SUPERIOR GAS AND DUAL FUEL ENGINES GENERAL DATA Description Model Nomenclature Ratings Fuel Gas Quality & Pressure -Pipeline Quality Natural Gas -100% Propane -Digester Gas Landfill Gas Deration ~Fuel Quality -Exhaust Back Pressure -Propane/Butane Lubrication System Cooling system Exhaust Emissions Schematics “Start Air -Fuel Gas -Lube 011 ~Coolant Miscellaneous AJAX-SUPERIOR INDEX Page No. meSUPERIOR GAS AND DUAL FUEL ENGINES PAGE 1 825 Series: MODEL NOMENCLATURE Al engines in this series have the same specific power cylinder displacement, viz 825 cubic inch/cylinder (13.5 liter/cylinder). All engines have the same bore and stroke: 10" x 10-1/2" (254 mm X 266.7 mm). They are all 4-cycle, spark-ignition, natural gas engines available in 6 and 8 cylinder Inline configuration, and 12 and 16 cylinder Vee configuration. Naturally Aspirated models are named as **G-825 where letter "6" ‘TaenETTies the model as a spark-ignition gas engine and the tirst (one or) two digits indicate the number of power cylinders. Thus 126-825 is a 12-cylinder spark-ignition, naturally aspirated gas engine. “Turbocharged” models are standard-emission turbocharged models as “distinct from low-emission "CleanBurn® engines which are also turbocharged. The nomenclature consists of two parts as in dd-AAA where "dd" is a one or two digit number giving the numbaer of power cylinders in the model and "AAA" is either GTL or SGT. GT stands for Turbocharged, spark-ignition gas engine. "L" stands for lower output (145 to 150 psi BMEP) level and "S" stands for higher (super) output (175 to 180 psi BMEP) level models. The Inline 6-cyTinder engine in this group is available in GTL version only whereas 8, 12 and 16 cylinder engines are available in both GTL and SGT versions. Thus, BGTL is an B-cylinder, 1100 BHP (146.7 psi BNEP) Turbocharged, spark-ignition gas engine, and SGT is an B-cyTinder, 1500 BHP (180 psi BMEP) Turbocharged, spark-ignition gas engine. CleanBurn mode1s are low-emission versions of the “Turbocharged” models. They are identified by the suffix A or B at the end of the corresponding Turbocharged models. Suffix A stands for the first generation CleanBurn models and suffix B stands for the second generation CleanBurn II models which have a micro- processor based Superior Electronic Control System (SECS) for engine's air-fuel ratio controls. CleanBurn models are rated at same shaft output levels as the standard-emission "Turbocharged" models but due to differences in air-fuel ratio control mechanisms and changes in engine operating parameters produce significantly lower NO, emission levels. Thus, ub \ccorre| AVAX-SUPERIORSUPERIOR GAS AND DUAL FUEL ENGINES PAGE 2 Model 40: 6GTLA is a first generation, 6 cylinder, Turbocharged, spark-ignition, low BMEP (146.7 psi) CleanBurn gas engine and 12SGTB is a second generation, 12-cylinder, Turbocharged, spark-ignition, high BMEP (176.7 psi) CleanBurn gas engine. ATI Mode] 40 engines are compression ignition engines requiring liquid fuel such as #2-D diesel for combustion, These engines are available in two versions - straight diesel and dual fuel. Straight diesel Model 40 engines are denoted as 40X-dd where "X" denotes a Turbocharged engine and dd is a one or two digit number giving number of power cylinders. Absence of "X" in the model nomenclature indicates that it is a naturally aspirated engine. Straight diese! engines require a single Niquid fuel such as #2-D iesel. Dual fuet Model 40 engines are denoted as 40-GOX-dd where "x" ‘agath denotes a Turbocharged engine. "GD" indicates gas-diese? dua? fuel capability which means that the engine is started as a straight diesel engine and when load and operating parameters have stabilized, the engine can be switched to dual fuel mode in which case it needs liquid pilot fuel (such as #2-D diesel) in the range of 6 to 10% of total energy input, the balance being a gaseous fuel such as pipe-line quality natural gas or digester gas, etc, The dual fuel switchover is accomplished while the engine is running and is loaded. Normally, the engine is switched back to straight diesel mode prior to a controlled shut- down but it can be shutdown in dual fuel mode in an emergency. Current production diesel and dual fuel Model 40 engines are available in Turbocharged versions only. The Inline 6 and 8 cylinder engines have a bore of 9-1/8" (232 mn) whereas the 12 and 16 cylinder Vee engines have a bore of 10" (254 mm) and they all have a common stroke of 10-1/2" (266.7 mm). Thus, 40-X-8 is an 8-cylinder, Inline, Turbocharged straight diesel engine, and 40-GOX-12 is a 12-cylinder, Vee, Turbocharged dual fuel engine ccren| AVAX- SUPERIOR:SUPERIOR GAS AND DUAL FUEL ENGINES PAGE 3 RATINGS (IN ENGLISH UNITS) ENGINE MODEL BORE & STROKE SPEED RATING BMEP INCHES RPM BHP FULL SPEED PSI CLEANBURN II ENGINES 6GTLB 10 x 10-1/2 600 - 900 550 - 625 146.7 SGTLB 10 x 10-1/2 600 - 900 730 - 1100 146.7 8sGTB 10 x 10-1/2 600 - 1000 900 - 1500 180.0 12GTLB 10 x 10-1/2 600 - 900 1100 - 1650 146.7 12SGTB 10 x 10-1/2 600 - 900 1330 - 2000 177.8 16GTLB 10 x 10-1/2 600 - 900 1470 - 2200 146.7 16SGTB 10 xX 10-1/2 600 ~ 900 1770 - 2650 177.8 TURBOCHARGED ENGINES 6cTL 10 x 10-1/2 600 - 900 550 - 825 146.7 acTL 10 x 10-1/2 600 - 900 730 - 1100 146.7 escT 10 x 10-1/2 600 - 1000 900 ~ 1500 180.0 12GTL 10 X 10-1/2 600 - 900 1100 - 1650 146.7 12SGT 10 x 10-1/2 600 - 900 1330 - 2000 177.8 16GTL 10 xX 10-1/2 600 - 900 1470 - 2200 146.7 16SGT 10 % 10-1/2 600 - 900 1770 - 2650 177.8 NATURALLY ASPIRATED ENGINES 6G-825 10 x 10-1/2 500 ~ 900 335 - 600 106.7 aG-825 10 x 10-1/2 500 - 900 445 - 800 106.7 126-825 10 x 10-1/2 500 - 900 670 - 1200 106.7 166-825 10 X 10-1/2 500 - 900 890 ~ 1600 106.7 DUAL FUEL ENGINES 40-GDx- 6 9-1/8 x 10-1/2 600 - 900 475 - 710 151.7 40-GDx- 8 9-1/8 x 10-1/2 600 - 900 545 - 820 151.4 40-GDX-12 10 % 10-1/2 600 - 900 1100 ~ 1650 146.7 40-GDX-16 10 x 10-1/2 600 - 900 1468 - 2200 146.7 NOTE: All Engine Ratings are based on the Altitude, Ambient Temperature, Compression Ratio, Intake Depression, Exhaust Backpressure, Inter- cooler Water Temperature, and Fuel Gas Quality given in the section for that Engine Model. Engine Ratings may have to be lowered for Site Conditions exceeding the levels given herein. (ceu| AUAX-SUPERIOR APPR re} NC 2 GEN 3/1-89 Superior? and Cleanturn™ are wademarks of Cooper Ineusties, Ine. Copyright © Cooper indusies, inc. 1989SUPERIOR GAS AND DUAL FUEL ENGINES PAGE 4 RATINGS (IN METRIC UNITS) ENGINE MODEL BORE & STROKE SPEED RATING BMEP INCHES RPM kW FULL SPEED Kg/em2 CLEANBURN II ENGINES 6GTLB 254 x 266.7 600- 900 410 - 615 10.32 acTLB 254 x 266.7 600 - 900 545 - 820 10.32 8SGTB 254 x 266.7 600 - 1000 670 ~ 1120 12.66 12GTLB 254 x 266.7 600 - 900 820 ~ 1230 10.32 12SGTB 254 x 266.7 600 - 900 990 - 1490 12.50 16GTLB 254 x 266.7 600 - 900 1090 - 1640 10.32 16SGTB 254 x 266.7 600 - 900 1315 - 1975 12.50 TURBOCHARGED ENGINES 6cTL 254 x 266.7 600- 900 410 - 615 10.32 acTL 254 x 266.7 600 - 900 545 - 820 10.32 ascT 254 x 266.7 600 - 1000 670 - 1120 12.66 12GTL 254 x 266.7 600 - 900 820 ~ 1230 10.32 1286? 254 x 266.7 600 - 900 990 ~ 1490 12.50 16GTL 254 x 266.7 600 - 900 1090 ~ 1640 10.32 16SGT 254 x 266.7 600 - 900 1315 - 1975 12.50 NATURALLY ASPIRATED ENGINES 66-825 284 x 266.7 500- 900 250 - 450 1.50 86-825 254 x 266.7 500 - 900 335 - 600 1.50 126-825 254 x 266.7 500 - 900 500 - 895 7.50 166-825 254 x 266.7 500 - 900 660 - 1190 7.50 DUAL FUEL ENGINES 40-GDX- 6 232 x 266.7 600 - 900 355 - 530 10.67 40-GDK- 8 232 x 266.7 600 - 900 405 - 610 10.65 40-GDX-12 254 x 266.7 600 - 900 820 - 1230 10.32 40-GDX-16 254 x 266.7 600 - 900 1095 - 1640 10.32 NOTE: All Engine Ratings are based on the Altitude, Ambient Temperature, Compression Ratio, Intake Depression, Exhaust Backpressure, Inter- cooler Water Temperature, and Fuel Gas Quality given in the section for that Engine Model. Engine Ratings may have to be lowered for Site Conditions exceeding the levels given herein. one, AVAX-SUPERIOR APPR BMC 2 GEN 4/1-89 ‘Superior® and CleanBurn™ Copyright © Cooper naust sdemarks of Cooper Industries, tc. 7989SUPERIOR GAS AND DUAL FUEL ENGINES JACKET HATER HEAT vs. PAGE 21 COOLANT TEMPERATURE Ss ENGINES WITH WATER COOLED) EXHAUST MBNIF OLDS 21.08 2 § 40.9 é 2 2.8 2.7 160 188 200 220 240 260 Jacket Hater Temperature out of engine - Deg. F. ie LURE OIL HEAT ve. COOLANT TEMPERATURE COIL TEMPERATURE OUT NOMINALLY 190 PEG. F) & Heat Rejection Multiplier 2.8 160 180 200 Jacket Hater Temperature | AJAX-SUPERIOR 228 240 260 out of engine ~ Deg. F aver. SMC Z GEN _21/9-88 Superior® and Cleanun"™ are wasemarks of Cooper Industries, Inc. Copyright © Cooper Inaustis, ne. 1968SUPERIOR GAS AND DUAL FUEL ENGINES PAGE 22 JACKET HATER HEAT vs. COOLANT TEMPERATURE 1 5 ENGINES WITH DRY TYPE ExHhUST HANIFpLDS Bie 2 Se.8 g 20.8 i 2.7 2.6 160 180 200 220 240 260 Jacket Hater Temperature out of engine - Deg. F na LUBE OTL HEAT vs. COOLANT TEMPERATURE Sis 2 | oe eta i Le as 162 180 200 zee 240 260 Jacket Hater Temperature out of engine AJAX-SUPERIOR APPR. BNC GEN 22/9-B8 Superior® and CieanBurn"™ are trademarks of Cooper Ingustries. Ine Copyright © Cooper industries, Inc. 1989SUPERIOR GAS AND DUAL FUEL ENGINES PAGE 23 JACKET WATER HEAT vs. COOLANT TEMPERATURE e & ENGIHES NITH [WATER COpLED ExHfuST Hew{roLos é | 21.0 Sy | 2 Se.3 & 3 te 2 as @.? 78 8a 38. ie 110 120 130 Jacket Hater Temperature out of engine ~ Deg. C 5 cor |remperature out hommNALL} 88 Dec] c» Bis 2 be 2 Sie « gil z 1.8 va es 70 ee Soy g ie) gin a e acket Hater Temperature out of engine ~ Deg. ¢ (| AJAX-SUPERIOR appr. SOMC- GEN 23/1-89 ee - ‘Superior? and CleanBura™ are trademarks of Cooper Industries, nc Copyright © Cooper Industries, In. 1989SUPERIOR GAS AND DUAL FUEL ENGINES PAGE 24 JACKET WATER HEAT ve. COOLANT TEMPERATURE 1 Bio b - 2 80.9 }— Ke = @ 2.8 - . 2 a.7 F _ he a6 76 ee eS 10 Jacket Hater Temperature out of engine ~ Deg. ¢ a LUBE_OTL HEAT ve. COOLANT TEMPERATURE 5 com. |renperaTure our WoMINALLY 88 DEG] c) Bie i pe 2 Si.2 Q etl 2 1.8 ZA 2.8 76 80”~8S~*~«SS@ see ae Jacket Hater Temperature out of engine - Deg. C AJAX-SUPERIOR APPR 3 XC GEN 24/1-89 ‘Superior® and CleanBurn™ are trademarks of Cooper Industrie, Ine. Copyright © Cooper industries, Inc, 1989COOPER INDUSTRIES ENGINEERING SERVICE BULLETIN #229 SUBJECT: SUPERIOR Engines and Compressors Lube Oil Change Intervals. MODELS: SUPERIOR Engines and Compressors. PURPOSE: To inform customers of a procedure to determine feasibility of extending lube oil change intervals. EXTENDING THE OIL CHANGE INTERVALS. The nature of the oil is to lubricate and cool the internal workings of the engine. If you compromise either of those functions, maintenance costs will increase. Consider the nature of your specific operation. 1 What is the maximum rating of your engine ? 2- Do you operate your equipment at or near maximum rating ? The closer you operate your equipment to its maximum rating, the less likely you will be able to successfully extend your oil change intervals beyond the 1000 hour recommendation in the manual. Next consider temperatures, including both engine coolant temperature and oil temperature. If your unit operates with coolant temperature higher than 180-185° F or with oil temperatures higher than 185° F then you should be very cautious when attempting to extend oil life. Finally consider what is going into your engine. e 1- _ Is the fuel quality good, clean, and free of any acidSERVICE BULLETIN # 229 PAGE2 forming compounds such as sulfur, fluorides, or carbon dioxide ? 2- What about the air ? Is unit in a dusty environment ? 3 Do you already extend your air filter life until the filters are no longer doing their job? 4 Tfyou inspect downstream of the air filters, can you find dirt ? Sometimes environmental conditions are such that one cannot successfully filter the air and fuel as well as it should be. In those cases, the oil will be required to carry some of the extra microscopic dirt load. It is important to understand that oil does not “fail” as a straight line function over time: but once oil starts to fail then it can degrade rapidly such that in a short time, serious damage can be caused to the equipment. The curve below pictures how the performance can degrade over time. Please note: The scales are generalizations for this example. Each specific unit situation will have a unique curve depending on such things as load, speed, choice of lubricant, etc. OIL LIFE 8 Unacceptable zZ s z ° Marginal j £ a a = 2 Good 3° 0 200 400 6008001000 1200 TIME (Hours)SERVICE BULLETIN # 229 If after you have considered all of the above and you still want to try extending your oil change intervals, then here is a plan to use as a guideline: Le Start with a fresh charge of oil and be sure the crankease and the complete oil system is cleaned thoroughly before the oil is put into the engine. Be sure that the oil meets or exceeds the recommendations for the unit. This is the time to start the oil sampling program. Take a sample of new oil and get an analysis performed on it to establish a "new oil” baseline. This is also useful in determining just what elements are present in the oil package and prevents later excitement trying to track down where the copper (or whatever) is coming from, when it is actually being put in with the oil. Take another oil sample after 500 hours of successful, trouble free operation on the unit and get an analysis performed on it. Process another oil analysis after the oil charge has 850 hours on it. At the 1000 hour interval, take an oil sample - drain the oil, remove the oil filters, put in a new charge of oil, and install new oil filters. Successful, trouble-free operation is necessary throughout the test. If the unit experiences any problems during this whole process, it will probably make the results unreliable for determining whether you should try to extend the oil change intervals. Itis important to use proper technique when taking the oil samples. The samples should be taken from a “flowing” line ahead of the oil filters with the unit operating at normal operating temperatures and conditions. Typically, some 1/4 inch tubing and a valve are permanently installed in a suitable, location to facilitate this sampling. One must be caréful to purge the sample line of all old fluid and discard it before taking the actual sample to be analyzed - it is good to PAGE3SERVICE BULLETIN # 229 discard about a quart of oil (or more depending on the sampling piping arrangement) before filling the sample bottle. The oil analysis should include information that allows one to evaluate the condition of the oil itself as well as the levels of wear metals, contaminants, etc. An infrared scan should be performed on the sample to check for oxidation and nitration. One needs to familiarize themselves with the details in the oil analysis that can be used to evaluate the condition of the oil itself. Is the detergent package getting used up, is the oil oxidizing, is the oil nitrating, ete ? Always deal with a reputable firm, this can be the oil company or an independent source. It is important that the oil analysis program provide a timely response, and urgent concerns should be telephoned to you. Repeat steps 1 through 4 above with the second charge of oil. If the new oil is from a new delivery, then it is best to again get an analysis performed on it to be certain that your oil supply is consistent. Evaluate the data gathered. We recommend that you provide us a copy of the data and discuss it with us and also with a knowledgeable representative of your oil supplier. If it then appears that you can probably safely extend your oil change interval, we recommend that you try it in reasonable increments and continue the oil analysis testing every 250 hours beyond 1000 hours service on each new oil charge. For example: If it was decided that you could likely extend the oil change intervals by 500 hours, then we would recommend testing the oil at 1000 hours, 1250 hours, and at 1500 hours. This would then be a repeat where you would do this cycle twice (and change the oil twice) before considering trying to extend it any further. FIELD ENGINEERING 8/20/92 PAGESSUPERIOR GAS AND DUAL FUEL ENGINES CONVERSION DATA INDEX Description Pormulae Units of Area Density Energy Flow Rates - Heat Flow Rates - Volume Force Heat Length Power Pressure Torque Velocity Volume Weight Work Average Unit Heat Value of Fuels Useful Equivalents Page No. BUHUaNOFeeuaneHSUPERIOR GAS AND DUAL FUEL ENGINES ! TO CONVERT i TO OBTAIN CONVERSION DATA 1 i MULTIPLY BY DIVIDE BY PAGE 1 TO OBTAIN TO CONVERT UNITS OF LENGTH Inches (in) Inches (in) Inches (in) Feet (ft) Yard (yd) Miles (Mi) UNITS OF AREA [Link] (sq. in) [Link] (sq. in) [Link] ([Link]) [Link] ([Link]) [Link] ([Link]) [Link] ([Link]) UNITS OF VOLUME [Link] (cu. in) Fluid Ounce([Link]) [Link] ([Link]) [Link] — (cu-yd) [Link] (cu. in) Fluid Ounce(fl.0z) [Link] ([Link]) [Link] — (cu-yd) US Gallon Imperial Gallon AJAX-SUPERIOR 25.40 2.54 0.0254 0.3048 0.9144 1.6093, 645.20 6.452 929.0 0.0929 0.8361 2.890 16.388 29.577 0.02832 0.7645 0.01639 0.02957 28.32 164.6 3.785 4.546 Millimeter (mm) Centimeter (cm) Meters (n) Meters (m) Meters (m) Kilometer (km) [Link] ([Link]) [Link] ([Link]) [Link] (sq. cm! [Link] (sq.m) Sq-Meters (sq.m) [Link] ([Link]) [Link] ([Link]) [Link] ([Link]) [Link] (cu,m) [Link] {cu.m) Liters Liters Liters Liters Liters Liters CONV 1/1-89SUPERIOR GAS AND DUAL FUEL ENGINES PAGE 2 CONVERSION DATA 1 TO CONVERT | MULTIPLY BY =| TO OBTAIN 1 I TO OBTAIN I DIVIDE BY ! 10 CONVERT I UNITS OF WEIGHT Grains 0.0648 Grams (a) Ounce (oz) 28.35 Grams (9) Ounce (oz) 0.02835 Kilogram (kg) Pound (1b) 453.6 Grams (9) Pound (1b) 0.4536 Kilogram (kg) Us tons 907.2 Kilogram (kg) US tons 0.9072 Tonnes Tons (long) 1016 Kilogram (kg) UNITS OF PRESSURE Pounds/[Link] (psi) 10.32 Grams/[Link] Pounds/[Link]( 1b. /cu. in) 27.70 Grams/[Link] Pounds/[Link] (psi) 0.07032 Kilogram/[Link] (kg/cm?) Inches of Hg (in. Hg) 0.03453 Kilogram/[Link] (kg/cm2) Inches of Water(in.H20) 0.00254 Kilogram/[Link] (kg/cm2) Feet of Water (ft.H20) 0.03048 Kilogram/[Link] (kg/cm2) Atmospheres (atm) 1.03327 Kilogram/[Link] (kg/cm2) Pounds/[Link] (psi) 703.10 Kilogram/sq.m (kg/m2) Pounds/[Link](1b./cu. ft) 16.0256 Kilogram/cu.m — (kg/m3) Pound/Feet (1b./ft) 1.4881 Kilogram/meter (kg/m) Pounds/[Link] (psi) 51.7063 Millimeter Hg (mm Hg) Inches of Hg (in. Hg) 25.40 Millimeter Hg (mm Hg) Feet of Water (ft.H20) 2.24215 Centimeter Hg ([Link]) Pounds/[Link] (psi) 5.17063 Centimeter Hg ([Link]) Inches of Hg (in. Hg) 0.3453, Meters Water (M.H20) Feet of Water (ft.H20) 0.3048 Meters Water — (M.H20) Pounds/[Link] (psi) 0.7032 Meters Water — (M.H20) Pounds/Sq: In (psi) 0.7032/sp gr _— Meters (Any Liguia) Pounds/Sq. In (psi) 6.89655 Kilo Pascal (kPa) Inches of Hg (in. Hg) 0.09342 Atmospheres (atm) Pounds/[Link] (psi) 0.06804 Atmospheres (atm) Inches of Hg (in. Hg) 0.03386 Bar Pounds/[Link] (psi) 0.06896 Bar AJAX-SUPERIOR CONV 2/1-89SUPERIOR GAS AND DUAL FUEL ENGINES PAGE 3 CONVERSION DATA Hl TO CONVERT | MULTIPLY BY Hl TO OBTAIN I 1 TO OBTAIN I DIVIDE BY ' TO CONVERT I VOLUME - FLOW RATES Gallons/min (gpm) 0.06309 Liters/sec Gallons/min (gpm) 3.7850 Liters/min [Link]/min (cfm) 28.32 Liters/min Gallons/min (gpm) 227.273 Liters/hour [Link]/min (cfm) 0.02832 [Link]/min (cu.m/min) Gallons/min (gpm) 0.003785 [Link]/min (cu.m/min) [Link]/min (cfm) 1.6998 [Link]/hour (cu.m/hr) Gallons/min (gpm) 0.22713 [Link]/hour (cu.m/hr) UNITS OF POWER Foot-Pounds/sec 1.356 Watts Horsepower (hp) 745.7 Watts Btu/min 17.57 Watts Foot -Pounds/sec 0.001356 Kilowatt (kW) Horsepower (hp) 0.7457 Kilowatt (kW) Btu/min 0.01787 Kilowatt (kW) Horsepower (hp) 1.014 Metric Horsepower ([Link]) Horsepower (hp) 10.70 kg-calories/min Btu/min 0.2530 kg-calories/min UNITS OF VELOCITY Feet/Sec (ft/sec) 0.3048 Meter/Sec (m/sec) Feet/Min (FPM) 0.00508 Meter/Sec (m/sec) Feet/Min — (FPM) 0.0183 Kilometer /Hour (km/hr) Miles/Hour (mph) 1.6093 Kilometer/Hour (km/hr)SUPERIOR GAS AND DUAL FUEL ENGINES PAGE 4 CONVERSION DATA I! TO CONVERT | MULTIPLY BY =| TO OBTAIN i TO OBTAIN 1 DIVIDE BY I TO CONVERT UNITS OF WORK, ENERGY & HEAT Foot Pounds (ft 1b) 0.9241 Gram-Calories (gr-cal) Btu 253.0 Gram-Calories (gr-cal) Btu/sq. ft 0.2712 Gram-Calories/[Link] Foot Pounds (ft 1b) 0.0003241 Kg-Calories (kg-cal) Btu 0.2530 Kg-Galories (kg-cal) Horsepower-Hour (hp-hr) 641.7 Kg-Calories (kg-cal} Btu/1b 0.5556 Kg-Calories/kg Btu/[Link] 8.899 Kg-Calories/cu.m Horsepower (hp) 10.70 Kg-Calories/Min Foot Pounds/sec 0.01945 Kg-Calories/Min Foot Pounds (ft 1b) 0.0003766 = Wat t-Hours Btu 0.000228 = Kilowatt-Hours Foot Pounds/sec 0.001386 Kilowatts Foot Pounds = (ft _1b) 0.1383, Kilogram Meter (kg-M) Foot Pounds (ft 1b} 1.356 Joules Btu 1054 Joules UNITS OF DENSITY Pound/[Link] (1b/in3) 27.68 Grams/[Link] — (g/cm3) Pound/[Link] — (1b/ft3) 16.0184 Kilogram/cu.m (kg/m3) UNITS OF FORCE Pound Force (1b f) 0.4535 Kilogram Force (kg f) Pound Force (ab £) 0.00445 Kilonewtons (kN) UNITS OF TORQUE Pound-feet (1b-£t) 0.1383 Meter-Kilogram (m kg) Pound-feet (1b-ft) 1.35875 Newton Meter (NM) | coons| AVAX-SUPERIOR CONV 4/1-89SUPERIOR GAS AND DUAL FUEL ENGINES PAGE 5 CONVERSION DATA 1 TO CONVERT | MULTIPLY BY =| TO OBTAIN I I TO OBTAIN I DIVIDE BY 1 TO CONVERT 1 HEAT FLOW RATE Btu/hr 0.29283 Watts (wy Btu/min 0.01757 Kilowatt (kW) Btu/hr 0.07003 Calories/sec (cal/sec) Btu/hr 0.2520 KiloCalorie/Hr(kcal/hr) USEFUL EQUIVALENTS 1 US Gallon = 0.833 Imperial Gallon 1 US Gallon of Water 8.33 lbs. @ 60 deg F 1 Cubic Feet of Water 62.34 lbs. @ 60 deg F 1 Cubic Feet of Water 7.48 US Gallons 1 Cubic Meter per Hour 4.40 gpm 1 Cubic Feet of Air 0.076 Ib. (STP) Pound of Air 19.15 [Link]. (STP) 1 Barrel of Oil 42 US Gallons British Thermal Unit 778 Foot~Pounds(ft 1b) Horsepower = 550 ft 1b/sec Horsepower 33,000 ft 1b/min Horsepower 145.7 watts Horsepower 2,844.48 Btu/hr Horsepower 5 1.014 metric hp Average Unit Heat Value of Fuels (LHV): Gasoline 18,900 BTU/1b. Diesel 18,400 BTU/1b. Propane Liquid 19,900 BTU/1b. Propane Gas = 2,300 BTU/[Link]. Natural Gas 1,000 BTU/[Link]. Sewage/Digester Gas 600 BTU/[Link]. Landfill Gas = 450 BTU/[Link]. AJAX-SUPERIOR CONV 5/1-89SUPERIOR GAS AND DUAL FUEL ENGINES PAGE 7 CONVERSION DATA FORMULAE ° ° ° ° TEMPERATURE c = 5/9( F - 32) F = (9/5 x C) + 32 ° ° R= ( F + 459.69) K = (C+ 273.16 B.M.E.P, x DISPLACEMENT x R.P.M POWER BHP. = (Four cycle) 792,000 BMEP is in psi Total Displacement is in [Link] BHP. xc e D x Lx RPM. BMEP is in psi BHP is Brake Horsepower per cylinder D is Diameter of cylinder bore in inches L is Length of stroke in inches © is constant ( = 1,010,000) B.H.P. x 5252 TORQUE = R.P.M Torque is in Pound-feet R.P.M. x Stroke in Inches PISTON SPEED FEET PER MIN. = - 6 Grams of Fuel Burned per Hour FUEL CONSUMPTION BS.F.C. = Brake Horsepower e 1 g/Hp-hr = 1.341 g/kW-hr Seen) AJAX-SUPERIOR ~CONY2/1-89 _ (es)SUPERIOR GAS AND DUAL FUEL ENGINES PAGE 8 CONVERSION DATA FORMULAE Head in PSI x 2.31 PRESSURE HEAD, IN FEET - = Specific Gravity GPM x 0,321 PIPE VELOCITY, V(Ft/Sec) = Area([Link].) Lbs. /Hour CAPACITY, GPM = ~ - 500 x [Link]. FREQUENCY in HZ x 120 SYNCHRONOUS SPEED, REM = ~ - NO. OF POLES Kw POWER FACTOR AND KVA, PF = .RVA = KVA MECHANICAL KILOWATT,, kW = 0.7457 x Horsepower ELECTRICAL KILOWATT, KW = 0.7457 x Horsepower x Eff. (Eff. 4s Generator Efficiency $252 x Full-load Horsepower MOTOR FULL-LOAD TORQUE =- Speed in RPM AJAX-SUPERIOR CONV 8/SUPERIOR CLEANBURN II GAS ENGINES MODEL 66TLB - ENGINE SECTION INDEX Description Page Air Intake System Bearing Dimensions Cooling system Dimensions and Weight Engine Operating Data -Units In English Units ~Units In Metric Units Engine Outline Drawing Engine Performance Engine Specifications Exhaust Emissions Exhaust System Fuel system Heat Rejection Data -Units In English Units ~Units In Metric Units Lubrication system Miscellaneous Starting System Turbocharger Unbalanced Forces and Couples “Units In English Units ~Units In Metric Units Water Pump Characteristics -Jacket Water, Straight Vane -Jacket Water, Curved Vane Intercooler,’ Straight vane -Intercooler, Curved Vane AJAX-SUPERIOR No. 104 107 105 107 122 332 119 103 101 113 104 104 aaa 112 106 108 103 104 109 110 215 116 N/A N/ASUPERIOR CLEANBURN II GAS ENGINES MODEL 6GTLB ENGINE SPECIFICATIONS Type Aspiration Cylinder Configuration Number of Cylinders Bore = in. (mm) Stroke - in. (mm) Displacement - [Link]. (liter) Compression Ratio Power Rated - BHP (kW) Speed Rated - RPM Piston Speed - FPM(m/s) Speed Range - RPM Ignition System Fuel system Governor Turbocharger Exhaust Manifold Jacket Water Pump Jacket Water Thermostat Lube 01] Pump Lube Oi] Thermostat Prelube Pump Lube Oil Cooler Intercooler Intercooler Water Thermostat Crankcase Breather Crankcase Doors Direction of Rotation PAGE 101 Four(4)-Cycle Turbocharged, Intercooled Inline Six (6 10 (254) 10.50 (266.7) 4948 (81.10) 8.20: 2 825 (615) 900 1875 (8.0) 900 - 600 Non-Shielded, Altronic III Fuel Injected with Electronic Air-Fuel Control and Manual Starting Logic Hydraulic (UG-8L) With Manual Speed Setting one(1) Dry Type, Insulation Blanketed Built-In Centrifugal, Belt Driven Remote Mounted Gear Type with Pressure Regulating Valve Engine Mounted Manual, Mounted and Piped Shell & Tube Type,Mounted and Piped Rectangular, Shell & Tube/Fin Type Remote Mounted Positive Ventilation Pressure Relief(Bicera Type) Doors Counterclockwise From Flywheel End aren. SSC ‘Superior? and CleanBurn™ are trademarks of Cooper Industies, Ine. Copyright © Cooper ndustrias, inc. 1988 CB 101/1-89SUPERIOR CLEANBURN II GAS ENGINES PAGE 103 MODEL 6GTLB PERFORMANCE Engine Operating Data See Page 111 & 112 Rating Conditions “Altitude feet 4000 meter (1219 ) ~Temperature Deg F 100 Deg ¢ (37.8 ) Rated Torque Over 900-600 RPM Range lb-ft 4a14 M-kg (666 ) Brake Mean Effective Pressure Rating/BMEP psi 146.7 keg/om2 (10-3 ) Rated Brake Specific Fuel Consumption/BSFC Btu/bhp-hr _—7150 (Plus or Minus 3 Percent Factory Tolerance) Kkeal/kW-hr ( 2416 ) Heat Rejection Data See Page 111 & 112 Emissions See Page 113 @ startius sxszex Air/Gas Starting Motor Make & Model IR / $8-825 Number of Starting Motors one(1) Supply Air/Gas Pressure psi 150 kg/om2 (10.5 ) Consumption Rate/Starter Motor -Air scfm 1400 liter/sec (661 ) -Gas scfm 1663 liter/sec ( 785 ) ~ Normal Starting Time sec 15 Connection Sizes -Inlet 3-1/2 In. NPT Outlet 2-1/2 In. NPT -Optional: Inlet Flange 1-1/2 In. Square Outlet Flange 2-1/2 In. 180 Lb. {sny| AJAX SUPERIOR APPR SINNG - cB 103/1-89 ‘Superior® and CleanBurn™ are vademarks of Cooper Industries, Inc. Copyright © Cooper ngusties, inc. 1989SUPERIOR CLEANBURN II GAS ENGINES PAGE 104 MODEL 6GTLB AIR INTAKE SYSTEM Intake Air Flow Rate See Page 111 & 112 Max. Allowable Pressure Drop In #20 10 mn H20 (254) Air Intake, Inlet Flange Connection 12 In, 150 Lb. FUEL SYSTEM Required Fuel Gas Pressure to Engine psi 35-40 Based on Pipeline Quality Natural Gas kg/om2 (2.5-2.8 ) (Regulated to within plus or minus 1 psig) Gas Inlet Flange Connection 2 In. 150 Lb. EXHAUST SYSTEM Max. Allowable Back Pressure In H20 10 mm H20 (254) Exhaust Outlet Flange Connection Size 14 In, 150 Lb, FF Exhaust Flow Rate See Page 111 & 112 Stack Temperature See Page 111 & 112 TURBOCHARGER ‘type Constant Pressure Manufacturer [Link], Model NR 20 Speed (Maximum) RPM 45000 AJAX-SUPERIOR APPR. Cun cB 104/1-89 ‘Superior? and CloanBurn"™ ate trademarks of Cooper Industries, ne Copyright © Cooper industries, Ine. 1989SUPERIOR CLEANBURN II GAS ENGINES PAGE 105 MODEL 6GTLB e COOLING SYSTEM Jacket Water Capacity - Engine Only Gallon 50 liter (189 ) Jacket Water Pump Jacket Water Outlet Temperature, Normal Deg F 165-180 Deg (74-82 ) -Design Flow Rate at Rated Speed Gem 275 liter/sec (17.3 ) -Available External Head: Straight Vane(Standard) psi 31 kg/em2 (2.38 ) Curved Vane(Optional) psi 36.2 kg/em2 (2.55 ) -Minimum NPSH Required: Straight Vane(Standard) feet 14 meter (4.27 ) Curved Vane(optional) feet 8.5 neter (2.88 ) Intercooler system @ —-insercooter water niet Temperature, Normal deg F 120 Deg ¢ (49.0) Design Flow Rate GPM 100 liter/sec (6.31 ) Pressure Drop (Includes Lube 011 Cooler, psi 11.5 Intercooler and Thermostat) kg/cm2 (0.81 ) Connection Sizes ~Jacket Water Inlet 4 In. 150 Lb. “Jacket Water Outlet 4 In. 150 Lb. “Intercooler water Inlet 3 In. Pipe “Intercooler Water Outlet 3 In. Pipe “vent Line to Surge Tank,Minimun Size 3/8 in. Tubing “surge Tank Return to Pump Inlet 1-1/2 In. NPT suna| AJAX-SUPERIOR appr. G3MC- £8 105/1-89 (ees) Superior® and CleanBumn™ are vademarks of Cooper Industries, Inc. Copyright © Cooper Industes, Inc. 1989.SUPERIOR CLEANBURN II GAS ENGINES PAGE 106 MODEL 6GTLB LUBRICATION SYSTEM Lube O11 Sump Capacity Gallon 65 liter (246 ) Lube Oil Consumption(Estimated) Gal./Day 1.65 liter/Day (6.25 ) Lube Oil Pressure - Normal psi 35 kg/cm2 (2.46) Temperature Out Of Engine - Normal Deg F 170-180 Deg ¢ ( 76-82 ) Flow Rate Through Oi] Filt GPM 35 liter/sec (2.21 ) Lube 0i] Filters, Remote Mounted(Standard) -Type Full Flow ~Microns of Filtration Fifteen(15) Connection Sizes Lube Oi] Sump Drain Plug 3-1/2 In, NPT -Lube 0i1 Inlet to Engine 2-1/2 In. 125 Lb. -Lube 011 Outlet to Filter 2 In. 125 Lb. AJAX-SUPERIOR APPR ENG CB 106/1-89 ‘Superior? and CleanBurn™ are trademarks of Cooper Industries, Ine. Copyright © Cooper industries, nc. 1989SUPERIOR CLEANBURN II GAS ENGINES PAGE 107 MODEL 6GTLB © eee eee Main Bearing, Split Shell -Dianeter in 6.00 aa (as204 ~wiath In 3.50 mm ( 88.9 ) -quantity Nos. 7 Crankpin Bearing, Split Shell Diameter In 5.75 an (146.0 ) “Width In 3.63 an (92.2) -Quantity Nos. 6 Wrist Pin Bearing -Diameter In 3.50 mn (88.9 ) “Width In 3.16 am ( 80.3 ) e -Quantity Nos. 6 Camshaft Bearing, Split Shell -Diameter In 2.25 mn (87.2) “Width In 1.63 mn (41.4) Quantity Nos. 8 DIMENSIONS AND WEIGHT (APPROXIMATE) Overall Length In 146 mm ( 3708 ) Overall width In 16 am (1930 ) Overall Height In 8B mm { 2235 ) Dry Weight -b 20000 kg ( 9072 ) coonn| AVAX-SUPERIOR APPR NCL £8 107/1-89_ Suporior® and CieanBurn™ are jernarks of Cooper Industries, nc Copyright © Cooper inaustis, Ine. 1960SUPERIOR CLEANBURN II GAS ENGINES PAGE 108 MODEL 6GTLB MISCELLANEOUS Clearance Required to Remove Piston In 81.75 mn ( 2076 ) Heaviest Engine Parts (Approximate Weights) -Cylinder Block Assembly Lb 3500 kg (1588 ) -Cylinder Head Assembly Lb 250 kg (113) ~Piston and Connecting Rod Assembly Lb 192 kg (87) -Turbocharger Assembly Lb 254 kg ¢ 5) -Exhaust Manifold Lb 325 kg (147) AJAX-SUPERIOR APPR G 5 XC ce 108/; ‘Superior? and CleanBurn"™ are rademarks of Cooper Industrie, Ine Copyright © Cooper industries, Inc. 1989SUPERIOR CLEANBURN II GAS ENGINES PAGE 109 MODEL 6GTLB MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN ENGLISH UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values PRIMARY FORCE ~ Lb. SECONDARY FORCE - Lb. \ mn \ ENGINE | i I RPM | VERTICAL HORIZONTAL || | VERTICAL HORIZONTAL | 1 tl ! e i " I 900} 576.743 335.115 || 60.407 ° 1 goo | 455.698 264.115 || 41.729 ° | too | 348.894 202.724 || 36.542 o | soo | 256.330 148.940 || 26.847 ° I 1 ul I SECONDARY COUPLE - Lb. Ft. ENGINE RPM VERTICAL HORIZONTAL 1 | 1 goo | 1181.979 723.894 114,522 ° goo | 933.910 571.965 90.486 ° 700) || 715.025 437.911 69.279 ° 600 ( 525.324 321.731 50.899 ° | (| Asax-SUPERIOR APPR. BNC Z cB 109/1-89 ‘Superior? and CleanBur™ are wademarks of Cooper Industries, nc. Copyright © Cooper IndustSUPERIOR CLEANBURN II GAS ENGINES PAGE 110 MODEL 6GTLB MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN METRIC UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted, that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. PRIMARY FORCE - kg SECONDARY FORCE - kg 1 a t ENGINE | 1 I RPM | ~—sVERTICAL = HORIZONTAL || = VERTICAL = —- HORIZONTAL | | Mt ! 1 1 ! 900 I 261.611 182,008 || 27.401 ° 1 goo | 206.705 119,803 || 21.650 ° I! 700 I 158.258 91.956 || 16.575 ° 1 600 1 116.271 67.859 || 12.178 ° { I | PRIMARY COUPLE - [Link] SECONDARY COUPLE - [Link] \ u ENGINE | i 1 RPM | —-* VERTICAL © HORIZONTAL || VERTICAL == HORIZONTAL | HW | | i soo | 163.468 300.115 || 15.838 ° goo | 129.160 79.103 || 12.514 ° 700 | 98.888 60.563 || 9.581 ° 600 | 72.652 44.498 || 7.039 ° I 1 | AJAX-SUPERIOR APPR. GC Z CB 110/1-89 ‘Superior? and CieanBurn™ are trademarks of Coopbr Industries, Ine. Copyright © Cooper industes, nc. 1989SUPERIOR CLEANBURN IT GAS ENGINES MODEL 6G6TLB PAGE 111 ENGINE OPERATING ATA AND HEAT REJECTION SUPERIOR 6G6TLB - CleanBurn™ II [PERCENT] pep ENGINE SPEED — RPM RATED A = T tonp_| sn {900 | 750 | 720 | 600 110 Ter 308 757 726 605 100 146.7 825 688 660 550 1s 110.0 619 516 495 ats 50 733 AIS 344 330 275 110 vera | — | — — | — 100 146.7 | 7150 | 7050 | 7090 | 7400 Eee ears 1100 | 7660 } 7650 | 7700 | 8030 50 733 | 8450 | 8¢00_| 8730 | 9500 110 1614 | 2104 | i719 | 1660 | 1455 100 146.7 | 1885 | 1594 | 1550 | 1359 75 1100 | 1400 | 1224 | 1190 | 1038 50 733 966 B65 845 763, 110 Tei | 166 135) 131 114, 100 146.7 | 149 125 121 107 15 woo | int 9% 93 82 50 733 76 68. 56 60 710) v1.4 | 1050 | 1040 | 1085 | 1020 100 146.7 | 1080 | 1060 | 1055 | 1050 75 woo | 1140 | 1120 | 1120 | 1120 50 733 | 11s0_| 160 | 115s | 1150 [110 161.4 | 12900 | 10700 | 10440 | 9400 | 100 146.7 | 12500 | 10100 | 9820 | 8700 15 1100 | 11900 | 9400 | 8960 | 7200 50 733 | 10300 _| e100 _| 7520 | 5200 110 ve14 | 4200 | 3200 | 3060 | 2500 100 146.7 | 4000 | 3000 | 2880 | 2400 75 110.0 | 3600 | 2700 | 2620 | 2300 50 733 | 3300 | 2500 | 2400 | 2000 110 1614 [~saoo | 4000 | 3770 | 2850 100 1467 | 4350 | 3200 | 3010 | 2250 75 1100 | 1950 | 1590 | 1470 990 50 733 | 500 550 540 500 AJAX-SUPERIOR pore SSN\CL Copyright © Cooper Industries, ine. 1989, 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTNENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 23% TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL I8OF JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-22/9-88 FOR HEAT REJECTION ADJUST! HOT WATER SYSTEMS OR EBULLIENT COOLING, HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE. ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS, SUBTRACT 10x RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. 3D INTERCOOLER HEAT RECTION BASED ON NOMINAL 4000 FT, ALTITUDE. 4) LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING 120F MAX. TO INTERCOOLER FOR RATED ENGINE PERFORMANCE. T FACTORS DUE TO cB Nii 1-89 Superior® and CleanBurn™ are racemarks of Cooper Industries, Ine.Se Nee eae ee een MODEL 6GTLB oes ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR >LB - CleanBurr™ IL PERCENT] auep ENGINE SPEED ~ RPM RATED LOAD. kkg/em2>|_ 900 750 720 600 BRAKE SPECIFIC 10 11.35 677 564 541 451 OUTPUT 100 10,32 615 513 492 410 ow) 715 714 462 335 OF 308 50 515. 308 25 Ab 05. 110 ee — CIFIC 11.35 FE CONSAETION 100 tos2 | 2416 | 2383 2396 2501 col HD iB 714 | 2589 2585 2602 2714 50 515 2856 2906 2950 S211 INTAKE AIR FLOW M0 11.35 cry 59 57 50 REQUIREMENT 100 1032 65 55 53 4 g/MIND 7s 714 48 42 at % 50 S15 3 30 29 26 110 7s 61 59 52 EXHAUST FLOW 1135 ar : 100 1032 68 57 55. 49 75 V4 50 44 42 a 50 1 34 3 30. 27 iS 11.35 366 | 560 357 349) Meter TEs 100 10332 582 $71 568 566 a2) 15 14 616 604 604 604 50 sis | 638 | 627 624 621 Jac 110 11.35, 3251 2697 2631 2369 HEAT HEECTION poo) 1032 | 3150 2545 2475 2193 (kcol/MIN) 75 114 2999 2369 2258 1815 50 15. 2596 2041 1895, 1310 ‘LUBE OIL. 110 11,35, 1058 806 7m 630 HEAT REJECTION 100 10.32 1008. 756 726 605 Geol IND 78 174 907 680 660 580 SO. 15. 832 630 605, 504 INTERCOOLER 10 11.35 | 1462 1008 950 m8 HEAT RESECTION 100 1032 | 1096 806 159 567 Gca/MIN S 774 491 401 370 249 50. 15. 126 139 136 126 NOTES = 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE [Link] FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 43£ TOLERANCE FOR FACTORY TESTS, 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 82°C JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-24/1-89 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE 10 HOT WATER SYSTEMS OF EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND ‘AMBIENT TEMPERATURE, ADO RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10x RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. 3D INTERCOOLER HEAT REJECTION BASED ON NOMINAL 1200 M ALTITUDE, ) LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING SOC MAX. TO INTERCOOLER FOR RATED ENGINE. PERF ORMANCE. “ou| AJAX-SUPERIOR aren, SON 8 112/1-89 ‘Superior? and GieanBurn™ are trademarks of Cooper Industles, Inc. Gopyright © Cooper indus, nc. 1989SUPERIOR CLEANBURN II GAS ENGINES MODEL 6GTLB PAGE 113. EXHAUST EMISSIONS MODEL : 6GTLB RPM eared BHPKKW) FEMISSIONS CRANE 900 100 825(615) 2.0 35 075 900 75 619(462) Ag 39 075 900 50 413308) 47 40 075 750 100 688(51D 2.0 3.0 075 750 75 516(385) 18 33 075 750 50. 344(257) 1.0 35 075 600 400 550(410) 4.0 34 075 eo | 75 | aiscom | 20 38 075 goo | 50 | 275205) | 10 43 075 (-] ® TONS PER YEAR = (GM/BHP-HR) x BHP + 103.6 #* DENOTES NON-METHANE HYDROCARBONS QUALIFYING CONDITIONS 1) PIPELINE QUALITY GAS IS ASSUMED. METHANE CONTENT SHOULD BE GREATER THAN 90x WITH A LOW HEATING VALUE OF 900 BTU/SCF = 154, FOR FUEL GAS OUTSIDE THESE PARAMETERS AN INDIVIDUAL REVIEW WILL BE REQUIRED TO DETERMINE EMISSION LEVELS AND FUEL CONSUMPTION RATES. 2) VALUES ARE BASED UPON 130" F MANIFOLD TEMPERATURE, <120" F INTERCOOLER WATER AND 100° F AMBIENT TEMPERATURE. REDUCED AIR MANIFOLD TEMPERATURES WILL RESULT IN LOWER NOx LEVELS. HIGHER AMBIENT. TEMPERATURES WILL NOT AFFECT EMISSION LEVELS AT RATED LOAD AND SPEED BUT WILL CAUSE SLIGHTLY HIGHER NOx LEVELS AT REDUCED SPEEDS. 3D DATA SHOWN ARE BASED ON ENGINE ADJUSTMENT FOR STANDARD BSFC. FULL SPEED EMISSION VALUES ARE VALID FOR ALTITUDES BELOW 4000 FT. HIGH ALTITUDE APPLICATIONS MAY REQUIRE TURBOCHARGER MODIFICATION. TO MAINTAIN EMISSION RATES, 4) WHEN NOx REQUIREMENTS LESS THAN THOSE EXPRESSED HERE ARE ENCOUNTERED, THERE ARE TRADE-OFFS BETWEEN NOx AND BSFC WHICH MAY BE APPLICABLE, BUT THESE MUST BE EVALUATED ON A SPECIFIC CASE BASIS. sore) AJAX-SUPERIOR sive. ca_3/1-89 ‘Superior? and CleanBur™ are wademarks of Cooper Industries, Ine. Copyright © Cooper industves, inc. 1989SUPERIOR CLEANBURN II GAS ENGINE MODEL 6GTLB PAGE 115 e WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS ° ENGINE RPM 7 i 900 a 20) ta Ae a 750 st ~ 60 |=] ana 600 © 40 2 30 20 = [ENGINE PRESSURE 10 = DROP, ° = e 0 100 200 300 400 500 FLOW (GPM) IMPELLER P/N D-016-879 (STRAIGHT VANE) PUMP RPM = 2.4 X ENGINE RPM DIRECTION OF ROTATION (BI-DIRECTIONAL CAPABILITY) NORMALLY CW (FACING DRIVE END) NPSHp = 14.0 FEET @ 900 RPM & 275 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 275 GPM = 111.0 FT- 39.4 FT. © 71.6 FT. SFT, + 2.31 = 31.0 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. {sew| MIAX SUPERIOR APPR, C SWC CB_115/1-89. Superior* and CleanBur"™ are waderarks of Cooper Industries, Inc. Copyright © Cooper industries, Inc. 1989SUPERIOR CLEANBURN II GAS ENGINE MODEL 66TLB PAGE 116 WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS 140 —EWGINE RPM 130 200 r io a prsich— ciel ered i Fa = @ 70 \ 30 20 ~~ 10 = LENGINE PRESSURE ° =—E= DROP, 3 100 200 300 400 500 FLOW (GPM) IMPELLER P/N D-OS3-655 (CURVED VANE) PUMP RPM = 2.4 X ENGINE RPM DIRECTION OF ROTATION (UNI-DIRECTIONAL) CW (FACING DRIVE END) NPSHg = 8.5 FEET @ 900 RPM & 275 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE, FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 275 GPM = 1230 FT.- 39.4 FT. = 836 FT. 836 FT. + 251 = 36.2 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. ‘APPR. ( 3h cB 116/1: Superior® and Cleanur™ are vademarks of Cooper Industries, Ine Copyright © Cooper industries, Ic. 189— AJAX-SUPERIOR TEEN 7 [oan oT CORTE Tee TT aE [a inc conte on Fos 10" 310-Pe “[AERET WATERS 1108 or 1 TUNE Dr ACK maith osc Ise TUNE Eo ase RATER WERT ir ser F iy SE Ta iW @ thewaree tT Fungo SPRL iter oi trae c: ee Oi se FRC E OST Ew Teas Tet Fie FTE Be [stamting woToR Watt Ve ner [STARTING MOTOR OXHAUET Byaner (| wAteR OOTY 10 ConPRe STOR Te WT | WaTtAC nT Flow CoNPar SSO Te WL Tove Fo FILTERS BieieseTE S| tse lc our to FuLeas Fes FFL “fevenss To Lo, rien. Fier U [wate R OUTLET To MERTEN] LA NEESTAUPE w [WATER THLET FROW RVERCOOLER [FLANGE SUPE NOTE:COW. May VARY WIth EACH UNIT rer Le = COL BRC ELECT EET BuPERTOR Sa = a) SUPERIOR _ SUPERTOR CLEANFII P= ONE DRA MODEL 6GTLB fee — Perea wrtuour ou. eruress, —le—{ectLs PAGE 119ACleanBurn'll Gas Engine “ Model 6GTLBSUPERIOR CLEANBURN II GAS ENGINES MODEL 8GTLB ENGINE SECTION INDEX Description Page No. Air Intake System 204 Bearing Dimensions 207 Cooling System 205 Dimensions and Weight 207 Engine Operating Data -Units In English Units 211 -Units In Metric Units 212 Engine Outline Drawing 219 Engine Performance 203 e Engine Specifications 201 Exhaust Emissions 213 Exhaust System 204 Fuel system 204 Heat Rejection Data -Units In English Units 211 -Units In Metric Units 212 Lubrication system 206 Miscellaneous 208 Starting System 203 Turbocharger 204 Unbalanced Forces and Couples Units In English Units 209 -Units In Metric Units 210 Water Pump Characteristics -Jacket Water, Straight Vane 215 -Jacket Water, Curved Vane 216 -Intercooler, | Straight Vane N/A -Intercooler, Curved Vane N/A | avax-SuPERIORSUPERIOR CLEANBURN II GAS ENGINES MODEL 8GTLB ENGINE SPECIFICATIONS Type Aspiration Cylinder Configuration Number of Cylinders Bore = in, (mm) Stroke - in. (mm) Displacement ~ [Link]. (liter) Compression Ratio Power Rated - BHP (kW) Speed Rated - RPM Piston Speed - FPM(m/s) Speed Range - RPM Ignition System Fuel system Governor Turbocharger Exhaust Manifold Jacket Water Pump Jacket Water Thermostat Lube 0i1 Pump Lube 011 Thermostat Prelube Pump Lube Oi] Cooler Intercooler Intercooler Water Thermostat Crankcase Breather Crankcase Doors Direction of Rotation AJAX-SUPERIOR PAGE 201 Four (4)-Cycle Turbocharged, Intercooled Inline Eight (8) 10 (254) 10.50 (266.7) 6597 (108.13) 8.20: 1 1100 (820) 900 1575 (8.0) 900 - 600 Non-Shielded, Altronic III Fuel Injected with Electronic Air-Fuel Control and Manual Starting Logic Hydraulic (UG-8L) With Manual Speed Setting One(1) Dry Type, Insulation Blanketed Built-In Centrifugal, Belt Driven Remote Mounted Gear Type with Pressure Regulating Valve Engine Mounted Manual, Mounted and Piped Shell & Tube Type,Mounted and Piped Rectangular, Shell & Tube/Fin Type Remote Mounted Positive Ventilation Pressure Relief(Bicera Type) Doors Counterclockwise From Flywheel End APPR Bc, or® and CleanBurn™ are trademarks of Cooper industies, Ine Copyright © Cooper industries, Inc. 1989 cB 201/1-89SUPERIOR CLEANBURN II GAS ENGINES PAGE 203 MODEL 8GTLB PERFORMANCE Engine Operating Data See Page 211 & 212 Rating Conditions ~Altitude feet 4000 meter (1219 ) -Temperature Deg F 100 Deg (37.8 ) Rated Torque Over 900-600 RPM Range b-ft 6420 M-kg (| B88 ) Brake Mean Effective Pressure Rating/BMEP psi 146.7 kg/em2 (10.3) Rated Brake Specific Fuel Consumption/BSFC Btu/bhp-hr 7100 (Plus or Minus 3 Percent Factory Tolerance) keal/kW-hr ( 2399 ) Heat Rejection Data See Page 211 & 212 Emissions See Page 213 STARTING SYSTEM Air/Gas Starting Motor Make & Model IR / SS-825 Number of Starting Motors one(1) Supply Air/Gas Pressure psi 150 Kg/em2 (10.5 ) Consumption Rate/Starter Motor -Air scfm 1400 liter/sec ( 661 ) ~Gas scfm 1663 liter/sec ( 785 ) - Normal Starting Time sec 15 Connection Sizes ~Inlet 1-1/2 In. NPT ~Outlet 2-1/2 In. NPT -Optional: Inlet Flange 1-1/2 In. Square outlet Flange 2-1/2 In. 150 Lb. {cp| AYAX-SUPERIOR a Mc CB 203/1-89 Superior? and CloanBurn"™ are trademarks of Cooper Industrie, Inc. Copyright © Cooper industries, Ine. 1989SUPERIOR CLEANBURN II GAS ENGINES PAGE 204 MODEL 8GTLB AIR INTAKE SYSTEM Intake Air Flow Rate See Page 211 & 212 Max. Allowable Pressure Drop In #20 10 mm H20 (254) Air Intake, Inlet Connection 12 In. I.D. Flex Connector FUEL SYSTEM Required Fuel Gas Pressure to Engine psi 35-40 Based on Pipeline Quality Natural Gas kg/em2 (2.52.8 ) (Regulated to within plus or minus 1 psig) Gas Inlet Flange Connection 2 In. 150 Lb. EXHAUST SYSTEM Max. Allowable Back Pressure In H20 10 mn H20 (254 Exhaust Outlet Flange Connection Size 14 In. 150 Lb. FF Exhaust Flow Rate See Page 211 & 212 Stack Temperature See Page 211 & 212 TURBOCHARGER Type Constant Pressure Manufacturer MOAN, Model NR 20R Speed (Maximum) REM 40000 [cep] AUAX-SUPERIOR APPR. q SINAC Z CB 204/1-89 ‘Superior? and CleanBurn™ are ademarks of Cooper Industies, nc. Copyright © Cooper industries, nc, 1989SUPERIOR CLEANBURN II GAS ENGINES MODEL 8GTLB COOLING SYSTEM Jacket Water Capacity - Engine Only Jacket Water Pump -Jacket Water Outlet Temperature, Normal -Design Flow Rate at Rated Speed Available External Head Straight Vane(Standard) Curved Vane(opt ional) -Minimum NPSH Required: Straight Vane(Standard) Curved Vane (optional) Intercooler System -Intercooler Water Inlet Temperature, Normal -Design Flow Rate -Pressure Drop (Includes Lube 0i1 Cooler, Intercooler and Thermostat) Connection Sizes -Jacket Water Inlet Jacket Water outlet Intercooler Water Inlet -Intercooler Water Outlet -Vent Line to Surge Tank,Minimum Size -Surge Tank Return to Pump Inlet AJAX-SUPERIOR APPR Gg 3N\C cB 205/: PAGE 205 Gallon 86 liter (212) Deg F 170-180 Deg ( 76-82 ) GPM 340 liter/sec (21.4 ) psi 35 keg/om2 (2.46 ) psi 39.6 keg/em2 ( 2.78 ) feet 15.5 meter (4.72) feet 9 meter (2.74) Deg F 120 Deg c (49.0) GPM 130 liter/sec ( 8.2) psi 11.5 kg/cm? (0.81 ) 4 In. 150 Lb. 4 In. 150 Lb. 3 In. Pipe 3 In. Pipe 3/8 In. Tubing 1-1/2 In. NPT 9 Superior and Cleanfun™ are trademarks of Cooper Industies, ne. Copyright © Cooper Industis, Inc, 1969SUPERIOR CLEANBURN II GAS ENGINES PAGE 206 MODEL 8GTLB LUBRICATION SYSTEM Lube 0i1 Sump Capacity Gallon 80 liter (303 ) Lube 0i1 Consumption(Estimated) Gal./Day 2.50 liter/Day (9.46 ) Lube Oil Pressure - Normal psi 35 kg/om2 (2.46 ) Temperature Out Of Engine - Normal Deg F 170-180 Deg © ( 76-82 ) Flow Rate Through 0i1 Filter GPM 60 liter/sec (3.78 ) Lube Oil Filters, Remote Mounted(Standard) ~Type Full Flow -Microns of Filtration Fifteen(15) Connection Sizes -Lube 0i1 Sump Drain Plog 1-1/2 In. NPT “Lube 01 Inlet to Engine 2-1/2 In, 128 Lb. -Lube Oil Outlet to Filter 2 In. 125 Lb. ,| AJAX-SUPERIOR aver, ONC CB 206/1-89 Superioe® and CleanBiin™ are trademarks of Cooper Industrie, Ine. Copyright © Cooper naustes, ne. 1989SUPERIOR CLEANBURN II GAS ENGINES PAGE 207 MODEL 8GTLB Main Bearing, Split Shell Diameter In 6.00 an (152.4) “Width In 3.50 am ( 88.9 ) ~Quantity Nos. 9 Crankpin Bearing, Split Shell -Diameter In 5.75 mn (146.0 ) “Width In 3.63 mn (92.2) -Quantity Nos. 8 Wrist Pin Bearing -Diameter In 3.50 mm ( 88.9 ) -Width In 3.16 mm (80.3 ) e -Quantity Nos. 8 Camshaft Bearing, Split Shell -Dianeter In 2.25 an (57.2) -Width In 1.63 mm (41.4) Quantity Nos. 10 DIMENSIONS AND WEIGHT (APPROXIMATE) Overall Length In 172 an ( 4369 } Overall Width In 79 mm (2007 ) overall Height In 84 mn ( 2134 ) Dry Weight Lb 24500 kg (321123 ) AJAX-SUPERIOR APPR i NC cB 207/ ‘Superior? and CleanBurn™ are trademarks af Cooper Industtes, nc. Copyright © Cooper industries, nc. 1988SUPERIOR CLEANBURN II GAS ENGINES PAGE 208 MODEL 8GTLB MISCELLANEOUS Clearance Required to Remove Piston In 81.75 mm ( 2076 ) Heaviest Engine Parts (Approximate Weights) ~Cylinder Block Assembly Lb 4400 kg { 1996 ) ~Cylinder Head Assembly Lb 250 kg (113) -Piston and Connecting Rod Assembly Lb 192 kg (e7) -Turbocharger Assembly Lb 645 kg (293) Exhaust Manifold Lb 375 kg (170) AJAX-SUPERIOR APPR RAC 7 £8 208/1-89 ‘Superior® and CleanBurn"™ are trademarks of Cooper Industries, Inc Copyright © Cooper indusires, Inc. 1989SUPERIOR CLEANBURN II GAS ENGINES PAGE 209 MODEL 8GTLB lew MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN ENGLISH UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. PRIMARY FORCE - Lb. 1 I 1 ENGINE | - i I REM =| «VERTICAL i t i | goo | 789.428 3 |I 120.814 ° I 800 I 623.745 41d 95.458 ° 1 700 | 477.555 270.839 || 73.085 ° i 600 | 350.857 198.984 || 53.695 ° I | i 1 SECONDARY COUPLE - [Link]. | Ut \ ENGINE | i | RPM t VERTICAL HORIZONTAL || VERTICAL HORIZONTAL | ! ~ ul | | in | soo | 1948.844 1160.555 || 261.763 ° 1 goo | ~—«1837.457 916.982 |} 206.825 ° | too =| -1177.116 702.064 || 158.350 ° i coo ed) 864.820 515.802 || 116.339 ° | \ ul \ AJAX-SUPERIOR APPR. CM Z cB 209/: 9 ‘Superior® and CleanBurn™ are trademarks of Cooper Industries, nc. Copyright © Cooper industries, ie. 1980SUPERIOR CLEANBURN II GAS ENGINES PAGE 210 MODEL 8GTLB MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN METRIC UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced, It is to be noted, that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. SECONDARY FORCE - kg I ENGINE -| RPM =| VERTICAL = HORIZONTAL || VERTICAL = HORIZONTAL | NW t ! it ! soo | 358.085 203.083 || 84.801, ° I 800 | 282.931 160.476 || 43.300 o \ 700 216.619 122.853 || 33.152 ° I 600 | 159.149 90.259 || 24.356 0 \ i I SECONDARY COUPLE ~ [Link] | i ! ENGINE |- I I RPM | ‘VERTICAL = HORIZONTAL || = VERTICAL = HORIZONTAL | 1 I =I | it ! 900 rT 269.110 160.505 |} 36.202 ° I 800 Il 212.630 126.819 || 28.604 ° | 700 i 162.795 97.095 || 21.900 ° I 600 | 119.605 71.335 || 16.090 ° 1 Ih I APPR. CnC CB 210/1-89 ‘Superior? and CloanBun"™ are trademarks of Cooper Industies, ne. Copyright © Cooper industries, inc. 1989SUPERIOR CLEANBURN II GAS ENGINES MODEL 8GTLB PAGE 211 ENGINE OPERATING DATA AND HEAT Pree SUPERIOR 8GTLB - CleanBurn”™ PERCENT] puep ENGINE SPEED — RPM RATED LOAD (Psi) 900 [ 750 | 720 | 600 AE 110 Tera] 1210 1009 368 B06 HORSEPOWER 100 146.7 | 1100 917 880 733 on 15 1100 | 825 688 660 550 50 733 | 550 459 440 367 110) i614 — | — wc weer | 133 | 1827 | Too | 7000 | Toso | 7400 (eTUBHeR) a 110.0 | 7400 7300 7350 7700 50 733 | e100 | 8000 | 8070 | 8600 TAKE AIR 110 161.4 | 2909 | 2443 | 2355 | 1991 Ramewnt | 100 146.7 | 2621 | 2205 | 2150 | 1923 cw) 75 1100 | ye94 | 1625 | 1570 | 1358 50 733_|_1287_| 1084 | 1044 a2 110 vera | 228 192 185 157 Boas 100 146.7 | 206 173 169 151 75 1100 | 149 128 124 107 50 733 | _102 86 83 70 110 Te14 | 960 970 965 950 iene 100 146.7 | 990 990 988 980 be 75 i100 | 1050 | 1060 | 1055 | 1050 50 733 |_1ni0_| 1100 | 1110 | 1120 110 ve14 | 17200 | 14300 | 13950 | 12500 wniceenoy | 190 146.7 | 16700 | 13500 | 13120 | 11600 renal 15 110.0 | 15900 } 12500 | 11920 | 9600 50 733_| 13700 _| 10800 | 10020 _| 6900 LUBE lL 110 1614 | 5600 | 4300 | 4100 | 3300 HEAT REXECTION 100 146.7 | 5300 | 4000 | 3850 | 3200 erm) 15 1100 | 4800 | 3600 | 3480 | 3000 50 733 | 4400 | 3300 | 3180 _| 2700 INTERCOOLER 110 761.4 [e500 | 5700 | S480 | 4600 eat Resection | 100 146.7 | 6200 | 4400 | 4240 | 3600 GTUMN) 75 110.0 | 2900 | 1800 | 1730 | 1450 50 733 | 550 450 440 400 NOTES 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTNENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 43£ TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 180F JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-22/9-88 FOR HEAT REVECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND ‘AMBIENT TEMPERATURE, ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10% RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. 3) INTERCOOLER HEAT REJECTION BASED ON NOMINAL 4000 FT. ALTITUDE. 4% LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING 120F MAX. TO INTERCOOLER FOR RATED ENGINE PERFORMANCE. _,| AJAX-SUPERIOR porn GNC cp ates Superior® and Cieanturn™ are vademarks of Cooper Industries, Ine. Copyright © Cooper Inaustnes, Ine. 1968SUPERIOR CLEANBURN II GAS ENGINES MODEL 8GTLB PAGE 212 ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR 8GTLB - CleanBurn II PERCENT] sep ENGINE SPEED ~ RPM RATED 7 PAN ltgrema [900 | 750 | 720 | 600 110 11.35, 902 752 T22 601 nna 100 10.32 820 684 656 547 aw 15 774 615 513 492 410 50 15 | aio | 342 B. 14 BRAKE SPECIFIC 110 135 | — cao — FUEL cONSPTION 100 1032 | 2399 2366 2383 2501 ‘eco HR) 15 174 | 2501 2467 2484 2602 50 5.15 2737 2704 2727 2906 ITA arr Flow | 110 11.35 100 84 ai 69 REQUIREMENT 100 1032 90 16 74 66 ‘Sg/MIND 75 V14 65 56 54 47 50 5.15 44 37 36 30. XHANST M0 1135 103 87 84 7 oyu how 100 10.32 93 78 7 68 15 114 68 58 56 ed 50 5.15 46 39 38 3 110 11.35 516 Bet 518 510 WR TO 100 tose | 532 Bue 531 527 aza0) 75 774 566 571 568 S66 50 515 599 593 599 604 110 1135 4S 3604 3516 3150 JACKET 35 HEAT TeecriON 100 oz | 4209 3402 3306 2923 Gealth 15 7.74 | 4007 3150 3004 2419 50 1 3453, 2722 2525 4739 LUBE OIL 110 11.35 1411 1084 1033 832 HEAT REJECTION 100 10.32 1336 1008 970 806 Akcal/MIND 15 374 | 1210 907 877 756 50. 5.15 1109 832 801 680 INTERCOOLER M0 11,35 | 2142 1436 1381 1159 Heat pegcrion | 100 tose | 1563 | 1109 | 1069 907 Geasuin 15 114 73 454 436 BS 50. 515 139 13 wt 101 NOTES : 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE [Link] FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 43 TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 82(C JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-24/1-89 FOR HEAT REVECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS Of EBULLIENT COOLING. HEAT REECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE. ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10% RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. 3D INTERCOOLER HEAT REJECTION BASED ON NOMINAL 1200 M ALTITUDE. % LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING SO°C MAX. TO INTERCOOLER FOR RATED ENGINE PERFORMANCE, |eeg| AVAX-SUPERIOR porn (ONC cw atart-e9 er ‘Superior? and CleanBure!™ a Copyright © Cooper industries, femarks of Cooper Industes, Ine. 1989SUPERIOR CLEANBURN II GAS ENGINES MODEL 8GTLB PAGE 213 EXHAUST EMISSIONS MODEL = 8GTLB PERCENT J 900 100 11008219 20 30 078 900 5, 8250615) 18 35 075 900 50 550(410) 16 40 010 750 100 9170684) 24 30 O75. 750 5 6886513) 20 38 080 750 50 459(342) 10 3 075, 600 100 7330547) 30 35 1.00 600 5 550(410) 20 36 090 600 50 3610274 10 32 090 © TONS PER YEAR = (GM/BHP-HR) x BHP + 103.6 #* DENOTES NON-METHANE HYDROCARBONS QUALIFYING CONDITIONS: 1 PIPELINE QUALITY GAS IS ASSUMED. METHANE CONTENT SHOULD BE GREATER THAN 90x WITH A LOW HEATING VALUE OF 900 BTU/SCF = 15x, FOR FUEL GAS OUTSIDE THESE PARAMETERS AN INDIVIDUAL REVIEW WILL. BE REQUIRED TO DETERMINE EMISSION LEVELS AND FUEL CONSUMPTION RATES, 2) VALUES ARE BASED UPON 130" F MANIFOLD TEMPERATURE, <120" F INTERCOOLER WATER AND 100° F AMBIENT TEMPERATURE, REDUCED AIR MANIFOLD TEMPERATURES WILL RESULT IN LOWER NOx LEVELS. HIGHER AMBIENT TEMPERATURES WILL NOT AFFECT EMISSION LEVELS AT RATED LOAD AND SPEED BUT WILL CAUSE SLIGHTLY HIGHER NOx LEVELS AT REDUCED SPEEDS. 3D DATA SHOWN ARE BASED ON ENGINE ADJUSTMENT FOR STANDARD BSFC. FULL SPEED EMISSION VALUES ARE VALID FOR ALTITUDES BELOW 4000 FT. HIGH ALTITUDE APPLICATIONS MAY REQUIRE TURBOCHARGER MODIFICATION TO MAINTAIN EMISSION RATES. 4) WHEN NOx REQUIREMENTS LESS THAN THOSE EXPRESSED HERE ARE ENCOUNTERED, THERE ARE TRADE-OFFS BETWEEN NOx AND BSFC WHICH MAY BE APPLICABLE, BUT THESE MUST BE EVALUATED ON A SPECIFIC CASE BASIS. —_ AJAX-SUPERIOR apo SON\ CB 213/1-89 Superior* and CleanBuen"™ are trademarks of Cooper Industrie, Ine. Copyright © Cooper industries, Inc. 1989SUPERIOR CLEANBURN IT GAS ENGINE MODEL 86TLB aca) e WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS feseine row | ow — 100 fi ec 90 a ee == @ 6° pf ee to ra 600 7| r A tef= s wo 20 _| 10 —|_ ENGINE. PRESSURE- © eet DROP, ® 0 100 200 300 abo 500 FLOW (GPM) IMPELLER P/N D-016-879 (STRAIGHT VANE) PUMP RPM = 2.4 X ENGINE RPM DIRECTION OF ROTATION (BI-DIRECTIONAL CAPABILITY) NORMALLY CW (FACING DRIVE END) NPSHR = 15.5 FEET @ 900 RPM & 340 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 340 GPM = 108.0 FT- 255 FT. = 825 FT. 82.5 FT. + 2.31 = 35.7 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. (py| AUAX-SUPERIOR peer SONA cB 215/1-89 ‘Superior? ang CloanBurn™ are trademarks of Cooper industries, In. Copyrignt © Cooper Industries, Inc. 1989SUPERIOR CLEANBURN II GAS ENGINE MODEL 86TLB PAGE 216 WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS 140 ENGINE RPM 130 901 120 DESIGN 110 LOWS 100 90 159 80 ——— 10 60 600 50 40 TDH (FEET) 20 10 =a] Tee TENGINE PRESSURE, o [baa = DROP, t t ° 100 200 300 400 500 FLOW (GPM) IMPELLER P/N D-OS3-655 (CURVED VANE) PUMP RPM = 2.4 X ENGINE RPM DIRECTION OF ROTATION (UNI-DIREC TIONAL) CW (FACING DRIVE END) NPSHp = 9.0 FEET @ 900 RPM & 340 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 340 GPM = 117.0 FT- 255 FT. = 91.5 FT. 915 FT. + 231 = 39.6 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. aoe GS \\C- cB 216/1-89 ‘Superior? and CleanBurn™ are wadamarks of Cooper Industries, nc. Copyright © Cooper industries, nc. 1989TERERD [oR SET CoCETION Tae TF Tn B [ame CET Counts ow CUE COMO —TrOw 1e 310_FE PAGE 219A LACE wanta cio eaiiar 5 TONE] BUT CRET watea SSCA Seiko FF Tact e_bACRE Watch Te [Tine Faow sw. See TR 1 oLnresconta waice mer Tce = SFC Wf wteReooutn waTea CUE Faso = 3 fuse or oar ir a | tone on sine FL a PETICN Fi Tas TnUeT io FONE sel [eas seat oF a WERT Tie we [StagriNG MOTOR INET FyeneE afi [stanting woror CxwausT ZVeReT ("| WATER LT [ROW WiEACOOLER fact = 5 FE B [waitR OUnET 10 HEAT CCHANGER [Phan =F Fur AC TLUBE_ OIL THOM TL TERS Bie TE ARE $-fourter To tuse 61 FILTERS Fs FTA ‘[ov-eAs5 10 (ue OI FiLtens ier [wares OUTLET 10 COWPRESSOR tie TF Wo LWATER INLET fRow COMPaCSSOR ET NOTE:CONN HAY VARY WITH EACH UNIT TGEND — CONTROL BULKHEADS ELECTRONIC PANELT] Gy zunearon oS @. surerzen — [SUPERIOR CLEANSURN TT fos] OUILRE_ DRAWING AJAX-SUPERIOR MODEL 8GTLB lox a co (ees) irmiour orn rutees. Sef eorLevwonanser | EF | Ww) S1LD8 PPC auibug se5 |_uinguea|) (@onaans)SUPERIOR CLEANBURN II GAS ENGINES MODEL 8SGTB ENGINE SECTION INDEX Description Page No. Air Intake System 304 Bearing Dimensions 307 Cooling System 308 Dimensions and Weight 307 Engine Operating Data ~Units In English Units 311 Units In Metric Units 312 Engine Outline Drawing 319 Engine Performance 303 Engine Specifications 302 Exhaust Emissions 313 Exhaust System 304 Fuel System 304 Heat Rejection Data -Units In English Units 311 -Units In Metric Units 312 Lubrication system 306 Miscellaneous 308 Starting System 303 Turbocharger 304 Unbalanced Forces and Couples -Units In English Units 309 -Units In Metric Units 310 Water Pump Characteristics -Jacket Water, Straight Vane N/A -Jacket Water, Curved Vane 315 “Intercooler, Straight Vane 317 Intercooler, Curved Vane N/A AJAX-SUPERIORSUPERIOR CLEANBURN II GAS ENGINES MODEL 8sGTB PAGE 301 ENGINE SPECIFICATIONS Type Aspiration Cylinder Configuration Number of Cylinders Bore = in, (mm) Stroke = dn. (mm) Displacement - [Link]. (liter) Compression Ratio Power Rated - BHP (kW) Speed Rated - RPM Piston Speed - FPM(m/s) Speed Range - RPM Ignition System Fuel system Governor Turbocharger Exhaust Manifold Jacket Water Pump Jacket Water Thermostat Intercooler Water Pump Intercooler Water Thermostat Lube 011 Pump Lube O41 Thermostat Prelube Pump Lube 041 Cooler Intercooler Crankcase Breather Crankcase Doors Direction of Rotation (ee AJAX-SUPERIOR Four (4)-Cycle Turbocharged, Intercooled Inline Eight (8) 10 (284) 10.80 (266.7) 6597 (108.13) 8.20: 1 1500 (1119) 1000 1750 (8.89) 1000 - 600 Non-Shielded, Altronic IIT Fuel Injected with Electronic Air-Fuel Control and Manual Starting Logic Hydraulic (UG-8L) With Manual Speed Setting One(1) Dry Type, Insulation Blanketed Built-In Centrifugal, Gear Driven Remote Mounted Built-In Centrifugal, Gear Driven Remote Mounted Gear Type with Pressure Regulating Valve Engine Mounted Manual, Mounted and Piped Shell & Tube Type,Mounted and Piped Rectangular, Shell & Tube/Fin Type Positive Ventilation Pressure Relief(Bicera Type) Doors Counterclockwise From Flywheel End BMC ‘Superior® and CieanBurn™ are wademarks of Cooper Industies, Ine. Copyright © Cooper Industries, In. 1988 Peer cB 301/1-89SUPERIOR CLEANBURN II GAS ENGINES MODEL sSGTB PERFORMANCE Engine Operating Data Rating Conditions Altitude ~Temperature Rated Torque Over 1000-600 RPM Range Brake Mean Effective Pressure Rating/BMEP Rated Brake Specific Fuel Consumption/BSFC (Plus or Minus 3 Percent Factory Tolerance) Heat Rejection Data Emissions STARTING SYSTEM Air/Gas Starting Motor Make & Model Number of Starting Motors Supply Air/Gas Pressure Consumption Rate/Starter Motor “Air -Gas - Normal Starting Time Connection Sizes -Inlet “outlet -Optional: Inlet Flange outlet Flange PAGE 303 See Page 311 & 312 feet meter ( Deg F Deg c C lb-ft M-kg ( psi kg/cm2 ‘ Btu/bhp-hr keal/kW-hr ( 4000 1219 ) 100 37.8 ) 1878 2090 ) 180.0 12.7 7200 2433 ) See Page 311 & 312 See Page 313 IR / SS-625 one(1) psi kg/om2 ( scfm liter/sec scfm liter/sec ( sec 3-1/2 In. NPT 2-1/2 In. NPT 150 10.5 ) 1400 661 ) 1663 785 1-1/2 In. Square 2-1/2 In. 150 AJAX-SUPERIOR APPR GMC cB 303/. Ine. 1988 Lb. 9 ‘Superior® and CloanBurn™ are vademarks of Cooper Industies, Inc Copyright © Cooper indusSUPERIOR CLEANBURN II GAS ENGINES MODEL 8SGTB @. INTAKE SYSTEM Intake Air Flow Rate Max. Allowable Pressure Drop Air Intake, Inlet Connection FUEL SYSTEM Required Fuel Gas Pressure to Engine Based on Pipeline Quality Natural Gas (Regulated to within plus or minus 1 psig) Gas Inlet Flange Connection EXHAUST SYSTEM Max. Allowable Back Pressure e Exhaust Outlet Flange Connection Size Exhaust Flow Rate Stack Temperature PAGE 304 See Page 311 & 312 In H20 10 mm H20 (254) 12 In. I.D. Flex Connector psi 35-40 Kg/em2 — (2.8-2.8 ) 2 In. 150 Lb. In H20 10 mn E20 (254) 14 In. 150 Lb. FF See Page 311 & 312 See Page 311 & 312 TURBOCHARGER Type Constant Pressure Manufacturer MOAN. Model NR 20R Speed (Maximum) RPM 40000 e AJAX- SUPERIOR aver. G3MC, ce 304-39 ‘Superior? and CleanBurn trademarks of Cooper Industries, Inc. Copyright © Cooper Industrias, Inc 1988.SUPERIOR CLEANBURN II GAS ENGINES MODEL 8SGTB COOLING SYSTEM Jacket Water Capacity - Engine only Jacket Water Pump -Jacket Water Outlet Temperature, Normal -Design Flow Rate at Rated Speed Available External Head: curved vane(Standard) -Minimum NPSH Required: Curved Vane(Standard) Intercooler Water Pump -Intercooler Water Inlet Temperature, Normal -Design Flow Rate at Rated Speed Available External Head: Straight Vane(Standard) -Minimum NPSH Required: Straight Vane(Standard) Connection Sizes -Jacket Water Inlet -Jacket Water Outlet -Intercooler Water Inlet ~Intercooler Water Outlet -Vent Line to Surge Tank,Minimum Size ~Surge Tank Return to Pump Inlet: Jacket Water Intercooler 1_] ASAX-SUPERIOR PAGE 305 Gallon 10 liter (| 265 Deg F 170-180 Deg ¢ ( 76-82 GEM 570 liter/sec ( 36.0 psi 16.9 kg/em2 (1.19 feet 13.5 meter (4.32 Deg F 120 Deg ¢ (49.0 GEM 170 liter/sec (10.7 psi 26 kg/em2 (1.83 feet 17.5 meter ( 5.33 6 In. 10 Lb. 6 In. 150 Lb. 4 In, 150 Lb. 3 In. 150 Lb. a/8 In. Tubing 2 In. NPT 2 In. NPT cB 305/1-89 Superior and CleanBurn"™ are trademarks of Cooper Industis, Ine. Copyright © Cooper Indust Ine. 1968 ) ) ) 7 ) ) ) )SUPERIOR CLEANBURN II GAS ENGINES PAGE 306 MODEL 8SGTB Lube 0i1 Sump Capacity Gallon 122 liter (| 462) Lube 041 Consumption(Estimated) Gal./Day 3.00 liter/Day (11.4 ) Lube Oi] Pressure - Normal psi 35 kg/om2 ( 2.46 ) Temperature Out Of Engine - Normal Deg F 170-180 Deg ¢ { 76-82 ) Flow Rate Through Oil Filter GPM 60 liter/sec (3.78 ) Lube Oil Filters, Remote Mounted(Standard) ~Type Full Flow -Microns of Filtration Fifteen(15) Connection Sizes e -Lube 041 Sump Drain Plug 3 In. NPT -Lube 0i1 Inlet to Engine 2-1/2 In. 150 Lb. -Lube 011 Outlet to Filter 2-1/2 In. 150 Lb. | JAX-SUPERIOR aper._ GNC LZ. CB 306/1-89 Superior® and CleanBurn"™ are wademarks of Cooper Industries, ne Copyright © Cooper industri, in. 1989,SUPERIOR CLEANBURN II GAS ENGINES PAGE 307 MODEL 8SGTB BEARING DIMENSIONS Main Bearing, Split Shell -Diameter In 8.00 mm ( 203.2 “Width In 4.88 mm (124.0 ~Quantity Nos. 9 Crankpin Bearing, Split Shell -Diameter In 6.38 an (162.2 -Width In 2.53 mn ( 64.3 -Quantity Nos. 8 Wrist Pin Bearing -Diameter In 3.50 mn ( 88.9 Width In 3.16 mn { 80.3 e -Quantity Nos. 8 Camshaft Bearing, Split Shell -Diameter In 2.75 mn (69.9 -Width In 2.38 an ( 60.5 Quantity Nos. 9 DIMENSIONS AND WEIGHT (APPROXIMATE) Overall Length In 184 mn ( 4674 Overall Width In 98 mm ( 2489 Overall Height, without Intake Filter In 90 mm ( 2286 Dry Weight Lb 34500 kg (15649 AJAX-SUPERIOR appr. (3MC cB 307/1-69 Superior* and CieanBurn" are wademarks of Cooper Industries, Ine Copyright © Cooper industria, In. 1988SUPERIOR CLEANBURN II GAS ENGINES PAGE 308 MODEL 8SGTB @ cerssvzovs Clearance Required to Remove Piston In 87.75 mm ( 2229 Heaviest Engine Parts (Approximate Weights) Cylinder Block Assembly Lb 7400 kg (3357 -Cylinder Head Assembly bb 250 kg (113 Piston and Connecting Rod Assembly Lb 198 kg (90 Turbocharger Assembly Lb 645 kg (293 -Exhaust Manifold Lb 400 kg (181 -Bed Plate Lb 9000 kg ( 4082 (eel AVAX-SUPERIOR APPR. FEIN Z CB _308/1-89 Superior? and CleanBum'™ are rademarks of Cooper Industties, ne ‘Copyright © Cooper Inaustie, Ine. 1969.SUPERIOR CLEANBURN II GAS ENGINES PAGE 309 MODEL 8SGTB MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN ENGLISH UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. SECONDARY FORCE - Lb. | i i ENGINE | I RPM | VERTICAL HORIZONTAL || | VERTICAL | HORIZONTAL | 1 1 W i I i 1000} 974.602 582.732 || 149.153 ° I 900 | 789.428 447.713 || 120.814 ° | 800 ! 623.745 353.784 || 95.458 ° ul 700 | 477.585 270.839 || 73.085 ° | 600} 350.857 198.984 |} 53.695 ° 1 I UN I SECONDARY COUPLE - [Link] ENGINE RPM VERTICAL HORIZONTAL, 1000 2402.277 432.784 ° 900 1945.844 1160.555 261.763 ° 800 1837.457 916.982 206.825 ° 100 1177.116 702.064 158.350 ° 600 864.820 615.802 116.339 ° tt i It tt I I 323.164 I iT tt i I ( sa] AVAX-SUPERIOR aper._ MWC) cB 309/2-89 : Superior? anc CieanBurn™ are vademarks of Cooper Industries, Inc. Copyright © Cooper Industries, Ine 1989SUPERIOR CLEANBURN II GAS ENGINES PAGE 310 MODEL 8SGTB MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN METRIC UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 60 percent of the calculated values. ENGINE REM VERTICAL — HORTZONTAL. 3 8 8 I | 442.079 250.719 |} 67.656 ° 900 358.085 203.083 || 54.801 ° 800 282.931 160.476 || 43.300 ° I 700 216.619 122.853 || 33.151 ° I 600 159.149 90.259 || 24.356 ° I ! PRIMARY COUPLE ~ || SECONDARY COUPLE - [Link] | ENGINE RPM HORIZONTAL i VERTICAL © HORIZONTAL | | VERTICAL ! 1 ! 1 1 t | I 1 ' I i- 1 ! ! ! 28.604 I 1000 332.235 198.154 | 44.694 ° I 900 269.110 160.505 | 36.202 ° ! 800 212.630 126.819 | ° j 700 162.795 97.095 | 21,900 ° 1 600 119.605 71.335 | 16.090 ° | 1 [nu] AJAX-SUPERIOR arer._ G3 MC Z CB 310/1-89 ‘Superior? and CloanSurn™ are vademarks of Cooper Industries, Inc. Copyright © Cooper industes, nc. 1889SUPERIOR CLEANBURN IT GAS ENGINES MODEL 8SGTB PAGE 311 ENGINE OPERATING DATA AND HEAT REJECTION TM SUPERIOR 8SGTB - CleanBurn'™ II PERCENT] pep ENGINE SPEED — RPM RATED foap_| (Psp TOOO] 900 | 750 | 600 BRAKE 110 198 1650 | 1485 | 1238 990 HORSEPOWER 100 180 1500 | 1350 | 1125 | 900 ae) 75 135 1125 | 1013 aaa | 675 5 30 750. 675. 3| 450 10 | we | — |— | — | — me srere | S| 128 | six | G00 | gor | zee0 ogee 715 iss | 7800 | 7560 | 7380 | 7440 So 20 asoo_| 8290 | soso | 8090 110 198 3e05 | 3571 | 2868 | 2576 RaRewent | 100 180 3705 | 3246 | 2705 | 2321 Geno 75 135 2951 | 2590 | 2159 | 1652 50. 30. 2o33_| 1756 | ‘1452 | 1121 110 198 306 281 226 202 bawarnion | 19 | ize | soe [gel | aes 7 20s 15 135 232 204 170 130 50 20 160. 138 114 a8 110 yoos | 1000 | 1000 | 970 ee 100 ae 1004 360 915 | 935 GuReR Gan 75 138 1009 985 985 | 1020 50 1015 | 1030 | 1000 | 1082 eT 110 198 | 22800 | 20500 | 17100 | 13700 wear cerion | 100 rao | 21300 | 19100 | 15900 | 12800 Grund 75 135 | 18800 | 16900 | 14100 | 11300 50 3o__| 17500 | 16300 | 13100 | 10500 LUBE OIL 10 198 6500 5800 4900 3900 A 100 1so | 6100 | ss00 | 4600 | 3700 ouie 75 135 | 5500 | S000 | «too | 3300 50 zo | 5400 | 4s00 | 4000 _| 3200 110 198 | 15600 | 13300 | 9300 | 7800 tarweucnon | 10 | 480 | 13700 | 10800 | 7300 | 6100 rum 75 135, 8100 | «6200 | 4400 | 2600 50 30 sz00_| 2200 | 1400 800 Nove = 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 43% TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 180F JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-22/9-88 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE. ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10 RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. BD INTERCOOLER HEAT REJECTION BASED ON NOMINAL 4000 FT. ALTITUDE, 4 LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING 120F MAX. TO INTERCOOLER FOR RATED ENGINE PERF ORMANCE. .| AJAX-SUPERIOR pep, “AMC, cp 311/189 Superior and CleanBurn™ are trademarks of Cooper Industries, Ine. Copyright © Cooper industries, Ine. 1989,SUPERIOR CLEANBURN || GAS ENGINES MODEL 8SGTB ENGINE OPERATING DATA AND HEAT REJECTION TM e SUPERIOR 8967B - CleanBurn™ II PERCENT] puep ENGINE SPEED — RPM pare? | ag OT 900 | 750 | 600 Coad | a/emar 100% BRAKE SPECIFIC 110 13.92 1230 1107 923 738 ‘OUTPUT 100 12.66 ANG 1007 839 671 aw 15 949 839 i} 629 503 10. 33. 12. 420. 3H nie} w92 | fae —_ — Sree aieaoal 100 12.66 2423 2399 2389 2454 eck) 15 9.49 | 2636 2555 2494 2514 50 633 | 2906 2802 2731 2734 TAKE AIR FLOW M0 13.92 134 123 99 89 woe 100 12.66 128 12 93 80 again) 78 9.49 102 89 14 s7 50 633 70 61 50, 39 nie) 1392 139 127 103 92 a wi 100 12.66 132 116 97 83 2 75 9.49 105, 93 7 59 50 73 63 = 40 110 1392 ‘S41 538 538 521 eee 100 neee 540 516 491 502 (ae) 15 9.49 543 529 829 549 e 50 63. 546 554 538 583 110 1392 | 5746 | 5166 | 4309 | 3453 McK WATER | 100 | q2e6 | 5368 | 4aia | 4007 | 3226 (kea/M iN) as 949 | 4738 4259 3553 2648 50 633 | 4410 | 4108 3301 2646 ‘LUBE OIL 110 13.92, 1638 1462 1235 983 HEAT REJECTION 100 12.66 1537 1386 bcd 932 (hea/MIND 75 949 1386, 1260 1033 832 50 a 1361 1210 1008 B06 110) iz92 | 3931 | 3352 | 2344 | 1966 aera 100 12.66 3453 2722 1994 1537 eeauino 15, 5.49 | 2041 | 1563 | 1109 655 50 b. 806 554 353. 202 NOTES 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 234 TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 82C JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-24/1-89 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE, ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS, SUBTRACT 10% RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. 3D INTERCOOLER HEAT REJECTION BASED ON NOMINAL 1200 M ALTITUDE. 4) LUBE OIL COOLER AND INTERCOOLER ARE INA COMMON CIRCUIT REGUIRING 5O'C MAX. TO INTERCOOLER FOR RATED ENGINE PERFORMANCE. [soe] AJAX-SUPERIOR porn MC, cB 312/1-89 Superior® ano CieanBurn™ are trademarks of Cooper Industis, Inc. Copynght © Cooper nusties, In, 1980 PAGE 312SUPERIOR CLEANBURN TI GAS ENGINES MODEL 8SGTB ace EXHAUST EMISSIONS MODEL : 8SGTB PERCENT x HE RPM | RATED BHP an a ~~ SN acanial 100 tose | 2484 | 2467 2487 2643 GcaWHARD 75 774 | 2619 2585 2616 2839 50 5.15. 2852 2788 2815 3028 INTAKE AIR FLOW 110 1135 149 122 47 99 REQUIREMENT 100 1032 136 112 108 94 i) 75 14 101 89 87 19 Kile SO 515 74 69. 68 62 110 154 126 122 103 “XHAUST FLOW W135 tan 100 10.32 140 116 112 97 715 774 105 92 89 80 50. 51 7 72 70 63 110 11.35 406 404 ‘410 439 TER TSO 100 1osz | 410 404 410 438 w2ee) Be 174 418 407 a3 436 50, S15 | 427 408 413 432 “JACKET WATER. 110 11.35 | 19096 | 12147 | 12314 | 10459 HEAT RECTION 100 tose | 14491 | 11316 | 11018 9829 Geauin 75 774 | 12752 9652 9425 8518 50. 515. 9728 8140 7933, 7107 LUBE OIL 10 W135 1689 1512 1482 1361 HEAT REJECTION 100 10.32, 1638 1436 1404 1274 eca/MIN) 75 174 1837 1310 1260 1058 50. S15 1386 1159 1086 196 WO 3125 2268 2137 1613 ERCOOLER 11.35, ea RESECTION 100 tose | 2545 1764 1653 1210 cea ar 174 983 806 761 580 50 5.15 76 i 16 7 NOTES = 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 23% TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 82C JACKET WATER OUTLET TEMPERATURE. REFER TO ‘GENERAL DATA SECTION. PAGE GEN-23/1-89 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND ‘AMBIENT TEMPERATURE, ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10x RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. D INTERCOOLER HEAT REJECTION BASED ON NOMINAL 1200 M ALTITUDE. 4) LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING 50% MAX. TO INTERCOOLER FOR RATED ENGINE PERFORMANCE. $j AJAX-SUPERIOR avon, (ONC Superior and CleanBurn"™ are trademarks of Cooper Industries, Ine. Copyright © Cooper industries, ne. 1989 CB 412/1-89SUPERIOR CLEANBURN IT GAS ENGINES MODEL 12GTLB PAGE 413 e EXHAUST EMISSIONS MODEL : 12GTLB PERCENT 7 = RPM |RareD BHPCKW) EMISSIONS (RA 900 100 165001231) 15 16 06 900 75 1238(924) 18 16 06 900 50 825(615) 15 16 06 750 100 1375(1026) 15 16 06 750 75 10314769) 1S 16 O7 750 50 688651D 1.0 16 O7 600 100 11001820) 40 1A 06 coo | 75 | seein | 20 14 06 coo | so | sso | _10 1 08 e ® TONS PER YEAR = (GM/BHP-HR) x BHP + 103.6 #8 DENOTES NON-METHANE HYDROCARBONS QUALIFYING CONDITIONS: 1) PIPELINE QUALITY GAS IS ASSUMED. METHANE CONTENT SHOULD BE GREATER THAN 90x WITH A LOW HEATING VALUE OF 900 BTU/SCF & 154. FOR FUEL GAS OUTSIDE THESE PARAMETERS AN INDIVIDUAL REVIEW WILL BE REQUIRED TO DETERMINE EMISSION LEVELS AND FUEL CONSUMPTION RATES. 2) VALUES ARE BASED UPON 130° F MANIFOLD TEMPERATURE, «120° F INTERCOOLER WATER AND 100° F AMBIENT TEMPERATURE. REDUCED AIR MANIFOLD TEMPERATURES WILL RESULT IN LOWER NOx LEVELS. HIGHER AMBIENT TEMPERATURES WILL NOT AFFECT EMISSION LEVELS AT RATED LOAD AND SPEED BUT WILL CAUSE SLIGHTLY HIGHER NOx LEVELS AT REDUCED SPEEDS. 3) DATA SHOWN ARE BASED ON ENGINE ADJUSTMENT FOR STANDARD BSFC. FULL SPEED EMISSION VALUES ARE VALID FOR ALTITUDES BELOW 4000 FT. HIGH ALTITUDE APPLICATIONS MAY REQUIRE TURBOCHARGER MODIFICATION TO MAINTAIN EMISSION RATES. 4) WHEN NOx REQUIREMENTS LESS THAN THOSE EXPRESSED HERE ARE ENCOUNTERED. THERE ARE TRADE-OFFS BETWEEN NOx AND BSFC WHICH MAY BE APPLICABLE, BUT THESE MUST BE EVALUATED ON A SPECIFIC CASE e Basis, 23) AJAX-SUPERIOR peer, S3MCL cB 413/1-89 Superior and CleanBurn"™ are radomarks of Cooper Industries, Ine Copyright © Cooper industries, In. 1988SUPERIOR CLEANBURN II GAS ENGINE MODEL 12GTLB Peoee e WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS ‘eo %° ee RPM. ead te 60 750. Ae 208 30 = = ee NE PRESSURE 10 = DROP 5 alee e 0 200 400 600 800 900 FLOW (GPM) IMPELLER P/N D-024-003 (STRAIGHT VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (BI-DIRECTIONAL CAPABILITY) NORMALLY [Link] (FACING DRIVE END) NPSHp = 20.0 FEET @ 900 RPM & 750 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 960 RPM DESIGN FLOWRATE OF 750 GPM = 97.0 FT. - 55.0 FT. = 42.0 120 FT, +231 = 182 88) ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. AJAX-SUPERIOR appa SONKC_ 8 415s1-89 ‘Supotior® and CloanBurn™ are trademarks of Cooper Industries, Inc. Copyright © Cooper industias, Inc. 1989SUTtRIOR Liman MODEL 12GTLB PAGE 416 WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS 110 ee ENGINE RPM 90 200. e% pe 5 i 70 & 6 = SS =x 77 ae 20 2 a ta ENGINE. PRESSURE —} ° =p DROP, 0 200 400 600 800 900 FLOW (GPM) IMPELLER P/N D-O33-744-002 (CURVED VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (UNIDIRECTIONAL) C.C.W (FACING DRIVE END) NPSHg = 14.0 FEET @ 900 RPM & 750 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 750 GPM = 80.0 FT- 55.0 FT. = 250 FT. 25.0 FT. + 2.31 = 108 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. AJAX-SUPERIOR APPR, BNE cB 416/1-89 ‘Superior? and CleanBurn™ are trademarks of Cooper Industrie, Inc. Copyright © Cooper Industis, Inc. 1988SUPERIOR CLEANBURN II GAS ENGINE. MODEL 12GTLB PAGE 417 WATER PUMP CHARACTERISTICS INTERCOOLER WATER SYSTEM DESIGN FLOWS AND PRESSURE DROPS TENGINE RPM 900, so _| DESIGN FLOWS i 50 750 600 a TDH (FEET) $8 ENGINE PRESSURE IP. 0 100 200 300 400 FLOW (GPM) IMPELLER P/N C-026-376 (STRAIGHT VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (BI-DIRECTIONAL CAPABILITY) NORMALLY. C.C.W (FACING DRIVE END) NPSHp = 16.0 FEET @ 900 RPM & 200 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT_THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 200 GPM = 67.0 FT-27.7 FT. = 39.3 FT. 39.3 FT. + 231 = 17.0 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. | AJAX-SUPERIOR APPR, GM cB 417/1-89 ‘Superi® and CleanBurn™ are trademarks of Cooper Industtes, nc. Copyright © Cooper industries, inc. 1989SUPERIOR CLEANBURN IT GAS ENGINES SEE LEGEND INFORMATION SHOWN ON THE OTHERSIDE OF THIS SHEETeee [TinneT eonET cowaction oC TT Stantive uDtOR wat Tye RET Stantixe-uoton CoMAgT ever ATER ootuct 10 cowpecsaon [UE wer PAGE 419A oor E EP rrerrr v0) Peas since Seaton nat NOTES COMN WAY VARY WITH EACH UNIT, kes STANOARO PANEL _CTUBING COND tT [irartg ie coniae sion [ve tno Fe. duit aae MAST EE PPED SUPARATECY = SUreRzOR ee | ZAN SUPERIOR pS —| oor DRAWN cueansuen 11. [Swe ane 4) AJAX-SUPERIOR MODEL 12GTLB tar [L2GTLB CHTTHOUT OIL FILTERS)(Surenor) CleanBurn'll Gas Engine + Model 12GTLB ce ai3/t-89SUPERIOR CLEANBURN II GAS ENGINES MODEL 12SGTB ENGINE SECTION INDEX Description Page No. Air Intake System 504 Bearing Dimensions 507 Cooling system 505 Dimensions and Weight 507 Engine Operating Data -Units In English Units sit Units In Metric Units 512 Engine Outline Drawing 519 Engine Performance 503 e@ Engine Specifications 501 Exhaust Emissions 513 Exhaust System 504 Fuel system 504 Heat Rejection Data Units In English Units 511 “Units In Metric Units 512 Lubrication system 506 Miscellaneous 508 Starting System 503 Turbocharger 504 Unbalanced Forces and Couples Units In English Units 509 -Units In Metric Units 510 Water Pump Characteristics ~Jacket Water, Straight Vane 515 Jacket Water, Curved Vane 516 -Intercooler, Straight Vane 517 Intercooler, Curved Vane N/A 4) AJAX-SUPERIORSUPERIOR CLEANBURN II GAS ENGINES MODEL 12SGTB PAGE 501 ENGINE SPECIFICATIONS Type Aspiration Cylinder Configuration Number of Cylinders Bore = in. (mm) Stroke - in. (mm) Displacement - [Link]. (liter) Compression Ratio Power Rated - BHP (kW) Speed Rated - RPM Piston Speed - FPM(m/s) Speed Range - RPM Ignition system Fuel system Governor Turbocharger Exhaust Manifold Jacket Water Pump Jacket Water Thermostat Intercooler Water Pump Intercooler Water Thermostat Lube 01] Pump Lube 011 Thermostat Prelube Pump Lube 011 Cooler Intercooler Crankcase Breather Crankcase Doors Direction of Rotation A] [Link] Four (4)-Cycle Turbocharged, Intercooled Vee Twelve (12) 10 (254) 10.50 (266.7) 9896 (162.20) 8.20 : 1 2000 (1491) 900 1875 (8.0) 900 - 600 Non-Shielded, Altronic III Puel Injected with Electronic Air-Fuel Control and Manual Starting Logic Hydraulic (UG-8L) With Manual Speed Setting one(1) Water Cooled Built-In Centrifugal, Chain Driven Remote Mounted Built-In Centrifugal, Chain Driven Remote Mounted Gear Type with Pressure Regulating Valve Remote Mounted Manual, Mounted and Piped Shell & Tube Type, Remote Mounted Rectangular, Shell & Tube/Fin Type Positive Ventilation Pressure Relief (Bicera Type) Doors Counterclockwise From Flywheel End APPR. ICING Zi “Supetio® and CleanBurn"™ are trademarks of Cooper Industries, Inc Copyright © Cooper industries, inc. 1989 CB 501/1-89SUPERIOR CLEANBURN II GAS ENGINES MODEL 12SGTB PERFORMANCE Engine Operating Data Rating Conditions Altitude Temperature Rated Torque Over 900-600 RPM Range Brake Mean Effective Pressure Rating/BMEP Rated Brake Specific Fuel Consumption/BSFC (Plus or Minus 3 Percent Factory Tolerance) Heat Rejection Data Emissions STARTING SYSTEM Air/Gas Starting Motor Make & Model Number of Starting Motors: Generator Drive Compressor Drive Supply Air/Gas Pressure Consumption Rate/Starter Motor -aAir -Gas ~ Normal Starting Time Connection Sizes -Inlet ~Outlet -Optional: Inlet Flange outlet Flange PAGE 503 See Page 511 & 512 feet 4000 meter (1219 Deg F 100 Deg c (37.8 lb-ft 21671 M-kg (1614 psi 177.8 kg/om2 (41205 Btu/bhp-hr 7150 keal/kW-hr ( 2416 See Page 511 & 512 See Page 513 IR / $S-825 one(1) Two(2) psi 150 kg/cm2 (10.5 scfm 1500 liter/sec (708 scfm 1781 liter/sec (841 sec 15 1-1/2 In. NPT 2-1/2 In. NPT 1-1/2 In. Square 2-1/2 In. 150 Lb. aver. GNC) cs s03/1-89 ) ) d ‘Superior® and CleanBumn™ are trademarks of Cooper industries, Inc. Copyright © Cooper Industries, Inc. 1989SUPERIOR CLEANBURN II GAS ENGINES MODEL 12SGTB AIR INTAKE SYSTEM Intake Air Flow Rate Max. Allowable Pressure Drop Air Intake, Inlet Connection FUEL SYSTEM Required Fuel Gas Pressure to Engine Based on Pipeline Quality Natural Gas (Regulated to within plus or minus 1 psig) Gas Inlet Flange Connection EXHAUST SYSTEM Max. Allowable Back Pressure Exhaust Outlet Flange Connection Size Exhaust Flow Rate Stack Temperature TURBOCHARGER Type Manufacturer Model Speed (Maximum) Gi] AJAX-SUPERIOR APPR PAGE 504 See Page 511 & 512 In #20 10 mm H20 ee 18 In, I.D, Flex Connector psi 35-40 kg/em2 — (2.5-2.8 ) 2 In. 150 Lb. In H20 10 mm H20 (254) 28 In. 125 Lb. FF See Page 511 & 512 See Page 511 & 512 Constant Pressure Cooper~Bessemer ET 13 REM 23000 BNC. CB 504/1-89 ‘Superior? and CleanBurn™ are trademarks of Cooper Indust, Inc. ‘Copyright © Cooper Incustis, In. 1980SUPERIOR CLEANBURN II GAS ENGINES PAGE 505 MODEL 12SGTB @ cccises sore Jacket Water Capacity - Engine Only Gallon 146 liter (553 ) Jacket Water Pump -Jacket Water Outlet Temperature, Normal Deg F 165-180 Deg ¢ ( 74-82 ) -Design Flow Rate at Rated Speed GPM 750 liter/sec (47.3 ) Available External Head: Straight Vane(Standard) psi 18.2 keg/cm2 (1.28 ) Curved Vane(Optional) psi 10.8 kg/em2 (0.76 ) -Minimum NPSH Required: Straight Vane(Standard) feet 20 meter (6.10 ) Curved Vane(Optional) feet 4 meter (4.27) Intercooler Water Pump e -Intercooler Water Inlet Temperature, Normal Deg F 120 Deg ¢ ( 49.0 ) Design Flow Rate at Rated Speed GPM 200 liter/sec (12.6 } Available External Head: Straight Vane(Standard) psi 17 kg/cm2 (1.20 ) Minimum NPSH Required: Straight Vane(Standard) feet 16 meter ( 4.88 ) Connection Sizes Jacket Water Inlet 6 In. 150 Lb. ~Jacket Water Outlet 6 In. 150 Lb. Intercooler Water Inlet 4 In. 150 Lb. -Intercooler Water Outlet 4 In. 150 Lb. Vent Line to Surge Tank,Minimum Size 3/8 In. Tubing ~Surge Tank Return to Pump Inlet: Jacket Water 2 In. NPT Intercooler 2 In. NPT AJAX-SUPERIOR aper._ (SNC y cB 505/1-89 ‘Superior® and ClaanBum"™ are trademarks of Cooper Industries, Inc. Copyrignt © Cooper industries, Inc. 1989SUPERIOR CLEANBURN II GAS ENGINES PAGE 506 MODEL 12SGTB LUBRICATION SYSTEM Lube 011 Sump Capacity Galion 165 liter (625 ) Lube 01] Consumption(Estimated) Gal. /Day 4.00 Liter/Day (18.1 ) Lube 011 Pressure - Normal psi 35 kg/om2 (2.46 ) Temperature Out Of Engine ~ Normal Deg F 165-175 Deg ¢ (14-79 ) Flow Rate Through Oi] Filter cpm 70 liter/sec (4.42 ) Lube Oil Filters, Remote Mounted(Standard) ~Type Full Flow ~Microns of Filtration Pifteen(15) Connection Sizes -Lube 0i1 Sump Drain Plug 1-1/2 In, NPT ~Lube 011 Inlet to Engine 3 In. 150 Lb. ~Lube 011 Outlet to Filter 3 In. NPT AJAX-SUPERIOR appr. GAC cB 506/1-89 ‘Superior? and CleanBurn™ are trademarks of Cooper Industries, ne. Copyright © Cooper industries, Inc. 1989SUPERIOR CLEANBURN II GAS ENGINES PAGE 507 MODEL 12SGTB Cen Main Bearing, Split shell -Diameter In 8.00 mm (203.2 ) “Width In 4.88 mn (124.0 ) -Quantity Nos. 1 Crankpin Bearing, Split Shell Diameter In 6.38 mn ( 162.1 ) “width In 2.83 nn ( 64.3 ) -Quantity Nos. 12 Wrist Pin Bearing -Diameter In 3.50 mm ( 88.9 ) “Width In 3.16 mm ( 80.3 ) e -Quantity Nos. 12 Camshaft Bearing, Split Shell -Diameter In 2.75 nm { 69.9 ) “Width In 2.38 mn (60.5 ) ~Quantity per Bank Nos. 7 DIMENSIONS AND WEIGHT(APPROXIMATE) Overall Length In 185 nm ( 4699 ) Overall width In 84 mn ( 2134 ) Overall Height In 115 mm ( 2921 ) Dry Weight Lb 42500 kg (19278 ) $4) asax-SuPERIOR appr._G3MCL cB 507/1-89 Superior® and CloanBurn™ ate trademarks of Cooper Industries, nc. Copyright © Cooper industries, nc. 1989SUPERIOR CLEANBURN II GAS ENGINES PAGE 508 MODEL 12SGTB MISCELLANEOUS Clearance Required to Remove Piston In 89 nm ( 2261 Heaviest Engine Parts (Approximate Weights) ~Cylinder Block Assembly Lb 10400 kg (4737 Cylinder Head Assembly Lb 250 kg (113) Piston and Connecting Rod Assembly Lb 198 kg (90) ~Turbocharger Assembly Lb 1170 kg (531) Exhaust Manifold Lb 1210 kg (549) AJAX-SUPERIOR appr. GNC L CB 508/1-89 ‘Superior® and CleanBurn™ Copyright © Cooper industries, jomarks of Cooper Inaustrie, Inc 1989SUPERIOR CLEANBURN II GAS ENGINES PAGE 509 MODEL 12SG7B MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN ENGLISH UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted, that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated value: PRIMARY FORCE - Lb. SECONDARY FORCE - Lb. RPM VERTICAL | HORIZONTAL VERTICAL | HORIZONTAL 111.206 49.512 800 753.915 573.713 87.866 39.121 700 577.216 439.249 67.273 29.952 600 424.077 322.713 49.425 22.005 in ie in =| |= II i ' i II a 1 I 1 oD | 954.174 126.105 1 1 1 1 SECONDARY COUPLE - [Link]. | iM ! i | | i | 4) AJAX-SUPERIOR aper._(3N\C cB 509/1-89 ‘Superior® and CioanBurn™ are trademarks of Cooper industie, Inc. Copyright © Cooper Industries, ie. 1989SUPERIOR CLEANBURN II GAS ENGINES PAGE 510 MODEL 12SGTB MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN METRIC UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. SECONDARY FORCE - kg | 1 | 1 1 ENGINE | I - RPM | ‘VERTICAL = HORIZONTAL || - VERTICAL = HORIZONTAL. ! Hh ! a | 900 i 432.813 329.361 || 50.443, 22.459 | 800 I 341.976 260.236 || 39.856 17.745 | Too | 261.825 199.243 || 30.515, 13.586 | 600 I 192.361 146.383 || 22.419 9.981 | | i 1 SECONDARY COUPLE - [Link] —+-1 1 i ENGINE | ul - RPM | ‘VERTICAL = HORIZONTAL || VERTICAL = HORIZONTAL. | i! 1 e001 =| 352.903 270.735 || 37.177 16.552 | goo | 278.837 213.914 || 29.375 13.078 | 700 | 213.485 163.778 || 22.490 10.013 | 600 | 186.846 120.327 || 16.523 7.357 | I t I 9 Gi) asax-SUPERIOR appr.__\3MC cB 510/1 ‘Superior? and CleanBurn™ are trademarks of Cooper Industrie, Ine. Copyright © Cooper Industies, Ic. 1989| AJAX-SUPERIOR appr, 3MCy SUPERIOR CLEANBURN IT GAS ENGINES MODEL 12SGTB peeerel ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR 12SGTB - CleanBurn™ IT PERCENT] pcp ENGINE SPEED — RPM Paap | esp [900 | 750 | 720 | 600 LOAD BRE 10 756] —2200 | 1834] 1760] 1466 HORSEPOWER 100 178 | 2000 | 1667 | 1600 | 1333 an) 15 133 | 1500 } 1250 | 1200 | 1000 50 89 tooo _| 833 | 900 | 667 ara secciric | 140 ed | aera eet Bae a 100 178 | 7150 | 7150 | 7230 | 7700 eriapepeaal: a2 133 | 7450 | 7400 | 7480 | @t00 50. ss_| 8100 | 7950 | 8040 | 8700 Tt0 196 | 4809 | 4169 | 3983 | sea7 Peace ft 100 178 | 4590 | 3826 | 3673 | 3060 ecra 75 133 | 3541 | 3060 | 2960 | 2557 50 so_| 24a | aise | ztoe | zo1e 110 196 379} "sea ] 314} 286 ld 100 178 361 301 290 2az 75 133 279 | 240 | 232 | 201 50 89 193 168 166 158. i10 196 745_| 752 | 770 | 850 Tue, | (100 «| (178 ys2 | 755 | 770 | 828 aren earn 133 rio | 62 | 710 | 819 50 89. 731 yee | 775 | ait TiO 196] T0800 [57800] 55900 | 48400 pretreat Uo) 178 | 64500 | 52500 | Sosao | 44400 bate 15 133 | 55500 | 42100 | 41000 | 36700 50 g9_| 44500 | 34500_| 33950 | 31800 feral T10 196 | 7300 | 6600 | 6600] 6600, teat rection | 100 178 | 7000 | 6300 | 6250 | 6000 frre 15 133 | 6300 | 5500 | 5350 | 4750 50 e9_| s7s0_| 4900 | 4660 | 3700 T10 136 | 17900} T3800] 12900 | 9.500 Seon | 100 178 | 15000 | 11000 | 10380 | 7900 bn 15 133 | 7300 | 5700 | 5420 | 4300 50. 89 1400 _| 1300 | 1260 | 1100 NOTES : 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 43% TOLERANCE FOR FACTORY TESTS, 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 18OF JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-21/9-88 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING, HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE. ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS, SUBTRACT 10x RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. ‘3D INTERCOOLER HEAT REJECTION BASED ON NOMINAL 4000 FT, ALTITUDE. 4) LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING 1Z0F MAX. TO INTERCOOLEF FOR RATED ENGINE PERF ORMANCE. CB S11/1-89 ‘Superor® and CleanBurn™ are trademarks of Cooper Industries, nc. Copyright © Cooper industries, ic. 1989SUPERIOR CLEANBURN IT GAS ENGINES MODEL 12S6TB PAGE 512 ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR 12SGTB - CleanBurn ™II PERCENT] BMEP ENGINE SPEED - RPM faa | “<2 900 [750 | 720 [600 BARE SECIFIC Tio | 1378 | 1641 | 1368 | 13i2 [1095 oureur 100 vase | 1491 | 1243 | 1193 994 aw 15 935 | 1119 932 895 746 50 626 |__746 621 597 497 BRNE SECIFIC 110 we | — | — | — | — FUEL CONSWPTION) — 100 tase | 2416 | 2416 | 2443 | 2602 eal WHR) 15 935 | 2518 | 2501 | 2528 | 2737 50 626 | 2737 | 2687 | 2717 | 2940 INTE AIR FLOW | 110 1378 | 166 144 137 112 REQUIREMENT 100 1ase | 158 132 127 105 ‘Gyn 15 935 | 122 105, 102 88 50Q__|__6.26 B4 TS. 1 62. 110 1378 | 172 149 142 116 aaa now 100 tas2 | 164 137 132 110 15 935 | 127 109 105, ” 50 626 88 16 75 72 710 1378 | 396 400 410 454 Paste 100 yes2 | 400 402 410 442 ey 15 935 | 410 406 Ato 437 50 26 | _422 408 AIS 433 110 1378 | 17843 | 14567 | 14088 | 12198 sAGKET WATER 100 yzs2 | 16255 | 13231 | 12823 | 11190 pee eee 15 9.35 | 13987 | 10610 | 10333 | 9249 Ly 50 626 | 11215 | 869! 8556 | 8014 110) ys7e | 1840 | 1663 | 1663 | 1663 LUBE On 100 1252 | 1764 | 1588 1575, 1512 HEAT RESECTION 15 935 | 1588 1386 1348 1197 Ged) 50 626 | 1449 | 1935 | 1174 | 32 110 1378 | 4511 | 3478 | 3251 | 2344 INTERCOOLER 100 ys2 | 3780 | 2772 | 2616 | 1991 HEAT REJECTION 15 935 | 1840 | 1436 | 1366 | 1084 Ge /MIN) 50 626 | __353 328 318 TT NOTES : 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 23% TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 82 JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-23/1-89 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE, ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 108 RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. 3D INTERCOOLER HEAT REJECTION BASED ON NOMINAL 1200 M ALTITUDE. 4 LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING 50 MAX. TO INTERCOOLER FOR RATED ENGINE PERFORMANCE. 4) AJAX-SUPERIOR appr, GNC, ‘Suporor® and CleanBum™ are vademarks of Cooper Indu ee Copyright © Cooper industries, nc. 1989SUPERIOR CLEANBURN II GAS ENGINES MODEL 12S6TB eeenols e EXHAUST EMISSIONS MODEL : 12SGTB PERCENT EMISSIONS (GRAMS/BHP-HR) RPM ae BHP(KW) NOx CO NMAC 900 100 200001491) net 16 0.6 900. 75 150041119) 18 16 06 900 50 1000(7 46) 18 16 06 750 100 166701243) 18 16 Ob 750 75 12501933) uf} 15 0.6 750 50 833621) 1.0 16 o7 600 100 133SHIGIA) 7.0 15 06 600 75 10007 46) 28 1.4 06 600 50 6674498) 12 14 06 ™ TONS PER YEAR = (GM/BHP-HR) x BHP + 103.6 we DENOTES NON-METHANE HYDROCARBONS QUALIFYING CONDITIONS: 1) PIPELINE QUALITY GAS IS ASSUMED. METHANE CONTENT SHOULD BE GREATER THAN 90x WITH A LOW HEATING VALUE OF 900 BTU/SCF 158, FOR FUEL GAS OUTSIDE THESE PARAMETERS AN INDIVIDUAL REVIEW WILL. BE REQUIRED TO DETERMINE EMISSION LEVELS AND FUEL CONSUMPTION RATES. 2) VALUES ARE BASED UPON 130" F MANIFOLD TEMPERATURE, «120° F INTERCOOLER WATER AND 100° F AMBIENT TEMPERATURE. REDUCED AIR MANIFOLD TEMPERATURES WILL RESULT IN LOWER NOx LEVELS. HIGHER AMBIENT TEMPERATURES WILL NOT AFFECT EMISSION LEVELS AT RATED LOAD AND SPEED BUT WILL CAUSE SLIGHTLY HIGHER NOx LEVELS AT REDUCED SPEEDS. 3) DATA SHOWN ARE BASED ON ENGINE ADJUSTMENT FOR STANDARD BSFC. FULL SPEED EMISSION VALUES ARE VALID FOR ALTITUDES BELOW 4000 FT. HIGH ALTITUDE APPLICATIONS MAY REGUIRE TURBOCHARGER MODIFICATION TO MAINTAIN EMISSION RATES, 4) WHEN NOx REQUIREMENTS LESS THAN THOSE EXPRESSED HERE ARE ENCOUNTERED, THERE ARE TRADE-OFFS BETWEEN NOx AND BSFC WHICH MAY BE APPLICABLE, BUT THESE MUST BE EVALUATED ON A SPECIFIC CASE e Basis. 4) AJAX-SUPERIOR appr, SMC CB 513/1-89 Superior® and Clesnurn"™ are trademarks of Cooper Industries, Inc. Copyright © Cooper industries, Ine. 1980SUPERIOR CLEANBURN IT GAS ENGINE MODEL 128GTB pe ee e WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS i 90 ENGINE_RPM I 7 5 900 a8 60 750 AG ra rE 30 ka — 20 = 10 = {ENGINE PRESSORE 4-7 T { e i 0 200 400 soo | 800 900 FLOW (GPM) IMPELLER P/N D-024-003 (STRAIGHT VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (BI-DIRECTIONAL CAPABILITY) NORMALLY C.C.W (FACING DRIVE END) NPSHp = 20.0 FEET @ 900 RPM & 750 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT_THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 750 GPM = 97.0 FT. ~ 55.0 FT. = 42.0 FT. 42.0 FT. + 2.31 = 182 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. AJAX-SUPERIOR appr,_G2MCy ©B 515/1-89 ‘Superior? and CleanBurn™ are trademarks of Cooper Industries, nc Copyright © Cooper industries, ine. 1989SUPERIOR CLEANBURN IT GAS ENGINE MODEL 12SGTB PAGE S16 WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS 110 ioe ENGINE RPM 90 200 80 DESIG! 4 F a FLOWS 7 i Rol 750 7 me i 7 Iv 60 600 2 30 20 ao t= ENGINE PRESSURE o apo R02} 1 ° 200 400 600 800 900 FLOW (GPM) IMPELLER P/N D-033-744-002 (CURVED VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (UNIDIRECTIONAL) C.C.W (FACING DRIVE END) NPSHg = 140 FEET @ 900 RPM & 750 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE! EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 750 GPM = 800 FT- 550 FT. = 250 FT. 25.0 FT. + 2.31 = 108 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. (a AJAX-SUPERIOR appr. SWC CB 516/1-89 ‘Superor® and CieanBurn™ are trademarks of Cooper Industries, Inc. Copyright © Cooper indusiries, nc. 1989SUPERIOR CLEANBURN I] GAS ENGINE. MODEL 12SGTB PAGE 517 id WATER PUMP CHARACTERISTICS INTERCOOLER WATER SYSTEM DESIGN FLOWS AND PRESSURE DROPS 80 —ENGINE RPM 909; TDH (FEET) ENGINE PRESSURE DROP ° 100 200 300 400 FLOW (GPM) IMPELLER P/N C-026-376 (STRAIGHT VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION @I-DIRECTIONAL CAPABILITY) NORMALLY C.C.W (FACING DRIVE END) NPSHp = 16.0 FEET @ 900 RPM & 200 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 200 GPM = 670 F277 FT. = S95 FT. SFT. + 231 = 17.0 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS, $3) AJAX-SUPERIOR aper,_2NCo cB 517/1-89 Superior® and CleanBurn™ are wademarks of Cooper Ingustis, ine. Copyright © Cooper inausties, nc. 1969—————, aa eel me | PAGE sig a ee ae eae ee) PPererr ee NOTESCOKN MAY VARY WITH EACH UNIT, Keer STANDARD PANEL CTUBING CONN To at aecne oa ia mr cutie sae |e Ee Ru A mae: |S ESS anes oer vr = SUPERIOR UPERTOR OUiLR DRA Cueansurn 11 [j—fn_# Jar MODEL 12S6TB = —fi2scTB THOUT-OTL FILTERS)a & o c Wi “ & Oo = € 3 a s 2 Gu Model 12SGTBSUPERIOR CLEANBURN II GAS ENGINES MODEL 16GTLB ENGINE SECTION INDEX Description Page No. Air Intake system 604 Bearing Dimensions 607 Cooling system 605 Dimensions and Weight 607 Engine Operating Data -Units In English Units 611 -Units In Metric Units 612 Engine Outline Drawing 619 Engine Performance 603 e Engine Specifications 601 Exhaust Emissions 613 Exhaust System 604 Fuel system 604 Heat Rejection Data -Units In English Units 611 -Units In Metric Units 612 Lubrication System 606 Miscellaneous 608 Starting system 603 Turbocharger 604 Unbalanced Forces and Couples Units In English Units 609 -Units In Metric Units 610 Water Pump Characteristics -Jacket Water, Straight Vane 615 -Jacket Water, Curved Vane 616 -Intercooler,’ Straight Vane 617 -Intercooler, Curved Vane N/A | AJAX-SUPERIORSUPERIOR CLEANBURN II GAS ENGINES MODEL 16GTLB PAGE 601 ENGINE SPECIFICATIONS Type Aspiration Cylinder Configuration Number of Cylinders Bore - in. (mm) Stroke - in. (mm) Displacement - [Link]. (liter) Compression Ratio Power Rated - BHP (kW) Speed Rated - RPM Piston Speed - FPM(m/s) Speed Range - RPM Ignition system Fuel system Governor Turbocharger Exhaust Manifold Jacket Water Pump Jacket Water Thermostat Intercooler Water Pump Intercooler Water Thermostat Lube 011 Pump Lube 011 Thermostat Prelube Pump Lube Oil Cooler Intercooler Crankcase Breather Crankcase Doors Direction of Rotation |) AJAX-SUPERIOR Four (4)-Cycle Turbocharged, Intercooled vee Sixteen (16) 10 (254) 10.50 (266.7) 13195 (216.27) 8.20: 1 2200 (1641) 900 1575 (8.0) 900 - 600 Non-Shielded, Altronic III Fuel Injected with Electronic Air-Fuel Control and Manual Starting Logic Hydraulic (UG-8L) With Manual Speed Setting one(1) Water Cooled Built-In Centrifugal, Chain Driven Remote Mounted Built-In Centrifugal, Chain Driven Remote Mounted Gear Type with Pressure Regulating Valve Remote Mounted Manual, Mounted and Piped Shell & Tube Type, Remote Mounted Rectangular, Shell & Tube/Fin Type Positive Ventilation Pressure Relief(Bicera Type) Doors Counterclockwise From Flywheel End appr. GNC ‘Superior? and CleanBurn™ are trademarks of Cooper Indusies, Ine. Copyright © Cooper industies, nc. 1989 cB 601/1-89SUPERIOR CLEANBURN II GAS ENGINES MODEL 16GTLB PERFORMANCE, Engine Operating Data Rating Conditions Altitude —Temperature Rated Torque Over 900-600 RPM Range Brake Mean Effective Pressure Rating/BMEP Rated Brake Specific Fuel Consumption/BSFC (Plus or Minus 3 Percent Factory Tolerance) Heat Rejection Data Emissions STARTING SYSTEM Air/Gas Starting Motor Make & Model Number of Starting Motors: Generator Drive Compressor Drive Supply Air/Gas Pressure Consumption Rate/Starter Motor Air ~Gas - Normal Starting Time Connection Sizes -Inlet Outlet -Optional: Inlet Flange outlet Flange PAGE 603 See Page 611 & 612 feet 4000 meter (1219 Deg F 100 Deg ¢ ( 37.8 Ib-ft 12838 M-kg (1775 psi 146.7 kg/om2 (10.3 Btu/bhp-hr 7350 keal/kW-hr ( 2484 See Page 611 & 612 See Page 613 IR / SS-825 One(1) Two(2) psi 150 kg/cm2 (10.5 scfm 1500 liter/sec (708 scfm 1781 liter/sec ( 641 sec 15 3-1/2 In, NPT 2-1/2 In. NPT 1-1/2 In. Square 2-1/2 In. 150 Lb. J) [Link] aver. ONC 2 cB ‘Superio® and CleanBurn™ are trademarks of Cooper Industies, ine, Copyright © Cooper industri, In. 1969 603/1-89SUPERIOR CLEANBURN II GAS ENGINES MODEL 16GTLB AIR INTAKE SYSTEM Intake Air Flow Rate Max. Allowable Pressure Drop Air Intake, Inlet Connection FUEL SYSTEM Required Fuel Gas Pressure to Engine Based on Pipeline Quality Natural Gas (Regulated to within plus or minus 1 psig) Gas Inlet Flange Connection EXHAUST SYSTEM Max. Allowable Back Pressure Exhaust Outlet Flange Connection Size Exhaust Flow Rate Stack Temperature PAGE 604 See Page 611 & 612 In H20 10 mm H20 (254) 18 In, I.D. Flex Connector psi 35-40 kg/em2 (2.5-2.8 ) 2 In. 150 Lb, In H20 10 mm H20 (| 254) 18 In. 150 Lb. FF See Page 611 & 612 See Page 611 & 612 TURBOCHARGER Type Constant Pressure Manufacturer Elliott Mode2 BC 370 Speed (Maximum) RPM 23000 AJAX-SUPERIOR appr. G3MC_ echicieiLees Superior® and CleanBurn"™ are trademarks of Cooper Industries, In. Copyright © Cooper Industrie, Inc. 1989SUPERIOR CLEANBURN II GAS ENGINES PAGE 605 MODEL 16GTLB e COOLING SYSTEM Jacket Water Capacity - Engine only Gallon 186 liter (704) Jacket Water Pump ~Jacket Water Outlet Temperature, Normal Deg F 165-1860 Deg ¢ ( 76-82 ) -Design Plow Rate at Rated Speed GPM 750 liter/sec ( 47.3) Available External Head: Straight Vane(Standard) psi 29 kg/cm2 (2.04 ) Curved Vane(Optional) psi 22 kg/cm2 (1.585) -Minimum NPSH Required: Straight Vane(Standard) feet 20 meter ( 6.10 ) Curved Vane(optional) i4 (4.27) Intercooler Water Pump e -Intercooler Water Inlet Temperature, Normal Deg F 120 Deg c ( 49.0 ) ~Design Flow Rate at Rated Speed GPM 340 liter/sec (21.4) ~Available External Head: Straight Vane(Standard) psi 17 kg/om2 (1.20) ~Minimum NPSH Required: Straight Vane(Standard) feet 15 meter ( 4.57) Connection Sizes Jacket Water Inlet 6 In. 150 Lb. Jacket Water Outlet 6 In. 150 Lb. ~Intercooler Water Inlet 4 In, 150 Lb. -Intercooler Water Outlet 4 In. 150 Lb. -Vent Line to Surge Tank,Minimum Size 3/8 In. Tubing -Surge Tank Return to Pump Inlet: Jacket Water 2 In. NPT Intercooler 2 In. NPT AJAX-SUPERIOR aver. QMC, £8 608/1-09 ‘Superior® and CleanBurn™ are trademarks of Cooper Industries, In. Copyright © Cooper Industias, inc. 1988SUPERIOR CLEANBURN II GAS ENGINES PAGE 606 MODEL 16GTLB LUBRICATION SYSTEM Lube 011 Sump Capacity Gallon 220 liter (833 ) Lube 0i1 Consumption(Estimated) Gal. /Day 4.39 liter/Day (16.6 ) Lube 011 Pressure - Normal psi 35 keg/om2 (2.46 ) Temperature Out Of Engine - Normal Deg F 165-175 Deg ¢ (74-80 ) Flow Rate Through 011 Filter pM 90 liter/sec (5.68 ) Lube 0il Filters, Remote Mounted(Standard) ~Type Full Flow -Microns of Filtration Fifteen(15) Connection Sizes -Lube 0i1 Sump Drain Plug 1-1/2 In. NPT -Lube 0i1 Inlet to Engine 3 In. 150 Lb. -Lube 011 Outlet to Filter 3 In. NPT | Gl) asax-suPERIOR appr. SOMC £8 606/189 (eR ‘Superio® and CleanBurn™ are trademarks of Cooper Industvies, nc. Copyright © Cooper Industries, Inc. 1980SUPERIOR CLEANBURN II GAS ENGINES PAGE 607 MODEL 16GTLB BEARING DIMENSIONS Main Bearing, Split Shell ~Diameter In 8.00 mm ( 203.2 ) “Width In 4.88 on (124.0) ~Quantity Nos. 9 Crankpin Bearing, Split Shell -Diameter In 6.38 mn (162.1) “Width In 2.53 mn ( 64.3 ) -Quantity Nos. 16 Wrist Pin Bearing -Diameter In 3.50 nm (88.9 ) -Wiath In 3.16 nm (80.3 ) e -Quantity Nos. 16 Camshaft Bearing, Split Shell -Diameter In 2.75 an (69.9 ) -Wiath In 2.38 mn (60.5 ) -Quantity per Bank Nos. 9 DIMENSIONS AND WEIGHT (APPROXIMATE) Overall Length In 221 on ( 8613 ) Overall Width In 93 mm ( 2362 ) Overall Height In 210 mm ( 2794 ) Dry Weight Lb 54000 kg ( 24494 ) $4) AJAX-SUPERIOR appr. GAMCL cB 607/1-89 ‘Superior® and CleanBurn™ are ademarks o! Cooper Industies, ne. Copyright © Cooper Industries, Inc, 1889SUPERIOR CLEANBURN II GAS ENGINES PAGE 608 MODEL 16GTLB MISCELLANEOUS Clearance Required to Remove Piston In 89 mm ( 2261 ) Heaviest Engine Parts (Approximate Weights) cylinder Block Assembly Lb 11000 kg (4990 ) -Cylinder Head Assembly Lb 250 kg (113) -Piston and Connecting Rod Assembly Lb 198 kg (90) ~Turbocharger Assembly Lb 1400 kg (635) -Exhaust Manifold Lb 1830 kg (694) 44) asax-SUPERIOR aver._ (AMC. cB 608/1-89 ‘Suparor® and Cloanurs™ are trademarks of Cooper Incustie, Ine. Copyright © Cooper industries, nc. 1989SUPERIOR CLEANBURN II GAS ENGINES PAGE 609 MODEL 16GTLB MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN ENGLISH UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. PRIMARY FORCE - Lb SECONDARY FORCE - Lb. ! in ! ENGINE | ia 1 RPM | ‘VERTICAL =-HORIZONTAL || = VERTICAL == HORIZONTAL | | it ! | ' | oy |] 1317.079 1000.657 |} 145.720 64.879 | 800 | 1040.655 790.643 || 115.137 51.262 | 700 1 796.751 605.336 |] 88.151 39.248 600 i 585.368 444.736 || 64.764 28.835 | it PRIMARY COUPLE - [Link]. SECONDARY COUPLE - Lb. Ft. ENGINE ‘RPM VERTICAL © HORIZONTAL VERTICAL | HORIZONTAL 900 4330.740 3254.756 800 3421.820 2571.659 383.114 170.574 00 2619.832 1968.926 293.921 130.596 600 1924.773 1446.558 215.501 95.948 1 ! 1 | ! 484.878 215.883 1 ! | 1 $A) ASAX-SUPERIOR arpr._G3MC 8 609/1-89 Suparior® and Cleanturn™ are trademarks of Cooper Industries, Ine. Copyright © Cooper Inaustis, ne. 1968SUPERIOR CLEANBURN II GAS ENGINES PAGE 610 MODEL 16GTLB MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN METRIC UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. SECONDARY FORCE - kg ! im | | | i ! | SECONDARY COUPLE - [Link] ENGINE RPM VERTICAL | HORIZONTAL 900 598.941 450.133 800 473.238 355.660 52.985 23.590 100 362.323 272.302 40.566 18.061 600 266.196 200.059 29.804 13.270 | | | | | ! | | | | | | | | avaX-SUPERIOR appr. (SMC. CB 610/1-89 ey ‘Superior? and CieanBurn™ are wademarks of Cooper Industries, Ine. Gopyright © Cooper industries, Inc. 1989SUPERIOR CLEANBURN IT GAS ENGINES MODEL 166TLB PAGE 611 ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR 16GTLB - CleanBurn™ IT PERCENT] pcp ENGINE SPEED - RPM iors | esp [900 | 750 | 720 [ 600 oe Ho Tet Ehz0 | 2017 [1936 1e 1S HORSEPOWER 100 147 | 2200 | 183s | 1760 | 1467 oP 75 rio | 1650 | 1375 | 1320 | 1100 #2 3_| 1100 | 917 | 80 | 7: wr | — | |— |. aE eoriox| 10 147 7350 | 7300 | 7380 | 7880 ean i 15 110 7830 7660 | 7720 | 8250 a 50. z 3430 | e260 _| 8320 | 8800 110 161 3500 | 4673 | 4420 | 3420 Raurewent | 190 147 | 5050 | 4170 | 3960 | 3110 aun 15 ito | 3890 | 3190 | 3110 | 2790 50 3__| 2690 | 2250 | 2210 | 2050 T10 161 434] 368 | 349 271 cannon 100 147 398 328 312 246 75 110 307 | 251 245 | 220 50. 213 177 174 161 110 61 FIO] 110 | 180820 | EMMIS TATENE, 100 147 710 780 785 810 AFTER TURBO 15 +10 780 780 781 800 URGE SOF) 50 B 790 760 165 790 TIO 161] 73810] 61520] 60290] 55380 Worrenetin | 122 147 | 7070 | 57130 | 56120 | 52080 an 15 110 | 62150 | 48810 | 48070 | 45100 50 73__| 48400 | 41270 | 40835 | 39100 iro T10 Ter] 8870 | 7930 | 7795 | 7260 feat excrion | 100 147 | 8620 | 7640 | 7455 | 6725 ea 15 110 | 8060 | 6880 | 6620 | 5590 50 73_| 7330 | e110 | 5730_| 4215 Tio Jer] 15930] 11760 | 10820 | 7040 waco | oo | 16 | tere | 'ases | ‘9neo | Seco ey 5 ito | 5640 | 3530 | 3310 | 2aso 50 z toso_| 520 | 510 | 460 NOTES © 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 23t TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 1B0F JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-21/9-88 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND ANBIENT TEMPERATURE. ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10% RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. BD INTERCOOLER HEAT REJECTION BASED ON NOMINAL 4000 FT. ALTITUDE. 4 LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING 120F MAX. TO INTERCOOLER FOR RATED ENGINE PERFORMANCE, AJAX-SUPERIOR ‘Copyright © Cooper Industries, Ine. 1989SUPERIOR CLEANBURN IT GAS ENGINES MODEL 16GTLB ua ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR 16GTLB - CleanBurn™ IT PERCENT] BMEP ENGINE SPEED — RPM Rayer | &s/em2)—900_]| 750 | 720 | 600 Want SPECIFIC | 110 Tras [1605 | 1504 | 1444_| 1205 ouput 100 vse | 1641 | 1367 | 1312 | 1094 a 75 774| 1230 | 1025 984 820 50 Su 820 684 656 47 BUKE SPECIFIC [110 uss} — |— | — | — FUEL CONSWeTION] 100 tose | 2484 | 2467 | 2494 | 2663 ca HRD 15 7.74 | 2646 | 2589 | 2609 | 2788 50 15 | 2049 | 2791 | a1: 2974 INTAKE AIR FLOW | 110 1135 | 190 161 152, 118 REQUIREMENT 100 tose | 174 144 137 107 gin) 15 114 | 134 110 107 96 50. 515 95. 18 1b u 110 197 167 158 123) min 100 181 149 ta2 ] 112 15 139 14 Wt 100 50 97 80 79 73 110 tras | 410 | 410 46 438 EXHAUST TEMP. 100 tose | 410 416 418 482 AT TB 15 yia| 416 416 416 427 50 1s | 421 404_| 407 421 110) 11.35 | 18601 | 18504 | 15194 | 13957 AWCKET WATER 100 sose | 17835 | 14398 | 14143 | 13125 PEAT FE RLIIDN) 18 174 | 15663 | 12301 | 12114 | 11366 calli 50 15.| 12198 | 10401 | 10291 | 9854 110 1135 | 2235 | 1998 | 1964 | 1830 WBE OIL 100 10.32 | 2172 1925 1879 1695 HEAT REAECTION 5 7.14 | 2031 1734 1668 1409 eer 50 515 | 1847 | 1540 | 1444 | 1062 110 jiss | 4015 | 2964 | 2727 | 1774 INTERCOOLER 100 tose | 3206 | 2164 | 2006 | 1373 HEAT REJECTION 75, 774 | 1421 890 834 | 615 ain) 50 1 60 131 129 | 116 NOTES ¢ 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 23% TOLERANCE FOR FACTORY TESTS. 2 HEAT REJECTION DATA ARE BASED ON NOMINAL 82°C JACKET WATER OUTLET TEMPERATURE, REFER TO ‘GENERAL DATA SECTION, PAGE GEN-23/1-89 FOR HEAT REJECTION [Link] FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE. ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10x RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. 3D INTERCOOLER HEAT REJECTION BASED ON NOMINAL” 1200 M ALTITUDE. 1) LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING 50'C MAX. TO INTERCOOLER FOR RATED ENGINE PERFORMANCE. J} AJAX-SUPERIOR poor, NC CB 612/1-89 ‘Superior? and CloanBurn™ are wademarks of Cooper Indust ‘Copyright © Cooper industries, inc. 1980SUPERIOR CLEANBURN IT GAS ENGINES MODEL 16GTLB PAGE 613 EXHAUST EMISSIONS MODEL : 16GTLB 900 100 22001641) 15 16 06 900 75 16501231) 15 16 06 900 50 1100821) 14 eS 06 750 100 1831367) 15 16 06 750 75 13751026) 14 16 06 750 50 917684) 1A 16 06 600 100 146701094) 40 1s 06 600 75 1100821) 25 15 06 600 50 733547) 2.0 16 06 ® TONS PER YEAR = (GM/BHP-HR) x BHP + 103.6 ‘* DENOTES NON-METHANE HYDROCARBONS QUALIFYING CONDITIONS: 1) PIPELINE QUALITY GAS IS ASSUMED. METHANE CONTENT SHOULD BE GREATER THAN 90x WITH A LOW HEATING VALUE OF 900 BTU/SCF = 15s, FOR FUEL GAS OUTSIDE THESE PARAMETERS AN INDIVIDUAL REVIEW WILL BE REQUIRED TO DETERMINE EMISSION LEVELS AND FUEL CONSUMPTION RATES. 2) VALUES ARE BASED UPON 130" F MANIFOLD TEMPERATURE, «120° F INTERCOOLER WATER AND 100" F AMBIENT TEMPERATURE. REDUCED AIR MANIFOLD TEMPERATURES WILL RESULT IN LOWER NOx LEVELS. HIGHER AMBIENT TEMPERATURES WILL NOT AFFECT EMISSION LEVELS AT RATED LOAD AND SPEED BUT WILL CAUSE SLIGHTLY HIGHER NOx LEVELS AT REDUCED SPEEDS. 3D DATA SHOWN ARE BASED ON ENGINE ADJUSTMENT FOR STANDARD BSFC. FULL SPEED EMISSION VALUES ARE VALID FOR ALTITUDES BELOW 4000 FT. HIGH ALTITUDE APPLICATIONS MAY REQUIRE TURBOCHARGER MODIFICATION TO MAINTAIN ENISSION RATES. 4) WHEN NOx REQUIREMENTS LESS THAN THOSE EXPRESSED HERE ARE ENCOUNTERED, THERE ARE TRADE-OFFS BETWEEN NOx AND BSFC WHICH MAY BE APPLICABLE, BUT THESE MUST BE EVALUATED ON A SPECIFIC CASE BASIS. AJAX-SUPERIOR appr MAC cB 613/1-89 Superior® and CieanBurn"™ are trademarks of Cooper industries, Ine. Copyright © Cooper ndustres, ne, 1989SUPERIOR CLEANBURN II GAS ENGINE. MODEL 16GTLB PAGE 615 ® WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS io 90 ENGINE_RPM wm 900 ~ 80 DESIGN, 5 70 FLOWS Tj] Z 60 750 feat | Se 7 a 40 600 + ——}—— iz wo > 20 aot 10 [ENGINE PRESSURE 4 -- t=] | e@ ° 0 200 400 Cr FLOW (GPM) IMPELLER P/N D-024-003 (STRAIGHT VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (BIDIRECTIONAL CAPABILITY) NORMALLY [Link] (FACING DRIVE END) NPSHg = 20.0 FEET @ 900 RPM & 750 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT_THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 750 GPM = 97.0 FT. ~ 30.0 FT. = 67.0 FT. 67.0 FT. + 231 = 29.0 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. AJAX-SUPERIOR appr, _Gah\ACe cB 615/1-89 ‘Superior? and CisanBurn™ are trademarks of Cooper Industrie, Inc. Copyright © Cooper industies, nc. 1989SUPERIOR CLEANBURN IT GAS ENGINE MODEL 166TLB PAGE 616 WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS 110 100 ENGINE RPM 90 200 80 DESIG! < 70 FLOWS i 60 | 750 | A] 7 50 \ ta 40 600 [| 30 7 TDH (FEET) = CaaS 10 a )hCLUhUrUr ° ieee DROP, ° 200 400 600 800 900 FLOW (GPM) IMPELLER P/N D-033-744-002 (CURVED VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (UNIDIRECTIONAL) C.C.W (FACING DRIVE END) NPSHp = 14.0 FEET @ 900 RPM & 750 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 750 GPM = 800 FT- 300 FT. = 500 FT. 50.0 FT. + 231 = 22.0 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. AJAX-SUPERIOR aspr, SNC ©B 616/1-89 ‘Superior? and CleanBurn™ are vadematks of Cooper Industrie, Inc. Copyright © Cooper industies, nc. 1989SUPERIOR CLEANBURN I! GAS ENGINE MODEL 16GTLB PAGE 617 WATER PUMP CHARACTERISTICS INTERCOOLER WATER SYSTEM DESIGN FLOWS AND PRESSURE DROPS 90 ENGINE RPI ad 900 70 DESIGN 7 co FLOWS - Ly 750 2% 7 40 B 600 4 P 30 z 20 ug ENGINE PRESSURE 0 beet [oROP, t ° 100 200 300 400 500 FLOW (GPM) IMPELLER P/N C-016-879 (STRAIGHT VANE) PUMP RPM = 2.053 X ENGINE RPM DIRECTION OF ROTATION @I-DIRECTIONAL CAPABILITY NORMALLY C.C.W (FACING DRIVE END) NPSHg = 15.0 FEET @ 900 RPM & S40 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 340 GPM = 740 FT- 35.0 FT. = 39.0 FT. 39.0 FT. + 2.31 = 17.0 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. (@llasaxsurenion appr, MC 8 617/1-89 ‘Superior? and CleanBurn™ ave trademarks of Cooper Industries, Inc Copyright © Cooper industries, Ic. 1989Tea Times ane tomacnoe [ee iea | PAGE 619A Baie mc? counterion Heo Ree com [are ett 8 ee Tact ef oeresccec wat Hise rr hat FTotcteoocte wat ise inet | Cf uae ou out 10 conte a reel swe Pater TT ine on a 780 Pos ma | statine ugton antT +e Teraatine voten coat ‘Ol watts out TO coveatsin on [eT ees sooner srr aa NOTE:CONN MAY VARY MITHEACH UNIT Fee STANDARD PANEL _CTUBING CONN? OTE: CONN MAY VARY WITH EACH UNIT (er TAINTEOAD PANEL (TUBING CONN? Ta iat concer waco we eurenion ea ay pureaion SUPERTOR To ORAS Gueawanmn 11 (ee st MODEL 16GTLB reer ‘WITHOUT OIL FILT s(Guremor) CleanBurn'll Gas Engine n. Model 16GTLB‘SUPERIOR CLEANBURN II GAS ENGINES MODEL 16SGTB ENGINE SECTION INDEX Description Page No. Air Intake system 04 Bearing Dimensions 107 Cooling System 105 Dimensions and Weight 107 Engine Operating Data -Units In English Units 711 Units In Metric Units 712 Engine Outline Drawing 719 Engine Performance 103 Engine Specifications 701 Exhaust Emissions 713 Exhaust System 704 Fuel system 104 Heat Rejection Data Units In English Units 711 -Units In Metric Units 712 Lubrication system 706 Miscellaneous 708 Starting System 103 Turbocharger 704 Unbalanced Forces and Couples -Units In English Units 709 -Unite In Metric Units 710 Water Pump Characteristics -Jacket Water, Straight Vane 715 -Jacket Water, Curved Vane 716 -Intercooler,| Straight Vane 717 -Intercooler, Curved Vane N/A | GU asax-suPERIOR &SUPERIOR CLEANBURN II GAS ENGINES MODEL 16SGTB PAGE 701 ENGINE SPECIFICATIONS Type Aspiration Cylinder Configuration Number of Cylinders Bore - in. (mm) Stroke - in. (mm) Displacement - [Link]. (liter) Compression Ratio Power Rated - BEP (kW) Speed Rated - RPM Piston Speed - FPM(m/s) Speed Range - RPM Ignition System Fuel system Governor Turbocharger Exhaust Manifold Jacket Water Pump Jacket Water Thermostat Intercooler Water Pump Intercooler Water Thermostat Lube 041 Pump Lube 0i1 Thermostat Prelube Pump Lube 0i1 Cooler Intercooler Crankcase Breather Crankcase Doors Direction of Rotation {Gl} auax-supenion Four (4)~Cycle Turbocharged, Intercooled Vee Sixteen (16) 10 (254) 10.80 (266.7) 43195 (216.27) 8.20: 1 2650 (1976) 900 1575 (8.0) 900 - 600 Non-Shielded, Altronic III Fuel Injected with Electronic Air-Fuel Control and Manual Starting Logic Hydraulic (UG-8L) With Manual Speed Setting one(1) Water Cooled Built-In Centrifugal, Chain Driven Remote Mounted Built-In Centrifugal, Chain Driven Remote Mounted Gear Type with Pressure Regulating Valve Remote Mounted Manual, Mounted and Piped Shell & Tube Type(Unmounted) Rectangular, Shell & Tube/Fin Type Positive Ventilation Pressure Relief (Bicera Type) Doors Counterclockwise From Flywheel End arer. QC. ‘Superior? and CloanBurn™ are trademarks of Cooper Industvies, In. Copyright © Cooper Industries, Ine. 1988 cB 701/1-89SUPERIOR CLEANBURN II GAS ENGINES MODEL 16SGTB PERFORMANCE Engine Operating Data Rating Conditions “Altitude -Temperature Rated Torque Over 900-600 RPM Range Brake Mean Effective Pressure (BMEP) Rating Rated Brake Specific Fuel Consumption (BSFC) (Plus or Minus 3 Percent Factory Tolerance) Heat Rejection Data Emissions STARTING SYSTEM Air/Gas Starting Motor Make & Model Number of Starting Motors: Generator Drive Compressor Drive Supply Air/Gas Pre Consumption Rate/Starter Motor -Air is - Normal Starting Time Connection Sizes -Inlet -Outlet -Optional: Inlet Flange outlet Flange AJAX-SUPERIOR aper._ MC ce ‘Superior? and CioanBurn™ PAGE 703 See Page 711 & 712 teet 4000 meter (1219 ) Deg F 100 Deg ¢ (37.8 ) lb-ft 15464 M-kg (2139 ) psi 177.8 kg/om2 (12.5 ) Btu/bhp-hr 7100 keal/kW-hr ( 2399 ) See Page 711 & 712 See Page 713 IR / S8-825 one(1) Two(2) pei 150 kg/cm2 (10.5 ) scfm 1500 liter/sec (708 ) scfm 1781 liter/sec ( 841 ) sec 15 3-1/2 In. NPT 2-1/2 In. NPT 1-1/2 In. Square 2-1/2 In. 150 Lb. pcOe70s/U=ooe= se vadomarks of Cooper Industies, ie. Copyright © Cooper Indust, In. 1988,SUPERIOR CLEANBURN II GAS ENGINES MODEL 16SGTB AIR INTAKE SYSTEM Intake Air Plow Rate Max. Allowable Pressure Drop Air Intake, Inlet Connection FUEL SYSTEM Required Fuel Gas Pressure to Engine Based on Pipeline Quality Natural Gas (Regulated to within plus or minus 1 psig) Gas Inlet Flange Connection EXHAUST SYSTEM Max. Allowable Back Pressure Exhaust Outlet Flange Connection Size Exhaust Flow Rate Stack Temperature TURBOCHARGER Type Manufacturer Model Speed (Maximum) PAGE 704 See Page 711 & 712 In H20 10 mm H20 (264) 18 In, I.D. Flex Connector psi 35-40 kg/em2 — (2.5-2.8 ) 2 In. 150 Lb. In H20 10 mm H20 (254) 18 In, 150 Lb. FF See Page 711 & 712 See Page 711 & 712 Constant Pressure Elliott BC 370 RPM 23000 (Gl) aiaxsurenion apr. G3MAC £8 708/1-89 Superior® and CleanBurn"™ ar trademarks of Cooper Industries, nc Copyright © Cooper industries, In. 1969SUPERIOR CLEANBURN II GAS ENGINES MODEL 16SGTB COOLING SYSTEM Jacket Water Capacity - Engine only Jacket Water Pump -Jacket Water Outlet Temperature, -Design Flow Rate at Rated Speed ~Available External Head: Straight curved -Minimum NPSH Required: Straight curved Intercooler Water Pump ~Intercooler Water Inlet Temperaturre, -Design Flow Rate at Rated Speed -Available External Head: Straight -Minimum NPSH Required: Straight Connection Sizes -Jacket Water Inlet ~Jacket Water Outlet Intercooler Water Inlet -Intercooler Water Outlet -Vent Line to Surge Tank, Minimum -Surge Tank Return to Pump Inlet: [4] wax-suPeRion PAGE 705 Gallon 186 liter (| 704 ) Normal Deg F 165-180 Deg (74-82 ) GPM 178 liter/sec ( 48.9 ) Vane(Standard) psi 29 keg/cm2 ( 2.04 ) Vane(Optional) psi 21.2 keg/om2 (1.49) vane(Standard) feet 20 meter ( 6.10 ) Vane(Optional) feet 14 meter (4.27) Normal Deg F 120 Deg c (49.0 ) GEM 340 liter/sec (21.4 ) Vane(Standard) psi 17 keg/cm2 (1,20) Vane(Standard) feet 15 meter (4.87) 6 In. 150 Lb. 6 In, 150 Lb. 4 In. 150 Lb. 4 In. 150 Lb. Size 3/8 In. Tubing Jacket Water 2 In. NPT Intercooler 2 In. NPT aper._ GM CB 705/1-89 ‘Superior? and CleanBumn™ are trademarks of Cooper Industries, nc. Copyright © Cooper industries, nc. 1988SUPERIOR CLEANBURN II GAS ENGINES PAGE 706 MODEL 16SGTB LUBRICATION SYSTEM Lube 011 Sump Capacity Gallon 220 liter (| 833 ) Lube 0i1 Consumption(gstimated) Gal. /Day 5.28 liter/Day (20.0 ) Lube Oil Pressure - Normal psi 35 kg/om2 (2.46) Temperature Out Of Engine - Normal Deg F 165-175 Deg © ( 74-80 ) Flow Rate Through Oil Filter GEM 90 liter/sec (5.68 ) Lube Oi] Filters, Remote Mounted(Standard) -Type Full Flow ~Microns of Filtration Fifteen(15) Connection Sizes -Lube 0i1 Sump Drain Plug 3-1/2 In. NPT -Lube 041 Inlet to Engine 3 In, 150 Lb. -Lube 011 Outlet to Filter 3 In. NPT AJAX-SUPERIOR APPR. BM¢ A. CB 706/1-89 Superior® and CleenBurn"™ are trademarks of Cooper industies, in. Copyright © Cooper industries, nc. 1989‘SUPERIOR CLEANBURN II GAS ENGINES PAGE 707 MODEL 16SGTB BEARING DIMENSIONS Main Bearing, Split Shell -Diameter In 8.00 mn (203.2 ) “Width In 4.88 mm (124.0 ) -Quantity Nos. 9 Crankpin Bearing, Split Shell Diameter In 6.38 an ( 162.1 ) -Width In 2.53 mm ( 64.3 ) -Quantity Nos. 16 Wrist Pin Bearing Diameter In 3.50 am ( 88.9 ) “Width In 3.16 am ( 80.3 ) r) -quantity Nos. 16 Camshaft Bearing, Split Shell -Diameter In 2.75 an (69.9 ) -Width In 2.38 mn (60.5 ) ~Quantity per Bank Nos. 9 DIMENSIONS AND WEIGHT (APPROXIMATE) Overall Length In 221 mn ( $613 ) Overall Width In 93 mn ( 2362 ) Overall Height In 110 mm ( 2794 ) Dry Weight Lb 54000 kg ( 24494 ) 4 AJAX-SUPERIOR arer._ MC cB _707/1-89 ‘Superior? and CleanBura™ are wademarks of Coopes Industries Inc. Copyright © Cooper ndustrios, io. 1889SUPERIOR CLEANBURN II GAS ENGINES PAGE 708 MODEL 16SGTB MISCELLANEOUS Clearance Required to Remove Piston In 89 mm ( 2261 ) Heaviest Engine Parts (Approximate Weights) ~Cylinder Block Assembly Lb 11000 kg (4990 ) ~Cylinder Head Assembly Lb 250 kg (413) -Piston and Connecting Rod Assembly Lb 198 kg (90) ~Turbocharger Assembly Lb 1400 kg (635 ) -Exhaust Manifold Lb 1530 kg (694 ) |G) Asax-SUPERIOR appr._(3MCy eceUOsiLeoee ‘Superio® and CleanBurn™ are trademarks of Cooper Industries, nc. Copyright © Cooper industries, Ic. 1989‘SUPERIOR CLEANBURN II GAS ENGINES PAGE 709 MODEL 16SGTB MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN ENGLISH UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. ENGINE RPM 900 1317.079 1000.657 800 1040.655 790.643 115.137 51.262 700 796.751 605.336 [Link] 39.248 600 585.368 444.736 64.764 28.835 | | | ! | it 145.720 64.879 ! ! f SECONDARY COUPLE - [Link] ENGINE RPM VERTICAL © HORIZONTAL 900 4330.740 3254.756 800 3421.820 2571.659 383.114 170.574 100 2619.831 1968.926 293.321 130.596 600 1924.773 1446.558 215.501 95.948 1 ! 1 1 ! 1 1 1 ! | ! 1 484.878 215.883 1 1 ! 1 | | | | AJAX-SUPERIOR appr. G3MC cB 709/1-89 ‘Superior® and CieanBurn™ are wademarks of Cooper Industries, Ine. Copyright © Cooper Industries, Ine. 1988SUPERIOR CLEANBURN II GAS ENGINES PAGE 710 MODEL 16SGTB MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN METRIC UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted, that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. SECONDARY FORCE - kg I! ! ENGINE | tH | RPM | “VERTICAL = HORIZONTAL || VERTICAL HORIZONTAL | ! Wl | l ' 1 900 | 897.427 453.898 || 66.099 29.429 | om | 472.041 358.636 || 52.226 23.252 | 700 | 361.406 274.580 |{ 39.985 17.803 | Cry 265.523 201.732 || 29.377 13.080 | | ul | SECONDARY COUPLE - [Link] ENGINE RPM VERTICAL | HORIZONTAL 900 598.941 450.133 67.059 29.857 800 473,238 355.660 52,985 23.590 700 362.323 272.302 40.566 18.061 600 266.196 200.059 29.804 13.270 t----~-+-4-1 AJAX-SUPERIOR appr. (MCU cB _710/1-89 Superior® and CleanBurn"™ are trademarks of Cooper Industries, Ine. Copyright © Cooper industries, Inc. 1980‘SUPERIOR CLEANBURN IT GAS ENGINES MODEL 16SGTB Celene ENGINE OPERATING DATA AND HEAT REJECTION ™ SUPERIOR 16SGTB - CleanBurn™ IT PERCENT] puicp ENGINE SPEED — RPM Mae _| esp [900] 750 | 720 | 600 BRAKE 110) 194 2915 ae | OSS 1945 HORSEPOWER 100 177, | 2650 | 2208 | 2120 | 1767 an 75 133 | 1988 | 1656 | 1590 | 1325 0 88 1325 | 1104 | 1060 | 88 cane seciric | 110 SA ee rete eet tae A corsuarrion) 100 177 | 7100 | 7150 | 7230 | 7680 aime ane 15 133 7530 | 7400 | 7470 | 8000 ae 50 28 ai30_| 7950 | 8010 | 8500 110 194 | 6500 | 5790 | 5450 | 4120 oon | 100 177, | 5970 | 5260 | 4960 | 3750 con 75, 133 | 4650 | 3a37 | 3655 | 2925 50. ae_| 3215 | 2680 | 2640 | 2470 : Tio 194 S10 | 453 | 430 | 327 eee 100 177 410 4i2 390 | 300 75 133 310 | 304 | 290 | 230 50. Ba 250 | 212 | 209 195. T Tk “TT 194 70 (44 B30 EXHAUST TENP. 100 7 780 760 715 820 - TERED 75 785 780 785 810 133 GuanceR 507) | 50 38 790 | 760 | 765 | 790 110 i94 | 85020 | 12060] -Toa7e_| 64120, einen | 190 177 | 77500 | 66600 | 65060 | 58900 ae 78 133 | 67590 | s3270 | 52330 | 48580 50. aa__| 54550 | 44160 | 43750 | 42090 iavon T10 194 | 9720 | 8740 | 8740 | 8740 enienenon 200 177, | 9275 | 8280 | 8220 | 7950 farina 75 133 | 820 | 7314 | 7110 | 6290 50 aa_| 7620 | 6440 | 6140 | 4930 110 194] 23750 | 20730) 18880] 11460, taraeeerion | 100 177 | 19560 | 16045 | 14660 | 9130 Leu 75 133 | 9940 | 6430 | 5990 | 4250, 50 ge_| 2450 | 1470 | 1365 | 950 notes 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES. SUBJECT TO 23% TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 180F JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-21/9-88 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING, HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE. ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10x RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. 3D INTERCOOLER HEAT REJECTION BASED ON NOMINAL 4000 FT. ALTITUDE, 4) LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING 120F MAX. TO INTERCOOLER FOR RATED ENGINE PERF ORMANCE. $4) AJAX-SUPERIOR Post-it" Fax Note ert 3) lon eis” 2 PP Por mB YER Pep es HokC. 4 aibont B29 PeF SD Gey ~ £759 Cooper industvies, ine,SUPERIOR CLEANBURN II GAS ENGINES MODEL 16SGTB pase le ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR 16SGTB - CleanBurn™ IT PERCENT] BWEP ENGINE SPEED — RPM RATED | tka/em2) 900 | 750 | 720 | 600 BRA SFECIFIC [110 sea | 2iva | ier [i739 | 1449 oureut 100 1245 | 1976 | 1647 | 1581 | 1318 ap 15 935 | 1482 | 1235 | 1186 988 50 6.19 | 988 | 92 730 658 BRAKE SPECIFIC. [110 isos | — | — | — | — FUEL CONSWATION| 100 1245 | 2309 | 2416 | 2443 ] 2595 cd HD 15 935 | 2545 | 2501 | 2525 | 2704 50 gio | 2748 | 2687 o7_|_ 287: INTAKE AIR FLOW | 110 7364 | 224 | 200 188 142, REQUIREMENT 100 1245 | 206 181 71 129 agMinn 15 935 | 160 132 126 101 50 619 | itt 92 ot BS 110) 1364 | 231 205 195 148 ae Led 100 1245 | 213 187 17 136 15 gas | 168 138 132 104 0. 619 | ize 96 95 88 110) 1364 | 410 404 a3 443 Pats 100 1245 | 416 404 | 413 438 eee 15 935 | 418 416 418 432 50 gig | 421 404 407 421 110) 7364 | 2426 | 18160 | 17760 | 16159 SMCIET WATER 100 1245 | 19531 | 16784 | 16396 | 14844 eae 75 935 | 17034 | 13425 | 13188 | 12243 Cau) 50 19 | 13747 | 11129 | t10z6 | 10607 110 1364 | 2450 | 2203 | 2203 | 2203 LUBE OL 100 1245 | 2337 | 2087 | 2072 | 2004 HEAT REJECTION 15 935 | 2087 | 1843 | 1792 | 1585 ea) 50 619 | 1920 | 1625 | 1547 | 124% 110 j364 | 5985 | se24 | 4758 | 2888 INTERCOOLER 100 1245 | 4929 | 4044 | 3695 | 2501 HEAT REJECTION 15 535 | 2505 | 1620 | 1510 | 1071 {ica utNo 50 619 | __ 617 370 344 | _239 NOTES © 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO #31 TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 82% JACKET WATER OUTLET TENPERATURE, REFER TO ‘GENERAL DATA SECTION, PAGE GEN-23/1-89 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE. ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10x RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. 3) INTERCOOLER HEAT REJECTION BASED ON NOMINAL 1200 M ALTITUDE. 14) LUBE OIL. COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING 50% MAX. TO INTERCOOLER FOR RATED ENGINE PERFORMANCE. (4) asax-SuPERIOR por, GNC eORIEIEe ‘Superior® and CleanBur™ are Copyright © Cooper industies, marks of Cooper Industries, Inc. 988SUPERIOR CLEANBURN II GAS ENGINES MODEL 16SGTB ee e EXHAUST EMISSIONS MODEL : 16SGTB PERCENT RAMS/BHP-HR) RPM |rario” | BHPCKW) oe ee 900 100 265001977) 15 16 06 900 15. 199801483) 15. 16 06 900 50 1325(988) 14 16 06 750 100 2208(1647) 4S 16 06 750 75 165601235) 14 — 06 750 50 11041824) 13 15 06 600 100, 176701318) 6.0 VA 06 coo | 75 | 1325080 | 30 La 08 600 50 88659) 20 16 06 e ®* TONS PER YEAR = (GM/BHP-HR) x BHP + 1036 ‘DENOTES NON-METHANE HYDROCARBONS ‘QUALIFYING CONDITIONS. 1) PIPELINE QUALITY GAS IS ASSUMED. METHANE CONTENT SHOULD BE GREATER THAN 90: WITH A LOW HEATING VALUE OF 900 BTU/SCF + 151, FOR FUEL GAS OUTSIDE THESE PARAMETERS AN INDIVIOUAL REVIEW WILL BE REQUIRED TO DETERMINE EMISSION LEVELS AND FUEL CONSUMPTION RATES. 2) VALUES ARE BASED UPON 130" F MANIFOLD TEMPERATURE, <120" F INTERCOOLER WATER AND 100" F AMBIENT TEMPERATURE, REDUCED AIR MANIFOLD TEMPERATURES WILL RESULT IN LOWER NOx LEVELS. HIGHER ‘AMBIENT TEMPERATURES WILL NOT AFFECT EMISSION LEVELS AT RATED LOAD AND SPEED BUT WILL CAUSE SLIGHTLY HIGHER NOx LEVELS AT REDUCED SPEEDS. 5D DATA SHOWN ARE BASED ON ENGINE ADJUSTMENT FOR STANDARD BSFC. FULL SPEED EMISSION VALUES ARE VALID FOR ALTITUDES BELOW 4000 FT. HIGH ALTITUDE APPLICATIONS MAY REQUIRE TURBOCHARGER MODIFICATION TO MAINTAIN EMISSION RATES. 4) WHEN NOx REQUIREMENTS LESS THAN THOSE EXPRESSED HERE ARE ENCOUNTERED, THERE ARE TRADE-OFFS BETWEEN NOx AND BSFC WHICH MAY BE APPLICABLE, BUT THESE MUST BE EVALUATED ON A SPECIFIC CASE e BASIS, AJAX-SUPERIOR appr 3M Cy cB 715/1-89 ‘Superior® and CleanBumn™ are wademarks of Cooper Industries, ne. Copyright © Cooparindusties, Inc. 1869SUPERIOR CLEANBURN II GAS ENGINE MODEL 16SGTB PAGE 715 e WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS 110 . ae RPM an 9 = ea rows S| 7 60 750 x 80 z a 40 600 * x0 [> . A SSURE ° TE @ ° 200 400 600 800 900 FLOW (GPM) IMPELLER P/N D-024-003 (STRAIGHT VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION @I-DIRECTIONAL CAPABILITY) NORMALLY C.C.W (FACING DRIVE END) NPSHp = 20.0 FEET @ 900 RPM & 775 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT_THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 775 GPM = 97.0 FT. - 30.0 FT. = 67.0 FT. 67.0 FT. + 2.31 = 29.0 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. $)| asax-SUPERIOR ‘appr_SA3MWC CB 715/1-89 ‘Superor® and CleanBurn™ are wademarks of Cooper Industrie, Inc. Copyright © Cooper industries, nc. 1969SUPERIOR CLEANBURN II GAS ENGINE MODEL 16SGTB PAGE 716 WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS 110 Wy ans RPM 90 peo) es cel DESIGN| KF a9 IFLOws | WI Zz i 60 J = 50 a 40 600 4 30 20 ao ug Ss +- ENGINE PRESSURE ° =+=—4 DROP. ° 200 400 600 B00 900 FLOW (GPM) IMPELLER P/N D-033-744-002 (CURVED VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (UNIDIRECTIONAL) C.C.W (FACING DRIVE END) NPSHp = 14.0 FEET @ 900 RPM & 775 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 775 GPM = 79.0 FT~ 300 FT. = 49.0 FT. 49.0 FT. + 2.31 = 212 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. (Gi] aiax-surcrion appr AMC CB 716/1-89 ‘Superior? and CleanBurn™ are trademarks of Cooper Industries, Ine. Copyright © Cooper industries, Inc. 1989SUPERIOR CLEANBURN 11 GAS ENGINE MODEL 16SGTB PAGE 717 WATER PUMP CHARACTERISTICS INTERCOOLER WATER SYSTEM DESIGN FLOWS AND PRESSURE DROPS 90 ENGINE RPI ad 900 | —— DESIGN 7 60 FLows TS Z 50 is) Sa ao i 20 TDH (FEET) 8 3 \ y TN ue = LENGINE PRESSURE ° -k DROP, Fl t 0 100 200 300 400 500 FLOW (GPM) IMPELLER P/N C-016-879 (STRAIGHT VANE) PUMP RPM = 2.033 X ENGINE RPM DIRECTION OF ROTATION (BI-DIRECTIONAL CAPABILITY) NORMALLY C.C.W (FACING DRIVE END) NPSHp = 15.0 FEET @ 900 RPM & 340 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE. SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE Ca oil se leo 39.0 FT. + 2.31 S| ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. | asax-SUPERIOR appr, S3N\C CB 717/1-89 ‘Superioe® and ClaanBurn™ aro vademarks of Cooper Industries, nc. Copyright © Cooper Industries, Ine. 1968J fe PAGE 719A be S z £ ee Le: ee OTE: CONN MAY VARY WITH EACH UNIT m= “AIRE OAD PANEL_TUBING CORND ia Conc wae we his aine i tins ‘SUPERIOR _ oe (2), SUPERIOR SUPERIOR OUT DRAWN CLEANBURN 11 foe — fre ee MODEL 16SGTB | —fr6SCTB| “UTTHOUT OIL FITTERS(Seren) CleanBurn'll Gas Engine Model 16SGTB 3 noSUPERIOR TURBOCHARGED GAS ENGINES MODEL 6GTL ENGINE SECTION INDEX Cooling System 105 Dimensions and Weight 107 Engine Operating Data Engine Outline Drawing 119 Exhaust System 104 Puel System 104 Turbocharger 104 Unbalanced Forces and Couples -Intercooler, Curved Vane N/A AJAX-SUPERIORSUPERIOR TURBOCHARGED GAS ENGINES MODEL 6GTL PAGE 101 ENGINE SPECIFICATIONS Type Aspiration Cylinder Configuration Number of Cylinders Bore = in. (mm) Stroke - in. (mm) Displacement ~ [Link]. (liter) Compression Ratio Power Rated - BHP (kW) Speed Rated - RPM Piston Speed - FPM(m/s) Speed Range - RPM Ignition System Fuel system Governor Turbocharger Exhaust Manifold Jacket Water Pump Jacket Water Thermostat Lube 0i1 Pump Lube Oil Thermostat Prelube Pump Lube Oil Cooler Intercooler Intercooler Water Thermostat Crankcase Breather Crankcase Doors Direction of Rotation 5] AJax-SUPERIOR Four (4)-Cycle Turbocharged, Intercooled Inline Six (6) 10 (254) 10.50 (266.7) 4948 (81.10) 8.20: 1 825 (615) 900 1575 (8.0) 900 - 600 Non-Shielded, Altronic III Fuel Injected with Analog Type Electronic Air-Fuel Control and Manual Starting Logic Hydraulic (UG-8L) With Manual Speed Setting one(1) Water Cooled Built-In Centrifugal, Belt Driven Engine Mounted Gear Type with Pressure Regulating Valve Engine Mounted Manual, Mounted and Piped Shell & Tube Type,Mounted and Piped Rectangular, Shell & Tube/Fin Type Engine Mounted Positive Ventilation Pressure Relief (Bicera Type) Doors Counterclockwise From Flywheel End Te 101/1-89 aren, ONC, ‘Superior? and CloanBurn™ are trademarks of Cooper Industries, nc. Copyright © Cooper nausties, nc. 1989SUPERIOR TURBOCHARGED GAS ENGINES PAGE 103 MODEL 6GTL © rreroennce Rating Conditions Altitude feet 4000 meter (1219 ) -Temperature Deg F 100 Deg ¢ ( 37.8 ) Rated Torque Over 900-600 RPM Range Ab-ft 4016 M-kg ( 666 ) Brake Mean Effective Pressure Rating/BMEP psi 146.7 kg/cm2 (10.3 ) Rated Brake Specific Fuel Consumption/BSFC Btu/bhp-hr 7400 (Plus or Minus 3 Percent Factory Tolerance) keal/kW-hr ( 2501 ) Heat Rejection Data See Page 111 & 112 Emissions See Page 113 @ szacrmne syste Air/Gas Starting Motor Make & Model IR / SS-825 Number of Starting Motors one(1) Supply Air/Gas Pressure psi 150 keg/cm2 (10.5 ) Consumption Rate/Starter Motor Air scfm 1400 liter/sec (661 ) -Gas scfm 1663 liter/sec (785 ) - Normal Starting Time sec 15 Connection Sizes -Inlet 3-1/2 In. NPT Outlet 2-1/2 In. NPT ~Optional: Inlet Flange 1-1/2 In. Square outlet Flange 2-1/2 In. 150 Lb. AJAX-SUPERIOR Gike. TC 103/1-89 Superior® and CleanBuri™ are vademarks of Cooper Industries, nc. ‘Copyright © Cooper industries, Inc. 1989SUPERIOR TURBOCHARGED GAS ENGINES PAGE 104 MODEL 6GTL AIR INTAKE SYSTEM Intake Air Flow Rate See Page 111 & 112 Max. Allowable Pressure Drop In #20 10 mm H20 (254 Air Intake, Inlet Connection 10 In. 1.D, Flex Connector FUEL SYSTEM Required Fuel Gas Pressure to Engine psi 35-40 Based on Pipeline Quality Natural Gas kg/em2 — (2.5-2.8 (Regulated to within plus or minus 1 psig) Gas Inlet Flange Connection 2 In. 150 Lb. EXHAUST SYSTEM Max. Allowable Back Pressure In #20 10 mm H20 (254 Exhaust Outlet Flange Connection Size 10 In. 150 Lb. FF Exhaust Flow Rate See Page 111 & 112 Stack Temperature See Page 111 & 112 TURBOCHARGER Type Pulse Manufacturer Cooper-Bessemer Model ET ii Speed (Maximum) REM 27000 S| AJaX-SUPERIOR appr._ GNC Tc 104/1-89 Superior and CioanBurn™ are tradomarks of Cooper Industrie, Ine ‘Copyright © Cooper Industries, Inc. 1989SUPERIOR TURBOCHARGED GAS ENGINES PAGE 105 MODEL 6GTL e COOLING SYSTEM Jacket Water Capacity - Engine Only Gallon 54 liter (204) Jacket Water Pump -Jacket Water Outlet Temperature, Normal Deg F 165-180 Deg c ( 74-82 ) -Design Flow Rate at Rated Speed GEM 275 liter/sec (17.3 ) “Available External Head: Straight Vane(Standard) psi 23 kg/cm2 (1.62 ) Curved Vane(optional) psi 29 kg/om2 (2.04 ) -Minimum NPSH Required: Straight Vane(Standard) feet 4 neter (4.27) Curved Vane(Optional) feet 8.5 meter (2.89 ) Intercooler system e@ “Intercooler Water Inlet Temperature, Normal Deg F 120 Deg ¢ (49.0 ) -Design Flow Rate GPM 70 liter/sec (4.42 ) Pressure Drop (Includes Lube 041 Cooler, psi 9.6 Intercooler and Thermostat) keg/cm2 (0.68 ) Connection Sizes ~Jacket Water Inlet 4 In. 150 Lb. ~Jacket Water Outlet 3 In. 150 Lb. Intercooler Water Inlet 2-1/2 In. Pipe ~Intercooler Water Outlet 2 In. Pipe ~Vent Line to Surge Tank,Minimum Size 3/8 In, Tubing -Surge Tank Return to Pump Inlet 3-1/2 In. NPT |) Asax-SUPERIOR appr. G3N\\C/ TC 105/1-89 ‘Superior® and CleanBura™ are trademarks of Cooper Industries, Inc. Copyright © Cooper industries, ic. 1889SUPERIOR TURBOCHARGED GAS ENGINES PAGE 106 MODEL 6GTL LUBRICATION SYSTEM Lube Oil Sump Capacity Gallon 65 liter ( 246) Lube 011 Consumption(Estimated) Gal./Day 1.65 liter/Day (6.25 ) Lube Oil Pressure - Normal psi 35 kg/em2 (2.46) Temperature Out Of Engine - Normal Deg F 165-175 Deg c (74-80 ) Flow Rate Through 0i1 Filter GEM 35 liter/sec (2.21 ) Lube Oil Filters, Engine Mounted(Standard) -type Full Flow -Microns of Filtration Pifteen(15) Connection Sizes -Lube 011 Sump Drain Plug 1-1/2 In. NPT 4 AJAX-SUPERIOR appr. GNC __Te 106/1-89_ ‘Superor® and Cleanurn™ are wademarks of Cooper Industrie, Inc. Copyright © Cooper industries, Inc. 1989SUPERIOR TURBOCHARGED GAS ENGINES PAGE 107 MODEL 6GTL Oo eeetcente Main Bearing, Split Shell ~Diameter In 6.00 mn (152.4) “Width In 3.50 mm ( 88.9 ) ~Quantity Nos. 1 Crankpin Bearing, Split Shell -Diameter In 5.75 mm ( 146.0 ) -Width In 3.63 mn (92.2) ~Quantity Nos. 6 Wrist Pin Bearing -Diameter In 3.50 mn (88.9 ) -Width In 3.16 mm (80.3 ) e -Quantity Nos. 6 Camshaft Bearing, Split Shell -Diameter In 2.25 mm (87.2) -Width In 1.63 mn (41.4) -Quantity Nos. 8 DIMENSIONS AND WEIGHT (APPROXIMATE) Overall Length In 145 mm ( 3683 ) Overall Width In 67 an (1702 ) Overall Height In 96 mn ( 2438 ) Dry Weight Lb 18600 kg (8437 ) AJAX-SUPERIOR appr. (SNC, TC 107/1-89 ‘Superior® and Cloanfumn™ sre trademarks of Cooper Industies, inc. ‘Copyright © Cooper Inausties, nc. 1988SUPERIOR TURBOCHARGED GAS ENGINES PAGE 108 MODEL 6GTL MISCELLANEOUS Clearance Required to Remove Piston In 81.75 mn { 2076 ) Heaviest Engine Parts (Approximate Weights) -cylinder Block Assembly Lb 3500 kg (1588 ) ~Cylinder Head Assembly Lb 250 kg (113 ) -Piston and Connecting Rod Assembly Lb 192 kg (87) ~Turbocharger Assembly Lb 930 kg (022) ~Exhaust Manifold Lb 495 kg (225) Zi) AJAX-SUPERIOR appr. CMC TC 108/1-89 ‘Superio® and CloanBurn™ are wademarks of Cooper Industries, Ine. Copyright © Cooper industries, Ie, 1989SUPERIOR TURBOCHARGED GAS ENGINES PAGE 109 MODEL 6GTL MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN ENGLISH UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. PRIMARY FORCE ~ Lb. SECONDARY FORCE - Lb. ENGINE REM VERTICAL © HORIZONTAL VERTICAL | HORIZONTAL 900 576.743 335.115 60.407 ° 800 455.698 264.115 47.729 ° 700 348.894 202.724 36.542 ° 600 256.330 148.940 26.847 ° SECONDARY COUPLE ~ [Link] PRIMARY COUPLE - [Link] 1 ut ! ENGINE | i 1 RPM | _—-VERTICAL =—=-HORIZONTAL || VERTICAL HORIZONTAL | 1 Wl I 1 ! 900 | —1181.979 723.894 || 114.522 ° I soo | 933.910 571.965 || 90.486 ° 1 zoo | 715.025 437.911 |} 69.279 0 i 600 | 525.324 321.731 || 50.899 ° 1 ! | || Asax-SUPERIOR APPR. CNC Te 109/1-89 ‘Superio® and CleanBurn™ ar Copyrigt © Cooper Industries, xdemarks of Cooper Industries, In. 7989SUPERIOR TURBOCHARGED GAS ENGINES PAGE 110 MODEL 6GTL MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN METRIC UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. PRIMARY FORCE - kg ! ' ENGINE | i I RPM | ~—-s-VERTICAL = HORIZONTAL || VERTICAL —- HORIZONTAL | | ' | ! a ! 900 | 261.611 152.008 || 27.401 ° { B00 | 206.705 119.803 || 21.650 ° | 700 | 158.258 91.956 || 16.875 ° 1 600 | 216.271 67.559 || 12.178 ° | I I | SECONDARY COUPLE - [Link] ENGINE REM VERTICAL | HORIZONTAL 900 ° 800 129.160 79.103 12.514 ° 700 98.888 60.563 9.581 ° 600 12.652 44.495 7.039 ° I It {I I! 163.468 100.115 || 15.838 I I I i [,@iJ| asax-SuPERIOR appr. GMC Te 110/1-89 ‘Superior? and CleanBur™ ace rademarks of Cooper Industrie, Ine Copyright © Cooper industiee, inc, 1989SUPERIOR TURBOCHARGED GAS ENGINES MODEL 6GTL PAGE 111 ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR 6GTL PERCENT] purp ENGINE SPEED = RPM RATED LOAD. Pst) 900 750 600 HAE 110 Ter 908 756 605 HORSEPOWER 100 147 825 687 550 oP) 75 110 619 515 ats 50 73 413 344 275 BRAKE 110 161 — = = REN CuaRET alle 100 447 7350 7260 T320 Grune 75 110 7750 7500 7560 50 73 8650 8200 8200 aE AR FLOW | 110 161 1740 1410 1180 OURNEAT 100 147 1640 1310 980 crn 75 110 1320 1010 10 50 13 990 910 660 110 161 138) 113 93 else! 100 147 130 104 8 75 110 105 80 56 50 73 79 1 52 110 Ter 870 845 820 wien | 100 | 147 | 860 40 ass ea 15 110 850 B15 820 50 73 810 75 730 110 161 27200 23900 20900 winerery | 100 | 147 | 26100 | Be300 19300 GTUMIN) 75 atc 21100 18900 16500 50 73 18900 15200 13900 LUBE OL. 0 161 3480 3280 3280 HEAT REJECTION 100 a 3370 3150 3020 tum 75 110 3200 2570 2340 50 73 2620 2060 1490 110 161 ‘4000 2600 1700 HEAT RECTION 400 147 3400 2240 1270 Gru) 75 110 2100 1250 650 50 73 1000 640 450 NOTES 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 23% TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 180T JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-21/9-88 FOR HEAT REJECTION ADASTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING, HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE. ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10x RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. 3D INTERCOOLER HEAT REJECTION BASED ON NOMINAL 4000 FT. ALTITUDE. 4) LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING 120F MAX. TO INTERCOOLER FOR RATED ENGINE PERFORMANCE. AJAX-SUPERIOR APPR. BNE Te 111/1-89 Superior? and CieanBurn"™ are wademarks of Cooper Industries, ine. Copyright © Cooper industries, Ine 1988SUPERIOR TURBOCHARGED GAS ENGINES MODEL 6GTL PAGE 112 ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR >L Peony BMEP ENGINE SPEED — RPM POAD | tkg/emar] 900 750 600 BRAKE SPECIFIC 110 11.35) 677 564 451 oureuT 100 10.32 615 512 410 aw 15 774 462 3e4 308 50 515 08 51 05 BRAKE 10 11.35 oz a FUL consrrion| 100 10.32 2484 2454 2474 ca/WHD ie 114 2619 2535 2555 50 515. 2923 2771 2771 INTAKE AIR FLOW 10 11.35 60 49 4l REQUIREMENT 100 10.32 57 45 34 Gg/MIN) 15 46 35 24 50 34 3 23 110) 63 51 42 HAST FLC ogni ~ 100 59 47 35 75 48 36 25 50 36 32 24 110 466 452 438 HIER THB 100 460 449 446 (zt) od a54 435 438 50 A82 413 a8 TWA 110 6855 6025 5267 ierrencrin | 100 6578 5620 4864 (ecaHIN) 15 5318 4163 4158 50 4163 3831 3503, LUBE OL 110 877 827 827 HEAT REJECTION 100 849 794 761 GeodiND 15 806 648 590 50 660 519 316 110) 1008 655 428 N HEAT RECTION 100 857 565 320 Geol MIN) 15 529 35 164 50 252 161 U3, NOTES 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 23% TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 82°C JACKET WATER OUTLET TEMPERATURE. REFER TO ‘GENERAL DATA SECTION. PAGE GEN-23/1-89 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REAECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND ‘AMBIENT TEMPERATURE. ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10x RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. 3D INTERCOOLER HEAT REJECTION BASED ON NOMINAL 1200 M_ ALTITUDE. 44) LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING 50 MAX. TO INTERCOOLER FOR RATED ENGINE PERFORMANCE. Z| AvAX-SUPERIOR APPR, BNC ‘i Te 112/1-89 ‘Superior* and CloanBurn"™ are tradamarks of Cooper Industries, Ine. Copyright © Cooper industries, Inc. 1989SUPERIOR TURBOCHARGED GAS ENGINES MODEL 6GTL SI) asax. PAGE 113, EXHAUST EMISSIONS MODEL = 6GTL, BGTL, 12GTL, 16GTL RPM PERCENT BHP(KW) EMISSIONS (GRAMS/BHP-HR) COA NOx | CO__| NMHC 900 100, = 15.0 OF OS ™ TONS PER YEAR = (GM/BHP-HR) x BHP + 1036 w* DENOTES NON-METHANE HYDROCARBONS QUALIFYING CONDITIONS: 1 PIPELINE QUALITY GAS IS ASSUMED. METHANE CONTENT SHOULD BE GREATER THAN 90x WITH A LOW HEATING VALUE OF 900 BTU/SCF + 15 FOR FUEL GAS OUTSIDE THESE PARAMETERS AN INDIVIDUAL REVIEW WILL BE REQUIRED TO DETERMINE EMISSION LEVELS AND FUEL CONSUMPTION RATES. 2) VALUES ARE BASED UPON 130° F MANIFOLD TEMPERATURE, <120' F INTERCOOLER WATER AND 100° F AMBIENT TEMPERATURE. REDUCED AIR MANIFOLD TEMPERATURES WILL RESULT IN LOWER NOx LEVELS, HIGHER AMBIENT TEMPERATURES WILL NOT AFFECT EMISSION LEVELS AT RATED LOAD AND SPEED BUT WILL CAUSE SLIGHTLY HIGHER NOx LEVELS AT REDUCED SPEEDS. 3D DATA SHOWN ARE BASED ON ENGINE ADJUSTMENT FOR STANDARD BSFC. FULL SPEED EMISSION VALUES ARE VALID FOR ALTITUDES BELOW 4000 FT. HIGH ALTITUDE APPLICATIONS MAY REQUIRE TURBOCHARGER MODIFICATION TO MAINTAIN EMISSION RATES, 4) WHEN NOx REQUIREMENTS LESS THAN THOSE EXPRESSED HERE ARE ENCOUNTERED, THERE ARE TRADE-OFFS BETWEEN NOx AND BSFC WHICH MAY BE APPLICASLE, BUT THESE MUST BE EVALUATED ON A SPECIFIC CASE ASIS, SUPERIOR APPR. a NCU Te 113/1-89 ‘Superioe® and CleanBurn™ are trademarks of Cooper Industries, In. Copyright © Cooper industries, Ine. 1988,SUPERIOR TURBOCHARGED GAS ENGINE MODEL 6GTL ee e WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURF_DROPS he “pene wu Z 90 | = Ftows. c 6° tp a 60 eat { : B» { V4 40 L x0 | le 20 ca ° re [ara Frese e ° 0 ~ 100 200 300 400 500 FLOW (GPM) IMPELLER P/N D-016-879 (STRAIGHT VANE) PUMP RPM = 2.4 X ENGINE RPM DIRECTION OF ROTATION (BI-DIRECTIONAL CAPABILITY? NORMALLY CW (FACING DRIVE END) NPSHp = 14.0 FEET @ 900 RPM & 275 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE, OF 275 GPM = 111.0 FT- 56.0 FT. = 55.0 FT. 550 FT. + 2.31 = 230 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. | AJAX-SUPERIOR APPR. GNC Te 115/ = Superior and CloanBuen"™ are trademarks of Cooper Industrie, Ine. Copyright © Cooper industries, ne. 1980SUPERIOR TURBOCHARGED GAS ENGINE MODEL 6GTL PAGE 116 WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS 140 —JENGINE RPM. 130 i 120 ESIGN [er 110 LOWS -K— 100 \ 2 90 75 ec Se te 10 \ 7 600 \ 50 z 2 40 20 zt 10 zal ENGINE PRESSURE, o Lo=E= DROP, ° 100 200 300 400 500 FLOW (GPM) IMPELLER P/N D-O33-655 (CURVED VANE) PUMP RPM = 2.4 X ENGINE RPM DIRECTION OF ROTATION (UNI-DIRECTIONAL) CW (FACING DRIVE END) NPSHp = 8.5 FEET @ 900 RPM & 275 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE. OF 275 GPM = 123.0 FT- 56.0 FT. = 67.0 FT. 67.0 FT. + 231 = 29.0 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. AJAX-SUPERIOR pppn, SONNY Te 116/1-89 ‘Superior? and CloanBum™ are trademarks of Cooper Industrie, Ine. Copyright © Cooper industies, nc. 1988SUPERIOR TURBOCHARGED GAS ENGINES MODEL 8GTL ENGINE SECTION INDEX Description Page No. Air Intake System 204 Bearing Dimensions 207 Cooling System 205 Dimensions and Weight 207 Engine Operating Data -Units In English Units 211 -Units In Metric Units 212 Engine Outline Drawing 219 Engine Performance 203 Engine Specifications 201 Exhaust Emissions 213 Exhaust System 206 Fuel system 204 Heat Rejection Data “Units In English Units 211 -Units In Metric Units 212 Lubrication system 206 Miscellaneous 208 Starting System 203 Turbocharger 204 Unbalanced Forces and Couples -Units In English Units 209 -Units In Metric Units 210 Water Pump Characteristics Jacket Water, Straight Vane 215 -Jacket Water, Curved Vane 216 Intercooler, Straight Vane N/A “Intercooler, Curved vane N/A AJAX-SUPERIORSUPERIOR TURBOCHARGED GAS ENGINES MODEL 8GTL ENGINE SPECIFICATIONS Type Aspiration Cylinder Configuration Number of Cylinders Bore - in. (mm) Stroke - in. (mm) Displacement - [Link]. (liter) Compression Ratio Power Rated - BHP (kW) Speed Rated - REM Piston Speed - FPM(m/s) Speed Range - RPM Ignition system Fuel system Governor Turbocharger Exhaust Manifold Jacket Water Pump Jacket Water Thermostat Lube 011 Pump Lube 0il Thermostat Prelube Pump Lube 0i1 Cooler Intercooler Intercooler Water Thermostat Crankcase Breather Crankcase Doors Direction of Rotation | 4 AJAX-SUPERIOR PAGE 201 Four (4)-Cycle Turbocharged, Intercooled Inline Eight (8) 10 (254) 10.80 (266.7) 6597 (108.13) 8.20: 1 1100 (820) 900 1575 (8.0) 900 - 600 Non-Shielded, Altronic ITI Fuel Injected with Analog Type Electronic Air-Fuel Control and Manual Starting Logic Hydraulic (UG-8L) With Manual Speed Setting one(1) Water Cooled Built-In Centrifugal, Belt Driven Engine Mounted Gear Type with Pressure Regulating Valve Engine Mounted Manual, Mounted and Piped Shell & Tube Type,Mounted and Piped Rectangular, Shell & Tube/Fin Type Engine Mounted Positive Ventilation Pressure Relief(Bicera Type) Doors Counterclockwise From Flywheel End aver. (3NKCL ‘Superior? and CleanBurn™ are trademarks of Cooper Industies, ine, Copyright © Cooper Indusinos, ne. 1989 TC 201/1-89SUPERIOR TURBOCHARGED GAS ENGINES MODEL 8GTL PERFORMANCE Engine Operating Data Rating Conditions ~Altitude -Temperature Rated Torque Over 900-600 RPM Range Brake Mean Effective Pressure Rating/BMEP Rated Brake Specific Fuel Consumption/BSFC (Plus or Minus 3 Percent Factory Tolerance) Heat Rejection Data Emissions STARTING SYSTEM Air/Gas Starting Motor Make & Model Number of Starting Motors Supply Air/Gas Pressure Consumption Rate/Starter Motor Air -Gas - Normal Starting Time Connection Sizes Inlet outlet -Optional: Inlet Flange outlet Flange PAGE 203 See Page 211 & 212 feet 4000 meter (3219 Deg F 100 Deg c (37.8 Ib-ft 6420 M-kg (888 psi 146.7 kg/em2 (10.3 Btu/bhp-hr 7400 keal/kW-hr (2502 See Page 211 & 212 See Page 213 IR / SS-825 one(1) psi 150 kg/om2 (10.5 scfm 1400 liter/sec ( 661 scfm 1663 liter/sec ( 785 sec 15 1-1/2 In. NPT 2-1/2 In. NPT 1-1/2 In. Square 2-1/2 In. 150 Lb. AJAX-SUPERIOR apr. NC TC _203/1-89 ‘Superior? and CloanBurn™ ate vademarks of Cooper Industries, Inc. Copyright © Cooper industries, Inc. 1989 ) dSUPERIOR TURBOCHARGED GAS ENGINES MODEL 8GTL AIR INTAKE SYSTEM Intake Air Flow Rate Max. Allowable Pressure Drop Air Intake, Inlet Connection FUEL SYSTEM Required Fuel Gas Pressure to Engine Based on Pipeline Quality Natural Ga (Regulated to within plus or minus 1 psig) Gas Inlet Flange Connection EXHAUST SYSTEM Max. Allowable Back Pressure Exhaust Outlet Flange Connection Size Exhaust Flow Rate Stack Temperature TURBOCHARGER Speed (Maximum) PAGE 204 See Page 211 & 212 In H20 10 mm H20 (254 ) 10 In, I.D. Flex Connector psi 35-40 Kg/em2 = (2.5-2.8 ) 2 In. 150 Lb. In H20 10 mm H20 (254) 12 In, 150 Lb, FF See Page 211 & 212 See Page 211 & 212 Pulse Cooper-Bessener ET ii RPM 27000 AJAX-SUPERIOR aper._ (NC Te 208/1-89 ‘Superior? and CleanBuen™ are tradomarks of Cooper Industies, Inc. Copyright © Cooper Industnes, ine. 1980SUPERIOR TURBOCHARGED GAS ENGINES PAGE 205 MODEL 8GTL @ croisne crore Jacket Water Capacity - Engine only Gallon 70 liter (265 ) Jacket Water Pump ~Jacket Water Outlet Temperature, Normal Deg F 165-180 Deg ¢ (74-82 ) -Design Flow Rate at Rated Speed 340 (21.4) Available External Head: Straight Vane(Standard) psi 19 kg/om2 (1.34) Curved Vane(Optional) psi 23 kg/cm2 (1.62 ) -Minimum NPSH Required: Straight Vane(Standard) feet 15.5 meter (4.72 ) Curved Vane(Optional) feet 9 meter (2.74) Intercooler system @ —-ntercooier Water inlet Tenperature, Normal Deg F 120 Deg ¢ (49.0 ) -Design Flow Rate GPM 70 liter/sec (4.42 ) -Pressure Drop (Includes Lube 0i1 Cooler, psi 9.6 Intercooler and Thermostat) kg/em2 (0.68 ) Connection Sizes ~Jacket Water Inlet 4 In. 150 Lb. Jacket Water Outlet 3 In. 150 Lb. Intercooler Water Inlet 2-1/2 In. Pipe -Intercooler Water Outlet 2 In. Pipe -Vent Line to Surge Tank, Minimum Size 3/8 In, Tubing “Surge Tank Return to Pump Inlet 3-1/2 In. NPT AJAX-SUPERIOR arer._ GNC Te 205/1-89 ‘Superior? and CleanBurn™ are trademarks of Cooper Industios, ine. Copytigit © Cooper industries, Inc. 1989SUPERIOR TURBOCHARGED GAS ENGINES PAGE 206 MODEL 8GTL LUBRICATION SYSTEM Lube Oil Sump Capacity Gallon 80 liter (303 ) Lube 011 Consumption(Estimated) Gal./Day 2.50 liter/Day (9.46 ) Lube 0il Pressure - Normal psi 35 kg/cm2 (2.46) Temperature Out Of Engine - Normal Deg F 165-175 Deg c (74-80 ) Flow Rate Through 0{1 Filter GPM 45 liter/sec (2.84 ) Lube 0i1 Filters, Engine Mounted(Standard) ~Type Full Flow -Microns of Filtration Fifteen(15) Connection Sizes -Lube 011 Sump Drain Plug 1-1/2 In, NPT | 4 Asax-SUPERIOR APPR.. BNC a Te 206/1-89 ‘Superior? and CisanBum™ are ademarks of Cooper Industies, Inc. Copyright © Cooper Industries, Inc. 1989SUPERIOR TURBOCHARGED GAS ENGINES PAGE 207 MODEL 8GTL BEARING DIMENSIONS Main Bearing, Split shell ~Diameter In 6.00 mn (152.4 ) “Width In 3.50 mn ( 88.9 ) -Quantity Nos. 9 Crankpin Bearing, Split Shell -Diameter In 5.75 an (146.0 ) “Width In 3.63 mn (92.2) -Quantity Nos. 8 Wrist Pin Bearing Diameter In 3.50 mn ( 88.9 ) -Width In 3.16 mn ( 80.3 ) e Quantity Nos. 8 Camshaft Bearing, Split Shell -Diameter In 2.25 mn (57.2 ) -Width In 1.63 an (42.4) -Quantity Nos. 10 DIMENSIONS AND WEIGHT (APPROXIMATE) Overall Length In 156 an (3962 ) Overall Width In 67 an (1702 ) Overail Height In 96 on ( 2438 ) Dry Weight Lb 24000 kg ( 10886 ) AJAX-SUPERIOR aren. GMC Te 207/1-89 ‘Superior and CleanBurn™ are trademarks of Cooper Industries, Ine. Copyright © Cooper industries, Ine. 1988SUPERIOR TURBOCHARGED GAS ENGINES PAGE 208 MODEL 8GTL MISCELLANEOUS Clearance Required to Remove Piston In 81.75 mm ( 2076 ) Heaviest Engine Parts (Approximate Weights) ~Cylinder Block Assembly Lb 4400 kg (1996 ) ~Cylinder Head Assembly Lb 250 kg (113 ) -Piston and Connecting Rod Assembly Lb 192 kg (es 828)) ~Turbocharger Assembly Lb 930 kg (422) -Exhaust Manifold Lb 650 kg (295 ) 44) AJAX-SUPERIOR aper. G3N\CL mcreoeiLe2 SSuperior® and CleanBurn" are trademarks of Cooper Industries, Inc Copyright © Cooper Industries, nc. 1989SUPERIOR TURBOCHARGED GAS ENGINES PAGE 209 MODEL 8GTL MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN ENGLISH UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. SECONDARY FORCE - Lb. PRIMARY FORCE - Lb. ENGINE RPM VERTICAL | HORIZONTAL VERTICAL | HORIZONTAL 900 789.428 447.713 120.814 ° 800 623.745 353.784 95.458 ° 100 477.555 270.839 73.085 ° 600 350.857 198.984 53.695 ° SECONDARY COUPLE - Lb. Ft. 1 I 1 ENGINE | i ! RPM =| —s-VERTICAL == HORIZONTAL || VERTICAL == HORIZONTAL | ! ' | ! in 1 900) | 1945.844 1160.555 || 261.763 ° ' goo | 1537.457 916.982 || 206.825 ° 1 700) || 1177.116 02.064 || 158.350 ° 1 600 | 864.820 515.802 || 116.339 ° I ! i 1 1) asax-SUPERIOR appr. G32M\C Te 209/1-89 Superior® and CleanBurn™ are ademarks of Cooper Industrie, Inc. Copyright © Cooper industria, nc. 1960SUPERIOR TURBOCHARGED GAS ENGINES PAGE 210 MODEL 8GTL MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN METRIC UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. ENGINE RPM 3 54.801 ° 800 282.931 160.476 43.300 ° 700 216.619 122.853 33.151 ° 600 159.149 90.259 24.356 ° | 1 | soo || 358.085 203.08: ! 1 1 | ENGINE RPM VERTICAL | HORIZONTAL 900 269.110 160,505 36.202 800 212.630 126.819 28.604 700 162.795 97.095 21.900 600 119.605 71.335 16.090 e000 [eee AJAX-SUPERIOR appr. (SMMC Te 210/1-89 Superior? and CleanBurn" are trademarks of Cooper Industies, Ine. Copyright © Cooper industnes, ine. 1988SUPERIOR TURBOCHARGED GAS ENGINES. MODEL BTL PAGE 211 ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR 8GTL PERCENT ENGINE SPEED — RPM BMEP oan | esp FOO 750 600 AE 110 Te1 T210 1009 B06 HORSEPOWER 100 147 1100 917 133 ne 15 10 825 688 550 50 13 550 459 367 BRAKE 110) 761 — — — Ferconsmpvion | 100 147 7380 7340 7500 anew 715 110 7740 7400 7400 50 73 8490 8150 8150 i 110 161 2370 1880 1400 Ranmnt | 100 147 2170 1680 1230 GoW 15 110 1700 1300 910 50 3 1280 1000 840 110 161 186 150 114 emus tow | 00 | 17 170 136 98 75 110 134 104 15 50 73 402 78 67 110 161 925 900 900 pene 100 147 920 899 895 haan 75, 110 910 875 865 50 13 880 840 780 110 161 38400 31700 30600 Woriereroy | 100 147 35500 29800 27800 (BTUMIN) 78 110 30400 25000 22000 50 73 26400 21300 17500 LUBE OL 110 6 ‘4100 3800 3400 HEAT REection | 100 4000 3700 3200 TUM) 15 110 3500 3000 2600 50. 73 2600. 2200 1985) ci 110 164 5850 3530 2190 fitestiow | 100 | 147 2900 2815 1610 in. Stroke - in. Displacement - cu. in. (mm) (mm) (liter) Compression Ratio Power Rated - BHP (kW) Speed Rated - RPM Piston Speed - FPM(m/s) Speed Range - RPM Ignition system Fuel system Governor Turbocharger Exhaust Manifold Jacket Water Pump Jacket Water Thermostat Intercooler Water Pump Intercooler Water Thermostat Lube 0i1 Pump Lube Oil Thermostat Prelube Pump Lube 0il Cooler Intercooler Crankcase Breather Crankcase Doors Direction of Rotation | 4] asax-suPerion Four(4)-Cycle Turbocharged, Intercooled Inline Eight (8) 10 (254) 10.50 (266.7) 6897 (108,13) 8.20: 1 1500 (1119) 1000 1750 (8.89) 1000 - 600 Non-Shielded, Altronic III Fuel Injected with Analog Type Electronic Air-Fuel Control and Manual Starting Logic Hydraulic (UG-6L) With Manual Speed Setting one(1) Water Cooled Built-In Centrifugal, Gear Driven Remote Mounted Built-In Centrifugal, Gear Driven Remote Mounted Gear Type with Pressure Regulating Valve Engine Mounted Manual, Mounted and Piped Shell & Tube Type,Mounted and Piped Rectangular, Shell & Tube/Fin Type Positive Ventilation Pressure Relief(Bicera Type) Doors Counterclockwise From Flywheel End Te 301/1-89 APPR. QR MC ‘Superior® and CleanBum™ are vademarks of Cooper Industries, nc. ‘Copyright © Cooper Inaustres, Inc. 1989SUPERIOR TURBOCHARGED GAS ENGINES MODEL 8SGT PERFORMANCE Engine Operating Dat: Rating Conditions Altitude ~Temperature Rated Torque Over 1000-600 RPM Range Brake Mean Effective Pressure Rating/BMEP Rated Brake Specific Fuel Consumption/BSFC (Plus or Minus 3 Percent Factory Tolerance) Heat Rejection Data Emissions STARTING SYSTEM Air/Gas Starting Motor Make & Model Number of Starting Motors Supply Air/Gas Pressure Consumption Rate/Starter Motor -Air Gas - Normal Starting Time Connection Size: -Inlet -Outlet -Optional: Inlet Flange outlet Flange PAGE 303 See Page 311 & 312 feet 4000 meter (1219 Deg F 100 Deg c (37.8 lb-ft 1878 Mkg (1090 psi 180.0 kg/om2 (127 Btu/bhp-hr 7430 keal/kW-hr ( 2511 See Page 311 & 312 See Page 313 IR / SS-825 One(1) psi 150 kg/om2 (10.5 scfm 1400 liter/sec ( 661 scfm 1663 liter/sec ( 785 sec 15 1-1/2 In. NPT 2-1/2 In, NPT 1-1/2 In. Square 2-1/2 In. 150 Lb. | asax-SUPERIOR APPR RNC Te 303/1-89 ademarks of Cooper Industries, ne. Copyright © Cooper industries, inc. 1969SUPERIOR TURBOCHARGED GAS ENGINES MODEL 8scT AIR INTAKE SYSTEM Intake Air Flow Rate Max. Allowable Pressure Drop Air Intake, Inlet Connection FUEL SYSTEM Required Fuel Gas Pressure to Engine (Regulated to within plus or minus 1 psig) Based on Pipeline Quality Natural Gas Gas Inlet Flange Connection EXHAUST SYSTEM Max. Allowable Back Pressure Exhaust Outlet Flange Connection Size Exhaust Flow Rate Stack Temperature ‘TURBOCHARGER Type Manufacturer Model Speed (Maximum) PAGE 304 See Page 311 & 312 In H20 10 mm H20 (254) 12 In, I.D. Flex Connector psi 38-40 keg/om2 (2.5-2.8 ) 2 In, 150 Lb. In H20 10 mm H20 (254) 14 In, 150 Lb. FF See Page 311 & 312 See Page 311 & 312 Constant Pressure [Link], NR 20R REM 40000 44] AJAX-SUPERIOR appr. SAN\C Use ‘Superior? and CloanBurn™ are wademarks of Cooper Industries, ne. Copyright © Cooper ndustnes, nc, 1980SUPERIOR TURBOCHARGED GAS ENGINES PAGE 305 MODEL 8SGT Oe Jacket Water Capacity - Engine Only Gallon 85 liter (| 322) Jacket Water Pump ~Jacket Water Outlet Temperature, Normal Deg F 170-180 Deg c ( 76-82 ) Design Flow Rate at Rated Speed opm 870 iter/sec (36.0 ) Available External Head: Curved Vane(Standard) psi 21.2 kg/cm2 (1.49) “Minimum NPSH Required: Curved Vane(Standard) feet 13.5 meter (4.11) Intercooler Water Pump “Intercooler Water Inlet Temp, Normal Deg F 120 Deg c (49.0 ) Design Flow Rate at Rated Speed GPM 170 e Giter/eec (10-7) Available External Head: Straight Vane(Standard) psi 26 kg/em2 (1.83 ) -Minimum NPSH Required: Straight Vane(Standard) feet 17.5 meter (5.33 ) Connection Size: ~Jacket Water Inlet 6 In, 150 Lb. Jacket Water Outlet 6 In. 150 Lb. -Intercooler Water Inlet 4 In, 180 Lb. Intercooler Water Outlet 3 In. 150 Lb. -Vent Line to Surge Tank,Minimum Size 3/8 In. Tubing -Surge Tank Return to Pump Inlet: Jacket Water 2 In. NPT Intercooler 2 In. NPT $1) AJAX-SUPERIOR aver. SNC TC 305/1-89 Superior® and CloanBuen"™ are trademarks of Cooper Industries. Ine. Copyright © Cooper Industles, In. 1980SUPERIOR TURBOCHARGED GAS ENGINES PAGE 306 MODEL @sGT LUBRICATION SYSTEM Lube 011 Sump Capacity Gallon 322 liter (462 ) Lube 011 Consumption(Estimated) Gal. /Day 3.00 liter/Day (11.4 ) Lube 011 Pressure - Normal psi 35 kg/om2 (2.46) Temperature Out Of Engine - Normal Deg F 170-175 Deg ¢ (76-80 ) Flow Rate Through 04] Filter opm 60 liter/sec (3.78 ) Lube 0i1 Filters, Remote Mounted(Standard) ~Type Full Flow -Microns of Filtration Fifteen(15) Connection Sizes -Lube 041 Sump Drain Plug 3. In, NPT -Lube 01 Inlet to Engine 2-1/2 In. 150 Lb. Lube 011 Outlet to Filter 2-1/2 In. 150 Lb. AJAX-SUPERIOR appr. VNC TC 306/1-89 ‘Superior? and CloanBurn™ ace rademarks of Cooper Industrie, Ine. Copyright © Cooper industries, nc. 1989SUPERIOR TURBOCHARGED GAS ENGINES PAGE 307 MODEL sSGT e BEARING DIMENSIONS Main Bearing, Split Shell -Diameter In 8.00 an ( 203.2 ) “Width In 4.88 mm (124.0) Quantity Nos. 3 Crankpin Bearing, Split Shell -Diameter In 6.38 mm (162.1 ) “Width In 2.53 mn ( 64.3 ) ~Quantity Nos. 8 Wrist Pin Bearing -Diameter In 3.50 mn (88.9 ) -width In 3.16 mn ( 80.3 ) e -Quantity Nos. 8 Camshaft Bearing, Split Shell -Diameter In 2.75 an ( 69.9 ) “Width In 2.38 mm ( 60.5 ) ~Quantity Nos. 9 DIMENSIONS AND WEIGHT (APPROXIMATE) Overall Length In 184 mm, ( 4674) Overall Width In 98 an ( 2489 ) Overall Height In 90 mm ( 2286 ) Dry Weight Lb 34500 kg (15649 ) AJAX-SUPERIOR APPR. BNC TC_307/1-89 ‘Superior? and CleanBurn™ are wademarks of Cooper industries, nc Copyright © Cooper industries, nc. 1980SUPERIOR TURBOCHARGED GAS ENGINES PAGE 308 MODEL 8scT MISCELLANEOUS Clearance Required to Remove Piston In 81.75 am (2076 ) Heaviest Engine Parts (Approximate Weights) ~Cylinder Block Assembly Lb 7400 kg (3357 ) ~Cylinder Head Assembly Lb 250 kg (413 ) -Piston and Connecting Rod Assembly Lb 198 kg (2 foo} ~Turbocharger Assembly Lb 645 kg (293 ) Exhaust Manifold Lb 700 kg (318 ) ~Bed Plate Lb 9000 kg ( 4082 ) AJAX-SUPERIOR APPR. BM J TC 308/1-89 Superior® and CioanBurn"™ are trademarks of Cooper Industis, Inc ‘Copyright © Cooper Industries, nc. 1989SUPERIOR TURBOCHARGED GAS ENGINES PAGE 309 MODEL 8SGT MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN ENGLISH UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values: standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values SECONDARY FORCE - Lb ENGINE REM VERTICAL © HORIZONTAL 2 ° 900 789.428 447.713 120.814 ° 800 623.745 353.784 95.458 ° 700 477.555 270.839 13.085 ° 600 350.857 198.984 53.695 ° 1 | 1 | 1000 | 974.602 $52.73: 1 1 1 1 1 i i in) " nl i 149.153 a it i It ee SECONDARY COUPLE - [Link]. ENGINE RPM VERTICAL HORIZONTAL 1000 ° 900 1945.844 1160.555 261.763 ° 800 1537.457 916.982 206.825 ° 700 177.116 702.064 158.350 ° 600 864.820 515.802 116.339 ° | tt | " | I ! | tt ! I | ti | I 1 i }-------4-4+} | AsAX-SUPERIOR appr. SNC) Tc 309/1-89 ‘Superior® and CleanBurn™ are trademarks of Cooper industries, Ine Copyright © Cooper industries, ine. 1989SUPERIOR TURBOCHARGED GAS ENGINES PAGE 310 MODEL a8scT MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN METRIC UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. SECONDARY FORCE - kg ENGINE REM VERTICAL | HORIZONTAL ° 900 358.085 203.083 54,801 ° 800 282.931 160.476 43.300 ° 700 216.619 122.853 33.151 ° 600 189.149 90.259 24.356 ° 1 I | i 1 I i! 1000 I 442.079 250.719 || 67.656 | in ! tt 1 1 ! it 1 I | I ! ENGINE |- I | RPM | i | | f 1 | | appr. TAMC) re 310v1-89 ‘Superior? and CloanBurr"™ are trademarks of Cooper Industrie, Ine. Copyright © Cooper industiee, Inc. 1989SUPERIOR TURBOCHARGED GAS ENGINES MODEL 8scT Gee ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR 8SGT PERCENT ENGINE SPEED ~ RPM RaTeD | BMEP RATED | (sir [7000 | 900 | 750 | 600 om rid] 198] 1650] 1485] 1238 | 990 HORSEPOWER too | 180 | 1500 | 1350]. 1125 | 900 rt 75 | 135 | 1125 | 1013 | aa | 675 0. 20. 750 675_| 563 | _450 seme srecric | 110 198 7 100 igo | 7430 | 7325 | 7450 | 7900 fie) 75 135 7875 77150 | 7670 | 7740 50 30_| 9200 | 9000 | 9150 | 8950 110 ios | 3320 | 2820 | 2240 | 1730 ome | 100 180 2a85 | 2570 | 2060 | 1560 Lt 75 | 135 | 2310 | 2020 | 1665 | 1220 50. 9o_| 135 | 1615 | 1235 | 825 TIO} 798 265 225 | 180 [140 Pert 100 180 230 205 163 125 75 | 135 185 160 | 135 | 100 $0 30 14s 130_| 100 65 Ti ¥0-} 870 | 900 PTE TATEM 100 a0 880 880 | 865 | 900 ATER TBO | 75 135 880 aso | 870 | 900 cance (som | 50 30 870 870 | 850 | 890 110 | i98 | 53950 | 48780 | 41680 |~38780 One eet 100 igo | 49925 | 45700 | 3a360 | 35250 ae 75 | 135 | 43400 | 39090 | 32300 | 27560 50. 30__| 35790_| 32200 | 25060 | 24450 aaa 110 | 198 | 6630 | 6015 | 4850 | 4620 tearaexction | 100 | 180 | 6250 | 5535 | 4590 | 4350 lle 75 | 135 | 5530 | 4980 | 4150 ] 3320 50. 90 _| 5375 | aco | 4035 | 3225 710798] 10370] 7950} 5045] — 370 oe 100 180 8i4o | 6370 | 4080 | 2380 Lae 75 | 135 | 4840 | 3465 | 2290 | 1020 50 90_| 2940 | 1970 | 940 | 315 NOTES 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO +3¢ TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 18OF JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-22/9-88 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND ‘AMBIENT TEMPERATURE, ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10x RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. ‘3D INTERCOOLER HEAT REVECTION BASED ON NOMINAL 4000 FT. ALTITUDE. 4) LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING 120F MAX. TO INTERCOOLER FOR RATED ENGINE PERFORMANCE, ac NS ¢ S| AJAX-SUPERIOR APPR. AK Te 311/1-89 ‘Superior® snd CleanBuen™ are trademarks of Cooper Industrie, Ine. Copyright © Cooper industries, nc. 1989SUPERIOR TURBOCHARGED GAS ENGINES MODEL 8SGT epee ole: ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR 8SGT PERCENT] EMEP ENGINE SPEED — RPM RATED | fka/em2) T7000 900 | 750 [ 600 BRAKE SPECIFIC NO 1392 _|~ 1230_| 1107 9eS_|— 138 ouTPuT 100 1266 | 1119 1007 eso | 671 ww 75 9.49 | 839 755 629 | 503 50 633 | __ 559 03 420 | __336 BRAKE SPECIFIC 110) 1392 | — —— Coeeetted | ewrenl FUEL CONSUMPTION] 100 1266 | 2511 | 2476 | 2518 | 2670 Gecal/RHHR) 75 9.49 | 2661 2619 2592 | 2616 50 633 | 3109 | 3042 | 3092 | 302: INTAKE AIR FLOW | 110 1392 114 97 77 60 REQUIRENENT 100 peer 99 89 n 54 (kg/MIN) ory 9.49 80 10 s7 42 50 tS 43 56 4S 26 AHST 110) 120 102 82 64 ght few 100 12.66 104 93 74 37 75 9.49 84 13 61 45 SO 6.53, 66 9 45 29 710 392 | 474 493 466 | 482 ene 100 1266 | 471 ann 463 | 482 nora 75 9.49 | 471 any 466 | 482 50 6.53 | 466 466 454 | 477 110 7392 | 13591 | 12293 | 10504 | 9773 Pcie TEATER 100 12.66 | 12582 | 11517 | 9667 | 8884 HERRERO 75 9.49 | 10938 9a51 | 8140 | 6946 cre 50 6.53 | 9020 e115 | 6316 | 6162 110 T3592 | 1671 1516 ieee | 1164 LUBE ONL 100 12.66 | 1575 1395 1157 | 1096 HEAT RESECTION 15 9.49 | 1394 1255 | 104 | 837 crane 50 635 | 13! 1220 | 1017 | 813 110) 7392 | 2613 | 2004 | 1271 | 799 INTERCOOLER 100 1266 | 2051 1605 | 1028 | 600 HEAT REJECTION 75 9.49 | 1220 873 877 257 Ckca/ MIN). 50 £53 741 496 ST 79. NOTE 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 23% TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 62C JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-24/1-69 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE, ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10f RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. 3 INTERCOOLER HEAT REJECTION BASED ON NOMINAL 1200 M ALTITUDE. 4) LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING SOT MAX. TO INTERCOOLER FOR RATED ENGINE PERFORMANCE. Ai AJAX-SUPERIOR pon SOM CD Te 312/1-89 ‘Superio® and ClaanBurn™ are wademarks of Cooper Industries, ne. CCopyrign © Cooper industies, ic. 1989SUPERIOR TURBOCHARGED GAS ENGINES MODEL 8SGT PAGE 313 MODEL EXHAUST EMISSIONS : SGT PERCENT TEMTOSTONS _CORAMS/EHP-HRD Fem ESA BHP (KW "Nox [ CO__| s#NIMHC 900 100 1350(1007) 270 09 O75 1000 100, 15001119) 25.0 08 0.60 %® TONS PER YEAR = (GM/BHP-HR) x BHP + 1036 m4 DENOTES NON-METHANE HYDROCARBONS. QUALIFYING CONDITIONS: 1) PIPELINE QUALITY GAS 1S ASSUMED. METHANE CONTENT SHOULD BE GREATER THAN 90f WITH A LOW HEATING VALUE OF 900 BTU/SCF # 15%, FOR FUEL GAS OUTSIDE THESE PARAMETERS AN INDIVIDUAL REVIEW WILL BE REQUIRED TO DETERMINE EMISSION LEVELS AND FUEL CONSUMPTION RATES. 2) VALUES ARE BASED UPON 130° F MANIFOLD TEMPERATURE, <120° F INTERCOOLER WATER AND 100° F AMBIENT TEMPERATURE. REDUCED AIR MANIFOLD TEMPERATURES WILL RESULT IN LOWER NOx LEVELS, HIGHER AMBIENT TEMPERATURES WILL NOT AFFECT EMISSION LEVELS AT RATED LOAD AND SPEED BUT WILL CAUSE SLIGHTLY HIGHER NOx LEVELS AT REDUCED SPEEDS, 3D DATA SHOWN ARE BASED ON ENGINE ADUUSTMENT FOR STANDARD BSFC. FULL SPEED EMISSION VALUES ARE VALID FOR ALTITUDES BELOW 4000 FT. HIGH ALTITUDE APPLICATIONS MAY TO MAINTAIN EMISSION RATES. REQUIRE TURBOCHARGER MODIFICATION 4) WHEN NOx REQUIREMENTS LESS THAN THOSE EXPRESSED HERE ARE ENCOUNTERED, THERE ARE TRADE-OFFS BETWEEN NOx AND BSFC WHICH MAY BE APPLICABLE, BUT THESE MUST BE EVALUATED ON A SPECIFIC CASE. BASIS AJAX-SUPERIOR peer SONG Te 313/1-89 Superior® and Cleanturn™ ate vademarks of Cooper Industrie, Ine. ‘Copyright © Cooper Incusties, Ine. 1988SUPERIOR TURBOCHARGED GAS ENGINE == MODEL 8SGT PAGE 315 e WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS. 170 ENGINE" RPM 160 4000, ——} —— 140 DESIGN 130 FOO FLOWS 5 ENGINE PRESSURE- = F DROP ° 200 400 600 700 FLOW (GPM) IMPELLER P/N D-033-655 (CURVED VANE) PUMP RPM = 2.4 X ENGINE RPM DIRECTION OF ROTATION (UNI-DIRECTIONAL) CW (FACING DRIVE END) NPSHp =135 FEET @ 1000 RPM & 570 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 1000 RPM DESIGN FLOWRATE OF 570 GPM = 104.0 FT- 55.0 FT. = 49.0 FT. 49.0 FT. + 231 = 212 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. | | AJAX-SUPERIOR appr. SANNCU TC SIS/1-89 Superior® and CleanBu™ are wademarks of Cooper Industrie, tne. Copyright © Cooper Industries, Inc. 1909SUPERIOR TURBOCHARGED GAS ENGINE MODEL @sGT PAGE 317 WATER PUMP CHARACTERISTICS INTERCOOLER WATER SYSTEM DESIGN FLOWS AND PRESSURE DROP. 120 ENGINE RPM 110 _LENGINE 00 [> DESIGN 7 90 j ce Fook FLOWS E80 © 70 Ls = 60 750 \ B so _——T— a Z 40 FOO, 30 20 ‘| to ENGINE PRESSURE t ° 100 200 300 FLOW (GPM) IMPELLER P/N C-026-377 (STRAIGHT VANE) PUMP RPM = 2.4 X ENGINE RPM DIRECTION OF ROTATION (BI-DIRECTIONAL CAPABILITY) NORMALLY CW (FACING DRIVE END) NPSHp = 17.5 FEET @ 1000 RPM & 170 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 1000 RPM DESIGN FLOWRATE OF 170 GPM = 105.0 FT= 440 FT. = 61.0 FT. 61.0 FT. + 231 = 260 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. | AJAX-SUPERIOR appr AN Te 317/1-89 ‘Superior? and CleanBurn™ aro trademarks of Cooper Inc Copyright © Cooper Industries, ie. 1989SUPERIOR TURBOCHARGED GAS ENGINES MODEL 12GTL ENGINE SECTION INDEX Description Page No. Air Intake system 404 Bearing Dimensions 407 Cooling System 405 Dimensions and Weight 407 Engine Operating Data -Units In English Units 411 Units In Metric Units 412 Engine Outline Drawing 419 Engine Performance 403 Engine Specifications 402 Exhaust Emissions 413 Exhaust System 404 Fuel system 404 Heat Rejection Data -Units In English Units 4n2 -Units In Metric Units 412 Lubrication System 406 Miscellaneous 408 Starting System 403 Turbocharger 404 Unbalanced Forces and Couples -Units In English Units 409 ~Units In Metric Units 410 Water Pump Characteristics -Jacket Water, Straight Vane 415 ~Jacket Water, Curved Vane 416 -Intercooler,’ Straight Vane 417 -Intercooler, Curved Vane N/A AJAX-SUPERIORSUPERIOR TURBOCHARGED GAS ENGINES MODEL 12GTL ENGINE SPECIFICATIONS Type Aspiration Cylinder Configuration Number of Cylinders Bore = in. (mm) Stroke = in. (mm) Displacement - [Link]. (liter) Compression Ratio Power Rated - BHP (kW) Speed Rated - RPM Piston Speed - FPM(m/s) Speed Range - RPM Ignition system Fuel system Governor Turbocharger Exhaust Manifold Jacket Water Pump Jacket Water Thermostat Intercooler Water Pump Intercooler Water Thermostat Lube 0i1 Pump Lube Oil Thermostat Prelube Pump Lube 041 Cooler Intercooler Crankcase Breather Crankcase Doors Direction of Rotation | AJAX-SUPERIOR PAGE 401 Four(4)~Cycle Turbocharged, Intercooled Vee Twelve = (12) 10 (254) 10.50 (266.7) 9896 (162.20) 8.20: 1 1650 (1230) 900 1575 (8.0 900 - 600 Non-Shielded, Altronic III Fuel Injected with Analog Type Electronic Air-Fuel Control and Manual Starting Logic Hydraulic (UG-8L) With Manual Speed Setting one(1) Water Cooled Built-In Centrifugal, Chain Driven Remote Mounted Built-In Centrifugal, Chain Driven Remote Mounted Gear Type with Pressure Regulating Valve Remote Mounted Manual, Mounted and Piped Shell & Tube Type, Remote Mounted Rectangular, Shell & Tube/Fin Type Positive Ventilation Pressure Relief(Bicera Type) Doors Counterclockwise From Flywheel End appr. GAC ‘Superior? and CleanBurn™ are Copyright © Cooper industries, Te 401/1-89 sdomarks of Cooper Industries, ine, 1999SUPERIOR TURBOCHARGED GAS ENGINES MODEL 12GTL PERFORMANCE Engine Operating Data Rating Conditions Altitude ~Temperature Rated Torque Over 900-600 RPM Range Brake Mean Effective Pressure Rating/BMEP Rated Brake Specific Fuel Consumption/BSFC (Plus or Minus 3 Percent Factory Tolerance) Heat Rejection Data Emissions STARTING SYSTEM Air/Gas Starting Motor Make & Model Number of Starting Motors: Generator Drive Compressor Drive Supply Air/Gas Pressure Consumption Rate/Starter Motor -aAir Ga: ~ Normal Starting Time Connection Sizes Inlet Outlet Optional: Inlet Flange outlet Flange PAGE 403 See Page 411 & 412 feet 4000 meter (1219 Deg F 100 Deg c (37.8 lb-ft 9629 M-kg (1392 psi 146.7 kg/cm2 (10.3 Btu/bhp-hr 7400 keal/kW-hr (2501 See Page 411 & 412 See Page 413 IR / Ss-825 ‘One(1) Two(2) psi 150 kg/om2 (10.5 scfm 1500 liter/sec ( 708 scfm 1781 liter/sec (841 sec 15 1-1/2 In. NPT 2-1/2 In. NPT 1-1/2 In. Square 2-1/2 In. 150 Lb. 44) AJAX-SUPERIOR appr. Y3MC TC 403/1-89 Superior? and Cleanfur™ aro trademarks of Cooper Industries, Inc. Copyright © Cooper Industries, ine. 1989SUPERIOR TURBOCHARGED GAS ENGINES MODEL 12GTL AIR INTAKE SYSTEM Intake Air Flow Rate Max. Allowable Pressure Drop Air Intake, Inlet Connection FUEL SYSTEM Required Fuel Gas Pressure to Engine Based on Pipeline Quality Natural Gas (Regulated to within plus or minus 1 psig) Gas Inlet Flange Connection EXHAUST SYSTEM Max. Allowable Back Pressure Exhaust Outlet Flange Connection Size Exhaust Flow Rate Stack Temperature PAGE 404 See Page 411 & 412 In H20 10 mm H20 ( 254) 18 In. I.D. Flex Connector psi 35-40 kg/em2 — (2.5-2.8 ) 2 In. 150 Lb. In #20 10 mm H20 (254) 18 In. 125 Lb. FF See Page 411 & 412 See Page 411 & 412 ‘TURBOCHARGER Type Constant Pressure Manufacturer cooper-Bessemer Model Er 13 Speed (Maximum) RPM 23000 S| AJAX-SUPERIOR appr. SMC econ ae ‘Superior? and CloanBurn™ are trademarks of Cooper Industries, ne. ‘Copyright © Cooper Industes, ine. 1980SUPERIOR TURBOCHARGED GAS ENGINES PAGE 405 MODEL 12GTL @ cures rm Jacket Water Capacity - Engine Only Gallon 146 liter ( 553) Jacket Water Pump -Jacket Water Outlet Temperature, Normal Deg F 165-180 Deg c ( 74-82 ) -Design Flow Rate at Rated Speed Gem 600 liter/sec (37.8 ) Available External Head: Straight vane(Standard) psi 28 kg/cm2 (2.97 ) Curved Vane(Optional) psi 22.8 kg/cm2 (1.60 ) -Minimum NPSH Required: Straight Vane(Standard) feet 29 meter (8.79 ) Curved vane(Optional) feet 12 meter (3.66 ) Intercooler Water Pump @ —intercooter Water niet reaperature Normal veg F 120 Deg ¢ (48.9) Design Flow Rate at Rated Speed cpm 2140 liter/sec ( 8.83 ) -Available External Head: Straight Vane(Standard) psi 7.5 kg/cm2 (0.53 ) ~Minimum NPSH Required: Straight Vane(Standard) feet 15 meter (4.57) Connection Sizes ~Jacket Water Inlet 6 In, 150 Lb. ~Jacket Water Outlet 6 In. 150 Lb. -Intercooler Water Inlet 4 In. 150 Lb. Intercooler Water Outlet 4 In. 150 Lb. -Vent Line to Surge Tank,Minimum Size 3/8 In. Tubing -Surge Tank Return to Pump Inlet: Jacket Water 2 In. NPT Intercooler 2 In. NPT AJAX-SUPERIOR appr. S3NAC/ Tc 405/1-89 ‘Superior? and CloanBurn™ are trademarks of Cooper Industries, nc. Copyright © Cooper industries, nc. 1989SUPERIOR TURBOCHARGED GAS ENGINES PAGE 406 MODEL 12GTL LUBRICATION SYSTEM Lube 0i] Sump Capacity Gallon 165 liter ( 625 ) Lube 011 Consumption(Estimated) Gal. /Day 3.30 liter/Day (12.5 ) Lube Oi] Pressure - Normal psi 35 kg/em2 ( 2.46 ) Temperature Out Of Engine - Normal Deg F 165-175 Deg C (74-80 ) Flow Rate Through Oi1 Filter GPM 10 liter/sec (4.42 ) Lube 01] Filters, Engine Mounted(standard) ~Type Full Flow -Microns of Filtration Fifteen(15) Connection Sizes “Lube 041 Sump Drain Plug 3-1/2 In. NPT -Lube 041 Inlet to Engine 3 In. 150 Lb. -Lube 011 Outlet to Filter 3 In, NPT AJAX-SUPERIOR appr._SAN\CL Te 406/1-89 ‘Superior? and CleanBurn™ ate trademarks of Cooper Industrie, Inc. Copyright © Cooper industries, Inc. 1989‘SUPERIOR TURBOCHARGED GAS ENGINES MODEL 12GTL a Main Bearing, Split Shell -Diameter -Width -Quantity Crankpin Bearing, Split shell Diameter “Width -Quantity Wrist Pin Bearing Diameter -Width e Quantity Camshaft Bearing, Split Shell -Diameter -Width -Quantity per Bank DIMENSIONS AND WEIGHT (APPROXIMATE) Overall Length Overall Width Overall Height Dry Weight AJAX-SUPERIOR In In Nos. In mn In mn Nos In mn In Nos. In In Nos. In In In Lb kg aver. TSMC ‘Superior? and CleanBurn™ are trademarks of Cooper industries, ine. Copyright © Cooper Industries, Ic. 1 PAGE 407 8.00 ( 203.2 4.88 ( 124.0 1 6.38 (162.1 2.53 ( 64.3 3.50 ( 88.9 3.16 (80.3 12 (2.75 69.9 ( 2.38 60.5 185 ( 4699 84 ( 2134 115 ( 2921 42500 (19278 Te 407/1-89SUPERIOR TURBOCHARGED GAS ENGINES PAGE 408 MODEL 12GTL MISCELLANEOUS Clearance Required to Remove Piston In 89 mm ( 2261 ) Heaviest Engine Parts (Approximate Weights) cylinder Block Assembly Lb 10400 kg (4717 ) -Cylinder Head Assembly Lb 250 kg (113) -Piston and Connecting Rod Assembly Lb 198 kg (90) -Turbocharger Assembly Lb 1170 kg (531 ) -Exhaust Manifold Lb 1210 kg (549) 23) asax-SUPERIOR appr. SMC ca Superior® and CleanBurn"™ ar trademarks of Cooper Industrie, Ine. Copyright © Cooper industries, ine. 1988SUPERIOR TURBOCHARGED GAS ENGINES PAGE 409 MODEL 12GTL MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN ENGLISH UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa, It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 60 percent of the calculated values. SECONDARY FORCE - Lb. ENGINE RPM VERTICAL © HORIZONTAL 1 1 1 | 900) | 954.174 726.105 111.206 49.512 B00 | 753.915 573.713 87.866 39.121 7oo | | 577.216 439.249 67.273 29.952 600 | 424.077 922.713 49.425 22.005 ! | eames SECONDARY COUPLE - [Link]. ! 1 i ENGINE | iH I RPM =| ‘VERTICAL == HORIZONTAL || VERTICAL © HORIZONTAL | i : 1 900 | 2551.722 1957.595 || 268.815 119.685 | 800 1 206.175 1546.742 |} 212.397 94.566 | 00n @2 1543634 1184.224 || 162.616 72.402 | 600 | 1134.099 870.042 || 119.473 53.193 | | i 1 AJAX-SUPERIOR appr. SANCY Te 409/1-89 ‘Superior® and CleanBurn™ are trademarks of Cooper Industries, In. Copyright © Cooper Industries, nc. 1988SUPERIOR TURBOCHARGED GAS ENGINES PAGE 410 MODEL 12GTL MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN METRIC UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. PRIMARY FORCE - kg SECONDARY FORCE - kg ENGINE RPM VERTICAL © HORIZONTAL VERTICAL HORIZONTAL 900 432.813 329.361 50.443 22.459 800 341.976 260.236 39.856 17.745 700 261.825 199.243 30.515 13.586 600 192.361 146.383 22.419 9.981 1 1 1 | 1 7 1 | 1 | PRIMARY COUPLE - [Link] SECONDARY COUPLE - [Link] | It | RPM I VERTICAL | HORIZONTAL || VERTICAL HORIZONTAL | f | | i | AJAX-SUPERIOR appr. SOMWC) Te 410/1-89 ‘Suporor® and Cloanum™ are rademarks of Cooper Industrie, Ine. Gopyright © Cooper industies, Ic. 1969SUPERIOR TURBOCHARGED GAS ENGINES MODEL 12GTL eee ENGINE OPERATING DATA AND HEAT REJECTION e SUPERIOR 12GTL PERCENT] pup ENGINE SPEED — RPM eereeeeatesi 500 750 600 oS _— Ta1s 151s 1210 oneerose 100 | 147 1650 1375 1100 faa 75 110 1239 1031 825 50 825 688 0 arc sveciric. | 180 161 wecacio| | to | ie | ye | PR 110 eae ee 50 Z 8580 8410 9450 TiO [461 3300 2650 1675 eancentie 100) 147 3080 2425 1600 fa 75 110 2550 1875 1360 ate) 50. 1925 1300 1025 TiO 161 265 215 140 EXHAUST FLOW 100 147 245 195 134 sain 15 110 204 150 109 50 z 155, 95 is 110 B80 Ba PAS TATEe 100 a7 870 840 945 AFTER TURBO 75 | ito 845 809 880 cuancen cor) | 28 aa aaa ae eco TIO T7631 6500 —| 54200 2900 e ACKET WATER = | 100, 147 63000 51500 40600 HEAT RECTION | 75 110 55200 | 45100 35900 Be) 50 Bs 48000 39000 31000 Taran 110 | —t61 7600 7400 6800 toarrescrion | 100 | 147 7500 7100 6400 ena 75 110 6800 6000 5000 50 B 5000 3600 2000 10761 "7000 4000 7500 RATE eele 100 147 5100 2700 1200 eu 75 110 1700 1000 500 50 500 300 250 Notes 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 43% TOLERANCE FOR FACTORY TESTS, 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 180F JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-21/9-88 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING, HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE. ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10x RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. 3 INTERCOOLER HEAT REJECTION BASED ON NOMINAL’ 4000 FT. ALTITUDE. 4) LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING 120F MAX. TO INTERCOOLER FOR RATED ENGINE PERFORMANCE, $4) Asax-SUPERIOR aren, SANKC, Te 411/1-89 Superior® and CleanBurn”™ are trademarks of Cooper Industrie, ne. Copyright © Cooper industnes, inc. 1989,SUPERIOR TURBOCHARGED GAS ENGINES PAGE 412 MODEL 12GTL ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR 12GTL PERCENT] BVEP ENGINE SPEED — RPM Ro npeam lestucan 900 750, 600, ‘BRAKE SPECIFIC 110 1135 T3535 1128 902 OUTPUT 100 10.32 1230 1025 820 an 15 774 924 ‘169 615 50. 5) 615 1S. AIO BRAKE SPECIFIC M10 1135, —_ aml cen FUEL CONSWATION| 100 10.32 2501 2467 2433 kcaHHR) 15 714 2656 2s72 2501 50. 15. 2900 2842 3194 INTAKE AIR FLOW 110 11.35 4 cal 58 REQUIREMENT 100 1032 106 84 55 gM 75 174 88 65 47 SO. SAS 66. 45. 35. 110) 11.35 120 98 64 can flow 100 10.32 M1 88 61 75 774 93 68 49 50. 5.15 70 43 34 110 11.35 an 452 499 nnn 100 10.32 466 449 507 ee 5 174 452 432 47 50. _ 515 426 391 349 110 1135) 16633 13710 10811 SACKET WATER 100 10.52 15877 12979 10232 MEAT REECTION | 175 14 1391! 11366 9047 sean) 50 515 12097 9829 7813 110) 11.35 1915 1865 1714 LUBE OIL 100 10.32 1890 1789 1613 HEAT [Link] 15 114 1714 1512 1260 cL) 50. Sul 1260 20% 04. 110 W135 1764 1008 378 INTERCOOLER 100, 10.32 1285 680 wo2 ‘HEAT REECTION 15 774 428 252 126 cai MIND 50 515 126 76 63 NOTES = 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 43 TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 82C JACKET WATER OUTLET TENPERATURE. REFER TO ‘GENERAL DATA SECTION, PAGE GEN-23/1-89 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND ‘AMBIENT TEMPERATURE, ADO RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10x RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. 3D INTERCOOLER HEAT REJECTION BASED ON NOMINAL 1200 M ALTITUDE. LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING 50 MAX. TO INTERCOOLER FOR RATED ENGINE PERFORMANCE. AJAX-SUPERIOR appn_SWNC ‘Superor® and CloanBurn™ are trademarks of Cooper Industries, inc. Te 412/1-89 Copyright © Cooper industries, nc. 1989SUPERIOR TURBOCHARGED GAS ENGINES MODEL 12GTL PAGE 413 e EXHAUST EMISSIONS MODEL = 6GTL, BGTL, 12GTL, 16GTL Lai EMISSIONS (GRAMS/BHP-HR) RPM hate BHP(KW) NOx CO NMHC 900 100 = 15.0 09 05 * TONS PER YEAR = (GM/BHP-HR) x BHP + 103.6 we DENOTES NON-METHANE HYDROCARBONS QUALIFYING CONDITIONS: 1) PIPELINE QUALITY GAS IS ASSUMED. METHANE CONTENT SHOULD BE GREATER THAN 90% WITH A LOW HEATING VALUE OF 900 BTU/SCF 15, FOR FUEL GAS OUTSIDE THESE PARAMETERS AN INDIVIOUAL REVIEW WILL BE REQUIRED TO DETERMINE EMISSION LEVELS AND FUEL CONSUMPTION RATES. 2) VALUES ARE BASED UPON 130" F MANIFOLD TEMPERATURE, <120" F INTERCOOLER WATER AND 100° F AMBIENT TEMPERATURE. REDUCED AIR MANIFOLD TEMPERATURES WILL RESULT IN LOWER NOx LEVELS. HIGHER AMBIENT TEMPERATURES WILL NOT AFFECT EMISSION LEVELS AT RATED LOAD AND SPEED BUT WILL CAUSE SLIGHTLY HIGHER NOx LEVELS AT REDUCED SPEEDS, 3D DATA SHOWN ARE BASED ON ENGINE ADJUSTMENT FOR STANDARD BSFC. FULL SPEED EMISSION VALUES ARE VALID FOR ALTITUDES BELOW 4000 FT. HIGH ALTITUDE APPLICATIONS MAY REQUIRE TURBOCHARGER MODIFICATION TO MAINTAIN EMISSION RATES, 4) WHEN NOx REQUIREMENTS LESS THAN THOSE EXPRESSED HERE ARE ENCOUNTERED, THERE ARE TRADE-OFFS BETWEEN NOx AND BSFC WHICH MAY BE APPLICABLE, BUT THESE MUST BE EVALUATED ON A SPECIFIC CASE e BASIS. | G)| asax-SuPERIOR appr. VSMC Te 413/1-89 Superior® and ClsanBurn"™ are trademarks of Cooper Industries. Inc Copyright © Cooper industrias, ine. 1980SUPERIOR TURBOCHARGED GAS ENGINE MODEL 12GTL PAGE 415, WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS 110 100 90 ENGINE_RPM Ed ‘ ‘900 L 80 DESIGN eS FLOWS 70 | E60 eet ea = ~ = Ey Loew my 7 30 = fe ENGINE PRESSURE 10 — DROP 0 | af | oO 200 400 600 800 900 FLOW (GPM) IMPELLER P/N D-024-003 (STRAIGHT VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION @I-DIRECTIONAL CAPABILITY) NORMALLY C.C.W (FACING DRIVE END? NPSHp = 19.0 FEET @ 900 RPM & 600 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 600 GPM = 99.0 FT. ~ 343 FT. = 647 FT. 647 FT. + 231 = 28.0 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. #)| AJAX-SUPERIOR appr. SNC Tc 415/1-89 Superior® and CieanBurn"™ are radomarks of Cooper Industries, Ine. ‘Copyright © Cooper Industries, In. 1980‘SUPERIOR TURBOCHARGED GAS ENGINE MODEL 126TL PAGE 416 WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS 10 io ENGINE RPM 90 | SS it 2 ee] = 50 z -—— 5 600 2 Bo —— * 4 e—]_ ENGINE PRESSURE 10 ab +— pROP a ees 0 200 400 600 B00 900 FLOW (GPM) IMPELLER P/N D-033-744-002 (CURVED VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (UNIDIRECTIONAL? [Link] (FACING DRIVE END) NPSHp = 12.0 FEET @ 900 RPM & 600 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 600 GPM = 870 FT~ 343 FT. 5 523 FT 52.7 FT. + 231 = ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. $4| asax-SUPERIOR appr. TAN\C Te 416/1-89 Superior* and CleanBurn"™ are wademarks of Cooper Industries, Ine. Copyright © Cooper industries, Inc. 1969SUPERIOR TURBOCHARGED GAS ENGINE MODEL 126TL PAGE 417 SUPERCEDED BY PUMP CHARACTERISTICS SHOWN ON PAGE 417A WATER PUMP CHARACTERISTICS INTERCOOLER WATER SYSTEM DESIGN FLOWS AND PRESSURE DROPS 60 ENGINE RPM 50 900, a 40 z e cae 20 600 a= | * = Sage ne ° 50 100 150 200 FLOW (GPM) IMPELLER P/N C-026-377 (STRAIGHT VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (BI-DIRECTIONAL CAPABILITY) NORMALLY C.C.W (FACING DRIVE END) NPSHp = 15.0 FEET. @ 900 RPM & 140 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 140 GPM = 45.0 FT~ 27.7 FT. = 17.3 FT. 113 FT. + 231 = 7.5 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. APPR h RK Te 417/1-89SUPERIOR TURBOCHARGED GAS ENGINE MODEL 12GTL PAGE 417A WATER PUMP CHARACTERISTICS INTERCOOLER WATER SYSTEM DESIGN FLOWS AND PRESSURE DROPS 80 —LENGINE RPM To | 200, —— ae < DESTGN & so | _750 A FLOW: & 40 — 600 a” p 20 a an 1 ENGINE” PRESSURE ° = P ° 100 200 400 FLOW (GPM) IMPELLER P/N C-026-376 (STRAIGHT VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (BI-DIRECTIONAL CAPABILITY? NORMALLY C.C.W (FACING DRIVE END) NPSHp = 14.0 FEET ® 900 RPM & 140 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE, OF 140 GPM = 70.0 FT- 27.7 FT. = 42.3 FT. 42,3 FT. + 231 = 183 Psi ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. APPR. h kK TC 417A/6-91SUPERIOR TURBOCHARGED GAS ENGINES MODEL 12SGT ENGINE SECTION INDEX Description Page No. Air Intake system 504 Bearing Dimensions 507 Cooling System 508 Dimensions and Weight 507 Engine Operating Data -Units In English Units S11 -Units In Metric Units 512 Engine Outline Drawing 519 Engine Performance 503 Engine Specifications 501 Exhaust Emissions 513 Exhaust System 504 Fuel system 504 Heat Rejection Data Units In English Units sit “Units In Metric Units 512 Lubrication System 506 Miscellaneous 508 Starting system 503 Turbocharger 504 Unbalanced Forces and Couples -Units In English Units 509 Units In Metric Units 510 Water Pump Characteristics ~Jacket Water, Straight Vane 515 ~Jacket Water, Curved Vane 516 -Intercooler, Straight Vane 517 “Intercooler, Curved Vane N/A (@l] Asax-suPenionSUPERIOR TURBOCHARGED GAS ENGINES MODEL 12SGT PAGE 501 ENGINE SPECIFICATIONS Type Aspiration Cylinder Configuration Number of Cylinders Bore > in. Stroke - in, Displacement - cu. in. (mm) (mm) (liter) Compression Ratio Power Rated - BHP (kW) Speed Rated ~ RPM Piston Speed - FPM(m/s) Speed Range - RPM Ignition system Fuel system Governor Turbocharger Exhaust Manifold Jacket Water Pump Jacket Water Thermostat Intercooler Water Pump Intercooler Water Thermostat Lube 0i1 Pump Lube 0il Thermostat Prelube Pump Lube 0il Cooler Intercooler Crankcase Breather Crankcase Doors Direction of Rotation $4) AJAX-SUPERIOR Four(4)-Cycle Turbocharged, Intercooled vee Twelve (12) 10 (254) 10.50 (266.7) 9896 (162.20) 8.20: 1 2000 (1491) 900 1575 (8.0) 900 - 600 Non-Shielded, Altronic III Fuel Injected with Analog Type Electronic Air-Puel Control and Manual Starting Logic Hydraulic (UG-8L) With Manual Speed Setting one(1) Water Cooled Built-In Centrifugal, Chain Driven Remote Mounted Built-In Centrifugal, Chain Driven Remote Mounted Gear Type with Pressure Regulating Valve Remote Mounted Manual, Mounted and Piped Shell & Tube Type, Remote Mounted Rectangular, Shell & Tube/Fin Type Positive Ventilation Pressure Relief(Bicera Type) Doors Counterclockwise From Flywheel End APPR. BN Z ‘Superio® and CleanBurn™ are vademarks of Cooper industries, Ine Copyright © Cooper ndustis, ne. 1968 TC 501/1-89SUPERIOR TURBOCHARGED GAS ENGINES PAGE 503 MODEL 12SGT PERFORMANCE Engine Operating Data See Page 511 & 512 Rating Conditions Altitude feet 4000 meter (1219 ) ~Temperature Deg F 100 Deg ¢ (37.8 ) Rated Torque Over 900-600 RPM Range 1b-ft ii671 M-kg (1614 ) Brake Mean Effective Pressure Rating/BMEP psi 177.8 kg/om2 (12.5) Rated Brake Specific Fuel Consumption/BSFC Btu/bhp-hr 7250 (Plus or Minus 3 Percent Factory Tolerance) kcal/kW-hr ( 2450 ) Heat Rejection Data See Page 511 & 512 Emissions See Page 513 @ ccarerns srsten Air/Gas Starting Motor Make & Model IR / SS-825 Number of Starting Motors: Generator Drive One(1) Compressor Drive Two(2) Supply Air/Gas Pressure psi 150 kg/om2 (10.5 ) Consumption Rate/Starter Motor -Air scfm 1500 liter/sec (708 ) -Gas scfm 1781 liter/sec ( 841 ) - Normal Starting Time sec 15 Connection Sizes -Inlet 1-1/2 In. NPT ~Outlet 2-1/2 In. NPT -Optional: Inlet Flange 3-1/2 In. Square outlet Flange 2-1/2 In. 150 Lb. { 44] auax-suPERIOR appr._G3NKC_V Te 503/1-89 ‘Superior? and CleanBumn™ are trademarks of Cooper Industries, Inc. Copyright © Cooper néusties, nc. 1989SUPERIOR TURBOCHARGED GAS ENGINES MODEL 12SGT AIR INTAKE SYSTEM Intake Air Flow Rate Max. Allowable Pressure Drop Air Intake, Inlet Connection FUEL SYSTEM Required Fuel Gas Pressure to Engine Based on Pipeline Quality Natural Gas (Regulated to within plus or minus 1 psig) Gas Inlet Flange Connection EXHAUST SYSTEM Max. Allowable Back Pressure Exhaust Outlet Flange Connection Size Exhaust Flow Rate Stack Temperature TURBOCHARGER Type Manufacturer Model Speed (Maximum) PAGE 504 See Page 511 & 512 In #20 10 mm H20 oe 18 In, I.D. Flex Connector psi 35-40 kg/em2 (2.5-2.8 ) 2 In, 150 Lb. In #20 10 mn H20 (| 254) 18 In. 125 Lb. FF See Page 511 & 512 See Page 511 & 512 Constant Pressure Cooper-Bessemer ET 13 RPM 23000 AJAX-SUPERIOR appr. VANKC- Te $04/1-89 ‘Superior? and CieanBurs™ are wasemarks of Cooper Industrie, Ine. Copyright © Cooper industries, Inc. 1989SUPERIOR TURBOCHARGED GAS ENGINES PAGE 505 MODEL 12SGT COOLING SYSTEM Jacket Water Capacity - Engine Only Gallon (146) liter 583 Jacket Water Pump -Jacket Water Outlet Temperature, Normal Deg F 165-180 Deg ¢ (74-82 ) ~Design Flow Rate at Rated Speed GPH 750 liter/sec ( 47.3 ) Available External Head: Straight Vane(Standard) psi 18.2 kg/om2 (1.28 ) Curved Vane(Optional) psi 10.8 kg/cm2 (0.76 ) ~Minimum NPSH Required: Straight Vane(Standard) feet 20 meter (6.10 ) Curved Vane(Optional) feet 14 meter (4.27) Intercooler Water Pump Intercooler Water Inlet Temp, Normal Deg F 120 Deg (49.0 ) Design Flow Rate at Rated speed GPM 140 liter/sec (8.8 ) ~Available External Head: Straight Vane(Standard) psi 7.5 kg/cm2 (0.53 ) “Minimum NPSH Require Straight Vane(Standard) Ft.H20 15 M.H20 ( 4.57) Connection Sizes ~Jacket Water Inlet 6 In. 150 Lb. ~Jacket Water Outlet 6 In. 150 Lb. ~Intercooler Water Inlet 4 In. 150 Lb. ~Intercooler Water Outlet 4 In. 150 Lb. -Vent Line to Surge Tank,Minimum Size 3/8 In. Tubing ~Surge Tank Return to Pump Inlet: Jacket Water 2 In. NPT Intercooler 2 In. NPT 4) AJAX-SUPERIOR aper._S3NAC, TC 505/1-89 Superior and CloanBurn"™ are trademarks of Cooper industries, Inc. Copyright © Cooper Industries, Inc. 1969SUPERIOR TURBOCHARGED GAS ENGINES PAGE 506 MODEL 12SGT LUBRICATION SYSTEM Lube 011 Sump Capacity Gallon 165 liter (625 ) Lube 011 Consumption(Estimated) Gal. /Day 4.00 Liter/Day (15.1 ) Lube 011 Pressure - Normal psi 35 keg/om2 (2.46 ) Temperature Out Of Engine - Normal Deg F Deg ¢ ) Flow Rate Through 0i1 Filter cpm 70 liter/sec (4.42 ) Lube 011 Filters, Engine Mounted(Standard) -Type Full Flow -Microns of Filtration Fifteen(15) Connection Sizes Lube 0i1 Sump Drain Plug 3-1/2 In. NPT -Lube 011 Inlet to Engine 3 In, 150 Lb. -Lube 011 Outlet to Filter 3 In. NPT Gi) Asax-suPERIOR arer. WINKC Te 506/1-89 ‘Superior? and CioanBurn"™ are trademarks of Cooper Industies, Inc. Copyright © Cooper industries, ic. 1989SUPERIOR TURBOCHARGED GAS ENGINES MODEL 128GT © resets oveesroxs Main Bearing, Split Shell —Diameter -Width ~Quantity Crankpin Bearing, Split Shell -Diameter -Width -Quantity Wrist Pin Bearing -Diameter -Width e -Quantity Camshaft Bearing, Split Shell Diameter -Width -Quantity per Bank DIMENSIONS AND WEIGHT (APPROXIMATE) Overall Length Overall Width Overall Height Dry Weight AJAX-SUPERIOR In In Nos. In nn In Nos. In In Nos. In mn In Nos. In In In Lb kg appr. SNC) Suporior® and CleanBurn"™ are radomarks of Cooper Indu Copyright © Cooper Industries, Inc. 1988, PAGE 507 8.00 (203.2 ) 4.88 (124.0 ) 7 6.38 ( 162.1) 2.83 ( 64.3 ) 3.80 ( 88.9 ) 3.16 ( 80.3 12 2.75 ( 69.9 2.38 ( 60.5 ) 185 ( 4699 84 ( 2136 118 ( 2921 ) 42500 (19278 ) TC 507/1-89SUPERIOR TURBOCHARGED GAS ENGINES PAGE 508 MODEL 12SGT MISCELLANEOUS Clearance Required to Remove Piston In 89 mm ( 2261 ) Heaviest Engine Parts (Approximate Weights) Cylinder Block Assembly Lb 10400 kg (4717 ) -Cylinder Head Assembly Lb 250 kg (2123) ~Piston and Connecting Rod Assembly Lb 198 kg (90) Turbocharger Assembly Lb 1170 kg (531 ) Exhaust Manifold Lb 1210 kg (549) 4)! Asax-SUPERIOR appr. AMC) Te s08/1-89_ ‘Superior? and CleanBur™ ace trademarks of Cooper Industries, nc. Copyright © Cooper industries, Inc. 1989SUPERIOR TURBSOCHARGED GAS ENGINES PAGE 509 MODEL 12SGT MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN ENGLISH UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and norma. expectations should not exceed 50 percent of the calculated values. ENGINE RPM S 800 753.915 573.713 87.866 39.122 700 577.216 439.249 67.273 29.952 600 424.077 322.713 49.425 22.008 ' It t I i in 111.206 49.512 ia I {I i 1 | ( | goo | 954.174 726.10: i 1 \ 1 1 SECONDARY COUPLE ~ [Link]. PRIMARY COUPLE - [Link]. | I i | I 1 1 1 I 1 1 ! 1 ‘Superior? and CleanBurn™ ave trademarks of Cooper Industries, Copyright © Cooper industries, Inc. 1980 appr. SSNKC, 1 509/1-89SUPERIOR TURBOCHARGED GAS ENGINES PAGE 510 MODEL 12SGT MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN METRIC UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. PRIMARY FORCE ~ kg ! 1 | ENGINE | i i RPM | VERTICAL == HORIZONTAL || | VERTICAL HORIZONTAL | { in ! | in ! 00 | 432.813, 329.361 || 50.443 22.459 | g00 | 341.976 260.236 || 39.856 17.745 | 700 | 261.825 199.243 |} 30.515 13.586 | 600 | 192.361 146.383 || 22.419 9.981 | | it | PRIMARY COUPLE - [Link] ! i | ENGINE | ul t RPM | “VERTICAL == HORIZONTAL || ‘VERTICAL HORIZONTAL | | i I | I \ cH 352.903 270.735 || 37.177 16.552 | soo | 278.837 218.914 || 29.375 13.078 | i | 213.485 163.778 |] 22.490 10.013 | soo | 156.866 120.327 || 16.523 71387 | I I \ | $4) AJAX-SUPERIOR APPR On Te_510/1-89 Superior® and CleanBurn"™ ae trademarks of Cooper Industries, Ine Copyright © Cooper industries, inc. 1989.SUPERIOR TURBOCHARGED GAS ENGINES MODEL 12SGT PAGE 511 ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR 12S6T PERCENT] pup ENGINE SPEED — RPM OAD esp 900, 750 600 rr 110 156 2200 1833 Ta67 HORSEPOWER 100 178 2000 1667 1333 Gf) 15 133 1500 1250 1000 748 8: 1000 B33. 667 | 196 = — ea Fe er ariox| 100 178 7250 7250 7750 ine 15 133 7500 7350 7100 50 89 8200 8000 8350 110 196 3875 5200 1775 faneunn | 100 178 3575 2925 1725 corn 715 133 2875 2225 1525 50 89 2200 1550 1200 110 196 308 255 142 ne oe 100 178 285 234 140 15 133 230 175 122 50 89 175 120 90 EXHAUST TEV. too ize ore eee eon 178 PAN a 15 860 830 940 ‘CHARGER (A50F) es 50 29 830 780 780 110 196 74500 $1000 47600 ret | 100 178 70000 57500 45100 an 18 133 60000 49000 39000 50 39 51000 42000 33000 ian 110 196 7500 7500 7100 Hear wexcrion | 100 178 7500 7500 7000 ‘onan 15 133 7300 6600 5700 50 29 5700 5000 3500 710 196 T1500 "7000 3500 Hatecenon | 190 178 9000 5500 2500 cauadl 15 133 3990 2000 1000 50 a9 1000 500 400 NOTES 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 43t TOLERANCE FOR FACTORY TESTS, 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 180F JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-21/9-88 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE. ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10x RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. 3 INTERCOOLER HEAT REJECTION BASED ON NOMINAL 4000 FT. ALTITUDE. 4) LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING 120F MAX. TO INTERCOOLER FOR RATED ENGINE PERFORMANCE, WJAX-SUPERIOR APPR. SNC Te 511/1-89 ‘Superioe® and CleanBurn™ are wademarks of Cooper Industles, Ine. Copyright © Cooper industries, nc. 1968SUPERIOR TURBOCHARGED GAS ENGINES PAGE 512 MODEL 128GT ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR 12S6T PERCENT] OMEP ENGINE SPEED - RPM Poa _| 9/em2 900. 750 600 BRE SECIFIE | NO 7378 1647 1367 1094 ‘OUTPUT 100 1as2 1491 1243 994 an 15 935 1119 932 746 50 $2 746 621 497 BRE SPECIFIC 110 13.78 — — — FUEL CONSPTION| 100 1252 2450 2450 2619 dH 15 9.35 2535 2484 2399 50 6.26 2771 2704 2822 INTAE AIR FLOW | 110 1378 134 110 61 REQUIREMENT 100 1as2 123 101 59 Gg) 15 9.35 99 7 53 TE Tie] 4898 | 40 ie ea 110 1378 40 116 4 tym | 100 | tes 129 106 64 15 935 104 79 55 50 626 79 54 Ay 110 13.78 468 454 427 Se 100 1252 468 457 468 ee 15 935 460 443 504 50 626 a3 416 A16 110 13.78 18775, 15373 71996 JACKET WATER 100 1252 17641 14491 11366 PEASE ELTION| 15 935 15121 12349 9829 —_ 50 626 | 12853 10585 8317 110 13.78 1890 1890 1789 URE OTL 100 12.52 1890 1890 1764 HEAT RECTION 75 935 1840 1663 1436 coun 50 62 1456 1260 882 110) 1378 2898 1764 B82 INTERCOOLER 100 1252 2268 1386 630 HEAT RESECTION 15 935 1006 504 252 c/n) so_| 626 252 126 404 NOTES : 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 33% TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 82 JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-23/1-89 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND ‘AMBIENT TEMPERATURE. ADO RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10x RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. 3D INTERCOOLER HEAT REJECTION BASED ON NOMINAL 1200 M ALTITUDE, % LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING 50'C MAX. TO INTERCOOLER FOR RATED ENGINE PERFORMANCE. | S| AJAX-SUPERIOR porn SANG ‘Superir® and ClaanBurs™ are wademarks of Cooper Industries, ne. Te 512/1-89 Copyright © Cooper industries, nc. 1869SUPERIOR TURBOCHARGED GAS ENGINES MODEL 12S6T PAGE 513 e EXHAUST EMISSIONS MODEL + 12SGT, 16SGT PERCENT *EMISSIONS (GRAMS/BHP-HR) el CE 900 100 - 18.0 O8 os * TONS PER YEAR = (GM/BHP-HR) x BHP + 1036 #® DENOTES NON-METHANE HYDROCARBONS QUALIFYING CONDITIONS: 1) PIPELINE QUALITY GAS 1S ASSUMED. METHANE CONTENT SHOULD BE GREATER THAN 90% WITH A LOW HEATING VALUE OF 900 BTU/SCF & 15% FOR FUEL GAS OUTSIDE THESE PARAMETERS AN INDIVIOUAL REVIEW WILL BE REQUIRED TO DETERMINE EMISSION LEVELS AND FUEL CONSUMPTION RATES, 2) VALUES ARE BASED UPON 130" F MANIFOLD TEMPERATURE, «120° F INTERCOOLER WATER AND 100" F AMBIENT TEMPERATURE. REDUCED AIR MANIFOLD TEMPERATURES WILL RESULT IN LOWER NOx LEVELS. HIGHER AMBIENT TEMPERATURES WILL NOT AFFECT EMISSION LEVELS AT RATED LOAD AND SPEED BUT WILL CAUSE SLIGHTLY HIGHER NOx LEVELS AT REDUCED SPEEDS. 3D DATA SHOWN ARE BASED ON ENGINE ADJUSTMENT FOR STANDARD BSFC, FULL SPEED EMISSION VALUES ARE VALID FOR ALTITUDES BELOW 4000 FT. HIGH ALTITUDE APPLICATIONS MAY REQUIRE TURBOCHARGER MODIFICATION TO MAINTAIN EMISSION RATES. 4) WHEN NOx REQUIREMENTS LESS THAN THOSE EXPRESSED HERE ARE ENCOUNTERED, THERE ARE TRADE-OFFS BETWEEN NOx AND BSFC WHICH MAY BE APPLICABLE, BUT THESE MUST BE EVALUATED ON A SPECIFIC CASE BASIS. AJAX-SUPERIOR appr. SVANAC Te _513/1-89 ‘Superior? and CleanBur™ ate trademarks of Cooper Industries, Inc. Copyright © Cooper industries, nc. 1989SUPERIOR TURBQCHARGED GAB ENGINE MODEL 12S6T PAGE 515 ® WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS 00 90 ENGINE_RPM. pa 20) ae Os! ON ec ows zZ a 7 150 | Ss 90 - 7 mean 5 «|p att 7 = i P| ENGINE PRESSURE uo = 4 t—=prop z ae e@ ° 200 400 600 800 900 FLOW (GPM) IMPELLER P/N D-024-003 (STRAIGHT VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION G@I-DIRECTIONAL CAPABILITY) NORMALLY C.C.W (FACING DRIVE END) NPSHg = 20.0 FEET @ 900 RPM & 750 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 750 GPM = 97.0 FT. - 55.0 FT. = 42.0 FT. 42.0 FT. + 231 = 182 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. 4 asax-SuPERIOR aren SSMAC Te S15/1-89 ‘Superoe® and CloanBurn™ are trademarks of Cooper Industries, Ine. Copyright © Cooper industries, Inc. 1989‘SUPERIOR TURBOCHARGED GAS ENGINE MODEL 12sGT ee WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS 110 toot ENGINE RPM 90 900 4 80 fT DESIG! | < F wo | FLOWS Iv Be pS = 50 = a wen = 20 = ee 10 [oo == fexaine PRESSURE — ieee o 200 400 00 | BGO 900 FLOW (GPM) IMPELLER P/N D-033-744-002 (CURVED VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (UNIDIRECTIONAL) C.C.W (FACING ORIVE END) NPSHp = 140 FEET @ 900 RPM & 750 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 750 GPM = 80.0 FT~ 550 FT. = 250 FT. 25.0 FT. + 2.31 = 108 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. AJAX-SUPERIOR apprn__CANC TC 516/1-89 ‘Superor® and CloanBurn™ are wademarks of Cooper Industries, Inc. Copyright © Cooper industries, nc, 1989SUPERIOR TURBOCHARGED GAS ENGINE MODEL 12SGT PAGE 517 SUPERCEDED BY PUMP CHARACTERISTICS SHOWN ON PAGE 517A WATER PUMP CHARACTERISTICS INTERCOOLER WATER SYSTEM DESIGN FLOWS AND PRESSURE DROPS 60 ENGINE RPM ea 900 ey DESIGN ws ty a Flows “FS & 750 30 x 5 ea 20 600 pe 10 =<" [|__| “ToS IGINE PRESSURE P | } ENS DRO! 0 50 100 150 200 FLOW (GPM) IMPELLER P/N C-026-377 (STRAIGHT VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (BI-DIRECTIONAL CAPABILITY) NORMALLY C.C.W (FACING DRIVE END) NPSHp = 15.0 FEET @ 900 RPM & 140 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 140 GPM = 45.0 FT- 27.7 FT. = 17.3 173 FT. + 231 = 75 ri ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS appr. -f K k To 517/1-89‘SUPERIOR TURBOCHARGED GAS ENGINE MODEL 12SGT PAGE 517A WATER PUMP CHARACTERISTICS INTERCOOLER WATER SYSTEM DESIGN FLOWS AND PRESSURE DROPS. 80 ENGINE RPM 10 ae c 6 oa DESTGN F so | 759 fz 2 = - 600 eo < 10 2 > ° a Q 100 200 FLOW (GPM) IMPELLER P/N C-026~376 (STRAIGHT VANE) PUMP RPM = 1,788 X ENGINE RPM DIRECTION OF ROTATION (BIDIRECTIONAL CAPABILITY) NORMALLY C.C.W (FACING DRIVE END) NPSHR = 14.0 FEET ® 900 RPM & 140 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 140 GPM = 700 FT- 27.7 FT. = 42.3 FT. 42.3 FT. + 231 = 18.3 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. APPR. | KY TC S17A/6-91SUPERIOR TURBOCHARGED GAS ENGINES MODEL 16GTL ENGINE SECTION INDEX Description Page No. Air Intake System 604 Bearing Dimensions 607 Cooling system 605 Dimensions and Weight 607 Engine Operating Data -Units In English Units 611 -Units In Metric Units 612 Engine Outline Drawing 619 Engine Performance 603 Engine Specifications 601 Exhaust Emissions 613 Exhaust System 604 Fuel system 604 Heat Rejection Data -Units In English Units 611 -Units In Metric Units 612 Lubrication System 606 Miscellaneous 608 Starting Systen 603 Turbocharger 604 Unbalanced Forces and Couples -Units In English Units 609 -Units In Metric Units 610 Water Pump Characteristics “Jacket Water, Straight Vane 615 Jacket Water, Curved Vane 616 “Intercooler, Straight Vane 617 “Intercooler, Curved vane N/A AJAX-SUPERIORSUPERIOR TURBOCHARGED GAS ENGINES MODEL 16GTL PAGE 601 ENGINE SPECIFICATIONS Type Aspiration Cylinder Configuration Number of Cylinders Bore - in, (mm) Stroke - in. (mm) Displacement - [Link]. (liter) Compression Ratio Power Rated - BHP (kW) Speed Rated - RPM Piston Speed - FPM(m/s) Speed Range - RPM Ignition system Fuel system Governor Turbocharger Exhaust Manifold Jacket Water Pump Jacket Water Thermostat Intercooler Water Pump Intercooler Water Thermostat Lube 0i1 Pump Lube Oil Thermostat Prelube Pump Lube 0i1 Cooler Intercooler Crankcase Breather Crankcase Doors Direction of Rotation AJAX-SUPERIOR Four(4)-Cycle Turbocharged, Intercooled Vee Sixteen (16) 10 (254) 10.50 (266.7) 13195 (216.27) 8.20: 1 2200 (1641) 900 1575 (8.0) 900 - 600 Non-Shielded, Altronic IIT Fuel Injected with Analog Type Electronic Air-Fuel Control and Manual Starting Logic Hydraulic (UG-8L) With Manual Speed Setting One(1) Water Cooled Built-In Centrifugal, Chain Driven Remote Mounted Built-In Centrifugal, Chain Driven Remote Mounted Gear Type with Pressure Regulating Valve Remote Mounted Manual, Mounted and Piped Shell & Tube Type, Remote Mounted Rectangular, Shell & Tube/Fin Type Positive Ventilation Pressure Relief(Bicera Type) Doors Counterclockwise From Flywheel End arr. SQMA\C) Superior® and CleanBurn™ Copyright © Cooper industries, TC 601/1-89 rademarks of Cooper Industries, Inc. 1989SUPERIOR TURBOCHARGED GAS ENGINES PAGE 603 MODEL 16GTL © estenare Rating Conditions Altitude feet 4000 meter Sree -Temperature Deg F 100 Deg C ( 37.8 ) Rated Torque Over 900-600 RPM Range Ab-ft 12638 M-kg (1775 ) Brake Mean Effective Pressure Rating/BMEP psi 146.7 keg/em2 (10.3 ) Rated Brake Specific Fuel Consumption/BSFC Btu/bhp-hr 7376 (Plus or Minus 3 Percent Factory Tolerance) keal/kW-hr ( 2492 ) Heat Rejection Data See Page 611 & 612 Emissions See Page 613 @ starrixc syste Air/Gas Starting Motor Make & Model IR / ss-825 Number of Starting Motors: Generator Drive One(1) Compressor Drive Two(2) Supply Air/Gas Pressure psi 150 kg/om2 (10.5 ) Consumption Rate/Starter Motor Air scfm 1500 liter/sec ( 708 ) -Gas scfm 1781 liter/sec ( 841 ) - Normal Starting Time sec 15 Connection Sizes -Inlet 1-1/2 In, NPT ~Outlet 2-1/2 In. NPT -Optional: Inlet Flange 1-1/2 In. Square outlet Flange 2-1/2 In. 150 Lb. AJAX-SUPERIOR appr. SMC TC_603/1-89 ‘Superior® and CleanBurn™ are trademarks of Cooper Industes, In. Copyright © Cooper ncustis, In. 1988SUPERIOR TURBOCHARGED GAS ENGINES MODEL 16GTL AIR INTAKE SYSTEM Intake Air Flow Rate Max. Allowable Pressure Drop Air Intake, Inlet Connection FUEL SYSTEM Required Fuel Gas Pressure to Engine Based on Pipeline Quality Natural Gas (Regulated to within plus or minus 1 psig) Gas Inlet Flange Connection ‘EXHAUST SYSTEM Max. Allowable Back Pressure Exhaust Outlet Flange Connection Size Exhaust Flow Rate Stack Temperature TURBOCHARGER Type Manufacturer Model Speed (Maximum) PAGE 604 See Page 611 & 612 In H20 10 mm H20 (254) 18 In, I.D. Flex Connector psi 35-40 kg/em2 (2.8-2.8 ) 2 In, 150 Lb. In #20 10 mm H20 (254) 18 In, 150 Lb, FF See Page 611 & 612 See Page 611 & 612 Constant Pressure Cooper-Bessemer ET 13 RPM 23000 AJAX-SUPERIOR appr. TMC TC 604/1-89 ‘Superior® and Cleansura™ Copyright © Cooper Industri fe adematks of Cooper Industries, Inc. ‘ne. 1989SUPERIOR TURBOCHARGED GAS ENGINES MODEL 16GTL COOLING SYSTEM Jacket Water Capacity - Engine only Jacket Water Pump -Jacket Water Outlet Temperature, Normal -Design Flow Rate at Rated Speed -Available External Head: Straight Vane(Standard) Curved Vane(Opt ional) -Minimum NPSH Required: Straight Vane(Standard) Curved Vane (Optional) Intercooler Water Pump -Intercooler Water Inlet Temperature Normal -Design Flow Rate at Rated Speed -Available External Head: Straight Vane(Standard) -Minimum NPSH Required: Straight Vane(Standard) Connection Sizes -Jacket Water Inlet -Jacket Water Outlet Intercooler Water Inlet -Intercooler Water Outlet -Vent Line to Surge Tank,Minimum Size -Surge Tank Return to Pump Inlet: Jacket Water Intercooler PAGE Gallon liter ( Deg F 165 Deg c ry GPM liter/sec ( psi kg/om2 « psi kg/cm2 ( feet meter ( feet meter ( Deg F Deg c ( GEM liter/sec ( psi keg/om2 ( feet meter ( In. 150 Lb. In. 150 Lb. In. 150 Lb. In. 150 Lb. 3/8 In. Tubing 2 In. NPT 2 In. NPT aeao AJAX-SUPERIOR appr. GNC TC 605/ ‘Superiowand CleanBurn™ are trademarks of Cooper industries, In, CCopyrignt © Cooper industries, In. 1988 605 186 104 180 4-82 750 47.3 29 2.04 22 1.55 20 6.10 14 4.27 120 49.0 200 12.6 15.5 1.09 16 4.88 9SUPERIOR TURBOCHARGED GAS ENGINES PAGE 606 MODEL 16GTL LUBRICATION SYSTEM Lube 011 Sump Capacity Galion 220 liter ( 833) Lube 011 Consumption(Estimated) Gal./Day 4.39 liter/Day (16.6 ) Lube 0i1 Pressure - Normal psi 35 kg/cm2 ( 2.46) Temperature Out Of Engine - Normal Deg F 165-175 Deg ¢ (74-80 ) Flow Rate Through Oil Filter GPM 90 liter/sec ( 5.68 ) Lube 0i] Filters, Engine Mounted(Standard) ~Type Full Flow -Microns of Filtration Fifteen(15) Connection Sizes -Lube 041 Sump Drain Plug 1-1/2 In. NPT -Lube 011 Inlet to Engine 3 In. 150 Lb. ~Lube Oil Outlet to Filter 3 In. NPT aper._ GAC TC 606/1-89 ‘Superior? and CieanBurn™ are wademarks of Cooper Industles, Inc. Copyright © Cooper industies, nc. 1988SUPERIOR TURBOCHARGED GAS ENGINES PAGE 607 MODEL 16GTL @ eres onerszons Main Bearing, Split Shell -Diameter In 8.00 mm (203.2 ) -Width In 4.88 am (124.0 ) -Quantity Nos. 9 Crankpin Bearing, Split Shel] -Diameter In 6.38 mn (162.1 ) “Width In 2.53 mn ( 64.3 ) ~Quantity Nos. 16 Wrist Pin Bearing -Diameter In 3.50 am ( 88.9 ) -Width In 3.16 mm ( 80.3 ) e -Quantity Nos. 16 Camshaft Bearing, Split shell -Diameter In 2.75 mn (69.9 ) -Width In 2.38 mm ( 60.5 ) -Quantity per Bank Nos. 9 DIMENSIONS AND WEIGHT(APPROXIMATE) Overall Length In 221 mn ( 5613 ) Overall Width In 93 mn ( 2362 ) Overall Height In 112 mn ( 2845 ) Dry Weight Lb 54000 kg (24494) | 3) asax-SuPERIOR appr. GAM CTE 607/489 Suporior® and CieanBum™ are wademarks of Cooper Industis, Ine, Copyright © Cooper Industries, ne 1989SUPERIOR TURBOCHARGED GAS ENGINES PAGE 608 MODEL 16GTL MISCELLANEOUS Clearance Required to Remove Piston In 89 mn ( 2261 ) Heaviest Engine Parts (Approximate Weights) -Cylinder Block Assembly Lb 11000 kg (4990 ) “Cylinder Head Assembly Lb 250 kg (113) ~Piston and Connecting Rod Assembly Lb 198 kg te=e00)) -Turbocharger Assembly Lb 1170 kg (531 ) ~Exhaust Manifold Lb 1530 kg (694) AJAX-SUPERIOR appr. QAN\C_ TC 608/1-89 ‘Superio® and CleanBura™ are wademarks of Cooper Industries, In. Copyright © Cooper industries, ne. 1989.SUPERIOR TURBOCHARGED GAS ENGINES PAGE 609 MODEL 16GTL MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN ENGLISH UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit— ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly Procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. PRIMARY FORCE - Lb. SECONDARY FORCE - Lb. ENGINE RPM VERTICAL © HORIZONTAL VERTICAL HORIZONTAL 900 800 1040.655 790.643 115.137 51.262 700 796.751 605.336 88.151 39.248 600 585.368 444.736 64.764 28.835 | I | It | it t 1 I ! a | iM | i PRIMARY COUPLE - [Link]. SECONDARY COUPLE - [Link]. ENGINE RPM VERTICAL HORIZONTAL VERTICAL | HORIZONTAL 900 4330.740 3254.756 484.878 215.883 800 3421.820 2571.659 383.114 170.574 700 2619.831 1968.926 293.321 130.596 600 1924.773 1446.558 215.501 95.948 1 1 I 1 | | I ! 1 1 f | AJAX-SUPERIOR appr. GMC Te 609/1-89 Superior® and Cieanumn™ are rasemarks of Cooper Industries, Ine. Copyright © Cooper industries, Ine. 1989,SUPERIOR TURBOCHARGED GAS ENGINES PAGE 610 MODEL 16GTL MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN METRIC UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. SECONDARY FORCE - kg 1 I | ENGINE | o i 1 RPM | VERTICAL = HORIZONTAL || VERTICAL = HORIZONTAL | | a} | 1 i | goo} 597.427 453.898 || 66.099 29.429 | B00 | 472.041 358.636 || 52.226 23.252 | 700 | 361.406 274.580 || 39.985 17.803 | 600 | 265.523 201.732 || 29.377 13.080 | | ul 1 PRIMARY COUPLE - [Link] SECONDARY COUPLE - [Link] ENGINE RPM VERTICAL | HORIZONTAL VERTICAL © HORIZONTAL 3 800 473.238 355.660 52.985 23.590 700 362.923 272.302 40.566 18.061 600 200.059 29.804 13.270 | 1 1 I 67.059 29.857 i | 1 | I! 1 900 1 598.941 450.13: i ! 1 AJAX-SUPERIOR appr. MWC, Te 610/1-89 ‘Superior® and GloanBur™ are trademarks of Cooper Induetie, Ine. Copyright © Cooper industries, inc. 1989SUPERIOR TURBOCHARGED GAS ENGINES MODEL 16GTL race ell ENGINE OPERATING DATA AND HEAT REJECTION e SUPERIOR 16GTL PERCENT ENGINE SPEED - RPM RATED BMEP [oan _|_ esp 900 750 600 ane 110 TeT 2420 2016 Te14 eo 100 147 2200 1833 1467 let 75 110 1650 1375 1100 50 is Hoo 317 Ts 110 161 — — = Ret cowsaprion| 190 147 7370 7300 7310 aTiniea 75 110 7880 7600 7300 50 3 9150 8650 8350 tow | 110 161 "4550 3700 2600 PORE too | 147 4200 3410 2450 ocr 5 110 3400 2620 1900 50 3 2620 1860 1240 110 164 350 294 215 ie 100 147 325 265 200 7S 110 265 205 155 50 73 207 450, 95 an 910 265 B64 oe ee 100 147 909 870 846 ean 75 110 904 867 825 e 50 eed 900 855 795 rio | 61 73500 64700 53000 warioeeron | 100 | 147 | 70000 60500 49500 an 15 110 61800 50500 42000 50 73 54200, 41000 34000, ran 110 Tet 9500 9000 8300 IEAT RELECTION 100 147 9400 8700 8000 ABTU/MIN) Lin: 110 8400 7700 7200 50 73 7000 6100 5500 110 161 12500 9100 6100 anise | too | 147 11000 7550 $000 nian 15 110 6500 4500 3200 50 13 2500 1050 500 NOTES + FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 23% TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL I8OF JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-21/9-88 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING, HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE. ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10x RESERVE FACTOR TO COWPUTE RECOVERABLE HEAT. SUINTERCOOLER HEAT REJECTION BASED ON NOMINAL 4000 FT. ALTITUDE. 4) LUBE OIL COOLER AND INTERCOOLER ARE INA COMMON CIRCUIT REQUIRING IZ0F MAX, TO INTERCOOLER FOR RATED ENGINE PERFORMANCE. $4)| AJaX-SUPERIOR appr S3MC_ Te 611/189 ‘Superioe® and CloanBuen™ are trademarks of Cooper industries, In. Copyright © Cooper Industries, ine. 1988SUPERIOR TURBOCHARGED GAS ENGINES MODEL 16GTL PAGE 612 ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR 16GTL PERCENT] ouep ENGINE SPEED — RPM RATED LOAD kkg/cm2) 900 750 600 BRAKE SPECIFIC 11.35) 1805 1503 1204 ourPuT 10.32 1641 1367 1094 aw 774 1230 1025 820 515 820 a4 54] BRAKE 10 11.35, — = — ea 100 2491 2467 2491 FUEL CONSUMPTION 10.32 ‘cae 15 774 2663 2568 2467 50 515. 3092 2923 eaee INTAKE AR FLOW | 110 11.35 157 128 90 REQUIREMENT 100 10.32 145 118 84 Gg/MiN) 7s 174 N7 90 65 50 515 90 64 43 HAS 110 11.35 159 133 98 ou no 100 10.32 147 120 n 75 174 120 3 70 50 515 94 68 43 an 110 11.35 488 463 a2 fence TaD 100 10.32 487 466 482 carci 15 174 484 464 4a) 50 15 492 457 424 110 11.35 | 18523 16305 13357 Hear ReTION too 10.32 17641 15247 12475 ‘eelMN) 15 7:74 | 15575 12727 10585 50 51s | 13659 10333, 8569 LUBE OIL, N10 11.35 2394 2268 2092 HEAT REJECTION 100 10.32 2369 2193 2016 15 174 2017 1941 1815 fai 50 1 1764 1537 1386 macs 11.35 3150 2293 1537 HEAT RECTION 100 10.32 aria 1903 1260 Gea/WIN) 35 774 1638 1134 806 50 515 630 265 126 NOTES = 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBECT TO £31 TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 82 JACKET WATER OUTLET TEMPERATURE. REFER TO ‘GENERAL DATA SECTION. PAGE GEN-23/1-89 FOR HEAT REJECTION [Link] FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE. ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10% RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. 3 INTERCOOLER HEAT REJECTION BASED ON NOMINAL 1200 M ALTITUDE. 4) LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING 50% MAX. TO INTERCOOLER FOR RATED ENGINE PERFORMANCE. |) AJAX-SUPERIOR pen Sa MAC TC 612/1-89 ‘Superior? and CleanBum™ are trademarks of Cooper Industrie, inc. Copyright © Cooper industries, nc. 1989SUPERIOR TURBOCHARGED GAS ENGINES MODEL 16GTL ae els e EXHAUST EMISSIONS MODEL : 6GTL, 8GTL, 12GTL, 16GTL PERCENT #EMISSIONS (GRAMS/BHP-HR), RPM nee BHP(KW) NOx CO NMHC 900 100, = 15.0 09 05, ™ TONS PER YEAR = (GM/BHP-HR) x BHP + 103.6 we DENOTES NON-METHANE HYDROCARBONS QUALIFYING CONDITIONS: 1 PIPELINE QUALITY GAS 1S ASSUMED. METHANE CONTENT SHOULD BE GREATER THAN 90x WITH A LOW HEATING VALUE OF 900 BTU/SCF # 15%, FOR FUEL GAS OUTSIDE THESE PARAMETERS AN INDIVIDUAL REVIEW WILL BE REQUIRED TO DETERMINE EMISSION LEVELS AND FUEL CONSUMPTION RATES, VALUES ARE BASED UPON 130" F MANIFOLD TEMPERATURE, «120" F INTERCOOLER WATER AND 100" F AMBIENT TEMPERATURE, REDUCED AIR MANIFOLD TEMPERATURES WILL RESULT IN LOWER NOx LEVELS. HIGHER AMBIENT TEMPERATURES WILL NOT AFFECT EMISSION LEVELS AT RATED LOAD AND SPEED BUT WILL CAUSE SLIGHTLY HIGHER NOx LEVELS AT REDUCED SPEEDS, 3D DATA SHOWN ARE BASED ON ENGINE [Link] FOR STANDARD BSFC. FULL SPEED EMISSION VALUES ARE VALID FOR ALTITUDES BELOW 4000 FT. HIGH ALTITUDE APPLICATIONS MAY REQUIRE TURBOCHARGER MODIFICATION TO MAINTAIN EMISSION RATES, 4) WHEN NOx REQUIREMENTS LESS THAN THOSE EXPRESSED HERE ARE ENCOUNTERED, THERE ARE TRADE-OFFS BETWEEN NOx AND BSFC WHICH MAY BE APPLICABLE, BUT THESE MUST BE EVALUATED ON A SPECIFIC CASE e Basis AJAX-SUPERIOR appr, SNC Te 613/1-89 ‘Superior? and Cloanurn™ are rademarks of Cooper Industries, Ine. Copyright © Cooper naustis, Ine 1989 2SUPERIOR TURBOCHARGED GAS ENGINE MODEL 16GTL PAGE 415 e WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS fe 90 ENGINE_RPM t wr) ~ 8 i oesion E FLO\ g io 150 Ss | 32 Tes —b * 30 : a %0 axel S evan pre ssoRE ao) a a= DROP e ° ° ~ 200 400 600 800 900 FLOW (GPM) IMPELLER P/N D-024-003 (STRAIGHT VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION @I-DIRECTIONAL CAPABILITY) NORMALLY C.C.W (FACING DRIVE END) NPSHg = 20.0 FEET @ 900 RPM & 750 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE. OF 750 GPM = 97.0 FT. - 30.0 FT. = 67.0 FT. 67.0 FT. + 231 = 29.0 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. AJAX-SUPERIOR appr. _ SAM Ce TC 615/1-89 Superior® and CisanBur”™ are ademarks of Cooper Industries, Ine. Copyright © Cooper industri, ne. 1969SUPERIOR TURBOCHARGED GAS ENGINE PAGE 616 MODEL 16GTL WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS 110 te ENGINE RPM 90 4 L—— Ww DESIGN, a 50 eo a 600 7 es —— ZI 20 eal ue — {ENGINE PRESSURE —} ° +--+ DROP ° 200 400 600 800 900 FLOW (GPM) IMPELLER P/N D-O33-744-002 {CURVED VANE) PUMP DIREC RPM = 1.788 X ENGINE RPM TION OF ROTATION (UNIDIRECTIONAL) C.C.W (FACING DRIVE END) NPSHg = 14.0 FEET @ 900 RPM & 750 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 750 GPM = 80.0 FT. 30.0 FT. = 500 FT. 50.0 FT, + 2.31 = 22.0 PS fl ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. AJAX-SUPERIOR appr. ONC TC 616/1-89 ‘Superior? and CloanBurn™ are rademarks of Cooper Industries, Inc. Copyright © Cooper industries, Ic. 1988SUPERIOR TURBOCHARGED GAS ENGINE MODEL 16GTL PAGE 617 e WATER PUMP CHARACTERISTICS INTERCOOLER WATER SYSTEM DESIGN FLOWS AND PRESSURE DROPS eo TPENGINE RPM a > 8 a ia 50 750 Ale a [ zs tT 600 20 Le 10 at = | ENGINE PRESSURE ° ee e_| ° 100 200 300 400 e FLOW (GPM) IMPELLER P/N C-026-376 (STRAIGHT VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (BI-DIRECTIONAL CAPABILITY) NORMALLY C.C.W (FACING DRIVE END) NPSHg = 16.0 FEET @ 900 RPM & 200 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE! EXTERNAL HEAD FOR THE 900 RPM DONTE OF 200 GPM = 65.0 FT-29.0 FT. = 36.0 F Seo Fre 2a1 = 136. e61” ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. AJAX-SUPERIOR appr SOW TC 617/1-89 Superior® ang CieanBuen™ are trademarks of Cooper Industries, Inc. Copyrignt © Cooper industries, ne. 1989SUPERIOR TURBOCHARGED GAS ENGINES MODEL 16SGT ENGINE SECTION INDEX Description Page No. Air Intake System 704 Bearing Dimensions 107 Cooling System 708 Dimensions and Weight 101 Engine Operating Data -Units In English Units m1 Units In Metric Units 712 Engine Outline Drawing 79 Engine Performance 703 Engine Specifications 701 Exhaust Emissions 713 Exhaust System 104 Fuel System 104 Heat Rejection Data -Units In English Units m1 -Units In Metric Units 712 Lubrication System 706 Miscellaneous 708 Starting System 703 Turbocharger 04 Unbalanced Forces and Couples Units In English Units 709 -Units In Metric Units 710 Water Pump Characteristics -Jacket Water, Straight Vane 715 Jacket Water, Curved Vane 116 ~Intercooler,’ Straight Vane 737 “Intercooler, Curved Vane N/A AJAX-SUPERIORSUPERIOR TURBOCHARGED GAS ENGINES MODEL 16SGT PAGE 701 ENGINE SPECIFICATIONS Type Aspiration Cylinder Configuration Number of Cylinders Bore = in. (mm) Stroke = ins (mm) Displacement - [Link]. (liter) Compression Ratio Power Rated - BHP (kW) Speed Rated - RPM Piston Speed - FPM(m/s) Speed Range - RPM Ignition System Fuel system Governor Turbocharger Exhaust Manifold Jacket Water Pump Jacket Water Thermostat Intercooler Water Pump Intercooler Water Thermostat Lube 011 Pump Lube 0i1 Thermostat Prelube Pump Lube 011 Cooler Intercooler Crankcase Breather Crankcase Doors Direction of Rotation | Asax-SUPERIOR Four (4)-Cycle Turbocharged, Intercooled vee Sixteen (16) 10 (254) 10.50 (266.7) 13195 (216.27) 8.20: 1 2650 (1976) 900 1575 (8.0) 900 ~ 600 Non-Shielded, Altronic IIT Fuel Injected with Analog Type Electronic Air-Fuel Control and Manual Starting Logic Hydraulic (UG-8L) With Manual Speed Setting one(1) Water Cooled Built-In Centrifugal, Chain Driven Remote Mounted Built-In Centrifugal, Chain Driven Remote Mounted Gear Type with Pressure Regulating Valve Remote Mounted Manual, Mounted and Piped Shell & Tube Type(Unmounted) Rectangular, Shell & Tube/Fin Type Positive Ventilation Pressure Relief (Bicera Type) Doors Counterclockwise From Flywheel End Te 701/1-89 aver. S3MAC ‘Superior and CleanBurn™ aro trademarks of Cooper Indust Copyright © Cooper industries, ine. 1980SUPERIOR TURBOCHARGED GAS ENGINES PAGE 703 MODEL 16SGT ee Engine Operating Data See Page 711 & 712 Rating Conditions altitude feet 4000 meter (1219 ) -Temperature Deg F 100 Deg ¢ ( 37.8 ) Rated Torque Over 900-600 RPM Range Ib-ft 15464 M-kg (2139 ) Brake Mean Effective Pressure Rating/BMEP psi 177.8 kg/em2 (12.5 ) Rated Brake Specific Fuel Consumption/BSFC Btu/bhp-hr 7250 (Plus or Minus 3 Percent Factory Tolerance) keal/kW-hr ( 2450 ) Heat Rejection Data See Page 711 & 712 Emissions See Page 713 @ ssucsive svaren Air/Gas Starting Motor Make & Model IR / Ss-825 Number of Starting Motors: Generator Drive one(1) Compressor Drive Two(2) Supply Air/Gas Pressure psi 150 kg/cm2 (10.5 ) Consumption Rate/Starter Motor -Air scfm 1600 liter/sec ( 708 ) -Gas scfm 1781 liter/sec ( 841 ) - Normal Starting Time sec 18 Connection Sizes -Inlet 1-1/2 In. NPT -outlet 2-1/2 In. NPT -Optional: Inlet Flange 1-1/2 In. Square Outlet Flange 2-1/2 In. 180 Lb. | AJAX-SUPERIOR appr. (3M\C- Te_703/1-89 ‘Superior? and CloanBurn™ are trademarks of Cooper Industries, In, Copyright © Cooper Industri, nc. 1988SUPERIOR TURBOCHARGED GAS ENGINES MODEL 16SGT AIR INTAKE SYSTEM Intake Air Flow Rate Max. Allowable Pressure Drop Air Intake, Inlet Connection FUEL SYSTEM Required Fuel Gas Pressure to Engine Based on Pipeline Quality Natural Gas (Regulated to within plus or minus 1 psig) Gas Inlet Flange Connection EXHAUST SYSTEM Max. Allowable Back Pressure Exhaust Outlet Flange Connection Size Exhaust Plow Rate Stack Temperature TURBOCHARGER Type Manufacturer Model Speed (Maximum) PAGE 704 See Page 711 & 712 In H20 10 mm H20 (| 254 ) 18 In. I.D. Flex Connector psi 35-40 kg/em2(2.5-2.8 ) 2 In. 150 Lb. In H20 10 mm H20 (| 254) 18 In, 150 Lb. FF See Page 711 & 712 See Page 711 & 712 Constant Pressure Cooper-Bessemer ET 13 RPM 23000 (Gllasax-surerion appr. WON\C- TC 704/1-89 ‘Superior? and CleanBurn"™ are tadamarks of Cooper Industries, Inc. Copyright © Cooper industries, Inc. 1988$d AJAX-SUPERIOR SUPERIOR TURBOCHARGED GAS ENGINES MODEL 16SGT COOLING SYSTEM Jacket Water Capacity - Engine only Jacket Water Pump -Jacket Water Outlet Temperature, Normal -Design Flow Rate at Rated Speed “Available External Head: Straight Vane(Standard) Curved vane(optional) -Minimum NPSH Required: Straight Vane(Standard) Curved vane(optional) Intercooler Water Pump Intercooler Water Inlet Temperature Normal -Design Flow Rate at Rated Speed Available External Head: Straight Vane(Standard) -Minimum NPSH Required: Straight Vane(Standard) Connection Sizes -Jacket Water Inlet -Jacket Water Outlet “Intercooler Water Inlet -Intercooler Water Outlet -Vent Line to Surge Tank,Minimum Size -Surge Tank Return to Pump Inlet: Jacket Water Intercooler PAGE 705 Gallon 186 liter (704 Deg F 165-180 Deg c (74-82 GPM 116 liter/sec (48.9 psi 29 kg/cm2 ( 2.04 psi 21.2 kg/em2 (1.49 feet 20 meter (6.10 feet 14 meter (4.27 Deg F 120 Deg ¢ (49.0 GPM 200 liter/sec (12.6 15.5 (1.09 16 ( 4.88 6 In. 150 Lb. 6 In, 150 Lb. 4 In. 150 Lb. 4 In. 150 Lb. 3/8 In. Tubing 2 In. NPT 2 In. NPT aren. GMC _ te 705/1-09_ ) ) ) ) ‘Superior? and CleanBurn™ are trademarks of Cooper Industies Ine. Copyright © Cooper industries, ine. 1980SUPERIOR TURBOCHARGED GAS ENGINES PAGE 706 MODEL 16SGT LUBRICATION SYSTEM Lube 011 Sump Capacity Gallon 220 liter (833 ) Lube 0i1 Consumption(Estimated) Gal./Day 5.28 liter/Day (20.0 ) Lube Oil Pressure - Normal psi 35 kg/cm? (2.46 ) Temperature Out Of Engine ~ Normal Deg F 165-175 Deg ¢ (74-80 ) Flow Rate Through Oil Filter GPM 90 liter/sec ( 5.68 ) Lube Oil Filters, Engine Mounted(Standard) ~Type Full Flow ~Microns of Filtration Fifteen(15) Connection Sizes Lube 041 Sump Drain Plug 1-1/2 In. NPT -Lube 041 Inlet to Engine 3 In. 150 Lb. “Lube 041 Outlet to Filter 3 In. NPT AJAX-SUPERIOR arer._ GMC- Te 706/1-89 ‘Superior* and CleanBurn" are trademarks of Cooper Industries, Inc. Copyright © Cooper industries, Inc. 1980SUPERIOR TURBOCHARGED GAS ENGINES PAGE 707 MODEL 16SGT BEARING DIMENSIONS Main Bearing, Split Shell -Diameter In 8.00 mn ( 203.2 ) -Width In 4.88 nm (124.0 ) ~Quantity Nos. 9 Crankpin Bearing, Split Shell -Diameter In 6.38 mn (162.2 ) “Width In 2.53 an ( 64.3 ) -Quantity Nos. 16 Wrist Pin Bearing -Diameter In 3.50 an ( 88.9 ) “Width In 3.16 mm ( 80.3 ) e@ -Quantity Nos. 16 Camshaft Bearing, Split Shell -Diameter In 2.76 mn (69.9 ) -Width In 2.38 mm ( 60.5 ) -Quantity per Bank Nos. 9 DIMENSIONS AND WEIGHT (APPROXIMATE) Overall Length In 212 mn (5385 ) Overall Width In 93 mm ( 2362 ) Overall Height In 212 mm ( 2845 ) Dry Weight Lb 54000 kg ( 24494 ) AJAX-SUPERIOR appr. MC Te 707/1-89 ‘Supevior® and GloanBumn™ are trademarks of Cooper Industies Inc. Copyright © Cooper ndustes, nc. 1989SUPERIOR TURBOCHARGED GAS ENGINES PAGE 708 MODEL 16SGT MISCELLANEOUS Clearance Required to Remove Piston In 89 mm ( 2261 ) Heaviest Engine Parts (Approximate Weights) -cylinder Block Assembly Lb 11000 kg (4990 ) cylinder Head Assembly Lb 250 kg (413 ) -Piston and Connecting Rod Assembly Lb 198 kg (90) Turbocharger Assembly Lb 1170 kg (531 ) -Exhaust Manifold Lb 1530 kg (694 ) AJAX-SUPERIOR aper._ SANG TC_708/1-89 ‘Superio® and CleanBura™ are trademarks of Cooper Industties, Ine. Copyright © Caper industries, Ic. 1969SUPERIOR TURBOCHARGED GAS ENGINES PAGE 709 MODEL 16SGT MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN ENGLISH UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted, that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. SECONDARY FORCE - Lb. | it 1 ENGINE | I I RPM | VERTICAL © HORIZONTAL || © VERTICAL © HORIZONTAL | ! HW | | a 1 g00 | 1317.079 1000.657 || 145.720 64.879 | Ty | 1040.655 790.643 || 115.137 51.262 | 700 | 796.751 605.336 || ge.151 39.248 | 600 | 585.368 444.736 || 64.764 28.835 | | i I SECONDARY COUPLE - [Link]| PRIMARY COUPLE - [Link]. ENGINE RPM VERTICAL HORIZONTAL VERTICAL HORIZONTAL 484.878 215.883 800 3421.820 2571.659 700 2619.831 1968.926 293.321 130.596 600 1924.773 1446.558 215.501 95.948 It eile in | a It Ht It if i ! | 1 | g00 | 4330.740 3254.756 1 1 1 1 1 1 ' 383.114 170.574 | ! | ! AJAX-SUPERIOR appr. S3N\C- Te 709/1-89 Superior and CleanBurn™ are trademarks of Cooper Industies, Inc. Copyright © Cooper Incusiis, ine. 1989SUPERIOR TURBOCHARGED GAS ENGINES PAGE 710 MODEL 16SGT MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN METRIC UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted, that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. PRIMARY FORCE - kg excrwe | I \ RPM | VERTICAL HORIZONTAL || | VERTICAL HORIZONTAL | i iI goo | 897.427 453.898 || 66.099 29.429 | goo | 472.041 358.636 || 82.226 23.252 | 700} 361.406 274.580 || 39.985 17.803 | 600 | 265.523 201.732 || 29.377 13.080 | | ul | PRIMARY COUPLE - [Link] SECONDARY COUPLE - [Link] | i | | | 700 I 362.323 272.302 || 40.566 18.061 | | i | [@l]avax-surerion aper. G2NCY Te _710/1-89 ‘Superior* and ClesnBurn" are trademarks of Cooper Industries, Inc. ‘Copyright © Cooper industries, ic. 1989‘SUPERIOR TURBOCHARGED GAS ENGINES. MODEL 16SGT PAGE 711 ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR 168GT PERCENT] ENGINE SPEED — RPM RATED | BMEP (Si) 900 750 600 RAE - 2315 a7 194 Taisen too | 177 2650 2208 1767 oe 7 | 133 1988 1656 1325 0 89 1325 1104 B84 RAE SPECIFIC is 195 Soee Ja20 3000 100 177 7280 7420 8000 eee eS 133 7500 7360 7300 50 39 8450 8050 750 710 | 195 5380 4550 2890 Rant | 100 177 4900 4110 2770 na 75 133 3900 3100 2260 50 39 2920 2170 1510 710] 195 415 SO 240 Cee 100 17 380 325 230 15 133 308 245 190 50 a 230 175 120 asta ilOparieaioa 515 350 BEO ruaust TOP. | 300 | 177 905 865 850 75 135 900 870 830 cuancen 50m | 50 39 900 860 310 10 | 195, 82500 —] T5000 4000 piety || ie) in 77500 70000 59000 te i 15 133 67000 57000 46500 Go 50 39. $7500 45000, 37500, ion 710 | 195 T0000 9600 9300 fer teection | 190 | 177 9900 9400 8500 lun 75 133 9000 8500 7500 50 39 7500 7000 6000 T10 | 795 77500 13000 9000 wmencooleR | 100 | 497 15000 11000 7200 be 75 133 9000 6500 4000 50 a 4000 2500 1000 NaTes FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES. SUBJECT TO 43K TOLERANCE FOR FACTORY TESTS. ZIHEAT REJECTION DATA ARE BASED ON NOMINAL 180F JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-21/9-88 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE. ADO RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10x RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. SUINTERCOOLER HEAT REJECTION BASED ON NOMINAL 4000 FT. ALTITUDE. 4VLUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING I20F MAX, TO INTERCOOLER FOR RATED ENGINE PERFORMANCE. APPR. SIAC Te 711/189 ‘Superior? and Cieanfurn™ are rademarks of Cooper Industries, nc. Copyright © Cooper industies, nc. 1988SUPERIOR TURBOCHARGED GAS ENGINES: MODEL 16SGT PAGE 712 ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR L&6SGT PERCENT] BWEP ENGINE SPEED — RPM RATED | tig/em2)——900 | _750 300 ‘BRAKE SPECIFIC M0 TST 2174 1811 1450 OUTPUT 100 12.45 1976 1647 1318 aw 75 9.35 1482 1235 988 50 6.26 988 B23 659 BRAKE SPECIFIC 110 13.71 —_— — — FUEL CONSUMPTION 100 12.45 2450 2508 2704 kcal/HHRD 15 9.35 2535 2487 2467 50 6.26 2856 2721 619 INTAKE AiR Flow | 110 13.71 185) 157 100 REQUIREMENT 100 12.45 169 142 95 gti) 5 935 134 107 78 30 626 Jot 5 52. MW 1371 181 163 109 ey flow 100 12.45 172 147 104 75 9.35 138 mw 86 50 $26 104. 79 54 10 13.71 4a 454 460 ee aoe 100 12.45 485 463 454 eae) 5 935 482 466 443 50. 6.26 482 A60. 432. 110 13.71 20791 18901 16129 ae eT 100 12.45 19531 17641 14869 fen eee 75 9.35 16885 14365 44719 Gea UlN) 50 626 44491 11341 9451 10 13.71 2520 2419 2344 LUBE OL 100 12.45 2495 2369 2142 HEAT REXECTION 15 9.35 2268 2142 1890 Geen 50 626 1890 1764. 151 110 1371 4410 3276 2268 INTERCOOLER 100 12.45 3780 oe 1815 HEAT REJECTION 15 935 2268 1638 1008 Gea/MIN) 50 626 1008 630. 252 NOTES + 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 23% TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 82C JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL. DATA SECTION, PAGE GEN-23/1-89 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE. ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10% RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. 3D INTERCOOLER HEAT REJECTION BASED ON NOMINAL 1200 M_ ALTITUDE. 1% LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING SOC MAX. TO INTERCOOLER FOR RATED ENGINE PERFORMANCE. A AJAX-SUPERIOR APPR. BMC Te 712/1-89 Superior? and CleanBurn"™ are trademarks of Cooper Indusiies, Ine. Copytignt © Cooper industries, inc. 1989SUPERIOR TURBOCHARGED GAS ENGINES MODEL 16SGT ia AE) EXHAUST EMISSIONS MODEL = 12SGT, 16SGT PERCENT *EMISSIONS (GRAMS/BHP-HR) RPM |areD BHP CKD oe <0 | «NMHC 900 100 = 18.0 08 5 * TONS PER YEAR = (GM/BHP-HR) x BHP + 103.6 ‘* DENOTES NON-METHANE HYDROCARBONS ‘QUALIFYING CONDITIONS: 1) PIPELINE QUALITY GAS IS ASSUMED. METHANE CONTENT SHOULD BE GREATER THAN 90f WITH A LOW HEATING VALUE OF 900 BTU/SCF # 15%, FOR FUEL GAS OUTSIDE THESE PARAMETERS AN INDIVIOUAL REVIEW WILL BE REQUIRED TO DETERMINE EMISSION LEVELS AND FUEL CONSUMPTION RATES, 2) VALUES ARE BASED UPON 130° F MANIFOLD TEMPERATURE, «120° F INTERCOOLER WATER AND 100" F AMBIENT TEMPERATURE. REDUCED AIR MANIFOLD TEMPERATURES WILL RESULT IN LOWER NOx LEVELS. HIGHER AMBIENT TEMPERATURES WILL NOT AFFECT EMISSION LEVELS AT RATED LOAD AND SPEED BUT WILL CAUSE SLIGHTLY HIGHER NOx LEVELS AT REDUCED SPEEDS, 3D DATA SHOWN ARE BASED ON ENGINE ADJUSTMENT FOR STANDARD BSFC. FULL SPEED EMISSION VALUES ARE VALID FOR ALTITUDES BELOW 4000 FT. HIGH ALTITUDE APPLICATIONS MAY REQUIRE TURBOCHARGER MODIFICATION TO MAINTAIN EMISSION RATES. 4) WHEN NOx REQUIREMENTS LESS THAN THOSE EXPRESSED HERE ARE ENCOUNTERED. THERE ARE TRADE-OFFS BETWEEN NOx AND BSFC WHICH MAY BE APPLICABLE, BUT THESE MUST BE EVALUATED ON A SPECIFIC CASE BASIS. | | AJAX-SUPERIOR appr. ONC Te 713/1-89 ‘Superior® and CleanBurn™ are trademarks of Cooper Industries, In. Copyright © Cooper Industries, Inc. 1989,SUPERIOR TURBOCHARGED GAS ENGINE MODEL 16SGT PAGE TI5 e WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS too ao ENGINE. PM | ~ 80 DESIGN F 70 FLOWS 69 750 ima a A mi 600 "30 [_e * Be Fue PRESSURE 10 oe as -—DROP- e i ee a FLOW (GPM) IMPELLER P/N D-024-003 (STRAIGHT VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (BI-DIRECTIONAL CAPABILITY) NORMALLY C.C.W (FACING DRIVE END) NPSHp = 20.0 FEET @ 900 RPM & 775 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT_THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 775 GPM = 97.0 FT. ~ 30.0 FT. = 67.0 FT. 67.0 FT. + 2.31 = 29.0 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. | AJAX-SUPERIOR appr, S302 Te _715/1-89 ‘Superio® and CleanBurn™ aro trademarks of Cooper industries, Ine. Copyright © Cooper industries, Inc. 1989SUPERIOR TURBOCHARGED GAS ENGINE MODEL 16SGT PAGE 716 WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS 110 ioe ENGINE RPM 90 900 4 ~ 80 pesiof | 1} E 10 = lrLows | z 60 - == eS 40 600. x» I 20 = {_-7] 2 SS nein PRESSURE ~) o fet =—4 DROP, } oO 200 400 600 800 900 FLOW (GPM) IMPELLER P/N D-033-744-002 (CURVED VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (UNIDIRECTIONAL) C.C.W (FACING DRIVE END) NPSHg = 14.0 FEET @ 900 RPM & 775 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 775 GPM = 790 FT 300 FT. » 490 F 49.0 FT. + 2:31 = 212 P: ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. (a AJAX-SUPERIOR appr, SONA CL TC 716/1-89 ‘Superor® and CleanBurn"™ are trademarks of Cooper Industrie, Ine. Copyright © Cooper industries, nc. 1989SUPERIOR TURBOCHARGED GAS ENGINE PAGE 717 MODEL 16SGT ® WATER PUMP CHARACTERISTICS INTERCOOLER WATER SYSTEM DESIGN FLOWS AND PRESSURE DROPS 80 ENGINE RPM 30 _|__ 200) 0 | th 50 750 L a 40 = 00) 7 Ew 4 © 20 eo 2 = ENGINE PRESSURE ° an-- DROP ° 100 200 300 400 e FLOW (GPM) IMPELLER P/N C-026~376 (STRAIGHT VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (BI-DIRECTIONAL CAPABILITY) NORMALLY C.C.W (FACING DRIVE END) NPSHp = 16.0 FEET @ 900 RPM & 200 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE. OF 200 GPM = 65.0 FT=29.0 FT. = 36.0 FT. 36.0 FT. + 251 = 155 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS, 4 asax-SUPERIOR appr. GONACe Te 717/1-89 ~Superio® and CleanBurn™ are trademarks of Cooper Industries, Ine. Copyright © Cooper industries, ine. 1889SUPERIOR NATURALLY ASPIRATED GAS ENGINES MODEL 66-825 ENGINE SECTION INDEX Description Page No. Air Intake System 104 Bearing Dimensions 107 Cooling System 105 Dimensions and Weight 107 Engine Operating Data -Units In English Units aaa -Units In Metric Units 312 Engine Outline Drawing 417 Engine Performance 103 Engine Specifications 101 Exhaust Emissions 113 Exhaust System 104 Fuel System 104 Heat Rejection Data Units In English Units aaa -Units In Metric Units 112 Lubrication system 106 Miscellaneous 108 Starting Systen 103 Unbalanced Forces and Couples -Units In English Units 109 -Units In Metric Units 110 Water Pump Characteristics Jacket Water, Straight Vane 115 -Jacket Water, Curved Vane N/A AJAX-SUPERIORSUPERIOR NATURALLY ASPIRATED ENGINES MODEL 66-825 PAGE 101 ENGINE SPECIFICATIONS Type Aspiration Cylinder Configuration Number of Cylinders Bore = in. Stroke - in. Displacement - [Link]. (mm) (mm) (liter) Compression Ratio Power Rated - BHP (kW) Speed Rated - RPM Piston Speed - FPM(m/s) Speed Range - RPM Ignition system Fuel system Governor Exhaust Manifold Jacket Water Pump Jacket Water Thermostat Lube 011 Pump Lube 011 Thermostat Prelube Pump Lube 011 Cooler Crankcase Breather Crankcase Doors Direction of Rotation SA] Asax-SUPERIOR Four (4)-Cycle Naturally Aspirated Inline six (6) 10 (254) 10.50(266.7) 4948 (81.10) 10:2 600 (450) 900 1575 (8.0) 900 - 500 Non-Shielded, Altronic III Carbureted with Final Cut Regulator Hydraulic (UG-8L) With Manual Speed Setting Totally Water Cooled Built-In Centrifugal, Belt Driven Engine Mounted Gear Type with Pressure Regulating Valve Engine Mounted Manual, Mounted and Piped Shell & Tube Type,Mounted and Piped Positive Ventilation Pressure Relief (Bicera Type) Doors Counterclockwise From Flywheel End NA 101/1-89 APPR. 2B NC ‘Supesior® and CloanBurn™ are vrademarks of Cooper Industries, Ine. Copyright © Cooper Industrie, ine. 1988SUPERIOR NATURALLY ASPIRATED ENGINES MODEL 6G-825 PERFORMANCE Engine Operating Data Rating Conditions ~Altitude -Temperature Rated Torque Over 900-500 RPM Range Brake Mean Effective Pressure Rating/BMEP Rated Brake Specific Fuel Consumption/BSFC (Plus or Minus 3 Percent Factory Tolerance) Heat Rejection Data Emissions STARTING SYSTEM Air/Gas Starting Motor Make & Model Number of Starting Motors Supply Air/Gas Pressure Consumption Rate/Starter Motor Air -Gas -Normal Starting Time Connection Sizes -Inlet -outlet “Optional: Inlet Flange outlet Flange $i] asax-SUPERIOR appr. (3MMC_ NA 103/1-89 PAGE 103 See feet 1500 meter (457 Deg F 90 Deg C (32.2 Ib-£t 3501 M-kg (484 psi 106.7 kg/cm2 (7.50 Btu/bhp-hr 7850 keal/kW-hr ( 2653 See Page 111 & 112 See Page 113 IR / SS-825 one(1) psi 150 kg/om2 (10.5 scfm 1400 liter/sec ( 661 scfm 1663 liter/sec ( 785 sec 15 1-1/2 In. NPT 2-1/2 In. NPT 1-1/2 In. Square 2-1/2 In. 150 Lb. ) i ) d ‘Superor® and CleanBurn™ are trademarks of Cooper Industties, Ine. Copyright © Cooper naustnes, ne. 1989SUPERIOR NATURALLY ASPIRATED ENGINES MODEL 6G-825 AIR INTAKE SYSTEM Intake Air Flow Rate Max. Allowable Pressure Drop Air Intake, Inlet Connection FUEL SYSTEM Required Fuel Gas Pressure to Engine Based on Pipeline Quality Natural Gas Gas Inlet Connection EXHAUST SYSTEM Max. Allowable Back Pressure Exhaust Outlet Flange Connection Size Exhaust Flow Rate Stack Temperature PAGE 104 See Page 111 & 112 In #20 1.8 mn H20 (192 Flex Connection for 8 In. Pipe psi 5-10 keg/cem2 — (0.4-0.7 2 In, NPT In 20 15 nm H20 (382 8 In. 150 Lb. FF See Page 111 & 112 See Page 111 & 112 (| AJAX-SUPERIOR appr. G3NC__NA 104/1-89 ‘Superior® and Cleanurn™ are radamarks of Cooper Industrie, Ine Copyright © Cooper industries, Inc. 1989SUPERIOR NATURALLY ASPIRATED ENGINES PAGE 105 MODEL 6G-825 S COOLING SYSTEM Jacket Water Capacity - Engine Only Gallon 48 liter (182) Jacket Water Pump -Jacket Water Outlet Temperature, Normal Deg F 170-1860 Deg c (76-82 ) “Flow Rate at Rated Speed cem 224 liter/sec (14.1 ) “Available External Head: Straight Vane(Standard) psi 2a kg/em2 (1.48) “Minimum NPSH Required: Straight Vane(Standard) feet 2a meter ( 6.4) Connection sizes -Jacket Water Inlet 4 In. NPT Jacket Water Outlet 3 In. NPT -Vent Line to Surge Tank,Minimum Size 3/8 In. Tubing e ~Surge Tank Return to Pump Inlet 4-1/2 In. NPT appr. C3NC NA 105/1-89 ‘Superior® and CloanBurn™ are trademarks of Cooper industries, In. Copyright © Cooper industries, in. 1980SUPERIOR NATURALLY ASPIRATED ENGINES PAGE 106 MODEL 66-825 LUBRICATION SYSTEM Lube 011 Sump Capacity Gallon 65 liter (246 ) Lube 011 Consumption(Estimated) Gal/Day 1.30 liter/Day (4.92 ) Lube Oil Pressure - Normal psi 35-40 kg/em2 — (2.5-2.8 ) Temperature Into Engine ~ Normal Deg F 160-170 Deg c (71-77 ) Flow Rate Through 011 Filter cpm 30 liter/s (1.89 ) Lube Oil Filters, Engine Mounted(standard) ~Type Full Flow -Microns of Filtration Fifteen(15) Connection Size Lube 011 Sump Drain Plug 1-1/2 In. NPT appr. W3MC NA 106/1-89 ‘Superior® and CloanBur™ ate trademarks of Cooper Industries, Inc. Copyright © Cooper industies, inc. 1988SUPERIOR NATURALLY ASPIRATED ENGINES PAGE 107 MODEL 66-825 BEARING DIMENSIONS Main Bearing, Split Shell -Diameter In 6.00 mn (152.4 ) -Width In 3.50 mm (88.9 ) -Quantity Nos. 7 Crankpin Bearing, Split Shell -Diameter In 5.75 mn ( 146.0 ) “Width In 3.63 mn (92.1 ) -Quantity Nos. 6 Wrist Pin Bearing -Diameter In 3.50 mn (88.9 ) “Width In 3.16 an ( 80.3 ) e@ -Quantity Nos. 6 Camshaft Bearing, Split Shell -Diameter In 2.25 mm (87.2) “Width In 1.63 mm (41.3) -Quantity Nos. 8 DIMENSIONS AND WEIGHT (APPROXIMATE) Overall Length In 113 mm ( 2870 ) overai) width = 3 mm oe overali nesgnt a 7 om ( 1905 ) bry weight te 16800 kg ( 7484 ) [4] asax-suPERIOR appr. G3N\C NA 1071-89 _ Superior* and Ch 1 are trademarks of Cooper Industries, In. CCopyrigm © Cooper Industries, inc. 1989SUPERIOR NATURALLY ASPIRATED ENGINES PAGE 108 MODEL 66-825 MISCELLANEOUS Clearance Required to Remove Piston In 81.75 mm «2076 ) Heaviest Engine Parts (Approximate Weights) ~Cylinder Block Assembly Lb 3500 kg ( 1888 ) ~Cylinder Head Assembly Lb 250 kg (413) Piston and Connecting Rod Assembly Lb 392 kg (87) Exhaust Manifold Lb 335 kg (152 ) 41| asax-SUPERIOR apr. GNC NA 108/1-89 ‘Superior? and CloanBurn™ are trademarks of Cooper Industies, nc. Copyright © Cooper Incusties, Inc. 1989SUPERIOR NATURALLY ASPIRATED GAS ENGINES PAGE 109 MODEL 6G-825 MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN ENGLISH UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. SECONDARY FORCE - Lb. ENGINE RPM VERTICAL | HORIZONTAL 900 576.743 335.115 60.407 ° 800 455.698 264.115 47.729 ° 100 348.894 202.724 36.542 ° 600 256.330 148.940 26.847 ° SECONDARY COUPLE - Lb. Ft. | Wh 1 ENGINE | tI 1 RPM [| VERTICAL == HORIZONTAL || © VERTICAL © HORIZONTAL | | I { I it | 900 | = 181.979 723.894 || 114,522 ° 1 B00 | 933.910 571.965 || 90.486 ° 1 joo} 715.025 437.911 || 69.279 ° 1 600 | 525.324 321.731 || 50.899 ° 1 | i | AJAX-SUPERIOR arer._Q™ NA 109/1-89 ‘Superior? and Cleantum™ are trademarks of Cooper Industrie, Inc. Copyright © Cooper industies, nc. 1989SUPERIOR NATURALLY ASPIRATED GAS ENGINES PAGE 110 MODEL 66-825 MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN METRIC UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. SECONDARY FORCE - kg ENGINE RPM VERTICAL © HORIZONTAL 8 ° 800 206.705 119.803 21.650 ° 700 188.258 91.956 16.575 ° 600 316.271 67.559 12,178 ° f—-—-—-~+—+~ | iW It if It i i 27.401 iW It Wh It 1 | 1 | goo | 261.611 152.001 1 1 1 | | PRIMARY COUPLE - [Link] SECONDARY COUPLE - [Link] | ENGINE | I RPM =| ~—‘ VERTICAL VERTICAL © HORIZONTAL | | 1 ! ! 900 I 163.468 15.838 ° I goo | 129.160 12.514 ° I 100} | 98.888 9.581 ° ! 600 | 12.652 7.039 ° I | 1 AJAX-SUPERIOR APPR. BNC Z NA 110/1-89 Superior and CleanBurn"™ are trademarks of Cooper Industis, Ine. Copyright © Cooper industias, inc. 1989SUPERIOR NATURALLY ASPIRATED GAS ENGINES MODEL 66-825 eee ENGINE OPERATING DATA AND HEAT REJECTION e SUPERIOR 66825 PERCENT] — pute ENGINE SPEED — RPM RATED | eassoo wu | 1000] 900] 800] 700] 600 RUE TO 17 715] 660] 587] 513| 440 HORSEPONER 100 107 650] 600] 533] 467} 400 cer 75 80 488 | 450] 400] 350| 300 50 53 325| 300] _267| 2331 200 110 n7 | —f—]—]—]— Fa consuprion| 100 | 107 | 7750] 7750}. 7750| 7750| 7750 (GTUBHP-HR 15 80 8550 8450} 8450 8300 8300, 50 53 10300 | 10100] 9950 | 9700 9600, 110 W7 N93 983 839 734 603 are |p 100 107 1102] 944] 13} 695| 590 cnn 5S 80 91| 800] 682] 577} 485 50 53 eo | 630] sit| a72|__367 110 W7 95 85 67 56 48 eee 100 107 se| | 65| 55] 47 15 80 W W 54 46 39 50 53 54 50. 4) 38 29 110 VW? 1240 1240 1270 1255, 1205 oe ee 100 107 1265] 1250] 1265] 1250] 1200 5 so | 1300] 1265| 1255| 1220] 1170 @ 50 53 1295 | 1260| 1220] 1170] 1085 110 7 25000 | 22000 | 23400 | 19700 | 14700 woreeeerion | 100 107 | 24700 | 21900 | 21400 | 19400 | 14600 eTuane 78 80 | 22600 | 21100] 17900 | 16900 | 14600 50 53 20036 | 18320 | 17021 | 14400 | 12700 TIRE OL 110 117 | 2979 | 2640] 2201] 1881] 1270 HEAT RELECTION 100 107 2903 | 2540] 2123] 1845] 1267 orien 75 80 | 2407 | 2400| 1947] 1738 | 1250 50. 53 2454 2385 ATA 41587 1499 NOTES = 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO #3x TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 180F JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-21/9-88 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING, HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE. ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10x RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. (Gi) asax-suPenion aver S3MW\C- NA 111/189 ‘Superior® and CleanBura™ are vademarks of Cooper Indust Copyright © Cooper industries, In. 1989SUPERIOR NATURALLY ASPIRATED GAS ENGINES MODEL 66-825 PAGE 112 ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR &6825 PERCENT] 5 icp ENGINE SPEED - RPM RATED Pup _|tkgremar | 900 | 800 | 700 | 600 BANE SPEC 110) 823 492 438 Bas 328 om 100 7.52 441 37 348 298 an 15 563 336 298 261 2e4 50 313 zea 19: 174 149 FIC s10 823 peel al a a Fa consurion | 100 752 | 2619 | 2619 | 2619 | 2619 tea HH 15 563 | 2856 | 2856 | 2805 | 2805 50 373_| 3413_| 3363 | 3278 | sea INTAKE AR FLOW | 110 823 u 29 25 21 REQUIREMENT 100 152 3 28 24 20 Gg/Miny I 563 28 24 20 17 5o_| 373 22 18 16 13 ow pe} 8.23 3 30 25 22 cq! nm 100 752 34 29 25 ai 15 563 32 24 ai 18 50 IS 23 19 7 13 110 823 61 688 19 652 ceria 100 782 617 685 617 649 15 563 685 679 660 632 50 373 682 660 632 585 110 azs | 9544 | 5897 | 4965 | 3705 Wirrerction | 100 752 | 5519 | 5393 | 4aa9 | 3679 (cain) 3s 563 5318 4511 4259 3679 50 ts_| 4617 | 4290 | 3629 | 3201 LUBE O1L 110 8.23 665 555 474 320 HEAT RESECTION no) 7.52 640 535 465 39 kee MIND 35 5.63 605 491 438 BS 50 z 601 436, 400 378 NOTES = 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 435 TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 82C JACKET WATER OUTLET TEMPERATURE. REFER TO ‘GENERAL DATA SECTION, PAGE GEN-23/1-89 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE, ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10f RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. $l) AJAX-SUPERIOR avon GNC NA 112/1-89 ‘Superior® and CleanBurn™ are trademarks of Cooper Industries, ne. Copyright © Cooper Industries, nc. 1988SUPERIOR NATURALLY ASPIRATED GAS ENGINES MODEL 66-825 PAGE 113 EXHAUST EMISSIONS MODEL = 66825, 86825, 126825, 166825 PERCENT #EMISSIONS (GRAMS/BHP-HR)} RPM |RateD BHPCKW) FR S Sco NMC 900 100 = 15.0 18 02 ® TONS PER YEAR = (GM/BHP-HR) x BHP + 1036 ‘#* DENOTES NON-METHANE HYDROCARBONS QUALIFYING CONDITIONS: 1) PIPELINE QUALITY GAS IS ASSUMED. METHANE CONTENT SHOULD BE GREATER THAN 90x WITH A LOW HEATING VALUE OF 900 BTU/SCF = 15%. FOR FUEL GAS OUTSIDE THESE PARAMETERS AN INDIVIOUAL REVIEW WILL BE REQUIRED TO DETERMINE EMISSION LEVELS AND FUEL CONSUMPTION RATES, 2) VALUES ARE BASED UPON 90° F AMBIENT TEMPERATURE AND 1500 FT. ALTITUDE. HIGHER ALTITUDES AND/OR AMBIENT TEMPERATURES WILL REQUIRE THE APPLICATION OF STANDARD POWER DERATION FACTORS TO MANTAIN EMISSION RATES. THESE FACTORS REQUIRE THAT ENGINE CAPACITY BE DERATED 3-i/2 1 FOR EACH 1000 FEET ABOVE 1500 FEET ALTITUDE AND 2-1/2 £ PER EACH 10°F ABOVE 90°F AMBIENT TEMPERATURE. 3D DATA SHOWN ARE BASED ON ENGINE ADJUSTMENT FOR STANDARD BSFC, 4) WHEN NOx REQUIREMENTS LESS THAN THOSE EXPRESSED HERE ARE ENCOUNTERED, THERE ARE TRADE-OFFS BETWEEN NOx AND BSFC WHICH MAY BE APPLICABLE, BUT THESE MUST BE EVALUATED ON A SPECIFIC CASE BASIS. 44) AJAX-SUPERIOR APPR. GNC NA_113/1-89 ‘Superior and CisanBum™ are rademarks of Cooper Industries, Inc. Copyright © Cooper industries, nc. 1989SUPERIOR NATURALLY ASPIRATED GAS ENGINE MODEL 66825 Serene WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS 120 110 {ENGINE RM 100 t= Te sicn | 90 FLOWS e 80 900 [| 70 60 750 3 so fT r 40 30 $00. 20 10 = Law ENGINE PRESSURE. ° _-|- DROP. ° 100 200 300 FLOW (GPM) IMPELLER P/N C-026-377 (STRAIGHT VANE) PUMP RPM = 2.4 X ENGINE RPM DIRECTION OF ROTATION (GI-DIRECTIONAL CAPABILITY) NORMALLY CW (FACING DRIVE END) NPSHp = 21.0 FEET @ 1000 RPM & 224 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 1000 RPM DESIGN FLOWRATE OF 224 GPM = 1010 FT= 530 FT. = 48.0 FT. 48.0 FT. + 231 = 21.0 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. AJAX-SUPERIOR peer S3NKC NA 115/1-89 ‘Superio® and CleanBurn™ are trademarks of Cooper Industries, In. Copyrignt © Cooper Industries, Inc. 1989SUPERIOR NATURALLY ASPIRATED GAS ENGINES MODEL 86-825 ENGINE SECTION INDEX Description Page No. Air Intake system 204 Bearing Dimensions 207 Cooling systen 205 Dimensions and Weight 207 Engine Operating Data Units In English Units air Units In Metric Units 212 Engine Outline Drawing 217 Engine Performance 203 Engine Specifications 201 Exhaust Emissions 213 Exhaust System 204 Fuel system 204 Heat Rejection Data Units In English Units 211 -Units In Metric Units 212 Lubrication system 206 Miscellaneous 208 Starting system 203 Unbalanced Forces and Couples -Units In English Units 209 -Units In Metric Units 210 Water Pump Characteristics ~Jacket Water, Straight Vane 215 Jacket Water, Curved Vane N/A AJAX-SUPERIORSUPERIOR NATURALLY ASPIRATED ENGINES MODEL 86-825 PAGE 201 ENGINE SPECIFICATIONS Type Aspiration Cylinder Configuration Number of Cylinders Bore = in. Stroke - in. Displacement - [Link]. (am (am) (liter) Compression Ratio Power Rated - BHP (kW) Speed Rated - RPM Piston Speed - FPM(m/s) Speed Range - RPM Ignition system Fuel system Governor Exhaust Manifold Jacket Water Pump Jacket Water Thermostat Lube 041 Pump Lube 0i1 Thermostat Prelube Pump Lube 0i1 Cooler Crankcase Breather crankcase Doors Direction of Rotation $i) AJAX-SUPERIOR Four(4)-Cycle Naturally Aspirated Inline Eight (8) 10 (254) 10.50 (266.7) 6597 (108.15) 10:2 800 (600) 900 1575 (8.0) 900 - 500 Non-Shielded, Altronic III Carbureted with Final Cut Regulator Hydraulic (UG-8L) With Manual Speed Setting Totally Water Cooled Built-In Centrifugal, Belt Driven Engine Mounted Gear Type with Pressure Regulating Valve Engine Mounted Manual, Mounted and Piped Shell & Tube Type,Mounted and Piped Positive Ventilation Pressure Relief(Bicera Type) Doors Counterclockwise From Flywheel End NA 201/1-89 aver. BMC ‘Superior* and ClosnBum™ aro ademarks of Cooper Industries, ne. Copyright © Cooper industries, Inc. 1989SUPERIOR NATURALLY ASPIRATED ENGINES PAGE 203 MODEL 86-825 PERFORMANCE Engine Operating Data See Page 211 & 212 Rating Conditions ~Altitude feet 1600 meter (457) ~Temperature Deg F 80 Deg c (32.2) Rated Torque Over 900-500 RPM Range lb-ft 4668 M-kg (646 ) Brake Mean Effective Pressure Rat ing/BMEP psi 106.7 keg/om2 (7.80 ) Rated Brake Specific Fuel Consumption/BSFC Btu/bhp-hr 7750 (Plus or Minus 3 Percent Factory Tolerance) keal/kW-hr ( 2619 ) Heat Rejection Data See Page 211 & 212 Emissions See Page 213 ee Air/Gas Starting Motor Make & Model IR / S8-625 Number of Starting Motors one(1) Supply Air/Gas Pressure psi 150 kg/cm2 (10.5 ) Consumption Rate/Starter Motor -Air scfm 1400 liter/sec ( 661 ) -Gas scfm 1663 liter/sec ( 785 ) -Normal Starting Time sec 15 Connection Sizes ~Inlet 1-1/2 In. NPT outlet 2-1/2 In. NPT -Optional: Inlet Flange 1-1/2 In, Square outlet Flange 2-1/2 In. 150 Lb. $4) AJAX-SUPERIOR appr._QN\C_ NA_203/1-89 | ‘Superior? end Cloanurn™ are trademarks of Cooper Industies, nc. Copyright © Cooper industries, ne. 1969SUPERIOR NATURALLY ASPIRATED ENGINES MODEL 8G-825 AIR INTAKE SYSTEM Intake Air Flow Rate Max. Allowable Pressure Drop Air Intake, Inlet Connection FUEL SYSTEM Required Fuel Gas Pressure to Engine Based on Pipeline Quality Natural Gas Gas Inlet Connection EXHAUST SYSTEM Max. Allowable Back Pressure Exhaust Outlet Flange Connection Size Exhaust Flow Rate Stack Temperature PAGE 204 See Page 211 & 212 In #20 1.8 mn H20 (192 Flex Connection for 8 In. Pipe psi 5-10 kg/cm2 (0.40.7 2 In. NPT In H20 15 mm H20 (381 10 In. 150 Lb. FF See Page 211 & 212 See Page 211 & 212 AJAX-SUPERIOR APPR. Gh KC NA 204/1-89 ‘Superior® and Cloanfurn"™ are wademarks of Cooper Industries, Inc. Copyright © Cooper Industries, Inc. 1989SUPERIOR NATURALLY ASPIRATED ENGINES PAGE 205 MODEL 86-825 e COOLING SYSTEM Jacket Water Capacity ~ Engine only Gallon 62 liter (238 Jacket Water Pump -Jacket Water Outlet Temperature, Normal Deg F 170-180 Deg ¢ ( 76-82 -Flow Rate at Rated Speed GPM 275 Liter/sec (17.3 -Available External Head: Straight Vane(Standard) psi 21 kg/em2 (1.48 -Minimum NPSH Required: Straight Vane(Standard) feet 18 meter (5.49 Connection siz Jacket Water Inlet 4 In, NPT -Jacket Water Outlet 3 In. NPT -Vent Line to Surge Tank,Minimum Size 3/8 In. Tubing e -Surge Tank Return to Pump Inlet 3-1/2 In. NPT appr. NC NA_205/1-89 ‘Superio® and CleanBurn™ are trademarks of Cooper Industries, Ine, Copyright © Cooper industries, ine. 1969SUPERIOR NATURALLY ASPIRATED ENGINES PAGE 206 MODEL 86-825 LUBRICATION SYSTEM Lube 0i1 Sump Capacity Gallon 80 liter (303 ) Lube 011 Consumption(Estimated) Gal/Day 1.60 liter/Day ( 6.06 ) Lube 0il Pressure - Normal psi 35-40 kg/cm2 (2.52.8 ) Temperature Into Engine - Normal Deg F 160-170 Deg ¢ (71-77 ) Flow Rate Through 011 Filter GPM 40 liter/ss (2.52) Lube Oil Filters, Engine Mounted(Standard) Type Full Flow ~Microns of Filtration Fifteen(15) Connection Size -Lube 041 Sump Drain Plug 1-1/2 In. NPT AJAX-SUPERIOR APPR. WM J NA 206/1-89 Superior* and Cleanum"™ are trademarks of Cooper Industies, Ine. ‘Copyright © Cooper Industries, ne. 1988SUPERIOR NATURALLY ASPIRATED ENGINES PAGE 207 MODEL 8G-825 e BEARING DIMENSIONS Main Bearing, Split Shell -Diameter In 6.00 mm (152.4) -Width In 3.50 mn (88.9 ) -Quantity Nos. 9 Crankpin Bearing, Split Shell -Diameter In 5.75 mm (146.0 ) -Width In 3.63 mn (92.1 ) -Quantity Nos. 8 Wrist Pin Bearing -Diameter In 3.50 an ( 88.9 ) “Width In 3.16 mm ( 80.3 ) e@ Quantity Nos. 8 Camshaft Bearing, Split Shell Diameter In 2.25 an ( 87.2) -Width In 2.63 mm (41.3) -Quantity Nos. 10 DIMENSIONS AND WEIGHT (APPROXIMATE) Overall Length In 139 mn ( 3831 ) Overall Width In 67 mm (1702 ) Overall Height In 75 mm (2905 ) Dry Weight Lb 20500 kg (9299 ) | AJ] asax-SUPERIOR appr. NCL NA 207/1-89 ‘Super and CleanBurn™ are trademarks of Cooper industries, in, Copyright © Cooper industri, nc. 1960SUPERIOR NATURALLY ASPIRATED ENGINES PAGE 208 MODEL 86-825 MISCELLANEOUS Clearance Required to Remove Piston In 81.75 mm (2076 ) Heaviest Engine Parts (Approximate Weights) -Cylinder Block Assembly Lb 4400 kg (1996 ) Cylinder Head Assembly Lb 250 kg cree ~Piston and Connecting Rod Assembly tb 192 keg (87) -Exhaust Manifold Lb 430 kg (198 ) (Gi siax-surenion APPR. Bg NNO NA 208/1-89 ‘Superior® and CleanBuen"™ are trademarks of Cooper Industries, Inc. Copyright © Coopar industries, ic. 1989SUPERIOR NATURALLY ASPIRATED GAS ENGINES PAGE 209 MODEL 8G-825 MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN ENGLISH UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. PRIMARY FORCE - Lb. SECONDARY FORCE - Lb. ENGINE RPM VERTICAL © HORIZONTAL VERTICAL © HORIZONTAL 900 789.428 447.713 120.814 ° 800 623.745 353.784 95.458 ° 700 477.555 270.839 73.085 ° 600 350.857 198.984 53.695 ° PRIMARY COUPLE - [Link]. SECONDARY COUPLE - [Link]. | I 1 ENGINE | in I RPM | —-* VERTICAL == HORIZONTAL || = VERTICAL © HORIZONTAL | ! | | in i 900 I 1945.844 1160.555 || 261.763 ° I goo | 1837.457 916.982 || 206.825 ° I 100 | 1177.116 702.064 || 158.350 ° I 600 | 864.820 515.802 || 116.339 ° I | Wt I Sn Z NA 209/1-89 ‘Superior® and CleanBurn™ are trademarks of Cooper Industries, In. Copyright © Cooper industis, ne. 1988 APPR.SUPERIOR NATURALLY ASPIRATED GAS ENGINES PAGE 210 MODEL 86-825 MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN METRIC UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un— balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. ENGINE ! it | I RPM | tt ! " | it goo} 358.085 203.083 || 54,801 ° B00 | 282.991 160.476 || 43.300 ° 700 | 216.619 122.853 || 33.152 ° 600 | 159.149 90.259 || 24.356 ° | I 6 ° 800 212.630 126.819 28.604 ° 700 162.795 97.095 1.900 ° 600 119.605 71.335 16.090 ° 1 tl 1 i ! I 1 i ! I | 269.110 160.505 |} 36.202 1 it | 1 I || Asax-SUPERIOR arer._ GK NA 210/1-89 SSuperior® and CleanBurn"™ are trademarks of Cooper Industrie, Ine ‘Copyrignt © Cooper industris, Ine. 1988‘SUPERIOR NATURALLY ASPIRATED GAS ENGINES — MODEL 8G-825 PAGE 211 ENGINE OPERATING DATA AND HEAT REJECTION e SUPERIOR 86825 PERCENT ENGINE SPEED — RPM RATED BMEP Poap_|_@sp 300 | 800 | 700 | 600 a tio]? } 880] 788] — 8a] — 588 HORSEPOWER 100 107 800 mM 622 533 GH) 75 80 600 S33 467 400 50 53 400 356 su 267 110 V7 eel —_ —_— — Fe consmprion | 100 107 7750 | 7750 | 7800 | 7850 GTUBHE-HR 15 80 asio | 8550 | 8500 | 8500 50 53. 10150 10000 9900 9900 Tae aR flow | 110 7 1261 1150 1009 854 pee 100 107 1186 1055 927 791 (SCFM) 5 80 945 836 745 635 50 53 727 636 566 482 110 7 99 92 81 69 7 eaiaia oo 100 107, 96 85 75 64 os | ‘80 7% | 6 | 3 | St co | ss | oo | s: | i | 3 W100 V7 1330 1320 1305, 1270 oo 100 tor | 1340 | 1315 | 1305 | 1250 7s 80 1310 1280 1225 1140 e 50 | ss | tao | tis0 | tio | ito 110 Bey 29550 26550, 23730 21360 ricer wea |e ool ceccod bese ctova ‘eTUMND 75 80 28090 | 25100 | 22640 | 20000 50. 53 24090 21360 18636 16360 LUBE OIL 110 17 3600 3600 3600 3600 HEAT RESECTION 100 107 3600 3600 3600 3500 ‘GTUMID 75 80 3600 3510 3400 3400 50 53 3420 3240 3240 3200 NOTES 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 43% TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 180F JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-21/9-88 FOR HEAT REECTION [Link] FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE. ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10x RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. appr, XSMAC~ NA 211/1-69 ‘Superior? and CloanBurn™ are trademarks of Cooper industies, in. Copyright © Cooper Industries, In. 1989SUPERIOR NATURALLY ASPIRATED GAS ENGINES MODEL 86-625 PAGE 212 ENGINE OPERATING DATA AND HEAT REJECTION - SUPERIOR 86825 PERCENT] arp ENGINE SPEED — RPM RATED Pomp _|toremer [ FOO | 800 | 700 [ 600 BRAKE SPECIFIC 110 823 656 ‘583 510 437 ‘OUTPUT 100 152 597 530 464 397 ow) 75 563 447 37 4a 298 50 373_| 208 | 265 52 199 BRAKE 110 B23 —_ —_ — — FUEL cONSBPTION 100 152 2619 | 2619 | 2636 | 2653 eo 35 563 2876 | 2890 | 2873 | 2873 SO 373 3430 3380 S346 3346 INTAXE AIR FLOW M10 823 ag 40 3 29 REQUIREMENT 100 752 4 3 32 =a Gg/MiN 75 563 3B 29 26 22 50. 313 25 22 20 7 110 B23 45 42 7 3 gar hon | joo | tse | a | | se | os 75 563, 3 30 27 2 50 27 23 21 18 XHAUS 10 Tet 716 707 688 ® om me 100 727 3 707 677 75 710 693, 663 616 50. 660 643, 627 599 110 T4487 6691 5980 5383 JACKET WATER HEAT REJECTION 100 752 1334 | 6666 5980 | 5315 Gcol/MIN) “3 563 7079 6326 5706 5040 50 1 6071 5383 4697 A123 LUBE O1L 10 8.23 907 907 907 907 HEAT RECTION 100 7.52 907 907 907 Baz Gco/MIN) ae 5.63 907 885 857 857 50. 373 B62 BI7 817 B06 NOTES = 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADUSTMENT FOR STANDARD EXHAUST EMISSION RATES. SUBJECT TO 43% TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 82°C JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-23/1-89 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE, ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS, SUBTRACT 10K RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. AJAX-SUPERIOR aver. SANKC pnSieseinces ‘Superor® and CleanBumn™ are wademarks of Cooper Industries, Ine. Copyright © Cooper industries, Inc. 1989SUPERIOR NATURALLY ASPIRATED GAS ENGINES MODEL 86-825 PAGE 213 EXHAUST EMISSIONS MODEL : 66825, 86825, 126825, 166825 EERceny EMISSIONS (GRAMS/BHP-HR)| RPM hee BHP(KW) NOx CO NMHC 900 100 = 15.0 18 02 * TONS PER YEAR = (GM/BHP-HR) x BHP + 1036 ww DENOTES NON-METHANE HYDROCARBONS: QUALIFYING CONDITIONS: 1) PIPELINE QUALITY GAS IS ASSUMED. METHANE CONTENT SHOULD BE GREATER THAN 90x WITH A LOW HEATING VALUE OF 900 BTU/SCF & 15%. FOR FUEL GAS OUTSIDE THESE PARAMETERS AN INDIVIDUAL REVIEW WILL BE REQUIRED TO DETERMINE EMISSION LEVELS AND FUEL CONSUMPTION RATES. 2) VALUES ARE BASED UPON 90°F AMBIENT TEMPERATURE AND 1500 FT. ALTITUDE, HIGHER ALTITUDES AND/OR AMBIENT TEMPERATURES WILL REQUIRE THE APPLICATION OF STANDARD POWER DERATION FACTORS TO MANTAIN EMISSION RATES. THESE FACTORS REQUIRE THAT ENGINE CAPACITY BE DERATED 3-1/2 £ FOR EACH 1000 FEET ABOVE 1500 FEET ALTITUDE AND 2-1/2 & PER EACH 10" F ABOVE 90°F AMBIENT TEMPERATURE. 3) DATA SHOWN ARE BASED ON ENGINE ADJUSTMENT FOR STANDARD BSFC. 4 WHEN NOx REQUIREMENTS LESS THAN THOSE EXPRESSED HERE ARE ENCOUNTERED, THERE ARE TRADE-OFFS BETWEEN NOx AND BSFC WHICH MAY BE APPLICABLE, BUT THESE MUST BE EVALUATED ON A SPECIFIC CASE, BASIS. | | AAX-SUPERIOR poor, SAMNC NA 213/1-89 ‘Superior® and CleanBurn™ are trademarks of Cooper Industries, In. Copyright © Cooper industries, ic. 1989‘SUPERIOR NATURALLY ASPIRATED GAS ENGINE MODEL 86-825 PAGE 215 WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS re tenene ra 110 900 100 fc f . 90 DESIGN, e aa FLOWS "KL 7 Q 10 ee L 6 so 600 XY Iz ‘ers 2 ot — PE ea rE 10, t= + DROP ° i= ° 100 200 300 400 500 FLOW (GPM) IMPELLER P/N C-026-376 (STRAIGHT VANE) PUMP RPM = 2.167 X ENGINE RPM DIRECTION OF ROTATION (BI-DIRECTIONAL CAPABILITY) NORMALLY CW (FACING DRIVE END) NPSHg = 18.0 FEET @ 900 RPM & 275 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT_THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 275 GPM = 94.0 FT. ~ 45.0 FT. = 49.0 FT. 49.0 FT. + 231 = 21.0 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. Al | | Avax-SUPERIOR appr,__SANC~ NA 215/1-89 Superior? and CleanBurn™ are trademarks of Cooper Industries, nc. Copyright © Cooper inaustries, Inc. 1989SUPERIOR NATURALLY ASPIRATED ENGINES MODEL 126-825 PAGE 301 ENGINE SPECIFICATIONS Type Aspiration Cylinder Configuration Number of Cylinders Bore = in. (mm) Stroke - in. (mm) Displacement - [Link]. (liter) Compression Ratio Power Rated - BHP (kW) Speed Rated - RPM Piston Speed - FPM(m/s) Speed Range - RPM Ignition system Fuel system Governor Exhaust Manifold Jacket Water Pump Jacket Water Thermostat Lube 011 Pump Lube 0il Thermostat Prelube Pump Lube 0i1 Cooler crankcase Breather Crankcase Doors Direction of Rotation AJAX-SUPERIOR Four (4)-Cycle Naturally Aspirated vee Twelve = (12) 10 (254) 10.50 (266.7) gece = (162.2) 10:41 1200 (895) 900 1578 (8.0) 900 - 500 Non-Shielded, Altronic III Carbureted with Final Cut Regulator Hydraulic (UG-8L) With Manual Speed Setting Totally Water Cooled Built-In Centrifugal, Chain Driven Engine Mounted Gear Type with Pressure Regulating Valve Remote Mounted Manual, Mounted and Piped Shell & Tube Type, Remote Mounted Positive Ventilation Pressure Relief (Bicera Type) Doors Counterclockwise From Flywheel End APPR. CNC = ‘Superiow’ and CleanBurn™ are trademarks of Cooper industries, Ine Copyright © Cooper industries, Inc. 1989 NA 301/1-89SUPERIOR NATURALLY ASPIRATED ENGINES MODEL 126-825 PERFORMANCE Engine Operating Data Rating Conditions “Altitude ~Temperature Rated Torque Over 900-500 RPM Range Brake Mean Effective Pressure Rat ing/BMEP Rated Brake Specific Fuel Consumption/BSFC (Plus or Minus 3 percent Factory Tolerance) Heat Rejection Data Emissions STARTING SYSTEM Air/Gas Starting Motor Make & Model Number of Starting Motors: Generator Drive Compressor Drive Supply Air/Gas Pressure Consumption Rate/Starter Motor Air Gas -Normal Starting Time Connection Sizes -Inlet -outlet -Optional: Inlet Flange Outlet Flange $d| AJAX-SUPERIOR PAGE 303 See Page 311 & 312 feet 1500 meter (487 ) Deg F 90 Deg ¢ (32.2) lb-ft 7003 M-kg «969 ) psi 106.7 kg/cm2 (7.50 ) Btu/bhp-hr 7750 keal/kW-hr ( 2619 ) See Page 311 & 312 See Page 313 IR / SS-825 one (1) Two(2) psi 150 kg/om2 (10.5 ) scfm 1500 liter/sec (708 ) scfm 1781 liter/sec ( 641 ) sec 15 1-1/2 In. NPT 2-1/2 In. NPT 1-1/2 In. Square 2-1/2 In. 150 Lb. 303/1-89 APPR. RNC NA Superior? and CleanBurn™ are trademarks of Cooper Industie, Inc. ‘Copyright © Cooper Industries, Inc. 1989SUPERIOR NATURALLY ASPIRATED ENGINES MODEL 126-825 AIR INTAKE SYSTEM Intake Air Flow Rate Max. Allowable Pressure Drop Air Intake, Inlet Connection FUEL SYSTEM Required Fuel Gas Pressure to Engine Based on Pipeline Quality Natural Gas Gas Inlet Connection EXHAUST SYSTEM Max. Allowable Back Pressure Exhaust Outlet Flange Connection Size Exhaust Flow Rate Stack Temperature PAGE 304 See Page 311 & 312 In H20 7.5 mn H20 (191) Two Flex Connections for 8 In. Pipe psi §-10 kg/em2 (0.4-0.7 ) 2 In, 150 1b. In #20 15 mm H20 ( 381) 12 In. 150 Lb. FF See Page 311 & 912 See Page 311 & 312 $4 AJAX-SUPERIOR aper._G3N\C- NA 308/1-89 Supevior® and CleanBurn"™ are wadomarks of Cooper Industries, Inc. Copyright © Cooper industries, Inc. 1989SUPERIOR NATURALLY ASPIRATED ENGINES MODEL 126-825 COOLING SYSTEM Jacket Water Capacity - Engine only Jacket Water Pump ~Jacket Water Outlet Temperature, Normal -Flow Rate at Rated Speed Available External Head: Straight Vane(Standard) Curved vane(optional) -Minimum NPSH Required: Straight Vane(Standard) Curved Vane(Optional) Connection Sizes ~Jacket Water Inlet -Jacket Water Outlet -Vent Line to Surge Tank,Minimum Size -Surge Tank Return to Pump Inlet | AJAX-SUPERIOR aper._ GNC NA_305/1-89 ‘Superior? and Cle PAGE 305 Gallon 140 liter (530 Deg F 170-180 Deg C ( 76-82 GPM 600 liter/sec (37.8 psi 25 kg/om2 (1.76 psi 19.9 kg/cm2 (1.40 feet 19 meter (5.79 feet 12 meter (3.66 6 In. 150 1b. 4 In. NPT 3/8 In. Tubing 2 In. NPT Burn" are trademarks of Cooper Industries, Ic Copyright © Cooper Industries, Inc. 1988SUPERIOR NATURALLY ASPIRATED ENGINES PAGE 306 MODEL 126-825 LUBRICATION SYSTEM Lube 011 sump Capacity Gallon 165 liter ( 625) Lube 011 Consumption(Estimated) Gal/Day 2.40 liter/Day (9.08 ) Lube 0il Pressure - Normal psi 35-40 kg/om2 (2.5-2.8 ) Temperature Into Engine - Normal Deg F 160-170 Deg c (71-77 ) Flow Rate Through 011 Filter cpu 67 liter/sec (4.23 ) Lube 0il Pilters, Engine Mounted(Standard) -Type Full Flow -Microns of Filtration Pifteen(15) Connection Sizes -Lube 011 Sump Drain Plug 1-1/2 In. NPT -Lube 0i1 Outlet to Cooler 3 In. NPT -Lube 011 Inlet to Filter 3 In. NPT 45) Asax-SUPERIOR appr. S3C_ NA 306/1-89 ‘Superor® and Cleantumn™ ate trademarks of Cooper Industries, nc. Copyright © Cooper industries, Inc. 1989SUPERIOR NATURALLY ASPIRATED ENGINES MODEL 12G-825 BEARING DIMENSIONS Main Bearing, Split Shell -Diameter “Width ~Quantity Crankpin Bearing, Split Shell ~Diameter “Width -Quantity Wrist Pin Bearing -Diameter -Width -Quantity Camshaft Bearing, Split Shell -Diameter “width ~Quantity per Bank DIMENSIONS AND WEIGHT (APPROXIMATE) Overall Length Overall Width Overall Height Dry Weight AJAX-SUPERIOR PAGE 307 In 8.00 mn ( 203.2 ) In 4.88 mn ( 123.8 ) Nos. 1 In 6.38 mm ( 161.9 ) In 2.53 mm ( 64.3 ) Nos. 32 In 3.50 an ( 88.9 ) In 3.16 mn (80.3 ) Nos. 12 In 2.75 mm ( 69.9 ) In 2.38 am ( 60.3 Nos. 1 In 167 om (4242 ) In 126 an (3200 ) In 96 mm ( 2438 ) Lb 42000 kg (19051 ) appr. S3N\C ‘Superior® and CleanBurn™ are trademarks of Cooper Industies, nc. Copyright © Cooper industries, nc. 1989 NA_307/1-89SUPERIOR NATURALLY ASPIRATED ENGINES PAGE 308 MODEL 126-825 MISCELLANEOUS Clearance Required to Remove Piston In a9 an ( 2261 Heaviest Engine Parts (Approximate Weights) ~Cylinder Block Assembly Lb 10400 kg (4717 ~Cylinder Head Assembly Lb 250 kg (123 -Piston and Connecting Rod Assembly Lb 198 kg { 90 ~Exhaust Manifold Lb 830 kg (376 | 4) asax-SUPERIOR aper._G3M\\C~ NA 308/1-89 ‘Superior? and CloanBurn™ ace trademarks of Cooper Industie, ne. Copyright © Cooper industries, nc. 1989SUPERIOR NATURALLY ASPIRATED GAS ENGINES PAGE 309 MODEL 126-825 MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN ENGLISH UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 60 percent of the calculated values. PRIMARY FORCE - Lb. SECONDARY FORCE - Lb ENGINE RPM VERTICAL HORIZONTAL VERTICAL | HORIZONTAL | | ! I 111.206 49.512 I | | | PRIMARY COUPLE - [Link]. SECONDARY COUPLE - [Link]. ENGINE RPM VERTICAL | HORIZONTAL VERTICAL HORIZONTAL | | ! i 900 | 2851.722 1957.595 268.815 119.685 800 | 2016.175 1546.742 212.397 94.566 700 ! 1543.634 1184.224 162.616 12.402 600 | 1134,099 870.042 119.473 53.193 | appr. NC NA_309/1-89 ‘Suparior® and Cieanfur'™ are trademarks of Cooper Industles, Inc. Copyright © Cooper industnes, inc. 1689SUPERIOR NATURALLY ASPIRATED GAS ENGINES PAGE 310 MODEL 126-825 MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN METRIC UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted, that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. PRIMARY FORCE ~ kg ! i ! ENGINE | ' ! RPM | -—s VERTICAL = HORIZONTAL || | VERTICAL HORIZONTAL | | I | | it | soo | 432.813 329.361 || 50.443 22.459 | goo | 341.976 260.236 || 39.856 17.745 | oo} 261.825 199.243 |] 30.515 13.586 | 600 | 192.361 146.383 || 2.419 9.981 | | I 1 PRIMARY COUPLE - [Link] SECONDARY COUPLE - [Link] ENGINE RPM r VERTICAL © HORIZONTAL VERTICAL | HORIZONTAL 900 352.903 270.735 37.177 16.552 800 278.837 213.914 29.375 13,078 700 213.485 163.778 22.490 10.013 600 156.846 120.327 16.523, 7.357 | 1 1 1 1 1 1 | 1 | AJAX-SUPERIOR apr. G3NKC_- na 310/1-89 ‘Superior? and CleanBurn™ are trademarks of Cooper Industrie, Inc. Copyright © Cooper industries, nc. 1989‘SUPERIOR NATURALLY ASPIRATED GAS ENGINES MODEL 126-825 PAGE 311 ENGINE OPERATING DATA AND HEAT REJECTION e SUPERIOR 126825 PERCENT ENGINE SPEED — RPM RATED | BMEP rated | esp [900] 800 | 700 | 600 me t10—|_ 117] 1820] 11741026 | — 880 Pao wo | 107 | 1200 | 1067 | 938 | 800 ae 75 80 900 | 800 | 700 | 600 50. 53 goo | 538 _| 467 _| 400 NOs — Fie cosaerion| 100 | 107 | 7750 | 7750 | 7800 | 7200 ervey 75 80 | 550 | 500 | asco | 450 50 53__| 10150_| 10000_| 9950 _| 9850 WINE AA tio | 117 | 2000 | 1770 | 1460 | 1260 mount | 100 | 107 | 1990 | 1650 | 1400 | 1180 iow 75 80 | 1560 | 1350 | 1130 | 960 50, 53mm) z2} | e040 mace] e780 tio 417 164 139 120 | 100 Tenia too | 107 152 132 te 95 15 so | 123 107 1 % 50 53 58 83 69 59 i110 | 117] 1240 | 1200 [1180 [1150 Sone 100 1o7 | 1240 | 1200 | 1170 | 1130 75 so | 1230 | 1185 | 1140 | 1080 e 50 s3_| tteo | 1135 | 1090 | 1000 m0 | 117__| 45450 | 42300 | 38700 | 35550 farmecton | 100 | 107 | 44100 | 41400 | 38025 | 34200 ewuute 75 go | 42000 | 37350 | 33975 | 31500 50 s3_| 36450 | 32850 _| 30600_| 28350 Use OL 10 | 117 | 6750 | 6300 | 5400 | 4950 ter ection | 100 | 107 | 6750 | 6030 | 4950 | 4050 ane 75 so | 6300 | S400 | 4500 | 3600 50. 53__| 6300 | 4950 | 4050 _| 3150 NOTES = 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 231 TOLERANCE FOR FACTORY TESTS. 2 HEAT REJECTION DATA ARE BASED ON NOMINAL 18OF JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-21/9-88 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE. ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10% RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. appr, S2MKCU NA S11/1-89 _ Superior* and CloanBurn"™ are trademarks of Cooper Industrie, Ine Copyright © Cooper Industries, inc. 1968SUPERIOR NATURALLY ASPIRATED GAS ENGINES MODEL 126-825 PAGE 312 ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR 126825 PERCENT ENGINE SPEED — RPM RATED |BMEP PAM? lgremer [ 900 | 800 | 700 | 600 BRAKE SPECIFIC 110) 823 984 875 765 656 ourur 100 752 895 796 696 597 ww 15 563 67! 597 522 447 so_| 375 447 401 AB 298 IKE SPECI 110 8.23 a —— —— — Feccowsaprion| 190 qs2 | 2619 | 2619 | 2636 | 2636 cal 15 ses | 2890 | 2873 | 2873 | 2856 50 3r3_| 3430 _| 3380 | 3363 | 3329 INTAKE AR FLOW | 110 823 69 6 50 43 REQUIREMENT 100 752 65 s7 48 4 git 15 54 47 2 zB 50 42 36 30 26 XHAUST FLOW i 14 63 54 45 ognind 100 69 60 51 a8 15 56 49 at 34 50 44 38 31 27 TiO 67t 649 638 621 Soa 100 671 649 632 610 15 665 bal 616 582 50 638 613 588 538 JACKET WATER 10 11454 | 10660 9753 8959 HEAT REECTION 100 11114 | 10433 | 9583 | 9619 eau 15 roses | 9413 | g562 | 7939 50 gies | _8279_| 7712 | 7145 LUBE OL 110 ror | 1588 | 1361 | 1247 HEAT RESECTION 100 1701 | 1520 | 1247 | 1021 ed/MIND 15 ise | 1361 | 1134 907 50 1ssa_|_1247 | 1021 794 NOTES = 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES. SUBJECT TO +3t TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 82 JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-23/1-89 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE. ADO RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10x RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. [AJ] avax-SUPERIOR popn_GANNC NA Btestr89 ipa and Glandun" are wademarta of Cooper nds, Sxbyran © coopera: ne 1008SUPERIOR NATURALLY ASPIRATED GAS ENGINES MODEL 126-825 PAGE 3135 EXHAUST EMISSIONS MODEL + 66825, 86825, 126825, 166825 PERCENT EMISSIONS (GRAMS/BHP-HR). a tow BHPCKW) NOx co 3®NMHC 900 100 = 15.0 18 02 ® TONS PER YEAR = (GM/BHP-HR) x BHP + 1036 we DENOTES NON-METHANE HYDROCARBONS QUALIFYING CONDITIONS: 1) PIPELINE QUALITY GAS 1S ASSUMED, METHANE CONTENT SHOULD BE GREATER THAN 90x WITH A LOW HEATING VALUE OF 900 BTU/SCF + 15% FOR FUEL GAS OUTSIDE THESE PARAMETERS AN INDIVIOUAL REVIEW WILL BE REQUIRED TO DETERMINE EMISSION LEVELS AND FUEL CONSUMPTION RATES. 2) VALUES ARE BASED UPON 90° F AMBIENT TEMPERATURE AND 1500 FT. ALTITUDE, HIGHER ALTITUDES ANO/OR AMBIENT TEMPERATURES WILL REQUIRE THE APPLICATION OF STANDARD POWER DERATION FACTORS TO MANTAIN EMISSION RATES. THESE FACTORS REQUIRE THAT ENGINE CAPACITY BE DERATED 3-1/2 X FOR EACH 1000 FEET ABOVE 1500 FEET ALTITUDE AND 2-1/2 £ PER EACH 10" F ABOVE 90°F AMBIENT TEMPERATURE. 3D DATA SHOWN ARE BASED ON ENGINE ADJUSTMENT FOR STANDARD BSFC. 2 WHEN NOx REQUIREMENTS LESS THAN THOSE EXPRESSED HERE ARE ENCOUNTERED, THERE ARE TRADE-OFFS BETWEEN NOx AND BSFC WHICH MAY BE APPLICABLE, BUT THESE MUST, BE EVALUATED ON A SPECIFIC CASE BASIS. AJAX-SUPERIOR appr, SoC NA 313/1-89 ‘Superior? and CleanBurn™ are trademarks of Cooper Industtes, ne. Copyright © Cooper ndustias, Inc. 1989"SUPERIOR NATURALLY ASPIRATED GAS ENGINE — MODEL 126-825 PAGE 315 ® WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS 110 100 Sa ENGINE_RPM bd ‘900 — Zz ea th 70 i i 60 750 ~ 7 50 z ¥ B 40 600 6 7 ST 30 a 20 2 ~o \_ENGINE PRESSURE uy = DROP a _t= @ ° 200 400 600 800 900 FLOW (GPM) IMPELLER P/N D-024-003 (STRAIGHT VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (BI-DIRECTIONAL CAPABILITY? NORMALLY C.C.W (FACING DRIVE END) NPSHg = 19.0 FEET @ 900 RPM & 600 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 600 GPM = 99.0 FT. ~ 41.0 FT. = 58.0 FT. 58.0 FT. + 231 = 250 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. | asax-SUPERIOR appr, SMC NA 315/1-89 Superior® and CleanBurn™ are trademarks of Cooper Industries, Inc. ‘Copyeignt © Cooper inustries, Inc. 1989SUPERIOR NATURALLY ASPIRATED GAS ENGINE. MODEL 126-825 eth WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS 110 oe ENGINE RPM 90 1-200 = pesien — 7 EF 0 LOWS EE 60 4 13 a x 5° 7 F 6 e 600 | 7. TENG INE PRESSURE 10 —}——+ DROP ° ale ° 200 400 600 800 900 FLOW (GPM) IMPELLER P/N D-033-744~-002 (CURVED VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (UNIDIRECTIONAL? C.C.W (FACING DRIVE END) NPSHg = 12.0 FEET @ 900 RPM & 600 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF Scaloeue Ler Og 41.0 FT. aeciee FT. + 231 = 19.9 PS ENGINE PRESSURE DROP INCLUDES ALL. SUPERIOR SUPPLIED COMPONENTS, {Gi} asax-suPeRion appr, AADAC NA 316/1-89 ‘Superior* and CleanBurn"™ are radamarks of Cooper Industri, Ine Copyright © Cooper Industries, nc. 1SUPERIOR NATURALLY ASPIRATED GAS ENGINES MODEL 166-825 ENGINE SECTION INDEX Description Page No. Air Intake System 404 Bearing Dimensions 407 Cooling System 405 -Units In English Units 411 Exhaust System 404 Fuel System 404 Heat Rejection Data Miscellaneous 408 Unbalanced Forces and Couples -Units In English Units 409 -Units In Metric Units 410 Water Pump Characteristics -Jacket Water, Straight Vane 415 AJAX-SUPERIORSUPERIOR NATURALLY ASPIRATED ENGINES MODEL 166-825 PAGE 401 ENGINE SPECIFICATIONS Type Aspiration Cylinder Configuration Number of Cylinders Bore - in. (mm) Stroke = in. (mm) Displacement - [Link]. (liter Compression Ratio Power Rated - BHP (kW) Speed Rated - RPM Piston Speed - FPM(m/s) Speed Range - RPM Ignition system Fuel system Governor Exhaust Manifold Jacket Water Pump Jacket Water Thermostat Lube 041 Pump Lube Oil Thermostat Prelube Pump Lube 0i1 Cooler Crankcase Breather Crankcase Doors Direction of Rotation 4| AJAX-SUPERIOR Four (4)-Cycle Naturally Aspirated Vee Sixteen (16) 10 (254) 10.50 (266.7) 13195 (216.27) 10:2 1600 (2190) 900 1575 (8.0) 900 - 500 Non-Shielded, Altronic IIT Carbureted with Final Cut Regulator Hydraulic (UG-6L) With Manual Speed Setting Totally Water Cooled Built-In Centrifugal, Chain Driven Engine Mounted Gear Type with Pressure Regulating Valve Remote Mounted Manual, Mounted and Piped Shell & Tube Type, Remote Mounted Positive Ventilation Pressure Relief(Bicera Type) Doors Counterclockwise From Flywheel End NA 401/1-89 aver. 3MC ‘Superior? and CleanBum™ are trademarks of Cooper Industries, nc. Copyright © Cooper ncustes, ne. 1980SUPERIOR NATURALLY ASPIRATED ENGINES MODEL 166-825 PERFORMANCE Engine Operating Data Rating Conditions Altitude Temperature Rated Torque Over 900-500 RPM Range Brake Mean Effective Pressure Rating/BMEP Rated Brake Specific Fuel Consumption/BSFC (Plus or Minus 3 percent Factory Tolerance) Heat Rejection Data Emissions STARTING SYSTEM Air/Gas Starting Motor Make & Model Number of Starting Motors: Generator Drive Compressor Drive Supply Air/Gas Pressure Consumption Rate/Starter Motor -Air -Gas -Normal Starting Time Connection Sizes -Inlet outlet -Optional: Inlet Flange outlet Flange 41) AJAX-SUPERIOR See Page 4 feet meter Deg F Deg c lb-ft M-kg psi kg/cm2 Btu/bhp-hr keal/kW-hr See Page 4 See Page 4 IR / $S-82 one(1) Two(2) psi kg/cm2 scfm liter/sec scfm liter/sec sec 2-1/2 In. 2-1/2 In. 3-1/2 In. 2-1/2 In. aren, BNC ‘Superior? and CleanBura™ Copyright © Cooper industries, Inc. 1989 PAGE 403 11 & 412 1800 (| 457 90 ( 32.2 9337 eee 106.7 (7.50 77150 ( 2619 11 & 412 13 5 150 (10.5 1500 (708 1781 (Bar 15 NPT NPT Square 150 Lb. 403/1-89 ‘tademarks of Cooper Industries, ne.SUPERIOR NATURALLY ASPIRATED ENGINES MODEL 166-825 AIR INTAKE SYSTEM Intake Air Flow Rate Max. Allowable Pressure Drop Air Intake, Inlet Connection FUEL SYSTEM Required Fuel Gas Pressure to Engine Based on Pipeline Quality Natural Gas Gas Inlet Connection EXHAUST SYSTEM Max. Allowable Back Pressure Exhaust Outlet Flange Connection Size Exhaust Flow Rate Stack Temperature PAGE 404 See Page 411 & 412 In #20 1. 1 5 mm H20 (19a ) Two Flex Connections for 8 In. Pipe psi 5-10 kg/om2 (0.4-0.7 ) 2 In, 150 Lb. In H20 15 mm, 20 (381) 14 In, 150 Lb, FF See Page 411 & 412 See Page 411 & 412 AJAX-SUPERIOR APPR. NK NA 404/1-89 Superior® and CleanBurn"™ ate radamarks of Cooper Industrie, Ine. Copyright © Cooper Industis, Inc. 1980SUPERIOR NATURALLY ASPIRATED ENGINES PAGE 405 MODEL 166-825 COOLING SYSTEM Jacket Water Capacity - Engine Only Gallon 180 liter ( 681) Jacket Water Pump -Jacket Water Outlet Temperature, Normal Deg F 170-180 Deg ¢ ( 76-82 ) -Flow Rate at Rated Speed GPM 750 liter/sec (47.3 ) Available External Head: Straight Vane(Standard) psi 18.2 kg/cm2 (1.28 ) Curved vane(Optional) psi a kg/om2 (0.77 ) -Minimum NPSH Required: Straight Vane(Standard) feet 20 meter (6.10 ) Curved Vane(Optional) feet 14 meter (4.27 ) Connection Sizes e -Jacket Water Inlet 6 In. 150 1b. Jacket Water Outlet 4 In. NPT “Vent Line to Surge Tank,Minimum Size 3/8 In. Tubing -Surge Tank Return to Pump Inlet 2 In. NPT aper._93N\C_ NA 405/1-89 ‘Superior? and CleanBurn™ ara trademarks of Caopet industries, ne. Copyright © Cooper Industnes, Ine. 1980SUPERIOR NATURALLY ASPIRATED ENGINES PAGE 406 MODEL 166-825 LUBRICATION SYSTEM Lube 011 Sump Capacity Gallon 220 liter (833 ) Lube 011 Consumption (Estimated) Gal/Day 3.20 liter/Day ( 12.1 ) Lube Oil Pressure - Normal psi 35-40 kg/cm2 (2.5-2.8 ) Temperature Into Engine - Normal Deg F 160-170 Deg ¢ (71-77) Flow Rate Through Oi] Filter GPM 87 liter/sec (5.49 ) Lube Oil Filters, Engine Mounted(Standard) -Type Full Flow -Microns of Filtration Fifteen(15) Connection Sizes ~Lube 011 Sump Drain Plug 1-1/2 In. NPT Lube 011 Outlet to Cooler 3 In. NPT -Lube 041 Inlet to Filter 3 In. NPT AJAX-SUPERIOR APPR. BNK 2 NA 406/1-89 ‘Superior® and CioanBurn™ are trademarks of Cooper Industis, Ine Copyright © Cooper industries, Inc. 1989SUPERIOR NATURALLY ASPIRATED ENGINES PAGE 407 MODEL 166-825 @ sexes oveerszons Main Bearing, Split Shell -Diameter In 8.00 mn ( 203.2 ) -Width In 4.88 an (123.8 ) -Quantity Nos. 9 Crankpin Bearing, Split Shell -Diameter In 6.38 mn (161.9 ) “Width In 2.53 mm ( 64.3 ) -Quantity Nos. 16 Wrist Pin Bearing -Diameter In 3.50 mn ( 88.9 ) “Width In 3.16 mm ( 80.3 ) e ~Quantity Nos 16 Camshaft Bearing, Split Shel] -Diameter In 2.75 mm ( 69.9 ) “Width In 2.38 an ( 60.3 ) “Quantity per Bank Nos. 9 DIMENSIONS AND WEIGHT (APPROXIMATE) Overall Length In 180 mn (4572 ) Overall Width In 126 mm ( 3200 ) Overall Height In 96 mn ( 2438 ) Dry Weight Lb 51000 kg ( 23134 ) AJAX-SUPERIOR appr. I3N\C_ NA_407/1-89 ‘Superior? and CleanBurn™ aro trademarks of Cooper Industries. nc Copyright © Cooper industas, inc, 1980SUPERIOR NATURALLY ASPIRATED ENGINES PAGE 408 MODEL 166-825 MISCELLANEOUS Clearance Required to Remove Piston In 89 mm (2261 ) Heaviest Engine Parts (Approximate Weights) Cylinder Block Assembly Lb 13000 kg (8897 ) -Cylinder Head Assembly Lb 250 kg {4113 ) Piston and Connecting Rod Assembly Lb 198 kg ( (90) “Exhaust Manifold Lb 2175 kg (533 ) AJAX-SUPERIOR arrr._GAN\C MAae/ase2) ‘Superior® and CloanBurn™ are wademarks of Cooper Industrie, Inc. Copyright © Cooper Industries, nc. 1989SUPERIOR NATURALLY ASPIRATED GAS ENGINES PAGE 409 MODEL 166-825 MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN ENGLISH UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limi ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted, that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. PRIMARY FORCE - Lb. SECONDARY FORCE - Lb. | 1 | ENGINE | tH | Rew |" veksicai” woRiZowoau ||" vatican wontzowran | ti @ soo | 1217.079—sg00.087 || a4s.720 «ea. 079 | sco | jaoless © “yocees || Tieca34 stizee | moo | [Link]—Gosase || “8.81 solees | soo | Sescaee = Maaca3s {| oaste8 eles | 1 I | PRIMARY COUPLE - [Link] SECONDARY COUPLE - Lb. Ft. ! tI 1 ENGINE | =| |- i RPM =| ‘VERTICAL = HORIZONTAL || VERTICAL © HORIZONTAL | i 900 | 4330.740 3254.756 || 484.878 215.883 | goo =| «=: 3421820 2571.659 || 383.114 170.574 | 700 | 2619.831 1968.926 || 293.321 130.596 | 600 1 1924.773 1446.558 || 215.501 95.948 | ' I | appr. WNAC_ NA 409/1-89 ‘Superior? and CleanBurn™ are trademarks of Cooper Industries, nc. Copyright © Cooper industries, nc. 1989SUPERIOR NATURALLY ASPIRATED GAS ENGINES PAGE 410 MODEL 166-825 MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN METRIC UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted, that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. SECONDARY FORCE - kg | a | ENGINE | ue I RPM | ‘VERTICAL = HORIZONTAL || = VERTICAL = HORIZONTAL | 1 i | 1 it | goo | 597.427 453.898 || 66.099 29.429 | goo | 472,061 358.636 || 62.226 23.252 | 700 | 361.406 274.580 || 39.985 17.803 | 600 I 265.523 201.732 || 29.377 13.080 | 1 tt | SECONDARY COUPLE - [Link] 1 I 1 ENGINE | a ' RPM | —-VERTICAL © HORIZONTAL || | VERTICAL HORIZONTAL | | t | goo | 598.941 450.133 || 67.059 29.887 | goo | 473.238 355.660 || 52.985 23.590 | 700} 362.323 272.302 || 40.566 18.062 | 600 | 266.196 200.059 || 29.804 13.270 | 1 UN 4 AJAX-SUPERIOR aper._GANC NA 410/1-89 ‘Superio and CleanBumn™ are trademarks of Cooper Industries, nc. Copyright © Cooper industri, Inc. 1989SUPERIOR NATURALLY ASPIRATED GAS ENGINES MODEL 166-825 ey ENGINE OPERATING DATA AND HEAT REJECTION e SUPERIOR 166825 PERCENT ENGINE SPEED — RPM RATED | MEP er — cane 110117] 1760] 1564] 13681175 HORSEPOWER 1oo | 107 | 1600 | 1422 | taag | 1067 on 5 so | 1200 | 1067 | 933 | 800 50 53 goo_| 71 422 | $34 NE no foam | — | — | — | — FE et ey| 100 | 107 | 7750 | 7750 | 7800 | 7900 Pade 5 go | 8550 | 8500 | 500 | 8400 50 53__| 10150 _| 10000 _| 9900 | 9850 annow | 110 | 117 | 2570 | 234s | 1941 | 1705 MMe re | 100 | 107 | 2387 | 2ee2 | 1797 | 1587 cri) 75 so | i902 | teze | 1455 | 1272 50 s3_|_ 1430 | 1364 _| 1115 | 970 10 | _117 205 187 155 | 136 inci too | 107 191 io | 145 | 27 75 80 152 vas | ue | 102 50 53 15 | __109 89 a Tio] 117] 1330 | 1310 | 1284 [1270 See 100 107 1330 | 1310 | 1254 | 1250 5 30 | 1310 | 1290 | 1215 | 1200 e 50 s3_|_ i250 | 1230 | 1167 | 1140 aa Tio] 117 | 59000 | 52200 | 46900 | 42300 were tcrty | 100 | 107 | 57600 | 51300 | 46800 | 41850 ferian 75 ao | 55800 | 49500 | 44550 | 39600 50 53__| 47250 | 42650_| 37350_| 32400 arta Tio] 117] 7200 | 7200 | 7200] 7200 LE Ot ron | 192 | 107 | 7200 | 7200 | 7200 | 6750 ie 75 so | 7200 | 6750 | 6750 | 6750 50 s3_| 6750 | 6750 | 6750_| 6750 NOTES 1) FUEL. CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 43K TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 180T JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-21/9-88 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING, HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE, ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10% RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. AJAX-SUPERIOR appr, _CAM\C - NA 411/1-89 ‘Superior® and CleanBurn"™ are wademarks of Cooper Industries, Ine. Copyright © Cooper industias, Ine. 1989SUPERIOR NATURALLY ASPIRATED GAS ENGINES MODEL 166-825 PAGE 412 ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR 166825 PERCENT | auep ENGINE SPEED — RPM RATED Coad |tkg/emer [ 900 | 800 ] 700 | 600 110 8.23 1312 1166 1020 875 BRAKE SPECI r bets i 100 1.52 193 1060 928 796 ew 15 5.63 895 796 696 397 50 313. 597. 530 Abs 398 110 8.23 ae a —_— — mie consaerion| 100 152 2619 | 2619 | 2636 | 2670 kcol/HHHRD 15 5.63 2890 2873 2873 2839 50 313 3430 33a0_| 3346 3329 INTAKE AIR FLOW 110 8.23 89 81 6? 59 REQUIREMENT. woe 7.52 82 19 62 55 gt) 2 5.63 66 63 50 44 50. 373. 49 47 38 3 HAS 110) 8.23 93 5 70 62 ony no 100 152 87 77 66 58 I 563 69 66 53 46 50, 373 52 49 40 35 HAS 110 B23 721 710 696 688 8 eat al 100 752 721 710 679 677 15 563 710 699 657 649 50 R73. 677 666 631 616 110 14869 13155 11820 10660 R 8.23 HAT RCECTION 100 7s2e | 14516 | ta92a | 11794 | 10547 (keal/MIN) 15 5.63 14063 12475 1227 9980 50. 313 11908 10748 9413 8165 LUBE tL 110 8.23 1815 1815 1815, 1815 HEAT RESECTION 100 1.52 1815 1815 1815 1701 ee MIND a) 5.63 1815 1701 1701 1701 SO. 313 1701 1701 1701 1701 NOTES = 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBECT TO 83k TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 82°C JACKET WATER OUTLET TEMPERATURE, REFER TO GENERAL DATA SECTION, PAGE GEN-23/1-89 FOR HEAT REJECTION ADNSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING, HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE. ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10% RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. | AJaX-SUPERIOR APPR. Bc ~ NA 412/1-89 ‘Superior? and CleanBurn™ are wademarks of Cooper Incusties, Inc. Copyright © Cooper industries, inc. 1988SUPERIOR NATURALLY ASPIRATED GAS ENGINES MODEL 166-825 PAGE 415 e EXHAUST EMISSIONS MODEL : 66825, 86825, 126825, 166825 PERCENT *EMISSIONS (GRAMS/BHP-HR) RPM |RarED es) eer cty CO NMHC 900 100 E 15.0 18 02 * TONS PER YEAR = (GM/BHP-HR) x BHP + 1036 "DENOTES NON-METHANE HYDROCARBONS QUALIFYING CONDITIONS: 1) PIPELINE QUALITY GAS 1S ASSUMED. METHANE CONTENT SHOULD BE GREATER THAN 90% WITH A LOW HEATING VALUE OF 900 BTU/SCF 154. FOR FUEL GAS OUTSIDE THESE PARAMETERS AN INDIVIDUAL REVIEW WILL BE REQUIRED TO DETERMINE EMISSION LEVELS AND FUEL CONSUMPTION RATES. 2) VALUES ARE BASED UPON 90" F AMBIENT TEMPERATURE AND 1500 FT. ALTITUDE, HIGHER ALTITUDES AND/OR AMBIENT TEMPERATURES WILL REQUIRE THE APPLICATION OF STANDARD POWER DERATION FACTORS TO MANTAIN EMISSION RATES. THESE FACTORS REQUIRE THAT ENGINE CAPACITY BE DERATED 3-1/2 1 FOR EACH 1000 FEET ABOVE 1500 FEET ALTITUDE AND 2-1/2 x PER EACH 10" F ABOVE 90°F AMBIENT TEMPERATURE. 3D DATA SHOWN ARE BASED ON ENGINE ADJUSTMENT FOR STANDARD BSFC, 4) WHEN NOx REQUIREMENTS LESS THAN THOSE EXPRESSED HERE ARE ENCOUNTERED, THERE ARE TRADE-OFFS BETWEEN NOx AND BSFC WHICH MAY BE APPLICABLE, BUT THESE MUST BE EVALUATED ON A SPECIFIC CASE BASIS, AJAX-SUPERIOR appr SMC NA_413/1-89 Superior® and CieanBumn™ are trademarks of Cooper industries, Inc. Copyright © Cooper Industri, ine. 1989SUPERIOR NATURALLY ASPIRATED GAS ENGINE MODEL 166-825 PAGE 415 e WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS tea 90 ENGINE_RPM | wr ~ 80 ot DESIGN F 70 FLOWS “TT Zz 2 60 150, = 59 ea u a f= v O 40 600. hall re Ee 20 a_— = ENGINE PRESSURE 10 | DROP ° ees e 0 200 400 600 @00 © 900 FLOW (GPM) IMPELLER P/N D-024-003 (STRAIGHT VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (I-DIRECTIONAL CAPABILITY) NORMALLY [Link] (FACING DRIVE END) NPSHp = 20.0 FEET @ 900 RPM & 750 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 750 GPM = 92.0 FT. — S80 FT. » 420 FT. 0 FT. +231 = 182 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS, $)| asax-SUPERIOR appr __§3MC NA 415/1-89 ‘Superior and CleanBurn™ are trademarks of Cooper Industries, Ine. Copyright © Cooper industras, ine. 1980SUPERIOR NATURALLY ASPIRATED GAS ENGINE MODEL 166-825 PAGE 416 WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS 110 wo ENGINE RPM 90 ~ 80 DESIG < cz FLOWS 7 fo LE St = 50 i oo 6 40 400 2 30 | AS 20 = 1 a {ENGINE PRESSURE —| 0 ee DROP, 1 ° 200 400 600 800 900 FLOW (GPM) IMPELLER P/N D-033-744-002 (CURVED VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (UNIDIRECTIONAL) C.C.W (FACING DRIVE END) NPSHp = 140 FEET @ 900 RPM & 750 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 750 GPM = 800 FT- 550 FT. = 25.0 FT. 25.0 FT. + 2.31 = 108 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. fora 4 Be NA 416/1-89 ‘Superior? and GloanBurn™ are rademarks of Cooper Industrie, Inc. Copyright © Cooper Industes, In. 1980SUPERIOR DUAL FUEL ENGINES MODEL 40-GDx-6 ENGINE SECTION INDEX Description Page No. Air Intake System 104 Bearing Dimensions 107 Cooling Systen 105 Dimensions and Weight 107 Engine Operating Data -Units In English Units aa1 -Units In Metric Units 312 Engine Outline Drawing 219 Engine Performance 103 Engine Specifications 102 Exhaust Emissions 313 Exhaust System 104 Fuel System 104 Heat Rejection Data Units In English Units ait -Units In Metric Units 412 Lubrication System 106 Miscellaneous 108 Starting System 103 Turbocharger 104 Unbalanced Forces and Couples -Units In English Unite 109 -Units In Metric Units 210 Water Pump Characteristics -Jacket Water, Straight Vane 115 -Jacket Water, Curved Vane N/A -Intercooler,’ Straight Vane N/A Intercooler, Curved Vane N/A Eel AJAX-SUPERIORSUPERIOR DUAL FUEL ENGINES MODEL 40-GDx-6 PAGE 101 ENGINE SPECIFICATIONS Aspiration Cylinder Configuration Number of Cylinders Displacement - [Link]. Compression Ratio Power Rated Speed Rated Piston Speed - Speed Range Combustion Chamber Starting System Fuel system: Turbocharger Exhaust Manifold Jacket Water Pump Jacket Water Thermostat Lube Oi] Pump Lube 041 Thermostat Prelube Pump Lube 0i1 Cooler Intercooler Intercooler Water Thermostat Crankcase Breather Crankcase Doors Direction of Rotation a) | AJAX-SUPERIOR Four (4)-Cycle Turbocharged, Intercooled Inline Six (6) 9.125 (232) 10.50 (266.7) 4120 (68.00) 12.50: 1 710 (530) 900 1575 (8.0) 900 - 600 Direct Injection Direct Air-to-Head Starting Fuel Injected Individual Fuel Pumps and Injectors with Manual Priming Pump Air/Load Type Air-Fuel Control with Dual-Fuel Switch Over Logic Electro-Hydraulic 3199 Actuator one(1) Water Cooled Built-In Centrifugal, Belt Driven Engine Mounted Gear Type with Pressure Regulating Valve Engine Mounted Manual, Mounted and Piped Shell & Tube Type,Mounted and Piped Rectangular, Shell & Tube/Fin Type Engine Mounted Positive Ventilation Pressure Relief (Bicera Type) Doors Counterclockwise From Flywheel End ro GMC OF 101/1-89 ‘Suparior® and CloanBumn'™ are trademarks of Cooper Industries, Ine. Copyright © Cooper Industries, Inc. 1989SUPERIOR DUAL FUEL ENGINES PAGE 103 MODEL 40-GDx-6 e PERFORMANCE Engine Operating Data See Page 111 & 112 Rating Conditions Altitude feet 4000 meter (1219 ) -Temperature Deg F 90 Deg c (92.2) Rated Torque Over 900-600 RPM Range lb-ft 4143 M-kg (873 ) Brake Mean Effective Pressure Rating/BMEP psi 181.7 kg/om2 (10.7 ) Rated Brake Specific Fuel Consumption/BSFC See Page 111 & 112 Heat Rejection Data See Page 111 & 112 Emissions See Page 113 e STARTING AIR SYSTEM Consumption Rate scfm 290 liter/sec ( 137) Normal Starting Time 10 Supply Air Pressure psi 250 kg/em2 (17.6) Air Start Valve Signal Pressure psi 50-250 kg/om2 (3.8-17.6) Air Inlet Connection Size 1-1/2 In, NPT AIR INTAKE SYSTEM | Intake Air Flow Rate See Page 111 & 112 Max. Allowable Pressure Drop In #20 10 mn H20 (254) Air Intake, Inlet Connection 10 In, I.D. Plex Connector AJAX-SUPERIOR APPR. ( SMC DF _103/1-89 Suporior* and CieanSum"™ are wademarks of Cooper Industries, Ine. Copyright © Cooper Inaustrie, ne. 1989SUPERIOR DUAL FUEL ENGINES PAGE 104 MODEL 40-GDx-6 FUEL SYSTEM Fuel 0i1 Required for Dual Fuel Operation # 2 Diesel Fuel Fuel Oil Filters, Engine Mounted(Standard) -Type Duplex -Microns of Filtration Five(5) Fuel Oil Service Pump, Engine Mounted -Rated Flow GPM 21.5 liter/sec (0,09 ) -Maximum Vertical Lift on Suction Side feet 10 meter (3.05 ) Required Fuel Gas Pressure to Engine psi 25-30 Based on Pipeline Quality Natural Gas kg/cm2 = (1,8-2.1 ) (Regulated to within plus or minus 1 psig) Gas Inlet Flange Connection 2 In. 150 Lb. EXHAUST SYSTEM Max. Allowable Back Pressure In H20 10 mm H20 ( 254} Exhaust Outlet Flange Connection Size 10 In. 150 Lb. FF Exhaust Flow Rate See Page 111 & 112 Stack Temperature See Page 111 & 112 TURBOCHARGER Type Pulse Manufacturer Elliott Model H 30 Speed (Maximum) RPM 24000 $1| asax-suPERIOR appr. SONA DF 104/1-89 ‘Superior® and CleanBurn"™ are trademarks of Cooper Industis, Ine ‘Copyright © Cooper Industries, ine. 1989SUPERIOR DUAL FUEL ENGINES PAGE 105 MODEL 40-GDX-6 COOLING SYSTEM Jacket Water Capacity - Engine Only Gallon 54 liter (204 ) Jacket Water Pump ~Jacket Water Outlet Temperature, Normal Deg F 165-180 Deg c ( 74-82 ) -Design Flow Rate at Rated Speed GPM 225 liter/sec (14.2 ) ~Available External Head: Straight Vane(Standard) psi 23 kg/cm2 (1.62 ) -Minimum NPSH Required: Straight Vane(Standard) feet 16 meter (4.88 ) Intercooler system -Intercooler Water Inlet Temperature Normal Deg F 120 Deg ¢ (49.0 ) Design Flow Rate GPM 70 liter/sec (4.42 ) Pressure Drop (Includes Lube 011 Cooler, psi 9.6 Intercooler and Thermostat) keg/em2 (0.68 ) Connection Sizes -Jacket Water Inlet 4 In. NPT -Jacket Water Outlet 3 In, NPT Intercooler Water Inlet 3 In, NPT -Intercooler Water Outlet 2 In. 150 Lb. Flange -Vent Line to Surge Tank,Minimum Size 3/8 In, Tubing -Surge Tank Return to Pump Inlet 1-1/2 In. NPT AJAX-SUPERIOR aper._ ANC DF 105/1-89 Superior® and CloanBum™ are vader ‘Copyright © Cooper Inaustris, In. 1 of Cooper Industries, Ine.SUPERIOR DUAL FUEL ENGINES PAGE 106 MODEL 40-GDX-6 LUBRICATION SYSTEM Lube 0i1 Sump Capacity Gallon 65 liter (246) Lube 011 Consumption(Estimated) Gal. /Day 1.42 liter/Day (5.37 ) Lube 041 Pressure - Normal psi 35 kg/om2 (2.46 ) Temperature Out Of Engine - Normal Deg F 160-175 Deg c (71-80 ) Flow Rate Through 011 Filter cen 35 liter/sec (2.21 ) Lube Oil Filters, Engine Mounted(Standard) ~Type Full Flow -Microns of Filtration Fifteen(15) Connection Sizes ~Lube 041 sump Drain Plug 3-1/2 In. NPT | AJAX-SUPERIOR aper. D3MWC DE_106/1-89 Superior® and CieanBur™ are trademarks of Cooper Industies, Ine. Copyright © Cooper industries, ine. 1989SUPERIOR DUAL FUEL ENGINES PAGE 107 MODEL 40-GDx-6 e BEARING DIMENSIONS Main Bearing, Split Shell ~Diameter In 6.00 an (152.4) “Width In 3.50 mn ( 88.9 ) -Quantity Nos. 7 Crankpin Bearing, Split Shell -Diameter In 5.75 am (146.0 ) -Width In 3.63 an (92.2 ) ~Quantity Nos. 6 Wrist Pin Bearing -Diameter In 3.50 mm ( 88.9 ) “Width In 3.16 mn (80.3 ) 6 @ “Quantity Nos. Camshaft Bushing -Diameter In 2.125 mn (54.0 ) “Width In 1.68 mn ( 42.7) -Quantity Nos. 7 DIMENSIONS AND WEIGHT (APPROXIMATE) Overall Length In 143 mm ( 3632 ) Overall Width In ma mn (1803 ) Overall Height In a8 mm ( 2235 ) Dry Weight Lb 19200 kg (8709 ) AJAX-SUPERIOR appr. MAC OF 107/1-89 ‘Superior? and CleanBurn™ are wademarks of Cooper Industies, Inc. Copyright © Cooper industries, ne. 1989SUPERIOR DUAL FUEL ENGINES PAGE 108 MODEL 40-GDx-6 MISCELLANEOUS Clearance Required to Remove Piston and In (82.63 ) Connecting Rod Assembly mm 2099 Heaviest Engine Parts (Approximate Weights) ~Cylinder Block Assembly Lb 3500 kg (1588 ) ~Cylinder Head Assembly Lb 250 kg te 2797) -Piston and Connecting Rod Assembly Lb 192 kg (87) Turbocharger Assembly Lb 930 kg (422) Exhaust Manifold Lb 495 kg (225) A asax-suPeRIOR appr. (NVC DE 108/1-89 Superior® and CleanBurn"™ are trademarks of Cooper Industries, Ine. Copyright © Cooper industries, Ie. 1989| AJAX-SUPERIOR APPR. SUPERIOR DUAL FUEL ENGINES PAGE 109 MODEL 40-GDx-6 MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN ENGLISH UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. SECONDARY FORCE - Lb. PRIMARY FORCE - Lb. ENGINE RPM VERTICAL © HORIZONTAL VERTICAL © HORIZONTAL 900 576.743 335.115 ° 800 455.698 264.115 47.729 ° 700 348.894 202.724 36.542 ° 600 256.330 148.940 26.847 ° 1 ! 1 | ! 1 60.407 1 1 {------+--+- 1 ENGINE | " ! | "1 1 RPM | it | | i | | ul | 900 | =: 1181.979 723.894 || 114,522 ° | 800 1 933.910 571.965 || 90.486 oO I 700) a a 715.025 437.911 || 69.279 ° I 600 | 525.324 321.731 |} 50.899 ° | \ ul I QM OF 109/1-89 Superior? and CleanBurn"™ are wadamarks of Cooper Industrie, Inc. Copyright © Cooper ndustrias, Ine. 1980SUPERIOR DUAL FUEL ENGINES PAGE 110 MODEL 40-GDX-6 MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN METRIC UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted, that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. ENGINE 900 261.611 152.008 ° 21.650 ° 700 158,258 91.956 16.575 ° 600 116.271 67.559 12,178 ° | 1 | | I 27.401 1 1 | | ! ! goo | 206.705 119.803 | ! | PRIMARY COUPLE - [Link] SECONDARY COUPLE - [Link] ENGINE RPM VERTICAL © HORIZONTAL VERTICAL © HORIZONTAL 15.838 ° 800 129.160 79.103 12.514 ° 700 98.888 60.563 9.581 ° 600 72.652 44.495 7,039 ° | 1 I S008 || 163.468 100.115 | I 1 1 lap |G Avax-SUPERIOR appr. SNC DF_110/1-89 ee) Superior® and CleanBurn"™ are tradomarks of Cooper Industis, Ine. Copyright © Cooper industries, Inc. 1989SUPERIOR DUAL FUEL ENGINES MODEL 40-GDx-6 EXHAUST EMISSIONS MODEL + 40-GDX-6 (STANDARD WATER-COOLED EXHAUST MANIFOLD) PERCENT | RPM |RATED #2 OPERATING] sEMISSIONS (GRAMS/BHP-HR) LOAD. MODE NOx. co ae NMHC 900 100 DUAL FUEL, 93 30 1.00 900 100 DIESEL, 9.0 39 1.00 | AJAX- SUPERIOR * TONS PER YEAR = (GM/BHP-HR) x BHP + 103.6 #* DENOTES NON-METHANE HYDROCARBONS es FULL LOAD ‘QUALIFYING CONDITIONS: 1) PIPELINE QUALITY GAS IS ASSUMED. METHANE CONTENT SHOULD BE GREATER THAN 90x WITH A LOW HEATING VALUE OF 900 BTU/SCF # 15¢, FOR FUEL GAS OUTSIDE THESE PARAMETERS AN INDIVIDUAL REVIEW WILL. BE REQUIRED TO DETERMINE EMISSION LEVELS AND FUEL CONSUMPTION RATES, 2) VALUES ARE BASED UPON 130° F MANIFOLD TEMPERATURE, «120° F INTERCOOLER WATER AND 100" F AMBIENT TEMPERATURE. REDUCED AIR MANIFOLD TEMPERATURES WILL RESULT IN LOWER NOx LEVELS. HIGHER AMBIENT TEMPERATURES WILL NOT AFFECT EMISSION LEVELS AT RATED LOAD AND SPEED BUT WILL CAUSE SLIGHTLY HIGHER NOx LEVELS AT REDUCED SPEEDS. [Link] SHOWN ARE BASED ON ENGINE ADUSTMENT FOR STANDARD BSFC. FULL SPEED EMISSION VALUES ARE VALID FOR ALTITUDES BELOW 4000 FT. HIGH ALTITUDE APPLICATIONS MAY REQUIRE TURBOCHARGER MODIFICATION TO MAINTAIN EMISSION RATES. 4) WHEN NOx REQUIREMENTS LESS THAN THOSE EXPRESSED HERE ARE ENCOUNTERED, THERE ARE TRADE-OFFS BETWEEN NOx AND ESFC WHICH MAY BE APPLICABLE, BUT THESE MUST BE EVALUATED ON A SPECIFIC CASE BASIS, ‘Suporior® and CloanBurn™ Copyright © Cooper industas, In. 1980 arr. i DF tt PAGE 113 190 rademarks of Cooper Industries, Ine.SUPERIOR DUAL FUEL ENGINES. MODEL 40-GDX-6 DEM PAGE 114 EXHAUST EMISSIONS MODEL : 40-GDX-6 DEM (DRY-TYPE EXHAUST MANIFOLD) RPM PERCENT TOPERATING| EMISSIONS (GRAMS/BHP-HR) RATED ex LOAD. MODE, NOx. co a# NMHC 900 100, DUAL FUEL 93 58 1.50 900 100 DIESEL, 9.0 39 1.00 ~T * TONS PER YEAR = (GM/BHP-HR) x BHP + 1036 * DENOTES NON-METHANE HYDROCARBONS ee FULL LOAD QUALIFYING CONDITIONS: 1 PIPELINE QUALITY GAS IS ASSUMED MCTHANE CONTENT SHOULD HE GREATER THAN 90x WITH A LOW HEATING VALUE OF 900 BTU/SCF + 15x FOR FUEL GAS OUTSIDE THESE PARAMETERS AN INDIVIDUAL REVIEW WILL BE REQUIRED TO DETERMINE EMISSION LEVELS AND FUEL CONSUMPTION, RATES, 2) VALUES ARE BASED UPON 130° F MANIFOLD TEMPERATURE, <120" F INTERCOOLER WATER AND 100" F AMBIENT TEMPERATURE. REDUCED AIR MANIFOLD TEMPERATURES WILL RESULT IN LOWER NOx LEVELS. HIGHER ‘AMBIENT TEMPERATURES WILL NOT AFFECT EMISSION LEVELS AT RATED LOAD AND SPEED BUT WILL CAUSE SLIGHTLY HIGHER NOx LEVELS AT REDUCED SPEEDS, 3 DATA SHOWN ARE BASED ON ENGINE [Link] FOR STANDARD BSFC. FULL SPEED EMISSION VALUES ARE VALID FOR ALTITUDES BELOW 4000 FT. HIGH ALTITUDE APPLICATIONS MAY REQUIRE TURBOCHARGER MODIFICATION TO MAINTAIN EMISSION RATES. 4 WHEN NOx REQUIREMENTS LESS THAN THOSE EXPRESSED HERE ARE ENCOUNTERED, THERE ARE TRADE-OFFS BETWEEN NOx AND BSFC WHICH MAY BE APPLICABLE, BUT THESE MUST BE EVALUATED ON A SPECIFIC CASE as AJAX-SUPERIOR lerbbord APPR, DF_114/1-90 ‘Superior? and ClesnBum™ are trademarks of Cooper Indust, Inc. Copyright © Cooper ndusties, nc. 1969SUPERIOR DUAL FUEL ENGINE MODEL 40-GDX-6 Pe e WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS wd tence a 10 100 100 cee cece 90 DESIGN, 7 F 50 FLOWS a al 750. a Wa a = 600 . Pat |. Z a > 7 S < [ENGINE PRESSURE e 0 fe= ° 100 200 300 400 500 FLOW (GPM) IMPELLER P/N C-026-376 (STRAIGHT VANE) PUMP _RPM = 2.167 X ENGINE RPM DIRECTION OF ROTATION (BI-DIRECTIONAL CAPABILITY) NORMALLY CW (FACING DRIVE END) NPSHg = 16.0 FEET @ 900 RPM & 225 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 225 GPM = 100.0 FT. ~ 47.0 FT. = 530 FT. 530 FT. + 231 = 230 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. | AJAX-SUPERIOR appr, SONAC OF 115/1-89 Superior and CleanBun™ are trademarks of Cooper Industrie, nc Copyright © Cooper ndusties, nc. 1980SUPERIOR DUAL FUEL ENGINES MODEL 40-GDx-8 ENGINE SECTION INDEX Description Page No. Air Intake System 204 Bearing Dimensions 207 Cooling System 205 Dimensions and Weight 207 Engine Operating Data Units In English Units 211 -Units In Metric Units 212 Engine Outline Drawing 219 Engine Performance 203 Engine Specifications 201 Exhaust System 204 Fuel systen 204 Heat Rejection Data -Units In English Units 211 Units In Metric Units 212 Lubrication system 206 Miscellaneous 208 Starting System 203 Turbocharger 204 Unbalanced Forces and Couples -Units In English Units 209 Units In Metric Units 210 Water Pump Characteristics -Jacket Water, Straight Vane 215 ~Jacket Water, Curved Vane 216 -Intercooler, Straight Vane N/A Intercooler, Curved Vane N/A ‘ail AJAX-SUPERIORSUPERIOR DUAL FUEL ENGINES MODEL 40-GDX-8 PAGE 201 ENGINE SPECIFICATIONS Type Aspiration Cylinder Configuration Number of Cylinders Bore = in. (mm) Stroke - in. (mm) Displacement - [Link], (liter) Compression Ratio Power Rated - BHP (kW) Speed Rated - RPM Piston Speed - FPM(m/s) Speed Range ~ RPM Combustion Chamber @ Starting System Fuel system: Fuel Gas Fuel 0i1 controls Governor Turbocharger Exhaust Manifold Jacket Water Pump Jacket Water Thermostat Lube 041 Pump Lube 01] Thermostat Prelube Pump Lube 011 Cooler Intercooler Intercooler Water Thermostat Crankcase Breather Crankcase Doors Direction of Rotation 4) AJAX-SUPERIOR Four (4)-Cycle Turbocharged, Intercooled Inline Eight (8) 9.125 (232) 10.50 (266.7) 5493 (93.00) 12.50: 1 945 (705) 300 1875 (8.0) 900 - 600 Direct Injection Direct Air-to-Head Starting Fuel Injected Individual Fuel Pumps and Injectors with Manual Priming Pump Air/Load Type Air-Fuel Control with Dual-Fuel Switch Over Logic Electro-Hydraulic 3199 Actuator one(1) Water Cooled Built-In Centrifugal, Belt Driven Engine Mounted Gear Type with Pressure Regulating Valve Engine Mounted Manual, Mounted and Piped Shell & Tube Type,Mounted and Piped Rectangular, Shell & Tube/Fin Type Engine Mounted Positive Ventilation Pressure Relief (Bicera Type) Doors Counterclockwise From Flywheel End appr. S3MC OF 201/1-89 ‘Superior® and ClosnBumn™ are vademarks of Cooper Industles, nc. Copyright © Cooper industiee, inc. 1989.SUPERIOR DUAL FUEL ENGINES MODEL 40-GDX-8 PERFORMANCE Engine Ope: ting Data Rating Conditions Altitude -Temperature Rated Torque Over 900-600 RPM Range Brake Mean Effective Pressure Rating/BMEP Rated Brake Specific Fuel Consumption/BSFC Heat Rejection Data Emissions STARTING AIR SYSTEM Consumption Rate Normal Starting Time Supply Air Pressure Air Start Valve Signal Pressure Air Inlet Connection Size AIR INTAKE SYSTEM Intake Air Flow Rate Max. Allowable Pressure Drop Air Intake, Inlet Connection fay PAGE 203 See Page 211 & 212 feet 4000 meter (1219 ) Deg F 90 Deg c ( 32.2) lb-ft 5500 M-kg (| 761) psi 181.4 kg/em2 (10.6 ) See Page 211 & 212 See Page 211 & 212 See Page 213 scfm 325 liter/sec ( 153 ) sec 10 psi 250 kg/cm2 (17.6) psi 50-250 kg/om2 (3.5-17.6) 3-1/2 In. NPT See Page 211 & 212 In #20 10 mm H20 (284) 10 In. I.D. Flex Connector AJAX-SUPERIOR nope. (3MWC__ DF 203/1-89 Superior® ang CleanBum" are trademarks of Cooper Industries, Inc. Copyright © Cooper Industries, Ine. 1988SUPERIOR DUAL FUEL ENGINES MODEL 40-GDX-8 FUEL SYSTEM Fuel Oi] Required for Dual Fuel operation Fuel Oil Filters, Engine Mounted(Standard) ~Type -Microns of Filtration Fuel Oil Service Pump, Engine Mounted -Rated Flow -Maximum Vertical Lift on Suction Side Required Fuel Gas Pressure to Engine Based on Pipeline Quality Natural Gas (Regulated to within plus or minus 1 psig) Gas Inlet Flange Connection EXHAUST SYSTEM Max. Allowable Back Pressure Exhaust Outlet Flange Connection Size Exhaust Flow Rate Stack Temperature TURBOCHARGER Type Manufacturer Model speed (Maximum) PAGE 204 # 2 Diese? Fuel Duplex Pive(5) GPM 1.5 liter/sec ( 0,09 feet 10 meter (3.05 ) psi 25-30 kg/om2(1.8-2.1 ) 2 In. 180 Lb. In #20 10 mn H20 (254) 12 In, 180 Lb. FF See Page 211 & 212 See Page 211 & 212 Pulse Cooper-Bessemer ET 11 RPM 27000 23] avax-SUPERIOR APPR. QC DF 204/1-89 Superior® and CleanBurn" are trademarks of Cooper Industes, Ine. Copyright © Cooper ndusties, nc. 1989SUPERIOR DUAL FUEL ENGINES MODEL 40-GDx-8 COOLING SYSTEM Jacket Water Capacity - Engine only Jacket Water Pump -Jacket Water Outlet Temperature, Normal ~Design Flow Rate at Rated Speed -Available External Head: Straight Vane(Standard) Curved Vane (Optional) -Minimum NPSH Require: Straight Vane(Standard) curved Vane (optional) Intercooler System -Intercooler Water Inlet Temperature, Normal ‘Design Flow Rate -Pressure Drop (Includes Lube 0il Cooler, Intercooler and Thermostat) Connection Sizes -Jacket Water Inlet “Jacket Water Outlet Intercooler Water Inlet Intercooler Water Outlet -Vent Line to Surge Tank,Minimum Size -Surge Tank Return to Pump Inlet PAGE 205 Gallon 70 liter (265 ) Deg F 165-180 Deg c (74-82 ) cpm 300 liter/sec ( 18.9 ) psi 26 kg/om2 (1.76 ) psi 29.5 kg/em2 (2.07 ) feet 15.5 meter (4.72 ) feet 9 meter (2.74) Deg F 120 Deg c (49.0) Gem 10 liter/sec (4.42 ) psi 9.6 kg/cm2 (0.68 ) [Link]. NPT 3 In. NPT 2-1/2 In. Pipe 2 In. 150 Lb. Flange 3/8 In. Tubing 1-1/2 In. NPT ] . APPR. Ce DF 205/1-89 44) AJax-SUPERIOR envkze05/1=09 ‘Superor® and CloanBumn™ are trademarks of Cooper Indust Copyright © Cooper industries, in. 1988SUPERIOR DUAL FUEL ENGINES PAGE 206 MODEL 40-GDX-8 LUBRICATION SYSTEM Lube Oil sump Capacity Gallon 80 liter (303 Lube Oil Consumption(Estimated) Gal./Day 1.90 liter/Day (7.19 Lube Oil Pressure - Normal psi 35 kg/em2 (2.46 Temperature Out Of Engine ~ Normal Deg F 160-175 Deg (71-80 Flow Rate Through 0il Filter GPM 45 liter/sec (2.84 Lube 0i1 Filters, Engine Mounted(Standard) ~Type Full Flow -Microns of Filtration Fifteen(15) Connection Sizes -Lube 0i1 Sump Drain Plug 1-1/2 In. NPT AJAX-SUPERIOR aper._GAN\C —_or 206/1-89 Superiort and CleanBurn"Y are trademarks of Cooper Industis, Inc Copyright © Cooper industries, ic. 1968SUPERIOR DUAL FUEL ENGINES PAGE 207 MODEL 40-GDX-8 BEARING DIMENSIONS Main Bearing, Split Shell -Diameter In 6.00 mn (152.4) -Width In 3.50 mn ( 88.9 ) -Quantity Nos. 9 Crankpin Bearing, Split Shell -Diameter In 5.75 mn (146.0 ) -Width In 3.63 mn (92.2 ) -Quantity Nos. 8 Wrist Pin Bearing -Diameter In 3.50 an ( 88.9 ) “Width In 3.16 mn ( 80.3 ) @ —Quantity Nos. 8 Camshaft Bushing -Diameter In 2.125 mn (54.0 ) “Width In 1.68 mn 42.7) -Quantity Nos. 9 DIMENSIONS AND WEIGHT (APPROXIMATE) Overall Length In 168 mn ( 4267 ) Overall Width In 71 mm (1803 ) Overall Height In 88 mm (2235 ) Dry Weight Lb 24500 kg (42113) (Gil asax-surenion APPR CN« Z OF 207/1-89 ‘Superior? ang CleanBurn™ are trademarks of Cooper Industries, ne. Copyright © Cooper ndusties, Inc. 1988SUPERIOR DUAL FUEL ENGINES PAGE 208 MODEL 40-GDx-8 MISCELLANEOUS Clearance Required to Remove Piston and In ( 82.63 ) Connecting Rod Assembly mn 2099 Heaviest Engine Parts (Approximate Weights) -Cylinder Block Assembly Lb 4400 kg (1996 ) ~Cylinder Head Assembly Lb 250 kg G =D) -Piston and Connecting Rod Assembly Lb 192 kg @ iy }} -Turbocharger Assembly Lb 930 kg (422) -Exhaust Manifold Lb 650 kg (295 ) AJAX-SUPERIOR appr. CNC DF 208/1-89 ‘Superior? and CleanBurn™ are trademarks of Cooper Industries, Inc. Copyright © Cooper ndusties, ic. 1988SUPERIOR DUAL FUEL ENGINES PAGE 209 MODEL 40-GDx-8 MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN ENGLISH UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. SECONDARY FORCE - Lb. ENGINE RPM VERTICAL | HORIZONTAL 900 189.428 447.713 120.814 ° 800 623.745 353.784 95.458 ° 100 477.555 270.839 73.085 ° 600 350.857 198.984 53.695 ° 1 1 1 ! 1 1 1 ! 1 | PRIMARY COUPLE ~ [Link]. SECONDARY COUPLE - [Link]. ENGINE RPM VERTICAL HORIZONTAL VERTICAL HORIZONTAL 900 1945844 1160.555 261.763 ° B00 1537.457 916.982 206.825 ° 700 1177.116 702.064 158.350 ° 600 864.820 515.802 116.339 ° ! 1 ! 1 1 | ! I ! 1 appr. GMC DF _209/1-89 Superior® and CisanBurn™ ace trademarks of Cooper Industie Copyright © Cooper Industries, nc. 1909SUPERIOR DUAL FUEL ENGINES PAGE 210 MODEL 40-GDX-8 MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN METRIC UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted, that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. SECONDARY FORCE ~ ki | } RPM | ‘VERTICAL HORIZONTAL || | VERTICAL © HORIZONTAL | | 1 | ! ' | 900 | 358.085 203.083 || 54.801 ° I goo | 282.931 160.476 || 43.300 ° | 700 | 216.619 122.853 || 33.151 ° I 600 | 159.149 90.259 || 24.356 ° | | Wh | SECONDARY COUPLE ~ [Link] | I | ENGINE | I I RPM | VERTICAL = HORIZONTAL || = VERTICAL = HORIZONTAL | | 1 m= ! a | 900 | 269.110 160.505 || 36.202 ° ! 800 I 212.630 126.819 || 28.604 ° I 700) =) 162.795 97.095 |] 21.900 ° 1 600 I 119.605 71.335 | 16.090 ° I I i | 9 $i) asax-SUPERIOR aper._ YMC DF 210/ Superior® and CieanBurn"™ are trademarks of Cooper Industrie, Ine Copyright © Cooper industries, Inc. 1989‘SUPERIOR DUAL FUEL ENGINES: MODEL 40-GDX-8 PAGE 213 | EXNAUST EMISSIONS MODEL = 40-GDX-8 (STANDARD WATER-COOLED EXHAUST MANIFOLD) RPM [eaceetes | OPERATING] #EMISSTONS (GRAMS/BHP-HRY [Loan | MODE, Nox co +=NMHC | 100 puaL FUEL | 93 | too | bieset +0 ® TONS PER YEAR = (GM/BHP-HR) x BHP + 1036 8 DENOTES NON-METHANE HYDROCARBONS wae FULL LOAD QUALIFYING CONDITIONS: 1) PIPELINE QUALITY GAS IS ASSUMED. METHANE CONTENT SHOULD BE GREATER THAN 90x WITH A LOW HEATING VALUE OF 900 BTU/SCF + 15% FOR FUEL GAS OUTSIDE THESE PARAMETERS AN INGIVIDUAL REVIEW WILL. BE REGUIRED TO DETERMINE EMISSION LEVELS AND FUEL CONSUMPTION RATES. 2) VALUES ARE BASED UPON 130" F MANIFOLD TEMPERATURE, <120° F INTERCOOLER WATER AND 100° F AMBIENT TEMPERATURE, REDUCED AIR MANIFOLD TEMPERATURES WILL RESULT IN LOWER NOx LEVELS, HIGHER AMBIENT TEMPERATURES WILL NOT AFFECT EMISSION LEVELS AT RATED LOAD AND SPEED BUT WILL CAUSE SLIGHTLY HIGHER NOx LEVELS AT REDUCED SPEEDS. DATA SHOWN ARE BASED ON ENGINE ADJUSTMENT FOR STANDARD BSFC. FULL SPEED EMISSION VALUES ARE VALID FOR ALTITUDES BELOW 4000 FT. HIGH ALTITUDE APPLICATIONS MAY REQUIRE TURBOCHARGER MODIFICATION ‘TO MAINTAIN EMISSION RATES, 4) WHEN NOx REQUIREMENTS LESS THAN THOSE EXPRESSED HERE ARE ENCOUNTERED, THERE ARE TRADE-OFFS BETWEEN NOx AND BSFC WHICH MAY BE APPLICABLE, BUT THESE MUST BE EVALUATED ON A SPECIFIC CASE BASIS. AJAX-SUPERIOR ROP. DE_213/1-90 ‘Superor® and CleanBurn™ are trademarks of Cooper industries, In, Copyright © Cooper ndusties, Inc. 1989SUPERIOR DUAL FUEL ENGINES MODEL 40-GDX-8 DEM PAGE 214 EXHAUST EMISSIONS MODEL : 40-GDX-8 DEM (ORY-TYPE EXHAUST MANIFOLD) RPM PERCENT J OPERATING] #EMISSIONS (GRAMS/BHP-HR) RATED ax LOAD MODE. NOx. co ee NMHC 900 100 DUAL_FUEL 93 5.0 1.50 900 100 DIESEL, 9.0 32 1.00 TONS PER YEAR = (GM/BHP-HR) x BHP + 1036 #8 DENOTES NON-METHANE HYDROCARBONS. wer FULL LOAD QUALIFYING CONDITIONS 1) PIPELINE QUALITY GAS IS ASSUMED. METHANE CONTENT SHOULD BE GREATER THAN 90x WITH A LOW HEATING VALUE OF 900 BTU/SCF = 15%. FOR FUEL GAS OUTSIDE THESE PARAMETERS AN INDIVIDUAL REVIEW WILL BE REQUIRED TO DETERMINE EMISSION LEVELS AND FUEL CONSUMPTION RATES. 2) VALUES ARE BASED UPON 130" F MANIFOLD TEMPERATURE, <120" F INTERCOOLER WATER AND 100" F AMBIENT TEMPERATURE. REDUCED AIR MANIFOLD TEMPERATURES WILL RESULT IN LOWER NOx LEVELS. HIGHER AMBIENT TEMPERATURES WILL NOT AFFECT EMISSION LEVELS AT RATED LOAD AND SPEED BUT WILL CAUSE SLIGHTLY HIGHER NOx LEVELS AT REDUCED SPEEDS. BD DATA SHOWN ARE BASED ON ENGINE [Link] FOR STANDARD BSFC. FULL SPEED EMISSION VALUES ARE VALID FOR ALTITUDES BELOW 4000 FT. HIGH ALTITUDE APPLICATIONS MAY REQUIRE TURBOCHARGER MODIFICATION TO MAINTAIN EMISSION RATES. 4) WAEN NOx REQUIREMENTS LESS THAN THOSE EXPRESSED HERE ARE ENCOUNTERED, THERE ARE TRADE-OFFS BETWEEN NOx AND BSFC WHICH MAY BE APPLICABLE, BUT THESE MUST BE EVALUATED ON A SPECIFIC CASE BASIS. J) AJAX-SUPERIOR appr Lite dls OF _214/1-90 ‘Superior? and CleanBurn™ are vademarks of Cooper Industtes, ne. ‘Copyright © Cooper industres, ine. 1989SUPERIOR DUAL FUEL ENGINE MODEL 40-GDX-8 PAGE 215 @ WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS 120 te es wel pl | TOESTGN. 7 ie FLows B *. 750 = PSsZ B so |e z * o feep PS = ZS 7 = [ENGINE PRESSURE e ° o 100 200 300 400 500 FLOW (GPM) IMPELLER P/N D-016-879 (STRAIGHT VANE? PUMP RPM = 2.4 X ENGINE RPM DIRECTION OF ROTATION (BI-DIRECTIONAL CAPABILITY) NORMALLY CW (FACING DRIVE END) NPSHg = 155 FEET @ 900 RPM & 300 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP ‘AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 300 GPM = 1100 FT~ 52.0 FT. = 58.0 FT. 58.0 FT. + 2.31 = 250 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. #4) asax-SUPERIOR appa SNC DF_215/1-89 ‘Superior® and CisanBurn™ are trademarks of Cooper Industries, nc ‘Copyright © Cooper Inausties, Inc. 1989SUPERIOR DUEL FUEL ENGINE MODEL 40-GDx-8 PAGE 216 WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS 140 [ENGINE RPM. 209. 130 120 {DESIGN 110 LOWS -S— 100 90 75 80 —— 70 60 600 50 40 TDH (FEET) = 10 = ENGINE. PRESSURE. o te= f pom ° 100 200 300 400 500 FLOW (GPM) IMPELLER P/N D-O33-655 (CURVED VANE) PUMP RPM = 2.4 X ENGINE RPM DIRECTION OF ROTATION (UNI-DIRECTIONAL CW (FACING DRIVE END) NPSHp = 9.0 FEET @ 900 RPM & 300 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 300 GPM = 120.0 FT. 52.0 FT. = 68.0 FT. 68.0 FT, + 2.31 = 29.5 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. AJAX-SUPERIOR popr. NC OF 216/1-89 Superior and CieanBurn"™ are trademarks of Cooper Indust, Ine. Copyrignt © Cooper Incustris, Inc. 1989SUPERIOR DUAL FUEL ENGINES MODEL 40-GDx-12 ENGINE SECTION INDEX Description Page No. Air Intake System 304 Bearing Dimensions 307 Cooling system 305 Dimensions and Weight 307 Engine Operating Data -Units In English Units 311 -Units In Metric Units 312 Engine Outline Drawing 319 Engine Performance 303 e Engine Specifications 301 Exhaust Emissions 313 Exhaust System 304 Fuel system 304 Heat Rejection Data Units In English Units 322 -Units In Metric Units 312 Lubrication System 306 Miscellaneous 308 Starting System 303 Turbocharger 304 Unbalanced Forces and Couples Units In English Units 309 -Units In Metric Units 310 Water Pump Characteristics -Jacket Water, Straight Vane 315 Jacket Water, Curved Vane 316 “Intercooler, Straight Vane 317 Intercooler, Curved Vane N/A AJAX-SUPERIORSUPERIOR DUAL FUEL ENGINES MODEL 40-GDX-12 PAGE 301 ENGINE SPECIFICATIONS Type Aspiration Cylinder Configuration Number of Cylinders Bore = in. Stroke - in. Displacement - cu. in. (mm) (am. (liter) Compression Ratio Power Rated - BHP (kW) Speed Rated - RPM Piston Speed — FPM(m/s) Speed Range ~- RPM Combustion Chamber Starting System Fuel system: Fuel Gas Fuel 0i1 Controls Governor Turbocharger Exhaust Manifold Jacket Water Pump Jacket Water Thermostat Intercooler Water Pump Intercooler Water Thermostat Lube 011 Pump Lube 0i1 Thermostat Prelube Pump Lube 0{1 Cooler Intercooler Crankcase Breather Crankcase Doors Direction of Rotation $1) AJAX-SUPERIOR Four (4)-Cycle Turbocharged, Intercooled vee Twelve (12) 10 (284) 10.80 (266.7) 9896 (162.20) 12.00 : 1 1650 (1230) 900 1575 (8.0) 900 - 600 Direct Injection Direct Air-to-Head Starting Puel Injected Individual Fuel Pumps and Injectors with Manual Priming Pump Air/Load Type Air-Puel Control with Dual-Fuel Switch Over Logic Electro-Hydraulic EGB-35P Actuator one(1) Water Cooled Built-In Centrifugal, Chain Driven Remote Mounted Built-In Centrifugal, Chain Driven Remote Mounted Gear Type with Pressure Regulating Valve Remote Mounted Manual, Mounted and Piped Shell & Tube Type, Remote Mounted Rectangular, Shell & Tube/Fin Type Positive Ventilation Pressure Relief (Bicera Type) Doors Counterclockwise From Flywheel End appr. (AMC ‘Superior® and Cieanturn™ are trademarks of Cooper Industrie, Ine. ‘Copytignt © Cooper inaustries, nc. 1889 DF 301/1-89J AJAX-SUPERIOR APPR SUPERIOR DUAL FUEL ENGINES MODEL 40-GDX-12 PERFORMANCE Engine Operating Data Rating Conditions Altitude ~Temperature Rated Torque Over 900-600 RPM Range Brake Mean Effective Pressure Rating/BMEP Rated Brake Specific Fuel Consumption/BSFC Heat Rejection Data Emissions STARTING AIR SYSTEM Consumption Rate Normal Starting Time Supply Air Pressure Air Start Valve Signal Pressure Air Inlet Connection Size AIR INTAKE SYSTEM Intake Air Flow Rate Max. Allowable Pressure Drop Air Intake, Inlet Connection PAGE 303 See Page 311 & 312 feet 4000 meter (1219 ) Deg F 90 Deg c (32.2) b-ft 9629 M-kg (1332 ) psi 146.7 kg/cm2 (10.3 ) See Page 311 & 312 See Page 311 & 312 See Page 313 scfm 600 liter/sec (283 ) 10 psi 250 kg/cm2 (ame psi 50-250 kg/cm2 — (3.5-17.6) 1-1/2 In. NPT See Page 311 & 312 In 420 10 mm H20 (254) 18 In. I.D. Flex Connector ‘Superior® and CieanBur™ aro wademarks of Cooper Industries, ne. Copyright © Cooper industries, nc. 1986 meSUPERIOR DUAL FUEL ENGINES PAGE 304 MODEL 40-GDX-12 FUEL SYSTEM Fuel 011 Required for Dual Fuel operation # 2 Diesel Fuel Fuel 0i1 Filters, Engine Mounted(Standard) -Type Duplex -Microns of Filtration Five(5) Fuel Oil Service Pump, Engine Mounted -Rated Flow GPM 3.2 liter/sec (0.20 ) “Maximum Vertical Lift on Suction side feet 10 neter (3.05 ) Required Fuel Gas Pressure to Engine psi 35-40 Based on Pipeline Quality Natural Gas kg/em2 — (2.5-2.8 ) (Regulated to within plus or minus 1 psig) Gas Inlet Flange Connection 2 In. 150 Lb. EXHAUST SYSTEM Max. Allowable Back Pressure In H20 10 mm H20 (| 254 ) Exhaust Outlet Flange Connection Size 18 In. 125 Lb. FF Exhaust Flow Rate See Page 311 & 312 Stack Temperature See Page 311 & 312 TURBOCHARGER Type Constant Pressure Manufacturer Cooper-Bessemer Model ET 13 Speed (Maximum) RPM 23000 (Gi) tax-surerion appr._(SN\C- DF 304/1-89 ‘Superior? and Cleantum™ ate trademarks of Cooper Industries, Inc. Copyright © Cooper ndustios, nc. 1989SUPERIOR DUAL FUEL ENGINES PAGE 305 MODEL 40-GDX-12 @ crossnc sysree Jacket Water Capacity - Engine Only Gallon 146 liter { 853) Jacket Water Pump “Jacket Water Outlet Temperature, Normal Deg F 165-180 Deg c (74-82 ) -Design Flow Rate at Rated Speed cpm 600 liter/sec (37.8 ) Available External Head: Straight Vane(Standard) psi 28 kg/om2 (1.97 ) Curved Vane(Optional) psi 22.8 kg/om2 (1.60 ) -Minimum NPSH Required: Straight Vane(Standard) feet 19 neter (5.79 ) Curved Vane(Optional) feet 12 meter (3.66 ) Intercooler Water Pump @ —intercooier Water iniet Temperature, Normal Deg F 120 Deg c (49.0 ) -Design Flow Rate at Rated speed GPM 140 iter/sec ( 8.8 ) Available External Head: Straight Vane(Standard) psi 7.5 kg/cm2 (0.83 ) Minimum NPSH Required: Straight Vane(Standard) feet 15 meter (4.87 ) Connection Sizes Jacket Water Inlet 6 In. 150 Lb. Jacket Water Outlet 6 In. 150 Lb. -Intercooler Water Inlet 4 In, 150 Lb. ~Intercooler Water Outlet 4 In. 150 Lb. Vent Line to Surge Tank,Minimum Size 3/8 In. Tubing “Surge Tank Return to Pump Inlet: Jacket Water 2 In. NPT Intercooler 2 In. NPT 9 #3) asax-SuPERIOR aper._ (3M OF 305/ ‘Suparior® and CleanBum"™ are ademarks of Cooper Industries, Ine Copyright © Cooper Industis, ne. 1960SUPERIOR DUAL FUEL ENGINES PAGE 306 MODEL 40-GDX-12 LUBRICATION SYSTEM Lube 0i1 Sump Capacity Gallon 165 liter ( 625 ) Lube 011 Consumption(Estimated) Gal. /Day 3.30 liter/Day (12.5 ) Lube 011 Pressure - Normal psi 35 kg/em2 (2.46 ) Temperature Out Of Engine - Normal Deg F 165-175 Deg c (74-80 ) Flow Rate Through 0i1 Filter GPM 70 liter/sec (4.42 ) Lube 041 Filters, Engine Mounted(Standard) ~Type Full Flow ~Microns of Filtration Fifteen(15) Connection Sizes -Lube 011] Sump Drain Plug 1-1/2 In. NPT -Lube 0i1 Inlet to Filter 3 In. NPT -Lube 011 Outlet to Cooler 3 In, NPT 2) asax-suPERIOR appr._G3N\CL DF 306/1-89 ‘Superior® and CleanBurr"™ are wademarks of Cooper Industies, Inc Copyright © Cooper industries, nc, 1989SUPERIOR DUAL FUEL ENGINES MODEL 40-GDX-12 BEARING DIMENSIONS Main Bearing, Split Shell -Diameter “Width -Quantity Crankpin Bearing, Split Shel] -Diameter ~Width -Quantity Wrist Pin Bearing -Diameter “Width ~Quantity Camshaft Bearing, Split Shell -Diameter “Width ~Quantity per Bank DIMENSIONS AND WEIGHT (APPROXIMATE) Overall Length Overall Width Overall Height Dry Weight | asax-SUPERIOR In In Nos. In In Nos. In In Nos. In mn In Nos. In In In Lb kg arer._ ANC ‘Superior? and Cle PAGE 307 8.00 ( 203.2 4.88 ( 224.0 1 6.38 (162.2 2.53 ( 64.3 3.50 (88.9 3.16 ( 80.3 12 2.75 (69.9 2.38 ( 60.5 185 ( 4699 93 ( 2362 112 ( 2845 43700 (19822 DF 307/1-89 Burn" are trademarks of Cooper Industries, Ic. Copyright © Cooper Industries, In. 1980SUPERIOR DUAL FUEL ENGINES PAGE 308 MODEL 40-GDX-12 MISCELLANEOUS Clearance Required to Remove Piston In 89 mn ( 2261 ) Heaviest Engine Parts (Approximate Weights) “cylinder Block Assembly Lb 10400 kg (4737 ) ~Cylinder Head Assembly Lb 250 kg (123) -Piston and Connecting Rod Assembly Lb 198 kg (90) Turbocharger Assembly Lb 1170 kg (531) ~Exhaust Manifold Lb 1210 kg (549) | $e) AJAX-SUPERIOR aper._G2MKC DE 308/1-89 ‘Superor® and Cleanurn™ are trademarks of Cooper Industrie, Ine Copyright © Cooper industries, Inc. 1989SUPERIOR DUAL FUEL ENGINES PAGE 309 MODEL 40-GDX-12 MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN ENGLISH UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un- balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. SECONDARY FORCE - Lb. ! tt | ENGINE | i I RPM | VERTICAL © HORIZONTAL || VERTICAL = HORIZONTAL | : i! goo | 954.174 126.105 |} 111.206 49.512 | goo | 753.915 573.713 || 87.866 39.121 | oo | 877.216 439.249 || 29.952 | 600 | 424.077 322.713 || 22.005 | | I | SECONDARY COUPLE - Lb. Ft ENGINE RPM VERTICAL © HORIZONTAL 900 2551.722 1957.595 800 2016.175 1546.742 212.397 94.566 100 1543.634 1184.224 162.616 12.402 600 1134.099 870.042 119.473 53.193 1 1 1 1 ! 1 1 1 I 1 I ! 268.815 119.685 ! 1 | | 1 ! ! I | AJAX-SUPERIOR aper._ N\C- OF 309/1-89 ‘Suporor® and CleanBurn™ are rademarks of Cooper Industries, ne. Copyright © Cooper industies, Ine. 1980SUPERIOR DUAL FUEL ENGINES PAGE 310 MODEL 40-GDX-12 MAXIMUM UNBALANCED FORCES AND COUPLES DUE TO MANUFACTURING TOLERANCES (IN METRIC UNITS) The following data are based on the assumption that engine components may be machined to a maximum and/or minimum permissible weight limit- ations, and that assembly may be made in such manner that maximum un— balanced forces or couples may be produced. It is to be noted,that an unbalanced assembly which produces a maximum unbalanced force tends to produce a minimum unbalanced couple or vice-versa. It is also to be noted, that these are maximum calculated values; standard assembly procedures will rarely produce such an extreme conditions and normal expectations should not exceed 50 percent of the calculated values. SECONDARY FORCE - k; ENGINE RPM VERTICAL | HORIZONTAL 1 800 341.976 260.236 39.856 17.745 700 261.825 199.243 30.515 13.586 600 192.361 146.383 22.419 9.981 i——----+-4-1 i 1 1 | 1 i 50.443 22.459 | 1 ! 1 1 ! 1 900} 432.813 329.36 1 1 1 | SECONDARY COUPLE - [Link] ! it 1 ENGINE | tt | RPM | ‘VERTICAL © HORIZONTAL || «VERTICAL = HORIZONTAL | 1 I ! 1 it} | 000) | | 352.903 270.735 |} 37.177 16.552 | B00 | 278.837 213.914 || 29.375 13.078 | 00 | 213.485 163.778 || 22.490 10,013 | 600 | 156.846 120.327 || 16.523 7.357 | 1 i 1 AJAX-SUPERIOR appr. SAC DF_310/1-89 ‘Superior® and CloanBun"™ are rademarks of Cooper Industries, Inc. Copyright © Cooper industries, Inc. 1988SUPERIOR DUAL FUEL ENGINES MODEL 40-GDX-12 PAGE S11 ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR 49-GDX-12 PERCENT] pyep [APM-OUAL FUEL MODE | RPM-DIESEL MODE RATED | esi [900 300 ie M0] 161] 1815 1815 ne too | 147 | 1650 1650 an 75 | 0 | 1238 1238 50 73_| ee! 825 SOC Tio] te. — = cowaern | 100 | 147 | 6850 0385 Funes | 75 | 110 | 7200 0390 uoeapapinl 50 73_| 8150 o.i2 Tio [Tet] 3850, 4480 IME MR FLOW | 400 | 147 | 3500 4075 en 75 | 110 | 2680 3250 50 73_| ‘950 2580 Tio} 181] 305 355 Se too | 147 | 278 320 75 | uo | 213 255 50 73_| 149 200 caste | too | tar | 70 730 AFTER THRBO- wea Teo” | 75 | 110 | 770 700 Gul 50 73 770 625 TI} Tet] 49300 31425 warnereron | 100 | 147 | 46200 47000 ie 7s | 110 | 38200 38200 50 73__| 31600 28200 Tio} tei] 6350 2950 Herteecrion | 100 | 147° | 6325 6750 ern 75 | 110 | S800 5990 50 73_| 5370 5500 110} Tet] 8940 12900 terrreeetion | 100 | 147 | 7340 11200 ee 75 | 110 | 3790 6190 50. 73_| i110 3150 NOTES 'D FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 3x TOLERANCE FOR FACTORY TESTS. D HEAT REJECTION DATA ARE BASED ON NOMINAL 18OF JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-21/9-88 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE. ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10% RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. ‘D INTERCOOLER HEAT REJECTION BASED ON NOMINAL’ 4000 FT. ALTITUDE. ® LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING 120F MAX, TO INTERCOOLER FOR RATED ENGINE PERFORMANCE. | FUEL CONSUMPTION CALCULATED PER DEMA. DIESEL BSFC CORRECTED TO LHV = 18190 BTU/LB. $3) AJaX-SUPERIOR pee Ne DF_311/1-89 ‘Superior® and ClesnBurn™ are trademarks of Cooper industries, ne. Copyright © Cooper industries, nc, 1988SUPERIOR DUAL FUEL ENGINES MODEL 40-GDx-12 ee ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR 48-GDX-12 PERCENT] EMEP [RPM-DUAL FUEL MODE] RPM-DIESEL MODE. RATED | (kg/em2) [9.09 300 BRAKE SPECIFIC 110 TTse | 1353 1353 ourPuT 100 10.34 | 1230 1230 a 15 174 | 923 923 50 13. |__615 615 BRAKE SPECIFIC 110 it — = FUEL CORSWETION| 100 10.34 | 2315 234 DFMODEGcCVAHR) 75, 7.74 | 2433 237 DIESELGhVE+RD 50. 813 | 2754 251 INTAKE AIR FLOW | 110 V1.3 133, 154 REQUIREMENT 100 10.34 121 140 gM) 15 774 92 112 50 7 8 AL 89 110 E 138 161 Ae flow 100 1034 | 126 145 15 71.14 97 16 50 5.13 68 91 Tse PxieSTaT 100 tose | ate 338 AFTER TURBO si 774 | 410 a a) 50 5.13 | __410 329, 110 11-32 | 12576 12960 JACKET WATER 100 10.34 | 11643 11845, HEAT REJECTION 75 7.74 | 9627 9627 cdl MND 50 5.13 | 7964 107 110 LE 1600 1752 LUBE ONL 100 10.34 | 1594 1701 HEAT RESECTION 5 7.74 | 1462 1510 eeaMto 0. 5.13 |_ 1355 1386 710) Tse |" 2253 251 INTERCOOLER 100 10.34 | 1850 2823 HEAT REJECTION 75 24 955 1560 (kcal MIND 50. 5.13 280 794 NOTES : 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 3% TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 82C JACKET WATER OUTLET TEMPERATURE. REFER TO GENERAL DATA SECTION, PAGE GEN-23/1-89 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE. ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS. SUBTRACT 10f RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. 3D INTERCOOLER HEAT REJECTION BASED ON NOMINAL 1200 M ALTITUDE. 4) LUBE OIL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING 50 MAX. TO INTERCOOLER FOR RATED ENGINE PERFORMANCE. '5) FUEL CONSUMPTION CALCULATED PER DENA DIESEL BSFC CORRECTED TO LHV = 10,106 kcal/kg AJAX-SUPERIOR APPR. BME Z OF 312/1-89 ‘Superior® and ClaanBucn"™ are trademarks of Cooper Industries, Ine. Copyright © Cooper industries, Inc. 1989SUPERIOR DUAL FUEL ENOINES MODEL 40-GDX-12 PAGE 313 e EXHAUST EMISSIONS MODEL = 40-GDX-12 RPM RATED OPERATING] *EMISSIONS (GRAMS/BHP-HR) LOAD MODE. NOx. co we NMHC 900 100 DUAL FUEL b2 23 1.95 900 100 DIESEL 10 1.5. 1.00 # TONS PER YEAR = (GM/BHP-HR) x BHP + 1036 #% DENOTES NON-METHANE HYDROCARBONS wx FULL LOAD = 146.7 BMEP QUALIFYING CONDITIONS: 1) PIPELINE QUALITY GAS 1S ASSUMED. METHANE CONTENT SHOULD BE GREATER THAN 90% WITH A LOW HEATING VALUE OF 900 BTU/SCF + 15% FOR FUEL GAS OUTSIDE THESE PARAMETERS AN INDIVIDUAL REVIEW WILL BE REQUIRED TO DETERMINE EMISSION LEVELS AND FUEL CONSUMPTION, RATES. 2) VALUES ARE BASED UPON 130" F MANIFOLD TEMPERATURE, <120" F INTERCOOLER WATER AND 100" F AMBIENT TEMPERATURE. REDUCED AIR MANIFOLD TEMPERATURES WILL RESULT IN LOWER NOx LEVELS. HIGHER AMBIENT TEMPERATURES WILL NOT AFFECT EMISSION LEVELS AT RATED LOAD AND SPEED BUT WILL CAUSE SLIGHTLY HIGHER NOx LEVELS AT REDUCED SPEEDS. 3D DATA SHOWN ARE BASED ON ENGINE ADJUSTMENT FOR STANDARD BSFC. FULL SPEED EMISSION VALUES ARE VALID FOR ALTITUDES BELOW 4000 FT. HIGH ALTITUDE APPLICATIONS MAY REQUIRE TURBOCHARGER MODIFICATION TO MAINTAIN EMISSION RATES. 4 WHEN NOx REQUIREMENTS LESS THAN THOSE EXPRESSED HERE ARE ENCOUNTERED, THERE ARE TRADE-OFFS BETWEEN NOx AND BSFC WHICH MAY BE APPLICABLE, BUT THESE MUST BE EVALUATED ON A SPECIFIC CASE BASIS. AJAX-SUPERIOR APPR. GBC Z DF 3135/1 Supetior® and CleanBuri™ are wademarks of Cooper Industrie, ine. Copyright © Coope, industries, nc. 1989SUPERIOR DUAL FUEL ENGINE, MODEL 40-GDx-12 PAGE 315 ® WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS 110 100 90 ENGINE_RPM i 900" 80 }—— DESIGN a FLOWS FET 750 Z 50 40 600 . DE_411/1-89 ‘Superior? and CleanBurs™ are vademarks of Cooper Industries, ne. Copyright © Cooper industries, Inc. 1988.SUPERIOR DUAL FUEL ENGINES MODEL 40-GDX-16 LG ENGINE OPERATING DATA AND HEAT REJECTION SUPERIOR 48-GDX-16 PERCENT] SMEP — [RPM-DUAL FUEL MODE] RPM-DIESEL MODE RATED | tkg/em2) G06 300 LOAD RAE SPECIFIC T10 TES 11805 1805 oureut 100 1034 | 1641 1641 cw 1s 7.74 | 1230 1230 10 S13. B20 820 BARE SPECIFIC | 110 Tie | — FUEL CONSWMPTION| — 100 10.34 | 2315 234 DF MODEGcaV HR] 75 7.74 | 2433 237 DIESEL(g/kW-HRD 50. 513 2754 1 INTAKE AIR FLOW | 110 Tse 1177 206 REQUIREMENT 100 1034 | 161 187 Gg/MIND 75 Lebs 123 149 0 $3 20 119 710 TT 186 213 i | 100 | (1034) 168 195 : 15 774 | 129 154 50. 5.13 31 120. 1132 EXHAUST TEMP. a ul ae ba 100 10. 416 388 ae 15 7.74 | 410 m7 aa 50 513 | 410 329 710 1132 | 16767 17281 | Jncher warcr 100 10.34 | 15524 15794 HEAT RESECTION 75 7:74 | 12835 Reese aco 50 5.13 | 40617 SATE 110 Th32 | 2135 2336 or 100 10.34 | 2124 2268 HEAT RESECTION 5 7.74 | i948 2014 {kcal MIND 50. 5.13 | ya04 ‘1847 110 1132 |~3004 4335 INTERCOOLER 100 1034 | 2467 3163 HEAT RESECTION 75 7741 4273 2079 Skcol/MIN) 50 5.13 373. 4058 NOTES = 1) FUEL CONSUMPTION BASED ON PIPELINE QUALITY FUEL AND ENGINE ADJUSTMENT FOR STANDARD EXHAUST EMISSION RATES, SUBJECT TO 43K TOLERANCE FOR FACTORY TESTS. 2) HEAT REJECTION DATA ARE BASED ON NOMINAL 82 JACKET WATER OUTLET TEMPERATURE, REFER TO GENERAL DATA SECTION, PAGE GEN-23/1-89 FOR HEAT REJECTION ADJUSTMENT FACTORS DUE TO HOT WATER SYSTEMS OR EBULLIENT COOLING. HEAT REJECTION DATA ARE AVERAGE VALUES AND WILL VARY WITH OPERATING CONDITIONS AND AMBIENT TEMPERATURE. ADD RESERVE FACTOR FOR SIZING COOLING SYSTEMS, SUBTRACT 10x RESERVE FACTOR TO COMPUTE RECOVERABLE HEAT. 3D INTERCOOLER HEAT REJECTION BASED ON NOMINAL 1200 M ALTITUDE. 4) LUBE OlL COOLER AND INTERCOOLER ARE IN A COMMON CIRCUIT REQUIRING 50 MAX. TO INTERCOOLER FOR RATED ENGINE PERFORMANCE. 5) FUEL CONSUMPTION CALCULATED PER DEMA. DIESEL BSFC CORRECTED TO LHV = 10,106 kcal/kg : | AJAX-SUPERIOR poor SOMC—_F aizsina9 Suporior* and CleanBurn" ar trademarks of Cooper Industies, Inc. Copyright © Cooper industies, nc. 1989SUPERIOR DUAL FUEL ENGINES MODEL 40-GDX-16 PAGE 413 e EXHAUST EMISSIONS MODEL = 40-GDX-16 Ben SESE, [OPERATING] «EMISSIONS _(ORANS/BHP-FRD LOAD. MODE NOx. co ae NMHC 900 100, DUAL FUEL 62 23 1.95 900 100, DIESEL 7.0 15, 1.00 TONS PER YEAR = (GM/BHP-HR) x BHP + 103.6 #* DENOTES NON-ME THANE HYDROCARBONS: we FULL LOAD = 146.7 BMEP QUALIFYING CONDITIONS: 1) PIPELINE QUALITY GAS IS ASSUMED. METHANE CONTENT SHOULD BE GREATER THAN 90x WITH A LOW HEATING VALUE OF 900 BTU/SCF & 184, FOR FUEL GAS OUTSIDE THESE PARAMETERS AN INDIVIDUAL REVIEW WILL BE REQUIRED TO DETERMINE EMISSION LEVELS AND FUEL CONSUMPTION RATES. 2) VALUES ARE BASED UPON 130" F MANIFOLD TEMPERATURE, <120" F INTERCOOLER WATER AND 100" F AMBIENT TEMPERATURE. REDUCED AIR MANIFOLD TEMPERATURES WILL RESULT IN LOWER NOx LEVELS. HIGHER AMBIENT TEMPERATURES WILL NOT AFFECT EMISSION LEVELS AT RATED LOAD AND SPEED BUT WILL CAUSE SLIGHTLY HIGHER NOx LEVELS AT REDUCED SPEEDS. 3 DATA SHOWN ARE BASED ON ENGINE [Link] FOR STANDARD BSFC. FULL SPEED EMISSION VALUES ARE VALID FOR ALTITUDES BELOW 4000 FT. HIGH ALTITUDE APPLICATIONS MAY REQUIRE TURBOCHARGER MODIFICATION TO MAINTAIN EMISSION RATES 4 WHEN NOx REQUIREMENTS LESS THAN THOSE EXPRESSED HERE ARE ENCOUNTERED, THERE ARE TRADE-OFFS BETWEEN NOx AND BSFC WHICH MAY BE APPLICABLE, BUT THESE MUST BE EVALUATED ON A SPECIFIC CASE BASIS. AJAX-SUPERIOR apr, A 3NC DF_413/1-89 ‘Superior® and CloanBurn™ are wademarks of Cooper Industries, nc. Copyright © Cooper industnes, nc. 1989SUPERIOR DUAL FUEL ENGINE MODEL 40-GDX-16 PAGE 415, WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND PRESSURE DROPS 110 100 ENGINE_RPM Phe 0 ‘900 1 80 DESIGN 70 FLOWS zZ f 60 750 Ir TDH (FEET) 8s lo. r / 30 = 20 a-— > eC ENGINE PRESSURE 10 aa i= prop ° a e 0 400 600 800 900 FLOW (GPM) IMPELLER P/N D-O24-003 (STRAIGHT VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (BI-DIRECTIONAL CAPABILITY) NORMALLY C.C.W (FACING DRIVE END) NPSHp = 20.0 FEET @ 900 RPM & 750 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 750 GPM = 97.0 FT. ~ 30.0 FT. = 670 FT. 67.0 FT. + 2.31 = 29.0 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. $4) aJax-SUPERIOR pppr “ONC DF_415/1-89 ‘Superior? and CleanBurn™ are trademarks of Cooper Indus Copyright © Cooper industries, inc. 1989SUPERIOR DUAL FUEL ENGINE MODEL 40-GDXx-16 PAGE 416 WATER PUMP CHARACTERISTICS JACKET WATER COOLING SYSTEM DESIGN FLOWS AND. PRESS RE_DROPS 110 | Prepare oa ee ~ 80 DEsia < ty 70 FLOWS 7 eo aS SS, B wo Llp Z 30 Z| 2 20 aa 0 === [ENGINE PRESSURE —} ° = DROP, ' 0 200 40 600 ado 900 FLOW (GPM) IMPELLER P/N D-O33-744~002 (CURVED VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (UNIDIRECTIONAL) C.C.W (FACING DRIVE END) NPSHp = 14.0 FEET @ 900 RPM & 750 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 750 GPM = 80.0 FT- 30.0 FT. = 500 FT. 50.0 FT. + 231 = 22.0 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. AJAX-SUPERIOR seen SAMC DEA IGHISEY, -Supetion” and CieanBurn™ are trademarks of Cooper industries, In. Copyright © Cooper industries, Inc. 1989e SUPERIOR DUAL FUEL ENGINE MODEL 40-GDX-16 PAGE 417 WATER PUMP CHARACTERISTICS INTERCOOLER WATER SYSTEM DESIGN FLOWS AND PRESSURE DROPS 60 ENGINE. RPM 7 900 eG 750 =z 04 a © 20 t 600 0 Z i -—— eo] SS _ENGINE PRESSURE] ° 4—_--— DROP ° 50 100 ' 150 200 FLOW (GPM) IMPELLER P/N C-026-377 (STRAIGHT VANE) PUMP RPM = 1.788 X ENGINE RPM DIRECTION OF ROTATION (BI-DIRECTIONAL CAPABILITY) NORMALLY C.C.W (FACING DRIVE END) NPSHp = 15.0 FEET @ 900 RPM & 140 GPM EXTERNAL HEAD = THE DIFFERENCE BETWEEN THE SYSTEM PRESSURE DROP AND THE ENGINE PRESSURE DROP AT THAT FLOWRATE. FOR EXAMPLE: EXTERNAL HEAD FOR THE 900 RPM DESIGN FLOWRATE OF 140 GPM = 45.0 FT 27.7 FT. = 173 FT. 17.3 FT. + 2.31 = 7.5 PSI ENGINE PRESSURE DROP INCLUDES ALL SUPERIOR SUPPLIED COMPONENTS. AJAX-SUPERIOR appr BNC OF 417/1-89 ‘Superior® and Cleantum"™ are trademarks of Cooper Industrle, Ine. Copyright © Cooper industes, nc. 1989