The following slides were presented by Bert

Browning, Mgr. PD&E, Centek Industries at

IBEX 2010 during his ABYC Seminar entitled
“Exhaust System Design and Testing”.
We hope you enjoy the presentation and will
not hesitate to contact us if you have any
questions or if we may be of assistance on
your next project.
Exhaust System Design and Testing
IBEX 2010, [ABYC] Session 408
Bert Browning, Manager PD&E
Centek Industries
Exhaust systems

“All exhaust systems are designed and installed on

internal combustion engines for one primary
purpose; to conduct the products of the
combustion process from the engine to a point at
the extremity of the vessel without harm to the
engine, vessel or personnel.”
-John R. Ford
(Godfather of wet marine exhaust)

3
Topics for Discussion

• Design Considerations
• Design Advancements
• Design/System Selection
• Installation Standards, Rules and Guidelines
• Case Studies
• System Testing
• Results/Conclusion

4
Design Considerations
Material Options
• Metal • Plastic
– Used for both dry and – Wet exhaust only
wet exhaust – Low strength and
– Hi strength and temperature tolerance
temperature tolerances – Light weight
– Heavy – Non-corrosive
– Corrosive and non- – Cost effective
corrosive options
– Costly

5
Design Considerations (cont.)
Material Options

• Composite
– Wet exhaust only
– Fiber-Reinforced Polymer (Fiberglass)
– Carbon-Fiber Reinforced Polymer
– Wide range of design strength and temperature
tolerances
– Light weight
– Non-corrosive
– Cost effective

6
Design Considerations (cont.)

• Exhaust System Considerations

– Dry exhaust
• Must be metal
– Wet exhaust
• Can be either metal, composite or plastic
– Use highest temperature rated products available

7
Design Considerations (cont.)
The importance of temperature ratings

8
Design Considerations (cont.)
• Vessel and Sound Directives and Initiatives
– CE – Recreational Craft Directive (RCD)
• Pass-by test @ 75ft(25m): single engine - 75dB(A) or twin
engine - up to 78dB(A)
• Standards and Safety
– ABYC, ABS, Lloyd’s
– UL 94V, Test for Flammability of Plastic Materials
– Carbon Monoxide (ABYC, Standards and Technical
Information Reports for Small Craft, TH-22 and TH-23)

9
Design Advancements, Metal
• Past
– Custom designs difficult, required test fits
– Mild steel, cast iron, low grade stainless
– Diffuser/spray head best guess
– Insulation blankets
– Connection with pipe flanges; heavy, critical bolt
locations on replacement components

10
Design Advancements, Metal
(cont.)

11
Design Advancements, Metal
(cont.)
• Present
– Custom design seamless with CAD and modeling
– 316L standard, option of 25-6MO (high nickel
content)
– Diffuser/spray head calculated
– Insulation hardcoat
– Connection with marmon flanges; lighter, no hole
orientation issues, assembled with v-bland clamps

12
Design Advancements, Metal
(cont.)

13
Design Advancements, Composite

• Past • Present
– Resins
– Resins • Non-petroleum based
• 100% petroleum based • Renewable resources
• high styrene content • Low styrene content
– E-Glass • Higher corrosion
resistance
• Higher temperature
ratings
– ECR-Glass,
Carbon/Graphite,
Aramid (Kevlar)
– Laminate structure

14
Design/System Selection
• CONSULT WITH THE EXPERTS OF EXHAUST
SYSTEMS
– Registered engineering firm
• 3D Modeling
– Ease of communication between builder and exhaust
supplier
– More feasible custom design
– AutoCAD, SolidWorks, Pro/E, Rhino, Unigraphics
– Make certain of compatibility with vendor
– The right fit, the first time
• Almost anything is possible

15
Design/System Selection (cont.)

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Design/System Selection (cont.)
• Engine location relative to waterline
• Hull Type
– Planing
• Engine location above waterline
– Inline muffler exhaust
– Waterlift muffler exhaust
– Waterlift muffler and gas/water separator
– Muffler/gas/water separation combination unit
– Underwater exhaust (widely used in semi-displacement hulls)
– Displacement
• Engine location below waterline
– Waterlift muffler exhaust
– Waterlift muffler and gas/water separator

17
Design/System Selection (cont.)

• System Sizing
– Necessary for engine efficiency and vessel design
parameters
• Cleaner operation (fewer combustion byproducts)
• Achieve rated power and rpm
• Maximum fuel economy
– Not all engines are the same
– Proper sizing based on engine operating parameters
• Exhaust gas flow
• Allowed backpressure
• Raw cooling water flow
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Design/System Selection (cont.)

• Available space & desired exhaust noise

attenuation
– Maximum muffler volume = maximum possible
exhaust noise attenuation

19
Installation Standards, Rules and
Guidelines
• Prevent water intrusion back to the engine (ABYC P-1:
1.5.11 & 1.5.13)
• Isolate and Support exhaust components (ABYC P-1:
1.5.8)
– Minimize transmission of engine/mechanical noise to
superstructure
– Minimize risk of failure from vibration, shock, expansion and
contraction
– NEVER rigidly fix composite exhaust components at more than
one point
• Provision to drain components (ABYC P-1: 1.5.14)
– Minimize damage from freezing water or chemical action when
out of service
– Use gravity to your advantage
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Installation Standards, Rules and
Guidelines (cont.)
• Surface temperature < 200F (ABYC P-1: 1.5.10)
• Separate exhaust terminus for each engine and
generator (ABYC P-1: 1.5.7)
• Gas tight to hull exterior (ABYC P-1: 1.5.1 & 1.5.4)
• Double clamp all hose connections (ABYC P-1:
1.7.1.10.1)
• Muffler volume large enough to retain engine cooling
water and prevent backing up into the engine (ABYC P-
1: 1.7.2.4)

21
Installation Standards, Rules and
Guidelines (cont.)
• Sailboats, waterlift installed as near to centerline as
possible and as direct as possible to high point near to
centerline (ABYC P-1: 1.7.2.2)
• Seacock must be installed on dewatered system with
drain below waterline (ABYC P-1: 1.7.2.4)
• Carbon Monoxide, exhaust terminus should be located
either
– Hull side near hull side and transom intersection
– Transom as far outboard of centerline as practicable
– Bottom of the boat, OR
– Above highest occupied deck and its weather enclosure/cover
(ABYC P-1: 1.5.2, TH-22 & TH-23)

22
Case Studies
• CASE STUDY #1
– Application:
• 65ft Workboat with twin DDA Series 60 600hp
– Requirements/Constraints:
• Engine below waterline
• Dry exhaust
• Quiet but no sound directives applied
– Solution:
• Could use either wet or dry exhaust
• Customer requests dry exhaust
• Ø6.63” exhaust

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Case Studies (cont.)
Case Study #1

Courtesy of ABYC P-1 24

FIGURE 4
Case Studies (cont.)

• CASE STUDY #2
– Application:
• 86ft Sportfish with twin MTU 16V2000M93 2400hp
– Requirements/Constraints:
• Engine above waterline
• Available space is minimal
• Quiet but no sound directives apply
– Solution:
• Could use either inline, waterlift or muffler/gas/water
separation combination unit
• Due to space constraints, inline muffler
• Simple path to terminus
• Ø18” exhaust
25
 Case Studies (cont.)
Case Study # 2

Double Clamps Inline Muffler Surge Chamber Insulated Surfaces

Above WL
terminus

26
Case Studies (cont.)
• CASE STUDY #3
– Application:
• 43ft Cruiser/Sportfish with twin Cummins QSM11 670hp
– Requirements/Constraints:
• Engine above waterline
• Adequate space available to house large muffler inside
engine compartment
• Quietest possible solution and need to pass exhaust noise
initiatives (less than 75dB(A) on 75ft pass by)
– Solution:
• Could use either inline, waterlift or muffler/gas/water
separation combination unit
• Customized dual chambered waterlift muffler
• Ø8”In-Ø10”Out exhaust 27
 Case Studies (cont.)
Case Study # 3

Dual Chambered
Waterlift Muffler
(above WL option)

Above WL
terminus

28
Case Studies (cont.)

• CASE STUDY #4
– Application:
• 54ft Trawler with single Cummins QSM11 670hp
– Requirements/Constraints:
• Engine below waterline
• Sufficient space inside engine compartment
• Quiet but no sound directives apply
– Solution:
• Must utilize waterlift muffler
• Simple path to terminus
• Ø8” exhaust
29
 Case Studies (cont.)
Case Study # 4
High point “Loop” Waterlift Muffler, Anti-Siphon Valve
low point

Above WL
terminus

30
Case Studies (cont.)

• CASE STUDY #5
– Application:
• 70ft Sailing Yacht with single Yanmar 4JH3-DTE 125hp
– Requirements/Constraints:
• Engine below waterline; sailboat guidelines apply
• Sufficient space inside engine compartment
• Quiet but no sound directives apply
• Long exhaust run
– Solution:
• Must utilize waterlift muffler
• Simple path to terminus, but long run
• Ø4” exhaust
31
 Case Studies (cont.)
Case Study # 5
High point “Loop” Waterlift Muffler Anti-Siphon Valve
near longitudinal near longitudinal
centerline centerline, low
point

Above WL
terminus

32
Case Studies (cont.)
• CASE STUDY #6
– Application:
• 54ft Trawler with Northern Lights M864K 25kW
– Requirements/Constraints:
• Generator partially below waterline
• Sufficient space inside engine compartment
• Quietest option for generator night operation but no sound
directives apply
– Solution:
• Must utilize waterlift muffler, addition of water/gas
separation unit
• Simple path to terminus
• Ø2.5” exhaust 33
Case Studies (cont.)
Case Study # 6
Gas/Water Separator, Waterlift Muffler
high point

Above WL
dewatered
gas terminus

Below WL
raw water
terminus
34
Case Studies (cont.)
• CASE STUDY #7
– Application:
• 100ft Houseboat with Westerbeke 20kW (Gasoline)
– Requirements/Constraints:
• Generator above waterline
• Sufficient space inside engine compartment
• Quietest option for generator operation but no sound
directives apply
– Solution:
• Design for CO safety
• Customized muffler/gas/water separation combination unit,
Ø2”In/Out-Ø1.5”Drain exhaust with stack dewatered gas
discharge
• Simple path to terminus 35
Case Studies (cont.)
Case Study # 7

Courtesy of ABYC P-1 36

FIGURE 6B
Case Studies (cont.)
• CASE STUDY #8
– Application:
• 135ft M/Y with twin CAT C32 1100hp
– Requirements/Constraints:
• Engine above waterline
• Request Underwater exhaust discharge
• Adequate space available to house large muffler inside
engine compartment
• Quietest and cleanest possible solution
– Solution:
• Could use either inline, waterlift or muffler/gas/water
separation combination unit
• Ø12”In/Out – 6”Bypass/Relief with additional resonator on
relief 37
 Case Studies (cont.)
Case Study # 8
Resonator, relief Underwater muffler,
(vertical option)

Above WL
relief
terminus

Below WL
exhaust
terminus with 38
deflector
Testing
• Dynamometer (Pre-build)
– Facilitated by builder in conjunction with engine
supplier and exhaust supplier
– Allows developmental testing prior to build/sea-trial
• Duplicate planned system layout
• Test various muffler designs
• Obtain actual exhaust noise data
• Obtain backpressure results and resolve any concerns
• Total system backpressure
– Limits set by engine manufacturer
– Measure at designated port on turbo flange or 1”
after turbo flange
– Culmination of ALL components and piping in the
exhaust system from the turbo/manifold to the
terminus 39
Testing (cont.)
• Typical causes of elevated system backpressure
– Improperly sized system
– Too many sharp bends
– Improper terminus position
• Hull side terminus where wave pattern blocks terminus
• Hull bottom with no relief line/port
• Determining problematic components/sections to
system backpressure
– Utilize multiple backpressure test points
• Record pressure drop between components/bends in the
system
• Correcting system backpressure issues
– CONSULT WITH THE EXPERTS OF EXHAUST
SYSTEMS 40
Results/Conclusion

• A properly designed exhaust system will add

value to the builder and bring more enjoyment
to the owner
• The difference is night and day

Functional Highly customized

exhaust exhaust 41
References
• ABYC, Standards and Technical Information Reports for
Small Craft, Section P-1, www.abycinc.org
• Centek Industries, Inc., www.centekindustries.com
• DeAngelo Marine Exhaust, www.deangelomarine.com
• Manuflex Limited, www.manuflex.co.uk
• Metcalf Marine Exhaust, www.mmxhaust.com
• Owens Corning, www.owenscorning.com
• Ashland, www.ashland.com

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Contact Information

Bert Browning, Mgr. PD&E,

Centek Industries, Inc
browning@centekindustries.com
(229) 228-7653

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