GE-MA-041 MANUAL SCR SYSTEM Working File

Document no.
Revision: Page: 1(62)

GE-MA-040 A
Responsible: Approved by: Date:
Adrian Waser Johan Svenberg 2019-06-26
File Name:
GE-MA-040_A_USER MANUAL SCR SYSTEM
USER
MANUAL
GESAB SCR SYSTEM
GÖTEBORGS ENERGY SYSTEMS AB Phone +46 31 744 1950

Exportgatan 81A Fax +46 31 779 7841
42246 Hisings Backa E-mail: gesab@gesab.net
Sweden Website: www.gesab.net
Document no. Revision: Page: 2(62)
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INDEX
General technical information ................................................................................................................ 5

Safety precautions ............................................................................................................................... 5
SCR process description .......................................................................................................................... 8
The SCR chemical reaction .................................................................................................................. 8
Engine’s fuel/lube oil impact on the SCR system ................................................................................ 9
SCR DeNOx additive – AUS 40 ........................................................................................................... 11
Compressed air .................................................................................................................................. 12
System overview ................................................................................................................................... 13
System description and functionality: ................................................................................................... 14
Typical arrangement GESAB SCR System in vessel:........................................................................... 14
Functionality ...................................................................................................................................... 17
Detailed description GESAB SCR System ............................................................................................... 20
Dosing Unit (DU) ................................................................................................................................ 20
Dosing Unit control cabinet............................................................................................................... 21
Dosing Unit process panel ................................................................................................................. 24
Urea pump unit (PU) ......................................................................................................................... 26
Pump unit control cabinet ................................................................................................................. 28
Spill valve unit.................................................................................................................................... 29
Urea Injector ..................................................................................................................................... 30
3-way ball valve ................................................................................................................................. 30
Injection unit (IU) .............................................................................................................................. 31
SCR reactor ........................................................................................................................................ 32
Catalyst material................................................................................................................................ 33
Exhaust gas impacts on catalyst lifetime........................................................................................... 33
Installation and exchange of catalyst material.................................................................................. 34
Catalyst waste handling..................................................................................................................... 35
Temperature transmitter .................................................................................................................. 37
Soot blower unit ................................................................................................................................ 38
NOx sensor ........................................................................................................................................ 39
Urea storage tank (not scope of supply from GESAB)....................................................................... 41

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Urea bunker pipe (not scope of supply from GESAB) ....................................................................... 41

SCR system operation description..................................................................................................... 42
Start up .............................................................................................................................................. 42
Shut down ......................................................................................................................................... 42
Control and Monitoring of SCR System ................................................................................................. 43
User Interface .................................................................................................................................... 43
STRUCTURE 1 (DU) ................................................................................................................................ 43
DOSING UNIT DU ........................................................................................................................... 43
PRINT SCREEN’S DOSING UNIT .......................................................................................................... 44
DOSING UNIT OVERVIEW .............................................................................................................. 44
VISUAL INFO .................................................................................................................................. 45
ALARM LIST .................................................................................................................................... 46
LOGIN............................................................................................................................................. 46
INFO ............................................................................................................................................... 47
STRUCTURE 2 (PU) ................................................................................................................................. 48
PUMP UNIT PU .............................................................................................................................. 49
PRINT SCREEN’S PUMP UNIT ............................................................................................................. 49
MAIN OVERVIEW ........................................................................................................................... 49
ALARM LIST .................................................................................................................................... 49
LOGIN............................................................................................................................................. 50
Inspection and Maintenance SCR System ............................................................................................. 51
Set Point List SCR System ...................................................................................................................... 53
Dosing unit DU01................................................................................................................................... 53
General .............................................................................................................................................. 53
Start conditions ................................................................................................................................. 53
Warning settings ............................................................................................................................... 53
Failure settings .................................................................................................................................. 53
Sensor scaling .................................................................................................................................... 54
NOx sensor ........................................................................................................................................ 54
Load curve ......................................................................................................................................... 54
Pump unit PU01..................................................................................................................................... 55
Pressure settings ............................................................................................................................... 55

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Temperature settings ........................................................................................................................ 55

Sensor scaling .................................................................................................................................... 55
Alarm and Troubleshooting list SCR System ......................................................................................... 56

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General technical information

This User Manual describe the entire life cycle of the SCR system as provided by the supplier’s
scope of supply. This manual should be stored in such a way that it is easily accessible to every
user of the SCR system.
The operating manual must be read through carefully and understood by those responsible for
operating the system.
The GESAB SCR system and all the system components may only be used for the purpose and
engine exhaust that it is designed for.
Safety precautions
The operator(s) must employ safe working practices and observe all related work safety
requirements and regulations. Installation, operation, maintenance and repair work must only
be performed by authorized, trained, specialized personnel. The personnel should apply safe
working practices by use of personal protection equipment, appropriate tools and defined
procedures.

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Danger!
High risk that signifies an immediate impending danger. If not avoided, death or serious injury
will result.
Warning!
Medium risk that signifies a potentially dangerous situation. If not avoided, death or serious
injury may result.
Caution!
Low risk that signifies a potentially dangerous situation. If not avoided, minor injury or
equipment damage might occur.
Hazardous voltage
• Interference with electrical components will result in acute risk of
injury.
Danger! • Before starting work on relevant components, be sure to switch off
the supply voltage and prevent it from restarting.
• Observe all applicable accident prevention and safety regulations
for electrical equipment.
High temperature
• Contact with hot surfaces or exhaust gas will result in acute risk of
injury.
• All components that is a part of or directly connected to the
exhaust gas piping system has high surface temperatures when the
engine is running and after engine shut down until the exhaust gas
system is cooled down.
• The catalyst material has high heat capacity and thus the catalyst
housing will cool slowly. Do not open the catalyst until the
measured temperatures inside the housing is acceptable low.
• Do not remove insulation and expose or touch hot surfaces unless
necessary safety precautions are taken.
Hazardous substances
• Ammonia (NH3) is a hazardous substance and is toxic to humans
when exposed to high concentrations. It is formed from the
Warning! injected urea when exposed to the hot exhaust gas or other hot
surfaces.
• In case of exhaust leakage, stop urea injection to prevent ammonia
from entering enclosed compartments.
• Do not expose urea to hot surfaces, as this may release ammonia.

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• Loose fibres from the mats used to protect and fixate the catalyst
material inside the catalyst housing can be regarded as hazardous
to human health.
• Follow any instruction given in the Material Safety Datasheet
related to the product when handling the material.
High pressure
• Interference with pressurised parts of the system can result in acute
risk of injury. Pressurised parts of the system are the air supply to
Caution! the urea injection unit, air supply to the dust blow system and urea
supply to the injection unit.
• Switch off the compressed air and the urea pump before
disconnecting lines and valves.
Electrostatic sensitive components

• The system contains electronic components that react sensitively
to electrostatic discharge (ESD). Touching by electrostatically
charged persons or objects can endanger these components.
• Observe the requirements of EN 100 015 – 1 in order to avoid or
minimise the risk of damage caused by sudden electrostatic
discharges.
• Pay attention also not to touch electronic components when supply
voltage is switched on.
Unintentional operation
• Unintentional operation or impermissible damage can lead to
dangerous situations including injuries.
• Take suitable measures to prevent unintentional operation or
inadmissible damage.
• Operation and maintenance work may only be carried out by
personnel trained for this purpose and by using appropriate tools.
• Observe any general rules and regulation relevant for the
technology.

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SCR process description

This GESAB SCR system installed is using a Vanadium-Titanium based catalyst in
combination with SCR DeNOx additive (aqueous urea solution) to convert nitric oxides
(NOx) to nitrogen gas (N2) and water (H2O).
The aqueous urea solution is:

• sprayed into the exhaust gas, upstream the catalyst
• vaporised inside the injection pipe
• converted to ammonia due to the high exhaust gas temperature
• mixed with the exhaust gas
• reacting with the NOx-molecules in the exhaust gas on the catalyst surface
The reduction rate of NOx is dependent on the rate of the injected urea, by mass and the
available catalyst material surface area. Normally a mapping of the diesel engine NOx
emission is the main basis calculating and programming the injection rate of urea relative to
the engine load (the engine load – urea injection – NOx reduction curve). If no urea is
injected, the NOx reduction will be limited to between 0–5 %.
In order to optimise the NOx reduction, avoid secondary pollutions and minimise the
consumption of urea, the “injection” rate must be precise and regulated rapidly based on input
signals. Secondary pollution can be overdosing of urea, leading to ammonia (NH3) slip.
Independent of the urea injection rate, the Vanadium-Titanium based catalyst also has a high
conversion rate of hydrocarbons (HC), typically 70-95% which reduces the total amount of
particulate emissions.
The SCR chemical reaction
When urea is injected into the exhaust gas the urea is thermo-hydrolysed to ammonia (NH3)
and CO2 as seen below:
(1) NH2CONH2 (urea) + H2O → 2NH3 + CO2
The ammonia reacts with NO and NO2 and forms nitrogen (N2) gas and water (H2O) on the
catalyst surface as seen below:
(2) 4NH3 + 4NO + O2 → 4N2 + 6H2O
(3) 8NH3 + 6NO2 → 7N2 + 12H2O

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Engine’s fuel/lube oil impact on the SCR system
The GESAB SCR system has a maximum working exhaust gas temperature range of
approximately 250 – 550˚C, limited by catalyst material activity, sulphur content in the fuel,
risk for ammonia slip and the thermal stability of the catalyst material.
The start exhaust gas temperature for urea injection is dependent on the sulphur content in the
fuel. The lower the fuel sulphur content, the lower the initial start temperature can be used.
For MDO diesel fuel with a sulphur content of max 0.2 %, the corresponding start
temperature is set to 280˚C for a standard GESAB SCR system. For HFO the corresponding
start temperature must be increased to 310 – 340˚C, depending on sulphur content. GESAB
SCR is applicable for sulphur contents of up to 3.5%
Minimum exhaust gas temperature for urea injection

to avoid ammonium sulphates formation
380
360
340
320
Exhaust gas temp. °C
Start temperature for urea injection

300 increases with increased :
-fuel vanadium content
280 -exhaust gas SO2/SO3 ratio
-space velocity catalyst material
260
240
220
200
0 0,5 1 1,5 2 2,5 3 3,5 4
% Sulphur in fuel
If the urea is injected at too low exhaust gas temperature, the thermo-hydrolysed ammonia is
reacting with fuel derived sulphates (SO2 and SO3) forming ammonium sulphates (ABS), which
is a sticky deposit, potentially clogging the catalyst and increasing the backpressure. The ABS
formation is also dependent on the ratio between SO2 and SO3. Fuel borne vanadium increases
the catalyst material vanadium content, which increases the SO3 formation and hence the
temperature for the ABS formation. In case a problem with ABS has occurred increasing the
pressure drop, the urea injection shall be stopped, and the engine load should be adjusted for
exhaust gas temperature exceeding 350 ˚C until pressure drop has decreased to normal levels.
However, ABS cannot be removed completely, traces will always remain in the macro structure
of the catalyst material decreasing the DeNOx-efficiency of the SCR system. If ABS once has
been formed the risk for creating new ABS increases over time.

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At temperatures above 500 ˚C, the ammonia starts to self-oxidise (burn). The higher the
temperature, the larger fraction of the ammonia will be oxidised. In order to keep the NOx
reduction efficiency at higher temperatures, the urea consumption must be increased
correspondingly. Also, the standard catalyst material will start to deteriorate at temperatures
above 500 ºC due to sintering of the ceramics. The sintering effect will increase with increased
temperature. At temperatures above 550 ºC there is a big risk for rapid deterioration.
The sulphur in the fuel oil and calcium in the lube oil will react in the combustion chamber of
the diesel engine, forming calcium sulphates (gypsum). On the way from the combustion
chamber to the catalyst material, the calcium sulphates undergo the conversion from gas phase
to solid phase (particulates) and the particulates are growing in size. When the gypsum
particulates enter the catalyst material most of it will pass through, but some of the particulates
will be collected on the front side of the catalyst material. Over (running) time, more gypsum
particulates will be collected forming a layer, and the layer will grow in thickness, resulting in
an increased pressure drop over the catalyst material. In order to avoid this problem, the fuel
sulphur and lube oil calcium contents shall be kept as low as possible.
The collected gypsum is removed using the automatic “dust blowing system”, blowing air
streams through lances on the catalyst inlet, perpendicular to the gas direction. For best result,
pressurised air of > 7 Bar shall be used. When in use, the dust blowing system is in operation
for approximately 0,5 - 3 seconds per catalyst layer. It shall be used regularly, once every hour,
day or week, depending on the experienced amount of gypsum produced.
Also, high levels of hydrocarbons (HC) and particulate matter (PM) emitted from the diesel
engine can clog the catalyst, leading to an increased pressure drop. This can be avoided by
limiting the diesel engine operating at low exhaust temperatures for longer periods. If the
backpressure increases, the engine load can temporarily be adjusted for higher a exhaust
temperature (> 340˚C) for a period of approximately 1 - 3 hour, in order to oxidise the
HC/PM.
Fuel and lube oil pollutants according to list below also has a limiting effect on the lifetime of
the catalyst material. In order to maintain a reasonable lifetime, the pollutants concentration in
the exhaust gas must be limited to (approximate guideline values within brackets) :
Alkali metals (Na, K etc) Max. at wet 5 mg/Nm3 (45 mg/kWh)

Alkaline-earth metals (Ca, S etc) Max. at wet 1 mg/Nm3 (9 mg/kWh)
Hydrogen chlorides, HCl Max. at wet 100 mg/Nm3 (900 mg/kWh)
Hydrofluoric acids, fluorides Max. at wet 1 mg/Nm3 (9 mg/kWh)
P2O5, Organic Phosphorous Max. at wet 3 mg/Nm3 (27 mg/kWh)
Arsenic compounds, As Max. at wet 0.01 mg/Nm3 (0.09 mg/kWh)
Silicon compounds; Si Max. at wet 0.03 mg/Nm3 (0.27 mg/kWh)
Lead Max. at wet 0.1 mg/Nm3 (0.9 mg/kWh)
Zinc Max. at wet 0.1 mg/Nm3 (0.9 mg/kWh)
Mercury Max. at wet 0.1 mg/Nm3 (0.9 mg/kWh)
Cadmium Max. at wet 0,1 mg/Nm3 (0.9 mg/kWh)

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SCR DeNOx additive – AUS 40
In marine SCR catalyst systems, the most commonly used additive for NOx-reduction is a high-
quality urea-water solution with a concentration of 40 %wt. For urea-water solution quality
requirements and material safety datasheet it is referred to separate section in the Instruction
Manual.
The preferred 40% urea solution type to be used with GESAB SCR system is AUS 40. The
AUS 40 is of a specified quality (see table below), appropriate for marine SCR applications.
Please note, if urea-water solution not fulfilling the AUS 40 quality specifications is used
(example agricultural urea quality), the higher levels of pollutants will shorten the lifetime of
the catalyst material and possibly harm the components included in the process system. With
the urea derived pollutants, the risk for clogged catalyst material and an increased
backpressure over the catalyst material is impending.
Care must be taken when choosing material in contact with the AUS 40 solution. The solution
is slightly corrosive on steel; hence AISI304 or similar quality shall be used. Copper and brass
must be avoided, especially when under pressure. AUS 40 solution has an “ageing” effect on
some polymers/elastomers. Please check chemical compatibility with AUS 40 when choosing
appropriate components and sealing material.
The freezing point for AUS 40 is approx. -0.7 °C (32 F). In order to avoid the freezing risk,
the minimum temperature in AUS 40 tanks and pipes should be kept above +5 °C.
The lifetime of AUS 40 will be shortened at elevated temperatures. The temperature should be
kept below +35 °C in AUS 40 tanks and pipes.

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Compressed air
Both the urea injection and soot blowing needs compressed air. GESAB require for the SCR
system an instrument air quality (class 3) according to the ISO-8573-1 standards:
Class Solid Water Oil

Maximum Maximum Maximum Maximum
Particle concentration Pressure concentration
Size (micron) ppm (mg/m3) Dewpoint ppm (mg/m3)
°F (°C)
1 0.1 .08 (0.1) -94 (-70) .008 (0.01)
2 1 .8 (1) -40 (-40) .08 (0.1)
3 5 4.2 (5) -4 (-20) .83 (1)
4 15 6.7 (8) 37 (+3) 4.2 (5)
5 40 8.3 (10) 45 (+7) 21 (25)
6 - - - 50 (+10) - -
- Air pressure to dosing unit: 6 - 10 Bar

- Air consumption dosing : typically, 25 Nm3/h per unit
- Air pressure to soot blowing manifold: 6 - 10 Bar
- Air consumption soot blowing system: typically, 3 m3/h

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System overview (single system)

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System description and functionality:

Typical arrangement GESAB SCR System in vessel:

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Standard Scope of supply GESAB SCR System
Dosing Unit (1 off per engine / SCR system)
Urea pump unit (1 off per engine room)
Spill Valve unit (1 off per engine room)
Injection unit (1 off per engine / SCR system)
SCR reactor (1 off per engine / SCR system)

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NOx sensor with pitot pipe (1 off per engine / SCR system)
Differential pressure sensor (1 off per engine / SCR system)
Temperature transmitter (2 off per engine / SCR system, inlet + outlet)
-1 Temperature transmitter catalyst housing inlet

-1 Temperature transmitter catalyst housing outlet
Optional Scope of supply GESAB SCR system
Soot blow system
-Soot blow manifold

-Soot blow valves
-Metallic hoses

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Functionality
Please see flow chart below.
When the diesel engine starts, the urea pump unit is started, supplying urea to the dosing unit.
When the conditions for urea injection is met (engine load and SCR inlet/outlet temperatures
are high enough), the SCR system is preparing for start of urea injection; cooling air is fed to
the injector for a pre-set time (normally 5 minutes). Cooling is needed to avoid crystallisation
of urea inside the injector when suddenly exposed to hot surface.
After the cooling sequence, if no alarm exists, the 3-way valve on the injector is turned to
injection position and the metering pump is started regulating the flow according to the engine
load vs urea flow curve programmed in the PLC.
If an alarm occurs, or the engine load or temperatures are outside the limit values, the urea
metering is automatically stopped and the 3-way valve on the injector is turned to purge-
position letting air rinse the injector from urea residuals for a pre-set time (normally 5
minutes. When the diesel engine stops, the urea pump unit is stopped unless there are more
than one SCR system installed sharing the urea pump unit.

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SCR UREA INJECTION IN

STAND BY MODE
NO STOP UREA CIRCULATIONS

START
ENGINE PUMP
YES
START UREA
CIRCULATIONS PUMP
START INJECTOR PURGING

FOR ≥ 5 MINUTE
CLOSE AIR VALVES
START
CONDITIONS
FULFILLED STOP UREA DOSING
AUTO MODE CLOSE 3-WAY VALVE
SWITCH ON
YES
YES
START
OPEN AIR VALVES CONDITIONS NOT
START INJECTOR COOLING FULFILLED
FOR ≥ 5 MINUTE AUTO MODE
SWITCH OFF
OPEN 3-WAY VALVE

START UREA DOSING

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The engine load vs urea flow regulating curve is programmed into the PLC during the system
commissioning. The engine is run steady state at different predetermined loads (example 25,
50, 75 and 100 %). The baseline NOx is measured upstream the catalyst for comparison with
design data. Downstream the catalyst, the residual NOx level is measured when urea is injected.
See resulting finding in figure below.
For each engine load, the corresponding optimum urea consumption is found, based on
measured baseline and required NOx reduction. The urea consumption at all engine loads to be
taken into account, results in the engine load vs urea regulating curve that is utilised as a basis
for urea metering (see example in figure below) and programmed into the control system PLC.
Engine load vs Urea flow

100 300
80
200
NOx emission
60
Urea flow
Urea
flow
40 ppm
100 NOx
20
0 0
0 25 50 75 100
Engine load

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Detailed description GESAB SCR System

Dosing Unit (DU)
The dosing unit is serving one SCR system and consists of:
• control cabinet, including PLC and electronics
• process panel, including components for urea metering and instrument air to the injector
The design enables a swift and precise urea metering and control/monitoring of the instrument
air flow to the injector for optimized NOx-reduction and minimized secondary emissions
ensuring trouble-free operation of the SCR system.
The dosing unit shall be installed wall mounted in an accessible area and working height, as
close as possible to the injection unit (IU). Make sure there is a sufficient service space
(minimum 600 mm) in front of the unit. The dosing unit includes the most important and
advanced components of the SCR system, hence proper ventilation shall be provided for
maximum lifetime. Stable ambient temperature in the range 0-45°C should be achieved.
The control cabinet must also be protected from vibrations, hence anti-vibrations mounts shall
be used when installing the dosing unit to the structure of the vessel (please see class
requirements for maximum allowable vibration levels).
et

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Dosing Unit control cabinet
Failure
HMI
Warning
Mains switch
Status
Lamp
Cirk test
Emerg. pump Mode button
stop running switch Dosing
Reset
button
The control cabinet PLC is chosen for the application, to have a short cycle time and with
high signal sensitivity. It has both digital and analogue inlets and outlets. All communication
with the PLC is done via the HMI and the lamps/buttons on the cabinet door, such as viewing
alarm, to start/stop the process (urea injection) and to see the actual and historical process
data. Using fieldbus-communication, the control cabinet PLC is exchanging information with
other SCR system dosing units, the associated urea supply pump unit and the NOx sensor.
External communication with ECR/ECS of warning/failure in system, is done via relays.
For local indication, viewing and communication, a HMI and the following lamp indications
and buttons are included in the control cabinet:
Lamp indications:
Failure: indicates when there is a system failure (see section Alarm and Troubleshooting list
SCR system)
Warning: indicates when there is a system warning (see section Alarm and Troubleshooting
list SCR system)
Status: indicates when the system has 230 VAC power supplied
Dosing: indicates when urea is injected
Circulation pump running: indicates when circulation pump is running and urea supply
pressure is higher than the set value
Buttons:
Lamp test button (for testing the lamps)
Reset button (for resetting failures/warnings)
Mode switch (urea injection on or off).
Emergency stop
Mains switch.

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The HMI displays are presented later in this instruction manual (see section Control and
Monitoring of SCR system – User Interface).
The control system is designed to run fully automatic. Depending on what position the mode
switch is in, the urea is either injected (AUTO ON) or urea is not injected (AUTO OFF). If
the mode switch is in AUTO OFF position, the SCR system will still be running in auto mode
(all functions working) but urea is not injected.
If the mode switch is in AUTO ON position, the following conditions must be fulfilled to start
the urea injection:
Field bus is working properly

Urea tank level is OK (above failure level = low/low level)
Urea supply pressure is OK (see set point list)
Compressed air pressure is OK (see set point list)
Engine is running
Engine load is OK (see set point list)
Catalyst inlet/outlet exhaust gas temperatures are OK (see set point list)
No alarms (failures) present
When all conditions are met, the system starts with cooling the injector with compressed air
(cooling sequence, normally set to 5 minutes). After cooling, the urea metering is started.
As soon as one or several of the conditions are not fulfilled, the urea metering and injection is
stopped, and the injector is rinsed from urea automatically for 5 minutes (purge sequence).
If the emergency stop button is pressed, the urea transfer pump(s) is/are stopped, the urea and
air valves closed, and soot blow system stopped for the SCR system having the emergency
stop button. Due to the stopped urea transfer pumps, the urea injection for the surrounding
SCR systems will also be stopped.

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Cooling Mains Fuses 24 VDC Contactor PLC

fan switch power supply emerg. stop
Relays
Power supply
230 VAC
Interior of control cabinet.

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Dosing Unit process panel
Internal P&ID of the process panel.
4
7 9 10 11
2
5
Rinse air to
Rinse air to
Control air
rinse valve
ment air
transfer pump
injector
Instru-
injector
injector
Urea from
To
unit
Items:

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1. Control cabinet (see above)

2. Ball valve (for closing the urea supply line)
3. Metering pump (for precise metering of urea flow to injector)
4. Pressure transmitter (monitoring metering pump supply pressure, high/low alarm)
5. Non-return valve
6. Ball valve (for closing the compressed air supply line)
7. Pressure reducing valve (for setting pressure of cooling/rinsing and control air, normally 6
bar
8. Air tank for rinse air (if no 230 V power to cabinet, injector will be rinsed with air in tank)
9. Pressure reducing valve (for setting pressure of atomising air, normally 4 bar)
10. Air flow meter (to monitor atomising air flow)
11. On/off valve (for closing atomising airline)

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Urea pump unit (PU)
Internal P&ID of urea (single) pump unit.
The pump unit supplies urea from the urea storage or day tank to the process system(s).
Depending on the requirements, the urea supply pump unit contain of one (or two) urea
pump(s) and one (or two) urea filter(s). Two manometers (up- and downstream the filters) are
included to determine the filter differential pressure and the need for cleaning or exchanging
the filter inserts.
The urea supply pressure is set during commissioning via the spill valve unit installed in the
return line. The supply pressure is monitored by the urea pressure sensor included in the
supply pump unit.
A spill tray is included in the pump unit. For monitoring of a possible urea leakage, a leakage
sensor is included.
The pump(s), pressure sensor and urea leakage sensor are controlled and monitored by the
pump control cabinet.
For the installation of the pump unit, please consult GESAB for maximum suction and pressure
limitations of the pump unit. The pump unit shall be installed as close to the urea tank(s) as
possible in a well accessible area. Please arrange for necessary service space in front and above
the pump unit.
The pump control cabinet include PLC and electronics for the control and monitoring of the
urea supply pump(s). Stable ambient temperature in the range 0 - 45°C should be achieved
hence proper ventilation shall be provided for maximum lifetime. The control cabinet must also
be protected from vibrations, hence anti-vibrations mounts shall be used when installing the
pump unit to the vessel structure (please see class requirements for maximum allowable
vibration levels).
et

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5 1
5
2
7 6 7
4 9
2
8
Urea supply pump unit with two pumps and 2 parallel filters on suction side of pumps.
Items:
1. Pump control cabinet (lamp indications and buttons on door)
2. Urea leakage sensor (detect urea in spill tray)
3. Urea pump(s)
4. Pressure sensor urea supply
5. Manometers to control filter condition
6. Urea filter (0,25 mm strainer)
7. Manual ball valves
8. Urea spill tray
9. Cables (cable glands in switchboard bottom)

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Pump unit control cabinet
Power Circ. Circ. Failure

on/off pump 1 pump 2
running running
Mode switch Mode switch

pump 1 (on/off) pump 2 (on/off) Emerg.
Mains switch stop
Lamp Reset
test button
button
The pump unit control cabinet PLC is chosen for the application, to have a short cycle time
and with high signal sensitivity. It has both digital and analogue inlets and outlets. All
communication with the pump control cabinet PLC is done via the HMI in the metering
unit(s) and the lamps/buttons on the pump control cabinet door, such as viewing alarm, to
start/stop the pump(s) and to see the actual and historical process data (alarms). The pump
control cabinet PLC is exchanging information with the associated urea metering units using
fieldbus-communication.
External communication with ECR/ECS of warning/failure in system, is done via relays.
For local indication, viewing and communication, the following lamp indications and buttons
are included in the pump control cabinet:
Lamp indications:
: indicates when the cabinet has 230 VAC power supplied
Circulation pump 1 running: indicates when circulation pump 1 is running and urea supply
Circulation pump 2 running: indicates when circulation pump 2 is running and urea supply
Failure: indicates when there is a system failure
Buttons:
Lamp test button (for testing the lamps)

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Reset button (for resetting failures)

Mode switch pump 1 (on or off)
Mode switch pump 2 (on or off)
Emergency stop
Mains switch.
The pump control system is designed to run fully automatic (controlled by the SCR systems)
when the mains are powered on and the mode switch(es) for the pump(s) is/are in manual
OFF position. If the mode switch (pump 1 or 2) is in manual ON position, the pump (1 or 2) is
started immediately.
Spill valve unit
The spill valve is included to increase and

regulate the pressure of the urea in the
supply line. Typically, the pressure is set 1
between 0,2 – 1,0 Bar.
The spill valve unit shall be installed on
the urea supply line, near and downstream
the SCR dosing unit(s), upstream the urea
tank. 2
1. Spill valve
2. Flow direction

GE-MA-040 A
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Urea Injector
The urea injector is a dual media type using compressed (instrument)

air to create a fine mist of urea droplets when sprayed into the exhaust
gas stream, allowing a short urea evaporation length upstream the SCR
catalyst. 1
The injector has two connections included,
1. ½” inch female connection for compressed (atomization) air 2
2. ½” male connection for the 3-way ball valve.
Prior to installing the injector in the injection unit (IU), make sure the
nozzle air cap is in the right position (HOW ??) and that the nozzle is
securely tightened. Remove the blind flange on the IU (store in a safe
place) and use GESAB specified lubricant (??) on bolts/nuts when
mounting the injector.
3-way ball valve
The 3-way ball valve has four

connections,
1. connection to the injector
2. ½” female connection for the urea
solution
3. ½” female connection for the purge 4
air
4. ¼” female connection on the valve
actuator for control air.
The atomization air, urea solution, 3
purge air and control air are all supplied
from the dosing unit. 2
1
The GESAB SCR system has an added
feature to prevent injector from getting clogged with crystallized urea when power failure
occurs. In case no power (230 V) is supplied to the dosing unit, the instrument air in the air
tank included in the dosing unit will switch over the 3-way ball valve to “purge” position and
the contained air will “purge” the injector free from urea residuals.

GE-MA-040 A
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Injection unit (IU)

The injection/mixing unit is made of stainless-steel
material and delivered including flanges for
connecting to the exhaust gas piping. The unit
include:
-boss and flange for mounting of the injector
-a mixing plate on the inside (placed upstream the
injector)
The mixing plate causes a turbulence in the exhaust

gas for an efficient mixing of the injected urea with
the exhaust gas upstream the inlet of the catalyst
housing.
The exhaust gas pipe mounted on the outlet side of
the injection/mixing unit must be a straight pipe with
a pre-determined length and diameter for a complete
evaporation of the urea and an efficient mixing.
GESAB will engineer the length and diameter for
each installed SCR system. The straight pipe shall
be made of stainless steel (lowest grade Aisi304).
The injection unit shall be installed according to sketch below, with the injector pointing
upwards. Please make sure an adequate service space is available for installing/removing the
injector including the 3-way ball valve.

GE-MA-040 A
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SCR reactor
The SCR reactor is the housing for the catalyst material. 6

The reactor has
• fix points support for installation to the ships 1 2 3
structure
• support for the catalyst material
• hatches to access the internal of the reactor. Glass
fibre packing material seals the hatches, preventing 4
from leaking exhaust gas.
When the hatch has been removed, for installation of the

catalyst material or for inspection of catalyst material, 5
make sure a new hatch glass fibre sealing is used
The reactor can be installed both vertically and

horizontally, foundation and internal supports for catalyst
material varies with direction. Lifting lugs are included
and must be used during lifting/transport. The lifting lugs
shall also be used for connecting pendulum mounts when 7
stabilizing upper part of reactor (vertical installation).
Thermal expansion of the reactor must be included in the
design of the exhaust gas system. Possible top loading of reactor must be confirmed by
GESAB.
The reactor steel quality used is chosen for its application and can either be high temperature
resilient - high tensile black steel or stainless steel. External, high temperature insulation is
required (max surface temperature 60 °C), depending on application and requirements
thickness ranges between 70 - 150 mm covered with soft or metal sheet. Proper vibration
isolators should be used when installing the SCR reactor to eliminate the vibrations that
potentially could damage the catalyst material. A service space of at least 800 mm in front of
the hatches shall be provided and kept available.
At the inlet and outlet side of the reactor, ½” connections for connecting differential pressure
and temperature sensors are included. Two connections are also included for gas analysis
during commissioning and service. A service space of at least 500 mm shall be provided in
front of the connections in order to be able to install and remove the thermocouples.
1. G 1/2" Internal thread connection

differential pressure measurement.
temperature measurement.
service measurement point.
4. G 1 1/2" Internal thread connection
soot blowing pipe.
5. Hatch for access the reactor internal (for installation and service)

GE-MA-040 A
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6. Lifting lugs
7. Fix point supports
Catalyst material
The catalyst material is chosen for its

application by GESAB; volume,
geometrical dimensions and catalytically
active constituents. The catalyst material
is delivered including a wire mesh
mounted, for protection from vibrations
and leakage of exhaust gas.
For vertically installed reactors, the
catalyst material is placed on a supporting
grid. For horizontally installed reactors,
the grid is placed on outlet side of the
catalyst material.
Installation of catalyst material in SCR
reactor must be supervised by GESAB
personnel to avoid possible leakages of exhaust gas by-passing the catalyst material.
Exhaust gas impacts on catalyst lifetime
The life time of the catalyst material (catalytic activity), is depending on the “poisoning” of the
catalyst material with ammonium sulphates, unburned fuel and lube and fuel oil compounds
such as vanadium, phosphorous, sodium, calcium, zinc, potassium, magnesium etc., reducing
the available catalytic surface and hence the NOx reduction efficiency.
For maximum catalytic lifetime the exhaust gas concentration of “unburned” fuel and lube oil
from the engine and ammonium sulphates shall be kept as low as possible. As a guideline, the
following concentrations in the exhaust gas flow must be lower than (approximate guideline
values within brackets):
Alkali metals (Na, K etc) Max. at wet 5 mg/Nm3 (45 mg/kWh)

Alkaline-earth metals (Ca, S etc) Max. at wet 1 mg/Nm3 (9 mg/kWh)
Hydrogen chlorides, HCl Max. at wet 100 mg/Nm3 (900 mg/kWh)
Hydrofluoric acids, fluorides Max. at wet 1 mg/Nm3 (9 mg/kWh)
P2O5, Organic Phosphorous Max. at wet 3 mg/Nm3 (27 mg/kWh)
Arsenic compounds, As Max. at wet 0.01 mg/Nm3 (0.09 mg/kWh)
Silicon compounds; Si Max. at wet 0.03 mg/Nm3 (0.27 mg/kWh)
Lead Max. at wet 0.1 mg/Nm3 (0.9 mg/kWh)
Zinc Max. at wet 0.1 mg/Nm3 (0.9 mg/kWh)
Mercury Max. at wet 0.1 mg/Nm3 (0.9 mg/kWh)
Cadmium Max. at wet 0,1 mg/Nm3 (0.9 mg/kWh)
The formation of ammonium sulphates is dependent on the exhaust gas SO 2/SO3 relation and
respective concentrations, and the urea injection start temperature. The urea injection start

GE-MA-040 A
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temperature varies with the fuel oil sulphur content and is set according to the maximum used
fuel sulphur content during system start up. If other fuel oil with higher sulphur content is used
at a later stage, the start temperature must be corrected.
Also, high levels of hydrocarbons (HC) and particulate matter (PM) emitted from the diesel
engine, clogging the catalyst, can lead to a decreased SCR efficiency, catalyst lifetime and an
increased pressure drop. In order to avoid the problem with HC and PM, running the diesel
engine at low engine loads (i.e. exhaust gas temperatures < 300 ºC) for longer periods (> 6
hours) shall be limited.
If the engine is run at low engine loads, the exhaust gas temperature must be increased to >340
˚C for a period of at least 2 hours before the urea injection is started.
Avoiding urea injection at too low temperatures, using best possible fuel and lube oil,
minimizing the lube oil consumption, avoiding long periods at low engine loads etc. will
enhance the lifetime of the catalyst.
Make sure the catalysts are not exposed to water or humidity as catalyst then can be destroyed.
Unless the catalyst material is chosen for high temperature applications, longer periods with
exhaust gas temperatures >500 ˚C will deteriorate the catalytic activity and the material
properties.
Installation and exchange of catalyst material
In order to safeguard the performance guarantee, installation of the catalyst material should
only be performed under the supervision of a specialist from the GESAB. Installation includes
both first installation and exchange of catalyst material due to deteriorated catalytic activity.
Exchange of catalyst material should be performed according to the system specific catalyst
material exchange schedule. This schedule depends on engine specific information such as fuel
quality and operational conditions. As catalysts (and the catalysts’ individual layers) will
deactivate at different rates, information dictating which catalyst and layer should be replaced
at what time should be generated. Such an optimised catalyst management plan with follow-up
is normally provided as an additional service by the SCR system supplier.
See example of a catalyst management plan in the figure below. In this example catalyst
replacements are taking place after 15 000 h, 50 000 h and 70 000 h.

GE-MA-040 A
File Name:
Catalyst management plan

Three inital layers plus one spare layer
Catalyst potential Treshold: 80%, 10 ppm NH3 slip
100 20
95 18
Catalyst cleaning efficiency (%)
16
90
NH3 slip (ppm)

14
85 12
80 10
75 8
6
70
4
65 2
60 0
0 10000 20000 30000 40000 50000 60000 70000 80000
Hours of operation
Catalyst waste handling
Used catalysts, if relevant including mats and canning, that have been exchanged should be
handled as hazardous waste. Handling of this waste must be according to international, national
and local laws and regulation in the area (port) where the old catalysts are delivered to shore.
In most countries this requires:
• The material must leave the ship with information about the material’s origin, content
and properties. In many ports states a standard declaration form must be filled in and
delivered with the material.
• Old material must be stored in a way that prevents pollution. It should not be mixed
with any other waste.
• Only an organisation that is approved by the authorities to handle hazardous waste can
receive the material. Often ports have such approvals.
Delivery of old catalyst to an approved recipient should be clarified upfront the delivery to
ensure that the material can be taken to shore and to agree pricing.

GE-MA-040 A
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Differential pressure transmitter
The differential pressure transmitter is measuring the

differential pressure over the catalyst material. The
differential pressure is normally within 2 – 15 mBar,
depending on SCR system design. The differential
pressure is monitored to detect variations, mainly an
increase over time due to clogged catalyst material. The
signal from the transmitter is processed by the PLC,
where the differential pressure can be seen on the display
(HMI), presented in mbar. An alarm level for the
differential pressure is programmed into the PLC, at a
desirable level (see setting list GE-LI-148).
The correct use of the differential pressure transmitter is highly depending on a correct
installation and that both the connections (pipe etc) between the transmitter and catalyst housing
are kept clean from possible dust, soot, HC and condensate, otherwise giving an incorrect
reading. Make sure the transmitter is mounted with falling lines to the connections on the SCR
reactor, preferably minimum 0,5 m above highest connection point.
If the differential pressure is increasing, the reasons for the increased differential pressure must
be investigated and solved, example:
• Too high soot/PM levels from the diesel engine
• Too high HC levels from the diesel engine
• Long periods of “cold” and low load running of the diesel engine
• Too high levels of gypsum from the diesel engine
• Bad quality of the urea injection
For optimum lifetime of the transmitter, it shall be installed, free from vibrations and pulsations.
Proper ventilation shall be provided.
To reduce pulsations from the exhaust gas, a diameter 0,3 - 0,4 mm restrictor mounted inside
both high/low pressure connections shall be used.
Make sure the transmitter is installed above the connections on the SCR reactor, so the
condensate water is drained downwards through the pipes into the SCR reactor, without the
risk for entering the transmitter or clogging the pipes. The high-pressure connection = inlet
side of catalyst housing, low-pressure connection = outlet side of the catalyst housing. For
connections on the SCR reactor, see previous section – SCR reactor.
Make sure adequate service is provided and avoid hot spots for the cables, maximum
temperature shall be limited to 60 °C.

GE-MA-040 A
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Temperature transmitter
The two temperature transmitters (PT100) are measuring the catalyst

material inlet and outlet temperatures. The thermocouple signal is
converted internally to a 4 – 20 mA analogue signal processed by the
PLC, and the temperatures at catalyst inlet and outlet can be seen on the
HMI. The PLC controls the automatic start/stop of the urea injection.
For a given fuel sulphur content, the “urea injection start temperature”
(see setting list GE-LI-148) is programmed into the PLC.
The measured temperatures are also used by the PLC to
• detect too high temperatures for the catalyst material (see setting
list GE-LI-148)
• shut down the urea injection at elevated exhaust gas temperature
= 480 °C
The temperature transmitter shall be installed in the connections on the

SCR reactor (see previous section – SCR reactor). Make sure adequate
service is provided for removal of the transmitters and avoid hot spots
for the cables, maximum temperature shall be limited to 60 °C.

GE-MA-040 A
File Name:
Soot blower unit
The soot blower unit is used to

keep the inlet side of the catalyst
material free from dust build up 1
(gypsum formed in the diesel
engine) and collected soot. By 2
using compressed air bursts, the
collected dust/soot will be
blown away from the catalyst
material. 4
Compressed air (class 3) shall

be used. The air pressure used
for the soot blowing system 3
must be between 7 - 10 bar. A
receiver tank (manifold - 1) of a
certain volume is part of the
system.
Several soot blowing valves
(normally two valves per catalyst layer - 2) are connected to the manifold. On the outlet side of
the valves, a metallic (stainless steel) hose is connected (3). From each steel hose to the soot
blowing connections on the catalyst housing, pipes shall be connected.
A pressure transmitter (4) is supplied to each GESAB SCR system measures the pressure of the
soot blowing compressed air. The dust blow cycle will be interrupted if the air pressure is too
low (< 4 Bar - Failure).
The activation/cycle is set so the max dust/soot build up is prevented, not allowing the dust
layer thickness to grow. If the thickness of the dust layer is allowed to grow too much, the dust
blow system will not be able to remove the dust/soot.
The dust blow system cycle is controlled by the PLC (see chapter XXX) :
The following parameters are programmed during commissioning:
• Dust blow duration (= opening time for each dust blow valves used, set to 500 msec.)
• Waiting time (= time between 2 valves, normally set to 30 sec.)
The dust blow valves can also be operated manually from the display (HMI), to facilitate
valve function check during commissioning and service.
The soot blower manifold shall be installed maximum 2-meter pipe-length from the SCR
reactor. The manifold shall be installed vertically, with drain pointing downwards. Metallic
hoses/pipes must be supported to minimize vibrations and bending torques.

GE-MA-040 A
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NOx sensor
The NOx sensor is supplied with a pitot pipe to connect the NOx sensor to the exhaust gas
pipe and to .
Items:
1. Sensor control unit
2. Cable
3. NOx Sensor
4. Junction box 2
1
5. Pitot pipe 3
6. Boss for pitot pipe 4
The NOx analyzer is included to continuously measure
the resulting NOx level downstream the GESAB SCR
system. The NOx analyzer is measuring the NOx level
6
as “wet” (exhaust gas is not dried before analyzed). The
NOx level is measured and presented in ppm (parts per
million) on the GESAB SCR system HMI.
To reach the desired NOx cleaning efficiency for the

NOxCare SCR system, without creating secondary 5
pollutions, the control and metering of the urea flow
must be fast and precise. Especially on ships where the
engine load variation is frequent, rapid and extensive.
The fastest way to control the momentary flow of the urea injected into the exhaust gas stream
is to use a significant and repetitive engine load signal. The engine load is used to create a urea
flow vs engine load curve, mapped and programmed into the PLC during commissioning (see
setting list GE-LI-148). Normally, the optimum urea flow is mapped at 25, 50, 75 and 100
%MCR engine loads.
Complementary to the engine load vs urea flow regulation, a NOx analyzer is used to detect
and modify due to:
• variations in the engine NOx baseline levels
• variations in the GESAB SCR catalyst system (catalyst cleaning efficiency,
process/control system functionality)
At stable engine load conditions, the measured NOx level is used by the PLC to “fine tune”
the urea flow, continuously at every engine load, to reach a programmed set point (see setting
list GE-LI-148). The engine load vs urea flow curve will simultaneously be modified
continuously for the desired NOx set point.
NOx
ppm
Exportgatan 81A Alarm level high Fax +46 31 779 7841
42246 Hisings Backa 200 E-mail: gesab@gesab.net
Sweden Correction range => Website: www.gesab.net
160 increasing urea flow
120 Set point

GE-MA-040 A
File Name:
Example of NOx level set-point and alarm levels.
The GESAB SCR system is normally designed with its optimum NOx reduction efficiency at
engine loads < 75 %MCR. At lower engine loads, the efficiency is increasing (as long as the
exhaust temperature is above the urea start temperature) and at higher engine loads the
efficiency is decreasing.
In case the resulting NOx level is too high, the PLC will give a Failure/Warning see setting list
GE-LI-148). The alarm will not stop the urea injection and the metering of the urea flow.
The measuring principle for the NOx analyzer is based on a zirconium sensor. The sensor
measures both O2 and NOx (NO and NO2), but only the measured NOx level is used in the
GESAB SCR system.
The sensor is mounted inside the

stack probe (pitot pipe), but outside
the stack, easily removable without
disassemble the complete stack
probe.
The NOx sensor with pitot pipe

shall be installed minimum 2 meter
downstream the outlet of the SCR
reactor.
Item 1 - 4 are delivered separately
from item 5 – 6. After installation
of item 5 – 6, item 1 - 4 are
installed. Make sure the cable (item
2) is installed with a loop, with a
possibility to move without
restrictions when exhaust pipe is
expanding or vibrating.

GE-MA-040 A
File Name:
Urea storage tank (not scope of supply from GESAB)
The urea storage tank consists of filling, drain, venting, suction and return pipe connections.
Level gauge with two level switches one low level and one low/low level switches must be
integrated. If the urea reaches the low/low level switch the urea dosing system will stop to
protect the urea pump.
Also, a temperature sensor with high and low alarms must be integrated.
Suction pipe must be equipped with non-return valve.
Urea bunker pipe (not scope of supply from GESAB)
If urea bunker pipe has low levels where drain valves are fitted, they must be drained after
each bunkering of urea.

GE-MA-040 A
File Name:
SCR CONTROL SYSTEM DESCRIPTION
SCR system operation description
The SCR system is designed to run fully automated. It can be idling (AUTO MODE OFF)
while the engine is running, particularly if operation is stopped intentionally or due to a
failure. The operation mode of the SCR SYSTEM can be controlled by the mode selection
switch (AUTO MODE OFF/AUTO MODE ON) on the control and dosing unit.
Therefrom decoupled is the soot blower system. The soot blower system is turned on when
the corresponding engine is running.
Start up
As listed below, the control and dosing unit demands for a range of signals to be met before
starting up the SCR system if “AUTO MODE ON” is selected.
Power supply ok
Fuse ok
Field bus ok
Level control of urea tank ok
Pressure of urea piping system ok
Pressure of compressed air ok
Engine is running ok
Load signal threshold ok
Temperature threshold ok
When all relevant signals are present, then the feeding pump will automatically be switched
on. The launched air flow cools down the injector to prevent clogging of the injector. After an
adjustable cooling period, a controlled flow of urea solution starts to inject.
Shut down
When the engine shuts off, “AUTO MODE OFF” switch is selected, or a failure was detected
by the control and dosing unit, the operation of the SCR system will be stopped.
Whenever possible compressed air flow is preserved for some more minutes to flush the
injection system, thus preventing clogging of the nozzle by urea crystals.

GE-MA-040 A
File Name:
Control and Monitoring of SCR System
User Interface
This chapter must be rewritten, see Yarwil instruction manual …
STRUCTURE 1 (DU)
DOSING UNIT PUMP UNIT
MAIN SYSTEM LOGIN INFO

OVERVIEW STATUS
VISUAL INFO ALARM LIST ENTER

PASSWORD
SETTINGS
DOSING UNIT DU

GE-MA-040 A
File Name:
PRINT SCREEN’S DOSING UNIT
DOSING UNIT OVERVIEW

GE-MA-040 A
File Name:
SYSTEM STATUS
VISUAL INFO

GE-MA-040 A
File Name:
ALARM LIST
LOGIN

GE-MA-040 A
File Name:
INFO

GE-MA-040 A
File Name:
STRUCTURE 2 (PU)
PUMP UNIT
LOGIN ALARM LIST DOSING UNIT
SETTINGS

GE-MA-040 A
File Name:
PUMP UNIT PU
PRINT SCREEN’S PUMP UNIT
MAIN OVERVIEW
ALARM LIST

GE-MA-040 A
File Name:
LOGIN

GE-MA-040 A
File Name:
Inspection and Maintenance SCR System
Pump unit (if installed)

Cabinet Visual check / cleaning X
Skid Check for urea leakage X
Urea filter Clean / exchange filter X
Pressure sensors Exchange or recalibrate X
Dosing unit
Visual check / cleaning X
Cabinet
Check inside cabinet for urea leakage X
Pressure reduction Clean / empty condensate bin X
valve Clean / Exchange filter X
Pressure sensors Exchange or recalibrate X
Air flow meter Exchange or recalibrate X
Solenoid valves Check or exchange X
Visual check / cleaning X
Urea membrane pump Check pump exchange or recalibrate X
Membrane check or exchange X

GE-MA-040 A
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Soot blower (if installed)

Air manifold Clean / empty condensate X
Air valve Visual check / cleaning X
Pressure sensor Exchange or recalibrate X
Field instruments
Difference pressure
Exchange or recalibrate X
sensors
Temperature sensors Exchange or recalibrate X
3-way-valve Visual check / cleaning X
NOx sensor Exchange X
Reactor
Visual check / cleaning with
SCR catalyst X
vacuum cleaner
Gaskets Visual check / exchange X
Injections unit
Disassembly and visual check X
Injector
Cleaning / apply resistant grease X
Mixer / pipe Visual Check X

GE-MA-040 A
File Name:
Set Point List SCR System
Dosing unit DU01

General
SET engine number: _____ 1

SET max dosing pump capacity: _____l/h 60
SET engine name + no. for visualization: _____ DU01
SET max engine load: _____% 100
Start conditions
SET min start temp before SCR: _____°C 300

SET min stop temp before SCR: _____°C 295
SET min start temp after SCR: _____°C 300
SET min stop temp after SCR: _____°C 295
SET min engine load in percent: _____% 20
SET min time injector cooling: _____s 300
SET TON Open 3-way valve: _____s 4
SET min time injector purging: _____s 300
SET TON start conditions: _____s 1
SET TON next valve: _____s 120
SET TON valve open: _____s 0.5
SET Logging interval: _____s 20
Warning settings
SET temp before SCR high warning: _____°C 450

SET temp after SCR high warning: _____°C 450
SET diff press SCR high warning: _____mbar 20
SET urea pressure high warning: _____bar 6 _____s 10
SET urea pressure low warning: _____bar 1 _____s 10
SET SBM air pressure low warning: _____bar 4 _____s 10
SET air flow high warning: _____l/min 300 _____s 10
SET air flow low warning: _____l/min 170 _____s 10
SET NOx high warning: _____ppm 190 _____s 10
Failure settings
SET temp before SCR high failure: _____°C 480

SET temp after SCR high failure: _____°C 480
SET diff press SCR high failure: _____mbar 25
SET urea pressure high failure: _____bar 8 _____s 10
SET urea pressure low failure: _____bar 0.8 _____s 10
SET SBM air pressure low failure: _____bar 3 _____s 10

GE-MA-040 A
File Name:
SET air flow high failure: _____l/min 350 _____s 10

SET air flow low failure: _____l/min 150 _____s 10
SET NOx high failure: _____ppm 250 _____s 10
Sensor scaling
SET engine load 1 in %: _____% 100

SET max diff press: _____mbar 100
SET max temp before SCR: _____°C 800
SET max temp after SCR: _____°C 800
SET max. air flow: _____l/h 5000
SET max press soot blower: _____bar 10
SET max press urea bar: _____bar 10
SET min engine load signal IN: _____ 0
SET max engine load signal IN: _____ 32767
NOx sensor
SET NOx PID control kp: _____ 0.01

SET NOx PID control tn: _____ 5
SET NOx PID control tv: _____ 0
SET NOx PID control y min: _____ -1
SET NOx PID control y max: _____ 1
SET max. NOx PPM: _____ppm 2500
SET NOx setpoint: _____ppm 140
Load curve
AE / DG
SET Y1 (10 %): _____ l/h

SET Y2 (20 %): _____ l/h
SET Y3 (25 %): _____ l/h
SET Y4 (30 %): _____ l/h
SET Y5 (40 %): _____ l/h
SET Y6 (50 %): _____ l/h
SET Y7 (60 %): _____ l/h
SET Y8 (70 %): _____ l/h
SET Y9 (75 %): _____ l/h
SET Y10 (80 %): _____ l/h
SET Y11 (90 %): _____ l/h
SET Y12 (100 %): _____ l/h
SET Y13 (110 %): _____ l/h

GE-MA-040 A
File Name:
Pump unit PU01

Pressure settings
SET urea pressure low warning _____bar 0.6 _____s 10

SET urea pressure high warning _____bar 3 _____s 10
SET urea pressure too low failure _____bar 0.4 _____s 10
SET urea pressure too high failure _____bar 3.5 _____s 10
Temperature settings
SET max. temperature urea tank warning _____°C 40 _____s 10

SET min. temperature urea tank warning _____°C 5 _____s 10
SET max. temperature urea tank failure _____°C 45 _____s 10
SET min. temperature urea tank failure _____°C 2 _____s 10
Sensor scaling
SET max temp urea storage tank: _____°C 100

SET max press urea: _____bar 4

GE-MA-040 A
File Name:
Alarm and Troubleshooting list SCR System

Warning messages (Press reset button to quit
Type Value Most likely cause Corrective
error message)
SCR System: General warning to automation Check warning message in the control and dosing
Warning
system unit CDU
Check urea dosing pump
Pressure urea to injector Check whether injector nozzle is clogged
W001: Urea pressure high > 4.0 bar
is greater than specified Re-calibrate the sensor if required
Clean injector nozzle if required
Check whether urea pipe to urea injector is broken
Pressure urea to injector
W002: Urea pressure low < 1.0 bar Re-calibrate the sensor if required
is lower than specified
Repair urea pipe if required
Check non-return valve
Catalyst may be dusty or Open reactor and check catalyst
W003: Differential pressure SCR high > 20 mbar
clogged Remove dust/soot if required
Temperature upstream of Check engine for appropriate operation
W004: Temperature before SCR high > 450 °C the reactor is greater than Check sensor
specified Calibrate or replace sensor if required
Temperature downstream Check engine for appropriate operation
W005: Temperature after SCR high > 450 °C of the reactor is greater Check sensor
than specified Calibrate or replace sensor if required

GE-MA-040 A
File Name:
Check urea storage tank

W007: Temperature urea storage tank low < 5 °C Urea temperature to low
Check urea quality
W008: Temperature urea storage tank high > 40 °C Urea temperature to high
Check urea quality
Check pump for appropriate operation
Check piping system for leakage
Check valve unit
Pressure in urea Repair pump if necessary
approx. <
W009: Urea ring line pressure low feeding/ring line pipe Adjust or replace valve unit
0.6 bar
lower then specified Check urea ring line for leakages
Repair ring line if required
Check urea filter
Clean urea filter if necessary
Check pump for appropriate operation
Pressure in urea Check piping system for leakage
approx. >
W010: Urea ring line pressure high feeding/ring line pipe Check valve unit
3.0 bar
lower then specified Adjust or replace valve unit
Repair ring line if required
Urea tank is nearly Check urea tank level
W011: Urea storage tank level low
empty Refill urea tank

GE-MA-040 A
File Name:
Check compressed air supply

Air flow is not in
W012: Air flow high > 300 l/min Check air flow meter
specified range
Check air pipes for leak
Check air flow meter
Air flow is not in
W013: Air flow low < 170 l/min Check whether injector nozzle is clogged
specified range
Check if the system is running
Check general alarms of the system
W015: NOx limit reached > 190 ppm Insufficent urea injection
Check urea injection
Check quality of catalytic elements
Air pressure in soot Check compressed air supply
W018: Air pressure SBM low < 4.0 bar blower manifold pipe is Check sensor
lower than specified Re-calibrate the sensor if required
Change engine load / operation
Engine below low load
W020: Engine in low load operation < 10 %
limit

GE-MA-040 A
File Name:
Failure messages (Press reset button to quit error

Type Type Most likely cause Corrective
message)
Check failure message in the control and dosing
SCR System: General failure to automation system Failure
unit CDU
Cable break Check cable
F001: Communications failure PU0X
cable not connected Repair or replace cable if it is damaged
F002: Interrupt air flow meter Sensor failure Repair or replace cable if it is damaged
Replace sensor if required
F003: Interrupt engine 1 load signal Sensor failure Repair or replace cable if it is damaged
F005: Interrupt urea pressure sensor Sensor failure Repair or replace cable if it is damaged
F006: Interrupt temperature sensor before SCR Sensor failure Repair or replace cable if it is damaged
F007: Interrupt temperature sensor after SCR Sensor failure Repair or replace cable if it is damaged
F008: Interrupt differential pressure sensor Sensor failure Repair or replace cable if it is damaged

GE-MA-040 A
File Name:

Air flow is not in
F012: Air flow too high > 350 l/min Check air pipes for leak
specified range

Air flow is not in
F013: Air flow too low < 150 l/min Check whether injector nozzle is clogged
specified range
Pressure urea to injector Check whether urea pipe to urea injector is broken
F014: Urea pressure too high > 8 bar
is greater specified Re-calibrate the sensor if required
Repair urea pipe if required
Check sensor
Pressure urea to injector
F015: Urea pressure too low < 0.8 bar Re-calibrate the sensor if required
is lower than specified
Check non-return valve
Stop engine
Temperature upstream of Check engine for appropriate operation
F016: Temperature before SCR too high > 480 °C the reactor is greater than Check sensor
specified Calibrate or replace sensor if required
Catalyst damages with temperatures > 500°C.
Stop engine
Temperature downstream Check engine for appropriate operation
F017: Temperature after SCR too high DU01 > 480 °C of the reactor is greater Check sensor
than specified Calibrate or replace sensor if required
Catalyst damages with temperatures > 500°C.

GE-MA-040 A
File Name:
Catalyst may be dusty or Open reactor and check catalyst

F018: Differential pressure SCR too high > 25 mbar
clogged Remove dust/soot if required
F019: Interrupt NOx Sensor No sensor signal Repair or replace cable if it is damaged
Re-establish sensor signal
F021: Interrupt temperature sensor urea storage
Sensor failure Repair or replace cable if it is damaged
tank
F023: Temperature urea storage tank too high > 45 °C Urea temperature to high Check urea quality
Replace urea if necessary
F024: Temperature urea storage tank too low < 2 °C Urea temperature to low Check urea quality
Replace urea if necessary
Urea tank is nearly Check urea tank level
F027: Urea storage tank level too low
empty Refill urea tank
Check cable
Cable break Sensor
F029: Interrupt air pressure sensor SBM Repair or replace cable if it is damaged
failure
Air pressure in soot Check sensor
F032: Air pressure SBM too low < 3 bar blower manifold pipe is
lower than specified Re-calibrate the sensor if required

GE-MA-040 A
File Name:
Check if the system is running

Check general alarms of the system
F035: NOx limit reached > 250 ppm Insufficent urea injection
Check urea injection
Check quality of catalytic elements
Emergency stop button Check emergency stop button and what caused it to
F036: Emergency STOP 250 ppm
triggered be triggered, then reset the system


GE-MA-041 MANUAL SCR SYSTEM Working File

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GESAB SCR SYSTEM

GÖTEBORGS ENERGY SYSTEMS AB Phone +46 31 744 1950

General technical information ................................................................................................................ 5

GÖTEBORGS ENERGY SYSTEMS AB Phone +46 31 744 1950

Urea bunker pipe (not scope of supply from GESAB) ....................................................................... 41

GÖTEBORGS ENERGY SYSTEMS AB Phone +46 31 744 1950

Temperature settings ........................................................................................................................ 55

GÖTEBORGS ENERGY SYSTEMS AB Phone +46 31 744 1950

General technical information

GÖTEBORGS ENERGY SYSTEMS AB Phone +46 31 744 1950

GÖTEBORGS ENERGY SYSTEMS AB Phone +46 31 744 1950

Electrostatic sensitive components

GÖTEBORGS ENERGY SYSTEMS AB Phone +46 31 744 1950

SCR process description

The aqueous urea solution is:

The SCR chemical reaction

(1) NH2CONH2 (urea) + H2O → 2NH3 + CO2

(2) 4NH3 + 4NO + O2 → 4N2 + 6H2O

(3) 8NH3 + 6NO2 → 7N2 + 12H2O

GÖTEBORGS ENERGY SYSTEMS AB Phone +46 31 744 1950

Engine’s fuel/lube oil impact on the SCR system

Minimum exhaust gas temperature for urea injection

Start temperature for urea injection

GÖTEBORGS ENERGY SYSTEMS AB Phone +46 31 744 1950

Alkali metals (Na, K etc) Max. at wet 5 mg/Nm3 (45 mg/kWh)

GÖTEBORGS ENERGY SYSTEMS AB Phone +46 31 744 1950

SCR DeNOx additive – AUS 40

GÖTEBORGS ENERGY SYSTEMS AB Phone +46 31 744 1950

Class Solid Water Oil

- Air pressure to dosing unit: 6 - 10 Bar

GÖTEBORGS ENERGY SYSTEMS AB Phone +46 31 744 1950

System overview (single system)

GÖTEBORGS ENERGY SYSTEMS AB Phone +46 31 744 1950

System description and functionality:

GÖTEBORGS ENERGY SYSTEMS AB Phone +46 31 744 1950

Standard Scope of supply GESAB SCR System

Dosing Unit (1 off per engine / SCR system)

Urea pump unit (1 off per engine room)

Spill Valve unit (1 off per engine room)

Injection unit (1 off per engine / SCR system)

SCR reactor (1 off per engine / SCR system)

GÖTEBORGS ENERGY SYSTEMS AB Phone +46 31 744 1950

Differential pressure sensor (1 off per engine / SCR system)

Temperature transmitter (2 off per engine / SCR system, inlet + outlet)

-1 Temperature transmitter catalyst housing inlet

Optional Scope of supply GESAB SCR system

Soot blow system

-Soot blow manifold

GÖTEBORGS ENERGY SYSTEMS AB Phone +46 31 744 1950

GÖTEBORGS ENERGY SYSTEMS AB Phone +46 31 744 1950

SCR UREA INJECTION IN

NO STOP UREA CIRCULATIONS

START INJECTOR PURGING

OPEN 3-WAY VALVE

GÖTEBORGS ENERGY SYSTEMS AB Phone +46 31 744 1950

Engine load vs Urea flow

GÖTEBORGS ENERGY SYSTEMS AB Phone +46 31 744 1950

Detailed description GESAB SCR System

GÖTEBORGS ENERGY SYSTEMS AB Phone +46 31 744 1950

Dosing Unit control cabinet