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Catalytic Converter
Installation Guide
Rev. A
© Copyright 2012, GT Exhaust, Inc.
4121 NW 37th
Lincoln, NE 68524
1-888-894-3726
All Rights Reserved
Published: April 13, 2012
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Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Receiving Inspection & Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Product Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Testing & Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Maintenance & Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Product Registration…………. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
copyright © 2012 GT Exhaust, Inc. ERRORS AND OMISSIONS EXCEPTED.
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Introduction
Congratulations on your decision to partner with GT Exhaust in promoting a clean environment through the recent purchase of your emissions reduction system. GT Exhaust has provided over 100,000 exhaust solutions, which gives us confidence that you’ll be pleased with your purchase.
The product you have purchased is fitted with engineered modular rectangular active or blank catalyst elements as needed to provide the currently required destruction of Hazardous Air Pollutants (HAP), as well as accommodate for future emission reduction requirements. The elements have been manufactured to ISO standards and provide optimal HAP destruction for the application needs. The modular elements are mounted in special retainers, which are installed in the silencer housing. The elements are mounted parallel to each other and with their faces parallel to the normal end-to-end flow path of the silencer and are designed to prevent exhaust bypass around the catalysts.
This guide will walk you through the necessary steps to successfully install the catalyst elements and provide all other relevant information ensuring optimal effectiveness of your systems operation.
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Receiving Inspection and Storage Receiving Inspection
Upon receipt of the system, check the nameplate against the packing list to verify the correct part numbers are received. Verify all items on the packing list are present.
Keep the shipping container to protect the unit and catalyst until installation has been completed.
Prior to unpacking, check for shipping damage.
Advise [email protected] of shipping damage within three days of receipt of the product.
Storage
Leave any cardboard boxing, plywood covering, crating, and/or plastic covering intact until ready to install.
Be sure that all openings are closed so that no debris, vermin, rain, snow and/or ice can get into the unit.
Store the catalyst housing on blocks, a minimum of 4” high, so that air can freely circulate around the unit.
Do not store the catalyst element in contact with the ground or in a wet, humid or flooded area. It must be stored indoors in the original shipping container and protected from dust.
Do not store the silencer/housing in contact with the ground or in a wet, humid or flooded area.
Indoor ambient temperature storage is preferable. If this is not possible, keep the unit covered and protected from the weather.
Inspect the catalyst housing surfaces prior to installation. Clean and remove any minor corrosion and refinish per paint manufacturer’s recommendations. If major corrosion has occurred such that the integrity of the unit is in question, contact GT Exhaust.
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Product Specifications OVERVIEW
The dimensions of rectangular catalytic panels are 15.44” x 24.75 x 3.7”. The core substrates are formed from 3.5” stainless steel foil in a honeycomb structure. Catalyst elements are composed of the substrate and catalytically active elements from the Platinum Group Metals deposited via proprietary washcoat technology and cured under high temperature. The catalyst is 100% vacuum brazed to prevent telescoping under exhaust pressure conditions and mechanical shock. Cell densities are typically 300 CPSI but are available in other densities as required by the application, including 100 CPSI. There are also “blank” or “dummy” panels that act as placeholders when active panels are not being used. They are made from carbon steel and have no “active” core. The dimensions of blank panels are the same as the active panels.
Diesel Oxidation Panels
Diesel Oxidation catalysts are applicable to Compression Ignition (CI) engines for the oxidation of carbon monoxide (CO), hydrocarbons (HC) and soluble organic fractions (SOF) including condensable particulate matter. HC, CO and SOF pollutants are removed from the exhaust gas by oxidation by the oxygen in the exhaust gas at the surface of the oxidation catalyst. Basic requirements for the oxidation are adequate concentration of oxygen and a suitable high temperature. The efficiency of the oxidation catalyst is dependent on the type of hydrocarbon in the exhaust gas. Expected CO reduction for newly installed unit: 90-99%. Operating temperatures range from 550 °F to 1350°F
OXIDATION PANELS
Oxidation catalysts are applicable to Spark Ignition (SI) lean burn engines with sufficient oxygen available in the exhaust gas to oxidize the Carbon Monoxide (CO) and Hydrocarbons (HC). Oxidation elements are not effective, in any application, for reduction of nitrogen Oxides (NOx). Expected CO and NMNEHC for newly installed units are 90-99% and 70-98%, respectively. Operating temperatures range from 450 °F to 1350°F.
NOTE: Warranty will be null and void if catalyst elements are not purchased through GT Exhaust, Inc.
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Product Specifications
3-WAY PANELS
All 3-way catalysts are effective for the destruction of emissions from rich-burn gas SI engines that are equipped with an effective air-fuel ration controller to provide no more than 0.5% Oxygen in the exhaust gas. The 3-way catalysts reduce Nitrogen Oxides (NOx) and oxidized Carbon Monoxide (CO), Aldehydes, which include formaldehyde (HCHO), a designated carcinogen, as well as other Aldehydes that cause the characteristic exhaust odors most noticed with LPG fueled engines, and the residual Non-Methane or Non-Methane Non-Ethane Hydrocarbons (NMHC or NMNEHC) to Carbon Dioxide (CO2) and water vapor (H2O). Catalyzed Diesel Particulate Filters
Catalyzed Diesel Particulate Filters are effective in removing particulate matter (PM). PM’s consist of liquid heavy hydrocarbon, carbon soot, water, and hydrated sulfuric acid. PM’s are classified as a toxic contaminant by the California Air Resources Board (CARB). Exhaust gases enter a honeycombed maze of channels that actually captures the particulates. The filter is designed to be self-regenerating. The special catalytic coatings on the filter substrate interact with the gases and carbon particles to create complex chemical reactions. The interaction between the exhaust gas and the filter creates a chemical reaction, which converts CO and HC into Carbon Dioxide and water vapor. Particles larger than 35 nanometers are efficiently removed from the exhaust. Tests have shown that up to 99.6% of the PM is removed. Hydrocarbons and Carbon Monoxide are reduced by up to 99%.
NOTE: Warranty will be null and void if catalyst elements are not purchased through GT Exhaust, Inc.
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Installation Preparation
Handling
The metal monolith substrate on which the catalyst is supported is robust but fragile, and therefore should be handled with care. The cells of the substrate can be easily distorted or blocked, causing performance problems such as higher system backpressure and/or lower destruction efficiency.
When it has been determined from engine operations or emission measurements that the catalyst requires inspection, cleaning or replacement, this procedure should be followed for the efficient removal of the catalyst.
ACCESSING THE PANELS
1. Disable the engine’s starting ability (E-Stop, disconnect the battery).
2. Unfasten the bolts from the flanged access lid and store in a secure place for replacement.
3. Remove the access lid from the body of the silencer. Do not preserve the vermicular tape, as it
will be removed and replaced in later steps.
4. Review the position of all components before any servicing is commenced.
5. Unscrew the locking bolts, either side of the frame until the panel brace is loose and using the
handle on the brace, tilt it forwards and relocate the brace lugs in the holding slots.
6. The catalytic panel can now be slid out and removed.
IF REMOVING PANELS
1. Carefully remove the panel(s) from the holster. It is not necessary to remove blank panels (noted
by their solid center cores), but you may if you wish. Be sure to make note of the locations of the
removed panel(s) for reference when reinstalling.
2. Remove the gasket frames or gasket tape.
INSTALLING/REPLACING PANELS
1. Place the new gasket frame into the panel holster.
2. Grasping the panel by the stainless steel channel frame, place the panel into the brace. Repeat
these steps as needed for the number of panels being installed/replaced.
3. Once the catalytic panel is in place, lift the brace using the handle from the holding slots and tilt it
back to relocate the locking bolts into the location holes.
4. Torque the locking bolts to 25-28 ft-lbs. Ensure that the brace and catalyst panel are fully secure.
5. Replace the access lid and secure into place with the bolts.
IMPORTANT: If you are installing catalyst blanks, ensure that the seamless side is oriented in the holster face-in as illustrated.
NOTE: When catalyst elements are removed for any reason, all gaskets should be replaced. Replace gasket frame each time the panel is removed from the holster. Failure to do so renders the warranty null and void.
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Commissioning - Testing and Monitoring Engines in which excessive wear exists can compromise emission system performance. Ensure the compression ratio, oil consumption, ignition timing, fuel pressure, and other indicators are within normal limits. The catalyst element can be permanently damaged when exposed to continuous misfires, the engine is not operating to manufacture specifications, and when engine start-up procedures have been ignored. Therefore it is recommended that the catalyst element be removed during engine start-up.
Initial Engine Start-Up
Prior to emissions system commissioning it is recommended that the engine run, before installing the catalyst elements, for a sufficient period of time to clear all debris in the flow path upstream from the catalyst. This protects the catalyst from experiencing any adverse conditions such as over temperature or contamination during initial engine set-up. GT Exhaust silencers/catalyst housings provide multiple test ports upstream and downstream of the catalyst element to provide access to real time catalyst and exhaust operating parameters including temperature, pressure, and emissions reduction. Ensure all test port connections for any continuous parametric monitoring systems (CPMS) and remaining test port plugs are tight. Upon replacement of the access lid, start the engine and check all external connections and covers for leaks, correcting as necessary. Ensure the CPMS operates as directed by the manufacturer. For all regulated emissions commissioning and performance testing, follow all required guidelines to ensure compliance. After 24 hours, check the access lid to ensure the bolts have remained securely fastened and the gasket is tightly sealed. It is recommended that the unit is inspected every six months or as needed per the customers preventative maintenance program. NOTE: For all regulated emissions commissioning and performance testing, follow all required guidelines to ensure compliance. For remaining installations, GT Exhaust recommends performing an emissions test of the system within 100 hours of commissioning. During this test, perform before and after measurements of PM, CO and HC, inlet and exit temperature, and pressure drop across the catalyst, which enables you to establish a baseline from which future performance can be evaluated. If you have questions or want additional information regarding this procedure and/or the results of your testing contact GT Exhaust at: [email protected] or +1.888.894.3726.
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Maintenance & Performance When installed with a new or properly maintained and serviced engine, the elements are normally expected to provide a minimum of five years of service life with 24/7 operation time. A mal-maintained engine without the proper lubricating oil, excess oil consumption, excessive exhaust gas temperature and/or contaminated fuel will result in reduced element life of the panels due to the effects of heavy metal and other poisoning or sintering, which causes irreversible damage to the catalytic coating. Conditions detrimental to the catalyst will vary from installation to installation. In order to be effective, a periodic inspection and maintenance program must be tuned to the specific installation.
The catalyst should be inspected periodically for physical damage or fouling. The frequency of physical inspections required will vary. For installations where the gas stream is free of particulate, oil consumption is low, and the engine is natural gas fired, an annual or biannual inspection will be sufficient. In a dirty gas stream, (for example, engines with high lube oil consumption rates) where particulate or other fouling agents are a problem, a monthly inspection may be required. The optimum frequency of catalyst inspection will be based on experience. The catalyst should also be inspected any time the system suffers a physical upset or if a loss in conversion efficiency is observed.
To maintain catalyst performance the maximum operating temperature is limited to 1350°F. Damage due to over temperature is irreversible. Correct operating temperature is critical to catalyst longevity. Normally, this is not a problem since normal operating temperatures are in the range (950 to 1150°F) where catalyst life is not significantly affected. However, excessive temperatures caused by severe misfiring must be avoided in order to ensure catalyst longevity.
To inspect the catalyst unit, remove the element and visually examine the catalyst for any physical damage or obstructed passages, especially on the inlet face. Excessive cell blockage must be cleared by cleaning the catalyst. Follow the procedures within this guide for removal and installation of the catalyst element.
Cleaning
From time to time, carbon and other non-reactive contamination will be deposited on the surfaces of the core, resulting in a temporary masking of the precious metals and a loss of destruction effectiveness. This reduction is indicated by an increase of backpressure across the element of 2” H20 or more from the initial performance test. Cleaning the contaminating deposits from the core can reverse this masking.
If the deposits are dry, they can be cleaned by vacuuming the core with an industrial strength vacuum or by blowing low pressure (50 PSI maximum) oil free, dry and clean compressed air through the core, making sure the nozzle is kept at a distance of three feet from the surface to avoid severe velocity which may loosen the catalyst coating. When blowing the catalyst clean, the air jet should be in the direction opposite the normal flow through the catalyst. If accessible, vacuum any particulates out of the upstream ductwork before the engine is restarted.
In the case of oily soot, the core may be cleaned with a solution of de-mineralized (distilled) water and non-phosphate detergent such as Ivory Dishwashing Liquid. The solution may be flushed through the core much as one would clean parts with a petroleum solvent in a typical shop wash tank. Before reinstalling the cleaned elements, a new gasket frame should be installed. To make your next order, ask questions or request additional warranty information contact us at:
Website: www.gtehaust.com Email: [email protected] Customer Care +1.888.894.3726 RICE NESHAP Hotline: +1.855.4NESHAP (+1-855-463-7427) Fax: +1.402.323.7270
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Performance Guarantee and Catalyst Warranty Information
Warranty Information:
NOTE: BE SURE TO SEND THE PRODUCT REGISTRATION INFORMATION TO GT EXHAUST AT 4121 NW 37TH, LINCOLN, NE 68524 OR [email protected], IN ORDER TO REGISTER YOUR GT EXHAUST PRODUCT FOR PROPER WARRANTY AND PERFORMANCE GUARANTEE COVERAGE
For GT Exhaust Warranty information on the Catalyst Housing and Catalyst Element, please visit:
www.gtexhaust.com/library/technical_materials and select the “Warranty and Terms Info” tab.
Performance Guarantee:
Please reference the GT Exhaust RICE NESHAP Catalyst Element Performance Guarantee for HAP
Destruction and Applicable Conditions available the following web address:
www.gtexhaust.com/library/technical_materials and select the “Warranty and Terms Info” tab.
Contact Information:
4121 NW 37th
Lincoln, NE 68524
Tel: 402-323-7272
Toll Free: 1-888-894-3726
Fax: 402-323-7271 www.gtexhaust.com
Customer Care Tel: 402-323-7273 Email: [email protected]
Technical Support
Tel: 402-470-4750 Email: [email protected]
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Product/Warranty Registration Thank you for purchasing a GT Exhaust Catalytic Product. Register your product with GT Exhaust to claim your warranty.
NOTE: IN ORDER TO REGISTER YOUR GT EXHAUST PRODUCT FOR PROPER WARRANTY COVERAGE, THIS INFORMATION NEEDS TO BE SUBMITTED TO GT EXHAUST AT:
GT EXHAUST 4121 NW 37TH, LINCOLN, NE 68524 Or [email protected]
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Catalyst Warranty and Performance Guarantee Registration
Please Complete this form upon commissioning of your catalyst product and return to GT Exhaust within
30 days of commissioning unit.
Date Company
City State
ZIP Code
Contact Name Title
Office Phone Mobile Phone
Email Website
FAX #:
Industry
Installation Consists of: Engine Information
Gas – Rich Burn (O2 < .5%) Gas Lean Burn (O2 < 2%)
Engine Manufacturer: Model #:
Engine Manufacture Date:
Exh. Flow Rate (CFM): Exh. Temp (Deg F):
Engine HP or KW Rating: Lube Oil (API Type):
GT Exhaust Product Information
Housing Model #: Housing Serial #:
Catalyst Model #: Catalyst Serial #:
Engine Location
City: State:
ZIP
Installer
Date Contracting Company
City State
ZIP Code
Contact Name Title
Office Phone Mobile Phone
Email Website
FAX #:
Catalyst Requirements (Check all that apply):
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Controlled Emissions (ppmv @ 15% O2)
NOx CO HC PM
Initial Performance Test - RICE NESHAP Application Only Date Performed: Emissions Test Company (Name, State) Test Procedure Used CO Inlet PPMV @ 15% O2 CO Outlet PPMV @ 15% O2 CO Reduction % Pressure Drop Across Catalyst Element - (Inches H20) Catalyst Inlet Temperature °F
NOTE: IN ORDER TO REGISTER YOUR GT EXHAUST PRODUCT FOR PROPER WARRANTY COVERAGE, THIS INFORMATION NEEDS TO BE SUBMITTED TO GT EXHAUST AT:
GT EXHAUST 4121 NW 37TH, LINCOLN, NE 68524 or [email protected]
