APPLICATION AND INSTALLATION GUIDE

EXHAUST SYSTEMS

G3600 • G3500
G3400 • G3300
3600 • C175 • 3500
C32 • 3412E • 3400 • 3126B
C18 • C-16 • C-15 • C15
C13 • C-12 • C11 • C-10
C9 • C-9 • C7
Contents

Exhaust Systems ...................................................................1

System Components ......................................................... 2
Exhaust Manifold .......................................................... 2
Dry Manifolds........................................................... 2
Watercooled Manifolds .............................................. 2
Air Shielded Watercooled Manifolds ............................ 3
Heat Shielding .............................................................. 3
Blankets (Soft Manifold Shields) ................................. 3
Hard Wrap (Hard Manifold Shields).............................. 4
Guards and Shields ................................................... 4
Turbochargers .............................................................. 4
Wastegate ............................................................... 4
Flexible Exhaust Connections ......................................... 5
Flexible Metal Hose and Bellows ................................. 5
Slip Joints................................................................ 6
Silencer ....................................................................... 8
Silencer Rating ......................................................... 8
Silencer Selection ..................................................... 8
Exhaust System Piping .....................................................10
Exhaust System Design ................................................10
Exhaust Thimbles.....................................................12
Exhaust Pipe Insulation .............................................12
Water Ingress Prevention ..........................................13
 Exhaust System Backpressure .......................................13
Measuring Backpressure ...........................................14
Calculating Backpressure ..........................................15
Equivalent Length of Straight Pipe..............................16
Combined Exhaust Systems ......................................16
Pipe Support Considerations..........................................17
Thermal Growth.......................................................17
Turbocharger Loading ...............................................17
Loading Calculations ................................................17
Vertical Exhaust.......................................................18
Horizontal Exhaust ...................................................18
Vibration Transmission .............................................20
Exhaust Discharge .......................................................20
Common Exhaust Stack............................................20
Power Module or Drop-Over Enclosure........................21
Cleanliness During Installation .......................................23
Slobber or Wet Stacking ...............................................23
Exhaust Systems for Specific Applications..........................24
Marine Dry Exhaust System ..........................................24
Marine Exhaust Ejector Automatic Ventilation System ......24
Duct Design Guidelines.................................................24
Marine Wet Exhaust System .........................................30
Exhaust Risers .........................................................30
Water Lift Silencers......................................................31
Wave Action and Wet Exhaust Systems .........................32
 Surge Chamber........................................................33
Valve in Exhaust Discharge .......................................34
Hose vs. Rigid Exhaust Pipe ..........................................34
Location of Exhaust Discharge Opening ..........................34
Valves in Exhaust Water Cooling Lines .......................34
 Foreword
This section of the Application and Installation Guide generally describes
wide-ranging requirements and options for the Exhaust System on
Caterpillar® engines listed on the cover of this section. Additional engine
systems, components and dynamics are addressed in other sections of this
Application and Installation Guide.
Engine-specific information and data are available from a variety of
sources. Refer to the Introduction section of this guide for additional
references.
Systems and components described in this guide may not be available or
applicable for every engine. The listing below indicates which exhaust
component designs are utilized by each Caterpillar engine model. Refer to the
Price List for specific options and compatibility.

G3300/G3400
z =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 z z z z z z z z z z z z z z - z z
Watercooled
Manifolds - - - - z - z z - z - z - - z z -
Air Shielded
Watercooled - - - - - - - - - - - - - - z z -
Manifolds
Soft
Shields - - - - - - - - - - - z† - z - - z
Hard
Shields - - - - - z z z z z - z z z - z -
Exhaust
Silencers                 

† Soft shield covers turbocharger but not manifolds.

Information contained in this publication may be considered confidential. Discretion is

recommended when distributing. Materials and specifications are subject to change
without notice.
CAT, CATERPILLAR, their respective logos and “Caterpillar Yellow”, as well as corporate
and product identity used herein, are trademarks of Caterpillar and may not be used
without permission.

©2005 Caterpillar®
All rights reserved.
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 Caterpillar
components or Caterpillar approval.

SECTION CONTENTS

System Components ............ 2 • Slobbering

• Manifolds Exhaust Systems for Specific
• Heat Shielding Applications .......................23
• Turbochargers • Marine Dry Exhaust
• Connections • Ejector Automatic
Ventilation
• Silencers
• Duct Design
Exhaust System Piping ......... 9
• System Design • Marine Wet Exhaust
• Pipe Support Considerations • Water Lift Silencers
• Exhaust Discharge • Wave Action on Wet
Exhaust
• Thimbles
• Hose vs. Pipe
• Water Ingress
• Discharge Opening
• Backpressure
• Cleanliness

©2005 Caterpillar®
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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 to
components and their function are 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. For
give minimum backpressure and example, the Mining Safety and
turbulence. Caterpillar products Health Agency (MSHA), the
utilize dry, watercooled and air ATmospheres Explosibles (ATEX)
shielded watercooled (ASWC) directive and marine societies require
manifold designs, based on that engine surface temperatures
application and design requirements. remain below 200°C (400°F) for
Refer to Figure 1 for manifold certain mines.
configurations. Heat shields and blankets are
available for some Caterpillar
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
exhaust gases. Surface temperatures
Figure 1
of watercooled manifolds are
considerably lower than those of dry
manifolds, however heat rejection to

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Application and Installation Guide Exhaust Systems

the jacket water is increased by 20 installation type, environment and

to 40 percent. This increase requires legislative requirements. Guards may
a larger capacity cooling system. also be an effective means of
Watercooled manifolds also reduce providing protection. Shields that are
exhaust heat energy delivered to the designed and supplied by Caterpillar
turbocharger. This requires the use are fit for this purpose. Any
of an appropriately matched customer fitted shields must be
turbocharger for maximum carefully designed and applied to
efficiency. The turbocharger used on ensure that damage to the engine
dry manifold applications may not be does not result. Wraps and shields,
suitable for use on watercooled especially those not provided by
applications. Caterpillar, must be cautious of
increasing component skin
Air Shielded Watercooled Manifolds temperature. Significant airflow
Air shielded watercooled manifolds around the shield can help reduce
(ASWC) make use of an insulating increases in component skin
air cavity between the exhaust temperature.
manifold and the water shield.
Engine water circulates around the Blankets (Soft Manifold Shields)
air shield but does not come into Blankets are made of an insulating
direct contact with the inner layer of material with a thermal cloth
manifold. This reduces the necessary outer layer. Most blankets will be
jacket water cooling load and held in place with stainless steel
maintains higher exhaust energy springs or wire which will be laced
available to the turbocharger. over the blankets. Blankets will
isolate both heat and noise.
Heat Shielding Caterpillar does not recommend
Note: Installing non-approved shields use of blankets on exhaust
or softwrap can cause exhaust manifolds, turbochargers or other
system damage. Damage from non- engine components. The use of
approved components will not be manifold blankets often results in
subject to Quality and Workmanship premature failure of exhaust
warranty without approval from manifold components. Exceptions
Caterpillar. If lower exhaust skin may be made if the insulation is
temperatures are necessary, further supplied and approved for a
evaluation of displacement and particular application by Caterpillar;
rating (A-E) choices should be for these products, Caterpillar uses
considered. exhaust and turbocharger
Heat shielding may be used as a components that are made from
means of shielding hot surfaces and materials capable of withstanding
protecting components or operators higher temperatures. Caterpillar
from excessive heat. The use of engines that use wraps and shields
heat shields depends on many are developed to a lower exhaust
factors including, but not limited to, gas temperature limit.

©2005 Caterpillar®
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Exhaust Systems Application and Installation Guide

Hard Wrap (Hard Manifold Shields) output by converting some of the

Hard wrap is often used on the energy in the exhaust gas stream
engine itself, for example in the vee into energy in the inlet system in the
between cylinder banks. The hard form of raised inlet pressure (boost).
wrap consists of three layers; a This raised inlet pressure forces
thermal sheet, a blanket of fiberglass more air into the engine cylinders,
and sheet of bendable metal. It is allowing more fuel to be burned and
installed with the thermal sheet thus resulting in higher power
facing the hot surface but not output.
touching it. The air layer in between
works as an insulator. Holes for
bolts can be drilled in the metal
sheet, making it easy to install or
remove.
Guards and Shields
Guards and shields are usually
made using perforated sheet metal.
They are installed with an air gap
between the shield and the hot
surface. With adequate airflow
Figure 2
around the engine, the heat transfer
from iron to air will lower the
temperature of the shield
considerably. Refer to Figure 2. Hot exhaust
gases exit the cylinder and enter the
CAUTION: All heat shielding, turbine side of the turbocharger. The
whether blankets, hard wrap or turbine blades and the compressor
guards and shields should be blades share a common shaft.
designed in such a way that critical
engine components, such as The exhaust gases drive the
manifolds and turbochargers, do not turbine blades which in turn drive
reach critical temperatures, as this the compressor blades on the air
may lead to premature failure. intake side. This high speed rotation
Turbocharger turbine housings and compresses the intake air to provide
non-water cooled turbine housings more oxygen for combustion.
should not be wrapped. In some Wastegate
cases, Caterpillar designed and Turbochargers equipped with a
approved heat shielding/wrap is wastegate can efficiently operate in
available for specific engine models a much broader range of altitudes
and ratings. and ambient conditions. The
wastegate opens at a predetermined
Turbochargers pressure and vents some of the
Turbochargers are employed to exhaust flow away from the
achieve higher specific engine power turbocharger. The reduced exhaust

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Application and Installation Guide Exhaust Systems

flow slows the turbocharger to avoid Flexible Metal Hose and Bellows
overspeed and excessive boost Flexible metal hose is commonly
pressure. used for exhaust systems with a
On some natural gas engines, the diameter of 150 mm (6 in) and
wastegate may be manually adjusted smaller. Bellows are typically used
for site conditions to optimize the for exhaust systems with a diameter
throttle position for efficiency or of 200 mm (8 in) and larger.
improved response. Flexible connections should be
Note: The exhaust flow by-passing installed as close as possible to the
the two turbochargers of a G3600 engine exhaust outlet. A flexible
vee engine via the wastegate are exhaust connection has three
plumbed together and exit on one primary functions.
exhaust outlet. Therefore, if • To isolate the weight of the
measuring exhaust flow, you will exhaust piping from the
notice an uneven exhaust gas flow engine. The amount of weight
through the two exhaust outlets which the exhaust outlet for
when the wastegate is open. each engine model can
Typically, the right side flow will be withstand varies.
15% higher than the left side. • To relieve exhaust
CAUTION: Tampering with the boost components of excessive
line to the wastegate will raise vibrational fatigue stresses.
aftercooler heat rejection, increase • To allow relative shifting of
turbocharger speed and peak engine exhaust components. This has
cylinder pressure. This will numerous causes. It may
negatively affect engine reliability, result from expansion and
durability, stability, emissions and contraction due to
overall performance. temperature changes, by
creep processes that take
Flexible Exhaust Connections
place throughout the life of
The exhaust piping system must
any structure, or by torque
be isolated from the engine with
reactions.
flexible connections, designed for
zero leakage and flexible in all A typical piping layout with flexible
directions. Two types of flexible connections is shown in Figure 3.
connections are normally used a Flexible pipe connections, when
flexible metal hose type and a insulated, must expand and contract
bellows type. freely within the insulation. This
generally requires a soft material or
insulated sleeve to encase the
connection.

©2005 Caterpillar®
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Exhaust Systems Application and Installation Guide

Typical Exhaust Piping With Flexible Connection

Figure 3

The flexible connections should be should be soft enough to prevent

pre-stretched during installation to transmission of vibration beyond the
allow for expected thermal growth. connection.
Four small straps can be tack- The installation limitations of
welded between the two end flanges Caterpillar supplied flexible exhaust
to hold the engine exhaust flexible fittings are shown in the table
connections or bellows in a rigid below. For maximum durability,
position during exhaust piping allow the bellows to operate as
installation. This will prevent the close as possible to its free state.
bellows from being installed in a
flexed condition. Attach a warning Slip Joints
tag to the bellows noting that the Slip joints are another method of
weld straps must be removed prior handling the expansion and
contraction of exhaust systems. Slip
to starting the engine.
joints are designed to have
Any flexible connector must have controlled leakage when the system
good fatigue resistance. It should is cold. When the engine starts and
give acceptable service life while the exhaust pipes warm up, the
withstanding vibratory stress and it joints will expand and make a gas-

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Application and Installation Guide Exhaust Systems

tight fit. The slip joints are flexible in joints due to disadvantages such as
only one direction and require good 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

Installation Limits of Flexible Exhaust Fittings – Flexible Metal Hose-Type

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

Installation Limits of Flexible Exhaust Fittings - Bellows-Type

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.
8 & 12 in. 19.05 0.75 38.1 1.50 25.40 1.00
14 in. 19.05 0.75 76.2 3.00 25.40 1.00

18 in. 22.86 0.90 76.2 3.00 44.45 1.75

Spring Rate for Flexible Fittings -

Bellows-Type
Spring Rate
Diameter
kN/m lb/in.
8 in. 29.7 170

12 in. 33.9 194

14 in. 68.5 391
18 in. 19.3 110

Figure 4

©2005 Caterpillar®
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Exhaust Systems Application and Installation Guide

Silencer • Level 1 Silencer System

Exhaust noise is one of the “Residential” — Suitable for
principal noise sources of any engine industrial areas where
installation. The purpose of the background noise level is
silencer is to reduce the noise of the relatively high or for remote
exhaust before it is released to the areas where partly muffled
atmosphere. noise is permissible.
Exhaust noise arises from the • Level 2 Silencer System
intermittent release of high pressure “Critical” — Reduces exhaust
exhaust gas from the engine noise to an acceptable level in
cylinders, causing strong gas localities where moderately
pressure fluctuations in the exhaust effective silencing is required —
system. This leads not only to such as semi-residential areas
discharge noise at the exhaust where moderate background
outlet, but also to noise radiation noise is always present.
from exhaust pipe and silencer • Level 3 Silencer System
surfaces. A well designed and “Supercritical” — Provides
matched exhaust system will maximum silencing for
significantly reduce noise from these residential, hospital, school,
sources. The silencer makes a major hotel, store, apartment building
contribution to exhaust noise and other areas where
reduction. background noise level is low
Excessive noise is objectionable in and generator set noise must be
most applications. The required kept to a minimum.
degree of silencing depends on Silencer Selection
factors such as the application type, The silencer is generally the largest
whether it is stationary or mobile single contributor to exhaust
and whether there are any legal backpressure. Therefore, required
regulations regarding noise emission. noise reduction and permissible
For example, excessive noise is backpressure must be considered
objectionable in a hospital or when selecting a silencer.
residential area but may well be Application type, available space,
acceptable at an isolated pumping cost and appearance may also need
station. to be taken into account.
Silencer Rating To select a silencer, use silencer
Silencers are typically rated supplier data, corrected for outlet
according to their degree of temperature and velocity, to
silencing. “Residential”, “Critical” determine the silencer size and type
and “Supercritical”, are the terms that satisfies noise reduction criteria
commonly used to describe the with an acceptable maximum
different ratings. pressure drop.

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Application and Installation Guide Exhaust Systems

After calculating pressure loss, it

may be necessary to check a second
silencer, or a different pipe size,
before an optimum combination is
achieved.
Silencer design is a highly
specialized art. Responsibility for the
details of design and construction
should be assigned to the silencer
manufacturer.

©2005 Caterpillar®
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Exhaust Systems Application and Installation Guide

Exhaust System Piping

The function of the exhaust piping piping should be securely supported.
is to convey the exhaust gases from Allowances should be made for
the engine exhaust outlet to the system movement and vibration
silencer and other exhaust system isolation by using suitable flexible
components, terminating at the components such as rubber dampers
system outlet. Piping is a key feature or springs.
in overall exhaust system layout. Piping must be designed with
engine service in mind. In many
Exhaust System Design
cases, an overhead crane will be
The physical characteristics of the
used to service the heavier engine
engine room or engine bay will
components on the larger engines.
determine the exhaust system
layout. Exhaust piping should be The following recommendations
designed to minimize the exhaust should be followed when designing
backpressure while keeping engine an exhaust piping system.
serviceability in mind. The exhaust

Typical Silencer Details

Figure 5

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Application and Installation Guide Exhaust Systems

• All piping should be installed • Locate the exhaust pipe outlets

with a minimum clearance of away from the air intake
229 mm (9 in) from system. Engine air cleaners,
combustible materials. turbochargers and aftercoolers
• The exhaust piping must be contaminated with exhaust
properly supported, especially products can induce premature
adjacent to the engine, so that failures.
its weight is not borne by the • Avoid routing exhaust piping
engine or the turbocharger. This close to fuel pumps, fuel lines,
is discussed in more detail later fuel filters, fuel tanks and other
in this section. combustible materials.
• Exhaust piping should be sized • Exhaust pipe outlets cut at 30°
according to the maximum to 45° angles, rather than 90°
backpressure limit for the angles, will reduce exhaust gas
engine. turbulence and noise. Refer to
• Where appropriate, heat Figure 6.
radiation may be reduced by • Exhaust outlets should be
covering the off-engine exhaust arranged to keep water from
piping with suitable, high entering the piping system. Rain
temperature insulation. caps forced open by exhaust
• Install metal thimble guards for pressure will accomplish this;
exhaust piping passing through however, they will also
wooden walls or roofs. The introduce additional
thimble guards should be 305 backpressure into the system
mm (12 in) greater in diameter and should be carefully
than the exhaust pipes, see evaluated.
Figure 5.
• When exhaust stacks are used,
extend them upward and away
from the engine room to avoid
heat, fumes and odors.

©2005 Caterpillar®
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Exhaust Systems Application and Installation Guide

Pipe Design Joining Two Turbochargers

Figure 6

The exhaust system can thimbles must have diameters at

accumulate a considerable amount least 305 mm (12 in) larger than the
of condensed moisture. For example, exhaust pipe. Double thimbles (inner
gas engines burning natural gas and outer sleeve) should have
create one pound of water for each outside diameters at least 152 mm
10 ft3 of natural gas burned. For this (6 in) larger than the exhaust pipe.
reason, long runs of exhaust piping Exhaust Pipe Insulation
require traps to drain moisture. No exposed parts of the exhaust
Traps should be installed at the system should be near wood or
lowest point of the line, near the other combustible material. Exhaust
exhaust outlet, to prevent rain water piping inside the engine room or
from reaching the engine. Exhaust machinery space (and the silencer, if
lines should be sloped away from mounted inside) should be covered
engine, toward the trap, so with suitable insulation materials to
condensation will properly drain, see protect personnel and to reduce
Figure 3 in the previous section. room temperature. A sufficient layer
Exhaust Thimbles of suitable insulating material
Exhaust thimbles, as illustrated in surrounding the piping and silencer
Figure 5, are fabrications used for and retained by a stainless steel or
wall or ceiling penetrations. The aluminum sheath may substantially
thimble provides a separation of the reduce heat radiation to the room
exhaust pipe from walls or ceilings, from the exhaust system. An
in order to provide mechanical and additional benefit of the insulation is
thermal isolation. Single sleeve

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Application and Installation Guide Exhaust Systems

that it provides sound attenuation to Slots are cut into the exhaust pipe
reduce noise in the room. to allow rain/spray to drain
Water Ingress Prevention harmlessly. The edges of each slot
are deformed as shown in the
Exhaust system outlets must be
previous graphic. The engine side of
provided with an appropriate means
the slot is bent inward and the
of preventing snow, rainwater or sea
downstream side of the slot is bent
spray from entering the engine
outward. No more than a 60° arc of
through the exhaust piping. This can
the pipe circumference should be
be accomplished by several
slotted in this way.
methods, but must be given careful
consideration. The selected method For applications where none of the
can impose significant restrictions above methods is possible, it may be
that must be taken into account necessary to fit some form of rain
when calculating system cap to the end of the vertical pipe
backpressure. section. This method can provide a
positive means of water ingress
One simple method, used primarily
prevention, but not without imposing
with horizontal exhaust pipes, is to
a significant backpressure
angle cut the end of the pipe as
restriction.
shown in Figure 3, Figure 5 and
Figure 7. Exhaust System Backpressure
A common method used with Excessive exhaust restriction can
vertical exhaust pipes is to angle the adversely affect performance,
pipe at 45° or 90° from vertical resulting in reduced power and
using an appropriate elbow, then increased fuel consumption, exhaust
angle cutting the pipe end as temperatures and emissions. It will
previously described. also reduce exhaust valve and
Another feature that may be used turbocharger life. It is imperative
in conjunction with either of the that exhaust backpressure is kept
above methods are Rain/Spray Slots within specified limits for those
as shown in Figure 6. engines subject to emissions
legislation. 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
the “Systems Data” listed in the
Caterpillar Technical Marketing
Information (TMI) system.
Backpressure includes restrictions
due to pipe size, silencer, system
Figure 7 configuration, rain cap and other
exhaust-related components.

©2005 Caterpillar®
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Exhaust Systems Application and Installation Guide

Excessive backpressure is commonly

caused by one or more of the Many engine installations are
following factors: already equipped with a fitting in the
• Exhaust pipe diameter too exhaust discharge for measuring
small. backpressure. If the system is not
• Excessive number of sharp equipped with such a fitting, use the
bends in the system. following guidelines, Figure 9 and
Figure 10 to locate and install a
• Exhaust pipe too long. pressure tap.
• Silencer resistance too high. • Locate the pressure tap in a
Engines with a vee cylinder straight length of exhaust pipe
configuration should be designed so as close to the turbocharger
the exhaust piping gives equal as possible.
backpressure to each bank.
• Locate the tap three pipe
Measuring Backpressure diameters from any upstream
Exhaust backpressure is measured pipe transition.
as the engine is operating under full • Locate the tap two pipe
rated load and speed conditions. diameters from any
Either a water manometer or a downstream pipe transition.
gauge measuring inches of water
For example, in a 100 mm (4 in)
may be used. Refer to Figure 8.
diameter pipe, the tapping would be
placed no closer than 300 mm (12
in) downstream of a bend or section
change.

Figure 8

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Application and Installation Guide Exhaust Systems

Preferred Pressure Tap Location & Installation

Figure 9

If an uninterrupted straight length The pressure tapping can be made

of at least five diameters is not by using a 1/8 NPT “half coupling”
available, care should be taken to welded or brazed to the desired
locate the probe as close as possible location on the exhaust pipe. After
to the neutral axis of the exhaust the coupling is attached, a 3.05 mm
gas flow. This is necessary because (0.12 in) diameter hole is drilled
measurements taken on the outside through the exhaust pipe wall. Any
of a 90° bend at the pipe surface burrs on the inside of the pipe wall
will be higher than a similar should be removed so that the gas
measurement taken on the inside of flow is not disturbed. The gauge or
the pipe bend. gauge hose can then be attached to
the half coupling. The probe should
be inserted to a depth equal to half
the diameter of the pipe or a
minimum of 3 in. (76.2 mm) as
shown in Figure 10. The tip of the
probe should be cut parallel to the
exhaust gas flow.

Figure 10

©2005 Caterpillar®
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Exhaust Systems Application and Installation Guide

Calculating Backpressure Equivalent Length of Straight Pipe

Backpressure is calculated by: To obtain equivalent length of
straight pipe for various elbows:
L x S x Q2 x 3.6 x 106
P (kPa) = + PS
D5 33D Standard Elbow
L=
X elbow radius = pipe diameter
L x S x Q2 x 3.6 x 106
P (in. H2O) = + PS
187 x D5 20D Long Elbow
L=
X radius = 1.5 diameter
Where:
15D
P= Back pressure (kPa), (in. H2O) L= 45° elbow
X
psi = 0.0361 x in. water column
kPa =0.00981 x mm water column 66D
L= square elbow
X
L= Total Equivalent Length of
pipe (m) (ft)
Where X = 1000 mm or 12 in.
Q = Exhaust gas flow (m3/min),
(cfm) As shown by the equations, if 90°
elbows are required, long radius
D = Inside diameter of pipe (mm),
elbows with a radius of 1.5 times
(in.)
the pipe diameter helps to lower
S= Density of gas (kg/m3), (lb/ft3) resistance.
Ps = Pressure drop of
Combined Exhaust Systems
silencer/raincap (kPa),(in. H2O)
Although economically tempting, a
Useful conversion factors: common exhaust system for multiple
psi = 0.0361 x in. of water column installations is not acceptable.
psi = 0.00142 x mm of water Combined exhaust systems with
column boilers or other engines allow
exhaust gases to be forced into
psi = 0.491 x in. of mercury
engines not operating. Water vapor
column
created during combustion will
kPa =0.0098 x mm of water condense in cold engines and quickly
column causes engine damage. Duct valves
kPa =0.25 x in. of water column separating engine exhausts is also
kPa =3.386 x in. of mercury discouraged. High temperatures
column warp valve seats causing leakage.
kPa =0.145 psi Exhaust draft fans have been
applied successfully in combined
exhaust ducts, but most operate
only whenever exhaust is present.
To prevent turbocharger windmilling
(without lubrication), draft fans

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Application and Installation Guide Exhaust Systems

should not be operable when the Supports should also be located to

engine is shut down. The exhaust allow expansion away from the
system of non-running engines must engine. Supports can reduce strains
be closed and vented. or distortions to connected
3600 vee engines have two equipment and can allow component
exhaust outlets, one for each bank. removal without additional support.
Combining these together with a Y- Flexible pipe connection, when
type fabrication, while possible, may insulated, must expand and contract
result in unequal thermal growth and freely within the insulation. This
backpressure from one bank to the generally requires a soft material or
other. This unequal growth can put insulated sleeve to encase the
unwanted loading onto the connection.
turbocharger mounting or the flex Turbocharger Loading
bellows. The unequal backpressure Careful consideration must be
can adversely affect the operation
given to the load external piping may
and performance of the engine. If
induce on the turbocharger. To
the exhaust outlets are joined, these
minimize the load carried by the
problems can be minimized by turbocharger housing, a bellows
providing a flexible connection on
should be placed as close as
each leg and by keeping each leg
possible to the turbocharger outlet
equal in length.
and downstream exhaust piping
Pipe Support Considerations should be self supporting. The
thermal growth of horizontal piping
Thermal Growth connected to the turbocharger
Thermal growth of exhaust piping exhaust must also be accounted for
must be taken into account in order in the design.
to avoid excessive load on
Maximum allowable vertical load
supporting structures.
and bending moment limits are
Steel exhaust pipe expands 1.13 provided for each engine model.
mm/m (0.0076 in/ft) for each Consult the Technical Information
100°C (100°F) rise of exhaust Appendix for the appropriate
temperature. This amounts to 16.5 information.
mm (0.65 in) expansion for each
For 3600/G3600 series engines,
3.05 m (10 ft) of pipe from 35° to
the Caterpillar supplied bellows and
510°C (100° to 950°F).
adapter, or elbow and bellows
Piping systems must be designed options, account for the maximum
so thermal growth expands away allowable loading on the
from the engine. turbocharger. All other external
A restraint member may be used to piping must be self-supporting.
keep the ends of a long pipe run Loading Calculations
fixed in place, forcing all thermal The following example illustrates
growth towards the expansion the type of calculation used to
joints.

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Exhaust Systems Application and Installation Guide

determine vertical load and bending Horizontal Exhaust

moment at the engine exhaust outlet W = Adapter Weight
due to the weight of the adapter J= Elbow Adapter Weight
mounted directly to the exhaust
outlet. I= ½ Bellows Weight
Figure 11 shows measurement With Caterpillar Hardware:
points for the various distances W = 2.9 kg (6.4 lb)
when calculating the forces and I= 0.6 kg (1.4 lb)
moments on the turbocharger. J= 4.8 kg (10.7 lb)
This example assumes a Gas 3516 h1 = 0
with single exhaust outlet.
h2 = 100 mm (3.9 in)
Vertical Exhaust
h3 = 580 mm (22.8 in)
W = Adapter Weight
I= 1/2 Bellows Weight Forces:
FW = 28 N (6.4 lb)
g= gravity = 9.82 m/s (32.2 ft)
FI = 6 N (1.4 lb)
With Caterpillar Hardware:
FJ = F x g = 4.8 x 9.82 = 47 N
W = 2.9 kg (6.4 lb)
(10.7 lb)
I= 0.6 kg (1.4 lb)
Sum of Vertical Forces
Forces: FV = FW + FI + FJ =
FW = W x g = 2.9 x 9.82 = 28 + 6 + 47 =
28 N (6.4 lb) 81 N (18.5 lb)
FI= I x g = 0.6 x 9.82 = Sum of Moments
6 N (1.4 lb) M = (h1 x FW) + (h2 x FI) +(h3 x FJ) =
Sum of Vertical Forces: (0 x 28) + (.100 x 6) + (.580 x 47) =
FV = FW + FI = 28 + 6 = 27.9 N•m (20.8 ft-lb)
34 N (7.8 lb) Since for this particular engine
Sum of Moments: model FV < 111 N (25 lb) and M <
M = (h1 x FW) + (h2 x FI) = 120 N•m (89.5 ft-lb), the exhaust
(0 x 28) + (0 x b) = system meets the load and moment
0 N•m (ft-lb) requirements.
Since for this particular engine
model FV < 111 N (25 lb) and M <
120 N•m (89.5 ft-lb), the exhaust
system meets the load and moment
requirements.

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Application and Installation Guide Exhaust Systems

Vertical and Horizontal Exhaust

Figure 11

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Exhaust Systems Application and Installation Guide

Vibration Transmission This can occur when air,

Piping connected to stationary significantly above ambient, is
engines requires isolation, drawn through radiator equipped
particularly when resilient mounts cooling systems. Figure 13 through
are used. Without isolation, pipes Figure 17 show typical exhaust
can transmit vibrations long piping systems that are arranged to
distances. Isolator pipe supports avoid recirculation.
should have springs to attenuate low
frequencies and rubber or cork to Common Exhaust Stack
minimize high frequency The exhaust can be directed into a
transmissions. special stack that also serves as the
outlet for radiator discharge air and
may be sound-insulated. In such
instances the radiator discharge air
enters below the exhaust gas inlet
so that the rising radiator air tends
to cool exhaust system components
within the stack. Refer to the
following two graphics.
Figure 12 The silencer may be located within
the stack or in the room with its tail
pipe extending through the stack
To prevent build up of resonant and then outward. Air guide vanes
pipe vibrations, support long piping should be installed in the stack to
runs at unequal distances as shown turn radiator discharge airflow
in Figure 12. upward and to reduce radiator fan
air flow restriction. Alternatively the
Exhaust Discharge sound insulation lining may have a
Exhaust outlets, whether via an curved contour to direct air flow
exhaust pipe or stack, must be upward.
designed to ensure that engine
exhaust is discharged in such a An exhaust stack will remain
manner that exhaust gas will not cooler and cleaner if the engine
recirculate and be drawn back into exhaust is contained within the
the engine’s environment. Engine air exhaust piping throughout its run
cleaners, turbochargers and through the stack. If the exhaust
aftercoolers may become pipe terminates short of the stack
contaminated with spent combustion outlet, the discharged ventilation air
products such as hydrocarbons and will tend to cool the exhaust stack
soot. This contamination can lead to downstream of the point where it
various modes of failure. mixes with the exhaust gases.

Recirculation of hot exhaust gas

can also adversely affect the
ambient capability of the installation.

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Application and Installation Guide Exhaust Systems

Power Module or Drop-Over

Enclosure
For a generator set enclosed in a
power module or drop-over
enclosure, the exhaust and radiator
discharges should flow together,
either above or below the enclosure
without a stack.
This arrangement, as shown in
Figure 15 and Figure 16, will prevent
the recirculation of exhaust gases
Figure 13 back into the module or enclosure.
Sometimes, for this purpose, the
radiator can be mounted horizontally
Figure 13 is an example of a and the fan driven by an electric
horizontally mounted exhaust motor to discharge air vertically.
silencer with the exhaust pipe and
Note that the suction fan
radiator air utilizing a common stack.
arrangement in Figure 17 does not
provide adequate cooling air to the
generator. A separate source of
generator cooling air is required for
this configuration.

Figure 14

Figure 14 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

Typical Power Module or Drop-Over Enclosure Exhaust System

with Internal Silencer

Figure 15

Typical Power Module or Drop-Over Enclosure Exhaust System

with External Silencer

Figure 16

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Application and Installation Guide Exhaust Systems

Cleanliness During Installation operation at no load or lightly loaded

During exhaust system assembly, conditions (less than 15% load)
all openings on the turbocharger reduce the sealing capability of some
should be covered with an integral engine components, even
identifiable blanking plate to prevent when the engine is new.
debris from falling into the If slobber occurs, external signs of
turbocharger. The Caterpillar slobber will be evident, unless the
shipping cover can be used for this exhaust system is completely
purpose. This can be installed sealed.
directly onto the turbine housing Exhaust slobber is not usually
outlet. A warning tag should also be harmful to the engine, but the
attached to the plate or cover results can be unsightly and
indicating that it must be removed objectionable.
prior to engine starting.
If extended idle or light load
Slobber or Wet Stacking periods of engine operation are
Exhaust slobber is the black oily mandatory, the objectionable effect
fluid that can leak from exhaust of the engine slobber can be avoided
system joints. It consists of fuel by loading the engine to at least
and/or oil mixed with soot from the 30% load for approximately ten
inside of the exhaust system. minutes every four hours. This will
Oil leakage may be a result of remove any fluids that have
worn valve guides, piston rings or accumulated in the exhaust
turbocharger seals. Fuel leakage manifold. To minimize exhaust
usually occurs with combustion slobber, it is important that the
problems. engine is correctly sized for each
application.
Engines are designed to operate at
loaded conditions. Extended engine

©2005 Caterpillar®
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Exhaust Systems Application and Installation Guide

Exhaust Systems for Specific Applications

Some engine applications face • The exhaust pipe is provided
more installation challenges than with a drainage system to
others. Marine installations, for collect and remove any water
instance, are afforded very little that may get into the piping.
space and require considerable
protection from water entering the Marine Exhaust Ejector
exhaust system. Automatic Ventilation System
The information that follows A relatively simple system utilizing
addresses some of these challenges an engine’s exhaust for ventilating
and can be applicable to marine- an engine room can be arranged
based as well as some land based with most dry exhaust systems.
installations. Ductwork can be installed around
the engine exhaust piping in such a
Marine Dry Exhaust System way that the exhaust flow creates a
The marine dry exhaust system, in vacuum that is utilized to draw the
general, is similar to a typical land- hot air out of the upper part of the
based exhaust system and will be engine room. This method has been
subject to the same exhaust system used successfully in marine
design considerations as already applications with small engine rooms
discussed in this section. and minimal ventilation
Figure 17 shows a typical marine requirements.
exhaust system installation that An exhaust ejector system may
addresses these design draw out a quantity of ventilating air
considerations: approximately equal to the flow of
• The exhaust piping is exhaust gas. Figure 18, Figure 19
supported directly above the and Figure 20 show variations of
engine exhaust outlet, so that this design.
there is no external loading of Note: To make an exhaust ejector
the engine or turbocharger. system successful, air must be
• The exhaust piping is run in a allowed to enter the engine room
simple and direct manner, freely.
with a minimum number of Duct Design Guidelines
bends, in order to minimize To determine duct area, a useful
system backpressure. rule of thumb is:
• Intermediate section of piping Use 10 cm2 of duct cross sectional
is supported with a spring area per engine kilowatt and not
hanger to allow for movement more than three right angle bends.
due to thermal growth and to
minimize vibration Use 1.25 in2 of duct cross
transmission. sectional area per engine

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Application and Installation Guide Exhaust Systems

horsepower and no more than three can seriously affect the system’s
right angle bends. performance.
If more right angle bends are Furthermore, the exhaust stack will
required, increase the pipe diameter remain cooler and cleaner if the
by one pipe size. engine exhaust is contained within
For best results, the intake air the exhaust piping throughout its run
openings should discharge cool air through the stack. The discharged
into the engine room near the floor ventilation air will tend to cool the
level. After the intake air has been exhaust stack upstream of the point
heated by contact with hot surfaces where it is mixed with the exhaust
in the engine room, draw the gases.
ventilating air out from a point Exhaust ejectors are most effective
directly over the engines, near the on vessels with only one propulsion
engine room overhead. engine. On multiple engine
Place the ejector in the exhaust installations, if one engine is
system just prior to the exhaust’s operated at reduced load, the ejector
discharge to atmosphere to avoid air flow for the engine with reduced
backpressure on the mixture of load may reverse, pulling exhaust
exhaust gas and hot air through any gas from the more heavily loaded
length of stack. Any bends in the engine into the engine room.
exhaust stack following the mixture

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Exhaust Systems Application and Installation Guide

Typical Marine Dry Exhaust System

Figure 17

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Application and Installation Guide Exhaust Systems

Sample Exhaust Ejector System

Figure 18

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Exhaust Systems Application and Installation Guide

Sample Exhaust Ejector System

Figure 19

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Application and Installation Guide Exhaust Systems

Sample Exhaust Ejector System

Figure 20

©2005 Caterpillar®
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Exhaust Systems Application and Installation Guide

Marine Wet Exhaust System boat at or slightly below the vessels

Wet exhaust systems mix the waterline.
exhaust gases with the sea water With a relatively small elevation
discharged from the sea water side difference between the engine’s
of the engine’s jacket water heat exhaust discharge elbow and the
exchanger. See Figure 21 for an vessels waterline, it is difficult to
example of a wet exhaust system. design a system which will always
Wet exhaust piping may be cool prevent water from entering the
enough to be made of uninsulated engine through the exhaust system.
fiberglass reinforced plastic (FRP) or While a number of proprietary
rubber. exhaust components are available to
help avoid this problem, the most
Moisture of exhaust gases and
common generic methods are
seawater is discharged from the
exhaust risers and water lift
silencers.

Wet Exhaust System using Dry Exhaust Elbows at Engine Exhaust Discharge

Figure 21

1. Turbocharger Heat Shield 6. Exhaust Hose

2. Flexible Pipe Connection 7. Connecting Exhaust Pipe
3. Elbow (Centerline bend radius must be greater 8. Discharge Pipe
than or equal to the diameter of the pipe) 9. Surge Pipe
4. Insulation (Must not restrict flexibility of flexible 10. Raw Water Discharge Connection
pipe connection)
11. Support from overhead structure
5. Elbow (Minimum 15° with water discharge ring)

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Application and Installation Guide Exhaust Systems

Do not attempt to carry the weight

Exhaust Risers
of the risers from the boat’s
One way to minimize the
overhead or deck structure. The
possibility of water entering the
risers will vibrate and move with the
engine from backflow in the wet
engine-transmission. The risers must
exhaust system is to have a steep
be supported independently from the
downward slope on the exhaust
hull to avoid transmitting those
piping, downstream of the engine.
Refer to Figure 22. vibrations into the boat’s structure
and passenger compartments. A
flexible connection must be used
between the riser and the hull
mounted exhaust pipe to allow for
the engine transmission movement
during operation.
Except for a few small engines,
exhaust risers are not available from
Caterpillar. See fabricators of
custom exhaust components for
exhaust risers.
Figure 22 Water Lift Silencers
Another way to minimize the
Exhaust risers are pipes that possibility of water entering the
elevate the exhaust gases, allowing engine from backflow in the wet
a steeper slope in the downstream exhaust system is by using a water
piping. lift silencer. See Figure 23 for an
The risers must be insulated or example of a water lift silencer.
water-jacketed to protect personnel Water lift silencers are small,
in the engine compartment from the sealed tanks, mounted to the deck in
high temperatures of the exhaust the engine compartment. The tanks
gas in the riser. The seawater is not have two connections, an inlet
injected into the exhaust gases until connection and an outlet connection.
downstream of the top of the riser, An additional small drain connection
so the upward-sloping portion of the in the bottom is often provided. The
riser is dangerously hot if not inlet enters the tank through the top
insulated or water-jacketed. or side.
The weight of locally fabricated The tubing of the inlet connection
risers (not provided by Caterpillar) does not extend past the tank walls.
must be supported from the engine The tubing of the outlet connection
and marine transmission. Refer to enters the tank walls through the
the Technical Data Sheet for max top and extends to the bottom of
static bending moment on the the tank, where it terminates on an
exhaust connection. angle.

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Exhaust Systems Application and Installation Guide

Typical Water Lift Silencer the highest system elevation must

allow for a 25.4 m/sec (5000 ft/min)
flow velocity of the exhaust-gas-
and-water droplet mixture, with the
engine running at rated load and
speed.
If this velocity is not maintained,
the water droplets will not remain in
suspension. The water will be forced
out of the reservoir of the water lift
muffler as a solid slug of water. This
Figure 23 will cause the exhaust back pressure
to be the same as a column of water
As the mixture of seawater and the height of the upward sloping
exhaust gas enters the tank from the muffler discharge piping.
inlet connection, the water level If the velocity in the upward
rises in the tank. As the water level sloping muffler discharge piping is
rises, the water surface gradually kept above 25.4 m/sec (5000
reduces the gas flow area entering ft/min), then the exhaust
the discharge pipe. The reduced area backpressure will be much lower.
for gas flow causes a great increase
in gas velocity. The high speed of Wave Action and Wet Exhaust
the gases, entering the outlet pipe, Systems
finely divides the water. The finely While the previously discussed
divided water is transported to the methods will help prevent water
highest elevation of the exhaust from entering the engine through the
piping as a mist of water droplets. exhaust system in normal
If good design practice is not circumstances, wave action can
followed, the engines exhaust pose additional problems. Waves,
backpressure limit is easily striking the hull’s exhaust opening,
exceeded. can force water up into the exhaust
The vertical (upward sloping) system. If the waves are severe, or
portion of piping immediately if the exhaust system design allows,
downstream of a water lift muffler the water can reach the engine.
must be designed as a pneumatic Early turbocharger failure or piston
conveyer, using high exhaust gas seizure may result.
velocities to lift finely divided There are a number of ways the
droplets of the sea water to a point kinetic energy of waves entering the
from which the gas/water mixture engine’s exhaust system can be
can be safely allowed to drain to the harmlessly dissipated.
thru-hull fitting. The traditional method of
The diameter of the piping preventing water from entering an
between the water lift muffler and idle engine is to locate the engine far

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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 560
protects the engine from ingesting 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 24. 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 24

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.

©2005 Caterpillar®
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Exhaust Systems Application and Installation Guide

Valve in Exhaust Discharge and deck area exposed to the

A valve located where the exhaust eventual discoloration.
piping exits the hull can keep waves The best exhaust system to
from entering the exhaust piping minimize smoke and noise is to
when the engine is not running. The locate the exhaust exit under the
valve mechanism should not include water. These systems must also
any components that rely on sliding have a small above the water line
contact to maintain flexibility. This path for the exhaust for when the
type of action has proven boat is not moving. Care must be
troublesome in an atmosphere of salt taken when designing underwater
water and exhaust gas. A flexible exhaust systems to keep the
strip of one of the chemically inert backpressure within limits.
plastics can provide hinge action.
Valves in Exhaust Water Cooling
Hose vs. Rigid Exhaust Pipe Lines
The weight and heat of the water Never use shutoffs or valves of
and exhaust gases can cause non- any kind in the lines supplying
rigid exhaust piping to sag or cooling water to the water-cooled
deform, leaving low spots between exhaust fittings.
pipe supports. The cooling water that is injected
If the slope of the piping is too into the exhaust gas stream must
shallow, water will collect in the low not be interrupted, for any reason,
spots and reduce the flow of while the engine is running. Without
exhaust gas. This will lead to a dependable supply of cooling
excessive exhaust backpressure, water, the high temperature of the
smoke, high exhaust temperatures, exhaust gases will cause severe and
and in severe cases, premature rapid deterioration of plastic or
engine failures. rubber exhaust pipe, with potentially
disastrous consequences.
Hose and other non-rigid piping
must be evenly supported over its
entire length.

Location of Exhaust Discharge

Opening
All diesel engines will eventually
discharge some smoke through their
exhaust systems. Perhaps not when
they are new, but certainly near the
end of their useful time before
overhaul. Locating exhaust discharge
openings as far aft as possible and
on the sides of the vessel, if above
the water line, will minimize the hull

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LEBW4970-00 ©2005 Caterpillar Printed in U.S.A.
All rights reserved.