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EXHAUST SYSTEMS
Contents
G3300/G3400
=Standard
C-10/C-12
C-15/C-16
=Optional
C11/C13
C15/C18
C27/C32
G3500
G3600
3126B
3406E
- =Not 3412E
C175
3500
3600
Available
C-9
C7
C9
Dry
Manifolds -
Watercooled
Manifolds - - - - - - - - - -
Air Shielded
Watercooled - - - - - - - - - - - - - - -
Manifolds
Soft
Shields - - - - - - - - - - - - - -
Hard
Shields - - - - - - - -
Exhaust
Silencers
2013 Caterpillar
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Application and Installation Guide Exhaust Systems
Exhaust Systems
Well-designed exhaust systems collect exhaust gases from engine cylinders
and discharge them as quickly and silently as possible. Primary system
design considerations include:
Minimizing resistance to gas flow (back pressure) and keeping it within
the limits specified for the particular engine model and rating to
provide maximum efficiency.
Reducing exhaust noise emission to meet local regulations and
application requirements.
Providing adequate clearance between exhaust system components
and engine components, machine structures, engine bays, enclosures
and building structures to reduce the impact of high exhaust
temperatures on such items.
Ensuring the system does not overstress engine components such as
turbochargers and manifolds with excess weight. Overstressing can
shorten the life of engine components.
Ensuring the exhaust system components are able to reject heat
energy as intended by the original design. Dry turbochargers and
manifolds should not be wrapped or shielded without Cat components
or Caterpillar approval.
SECTION CONTENTS
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Exhaust Systems Application and Installation Guide
System Components
The main components of an Dry Manifolds
exhaust system include, but are not Dry manifolds are the preferred
limited to, the exhaust manifold, manifold design. They are cost
turbocharger, wastegate, piping and effective and by providing the
the silencer. The individual maximum possible exhaust energy
components and their function are to the turbocharger, they offer the
explained below.
highest overall efficiency. Dry
Exhaust Manifold manifolds, however, also radiate the
Engine exhaust manifolds collect most heat and reach the highest
exhaust gases from each cylinder surface temperatures.
and channel them into an exhaust Some applications require low
outlet. The manifold is designed to manifold surface temperatures.
give minimum backpressure and For example, the Mining Safety
turbulence. Cat products utilize dry, and Health Agency (MSHA), the
watercooled and air shielded Atmospheres Explosibles (ATEX)
watercooled (ASWC) manifold directive and marine societies require
designs, based on application and that engine surface temperatures
design requirements. Refer to remain below 200C (400F) for
Figure 1 for manifold configurations. certain mines.
Heat shields and blankets are
available for some Cat products
to meet lower surface temperature
requirements. A few marine
products offer optional watercooled
manifolds.
Gas engines run with a higher
exhaust temperature compared to
diesel engines. Due to these high
exhaust temperatures, some models
utilize watercooled or air shielded
watercooled manifolds.
Watercooled Manifolds
Passages within watercooled
manifolds allow engine jacket
coolant to flow around the manifold
removing heat otherwise carried by
Figure 1
exhaust gases. Surface temperatures
of watercooled manifolds are
considerably lower than those of dry
manifolds, however heat rejection to
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Exhaust Systems Application and Installation Guide
Figure 3
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Application and Installation Guide Exhaust Systems
tight fit. The slip joints are flexible in joints due to disadvantages such
only one direction and require good as leaking exhaust fumes, exhaust
support on each side. slobber and the inability of the joint
to flex in more than one direction.
However, Caterpillar does not
normally recommend the use of slip
A B C
Hose Maximum Offset Maximum Compression Maximum Extension
Diameter Between Flanges From Free Length From Free Length
mm in. mm in. mm in.
4 & 5 in. 25.4 1.0 6.25 .25 6.25 2.5
6 in. 38.1 1.5 6.25 .25 6.25 2.5
A B** C
Bellows Maximum Offset Minimum Acceptable Maximum Extension
Diameter Between Flanges Convolution Gap From Free Length
mm in. mm in. mm in.
6 in. 1.00 0.04 2.27 0.089 2.00 0.08
8 & 12 in. 19.05 0.75 3.07 0.121 25.40 1.00
10 in. 15.00 0.59 25.40/1.00*** 1.00/0.35***
14 in. 19.05 0.75 7.97 0.314 25.40 1.00
Figure 4
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Exhaust Systems Application and Installation Guide
Figure 5
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Application and Installation Guide Exhaust Systems
The minimum requirements for the Install metal thimble guards for
design of the exhaust system should exhaust piping passing through
be to contain explosions that could be wooden walls or roofs. The
encountered during the operation of thimble guards should be
the engine. Caterpillar recommends 305 mm (12 in) greater in
the use of explosion relief valves on diameter than the exhaust pipes,
all gas engines, particularly for the see Figure 5.
larger size engines due to the high When exhaust stacks are used,
fuel volumes. Explosion relief valves extend them upward and away
should be located as close to the from the engine room to avoid
engine as possible (typically at piping heat, fumes and odors.
elbows) to minimize any potential
exhaust system damage in the event Locate the exhaust pipe outlets
of an exhaust explosion. Additional away from the air intake system.
pressure relief valves can be used Engine air cleaners, turbochargers
prior to the muffler, catalytic and aftercoolers contaminated
converter, or heat recovery equipment with exhaust products can induce
to add additional protection for these premature failures.
devices. Explosion relief valves are Avoid routing exhaust piping
fitted on the exhaust pipe to relieve close to fuel pumps, fuel lines,
pressure in a safe manner and must fuel filters, fuel tanks and other
be vented to a safe area. (Reference combustible materials.
local codes.) Explosion relief valves Exhaust pipe outlets cut at 30
can be purchased from aftermarket to 45 angles, rather than
suppliers. 90 angles, will reduce exhaust
All piping should be installed with gas turbulence and noise. Refer
a minimum clearance of 229 mm to Figure 6.
(9 in) from combustible materials. Exhaust outlets should be
The exhaust piping must be arranged to keep water from
properly supported, especially entering the piping system. Rain
adjacent to the engine, so that its caps forced open by exhaust
weight is not borne by the engine pressure will accomplish this;
or the turbocharger. This is however, they will also introduce
discussed in more detail later in additional backpressure into the
this section. system and should be carefully
Exhaust piping should be sized evaluated.
according to the maximum Paint or other materials should
backpressure limit for the engine. not be applied directly on or near
Where appropriate, heat radiation the engine exhaust system or
may be reduced by covering the installation exhaust piping unless
off-engine exhaust piping with rated for high temperature
suitable, high temperature applications.
insulation.
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Exhaust Systems Application and Installation Guide
Figure 6
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Application and Installation Guide Exhaust Systems
to the room from the exhaust system. Slots are cut into the exhaust
An additional benefit of the insulation pipe to allow rain/spray to drain
is that it provides sound attenuation to harmlessly. The edges of each
reduce noise in the room. slot are deformed as shown in the
previous graphic. The engine side
Water Ingress Prevention
of the slot is bent inward and the
Exhaust system outlets must be
downstream side of the slot is bent
provided with an appropriate means
outward. No more than a 60 arc
of preventing snow, rainwater or sea
of the pipe circumference should be
spray from entering the engine
slotted in this way.
through the exhaust piping. This
can be accomplished by several For applications where none of the
methods, but must be given careful above methods is possible, it may be
consideration. The selected method necessary to fit some form of rain
can impose significant restrictions cap to the end of the vertical pipe
that must be taken into account when section. This method can provide a
calculating system backpressure. positive means of water ingress
prevention, but not without imposing
One simple method, used primarily
a significant backpressure
with horizontal exhaust pipes, is to
restriction.
angle cut the end of the pipe as
shown in Figure 3, Figure 5 and Exhaust System Backpressure
Figure 7. Excessive exhaust restriction can
A common method used with adversely affect performance,
vertical exhaust pipes is to angle the resulting in reduced power and
pipe at 45 or 90 from vertical increased fuel consumption, exhaust
using an appropriate elbow, then temperatures and emissions. It will
angle cutting the pipe end as also reduce exhaust valve and
previously described. turbocharger life. It is imperative
Another feature that may be used that exhaust backpressure is kept
in conjunction with either of the within specified limits for those
above methods are Rain/Spray Slots engines subject to emissions
as shown in Figure 6. legislation. When designing an
exhaust system, the design target
for backpressure should be half the
maximum allowable system
backpressure. To ensure compliance,
exhaust system backpressure must
be verified to be within the
Caterpillar EPA declared maximum
value for the engine configuration
and rating. Values can be found in
Figure 7 the Systems Data listed in the Cat
Technical Marketing Information
(TMI) system.
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Figure 8
The pressure tapping can be made
by using a 1/8 NPT half coupling
welded or brazed to the desired
location on the exhaust pipe. After
the coupling is attached, a 3.05 mm
(0.12 in) diameter hole is drilled
through the exhaust pipe wall. Any
burrs on the inside of the pipe wall
should be removed so that the gas
flow is not disturbed. The gauge or
gauge hose can then be attached to
the half coupling. The tip of the
probe should be cut parallel to the
exhaust gas flow.
Figure 9
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Figure 10
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Figure 13
Figure 13 is an example of a
vertically mounted exhaust silencer
with the exhaust pipe and radiator
air utilizing a common stack.
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Exhaust Systems Application and Installation Guide
Figure 14
Figure 15
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Use 1.25 in2 of duct cross exhaust stack following the mixture
sectional area per engine can seriously affect the systems
horsepower and no more than performance.
three right angle bends. Furthermore, the exhaust stack will
If more right angle bends are remain cooler and cleaner if the
required, increase the pipe diameter engine exhaust is contained within
by one pipe size. the exhaust piping throughout its run
For best results, the intake air through the stack. The discharged
openings should discharge cool air ventilation air will tend to cool the
into the engine room near the floor exhaust stack upstream of the point
level. After the intake air has been where it is mixed with the exhaust
heated by contact with hot surfaces gases.
in the engine room, draw the Exhaust ejectors are most effective
ventilating air out from a point on vessels with only one propulsion
directly over the engines, near the engine. On multiple engine
engine room overhead. installations, if one engine is
Place the ejector in the exhaust operated at reduced load, the ejector
system just prior to the exhausts air flow for the engine with reduced
discharge to atmosphere to avoid load may reverse, pulling exhaust
backpressure on the mixture of gas from the more heavily loaded
exhaust gas and hot air through any engine into the engine room.
length of stack. Any bends in the
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Figure 16
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Figure 17
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Figure 18
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Figure 19
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Exhaust Systems Application and Installation Guide
Wet Exhaust System using Dry Exhaust Elbows at Engine Exhaust Discharge
Figure 20
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Application and Installation Guide Exhaust Systems
enough above the water line that of wave energy dissipation, the
breaking waves do not reach the lower the elevation difference
height of the exhaust elbow. While required.
the relative elevation of the engine In no case should the elevation
to the water line is fixed and difference between the water
unchangeable, it is possible to line and the highest point in the
design an exhaust system that exhaust piping be less than
protects the engine from ingesting 560 mm (22 in.).
water.
Surge Chamber
Features of such an exhaust
A surge chamber is a branch of the
system include:
exhaust piping, near the engine that
Sufficient elevation difference has one end closed off, as shown as
between the water line and the Item 3 in Figure 23. When a wave of
highest point in the exhaust water enters the exhaust pipe and
piping to prevent even small moves toward the engine, the air
amounts of water from reaching trapped in front of the wave will be
the engine. compressed into the surge chamber.
Some method of dissipating the The cushion of compressed air in the
kinetic energy of the waves as surge chamber will force almost all
they enter the exhaust piping. waves back out.
The more effective the method
Typical Wet Exhaust System with Engine Mounted Above Water Line
Figure 23
1. Water-cooled Exhaust Elbow sea water cools 3. Backwater Surge Chamber prevents sea water
elbow, then discharges into exhaust pipe through surging into engine exhaust from oncoming waves
peripheral slot at end of elbow. when vessel is at rest.
2. Rubber Exhaust Hose Flexible Connection must 4. Exhaust Pipe - should have slight downward
be oil and heat resistant. gradient toward discharge end.
5. End Cover Plate removable for inspection and
cleanout purposes.
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LEBW4970-07 2013 Caterpillar Printed in U.S.A.
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