, where seawater (or
in some cases, river water or another source of cooling water) is used to absorb
heat from the engine’s freshwater coolant. The freshwater coolant is circulated
through a heat exchanger in the cooling tower, where the heat from the coolant is
transferred to the seawater.
o The seawater enters the cooling tower, and part of it is allowed to evaporate,
carrying heat away. The rest of the seawater absorbs the heat and exits the cooling
tower at a lower temperature.
2. Evaporation:
o As the warm freshwater coolant flows through the cooling tower heat exchangers
(often shell and tube heat exchangers), it exchanges heat with the seawater or
river water.
o The heat absorbed by the seawater increases its temperature. Part of the seawater
evaporates due to the large surface area and airflow in the cooling tower,
removing the heat from the system.
o The resulting warm, moist air is discharged into the atmosphere through the
cooling tower exhaust, while the remaining seawater, now cooler, is recirculated
back into the cooling system.
3. Airflow:
o Forced draft or induced draft fans are used to maintain a steady airflow through
the cooling tower to promote evaporation. These fans can be located either at the
top (induced draft) or at the bottom (forced draft) of the tower.
o The fans push or pull air through the tower to facilitate heat exchange between the
cooling water and the atmosphere. This enhances the evaporation process,
increasing the cooling efficiency.

Cooling Tower Components

1. Heat Exchanger (Cooling Coil or Tube Bundle):
o The heat exchanger is the heart of the cooling tower. Freshwater from the
engine’s cooling system flows through the heat exchanger, where it comes into
contact with the cooler seawater. The heat is transferred from the freshwater
coolant to the seawater, which absorbs the thermal energy and dissipates it.
o The design of the heat exchanger may vary depending on the system, but shell
and tube heat exchangers or plate heat exchangers are common.
2. Fan System:
o Induced draft fans or forced draft fans are used to create airflow over the heat
exchange surfaces. The fan's primary role is to increase the rate of evaporation by
enhancing air circulation and promoting the exchange of heat between the
seawater and the atmosphere.
o The fans are generally equipped with adjustable speed drives to optimize energy
consumption and control cooling performance based on the engine's operating
conditions.
3. Fill Media:
o Fill media (or packing) inside the cooling tower increases the surface area for
heat exchange. The fill provides more surface for the seawater to spread out and
evaporate, improving the heat transfer rate. The fill is typically made from plastic
or other materials designed for resistance to corrosion and the harsh marine
environment.
4. Water Distribution System:
o The cooling tower typically has a water distribution system at the top that
ensures the seawater is evenly distributed over the fill media. This system usually
consists of spray nozzles or a distribution basin to maximize the surface area of
the water and improve heat dissipation.
5. Drift Eliminators:
o Drift eliminators are installed at the top of the cooling tower to capture water
droplets that may be carried away by the airflow. These are critical to reducing
water loss and minimizing environmental impact by ensuring that only water
vapor is released into the atmosphere.
6. Make-Up Water System:
o Over time, some water evaporates, and there is a need to replenish this water,
known as make-up water. This water can come from seawater, freshwater, or
other available sources, depending on the location of the engine and cooling
tower.
o The make-up water is typically introduced into the system via a dedicated pipe or
reservoir.
7. Blowdown System:
o To maintain water quality, the cooling tower will also have a blowdown system
that periodically removes water from the system. This is done to eliminate
contaminants, such as dissolved solids and impurities, that accumulate in the
cooling tower water over time.
8. Cooling Tower Basin:
 o The cooling tower basin serves as a collection point for the cooled seawater after
it has passed through the heat exchanger. This cooled water is pumped back to the
engine's cooling system for reuse.
o The basin helps regulate water flow and ensures consistent water levels in the
cooling tower.

Cooling Tower Types

There are several types of cooling towers that may be used in Wärtsilä 18V46 systems:

1. Open Loop Cooling Tower (Wet Cooling Tower):

o In an open-loop system, the seawater or cooling water is used directly in the
cooling tower. As the seawater absorbs heat from the engine's cooling system,
part of it evaporates, carrying away heat, and the remaining water is discharged
into the ocean or another body of water.
o This is the most common type for marine engines since seawater is readily
available.
2. Closed Loop Cooling Tower:
o In a closed-loop cooling tower system, the engine’s coolant flows through a
secondary closed circuit, which is separate from the cooling tower water. The heat
exchanger inside the cooling tower transfers heat from the closed-loop system to
the seawater or cooling tower water.
o In some cases, a closed cooling system may use antifreeze or other special
fluids, especially in areas with cold climates or where contamination is a concern.
3. Hybrid Cooling Tower:
o Some systems combine features of both open-loop and closed-loop designs,
allowing for flexible operation depending on water quality, temperature, and
environmental regulations.

Performance Monitoring of the Cooling Tower

The performance of the cooling tower is closely monitored to ensure it is operating efficiently
and effectively. Key parameters include:

• Water Temperature: The temperature difference between the hot inlet water (coming
from the engine) and the cooler outlet water (after heat exchange) is monitored to assess
the cooling tower's effectiveness.
• Airflow Rate: The airflow through the tower, influenced by fan speed and design, is
continuously monitored to ensure proper evaporation and heat dissipation.
• Water Quality: The seawater used in the cooling tower must be regularly tested for
contaminants such as salt, silt, and organic matter. Poor water quality can lead to fouling
and scaling of heat exchangers and other components.
• Cooling Tower Efficiency: This is typically assessed by the temperature drop across the
heat exchanger and the amount of heat removed from the system. Monitoring the
efficiency of the fill media and the fan power consumption is also important.
Maintenance of the Cooling Tower

To ensure continuous and efficient operation, regular maintenance of the cooling tower is
required. This includes:

1. Cleaning and Inspection: Periodic cleaning of the fill media, heat exchangers, and
water distribution system is essential to remove dirt, scale, and biological growth.
Inspection of drift eliminators ensures there is no significant water loss due to mist or
droplets escaping.
2. Water Treatment: Water used in the cooling tower should be treated to prevent scaling,
corrosion, and biological growth (algae or bacteria). Water treatment chemicals are
commonly used to maintain water quality.
3. Fan and Motor Maintenance: The fans should be regularly checked for wear and
balanced to ensure that airflow is optimal. Motor lubrication and bearing inspection are
part of regular maintenance.
4. Structural Inspection: The cooling tower structure itself should be inspected for signs
of corrosion, damage, or structural integrity issues, especially in marine environments
where saltwater corrosion can be a concern.

Conclusion

The cooling tower is an essential component in the Wärtsilä 18V46 engine's cooling system,
responsible for dissipating heat from the engine’s freshwater cooling circuit and helping maintain
safe operating temperatures. By utilizing seawater or other external cooling sources, the cooling
tower ensures the engine operates efficiently while minimizing the impact of heat buildup.
Proper maintenance, monitoring, and operation of the cooling tower are critical for maximizing
the engine's performance, reliability, and longevity, particularly in marine environments.