TSM - U1 V1.0 Trouble Shoting Manual

Troubleshooting
Manual
PureSOx Exhaust Gas Cleaning

U-type system
Alfa Laval © 2017

TROUBLESHOTING MANUAL
Document data
Document Title: Troubleshooting Manual, U-type EGC systems
Document Reference: TSM_U1
Version: V1.0
Release Date: 23 March 2017
Revisions
Date Version Revision
23-Mar-2017 V1.0 First publication
Contact information
Alfa Laval Nijmegen B.V.
P.O. Box 6664, 6503 GD Nijmegen, The Netherlands
Phone: +31 24 35 23 100 (Reception)
+31 24 35 23 200 (Support Desk)
Web: www.alfalaval.com
E-mail: egc.service@alfalaval.com (Support Desk)
egc.spares@alfalaval.com (Spares Department)
T R O U B L E S H O O T I N G M A N U AL
Contents
1. ABOUT THIS MANUAL..................................................................... 1
1.1. Sea-Water/Fresh-Water or Open-Loop/Closed-Loop ...................... 1
2. INFORMATION SOURCES................................................................ 2
2.1. Use the FBD and P&IDs ................................................................... 3
2.2. Find sub-supplier manuals .............................................................. 5
2.3. Use the electrical drawings ............................................................. 5
2.3.1. Single-line diagram................................................................. 6
2.3.2. Circuit diagram ...................................................................... 8
2.4. View status on the touchscreen ...................................................... 9
2.5. Show tag numbers ........................................................................ 10
2.6. Create a screen print of the touchscreen ...................................... 10
2.7. Contact Alfa Laval ......................................................................... 11
3. TROUBLESHOOTING METHOD ...................................................... 12
3.1. Primary troubleshooting method .................................................. 13
3.1.1. Identify the type of issue ....................................................... 15
3.1.2. Choose an alarm to troubleshoot ............................................ 16
3.1.3. View the alarm message in context ......................................... 17
3.1.4. Solutions ............................................................................. 18
3.2. Extended troubleshooting method ................................................ 19
3.2.1. Define and locate the problem ............................................... 20
3.2.2. List contributing factors ......................................................... 21
3.2.3. Identify possible cause-and-effect scenarios ............................ 21
3.2.4. Focus on the most likely possible cause ................................... 22
3.2.5. Verify if your hypothesis is true .............................................. 23
3.2.6. Solve possible causes............................................................ 25
TSM_U1 V1.0 Page i of 3

3.3. Restore the EGC system to normal operation ................................ 25
4. WHAT IF? ..................................................................................... 26
4.1. Touchscreen does not work or does not show all information ...... 26
4.1.1. Make a control panel the active panel ..................................... 26
4.2. System stays 'busy' or does not stop ............................................ 27
4.3. System does not start ................................................................... 28
4.4. System does not switch modes (OL / CL) ..................................... 29
4.5. Readings from a water analyzer panel are incorrect ..................... 30
4.6. EGC system generates loud noises ................................................ 31
4.6.1. Sudden loud noises near the sealing air fans ............................ 31
4.6.2. Loud noises near the scrubber or the WCU .............................. 31
4.7. Display of gas analyzer shows an alarm ....................................... 32
4.8. Display of WCU shows LL turbidity alarm ...................................... 33
4.9. WCU in bleed-off mode, but no water is discharged ...................... 33
5. COMPLIANCE ISSUES .................................................................... 34
5.1. SOx/CO2 ratio out of compliance ................................................... 35
5.1.1. Bring SOx/CO2 ratio back in compliance ................................... 36
5.1.2. If the compliance issue remains ............................................. 37
5.1.3. Possible root causes of incorrect SOx/CO2 ratio ......................... 37
5.2. pH out of compliance .................................................................... 39
5.2.1. Bring pH back in compliance .................................................. 39
5.2.3. Possible root causes of low pH ............................................... 40
5.3. PAH out of compliance .................................................................. 42
5.3.1. Bring PAH back in compliance ................................................ 42
5.3.3. Possible root causes of high PAH ............................................ 43
Page ii of 3 TSM_U1 V1.0

5.4. Turbidity [FNU] out of compliance ................................................ 45
5.4.1. Bring turbidity [FNU] back in compliance ................................. 45
5.4.3. Possible root causes of high turbidity [FNU] ............................. 46
5.5. Procedures to resolve compliance issues ...................................... 48
5.5.1. Check process settings .......................................................... 48
5.5.2. Increase water to absorber (Open-Loop mode) ........................ 49
5.5.3. Increase water to absorber (Closed-Loop mode) ...................... 50
5.5.4. Increase water to jet(s)......................................................... 51
5.5.5. Increase NaOH dosage (Closed-Loop mode)............................. 52
5.5.6. Reduce flow to the Water Cleaning Unit (Closed-Loop mode) ..... 54
6. ALARMS AND WARNINGS FOR MODULES ..................................... 55
6.1. All modules ................................................................................... 56
6.2. Gas Analysis module ..................................................................... 57
6.3. Touchscreen (HMI panel) ............................................................. 57
6.4. Main .............................................................................................. 58
7. ALARMS AND WARNINGS FOR DEVICES ....................................... 59
7.1. Hand valves (HV) .......................................................................... 60
7.2. Pressure valves (PV) .................................................................... 61
7.3. Process controlled valves (PCV) ................................................... 63
7.4. Pumps and fans (MCP, MCF) ......................................................... 64
7.5. Transmitters (FT, PT, TT, QT, LAh, LSA, LT) .................................. 65
7.5.1. Examples of pressure transmitters (PT) ................................... 66
7.5.2. Examples of pH, PAH, and turbidity transmitters (QT) ............... 68
7.5.3. Examples of level transmitters (LAh, LSA, LT) .......................... 69
8. LIST OF ABBREVIATIONS AND ACRONYMS .................................. 71
TSM_U1 V1.0 Page iii of 3

1. About this manual

This manual advises the operator of the PureSOx Exhaust Gas Cleaning
(EGC) system what to do if the system does not perform as expected.
Securing the safety of the ship and all life on board always takes priority over
the EGC system.
This manual contains information about how to:
 Use the information sources in the Customer Manual and how to
contact Alfa Laval (Chapter 2).
 Troubleshoot (Chapter 3).
 Handle specific issues that do not trigger alarms (Chapter 4).
 Handle compliance issues (Chapter 5).
 Handle module alarms and warnings (Chapter 6).
 Handle device alarms and warnings (Chapter 7).
1.1. Sea-Water/Fresh-Water or Open-Loop/Closed-Loop

On most EGC systems, cleaning the exhaust gas with seawater is called
Open-Loop (OL) mode. Cleaning the exhaust gas with freshwater from a
water circulation circuit is called Closed-Loop (CL) mode.
On some EGC systems, different terms are used:
 Open-Loop mode is called Sea-Water (SW) mode.
 Closed-Loop mode is called Fresh-Water (FW) mode.
This manual uses the terms Open-Loop (OL) and Closed-Loop (CL).
TSM_U1 V1.0 Page 1 of 72

2. Information sources
When troubleshooting, it helps to know how the EGC system and its
components work. You can find this information in the following documents:
 EGC Technical Manual (ETM-B): contains the discharge limits for
the exhaust gas and for the water that is used in the cleaning
process. It describes the actions that must be taken when the EGC
system is out of compliance.
 EGC record book: to record activities related to the EGC system,
such as refilling chemicals, calibrations, and actions taken when out
of compliance. All activities related to the EGC system should be
recorded.
 Customer Manual: a set of books that contains the following
documentation about the EGC system:
- Operations manual: explains how the EGC system works and
how to operate the EGC system.
- Maintenance manual: contains maintenance schedules and
maintenance procedures for the EGC system, and start and stop
procedures.
- Parts list: specifies the name and supplier of each tag-numbered
device.
- Functional Block Diagram (FBD): provides an overview of the
functional blocks into which the EGC system is divided. See
Section 2.1 for information on how to use the FBD.
- Process & Instrumentation Diagrams (P&IDs): show all flow
lines and all attached equipment of the EGC system. The
diagrams also contain the tag numbers of all devices. See Section
2.1 for information on how to use P&IDs.
- Electrical Drawings: contain all electrical wiring diagrams. See
Section 2.3 for information on how to use the electrical drawings.
- Sub-supplier manuals: contain instructions for components and
devices from sub-suppliers. See Section 2.2 for information on
how to find a specific sub-supplier document.
In several sections of this manual it is assumed that you know the tag
number of the item you are interested in. Tag numbers can be displayed on
the touchscreen of the EGC system. If the tag numbers are not visible, see
Section 2.5 for instructions on how to display them.
The touchscreen also shows status lines and status indicators. See
Section 2.4.
Page 2 of 72 TSM_U1 V1.0

2.1. Use the FBD and P&IDs

The Functional Block Diagram (FBD) and Process & Instrumentation
Diagrams (P&IDs) are included in the Customer Manual of the EGC system.
The EGC system is divided into functional blocks. The FBD provides an
overview of all these functional blocks. Each functional block has a P&ID
drawing. The P&ID drawings show all flow lines and all equipment that is part
of the EGC system, and contain the tag numbers of these devices.
You can use the FBD to locate a system section and the P&ID drawing of that
section. You can then use the P&IDs to find a device, and to follow the flow of
water or gas through the device and the rest of the EGC system.
Find the correct functional block

Based on the tag number of a device, you can find the FBD that the device
belongs to. The first two digits of the tag number indicate the functional
block where the device is located. For example, tag no. 4017 is located in
functional block 4000.
Figure 1: Example of a FBD
Note that some function block numbers are preceded by a letter. For
example, when two combustion units are connected to the scrubber, there is
a function block A1000 and a function block B1000. The tag number of
devices in a function block that starts with a letter, start with the same letter
as the function block. For example, the tag number of devices in A1000
starts with an 'A'.

Identify the flow through the device

When you know the functional block, select the corresponding P&ID drawing
(see Figure 2). In the drawing, follow the flow-lines to identify the route of
the water or the gas. If a line leads to another functional block, check the
line name (for example 'L33' in Figure 2), and find the same line name in the
next drawing (see Figure 3).
L33
Figure 2: Example of a P&ID (1)
L33
Figure 3: Example of a P&ID (2)

When troubleshooting the flow through a device, follow that flow and
consider the following possible issues:
 Possible leakage because of a breached barrier. For example a valve

or pipe that is leaking, a safety or limit switch that does not work, or
wire isolation that is broken.
 Additional equipment that is installed but not shown on the
touchscreen of the EGC system.
 Alternate routes the water or gas can take.
2.2. Find sub-supplier manuals

To find a specific sub-supplier manual:
1. In the Customer Manual of the Exhaust Gas Cleaning system, open the
Parts List.
2. In the Parts List, find the tag number of the device and check the brand
name (the supplier).
3. In the Customer Manual, find the brand name and then find the supplier
manual you are looking for.
In the Customer Manual, suppliers are sorted by brand name.
2.3. Use the electrical drawings

The electrical drawings are included in the customer manual of the EGC
system.
To understand the coding that is used in the electrical drawings, view the
'Directions' section at the beginning of the set of electrical drawings.
To find a specific item in the electrical drawings, it is important to know how
the electrical drawings are grouped:
1. Location.
Drawings can be grouped by location in the ship, for example indicated
with SB (starboard) or PS (port side).
2. Cabinet.
Within a location, drawings are grouped by control panel or terminal box.
For example 803 (Engine Control Room Panel).
3. Function group.
Within a cabinet or terminal box, drawings are grouped by functional
block. For example 2000 (jet section).
4. Document.
For each function group, various document types are available. For
example 21 (single-line diagrams).

The page numbers reflect this grouping (see Figure 4).
Figure 4: Example of a page number
The first line of the page number identifies the electrical drawing as shown in
the following table.
Code Description
==SB Location: starboard.

=840 Cabinet: 840, feed pumps control cabinet.
+4000 Function group (functional block): 4000, feed pumps.
&07 Document type: 07, circuit diagram.
The second and third lines of the page number identify the number of the
page in a document type. The example in the figure is page 4 of the 'circuit
diagram' drawings.
To identify functional blocks, see Section 2.1.
2.3.1. Single-line diagram

A single-line diagram (see Figure 5) provides an overview of all cables
entering and exiting an electrical cabinet.
C D E
B
A
Figure 5: Example of a single-line diagram

The top dashed line in Figure 5 (see arrow) is a cable connecting terminal
strip -2x21 to a device with tag no. 2105. Using the example in Figure 5, the
following table explains the coding in this diagram.
Indicator Description
A Reference to another page:

=802+2100&07/4.1 is page 4, column 1 of a circuit
diagram.
B Terminal strip ID:
-2X21 means terminal strip (X) number 21 inside cabinet
802.
C Cabinet number:
=802, the main control panel.
D Cable number:
-C2105 is the number on the cable label.
E Target ID:
=802-2105 means the device with tag number 2105 in
cabinet 802.

2.3.2. Circuit diagram

A circuit diagram (see Figure 6) shows an overview of electrical cables and
instrumentation.
F
E
Figure 6: Example of a circuit diagram
Using the example in Figure 6, the following table explains the coding in a
circuit diagram.
Indicator Description
A and F Reference to another page:

3.9 means page 3, column 9
21L refers to power group 21.
B PLC card number:
-21A3 means PLC card (A) number 21, inside cabinet 803
C PLC card terminal number:
21 is the terminal number of the PLC card.
D Terminal ID:
-2X21 6 means terminal number 6 on terminal strip
(X) number 21 inside cabinet 802.
E Tag number
-2105 is the tag number of the connected device.

2.4. View status on the touchscreen

On the touchscreen, status lines and status indicators show the status of the
EGC system.
Figure 7: Example of Main status line and module status lines
Status lines: The Main status line at the top of the screens shows the status
of the entire EGC system. The module status lines display on module screens
and show the status of components in that module.
Note: The login requirements for viewing these status lines depend on the
installed software configuration.
Figure 8: Example of status indicators

Status indicators: On the Global Overview screen, each module has a field
that shows the status of the module. The status for the module 'Main' is the
status of the entire EGC system.
Note: The number in a status is a sequence number. Alfa Laval software
engineers use these sequence numbers to trace what the system is
doing.
2.5. Show tag numbers

Each device has a unique tag number (for example PVo_2170) that you can
use to find the device in the P&IDs. To show tag numbers on the
touchscreen:
1. Go to the 'TP info and settings' screen (see Figure 9).
2. Touch the 'Show Tag Names' switch until the switch is ON ('I' is visible).
Figure 9: Switch tag numbers ON/OFF
2.6. Create a screen print of the touchscreen

If you contact the Alfa Laval support desk about a specific problem, it is
possible that they ask you to send a screen print of a certain screen. Screen
prints are saved to a USB device.
To create a screen print:
1. Insert a USB device in the USB slot of the control panel.
The USB slot is located at the front of the control panel (at the outside of
the cabinet door), or at the back of the control panel (at the inside of the
cabinet door).
2. On the touchscreen, go to the screen that you want to create a screen
print of.
3. On the button bar at the bottom, touch the Utilities button.
4. In the menu, touch Print.
5. Close the message window that is displayed.
6. Remove the USB device.

2.7. Contact Alfa Laval

If there is a problem with the Exhaust Gas Cleaning gas system that you
cannot solve, contact Alfa Laval. You can find the contact details:
 On the inside cover page of this manual, see 'Contact information'.
 On the touchscreen, go to the TP Info and Settings > Contact Information
screen.
Before you contact Alfa Laval, complete the following steps to ensure all
necessary information is available.
1. Gather the details of your investigation.

2. On the touchscreen, log in as admin.
3. Make screen prints of the following screens.
 The Global Overview screen.
 The screen showing the section of the EGC system where the problem
occurred.
 The same screen with the pop-up window, messages window, and (if
available) settings windows of the affected device or module opened.
 The Actual alarms/warnings screen.
See Section 2.6 for instructions to make screen prints.
The Alfa Laval Support Desk may ask for the data logger data and the
settings of the EGC system. Instructions on how to export data and settings
are in the operations manual.

3. Troubleshooting method
A compliance issue is when the SOx/CO2 ratio in the exhaust gas or the pH,
PAH, or turbidity in the discharge water are not within the emission control
limits. In the event of a compliance issue, carry out the mandatory actions to
bring the ship back into compliance. These mandatory actions are
described in Chapter 5.
When the ship is back in compliance, or when there are other problems with
the EGC system not directly related to compliance issues, try to find and
solve the root cause of the problem. This chapter explains how to do that:
 First follow the primary troubleshooting method to find the
problem, and apply short-term measures and known solutions.
 If the problem persists, follow the extended troubleshooting
method to find and eliminate the root-cause of the problem.
For both troubleshooting strategies, your starting point is a flowchart. The
sections following each flowchart explain how to perform certain steps in the
flowchart.

3.1. Primary troubleshooting method

Carry out the primary troubleshooting method in the following (two-page)
workflow to find the problem, and apply simple or short-term solutions.
Figure 10: Primary troubleshooting – page 1

Figure 11: Primary troubleshooting – page 2

3.1.1. Identify the type of issue

If there is an active alarm or warning, complete the following steps to
determine if you are dealing with a compliance issue, a warning, or an alarm.
1. Log in.
2. If needed, make the control panel you are standing at the active panel.
3. Make sure tag numbers are visible (see Section 2.5).
4. Go to the Global Overview screen (see Figure 12).
C B A
Figure 12: Example of alarms and warnings on the touchscreen
5. Identify the type of problem:

 Blinking red measurements field (A in Figure 12): this analyzer
reading is outside specifications. The ship's emissions are probably
out of compliance.
 Yellow triangle icon (B in Figure 12): warning.
 Red alarm icon (C in Figure 12): alarm.
Note: In the event of a compliance issue, continue with Chapter 5.

Note: When multiple alarms are present, the next step is to focus on a
single alarm (see Section 3.1.2).

3.1.2. Choose an alarm to troubleshoot

Usually, a single alarm can cause many more alarms. For fast
troubleshooting, complete the following steps to find the issue that started
the problems.
1. Go to the Actual alarms / warnings screen (see Figure 13).
Figure 13: Example of an actual alarms / warnings screen
2. Use the following guidelines to choose a single alarm to focus on:

 Focus on alarms (red background, or green background when
acknowledged).
 Focus on more general, higher level alarms such as a module alarm
or a group alarm, because such an alarm can cause many devices to
not work properly.
 Focus on the alarm furthest upstream in the process, because a
failure upstream can cause other alarms downstream. For example, a
problem with pumps can result in low pressure alarms downstream of
those pumps.

3.1.3. View the alarm message in context

For a better understanding of what is going on, complete the following steps
to view the alarm message in the context of its functional block.
1. Go to the module screen with the alarm you want to troubleshoot.
Tip: On the Global Overview screen, touch the relevant module to go to
the module screen.
B A
Figure 14: Example of alarms in a module
2. Identify the source of the alarm. This can be a:

 Device (B in Figure 14).
 Module (A in Figure 14).
An alarm in a module can cause alarms in devices belonging to that
module.
3. Touch the module or device that has an alarm.
4. Open the messages window to see the active alarm message(s).
Note: You can use the name of the message to find a solution in
Chapters 6 and 7.

3.1.4. Solutions
1. If the EGC system was stopped because of an alarm, first acknowledge,
troubleshoot, and reset the alarm, then try starting the scrubber again.
2. If the EGC system is running and out of compliance, see Chapter 5 for
mandatory actions to bring the EGC system back into compliance.
Note: When the EGC system is back in compliance, the root cause of the
problem can still be present. Further troubleshooting may be
required.
3. Refer to the alarms and warnings lists in this manual for advice:
 If a module gives an alarm or warning, see Chapter 6.
 If a device gives an alarm or warning, see Chapter 7.
4. If the problem is not in this manual, or if the problem continues, go to
Section 3.2.

3.2. Extended troubleshooting method

If the problem continues after primary troubleshooting, carry out the
following workflow to find and eliminate the root cause of the problem.
Figure 15: Extended troubleshooting

You may need to repeat steps in the workflow several times, using the new
information you gather in each iteration.
You can check most items in the workflow while standing in front of a control
panel.
Write down all your ideas and research findings.
3.2.1. Define and locate the problem

To help define and locate the problem, ask yourself the following questions:
1. What is the object that presents the problem?
For example: a sensor, valve, device, group, section, frequency drive,
screen, circuit-breaker, and so on.
2. What is the deviation?
Compare the current situation with 'expected operating conditions'. For
example:
 Alarms mention HH (high-high) and LL (low-low) values as deviation.
 Valves that you expect to be open in the current situation are closed.
 Devices that should be ON are turned OFF.
 Expected transmitter readings are not reached. For example, a high
CO2 reading is expected on the gas analyzer when engines are ON
and the uptake valve is open.
3. Was any maintenance done on the EGC system recently?
4. When did the problem start?
5. Is it the first time that this problem has happened?
6. When applicable: Is the problem caused by a faulty sensor?
Compare the transmitter readout with the readings of another, similar or
equivalent transmitter. For example:
 Flow in a pipe is equivalent to positive pressure in most cases.
 The backpressure transmitters for the demister, PT_2105 and
PT_2106, should have similar values (~10% off).
 In Closed-Loop mode, pH transmitters QT_7607 (inlet) and QT_7720
(WCU) should have similar values as one another.
7. Has the device been properly calibrated and maintained?
8. Does the device have its own, independent user interface. If so, does the
user interface show an alarm?

3.2.2. List contributing factors

This section helps determine the external factors that may influence the
problem. Further sections help verify if an external factor is the actual cause
of the problem.
1. Identify any unusual events in the environment of the ship. For example:
 The ship is sailing in a storm.
 The ship is sailing in an area with mixed waters, such as in the
transition between seawater and low alkalinity water.
 The seawater temperature is unusually high or low.
 The ship is sailing close to another ship.
2. Identify any recent changes on the ship. For example:
 The ship has left harbour and is now sailing.
 Engine load changes.
 Change in fuel, chemicals, or flocculant.
 For a Hybrid EGC system: the running mode of the EGC system
switched from Open-Loop to Closed-Loop or from Closed-Loop to
Open-Loop.
 Ballast or cargo sailing.
 A power spike occurred.
 Pressure loss in the technical water system.
3. Check the logbook for recent maintenance work to the ship.
3.2.3. Identify possible cause-and-effect scenarios

This section helps to identify possible cause-and-effect scenarios. Try to
identify as many possible causes as possible. The ultimate goal is to find the
actual cause of the problem.
1. Are there other problems with the EGC system that recently occurred?
 Can these problems influence each other?
 Can these problems have a similar cause?
2. Is it possible that unusual events in the environment of the ship cause
this issue? How?
3. Is it possible that recent changes in operation on the ship cause this
issue? How?
4. Do other parts of the EGC system have the same problem?
 Using the P&IDs, identify the entire flow route through the EGC
system.
 Do any transmitters show fluctuations with unusually high, low or
stable values?

 In the parts of the EGC system that have the same problem, is the
same fluid involved? Do you expect similar measured values?
 Are the values measured by the transmitters similar?
 What can cause the differences in measured values?
5. Are other devices showing similar problems right now?
 What do these devices have in common?
 Using the P&IDs, identify all possible flow connections between the
devices.
 Using the electrical drawings, identify all devices on a circuit breaker.
6. Should there be flow through the device?
 Is there flow through the device?
 Is the flow speed fluctuating?
7. Do you suspect that the presence of other substances causes the
problem? For example, water in an air line or gas line, air in a water line.
 Where do water and air/gas come into contact?
 Using the P&IDs, identify all possible flow connections.
 Where can the water, air, or gas enter into the problem area?
8. Do you suspect that barriers are breached? For example:
 A closed valve that is leaking internally.
 Safety switch or limit switch that does not work correctly.
 Broken wire isolation, causing a short circuit.
 Leaking pipe.
9. Are control systems involved that normally prevent this problem? For
example, a controlled pump normally prevents low water pressure.
10. If you have discovered several possible causes, try to answer 'Why?' for
each possible cause.
Even if the answer is 'do not know', write this down.
3.2.4. Focus on the most likely possible cause

You may not identify the correct cause and effect scenario immediately.
Therefore, you may need to repeat checking hypotheses several times.
However, the questions in this section can help select a cause and effect
scenario that you want to focus on first.
1. Are there causes that seem likely? For example:

 Is it likely that a storm causes sudden engine load variations?
2. Are there causes that seem unlikely? For example:
 Is it likely that the sample probe filter is blocked if it was cleaned
recently?

 Is it likely that a pump impeller is corroded away one week after

inspection?
3. Are there causes that are easy to investigate? For example:
 Is the instrument calibrated?
 How is the weather outside?
3.2.5. Verify if your hypothesis is true

Before trying to solve an issue, you must verify if your cause and effect
hypothesis is likely to be true.
3.2.5.1. Verification for flow or pressure issues
Touch items on the touchscreen (see Figure 16) to navigate upstream and
downstream of the device or section that has the problem. Check the
following points:
 Verify if all transmitter readings along the line have readings that
match your hypothesis.
 Can you verify that transmitter readouts are correct?
 Is there still flow in all locations upstream and/or downstream?
Figure 16: Example of items you can touch to navigate upstream/downstream

3.2.5.2. Verification for measurement device issues

Check the following points:
1. Are the readouts of other transmitters similar?

2. If applicable for this device, calibrate the transmitter.
3. Check the system property that is measured (such as flow, temperature,
pressure), the wiring, and the mechanical connections.
4. If the device that is possibly faulty has its own sub-supplier manual:
 Find the sub-supplier manual in the Customer Manual of the EGC
system.
 Did the required maintenance take place?
 Does the manual contain troubleshooting information?
3.2.5.3. Verification for control system issues
A 'control system' is a system where a device operates based on readings
from a transmitter. Figure 17 shows an example where pump MCPt_A4040 is
controlled by pressure transmitter PT_4060. Check the following points:
1. Is there a system that normally prevents this problem from happening?
2. How is this system controlled? What devices and setpoints are involved?
3. Are the transmitter(s) that are used in the control system working
correctly?
4. Compare the readings of these transmitters with other transmitters that
measure the same item, but at a different location or with a different
parameter (for example, pressure instead of flow).
Figure 17 shows the control transmitter for a pump (on the left). The
pressure transmitter and the flow transmitter (on the right) are expected
to have matching values.
Figure 17: Example of comparing transmitter readings

3.2.5.4. Verification for electrical issues

Check the following points:
1. Is power available to the group or device?

2. Try to isolate the problem: find the group, device or wire that causes the
problem.
3. How many electrical connections does the group or device have?
4. Is it likely that any of the electrical signals are interrupted?
5. Is it likely that any of the electrical signals are distorted (for example, by
a strong magnetic field or loops in its cable)?
3.2.6. Solve possible causes

When you have identified possible causes, you must verify and solve them
one at a time. If the first possible cause does not lead to a solution, try again
with the next most logical cause.
If you are unable to solve the problem after multiple attempts or if the
problem keeps reappearing, contact Alfa Laval (see Section 2.7).
3.3. Restore the EGC system to normal operation

After you have solved the cause of the alarm, you can return the EGC system
to normal operation as follows:
1. If settings were changed during troubleshooting, reset these settings to
their original values.
2. Acknowledge and reset the alarm (see the operations manual).
3. Start the EGC system (see the operations manual).

4. What if?
This chapter describes problems that do not immediately result in alarms or
warnings on the touchscreen of the EGC system.
4.1. Touchscreen does not work or does not show all

information
If a touchscreen is ON but does not respond anymore, contact the Alfa Laval
Support Desk. It is important that you follow their instructions on how to
retrieve a backup of the data logger data.
If the touchscreen does not perform a given command or does not show all
details and functionality that you were expecting, maybe one of the following
situations is true:
 You are not logged in. If you cannot login, check if someone else is
logged in on the other control panel.
 The control panel is not selected as the active panel.
See Section 4.1.1 for instructions.
 The 'show tag names' function is OFF.
See Section 2.5 for instructions.
4.1.1. Make a control panel the active panel

To make a control panel the active panel, complete the following steps.
1. On the touchscreen, log in as 'admin'.
2. Touch the LCRP button or the ECRP button (see Figure 18):
 Touch the LCRP button to make panel 802 (Local Control Room
Panel) the active panel.
 Touch the ECRP button to make panel 803 (Engine Control Room
Panel) the active panel.
Figure 18: LCRP / ECRP buttons

4.2. System stays 'busy' or does not stop

The status of the EGC system and its modules can for example be:
 STOP 1000: Module is fully stopped.

 STOP busy: Module is busy stopping.
 CL 81000: Module is running in Closed-Loop mode.
 OL -> CL: Module is switching from Open-Loop mode to Closed-Loop
mode.
You can check the status by looking at the status lines and the status
indicators (see Section 2.4).
When the system stays busy or does not stop, complete the following steps.
1. Log in.
2. Go to the Global Overview screen and check the status of the whole EGC
system and its modules.
3. Go to the screens for modules that seem to have a problem and view the
module status lines for more information about what is happening in the
module.
4. If a module stays in the status 'STOP BUSY', check if all devices are set to
automatic mode.
5. Make sure that all alarms are acknowledged, solved, and reset.
6. Check the reading of level transmitter LT_2902. Depending on your
software configuration, the system does not stop when level transmitter
LT_2902 has a reading above the minimum limit (usually 0.5 m).
7. If the system does not stop after 15 minutes and solving the causes of
alarms did not work, press and hold the SCRUBBER STOP button on the
ECRP or the LCRP for 5 seconds to force the system to an immediate
stop.
This results in an uncontrolled system stop.

4.3. System does not start

If you pressed the SCRUBBER START button but the scrubber does not start,
refer to the following table to determine what to do.
Event Possible Causes Advice
Scrubber does not Possible causes include:

start  The control panel is not the active panel. 1) Follow the full procedure to start the
 An alarm is active (the consequence of scrubber, as described in the Maintenance
failure of the alarm may only affect part Manual.
of the system). 2) If an alarm is active, troubleshoot the
 For Hybrid and Closed-Loop systems: the alarm (see Section 3.1).
water level in the circulation tanks is too 3) For Hybrid and Closed-Loop systems,
low (start condition for Closed-Loop check the fill level of the circulation tanks,
mode). using LT_x5101. Make sure that the fill
 The minimum requirement for the water level in both tanks is at least 60%.
flow and pressure to the scrubber is not 4) If the EGC system was stopped using an
reached. emergency stop button:
 The Emergency Stop is activated. a. Turn the emergency stop button
 For Hybrid systems: no mode is selected. clockwise to release it. The button
 The EGC system is not in the status returns to its home position.
'STOP x000' (for example, 'STOP 1000'). b. Press the RESET EMERCENCY STOP
See Section 4.2 for advice. (RELAY) button.
c. Press the RESET button.
5) For a Hybrid EGC system, on the
touchscreen select an operational mode:
Open-Loop (OL) or Closed-Loop (CL).

4.4. System does not switch modes (OL / CL)

This section applies to Hybrid systems only.
If you touched the OL button to switch to Open-Loop mode or the CL button

to switch to Closed-Loop mode but the EGC system does not switch running
mode, refer to the following table to determine what to do.
System does not Possible causes include:

switch modes.  You are not logged in on the touchscreen 1) Log in and make this control panel the
at the correct user level. active panel (see Section 4.1.1).
 The control panel is not the active panel. 2) If the system stays busy switching, see
Section 4.2.
 An alarm is active (the consequence of
3) If an alarm is active, troubleshoot the
failure of the alarm may only affect part
alarm (see Section 3.1).
of the system).
4) Check the fill level of the circulation tanks,
 A device is in manual mode.
using LT_x5101. Make sure the fill level in
 Water level in the circulation tanks is too
both tanks is at least 60%.
low (start condition for Closed-Loop
5) For Open-Loop: make sure that the inlet
mode). LT_x5101 is below minimum
valve is open, and that the strainer is not
operational level.
clogged or filled with air (after or during a
 The EGC system has started to switch, storm).
but during start-up of the pumps, the
minimum requirement for water flow and
pressure to the scrubber is not reached.
 A switching valve is stuck.

4.5. Readings from a water analyzer panel are incorrect

The readings from a water analyzer panel are probably incorrect if:
 The readings are unusually stable.

 The readings do not match the readings from other panels.
 The water analyzer panel does not give any readings.
Refer to the following table to determine what to do.
 The controller on the analyzer panel has 1) If the controller has crashed:
Incorrect readings
crashed.
a. Disconnect all sensors and reconnect
 There is no water flow through the panel.
the sensors one by one.
 A sensor or gateway on the analyzer
b. If the previous action does not help, re-
panel has crashed.
start the analyzer panel by switching it
off and on using the group-fuse in the
Main cabinet 802.
2) Check if there is flow through the panel
according to procedure EGC01-020-0x
'Check water flow through water analyzer
panels' in the Alfa Laval Maintenance
Manual.
3) If the following conditions apply:
 The problem was in panel 7500,

and
 The system is a Hybrid EGC system ,
and
 The sample point is at the bottom of
the main pipe
Check if a blockage can be prevented in the

future:
Check the mechanical limits of switching
valve tag 2810. The valve should fully close.
If this valve leaks when the EGC system runs
in Closed-Loop mode, a steady flow of water
with a lot of soot enters and clogs this
sample line.

4.6. EGC system generates loud noises

4.6.1. Sudden loud noises near the sealing air fans
When the scrubber is ON and the engines are OFF and you hear loud noises
near the sealing air fans, refer to the following table to determine what to do.

 Air flow through the non-return valves 1) Adjust purge hand valve HV_1180 a little
Hammering noises
(tag no. 1114 and 1118) is too low. This bit to the open position. In this way, there
causes the valves to start hammering. will always be air flow to the scrubber
when sealing fans are on.
2) Adjust the close feedback position on the
valve, to prevent an alarm on the EGC
system.
4.6.2. Loud noises near the scrubber or the WCU
When you hear loud hammering noises near the scrubber or the Water
Cleaning Unit (WCU), one of the following events most likely happened:
 If hammering noises are heard near the scrubber, the engine load
recently changed. This change to the engine load causes the scrubber
to change sprayer layers.
 If hammering noises are heard near the WCU, the WCU switched
between production and bleed-off mode.
Refer to the following table to determine what to do.

 If the WCU is periodically producing a 1) If periodic loud bangs caused by the WCU
Hammering noises
loud 'bang', the WCU is probably cleaning cleaning the separator bowl are heard, no
the separator bowl. action is required.
 Pressure hammering due to valves 2) If the hammering noises are in the
closing too quickly. scrubber during opening or closing of jet
layers, open the top valve manually in the
jet section(s) of the scrubber.
This is a temporary fix. Contact Alfa Laval
to request:
a. Speed regulators for the valves in the

jet(s) and absorber.
b. A software update, so that the top jet
valve stays open when the scrubber is
in operation and closes after a delay
when the scrubber is stopped.

4.7. Display of gas analyzer shows an alarm

If the display of the gas analysis unit shows an alarm message, refer to the
following table to determine what to do.
Note: There are also gas analysis alarms that display on the touchscreen
of the EGC system. For these messages, see Section 6.2.
Message Possible Causes Advice

 Gas analyzer requires a calibration. 1) If the message on the gas analyzer display
Maintenance request
U6  Filters are clogged. includes a request, carry out the request.
 Temperature of the sample probe or 2) Calibrate the gas analyzer.
Sample Conditioning System (SCS) is too 3) Check the sample probe filter and the
low. sample gas filter for contamination.
 Pump is faulty. Caution: hot!
 Sample lines are blocked with water. If filters are dirty very often, contact Alfa
 Calibration gas bottle is empty. Laval for advice.
4) Check the temperature of the sample
probe and the SCS.
5) Check if the pump is working.
6) Open the drain plug to drain water from
the sample lines.
7) Check the pressure of the calibration gas
bottle. The pressure must be at least 3-5
bar.
8) Try pressing 'MEAS' on the analyzer two
times. This action resets the gas analyzer.
1) If the message on the gas analyzer display

Low flow U6 Not enough gas flow is passing through the
sample probe and gas analyzer: includes a request, carry out the request.
 Filters are clogged. 2) Check the sample probe filter and the
 Temperature of the sample probe or sample gas filter for contamination.
Sample Conditioning System (SCS) is too Caution hot!
low. If filters are dirty very often, contact Alfa
 Pump is faulty. Laval for advice.
3) Check the temperature of the sample
 Sample lines are blocked with water.
probe and the SCS.
4) Check if the pump is working.
5) Open the drain plug to drain water from
the sample lines.
6) Check for blockages in the sample lines
between the sample probe and the SCS.
If blockages are present in the sample lines:

 Blow air through the sample line to eliminate
the blockage.
 Check if the sample probe was installed
correctly in the stack. The sample probe
must have a slight downward angle, so water
flows back into the stack.
 Try pressing 'MEAS' on the analyzer two
times. This action resets the gas analyzer.

4.8. Display of WCU shows LL turbidity alarm

If the display of the Water Cleaning Unit (WCU) shows an LL turbidity alarm,
complete the following steps to solve this issue.
1. On the control panel of the WCU, log in as Admin.
2. Change the setpoint of the alarm to '-1'.
3. Contact Alfa Laval to request a software update in which this alarm is
removed.
4.9. WCU in bleed-off mode, but no water is discharged

If no water is discharged overboard when the Water Cleaning Unit (WCU) is
in bleed-off mode, refer to the following table to determine what to do.
Note: This section is applicable only when the EGC system does not have a
zero discharge tank.

1) If the EGC system has an alarm,
No water discharge Bleed-off valve (PVc_6620) is closed. This
valve is closed in the following situations: troubleshoot the alarm (see Section 3.1).
 The turbidity of the bleed-off water is too 2) Make sure all devices are in automatic
high (warning on touchscreen). mode.
 The pH of the bleed-off water is too high 3) If the WCU is in 'local' mode, return the
or too low (warning on touchscreen). WCU to 'remote' mode.
 The water level in the circulation tank is
too low (warning on touchscreen).
 A WCU discharge valve (PVo_6610 or
PVc_6620) was closed manually and is
still in manual mode.
 The WCU is in local mode, and the EGC
system does not request bleed-off
because the discharge conditions are not
reached.

5. Compliance issues
The SOx/CO2 ratio in the exhaust gas and the pH, PAH, and turbidity in the
discharge water determine if the ship's emissions are in compliance. If the
ship's emissions are out of compliance, the EGC control system warns the
operator. Also, the touchscreen shows a blinking red field at the analyzer
reading that is outside specifications (see Figure 19).
Figure 19: Example of a compliance warning
The legal discharge limits for your ship are stated in your EGC Technical
Manual (ETM-B).
This chapter describes the actions that must be taken when ship's emissions
are out of compliance, to bring the emissions back in compliance. Depending
on the alarm message that displays, refer to the following sections for
instructions:
 For the message 'Max. SOx/CO2 reached', see Section 5.1.
 For the message 'pH content Low pH', see Section 5.2.
 For the message 'Max. PAH reached', see Section 5.3.
 For the message 'Max. Limit[FNU] reached', see Section 5.4.
FNU refers to turbidity.
 For a wirebreak warning on any of the gas or water analyzer sensors,
see Section 7.5.
Note: The instructions in this chapter are taken from the EGC Technical
Manual (ETM-B). Always refer to your ETM-B. If there are
differences, the ETM-B takes precedence over this manual.
Note: When the EGC system is out of compliance, always write all
troubleshooting and maintenance activities in the log book.

5.1. SOx/CO2 ratio out of compliance

Depending on the location of the vessel, there are different SOx emission
requirements. Figure 20 shows an example of sulphur emission control areas.
Figure 20: Sulphur emission control areas (November 2015)
If the SOX/CO2 ratio limit in the exhaust gas is exceeded, a warning blinks in
the gas analyzer (see Figure 21).
Figure 21: Example of SOX/CO2 ratio out of compliance
In Open-Loop and Closed-Loop mode, a larger volume of water through the

jet and absorber can help correct the SOx/CO2 ratio. In Closed-Loop mode,
an additional option is to increase the NaOH dosage.

5.1.1. Bring SOx/CO2 ratio back in compliance

Short-term solutions in Open-Loop mode
If the EGC system is operating in Open-Loop mode and exceeding the
SOX/CO2 ratio limit, take the following actions in the order in which they are
listed. If an action does not have the desired effect, try the next action, and
so on.
1. Make sure that all process settings are correct (see Section 5.5.1).
2. Increase the water flow to the absorber (see Section 5.5.2).
3. Increase the water flow to the jet (see Section 5.5.4).
4. On Hybrid systems, switch to Closed-Loop mode, unless you already tried
this action without achieving the desired effect. Complete the following
actions:
a. Reset the absorber settings to their original values.
b. Switch manual mode OFF for all devices.
c. Switch the system from Open-Loop mode to Closed-Loop mode.
5. If possible, lower the engine load.
Short-term solutions in Closed-Loop mode

If the EGC system is operating in the Closed-Loop mode and exceeding the
SOX/CO2 ratio limit, take the following actions in the order in which they are
listed. If an action does not have the desired effect, try the next action, and
so on.
2. Increase the NaOH dosage (see Section 5.5.5).
4. Increase the water flow to the jet (see Section 5.5.4).
5. On Hybrid systems, switch to Open-Loop mode, unless doing so is not
allowed or is impossible, or you already tried this action without
achieving the desired effect. Complete the following actions:
c. Reset the NaOH dosage settings to normal.
d. Switch the system from Closed-Loop mode to Open-Loop mode.

5.1.2. If the compliance issue remains

If the maximum SO2/CO2 ratio is exceeded and the actions taken are not
enough to fix the problem, try the following actions:
 If available, switch to low sulphur fuel.
 Rectify the problem at the next harbour visit.
 If the gas analysis unit has not been maintained according to
schedule, perform all overdue maintenance as soon as possible.
Record all actions you take when trying to bring the SOx/SO2 ratio back in
compliance and remember to inform the authorities.
When the system is operating within the emission control limits again, or at
any convenient time thereafter, further troubleshooting or maintenance may
be needed. See Section 5.1.3 for possible root causes. When the issue is
permanently solved, restore original settings to return the system to normal
operation.
5.1.3. Possible root causes of incorrect SOx/CO2 ratio

Your actions to bring the EGC system back in compliance do not always solve
the root cause of why the system went out of compliance in the first place.
Some of the possible root causes of an incorrect SOx/CO2 ratio include:
 Air is entering the gas analysis unit. Check the trend of the CO2
content in the exhaust gas. For running engines, the CO2 content is
normally ±5-6%. If the CO2 content trend is decreasing and the
sulphur trend is stable, check the sample-probe and search for water
signs in the sample preparation system.
 The gas analysis unit is not working correctly.
 The gas analysis unit is not calibrated correctly.
 Not enough water flows through the absorber and jet.
 The water pressure at the sprayers in the absorber and jet is too low.
The pressure indicator in a sprayer layer, located between the valve
and the sprayers, reads below 0.8 bar.
 The sprayers in the jet and absorber are worn out.
 There have been prolonged periods of sudden changes in engine load,
for example in bad weather. In this case, temporarily change the
settings in the Absorber Settings window. As a result, sudden engine
load changes do not trigger changes in the use of sprayer layers.
Contact Alfa Laval for instructions.
 During start-up of the EGC system, a possible root cause is that the
air around the ship contains SOX from other ships.

 In Open-Loop mode, a possible root cause is that the vessel is sailing

in very low alkalinity waters.
 In Closed-Loop mode, possible root causes are:
- The temperature of the water for exhaust gas cleaning is too
high.
- The pH level of the water for exhaust gas cleaning is too low.
 If you cannot find the root cause, refer to Section 3.2 for a
troubleshooting method.
Note: As soon as the root cause is solved, reset all settings to their
original values.

5.2. pH out of compliance

If the lower pH limit in the wash-water is exceeded, a warning blinks in the
Effluent Analyzer (Open-Loop) or the WCU Effluent Analyzer (Closed-Loop).
See Figure 22.
Figure 22: Example of pH out of compliance
In Open-Loop mode, a larger volume of water through the jet and absorber
can help correct the pH. More water increases the pH level of the wash-
water. Less water lowers the pH level.
In Closed-Loop mode, the pH can be corrected by increasing the NaOH
dosage.
5.2.1. Bring pH back in compliance

If the EGC system is operating in Open-Loop mode and exceeding the pH
limit, take the following actions in the order in which they are listed. If an
action does not have the desired effect, try the next action, and so on.
3. Increase the water flow to the jet(s) (see Section 5.5.4).
5. Increase the water flow to the absorber again (see Section 5.5.2).
this action without achieving the desired effect. Complete the following
actions:
c. Switch the system from Open-Loop mode to Closed-Loop mode.


If the EGC system is operating in Closed-Loop mode and exceeding the pH
2. Increase the NaOH dosage (see Section 5.5.5).
achieving the desired effect. Complete the following actions:
a. Switch manual mode OFF for all devices.
b. Reset the NaOH dosage settings to normal.
c. Switch the system from Closed-Loop mode to Open-Loop mode.

If the pH limit is exceeded and the actions taken are not enough to fix the
problem, try the following actions:
Record all actions you take when trying to bring the pH back in compliance
and remember to inform the authorities.
operation.
5.2.3. Possible root causes of low pH

The actions to bring the EGC system back in compliance do not always solve
Some of the possible root causes of a low pH include:
 There is no water flow through the water analyzer panels that
measure pH.
 Not enough water flows through the absorber and jet.
 In Open-Loop mode, possible root causes are:
- The vessel is sailing in very low alkalinity waters.
- Transmitter QT_7520 is faulty.


- The NaOH storage tank is empty.
- The vent on the NaOH storage tank is closed.
- The NaOH pump is not working.
- The NaOH pump 'stroke' setting is too low.
- The NaOH dosage is too low.
- The temperature of the NaOH dosing line is incorrect.
- The NaOH dosing line is blocked.
 Shortly after switching to Closed-Loop mode, the NaOH dosage
control has to start up. This causes a low peak in pH. This peak
becomes larger with a low water level in the circulation tank(s), or
when the tank(s) were recently refilled with fresh water.
original values.

5.3. PAH out of compliance

Incomplete combustion of fuel oils causes Polycyclic Aromatic Hydrocarbons
(PAH) to occur. Some of the PAH in the exhaust gas ends up in the wash-
water.
If the PAH limit in the wash-water is exceeded, a warning blinks in the
Effluent Analyzer (Open-Loop) or the WCU Effluent Analyzer (Closed-Loop).
See Figure 23.
Figure 23: Example of PAH out of compliance
In Open-Loop, it is not possible to change the PAH level in the wash-water.

In Closed-Loop, the Water Cleaning Unit (WCU) can help correct the amount
of PAH that is discharged.
5.3.1. Bring PAH back in compliance

If the EGC system is operating in Open-Loop mode and exceeding the PAH
1. Perform maintenance on the PAH sensor as described in the maintenance
manual.
2. Replace the PAH sensor as described in the maintenance manual.
this action without achieving the desired effect.

If the EGC system is operating in Closed-Loop mode and exceeding the PAH

1. Perform maintenance on the PAH sensor as described in the maintenance

manual.
2. Replace the PAH sensor as described in the maintenance manual.
3. If possible, decrease the flow to the WCU (see Section 5.5.6).
This action is only possible if the engines are not running at full engine
load on fuel with a maximum sulphur content.
4. Contact Alfa Laval.
The WCU may need adjustments that cannot be done by the ship crew.
achieving the desired effect.

If the PAH limit is exceeded and the actions taken are not enough to fix the
problem, try the following actions:
Record all actions you take when trying to bring the PAH back in compliance
and remember to inform the authorities.
operation.
5.3.3. Possible root causes of high PAH

Some of the possible root causes of a high PAH include:
 Poor combustion.
 Engine maintenance.
measure PAH.
- The inlet seawater contains a high level of PAH.

- The Water Cleaning Unit is not working correctly.

original values.

5.4. Turbidity [FNU] out of compliance

The turbidity value indicates the degree to which the water loses its
transparency (for example because of soot, sand, algae, and so on). The
more suspended particles are present in the water, the higher the turbidity
is.
In Open-Loop mode, the rolling average turbidity is calculated using the

Effluent Analyzer turbidity value (QT_A7515) minus the Inlet Analyzer turbidity
value (QT_7605). In Closed-Loop mode, the rolling average turbidity is
calculated using the turbidity sensor (QT_WTS) value of the Water Cleaning
Unit.
If the turbidity limit in the wash-water is exceeded, a warning blinks in the
Effluent Analyzer (Open-Loop) or the Water Cleaning Unit (Closed-Loop). See
Figure 24.
Figure 24: Example of turbidity out of compliance
In Open-Loop mode, it is not possible to change the turbidity value of the

wash-water. In Closed-Loop mode, the Water Cleaning Unit (WCU) can help
correct the turbidity value.
5.4.1. Bring turbidity [FNU] back in compliance

If the EGC system is operating in Open-Loop mode and exceeding the

turbidity limit, take the following actions in the order in which they are listed.
If an action does not have the desired effect, try the next action, and so on.
1. Perform maintenance on the turbidity sensor as described in the

maintenance manual.
2. Replace the turbidity sensor as described in the maintenance manual.
this action without achieving the desired effect.


If the EGC system is operating in Closed-Loop mode and exceeding the
turbidity limit, take the following actions in the order in which they are listed.
If an action does not have the desired effect, try the next action, and so on.
1. Perform maintenance on the turbidity sensor as described in the
maintenance manual.
2. If possible, decrease the flow to the WCU (see Section 5.5.6).
This action is only possible if the engines are not running at full engine
load on fuel with a maximum sulphur content.
3. Contact Alfa Laval.
The WCU may need adjustments that cannot be done by the ship crew.
achieving the desired effect.

If the turbidity limit is exceeded and the actions taken are not enough to fix
the problem, try the following actions:
Record all actions you take when trying to bring the turbidity back in
compliance and remember to inform the authorities.
operation.
5.4.3. Possible root causes of high turbidity [FNU]

Some of the possible root causes of high turbidity include:
 Poor combustion.
 Engine maintenance.
measure turbidity.

 Air in the WCU. If the WCU is equipped with a sight glass, check for
bubbles. If bubbles are present, increase the backpressure as follows:
a. Log in on WCU control panel.
b. Go to the second screen of Main parameters.
c. In the table for Main in BLEED OFF, check the outlet backpressure
setpoint.
d. Write down the current setting for later reference.
e. Increase the backpressure setpoint for bleed-off by 50 kPa, but
do not use a value higher than 650 kPa.
f. Check the sight glass again. If bubbles are still present, check if
the new backpressure setpoint was actually reached. If the
setpoint was reached, repeat the procedure. If the backpressure
setpoint was not reached, contact Alfa Laval.
g. Return the WCU to normal by resetting the setting(s) in the WCU
control panel to their original values.
- Transmitter QT_A7515 is faulty.
- The Water Cleaning Unit (WCU) is not working correctly.
- Transmitter QT_WTS is faulty.
original values.

5.5. Procedures to resolve compliance issues

5.5.1. Check process settings
Figure 25: Example of a process settings window
If the SOx/SO2 ratio or the pH is out of compliance, check the process

settings as follows:
2. On the Global Overview screen, touch the Process Settings button to open
the NaOH/Sulphur window.
3. Check and, if needed, correct the values in the following fields.
Field Correct value
NaOH concentration NaOH concentration (%) of the NaOH storage

tank.
This value must match the NaOH delivery notes.
Sulphur content in fuel Sulphur content (%) of the fuel that is currently
used.
This value must match the bunker delivery notes.
FO Sulphur limit Legal limit for the sulphur content of the fuel oil
(FO) for the area where the vessel is sailing.
For example, within the ECA this value is 0.1%.

5.5.2. Increase water to absorber (Open-Loop mode)
Figure 26: Part of the Absorber Settings window, for a Hybrid system
The following steps can help when the SOx/SO2 ratio or the pH is out of
compliance.
2. On the Global Overview screen, touch the blue Absorber module button to
open its window.
3. Touch the Settings button to open the absorber settings window.
4. Write down the current settings for later reference.
5. Increase the amount of water though the absorber sprayers by lowering
the Load OL[%] values.
These Load OL[%] values determine at which engine load a sprayer layer
is opened. Lowering the value means more water with the same engine
load.
Note: Do not change the settings in the column Water[%].

5.5.3. Increase water to absorber (Closed-Loop mode)
Figure 27: Part of the Absorber Settings window, for a Hybrid system
compliance.
2. On the Global Overview screen, touch the blue Absorber module button to
open its window.
3. Touch the Settings button to open the absorber settings window.
5. Increase the amount of water though the absorber sprayers by lowering
the Load CL[%] values.
These Load CL[%] values determine at which engine load a sprayer layer
is opened. Lowering the value means more water with the same engine
load.
Note: Do not change the settings in the column Water[%].

5.5.4. Increase water to jet(s)
Figure 28: Manual operation of jet sprayer valve
There are two sprayer layers in the jet(s). The top layer (valve PVo_x2004)
is always open when the scrubber is in operation. The valve for the second
layer (PVo_x2015) opens only above a certain engine load that is set by Alfa
Laval. To increase the amount of water at lower engine loads, complete the
following steps to manually open the second sprayer layer. This action can
help when the SOx/SO2 ratio or the pH is out of compliance.
2. On the Global Overview screen, touch the icon in the Jet Section module to
open the Overview Jet Section screen.
3. Touch the device icon of valve PVo_x2015 to open its window.
4. If the valve is closed, open the valve as follows:
a. Switch the valve to manual mode by touching the Manual mode slide-
switch until the 'I' is visible.
b. Touch the Activate (=close) valve slide-switch until the 'O' is visible
to open the valve.

5.5.5. Increase NaOH dosage (Closed-Loop mode)
Figure 29: NaOH concentration in the process settings window
compliance.
Note: A high NaOH dosage can damage components in the EGC system.
Therefore, gradually increase the NaOH dosage.
Method 1, using software settings
To increase NaOH dosage:

2. On the Global Overview screen, touch the Process Settings button to open
the NaOH/Sulphur window.
4. Check the actual NaOH concentration in the NaOH storage (for example,
45%). Refer to the NaOH delivery notes.
5. To increase the NaOH dosage, fill in a lower value in the 'NaOH
concentration' field.
Note: The lowest acceptable value is a factor 0.9 below the actual NaOH
concentration, for example 45% x 0.9=40.5%. This is a ±10%
increase in NaOH dosage.
6. Closely monitor the effect on the emission values. If needed, increase the
NaOH dosage a little bit more.

Method 2, using settings on the pump

To increase NaOH dosage:
1. Make sure that the caustic soda dosage pump is running.

Note: If the pump is not running, the pump will be damaged if you
increase the dosage.
2. Go to the location of the caustic soda dosage pump. The pump is usually
near the caustic soda storage tank.
3. Increase the stroke on the caustic soda dosage pump.
4. Closely monitor the effect on the emission values. If needed, increase the
NaOH dosage a little bit more.

5.5.6. Reduce flow to the Water Cleaning Unit (Closed-Loop mode)

The following steps can help when the PAH or the turbidity is out of
compliance. You can either decrease the flow to the Water Cleaning Unit
(WCU), or increase the backpressure on the WCU, or both.
Note: You can only decrease the flow to the WCU if the engines are not
running at full engine load on fuel with the maximum sulphur
content.
1. Check if the WCU is in bleed-off mode.
If not, there is no out of compliance situation that needs to be solved.
2. To decrease the flow to the WCU:
c. In the table for Main in BLEED OFF, check the feed flow rate.
e. Lower the setpoint by 1 m3/h, but do not use a value lower than
4 m³/h.
3. To increase the backpressure:
c. In the table for Main in BLEED OFF, check the outlet backpressure
setpoint.
e. Increase the backpressure setpoint for bleed-off by 50 kPa, but do
not use a value higher than 650 kPa.
4. Check the PAH and turbidity readings: the reading must become lower
shortly after changing the flow or backpressure setpoint. If not, continue
with the next step.
5. If the PAH and turbidity levels are below the allowed limits, or if the
procedure did not work, return the WCU to normal by resetting the
setting(s) in the WCU control panel to their original values.

6. Alarms and warnings for modules

This chapter gives troubleshooting advice for the most common alarms and
warnings that occur in system modules. Alarms and warnings for modules
are shown on the touchscreen as shown in Figure 30.
Figure 30: Example of alarms and warning in a module
Use this chapter as follows:

1. First see Section 6.1. This section contains alarms that are valid for all
modules.
2. If Section 6.1 does not solve the problem, see the remaining sections for
module-specific alarms.
Note: For compliance alarms, regarding SOx/CO2 ratio, pH, PAH, or
turbidity (FNU), see Chapter 5.

6.1. All modules

1) Reset the fuse.
Power Fault Automated fuse blown.
2) If the fuse blows again:
Additional alarms: usually there are other a. Check all devices directly under the
errors related to power supply or module
fuse.
failures.
b. Check for glass fuses that belong to
this group. Take out the fuses and
restore them one by one till the fuse
blows again.
c. Disconnect sensors/actuators that
belong to the same group as the glass
fuse. Reconnect the sensors/actuators
one by one until the fuse blows again.
d. Check the wiring of the sensor for a
short circuit. Another option is to
replace the sensor.
1) Identify the I/O card inside the electrical

IO card warning I/O card failure (PLC). In this example, card
(Module_OK=false) U43 failed. Possible causes include: cabinet. The LEDs on the failing I/O card
U43  Power Supply to the I/O card is too high are OFF or (blinking) red.
or too low. 2) Check if there are alarms for the Power
Note: The message
shows the number of  The I/O card is faulty. Supply to the module before the I/O card.
the card that failed.  The bus module is faulty. If there is no power (blinking red), check
the (glass) fuse.
3) Check the I/O card and bus module and, if
needed, replace with a new one.
Hardware module I/O card failure (PLC). This warning is only Troubleshoot all other alarms/warnings on the
fault active in combination with another module touchscreen that are related to I/O card failure.
warning.
1) Check if all touchscreens, the PLC, and the
Ethernet Switch Problem with the Ethernet switches in the
Failure main cabinet. Honeywell data logger (if present) are
connected to the Ethernet switches.
2) Check if all touchscreens, the PLC, and the
Honeywell data logger (if present) are ON.
3) Check if a fuse is blown in the Ethernet
power supply.

6.2. Gas Analysis module

1) On the gas analyzer user interface, check
GasAnalysis_Warning8 The gas analyzer is performing
maintenance. Possible causes are: the cause of the maintenance.
Maintenance in 2) If no apparent cause was found, try
 The gas analyzer is powering up. The
progress
self-check may take up to an hour. pressing 'MEAS' twice to reset the gas
 The gas analyzer is in calibration mode. analyzer.
 The gas analyser is in programming
mode.
GasAnalysis_Alarm6 See Section 4.7. See Section 4.7.

Maintenance request
GasAnalysis_Alarm9 When powering up the scrubber or the gas Check the following components:
analyzer, this is a normal message because 1) Temperature switch of the sample probe:
SCS1 alarm active the cabinet and the sample probe have to must make contact and be hotter than
heat up.
150°C.
Usually this alarm comes with other alarms 2) Temperature sensor in the conditioning
related to the gas analyzer. cabinet: must read above 55°C.
The following devices can trigger this alarm: 3) Sample gas filter: check the sample gas
 Temperature switch of the sample probe. filter in the electrical cabinet of the
 Temperature sensor in the conditioning Sample Conditioning System for moisture.
cabinet. If necessary, replace the filter.
 Moisture sensor in the electrical cabinet 4) Drying flow of the compressed air: if too
of the Sample Conditioning System. low, check the filters in the gas analyzer.
 Sensor for drying flow of compressed air.
6.3. Touchscreen (HMI panel)

1) Make sure that the HMI and PLC cables are
Communication Loss This touchscreen has lost communication
with the PLC. Possible causes are: connected securely.
 PLC power is OFF. 2) Contact Alfa Laval (see Section 2.7) and
Example:  Cables are disconnected. ask for instructions on how to safeguard
HmiPanel_Warning1 logging data.
HMI panel has lost 3) Disconnect the power to the touchscreen
communication with by disconnecting the green connector at
PLC the back of the touchscreen. Then restart
the touchscreen by reconnecting the
connector.

6.4. Main
1) Check the filter in the cabinet for dust and
Temperature PLC too The temperature in the PLC is too high. This
high can cause damage to electrical components. contamination. Clean and/or replace the
Possible causes are: filter if required.
 Ambient temperature is too high. 2) Make sure the thermostat inside the
Example:  Insufficient ventilation of the electrical cabinet is set to a temperature <20°C.
Main_Warning12 cabinet. 3) If the previous steps did not resolve the
CPU temperature too problem, contact the Alfa Laval support
high desk. A small ventilator for air flow in PLC
may need to be installed.
1) Make sure that the HMI and PLC cables are

No heartbeat HMI A touchscreen (on the ECRP or LCRP) has
lost communication with the PLC. Possible connected securely.
causes are: 2) Check the heartbeat relay and replace if
Example:  PLC power OFF. needed.
Main_Warning20  Cables disconnected. 3) Disconnect the power to the touchscreen
No heartbeat HMI  Relay is faulty. by disconnecting the green connector at
LCRP => PLC  Touchscreen has crashed. the back of the touchscreen. Then restart
the touchscreen by reconnecting the
connector.

7. Alarms and warnings for devices

This chapter gives troubleshooting advice for the most common alarms and
warnings that occur in devices. Alarms and warnings for devices are shown
on the touchscreen as shown in Figure 31.
Figure 31: Example of a device alarm and a device warning
This chapter contains the following sections:

 Section 7.1 for Hand valves (HV)
 Section 7.2 for Pressure valves (PV)
 Section 7.3 for Process controlled valves (PCV)
 Section 7.4 for Pumps and fans (MCP, MCF)
 Section 7.5 for Transmitters (FT, PT, TT, QT, LAh, LSA, LT)
Note: For compliance alarms, regarding SOx/CO2 ratio, pH, PAH, or

turbidity (FNU), see Chapter 5.

7.1. Hand valves (HV)

1) Move the hand valve to the open position.
Not Open Valve is not open, but it should be open.
Possible causes are: 2) If the hand valve is already fully open:
 Valve is closed or not fully opened. a. Make sure that the feedback switch is
Example:  Feedback open (GSo) is not activated. making contact, and adjust the
HV_2990_Alarm1 feedback switch if needed.
 Wirebreak between feedback switch and
Discharge overboard the PLC. b. Check the feedback switch wiring
valve Not open. towards the PLC input.
1) Move the hand valve to the closed position.

Not Closed Valve is not closed, but it should be closed.
Possible causes are: 2) If the hand valve is already fully closed:
 Valve is open or not fully closed. a. Make sure that the feedback switch is
Example:  Feedback closed (GSc) is not activated. making contact, and adjust the
HV_2990_Alarm2 feedback switch if needed.
Discharge overboard the PLC. b. Check the feedback switch wiring
valve Not closed. towards the PLC input.
1) Check the position of the hand valve.

GSc GSo both active The close (GSc) and open (GSo) feedbacks
of the hand valve are activated at the same 2) Make sure that the feedback switch is
time. making contact, and adjust the feedback
Example:  Feedback switch not adjusted correctly. switch if needed.
HV_2990_Alarm3  Wirebreak between feedback switch and 3) Check the feedback switch wiring towards
Discharge overboard the PLC. the PLC input.
valve Feedbacks GSc
GSo both active

7.2. Pressure valves (PV)

1) Make sure that the instrument air pressure
Feedback close (GSc) Close Command given but Close Contact not
not reached reached in time. is within specifications.
 Valve is moving too slowly. 2) If the gearbox shows signs of corrosion,
 Actuator is damaged. lubricate the gearbox.
Example: 3) Make sure the gearbox and/or the solenoid
 Actuator is not adjusted correctly (valve
PVo_4560_Alarm1 valve do not have manual override active.
cannot fully close).
PlateHeatExchanger 4) If the valve moves slowly, adjust the
 End position feedback switches are not
outlet valve Feedback speed control valve for faster
adjusted correctly.
closed (GSc) not opening/closing. The speed control valve is
reached  Wirebreak between feedback switch and
located in the instrument air inlet of the
the PLC.
valve.
 Gearbox of the valve is not lubricated.
5) Check the position of the valve. If the
 Gearbox of the valve is in manual
valve is already fully closed:
override.
a. Make sure that the feedback switch is
making contact, and adjust the
feedback switch if needed.
b. Check the feedback switch wiring
towards the PLC input.
c. After adjustment, make sure that the
feedback switches match the position
of the valve.
Feedback open (GSo) Open Command given but Open Contact not
not reached reached in time. is within specifications.
 Valve is moving too slowly. 2) Check the mechanical limits of the valve to
 Valve is stuck in its liner. make sure the valve is not stuck in its liner
Example: when closed.
 Actuator is damaged.
PVo_4560_Alarm3 3) If the gearbox shows signs of corrosion,
 Actuator is not adjusted correctly (valve
PlateHeatExchanger lubricate the gearbox.
cannot fully open).
outlet valve Feedback 4) Make sure the gearbox and/or the solenoid
open (GSo) not  End position feedback switches are not
valve do not have manual override active.
reached adjusted correctly.
5) If the valve moves slowly, adjust the
speed control valve for faster
the PLC.
opening/closing. The speed control valve is
 Gearbox of the valve is not lubricated.
 Gearbox of the valve is in manual valve.
override. 6) Check the position of the valve. If the
valve is already fully open:
a. Make sure that the feedback switch is

making contact, and adjust the
feedback switch if needed.
b. Check the feedback switch wiring
c. After adjustment, make sure that the
feedback switches match the position
of the valve.


Feedback close (GSc) Close Command no longer given but Close
still active Contact still active. is within specifications.
 Valve is stuck in its liner. 2) Check the mechanical limits of the valve to
 Actuator is damaged. make sure the valve is not stuck in its liner
Example: when closed.
 Gearbox of the valve is in manual
PVo_4560_Alarm2 3) If the gearbox shows signs of corrosion,
override.
PlateHeatExchanger lubricate the gearbox.
outlet valve Feedback 4) Make sure the gearbox and/or the solenoid
close (GSc) still valve do not have manual override active.
active
5) Check the feedback switch and its wiring

Feedback open (GSo) Open Command no longer given but Open
still active Contact still active. is within specifications.
 Actuator is damaged. 2) If the gearbox shows signs of corrosion,
 Gearbox of the valve is in manual lubricate the gearbox.
override. 3) Make sure the gearbox and/or the solenoid
1) Make sure that the feedback switch is

GSc GSo both active Close AND Open Contact both active.
 End position feedback switches are not making contact.
adjusted correctly. 2) Check the feedback switch and its wiring
 Water in the actuator. towards the PLC input.
3) If this happens during start-up of the EGC
 During start-up of the actuator, the
system, contact Alfa Laval to increase the
actuator briefly triggers this message.
delay of this alarm.
PVx_xxxx also open This valve is also open or is still busy closing Do the following checks on both valves:
because: 1) Make sure that the air pressure is within
 Actuator is damaged. specifications.
 Gearbox of the valve is in manual 2) If the gearbox shows signs of corrosion,
override. lubricate the gearbox.
3) Make sure the gearbox and/or the solenoid
PVx_xxxx also closed This valve is also closed or still busy Do the following checks on both valves:
opening, because: 1) Make sure that the air pressure is within
 Valve is stuck in its liner. specifications.
Example:  Actuator is damaged. 2) Check the mechanical limits of the valve to
PVo_2810_Alarm6
 Gearbox of the valve is in manual make sure the valve is not stuck in its liner
Scrubber Switching override. when closed.
discharge valve 3) If the gearbox shows signs of corrosion,
PVc_2820 also closed
lubricate the gearbox.
4) Make sure the gearbox and/or the solenoid

7.3. Process controlled valves (PCV)

1) Check the working of the pump.
SP not reached in Setpoint is not reached in time.
time  Pump upstream of the valve (if present) 2) Check the sensor used in the control loop.
is not working correctly. 3) Check system conditions that do not allow
reaching of the setpoint. For example, too
 Sensor in control loop is not working
Example: high water flow in degassing section. Apply
correctly.
PCVot_2910_Alarm2 changes if possible.
 System cannot handle the used setpoint.
Scrubber level control
valve SP not reached
in time
Wirebreak transmitter A wirebreak was detected on the transmitter Troubleshoot the wirebreak alarm on the
that controls the device. transmitter that is used to control this device.
See Section 7.5.
Example:
PCVot_2910_Alarm3
valve Wirebreak
transmitter
1) Go to the controller (Sipart) of the
GSc versus Feedback 'GS_closed' does not correspond
O_aoSignal fault to O_aoSignal (from [setting]% to 100%). pressure controlled valve.
2) Perform a self-learning run on the
controller of the valve.
Example:
PCVot_2910_Alarm8
valve GSc versus
O_aoSignal fault
1) Go to the controller (Sipart) of the
GSo versus Feedback 'GS_opened' does not correspond
O_aoSignal fault to O_aoSignal (from 0% to [setting]%). pressure controlled valve.
2) Perform a self-learning run on the
controller of the valve.
Example:
PCVot_2910_Alarm9
valve GSo versus
O_aoSignal fault
 Double contact.
GSc GSo both active 1) Check the position of the valve and the
 Rapidly changing valve movements. position indicator for a possible double
contact.
Example: 2) Check if valve movements are changing
PCVot_2910_Alarm10 rapidly.
valve GSc GSo both
active

7.4. Pumps and fans (MCP, MCF)

1) Make sure that the frequency converter
Power fault Power fault in the frequency converter or
pumps. cabinets are switched on.
2) Check the fuse in the frequency converter
Example: cabinet (note 440 or ~600 V on freq.
MCPt_A4040_Alarm1 converter).
Feed OCL Pumps Tip to find the electrical cabinet:
Power fault Cabinet 840 is for tag numbers 4000 -
4099,
Cabinet 843 is for tag numbers 4300 -
4399, and so on.
1) Make sure that the frequency converter

Frequency converter Power fault in the frequency converter or
pumps. cabinets are switched on.
2) Check the fuse in the frequency converter
Example: cabinet (note 440 or ~600 V on freq.
MCPt_A4040_Alarm2 converter).
Feed OCL Pumps Tip to find the electrical cabinet:
Frequency converter Cabinet 840 is for tag numbers 4000 -
4099,
Cabinet 843 is for tag numbers 4300 -
4399, and so on.
1) Check the working of the pump or fan.

Setpoint not reached in Setpoint is not reached in time.
time  Pump or fan is not working correctly. A 2) Check the sensor used in the control
likely cause is damaged or worn bearings. loop.
 Sensor in control loop is not working
Example:
correctly.
MCPt_A4340_Alarm3
Circulation Pump
Setpoint not reached in
time
Wirebreak transmitter A wirebreak was detected on the transmitter Troubleshoot the wirebreak alarm on the
that controls the device. transmitter that is used to control this device.
See Section 7.5.

7.5. Transmitters (FT, PT, TT, QT, LAh, LSA, LT)

1) Check the sensor wiring towards the PLC
Wirebreak An undefined transmitter signal is detected.
The signal is below 3.2 mA instead of a input.
normal reading of 4-20 mA. Possible causes 2) Check the transmitter for corrosion or
Example: are: damage. If needed, replace the
PT_A0990_Alarm5  Wirebreak between sensor and PLC. transmitter.
Exhaustgas line
 The transmitter is faulty. 3) Check the transmitter for blockages that
pressure Wirebreak  The transmitter reading is below its cause a low reading.
operating range. For example, a pressure 4) If the transmitter is measuring below its
transmitter measuring a vacuum operating range, contact Alfa Laval for a
(-1 Bar). replacement.
 Signal loss in the cable. 5) If the controller has crashed:
 If present, the controller between the
a. Disconnect all sensors and reconnect
transmitter and the PLC has crashed.
them one by one.
b. If needed, re-start the analyzer panel
by switching it off and on, using the
fuse in the Main cabinet 802.
1) Check the next sections in this document;
High High active (HH) An alarm limit is exceeded. The possible
causes are different for each transmitter. the alarm may be listed as an example.
High active (H) 2) If the alarm is not in the list, go to
Low active (L) Section 3.1.
Low Low active (LL)
The next sections contain examples of the most common transmitter alarms.

7.5.1. Examples of pressure transmitters (PT)

PT_x0990

1) On the Datalogger Overview screen, open
PT_x0990_Warning7 There is a big difference between one of the
pressure transmitters (PT_x0990) in the the engine pop-up window and check the
Exhaust line pressure exhaust gas inlet of the scrubber and the pressure drop (PT_x0990 – PT_2106). If
High Delta P with outlet pressure transmitter in the absorber the software version does not provide the
PT_2106 section of the scrubber (PT_2106). Possible pressure drop, check the values of
causes include:
PT_2106 and PT_x0990. If you see a
 Bypass damper (PVo_x1010) and uptake
slowly increasing trend, the demister is
damper (PVb_x1030) are not open or are
most likely blocked with soot.
partially open. One of these dampers
To clean the demister:
should always be fully open.
 The demister in the absorber is being a. Lower the engine load or stop the
slowly blocked with soot. scrubber to start the automatic
 The water load on the scrubber is too demister cleaning.
high. b. If the previous step did not work, then
 The water level in the ducting is too high visually inspect and, if needed, clean
(the water level is monitored by alarm the demister according to the
switches). procedure in the Maintenance Manual.
 One transmitter is faulty. 2) Make sure that there are no blockages in
 One transmitter has its measuring tube the bypass/uptake dampers.
blocked. 3) Check if too many sprayer layers in the
scrubber are open. Contact Alfa Laval for
instructions. It may be necessary to reduce
the water load on the absorber if:
a. In OL mode the discharge pH is far
higher than the limit specified in the
ETM-B.
b. In CL mode the SOx/CO2 ratio is far
lower than the limit specified in the
ETM-B.
4) Check if engines are running on HFO. On
MGO, more backpressure is a contributing
factor. If running on MGO, the scrubber
can be stopped.
5) Check if the pressure reading of PT_2106
is close to atmospheric. If not, the
transmitter or the sensor might be faulty.
PT_x0200

1) Make sure that there are no blockages in
PT_A0200_Warning2 Too high pressure in the exhaust gas outlet
of the engine. the Waste Heat Recovery unit.
Engine backpressure Possible causes include: 2) See the advice that is mentioned in the
High Limit reached
 If, for the same engine, PT_x0990 is table for PT_x0990.
correct, but PT_x0200 is too high:
PT_A0200_Alarm1 increased resistance in the Waste Heat
Recovery unit (if present).
Engine backpressure
High High Limit
 If, for the same engine, both PT_x0990
reached and PT_x0200 are too high: see the
possible causes that are mentioned in the
table for PT_x0990.

PT_2103

1) Check if pumps are reaching pressure set
Low Limit reached Water pressure too low near absorber.
 The control of the pumps that supply point.
water for the absorber sprayers is not 2) If in CL: check if there is a higher than
Example: functioning properly. usual pressure drop over the Plate Heat
PT_2103_Warning3 Exchanger. Back-flush the PHE and verify
 The piping has a high resistance.
Absorber sprayer that the alarm/warning is gone.
 Transmitter is faulty.
inlet pressure: Low 3) Check pipeline for leaks.
Limit reached
 The pipeline may be leaking.
4) Check the condition of the transmitter.
Example:
PT_2103_Alarm4
Absorber sprayer
inlet pressure: Low
Low Limit reached
PT_4017

 Blockage inside the body of the sensor. 1) Check the body of the sensor for
PT_4017_Warning3
 Blockage in the piping upstream of the blockages.
Feed Pump (External) feedpumps (seawater inlet filter or a 2) Check the position of all hand valves
Inlet pressure: Low
hand valve). upstream of the feedpumps.
Limit reached
3) Check the inlet filter(s) upstream of the
feedpumps for blockages.
PT_4960

 Leaking piping. 1) Check the piping between the pumps and
PT_4960_Warning3
 Pump supply pressure is too low. the Plate Heat Exchanger (PHE) for leaks.
PHE pumps pressure 2) Check the pumps for unusual sounds and
 Required water flow is too high for the
Low Limit reached
pumps. vibrations.
3) Increase the backpressure in the Plate
Heat Exchanger, by adjusting the end
position of the PHE pressure regulating
valve on the controller (Sipart) of the
valve:
Adjust the opening limit of the valve. The
valve should not be fully open (for
example, 35% open) when the feedback
indicates that it is 100% open. Otherwise,
too much water would pass.

7.5.2. Examples of pH, PAH, and turbidity transmitters (QT)

In general, the following advice applies to pH, PAH and turbidity
transmitters:
1. Calibrate the transmitter.
2. Check if there is a water flow through the analyzer panel according to
procedure EGC01-020-0x 'Check water flow through water analyzer
panels' in the Alfa Laval Maintenance Manual.
The following examples are specific for pH transmitters.
QT_7606

1) Calibrate the transmitter.
QT_7606_Warning2: In Open-Loop (OL) mode:
 Sensor is faulty. 2) Check if there is a water flow through the
Inlet Water Analyzer analyzer panel according to procedure
PH High Limit In Closed-Loop (CL) mode: EGC01-020-0x 'Check water flow through
reached  Overshooting: pH in circulation tank was water analyzer panels' in the Alfa Laval
very low during start-up and a high Maintenance Manual.
corrective dosing was needed. 3) If in CL, check if the process settings on
 Dosing settings are incorrect. the touchscreen are filled in correctly (see
 Sensor is faulty. Section 5.5.1).
4) If in CL, on the device pop-up of the NaOH
pump:
a. Check if the setpoint of the NaOH pump

is still pH 7.
b. Check if the dosing pump is paused
(default when pH > 9). This indicates a
large overshoot of pH.
5) If in CL, check if the dosing pump stroke is
approximately 50%.
6) If in CL and the dosing is consistently too
high, decrease the stroke on the NaOH
pump.
1) Calibrate the transmitter.

QT_7606_Warning3 In Open-Loop (OL) mode:
 Sensor is faulty. 2) Check if there is a water flow through the
Inlet Water Analyzer analyzer panel according to procedure
PH Low Limit reached  Seawater has an unusually low pH.
EGC01-020-0x 'Check water flow through
In Closed-Loop (CL) mode: water analyzer panels' in the Alfa Laval
 NaOH dosage is too low. Maintenance Manual.
 Sensor is faulty. 3) In CL, check if percentage of Sulphur and
NaOH concentration settings are correct.
4) In CL, check the fill level of the NaOH
container.
5) In CL, check if the air escape on the NaOH
container is open.

7.5.3. Examples of level transmitters (LAh, LSA, LT)

LZA_2101 and LAh_2505

1) Make sure all pumps are running in
High active The water level in the jet or ducting is too
high because: automatic mode.
 Wash-water blockage. 2) During start-up in OL, check the sample
Example:  Overboard valve is not open and/or sea- lines of LT_2902 for blockades. Blow the
LZA_2101_Alarm1 water pumps are started in manual sample lines with air.
Limit safety alarm mode. 3) In OL, make sure that the overboard
high active  Transmitter is not working correctly. valves, degassing valve and switching
valve are open.
Example:  During start-up in Open-Loop mode, the
LAh_2505_Alarm1 4) In CL, make sure that the switching valve
degassing valve (PVCot_2910) opens too
to the circulation tanks is open.
Jet level switch high slowly.
5) Make sure that there are no blockages in
active
the pipeline.
6) Check the transmitter.
LT_x5101

1) Check if filling valves (PVx_5110) are
Low limit reached Water level in circulation tank is too low.
Possible causes are: closed manually. If the valves are closed
 Filling valves (PVx_5110) are closed. manually, return these valves to automatic
Example:  Too much water drained due to switch- operation if possible.
LT_x5101_Warning3 over from Open-Loop mode to Closed- 2) Check if the switch-over time from CL to
Circulation tank Low Loop mode. OL is set too long. If the switch-over time
Limit reached  Switching valve (PVx_2810) is not fully is too long, the tank drains too much while
closed (adjustments incorrect). switching over.
Example:
LT_x5101_Alarm4 3) Check the mechanical limits of switching
 Water evaporates in the scrubber,
valve (PVx_2810). Adjust if needed.
Circulation tank Low probably due to high temperatures.
4) If the switching valves move too slowly,
low Limit reached
adjust the speed control valve for faster
opening/closing. The speed control valve is
valve.
5) Check the environmental conditions of the
ship (temperatures) for possible causes.
6) Check if the circulation and/or cooling
water that comes out of the PHE is
unusually hot. If so, troubleshoot the PHE.

LSA_A5242

1) Visually check the fill level of the
LSA_A5242_Alarm1 The fill level of the sludge container is high.
Possible causes are: container.
Sludge level switch 2) If the container is full, arrange for the
 The container is full.
High alarm active
 Transmitter is not working correctly. container to be emptied. Dispose the
content according to local regulations.
3) If the container is not full:
a. Check the transmitter.

b. Check the sensors wiring towards the
PLC input.
LSA_x5247

1) Visually check the fill level of the
LSA_A5247_Alarm2 The fill level of the flocculants container is
low. Possible causes are: container.
Chemical level switch 2) If the container is empty, make sure the
 The container is empty.
low alarm active
 Transmitter is not working properly. container gets refilled.
3) If the container is not empty:
a. Check the transmitter.

b. Check the sensors wiring towards the
PLC input.

8. List of abbreviations and acronyms
Term Description
CF Compact Flash
CL Closed-Loop (mode, system, button,…..)
CO2 Carbon Dioxide
ECA Emissions Control Area
ECR Engine Control Room
ECRP Engine Control Room Panel
EG Exhaust Gas
EGC Exhaust Gas Cleaning
FBD Functional Block Diagram
FT Flow Transmitter
FW Fresh-Water (mode, system, button,…..)
HC Hydrocarbon(s)
HFO Heavy Fuel Oil
HMI Human Machine Interface
HV Hand Valve
LA Level Alarm switch
LCR Local Control Room
LCRP Local Control Room Panel
LT Level Transmitter
M Motor
MCF Motor Controlled Fan
MCR Maximum Continuous Revolution
MCP Motor Controlled Pump
MF Motor Fan
MGO Marine Gas Oil
NaOH Caustic Soda; Sodium Hydroxide
OL Open-Loop (mode, system, button, …)
P&ID Process and Instrumentation Diagram
PAH Poly Aromatic Hydrocarbon
PCV Pressure Controlled Valve
pH Potenz power + H (hydrogen) is a measure of acidity and alkalinity of a solution
PHE Plate Heat Exchanger
PLC Programmable Logic Controller
PM Particulate Matter (soot)
PT Pressure Transmitter
PV Pressure Valve
QT Quality Transmitter
SOx Sulphur Oxides
SW Sea-Water (mode, system, button,…..)

TP Touch Panel
TT Temperature Transmitter
UI User Interface
WCU Water Cleaning Unit

TSM - U1 V1.0 Trouble Shoting Manual

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Troubleshooting

PureSOx Exhaust Gas Cleaning

Alfa Laval © 2017

1.1. Sea-Water/Fresh-Water or Open-Loop/Closed-Loop ...................... 1

2.1. Use the FBD and P&IDs ................................................................... 3

2.2. Find sub-supplier manuals .............................................................. 5

2.3. Use the electrical drawings ............................................................. 5

2.3.1. Single-line diagram................................................................. 6

2.3.2. Circuit diagram ...................................................................... 8

2.4. View status on the touchscreen ...................................................... 9

2.5. Show tag numbers ........................................................................ 10

2.6. Create a screen print of the touchscreen ...................................... 10

2.7. Contact Alfa Laval ......................................................................... 11

3. TROUBLESHOOTING METHOD ...................................................... 12

3.1. Primary troubleshooting method .................................................. 13

3.1.1. Identify the type of issue ....................................................... 15

3.1.2. Choose an alarm to troubleshoot ............................................ 16

3.1.3. View the alarm message in context ......................................... 17

3.1.4. Solutions ............................................................................. 18

3.2. Extended troubleshooting method ................................................ 19

3.2.1. Define and locate the problem ............................................... 20

3.2.2. List contributing factors ......................................................... 21

3.2.3. Identify possible cause-and-effect scenarios ............................ 21

3.2.4. Focus on the most likely possible cause ................................... 22

3.2.5. Verify if your hypothesis is true .............................................. 23

3.2.6. Solve possible causes............................................................ 25

TSM_U1 V1.0 Page i of 3

3.3. Restore the EGC system to normal operation ................................ 25

4. WHAT IF? ..................................................................................... 26

4.1.1. Make a control panel the active panel ..................................... 26

4.2. System stays 'busy' or does not stop ............................................ 27

4.3. System does not start ................................................................... 28

4.4. System does not switch modes (OL / CL) ..................................... 29

4.5. Readings from a water analyzer panel are incorrect ..................... 30

4.6. EGC system generates loud noises ................................................ 31

4.6.2. Loud noises near the scrubber or the WCU .............................. 31

4.7. Display of gas analyzer shows an alarm ....................................... 32

4.8. Display of WCU shows LL turbidity alarm ...................................... 33

4.9. WCU in bleed-off mode, but no water is discharged ...................... 33

5. COMPLIANCE ISSUES .................................................................... 34

5.1. SOx/CO2 ratio out of compliance ................................................... 35

5.1.1. Bring SOx/CO2 ratio back in compliance ................................... 36

5.1.2. If the compliance issue remains ............................................. 37

5.1.3. Possible root causes of incorrect SOx/CO2 ratio ......................... 37

5.2. pH out of compliance .................................................................... 39

5.2.1. Bring pH back in compliance .................................................. 39

5.2.2. If the compliance issue remains ............................................. 40

5.2.3. Possible root causes of low pH ............................................... 40

5.3. PAH out of compliance .................................................................. 42

5.3.1. Bring PAH back in compliance ................................................ 42

5.3.2. If the compliance issue remains ............................................. 43

5.3.3. Possible root causes of high PAH ............................................ 43

Page ii of 3 TSM_U1 V1.0

5.4. Turbidity [FNU] out of compliance ................................................ 45

5.4.1. Bring turbidity [FNU] back in compliance ................................. 45

5.4.2. If the compliance issue remains ............................................. 46

5.4.3. Possible root causes of high turbidity [FNU] ............................. 46

5.5. Procedures to resolve compliance issues ...................................... 48

5.5.1. Check process settings .......................................................... 48

5.5.2. Increase water to absorber (Open-Loop mode) ........................ 49

5.5.3. Increase water to absorber (Closed-Loop mode) ...................... 50

5.5.4. Increase water to jet(s)......................................................... 51

5.5.5. Increase NaOH dosage (Closed-Loop mode)............................. 52