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Specifications
MTU Fluids and Lubricants Specifications for Series 4000 Gas
A001067/00E
2015 MTU Onsite Energy GmbH, Augsburg
The original document was created in the German language.
This publication including all of its parts is protected by copyright. Each instance of use requires the prior written con-
sent of MTU Onsite Energy GmbH. This applies in particular to duplication, dissemination, editing, translation, microfilm-
ing, and storage and/or processing in electronic systems, including databases and online services.
All of the information presented in this publication was current and up-to-date at the time of publishing. MTU Onsite
Energy GmbH reserves the right to make changes to, delete, or supplement the provided information and data as need-
ed.
Table of Contents
1 Confirmation for Fluids and Lubricants 6.2 Requirements imposed on heating water up
to 100 C 30
1.1 Confirmation by the operator 4 6.3 Requirements imposed on heating water
above 100 C 31
2 Preface
2.1 General information 5 7 Lubricating Oil
7.1 General information 32
3 Liquid Fuels 7.2 Approved lubricating oils 33
3.1 General information 7 7.3 Lubricating oil change intervals 34
3.2 Natural gas 10
3.3 Biogas 13 8 Transmission oils
8.1 General information 36
4 Inlet Air and Combustion Air
4.1 General information 18 9 Exhaust Condensate
9.1 General information 37
5 Coolants
5.1 General information 19 10 Appendix A
5.2 Requirements imposed on engine coolant 20 10.1 Abbreviations 38
5.3 Requirements imposed on mixture coolant 21 10.2 Conversion table of SI units 39
5.4 Requirements for the quality of water for 10.3 MTU Onsite Energy contact person / service
the gas sequential heater 22 partner 40
5.5 Requirements for the quality of water for
the gas cooler and gas sequential heater 23
11 Appendix B
5.6 Treatment with corrosion inhibitor /
antifreeze 24 11.1 Index 41
5.7 Approved corrosion inhibitors / antifreezes 25
6 Heating Water
6.1 General information 29
DCL-ID: 0000032648 - 001
Plant description:
Customer:
Operator:
We hereby confirm that the quality of the fluids and lubricants (coolant, gas, lubricating oil, heating wa-
ter, etc., where applicable) conforms to the Fluids and Lubricants Specifications of MTU Onsite Energy.
MTU Onsite Energy does not provide any warranty for damage incurred as a result of deviating fluid and
lubricant quality.
City / date
Note:
A note indicates whether special attention is required when executing a task.
The customer must comply with the instructions specified in the safety data sheets of the re-
spective manufacturers.
http://www.mtu-online.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation
If you have further queries, please contact your MTU representative.
Warranty
Use of the approved fluids and lubricants, either under the brand name or in accordance with the speci-
fications given in this publication, constitutes part of the warranty conditions.
The supplier of the fluids and lubricants is responsible for the worldwide standard quality of the named
products.
These regulations are contained in the manufacturers' instructions, legal requirements and technical
guidelines valid in the individual countries. Since there can be major differences from country to coun-
try, it is not possible to provide a universally applicable statement on the rules to be observed within
the framework of these Fluids and Lubricants Specification.
Users of the products named in these specifications are therefore obliged to inform themselves of the
locally valid regulations. MTU accepts no liability whatsoever for improper or illegal use of the fluids and
lubricants that it approves.
When handling fluids and lubricants the "Rules for the protection of the environment (see Safety Regula-
tions, Disassembly and Disposal)" are to be adhered to, since they are hazardous to health and flamma-
ble.
Incorrect use of fluids and lubricants causes environmental pollution.
Fluids and lubricants must not enter the ground or the sewerage system.
Used fluids and lubricants must be disposed of through used oil recycling or hazardous waste dispos-
al.
Used filter elements and cartridges must be disposed of with hazardous waste.
The customer / operator bears the responsibility for adhering to the fuel values.
Preservation
All information concerning corrosion protection, reapplication of corrosion inhibitors and removal of
corrosion inhibitors, including the approved corrosion inhibitors is provided in the MTU Corrosion Inhibi-
tor and Subsequent Application of Corrosion inhibitor Guidelines. The latest version is also available at:
http://www.mtu-online.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation
CAUTION
Harmful substances / contamination in the fuel
Long-term damage due to corrosion
It must be ensured that no corrosive compounds (e.g. siloxane, phosphor, arsenic, heavy metal,
sulfur, ammonia, chlorine, fluorine, bromine, iodine compounds) enter the fuel lines. Or their lim-
it values must not be exceeded. Exceeding the limit values voids the warranty.
CAUTION
Harmful substances / contamination in the intake air
Long-term damage due to corrosion
It must be ensured that no corrosive compounds (e.g. siloxane, phosphor, arsenic, heavy metal,
sulfur, ammonia, chlorine, fluorine, bromine, iodine compounds) enter the intake air. Or their
limit values must not be exceeded. Exceeding the limit values voids the warranty.
CAUTION
Harmful substances / contamination in the exhaust gas
Long-term damage due to corrosion
It must be ensured that no metal such as iron, nickel, chromium, copper, zinc and tin enters the
exhaust gas system / catalytic converter. If the cumulative quantity of these metals together
with the heavy metals exceeds the total limit value of 350 g/m3 of the catalytic converter space
volume, this voids the warranty of the catalytic converter.
CAUTION
Exceeding the temperature in the exhaust gas system
Damage / destruction of the catalytic converter
It must be ensured that the maximum operating temperature of 600 C is not exceeded. Ex-
ceeding the limit values voids the warranty.
It is essential to make sure - at the latest prior to commissioning - by consulting the relevant gas supply
company that the minimum methane number specified in the respective data sheet and the calorific
value range are observed. It is also necessary here to inquire about the temporary admixture of butane-
or propane-air mixtures.
The fuel must be technically free of mist, dust and liquid. Condensation in the gas system is to be pre-
vented by suitable measures (dehumidification, protection against cooling down, heating, etc.). Corro-
sive constituents may only be present in the concentrations set out below.
TIM-ID: 0000061505 - 001
Silicone compounds in the gas lead to deposits and promote wear. Even catalytic converters are deacti-
vated by these compounds. Damage caused by silicon compounds is not covered by the warranty.
If the quality of the raw gas exceeds the sulfur limit values, a gas desulferization system that is de-
signed for the quality of the gas must be installed.
If these limit values are exceeded in operation, for exhaust heat use a stronger formation of corrosive
deposits occurs. This requires an earlier cleaning of the exhaust gas heat exchanger.
With the non-stainless steel formaldehyde-optimized MTU special oxidizing catalytic converter, opera-
tion without fine desulfurization is admissible when adhering to the specified sulfur components in the
fuel.
MTU Onsite Energy excludes silicon-related engine and catalytic converter damage from the
warranty.
For operation with gases that contain silicon you must pay explicit attention to the silicon content in the
oil. For this the silicon operating value SiB must be calculated using the formula cited. The limit value for
this is 0.01. If this limit value is exceeded, the engine will be operated outside of the fuel guideline,
which voids the warranty. More detailed information is provided in the chapter Fuels (natural gas / bio-
gas), fuels for gas engines.
Compliance with the SiB must be seamlessly verified by the operator's analyses.
Example:
Delta Si between oil analysis A and B 20 ppm (mg/kg)
Oil fill quantity in circulation 800 dm3
Topped up oil quantity 200 dm3
Generated electrical work between oil analysis A and B 2000000 kWh
At the silicon limit values SiBG a distinction is made between operation with or without catalytic exhaust
cleaning.
SiBG
With catalytic exhaust gas cleaning 0
TIM-ID: 0000061505 - 001
Table 5: Silicon operating limit values SiBG for for different operating modes.
Silicon operating limit values SiBG for for different operating modes.
Experience has shown that for the required use of oxidation catalytic converters, the impossibility of
verification must be requested (Si B = 0).
Nevertheless, due to the high sensitivity of the catalytic converter, premature activity loss can occur,
particularly at formaldehyde conversion.
In this case the findings of the manufacturer of the catalytic converter are authoritative.
8 | Liquid Fuels | A001067/00E 2015-06
Determination of the silicon proportion in the fuel gas from the gas analysis
The measured concentrations of the individual compounds are multiplied by the Si mass fractions and
the atomic silicon content is determined.
The result is based on the calorific value of the fuel gas and standardized at 10 kWh energy content
(equals 1 m3 NTP. CH4).
Table 6: Calculation of the silicon proportion in the fuel gas from the gas analysis
Example:
10 (kWh/m3NTP)
K Si (mg/m3NTP) x
Hu (kWh/m3NTP)
KSi10 kWh =
10 (kWh/m3NTP)
Hu (kWh/m3NTP) x
Hu (kWh/m3NTP)
10 (kWh/m3NTP)
K Si (mg/m3NTP) x
Hu (kWh/m3NTP)
KSi10 kWh =
10 kWh/m3NTP
10
5.1 (mg/m3NTP) x
6.5
KSi10 kWh =
10 kWh/m3NTP
7.8 mg
KSi10 kWh =
10 kWh
TIM-ID: 0000061505 - 001
max. relative mois- g/kg < 20 ers carrying fuel gas and fuel gas-air
ture in gas, abso- mixtures.
lute
Oils / oil fumes mg/m NTP < 0.4 No condensation in lines carrying fuel
(HC with carbon gas and fuel gas-air mixture, nor for-
number >5) mation of condensable oil mists
Long-chain hydro- mewl % No information Consultation with MTU necessary.
carbons (C6 - CK)
HC solvent vapors mg/m NTP 0 Consultation with manufacturer and
analysis necessary
Table 8: Requirements and site conditions for natural gas fuel and the corresponding fuel supply
* = For engines with exhaust after-treatment and/or exhaust gas heat recovery, lower limit values may
apply. When using oxidizing catalytic converters; analysis and consultation with MTU are required.
The limit values refer to a calorific value of 10 kWh/m3 NTP. This corresponds to a references to fuels
with 100 % by vol. methane, or the existence of other combustible components in the fuel with the
same energy equivalent and the same input of hazardous materials.
Example:
TIM-ID: 0000051849 - 001
Russian natural gas with a calorific value of 10 kWh/m3 N is used. The permissible value for total sulfur
in the gas thus corresponds exactly to the limit value specified in the table.
When using a gas with the example of East Hanover with Hu = 8.15 kWh/m3 NTP the permissible maxi-
mum value for the total sulfur is calculated as:
Permissible total sulfur content = 30 mg/m NTP (8.15 kWh/m3NTP. : 10.0 kWh/m3 NTP) = 24.5 mg/
m NTP.
No warranty is given in the event of impairment and / or damage (corrosion, contamination
etc.) resulting from gases or materials the presence of which was unknown and not agreed
upon on conclusion of contract.
Table 9: Main ingredients of fuel gases of biogenic origin, mainly from fermentation processes
Table 10: Typical condition of fuel gases of biogenic origin, mainly from fermentation processes (in
accordance with DVGW Worksheet - G262)
* = These values are recommended values for series 4000 engines, for engines with exhaust after-treat-
ment, lower limit values can apply.
When using the series 4000 in gensets, with and without exhaust heat coupling and/or exhaust after-
treatment systems, the respective instructions provided by the genset manufacturer must be complied
with.
The limit values refer to a calorific value of 10 kWh/m3 NTP. This corresponds to a reference to fuels
with 100 % by vol. methane, or the existence of other combustible components in the fuel with the
same energy equivalent and the same input of hazardous materials.
Example:
When using a gas with the example of northern Germany with Hu = 5,18 kWh/m3 NTP. (The admissible
maximum value for the total sulfur is calculated as: Permissible total sulfur content = 800 mg/m3 NTP.
(5.18 kWh/m3 NTP : 10.0 kWh/m3 NTP) = 414.4 mg/m3 NTP
There is no warranty in case of impairments and / or damages (corrosion, contamination, etc.) that are
caused by gases or substances whose existence was not known or agreed upon at the time of signing
the contract.
Depending on the application, the following maximum permissible pollutant concentrations in the fuel
TIM-ID: 0000051850 - 001
When operating the plant in swimming pool facilities or in the vicinity of refrigerating installations, it is
important to bear in mind that even small traces of halogen compounds (chlorine, fluorine) in the intake
air may cause corrosion in the engine or on peripheral components (e.g. on electric motors). It must
likewise be noted that even cleaning agents may also contain aggressive substances that encourage
corrosion.
The input in the engine in total (fuel and air) must not exceed the limit values specified under fuels.
In case of doubt, MTU Onsite Energy, Augsburg, is to be consulted.
Coolant definition
Coolant = coolant additive (concentrate) + freshwater in the specified mixing ratio ready for use in the
engine.
TIM-ID: 0000051961 - 001
For the engine coolant system, it is imperative to use filling and top-up water which complies with the
following stipulations and which has been premixed with approved corrosion inhibitor/antifreeze:
For the engine coolant system, it is imperative to use filling and top-up water which complies with the
following stipulations and which has been premixed with approved corrosion inhibitor/antifreeze:
Table 14: Requirements for the quality of water for the gas sequential heater
The operator must specially prepare and monitor the initial water and the filling and top-up water. As
filling and top-up water, low-salt water or desalinated water (e.g. permeate) or faultless condensate
must be used.
The cold-water system and the sequential circuit may only be filled with the antifreeze Antifrogen N
from the company Hoechst AG.
We recommend (bearing in mind the VdTV instructions TCh 1466) adherence to the following require-
ments for a low-salt operating mode:
Table 15: Requirements for the quality of water for the gas cooler and gas sequential heater
TIM-ID: 0000052024 - 001
Add antifreeze to the water with a concentration of at least 40 % by volume when antifreeze protection
to minus 25 C is sufficient. If lower ambient temperatures are expected, increase the concentration
accordingly, but do not under any circumstances increase to values in excess of 50 % by volume. Mix-
tures containing a proportion of antifreeze below 40 % by volume do not guarantee adequate corrosion
protection.
Use the treated water in both summer and winter operation. Compensate for coolant losses in such a
way as to maintain the antifreeze concentration.
Check the concentration at regular intervals in accordance with the maintenance schedule. The coolant
should be checked at least once a year or at each filling. Due to antifreeze aging, change the coolant
after 9,000 operating hours or at the latest after, see Table 5.7.
Premix (45 %)
Castrol Castrol Radicool NF Pre- 9000 / 5
mix (45 %)
CCI Corporation L415 (50 %) 9000 / 3
CCI Manufacturing IL C521 (50 %) 9000 / 3
Corporation
Detroit Diesel Corp. Power Cool Plus Predilut- 9000 / 3
ed Coolant (50 / 50)
Supplementary notes
It is pointed out as a precaution that generally costs for foreseeable damage, e.g. by unsuitable water
quality, are not absorbed by machine breakdown insurance either.
The term "Sum total, alkaline earths" refers to the content of hardness-forming, dissolved calcium and
magnesium salts. To convert to the former standard unit of measurement of "Total hardness", the fol-
lowing applies:
1 mol/m 3 = 5.6 dH
The pH value is a measure of the acidity or alkalinity of a solution.
pH = 7 neutral, < 7 acid, > 7 alkaline.
Max. permissible fluctuation of the heating water inlet temperature: Max. 3 K / min.
TIM-ID: 0000051994 - 001
Filling and top-up water, permissible flow temperatures over 100 C and for large heating systems or
long-distance heating systems.
The base alkalization must occur with trisodium phosphate.
The definitive specification is the VdTV Directive TCh 1466 governing the quality of water in heating
installations which are operated with a supply temperature above 100 C. The following guide values
subsequently apply for low-salt method of operation:
When using biogas, sewer gas or landfill gas the quantity of oil in the engine oil sump is not
adequate. A larger volume of oil is required!
Used-oil analysis
The results of the oil analyses must be archived and the must recent oil sample must be stored possible
follow-up examinations.
In the event that the limit values are not reached, an oil change must be executed at the latest after one
year.
The test methods and limit values listed in the table (analytical limit values for gas engine oils) show
when the result of a single analysis of an oil sample is to be considered as being abnormal.
An abnormal result (e.g. increased wear of the oil) requires an immediate investigation and rectification
of the irregular operating condition (e.g. check of the gas preparation or analysis of the gas samples).
The limit values relate to individual oil samples. When these limit values have been reached or exceeded
an immediate oil change is indicated. The results of the oil analysis do not necessarily indicate the wear
taking place on specific elements and components
Aside from the analytical limit values also the condition, operating condition and possible malfunctions
of the engine and the periphery of the system are of equal importance.
Total acid number, TAN ASTM D664 New oil value +2.5
(mgKOH/g)
iph value Min. 4.5
Water (% by vol.) ASTM D6304 Max. 0.2
EN 12937
ISO 6296
Glycol (mg/kg) ASTM D2982 Max. 100
Oxidation (A/cm) DIN 51453 Max. 20
Nitration (A/cm) IR method Max. 20
Table 23: Limit values for used gas engine oils SAE 40
*) The limit value for the Si wear element only refers to natural gas operation.
**) Si is not a wear element for special gases! Presumably any Si-Al compounds.
TIM-ID: 0000051978 - 001
When fuel is burned in the engine, nitrogen oxides NOx are created in addition to carbon dioxide and
water vapor. These transform into nitric acid in the downstream components in the presence of con-
densed water. Other inorganic and organic acids, e.g. sulfuric acid or sulfurous acid, can likewise be
created depending on the fuel composition. Condensate samples therefore display a lightly pungent
smell and dissolved iron as a corrosion product. The hydrogen ion concentration, i.e. the pH value of
such condensate samples, is usually in the strong to weak acid range of pH = approx. 0.5 ... 4.
Condensate starts to form, depending on the acid-forming constituent, at exhaust temperatures below
approx. 160 C.
Theoretically, 1.5 kg condensate can be created from 1 m3 NTP. of natural gas.
In the case of gensets with exhaust cooling in a heat exchanger, at exhaust temperatures not below
110 C, with properly insulated exhaust lines and with a normal number of start/stop procedures (ratio
of operating hours to starts at least 2:1), the condensate accumulation in the heat exchanger and in the
downstream silencer is reduced to a few kilograms per day.
A free discharge via a siphon at a height of approx. 300 mm1) must be provided for the condensate to
prevent exhaust gas from escaping from the condensate line. The exhaust condensate should be neu-
tralized in a neutralization plant before being discharged into the sewerage system. An oil separator is
additionally required.
Exhaust condensate may only be discharged into the sewage system without being treated after consul-
tation with the local waste water authority, and must not under any circumstances be discharged to
atmosphere. Municipalities in Germany, or the authorities instructed by them, are obliged to remove
accumulated waste water which also contains condensate. Condensate can also be classified in the
"Special waste" category.
1)
At least 50 mm above the corresponding max. exhaust backpressure according to the module
TIM-ID: 0000051981 - 001
Local Support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
24-h Hotline
With our 24-h hotline and the flexibility of our service staff, we are always ready to assist you - either
during operation, for preventive maintenance, corrective work in case of malfunction or changed oper-
ating conditions, or for spare parts supply.
For our locally available support, go to MTU's Internet site:
http://www.mtuonsiteenergy.com/haendlersuche/index.de.html
Your contact at Headquarters:
support-oeg@mtu-online.com
Lubricating oil 34
Requirements 23 Operator
Water quality for gas sequential heater Confirmation 4
Requirements 22
R
Corrosion protection of the engine5
Ready-mixed
D Approved corrosion inhibitors / antifreezes 25
Definition
Coolant 19
S
Service partner
MTU Onsite Energy 40
Silicon content
Fuels 7
Supplemental concentrations
Approved corrosion inhibitors / antifreeze 25
Supplemental notes
Heating water 29
T
Topicality of the publication5
Transmission fluid36
Treatment
Corrosion inhibitor / antifreeze 24
U
Used oil analysis
Lubricating oil 34
W
Water-soluble concentrates
Approved corrosion inhibitors / antifreezes 25