Tier 3 Tech 2016-12

Tier III service experience
September 2016
MAN Diesel & Turbo LEO8@mandieselturbo.com EGR Service experience  04.08.2016 < 1 >
Agenda
1 EGR plant overview
2 EGR on high Sulphur HFO
3 EGR on low Sulphur fuel
4 General
5 SCR plant overview
6 Santa Vista service experience
EGR plant overview
Name Type EGR Fuel EGR Trade pattern

configuration run hrs.
Maersk 6S80ME-C Cut out HFO 3500 Asia↔W. Africa

Cardiff Mk. 9.2 TIII 2 MET T/Cs 1 - 3,5%
Pegasus 6S70ME-C Cut out MDO 80 San Francisco ↔
Voyager Mk. 9.2 TIII 2 MET T/Cs S≤0,1% L.A. ↔ PAL.
Polaris 6S70ME-C Cut out MDO 120 San Francisco ↔
Voyager Mk. 9.2 TIII 2 MET T/Cs S≤0,1% L.A. ↔ PAL.
Key 6S60ME-C By-pass HFO 215 World Wide
Pacifico Mk. 8.2 TIII 1 MET T/C 1 - 3,5%
Agenda
4 General
EGR on high Sulphur HFO
Materials:
Carry-over of proces water with the EGR-gas to the mixing chamber, has led to an update of the
coating quality of quite a few components. The water is found as greenish liquid with a PH value
as low as 1.
Extensive corrosion has been found around the EGR inlet pipes in the mixing chamber; in the
WMC drain connections; in the auxillary blower drains and auxillary blower inlet funnel.
Ensuring coating quality in a large scale production

is a challenge.
Various components have been upgraded to 316L on

new design specifications.
EGR liquid ingression in PDT-sensor.
Corrosion challenges
Aux blower inlet
Coating:
Damaged or incorrectly applied coating will break down, resulting in

exposed metal underneath.
New coating supplier and design updates
Mixing chamber Mixing chamber Aux blower drain
Maersk Cardiff
 Top layer pre-scrubber nozzles corroded – root
cause hypothesis is build-up of Sulphur and
abbrasive wear, since only top layer is affected
 Countermeasure higher quality steel and more
frequent check in maintenance procedure, design
changed to support this
 EGR cooler corrosion – root cause outside MDT
control
 Countermeasure: MDT takes control of parameters
that was root cause, and enhances automatic
supervision
 WTS pipe corrosion – root cause welding
workmanship
Dirt build-up
EGR “Dirt” build up in EGR Suction Chamber, Pipes and EGR Mixing Chamber
The “dirt” is insoluble and has to be scraped out manually, but has not been a
problem to normal operation.
For High Sulphur Design, a dirt trap has been introduced to collect possible excess
dirt.
Significantly less dirt is to be expected in Low Sulphur design.
cylinder condition
 Scrape down indicate some small
CLO penalty, but within control by
lubrication adjustment and air/gas
quality
 Cylinder condition seems finally
under control (ME-C9.2)
 Further extensive testing planned
for next voyage from Africa to Asia
with Maersk Cardiff
Agenda
4 General
EGR on low Sulphur fuel
We only have very few running hours on the two plants running Low Sulphur MDO,
however the following expectation for LS operation have been confirmed:
• Very limited build up of deposits.

• No problems with EGR start up after long periods of standstill.
• Ship owner is able to handle the logistics regarding sludge and NaOH.
EGR on low Sulphur fuel
Internals after 120 EGR running hours
Significant difference from what is

seen when operating on HFO.
Agenda
4 General
General
EGR SUC & EGR SPC
Sensor Unit Cabinet (SUC)

• SUC has proved extremely robust and
accurate in service.
• The system is running continuously (with
the M/E) and apart from the expected
routine calibration, no significant issues
have been observed.
• +9000 running hrs. on each Chevron
vessel.
O2 sensor stability
 From sea trial

with Polaris
Voyager, SUC
(cabinet solution)
 From ‘start-up’
visit on Polaris
Voyager, it was
observed that O2
measurment
showed good
stability and
good linearity
General – Valve position controllers
 Siemens Sipart PS/2

valve positioner vital part
of system.
 Several 1000s in service
– applied on EGB as well
 A number of errors have
been seen, almost all
related to control air
quality or pressure
 MDT and Siemens have
initiated service test of
pressure damper and
oil/water separator for
valve controllers
General
Components
Valves:
The valves used in the EGR system are shared with the valves used in the MDT SCR design.
• No significant breakdowns or major design changes based on service experience from both TIII
technologies.
• We have however been made aware that care must be taken when installing the gas tight
valves.
EGR Blowers:
Currently there are two suppliers of EGR blowers, Siemens and MDT.
• No breakdowns or major issues found after 2500 hr inspection on HFO. (Siemens)
• Only minor sensor problems observed
• Only minor design changes so far. (Siemens)
• MDT blower only has 215 run Hrs. but no problems have been reported thus far.
Agenda
4 General
6 SCR service experience
SCR plant overview
Name Type SCR Fuel SCR Trade pattern

Configuration run hrs.
Santa 6S46MC- HP SCR HFO 2500 WorldWide

Vista C7 1 - 3,5%
Yara 6S50ME- HP SCR HFO 100 Northern Europe
Kara C8.2-TIII 1 - 3,5%
 Additional 2 HP SCR plants and 2 LP SCR plants in shipyard at the moment
Agenda
4 General
6 SCR service experience
Santa Vista
Joint Development with Hitachi Zosen

regarding HP SCR for HFO
 Santa Vista commissioned in 2011
 Validation of Tier III compliance

with SCR on 2-stroke HFO
 ClassNK emission certification Operator / Vessel Nissho Shipping Co., Ltd / M/V Santa Vista
Engine 1 x 6S46MC-C
 Commercial vessel operating as MCR kW 8280

Ship type &
Service ship  not typical Tier III capacity 38,000 DWT, general cargo carrier
mode Builder Hitachi
Stand alone High pressure upstream TC SCR
Technology First commercial TIER III compliant
Engine hours 24920h SCR engine.
Reactor hours >15000h

Urea Dosing hours >5000h
Santa Vista
Service Experience
Issues identified 2011-2013

Boiler clogging when
running on HFO with
 Ammonia slip from SCR reactor gave high NH3 slip
deposits on downstream boiler. Boiler  Rapid buildup of ABS
could not operate with SCR engaged
 Reduce ABS formation by minimizing
ammonia slip
Boiler issues solved by

Reducing ammonia slip
 Corrosion of SCR line during Tier II (improved reactor design)
operation due to exhaust gas leaks into
2015
cold SCR system. Boiler operating well
 Venting of SCR line in Tier II mode • 1000h operation with
 Tight Valve design HFO
• 1000h operation with
 Heating during short time LSFO
disengagement
Santa Vista update
 High ammonia slip is

believed to be caused by
too much leakage
between catalytic
elements
 A revised design of
sealing method has
recently been approved
by MDT, and is planned to
be implemented Q3/Q4
2015.
 Some elements were
found damaged, most
believed to be caused by
fitters entering the reactor
housing (mechanical
damage). Some damage
may have been caused
by soot blowers.
Santa Vista
Example of operation
 Stable long-term operation of SCR system and MDT SCR control

system
Yara Kara inside SCR reactor
inspection
 Very recently, Yara Kara was

visited for the first time since
delivery from shipyard.
 All inspections indicate
healthy condition
Summary
 Many lesson learned and implemented in design,

both cost-down and improvement of design
 High sulphur systems challenging material-wise,

but under control
 Low sulphur systems far less exposed to these

challenges
 No indication of impact on cylinder condition that

cannot be controlled from EGR running
 HS SCR able to avoid ABS formation with proper

reactor design
 Both EGR and SCR very good reductions in NOx
Disclaimer
All data provided in this document is non-binding.

This data serves informational purposes only and is especially
not guaranteed in any way. Depending on the subsequent
specific individual projects, the relevant data may be subject
to changes and will be assessed and determined individually
for each project. This will depend on the particular
characteristics of each individual project, especially specific
site and operational conditions.
Do you have any more questions?
Operation Department
LEO8@mandieselturbo.com

Tier 3 Tech 2016-12

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Tier III service experience

1 EGR plant overview

2 EGR on high Sulphur HFO

3 EGR on low Sulphur fuel

5 SCR plant overview

6 Santa Vista service experience

Name Type EGR Fuel EGR Trade pattern

Maersk 6S80ME-C Cut out HFO 3500 Asia↔W. Africa

1 EGR plant overview

2 EGR on high Sulphur HFO

3 EGR on low Sulphur fuel

5 SCR plant overview

6 Santa Vista service experience

Ensuring coating quality in a large scale production

Various components have been upgraded to 316L on

EGR liquid ingression in PDT-sensor.

Damaged or incorrectly applied coating will break down, resulting in

New coating supplier and design updates

Mixing chamber Mixing chamber Aux blower drain

1 EGR plant overview

2 EGR on high Sulphur HFO

3 EGR on low Sulphur fuel

5 SCR plant overview

6 Santa Vista service experience

• Very limited build up of deposits.

Significant difference from what is

1 EGR plant overview

2 EGR on high Sulphur HFO

3 EGR on low Sulphur fuel

5 SCR plant overview

6 Santa Vista service experience

Sensor Unit Cabinet (SUC)

 From sea trial

 Siemens Sipart PS/2

1 EGR plant overview

2 EGR on high Sulphur HFO

3 EGR on low Sulphur fuel

5 SCR plant overview

6 SCR service experience

Name Type SCR Fuel SCR Trade pattern

Santa 6S46MC- HP SCR HFO 2500 WorldWide

 Additional 2 HP SCR plants and 2 LP SCR plants in shipyard at the moment

1 EGR plant overview

2 EGR on high Sulphur HFO

3 EGR on low Sulphur fuel

5 SCR plant overview

6 SCR service experience

Joint Development with Hitachi Zosen

 Santa Vista commissioned in 2011

 Validation of Tier III compliance

 Commercial vessel operating as MCR kW 8280

Reactor hours >15000h

Issues identified 2011-2013

Boiler issues solved by

 High ammonia slip is

 Stable long-term operation of SCR system and MDT SCR control

 Very recently, Yara Kara was

 Many lesson learned and implemented in design,

 High sulphur systems challenging material-wise,

 Low sulphur systems far less exposed to these

 No indication of impact on cylinder condition that

 HS SCR able to avoid ABS formation with proper