3.

3 Layout
3.3 Layout

The EGR cooler and water mist catcher are installed in the EGR unit. The
unit, shown in Fig. 9, Page 20, includes a cooler spray with a function to
increase the cooling efficiency and to keep the cooler clean. A pre-spray
used to pre- pare the EGR gas for cooling and cleaning is installed in the
gas pipe up- stream of the EGR unit.
The EGR unit used for a low sulphur EGR system (LS EGR) is designed for a
fuel sulphur limit of 0.5% S, covering not only the ECA sulphur limit of 0.1% S
but also the 2020 global limit of 0.5% S. The EGR unit used for high
sulphur system (HS EGR) is designed for a maximum of 3.5% S and will be
slightly changed compared to the LS EGR unit. The EGR unit is integrated
on the en- gine, similar to a scavenge air receiver. The layout of the EGR
engines is shown in Fig. 10, Page 21 and Fig. 11, Page 21.
The presence of sulphur in the EGR gas requires that different grades of stain-
less steel are used for the EGR unit and the EGR cooler. These steel grades
cannot be used in connection with seawater, as chlorides in the water will
lead to corrosion, and accordingly a central cooling system using freshwater
as cooling media is specified for the EGR cooler.

Figure 9: Model of EGR unit

The supply of water to the pre-spray and EGR cooler spray, and the
removal of water from the EGR unit is part of the EGR water handling
3 EGR – Exhaust Gas Recirculation

system, which will control and recirculate the water. The system – which
also includes dis- charge of excess water generated in the combustion
process - is described and illustrated in Chapter Water Handling System
(WHS), Page 26. Part of the water handling system, i.e. the Receiving Tank
Unit (RTU) which includes a small tank and a circulation pump, is
integrated on the engine.
 3.3 Layout
Figure 10: Integrated EGR layout for bypass matching – 5G70ME-C

3 EGR – Exhaust Gas Recirculation

Figure 11: Integrated EGR layout for cut-out matching – 7G80ME-C

 3.4 Configuration
3.4 Configuration

Bypass matching
On an EGR system with bypass matching, the turbocharger is mounted
either on the exhaust side or aft. In both cases, the EGR unit is mounted
on the ex- haust side. The two configurations are shown in Fig. 12, Page
22 and Fig.
13, Page 22.

Figure 12: Side-mounted turbocharger and side-mounted EGR unit

3 EGR – Exhaust Gas Recirculation

Figure 13: Aft-mounted turbocharger and side-mounted EGR unit (RTU is not
shown)
 TC cut-out matching
The configurations of EGR systems with TC cut-out matching are shown in

3.4 Configuration
Fig. 14, Page 23 and Fig. 15, Page 23.

Figure 14: One basic T/C, one cut-out T/C, and one EGR unit

Figure 15: Two basic T/Cs, one cut-out T/C, and one EGR unit
3 EGR – Exhaust Gas Recirculation
 3.5 Engine outline
3.5 Engine outline

Bypass matching
The outline of an EGR system with bypass matching is shown in Fig. 16, Page
24. The engine is shown with a side-mounted turbocharger but engines with
aft-mounted turbochargers will also be available.

Figure 16: EGR engine with bypass matching, 6G70ME-C9

3 EGR – Exhaust Gas Recirculation
TC cut-out matching
The outline of an EGR system with TC cut-out matching is shown in Fig.

3.5 Engine outline

17, Page 25.

Figure 17: Outline of a 7S90ME-C9 Tier III engine with one basic T/C, one cut-
out T/C and one EGR unit
3 EGR – Exhaust Gas Recirculation
 3.6 Water Handling System (WHS)
To prevent sulphur and particles from damaging the engine, cleaning of the
recirculated exhaust gas is required. This is performed in a combined cooling
3.6 Water Handling System (WHS)

and cleaning process by a pre-spray and an EGR cooler spray in the EGR
string, using recirculated water.
In order to maintain the ability of the water to clean, cool and neutralize the
exhaust gas, a Water Handling System (WHS) is needed. The system must
ensure the removal of accumulated particles and neutralisation of sulphuric
acid in the water, and ensure the delivery of water at a sufficient pressure and
supply rate to the EGR unit. In addition, the WHS handles the bleed-off water,
which is the surplus of water accumulated in the system from the combustion
process.
Two WHS systems are available:
▪ WHS 2: operates with a combined internal and external circulation of EGR
water to control the water quality during operation. WHS 2 is used for
LS fuels as well as for HS fuels.
▪ WHS 3: operates with an internal circulation of EGR water, using a
direct supply of NaOH and FW to the engine to maintain the water quality
during operation. WHS 3 is used for LS fuels only (max 0.5% S)
The naming, WHS 2 and WHS 3, replaces the name of the original Water
Handling System, WHS, for high sulphur and low sulphur fuels.

WHS 2: Principle (External circulation)

The principle of the WHS 2 is shown in Fig. 18, Page 27 for low-sulphur fuel
(LS-WHS 2) and in Fig. 19, Page 27 for high-sulphur fuel (HS-WHS 2). The
receiving tank, circulation pump and control valve are part of the Receiving
Tank Unit (RTU), placed on the engine below the EGR unit. The supply pump,
the NaOH pump and the supply of fresh water are part of the supply unit (SU)
installed in the engine room. The water from the EGR unit is drained to the re-
ceiving tank and recirculated to the EGR unit by the circulation pump. Part
of the water is directed to the buffer tank by the control valve and returned to
the EGR unit by the supply pump. In this string, an appropriate amount of
NaOH is supplied to neutralise the sulphuric acid in the system. The bleed-off
water is discharged to the drain tank by an overflow pipe on the buffer tank.
The water accumulated in the drain tank may be discharged to the sea, as
de- scribed later in this chapter, provided the specified discharge criteria are
3 EGR – Exhaust Gas Recirculation

met.
The WHS is designed according to the specified sulphur limits for the fuel oil
used, when the engine is running in EGR mode:
▪ LS-WHS 2 for EGR designed for low-sulphur fuels (max 0.5% S)
In case the EGR system is designed for fuels of max 0.5% sulphur, the
production of particles is ignorable and cleaning of the recirculation water
will not be required. However, neutralisation of the recirculated water will
still be required. For LS-WHS 2 the flow of water in the SU loop and the
amount of NaOH is relatively low.
▪ HS-WHS 2 for EGR designed for high-sulphur fuels (> 0.5% S)
In case the EGR system is designed for fuels not complying with the
SOX requirements, the production of particles is significant and the
recirculated water will need cleaning to prevent damage to the engine. A
Water Treat-
 ment System (HS-WTS) is installed in the buffer tank loop to reduce par-
ticulate matter in the water. For HS-WHS 2 the flow of water in the SU
loop and the amount of NaOH is relatively high.

3.6 Water Handling System (WHS)

Figure 18: Diagram for LS-WHS 2

3 EGR – Exhaust Gas Recirculation

Figure 19: Diagram for HS-WHS 2

 3.6.1 WHS 2: Buffer tank
The buffer tank is part of the WHS 2 and required for control of the amount
and quality of water in the EGR process. The tank size is defined by the
3.6 Water Handling System (WHS)

volume of water needed in the EGR system during start up. The buffer tank is
arranged with an overflow pipe for automatic discharge of bleed-off water,
which accumulates in the system due to condensation of exhaust gas.

LS buffer tank (>0.5% S)

In case the EGR system is designed for low-sulphur fuel, see Fig.18, Page
27, cleaning of the recirculated water will not be needed. However, to prevent
ac- cumulation of particulate matter of high density at the tank bottom, the
over- flow pipe (low overflow) is connected to the lowest possible point of the
tank. In addition, to avoid trapping of foam, particulate matter and similar low
dens- ity substance in the top of the tank, an overflow pipe (high overflow)
with a slightly higher discharge level is also arranged. Due to the ship
movements at sea, bleed-off water will occasionally be discharged this way.

HS buffer tank (>0.5% S)

In case the EGR system is designed for high-sulphur fuel, see Fig. 19,
Page 27, the recirculated water will need cleaning by a water treatment
system,
HS-WTS. The outlet for the WTS is taken from the lowest possible point of
the buffer tank to ensure that particulate matter of a high density is removed
from the system. The treated water is returned to the buffer tank at a level
similar to the water inlet from the EGR circuit. Bleed-off water including foam,
particu- late matter and other low density substance is discharged by an
overflow pipe, similar to the high overflow at LS buffer tank.
3 EGR – Exhaust Gas Recirculation

Figure 20: Principle sketch of LS buffer tank

 3.6 Water Handling System (WHS)
Figure 21: Principle sketch of HS buffer tank

3.6.2 WHS 2: HS-WTS

When the engine operates on high-sulphur fuels in EGR mode, the particulate
matter accumulated in the EGR water must be removed. This function is
handled by the Water Treatment System for high-sulphur fuels (HS-WTS).
The HS-WTS must fulfil the requirements specified for “EGR WTS for high-sul-
phur fuels”, which is available on request. The task for the system is to re-
ceive, clean and return EGR water to the buffer tank and thereby keep the
amount of suspended solids in the EGR system below the specified level.
The residues from the cleaning process are discharged to the sludge tank.
Different methods for treatment of the EGR water could be used. This may be
technologies using centrifuges, filters or similar appropriate equipment.
The bleed-off water accumulated in the EGR drain tank may be discharged
to the sea combined with water discharged from the Exhaust Gas Cleaning
Sys- tem. However, as sludge accumulated aboard must be delivered at
port, it may be convenient to minimize the amount of sludge accumulated by
the HS WTS. The reduction of sludge may be obtained by:
3 EGR – Exhaust Gas Recirculation

▪ A. redirecting water, which is separated by settling in the sludge tank, to

the EGR drain tank, or
▪ B. arranging the WTS to work as a concentrator including the total bleed-
off water in the discharge.
The principles of the sludge reduction compared to the standard set-up
are shown in Fig. 22, Page 30. See the following paragraph “Discharge of
bleed- off water".
3.6 Water Handling System (WHS)

Figure 22: Sludge reduction by water removal from sludge tank (A), or by WTS
working as concentrator (B)

Suppliers of the HS-WTS must be approved by MAN Energy Solutions. For

detailed information please contact MAN Energy Solutions.

3.6.3 WHS 3: Principle (Internal circulation)

The principle of the WHS 3, which is available for ME-GA engines and other
engines operating on LS fuels, is shown in Fig. 23, Page 31.
The circulation of process water on the engine is similar to the WHS 2
concept, except that NaOH and FW is supplied directly to the engine. The
ex- ternal circulation, the buffer tank and the supply unit are omitted in this
sys- tem. Accordingly, the bleed-off water is discharged directly to the drain
tank
Similar to the WHS 2 system, the water accumulated in the drain tank may be
discharged to the sea, provided the specified discharge criteria are met.
3 EGR – Exhaust Gas Recirculation
 3.6 Water Handling System (WHS)
Figure 23: Diagram for WHS 3 used for LS fuels only

Discharge of bleed-off water

Bleed-off water generated by the EGR system may be discharged to the
sea, provided the Guidelines for discharge of bleed-off water are met –
2018 Guidelines for the discharge of exhaust gas recirculation (EGR) bleed-off
wa- ter, MEPC.307(73). The criteria for discharge depend on the specified
sulphur limits for the fuel oil used when the engine is running in EGR mode.

Discharge of bleed-off water from EGR designed for low-sulphur fuels

In case the engine is operating in EGR mode on compliant fuels, i.e. fuels that
3 EGR – Exhaust Gas Recirculation

meet the sulphur requirements in the area, the bleed-off water may be dis-
charged to the sea provided the oil content in the discharge does not
exceed 15 ppm. A Water Treatment System (LS-WTS), including an
arrangement for continuous monitoring and recording of oil content, is required
to ensure com- pliance before discharge.

A combined LS-WTS and Oily Bilge Water cleaning system may be

installed to handle the discharge of both EGR drain and Bilge Water by the
same sys- tem. In this case EGR drain and Bilge Water must be handled
separately without mixing the two streams

A diagram for the discharge of bleed-off water on LS-EGR is shown in Fig.

24, Page 32. A diagram for the combined EGR and OBW discharge is shown
in Fig. 25, Page 32.
 If local restrictions prevent discharge in the area, the bleed-off water must be
retained in the drain tank or in a separate storage tank, until discharge outside
the restricted area is possible. Accumulated bleed-off water may alternatively
be delivered at port.
3.6 Water Handling System (WHS)

Figure 24: Diagram for the discharge of bleed-off water for LS-EGR (max
0.5% S)
3 EGR – Exhaust Gas Recirculation

Figure 25: Diagram for the combined discharge of bleed-off water for LS-
EGR and OBW

Discharge of bleed-off water from EGR designed for high-sulphur fuels

In case the engine is operating on fuels, which do not meet the fuel-sulphur
requirements, an exhaust gas cleaning system, (EGCS) must be installed on
board. The total amount of exhaust gas treated by the EGCS and EGR will
largely be independent of the EGR rate, due to the recirculation of exhaust
gas. Accordingly, the amount of exhaust gas passing the EGC scrubber will
decrease, when the EGR rate increases. For this reason, the EGR bleed-off
water may be discharged combined with discharge water from the Exhaust
Gas Cleaning System EGCS, provided the combined discharge meets the
cri- teria in the EGCS Guidelines – 2015 Guidelines for exhaust gas cleaning
sys- tems MEPC.259(68).
 An example of the combined discharge is shown in Fig. 26, Page 33. Bleed-
off water from the EGR drain tank is pumped, controlled by the EGCS, to
an appropriate inlet point in the scrubber water stream prior to the quality

3.7 Control System

control equipment, (QC). The system must include the proper arrangements to
en- sure, that discharge of EGR bleed-off water could be properly controlled.
This may be solved by a control valve which redirects the EGR drain as
shown in the Fig. 26, Page 33, or by other means.
In case a discharge through EGCS is not installed, an alternative system must
be arranged to comply with the requirements in the guidelines.

Figure 26: Diagram (example) for discharge of EGR bleed-off water for HS
fuels

3.7 Control System

3 EGR – Exhaust Gas Recirculation

The EGR control is handled by the ME-ECS engine control system on

engines with EGR, ME-ECS controls the EGR valves, the EGR blowers and
part of the water handling system (WHS), i.e. the receiving tank unit (RTU),
the supply unit (SU) and the interface to the water treatment system
(WTS).
The O2 amount in the scavenge air receiver is controlled by the EGR controller
in ME-ECS by adjusting the speed of the EGR blowers and thus the amount
of recirculated exhaust gas.

EGR blower control

The EGR blower control system consists of a frequency converter with a
local operating panel which supplies the EGR blower with power. An EGR
system can have up to two EGR blowers, each one with a frequency
converter.
 The blower control system monitors and controls the blowers and adjusts the
exhaust gas flow in the EGR line, in accordance with input from the EGR
con- trol system.
3.8 Installation

Special requirements apply for the power cabling between the frequency con-
verter and the blower to ensure compliance with EMC directives. The interface
between the EGR blower control and ERCS is hardwired.

3.8 Installation

Engine room arrangement

A high degree of flexibility for installation of the WHS in the engine room is
possible, provided that some specific requirements for the arrangement are
followed. Examples of EGR installation, including the elements in the Water
Handling System, are found in Fig. 27, Page 34 and in Fig. 28, Page 35.
3 EGR – Exhaust Gas Recirculation

Figure 27: Example of arrangement on EGR designed for low-sulphur fuels

Specific requirements for arrangements of WHS in the engine room:
1. The buffer tank may be positioned as found convenient, but the tank
should not be placed more than 20 m above the RTU.

3.8 Installation
2. The supply unit should be positioned at the level of the buffer tank or
lower.
3. The NaOH tank should be located at the level of the supply unit or higher.
4. The position of the drain tank should allow a natural flow from the buffer
tank.
5. The position of the LS-WTS or HS-WTS should be in accordance
with the supplier’s requirements
6. The position of sludge tank should allow a natural flow from the WTS.

3 EGR – Exhaust Gas Recirculation

Figure 28: Example of arrangement on EGR designed for high-sulphur fuels

 EGR cooling system
The EGR engines are specified with a central cooling system using freshwater
3.8 Installation

as cooling media to prevent material damage to the EGR cooler and unit. In
certain cases, if special precautions are taken, a combined cooling system
can be used, using central cooling for the EGR cooler and seawater cooling
for the scavenge air cooler.
An optimised cooling system for EGR could be installed to reduce the pump
power consumption, when the EGR system is not operating. In this case
the vessel cooling water pumps must be prepared for variable flow regulation
in way of either variable frequency drives or a well-defined two-speed
operation. The ad-on functionality at the engine comprises of a valve
arrangement, which automatically shuts off the water supply to the EGR cooler
when the engine runs in Tier II mode.

Pipes for Water Handling System

The pipes installed for the WHS should be designed for a pH range of 3-9
and a maximum pressure of 10 bar. The material could be stainless steel,
but other materials such as glass-fibre reinforced plastic suitable for the
medium can be used. The sealing material between pipe flanges of stainless
steel and normal steel must be of a suitable isolation material. Bolts and nuts
for flanges must be of stainless steel. The pipe dimensions must be
adequate for the wa- ter flow which is related to the engine power. The
estimated water flow is found in Section Consumptions and capacities, Page
47.

NaOH tank
NaOH is a corrosive and harmful product with a tendency to crystallise at
low temperatures, and the NaOH tank installation must therefore be designed
with this in mind. The material could be stainless steel, specially coated steel,
poly- mer or other materials suitable for the product. If a 50% NaOH solution
is used, the liquid will start to crystallise at temperatures below 12 °C and the
tank and pipes should therefore keep a minimum temperature of 16 °C. Ac-
cordingly, the tank should be installed in a room with a controlled temperature
or be insulated and fitted with means for heating. Similar protection against
crystallisation will be required for the NaOH supply pipes between the tank
and the NaOH inlet point. However, if a 30% NaOH solution is chosen, the
crystallising temperature is 4 °C and the temperature demand does not call
for special requirements. However, the required volume of the tank will be lar-
3 EGR – Exhaust Gas Recirculation

ger due to the lower NaOH concentration. The installation of the tank should
include precautions to prevent any leakage from the tank and tank connec-
tions.
When estimating the required capacity of the NaOH tank, several parameters
must be considered: the Tier III sailing time and sailing pattern, the fuel sul-
phur content, the NaOH concentration and the planned bunker frequency. An
example of estimating the NaOH tank capacity is given in Section
Calculation of EGR data, Page 54.

Sludge tank
The sludge outlet from the WTS is an aqueous solution including the remains
accumulated from the treatment of bleed-off water. The pH value normally
varies between 6 and 9. The water content in the sludge is more than 90%,
 which makes it easy to discharge by a pump. The sludge tank could be a
separate tank or part of another tank, which holds similar sludge to be dis-
charged to reception facilities. The capacity of the sludge tank depends on

3.8 Installation
the Tier III sailing time and sailing pattern, the fuel sulphur content and the
planned discharge period. An example of estimating the sludge tank capacity
is found in Section Calculation of EGR data, Page 54.

Drain tank
The drain tank holds the bleed-off water to be discharged to the sea when the
relevant discharge criteria are met. In case of LS-EGR systems the bleed-off
water is discharged through an LS-WTS. In case of HS-EGR systems the
bleed-off water is discharged through the EGCS, which will be required,
when engine runs on HS fuels. The tank should be designed with a sufficient
volume to hold the amount of bleed-off water generated in periods where
discharge is not possible.
The design of the drain tank could be based on an estimate of the
expected time and sailing distance in which a discharge could not take
place. This may include time for an overhaul of the WTS.

Example of engine room arrangements

On the following pages in Fig. 29, Page 38 an example of EGR installation
for HS-fuel in a 182,000 DWT bulk carrier is shown. Consumption and
capa- city data for the EGR system, including capacities of the NaOH tank,
drain
tank and sludge tanks, are given as an example in Section Calculation of
EGR data, Page 54.

3 EGR – Exhaust Gas Recirculation

3.8 Installation

Figure 29: Example of HS EGR System on a 182,000 DWT Bulk carrier, arrangement by Odense Maritime
Technology (OMT). SOx scrubber arrangement is not shown.

Ship: 182,000 DWT Bulk carrier

Engine: 6G70ME-C9.5, 16.4 MW
3 EGR – Exhaust Gas Recirculation

EGR system: By-pass matching

Fuel sulphur: 3.5% S
 MAN Energy Solutions
3 EGR – Exhaust Gas Recirculation 3.8 Installation
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3
 MAN Energy Solutions 3

Figure 30: Example of HS EGR System

3.9 Spare parts

3.9 Spare parts

Recommended spare parts that support unrestricted EGR operation:
▪ 1 pcs. blindflange for Exhaust gas receiver
▪ 1 pcs. blindflange for EGR mixing chamber
▪ 2 pcs. pre-spray nozzles
▪ 1 pcs. O-ring for EGR cooler
▪ 1 pcs. complete Siemens Sipart controller incl. NCS and magnet
▪ 2 pcs. pH-sensor probes
▪ 1 pcs. level sensor for RTU (can be used in various EGR applications)
▪ 1 bottle gas for SUC 2-point calibration
▪ 2 pcs. seals for EGR sludge trap
Spare parts for water treatment system and supply unit should be in accord-
ance with the supplier’s recommendation.
3 EGR – Exhaust Gas Recirculation

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3.10 Retrofit

3.10 Retrofit
If a ship is not intended during its lifetime to enter a NO X ECA, in which it
would be required to meet Tier III regulation, there would be no reason to in-
clude a comprehensive Tier III installation. However, any doubt on whether the
ship in the future would enter the area could lead to a decision to install the
equipment anyway or at least prepare the ship for a retrofit installation.
Two methods to prepare for EGR retrofit installation are available:
▪ EGR Tier III DS (Design Specification)
▪ EGR prepared Tier III DS (Design Specification)

EGR Tier III DS

EGR Tier III DS is the solution for ships where an EGR solution most likely will
be needed in a later period of the ship. This gives the opportunity to postpone
the purchasing and installation of several sub-components and thereby delay
the related first cost expenses, installation cost and aging of components in
the system. However, it should be kept in mind that installation on a ship in
service, even when planned for docking period in connection with a renewal
survey, is more complicated and time consuming than installation during new
building. Accordingly, the extent of preparation for the EGR retrofit installation
should be carefully considered.
The EGR Tier III DS solution would include the parent engine of a certain
series of vessels to be tested and certified as a Tier III engine. If installed on
board, including required auxiliary systems, the ship owner is provided with a
Tier III compliant ship. However, if the date for Tier III compliance on this
ship is uncertain, some Tier III components already produced and tested for
this engine needs not be installed, and the additional Tier III auxiliary systems
re- quired for the system needs not be purchased before it is actually
required.
The subsequent member engines for the ships in the series could be con-
figured more or less prepared for EGR retrofit or as fully EGR Tier III compliant
engines if convenient. It must be noted that in case some ships in the series
are planned for alternative fuel sulphur compliance (HS versus LS) for Tier III
mode, the engines for these ships need another parent engine certification for
compliance even in case the engine rating is unchanged.
The extent of EGR preparation and retrofit installation can be organised in 4
categories:
3 EGR – Exhaust Gas Recirculation

▪ Required: Preparations and installations required for retrofit installation

▪ Recommended: Installations recommended for the EGR prepared engine
▪ Convenient: Installations convenient for inclusion in the EGR prepared en-
gine
▪ Postponed: Sub components recommended for postponement for
final Tier III installation

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 MAN Energy Solutions 3

In Table 6, Page 42 and Fig. 31, Page 43 and 32, Page 44 a suggestion
of components and preparations for Tier III DS retrofit based on the 4 cat-
egories are given..
3.10 Retrofit

EGR Tier III DS retrofit

preparation
Phase EGR TC by-pass EGR TC cut-out
Required Tier III certified parent engine Tier III certified parent engine
- EGR TC configuration
- TC cut-out valves
EGR unit holding brackets EGR unit holding brackets
Reinforcement for RTU Reinforcement for RTU
Scavenge air mixing chamber Scavenge air mixing chamber
- EGR unit
- EGR/scav. air cooler
EGR gas pipe connections EGR gas pipe connections
Exhaust gas by-pass valve Cylinder by-pass valve
EGR engine platforms and galleries EGR engine platforms and galleries
Relevant blind flanges and dummies Relevant blind flanges and dummies
Sufficient auxiliary power Sufficient auxiliary power
Sufficient central cooling capacities Sufficient central cooling capacities
Reservation of space WTS, tanks etc. Reservation of space WTS, tanks etc.
Recommended EGR unit -
RTU Platform RTU Platform
Integrated tanks (i.e. sludge/drain tanks) Integrated tanks (i.e. sludge/drain tanks)
Convenient EGR Gas pipes EGR Gas pipes
Water pipes/valves on engine Water pipes/valves on engine
EGR power cabling EGR power cabling
Access for retrofit installation Access for retrofit installation
3 EGR – Exhaust Gas Recirculation

Table 6: Components and preparations for EGR Tier III DS retrofit installation

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 MAN Energy Solutions 3

EGR Tier III DS retrofit

preparation

3.10 Retrofit
Phase EGR TC by-pass EGR TC cut-out
Postponed EGR control system EGR control system
Receiving tank unit, RTU Receiving tank unit, RTU
Cabling Cabling
EGR blower EGR blower
EGR cooler -
EGR shut down valve EGR shut down valve
EGR closing valve EGR balance valve
Cylinder by-pass valve -
Water treatment system, WTS Water treatment system, WTS
Supply unit, SU Supply unit, SU
Independent tanks (i.e. NaOH tank) Independent tanks (i.e. NaOH tank)
Water pipes Water pipes
NaOH pipes NaOH pipes
Bunker pipes Bunker pipes
Venting pipes Venting pipes
Table 7: Components and preparations for EGR Tier III DS retrofit installation

3 EGR – Exhaust Gas Recirculation

Figure 31: Retrofit preparations for EGR Tier III DS installation

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 MAN Energy Solutions 3
3.10 Retrofit

Figure 32: Retrofit preparations for EGR Tier III DS installation

3 EGR – Exhaust Gas Recirculation

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MAN Energy Solutions 3

EGR prepared Tier III DS

3.10 Retrofit
EGR prepared Tier III DS is the solution for ships where the Tier III compliance
will not be needed during the planned lifetime of the ship. However, the uncer-
tainty of the future trade of the ship could be met by a minimum preparation
of a later EGR retrofit installation. This gives the opportunity to avoid the cost
of the EGR system and still keeping a door open for a later installation.
In case a retrofit is later decided, a major retrofit job would be required. In ad-
dition to the cost of the Tier III equipment and its installation, expenses for
modification of the engine and T/C components should be included. The
en- gine will need re-certification for both Tier II and Tier III modes, which
calls for a new sea trial, on-board survey and class approval.
The extent of EGR preparation is given as example in Table 8, Page 45 and
Fig. 33, Page 46 and 34, Page 46.

EGR prepared Tier III DS

Phase EGR TC by-pass EGR TC cut-out
Required - TC configuration according to EGR
spec.
- TC cut-out valves
EGR unit holding brackets EGR unit holding brackets
Reinforcement for RTU Reinforcement for RTU
Scavenge air mixing chamber Scavenge air mixing chamber
- EGR unit
- EGR cooler
- Cylinder by-pass valve
EGR gas pipe connections EGR gas pipe connections
Relevant blind flanges Relevant blind flanges
Sufficient auxiliary power Sufficient auxiliary power
Sufficient central cooling capacities Sufficient central cooling capacities
Reservation of space for Reservation of space for
WTS, tanks etc. WTS, tanks etc.
3 EGR – Exhaust Gas Recirculation

Table 8: EGR prepared Tier III DS

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 MAN Energy Solutions 3
3.10 Retrofit

Figure 33: EGR prepared Tier III DS installation

3 EGR – Exhaust Gas Recirculation

Figure 34: EGR prepared Tier III DS installation

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MAN Energy Solutions 3

3.11 Consumptions and capacities

Performance and consumption data for EGR engines are available by the
en- gine calculation program, CEAS. CEAS is found at [Link]

3.11 Consumptions and capacities

[Link]/ceas/[Link]. The data presented in the following are based
on CEAS output for a specific engine in two different configurations, EGR
and EcoEGR. For each of these configurations data for a low sulphur and a
high sulphur installation are presented.
Engine: 6G70ME–C9.5
Power: 16,440 kW
Speed: 83.0 r/min
Condition: ISO condition
Configurations: EGR LS fuel (0.1% S and 0.5% S)
EGR HS fuel (3.5% S)
EcoEGR LS fuel (0.1% S and 0.5% S)
EcoEGR (3.5% S)

Specific fuel oil consumption

The specific fuel oil consumption (SFOC) of an EGR engine operating in Tier II
mode is similar to the SFOC of a standard low-load tuned engine. When the
EGR engine operates in Tier III mode, the SFOC will increase due to the
change of the combustion process. The SFOC in Tier II and Tier III mode is
shown in Fig. 35, Page 47.

3 EGR – Exhaust Gas Recirculation

Figure 35: SFOC of EGR engines in Tier II and Tier III mode

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The concept of EcoEGR, which is introduced in chapter EcoEGR, Page 17,

reduces the fuel consumption by using EGR to optimize the SFOC in both
Tier II and Tier III mode. Compared to the EGR engine, the EcoEGR engine will
provide an SFOC reduction of 2-4 g/kWh in Tier II mode, shown in Fig. 36,
Page 48, and 0-3 g/kWh in Tier III mode, shown in Fig. 37, Page 48.
3.11 Consumptions and capacities

Figure 36: Comparison of SFOC between EGR and EcoEGR engines in Tier
II mode
3 EGR – Exhaust Gas Recirculation

Figure 37: Comparison of SFOC between EGR and EcoEGR engines in Tier
III mode

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Power consumption
The electrical power required for the EGR system is related to the WHS and
the EGR blower.

3.11 Consumptions and capacities

The power required for the WHS is independent of the engine load, as the
WHS circulates a constant flow in the system during EGR operation. Due to
various technologies used by suppliers of water treatment systems, the WHS
power may differ significant from the estimated values in Fig. 38, Page 49.
The power required for the EGR blower depends on the engine load and
the EGR rate. Due to a relative high rate used for EcoEGR, the power
required for this configuration is slightly higher than the power required for
the standard EGR. Furthermore, as EcoEGR also operates with EGR in Tier
II mode, power for blower will also be required for EcoEGR in this mode.
The power required is shown in Fig. 38, Page 49.

Figure 38: Estimated power consumption for WHS and EGR blower

3 EGR – Exhaust Gas Recirculation

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NaOH consumption
The NaOH consumption depends on the engine load, fuel sulphur content,
EGR ratio and NaOH concentration. The estimated consumption for different
3.11 Consumptions and capacities

configurations are shown in Fig 39, Page 50.

When operating on HS fuels in Tier II mode, the cost of NaOH for EcoEGR
en- gines will be significant. A lower fuel sulphur content may be chosen to
reduce the NaOH consumption. However, a lower Sulphur content may
increase the fuel cost and careful considerations should be given to this.

Figure 39: Estimated NaOH consumptions

NaOH tank

The NaOH is usually supplied in a 50% solution, but a 30% solution can be
selected to prevent potential heating requirements, as explained in chapter In-
stallation, Page 34. In case a 30% solution is chosen, the NaOH
consumption will increase in accordance with the dilution ratio.
The volume of the NaOH tank should be designed to hold an appropriate
volume for EGR operation. An example for designing the NaOH tank, based
on specific criteria, is given in chapter Calculation of EGR data, Page 54.
3 EGR – Exhaust Gas Recirculation

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Bleed-off water
The surplus of water generated by the EGR process is discharged as
bleed- off water to the EGR drain tank. The amount of water relates to the

3.11 Consumptions and capacities

engine power, the EGR rate and the fuel type.
In Tier III mode, the bleed-off amount will virtually be the same on EGR and
EcoEGR engines. In Tier II mode, the EcoEGR engine generates bleed-off wa-
ter in a reduced amount related to the EGR rate.
The estimated bleed-off amount are shown in Fig. 40, Page 51.

Figure 40: Estimated discharge of bleed-off water

Drain tank

The EGR drain tank should be designed to include the estimated bleed-off
water accumulated when discharge is not possible, either during an overhaul
of the WTS or during a period when discharge is not allowed, i.e. in port, har-
bours or similar restricted areas. An example to estimate a proper volume of
the EGR drain tank is given in chapter Calculation of EGR data, Page 54.

Sludge production
3 EGR – Exhaust Gas Recirculation

When operating on non-compliant fuels, the total amount of suspended solids

removed from EGR circuit is relative high. A major part is removed by the HS
WTS and discharged to the sludge tank. The amount of sludge
accumulated in the tank may vary depending on the method used by the
HS WTS, as ex- plained in chapter Water Handling System (WHS), Page
26.
When operating on compliant fuel no cleaning will be required for the EGR cir-
cuit. However, the bleed-off water accumulated in the EGR drain tank must
comply with the 15 ppm criteria before discharge as explained in chapter Wa-
ter Handling System (WHS), Page 26. The LS WTS, installed for this purpose,
will accumulate a limited amount of sludge.
The estimated sludge amounts are shown in Fig. 41, Page 52. In case spe-
cial features are installed related to HS-WTS, the amount of sludge from non-
compliant fuels may be significantly reduced.

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3.11 Consumptions and capacities

Figure 41: Estimated accumulation of sludge

Sludge tank

The sludge tank should be designed to include the estimated amount of

sludge accumulated during the voyage. An example to estimate a proper
volume of the sludge drain tank based on sailing pattern and discharge fre-
quency is given in chapter Calculation of EGR data, Page 54.

Freshwater consumption
When operating in certain conditions on non-compliant fuels, addition of
freshwater may be required to compensate for accumulation of sulphates in
the recirculated water. Although consumption of FW is considered small,
CEAS will provide data for FW when required in specific ambient
conditions. In addition to CEAS data freshwater may also be required for
proper function of the installed WTS equipment. This information should be
provided by the supplier of the WTS.

EGR cooling water capacity

The capacity of cooling water for the EGR engine is increased due to the
3 EGR – Exhaust Gas Recirculation

need for cooling of recirculated exhaust gas, which has a significantly higher
tem- perature than the scavenge air it is replacing. The amount of cooling
water for scavenge air cooling is increased by 45% in Tier III mode compared
to Tier II mode.

Lube oil capacity

The lubricating oil flow is only slightly increased on an EGR engine. The lubric-
ating oil flow for the EGR blowers, which are the only additional consumers,
will be around 0.3 m3/h/MW SMCR with a minimum of 3.6 m3/h.

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Compressed air capacity

Compressed air is needed for sealing of the EGR blower and for control pur-
poses throughout the EGR system. The required sealing air for the EGR

3.11 Consumptions and capacities

blower will be around 2.5 kg/h/MW SMCR with a minimum of 30 kg/h.

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3.12 Calculation of EGR data

In the following, an example of EGR data for a ship are presented for a spe-
3.12 Calculation of EGR data

cific sailing pattern inside and outside the emission control areas (ECA). The
data of the scenario, which is based on an EcoEGR engine designed for low
sulphur fuels, are given in Table 9, Page 54, Table 10, Page 54 and Table
11, Page 55.

Scenario for calculation for EcoEGR on LS fuel

General data
Ship type Bulk carrier
Ship size 182,000 DWT
Engine model 6G70ME - C9.5
EGR type EcoEGR
Sailing condition ISO
Engine power 16,440 kW
Engine speed 83.0 r/min
Fuel sulphur ECA 0.1 %S
Fuel sulphur global 0.5 %S
NaOH solution 50 % NaOH
Sailing time, Tier II 5400 hours/year
Sailing time, Tier III 600 hours/year
Table 9: General data for scenario

Sailing profile Sailing profile MCR% Time % Time

Tier II 25% 5% 270 hours/year
50% 20% 1080 hours/year
75% 60% 3240 hours/year
3 EGR – Exhaust Gas Recirculation

85% 10% 540 hours/year

100% 5% 270 hours/year
Tier III 25% 15% 90 hours/year
50% 30% 180 hours/year
75% 50% 300 hours/year
85% 5% 30 hours/year
100% 0% 0 hours/year
Table 10: Sailing profile for scenario

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Tank capacity Margin Tier II Tier III

NaOH tank 30% 540 60 sailing hours
Sludge tank 30% 540 60 sailing hours

3.12 Calculation of EGR data

Drain tank – no discharge 30% 0 24 sailing hours
Table 11: Scenario for tank capacities

CEAS output for EcoEGR on LS fuel

The consumption and capacities of the specified engine are found by the
en- gine calculation programme, CEAS, as explained in the previous
section. The result is shown in Table 12, Page 55.

EcoEGR - LS MCR SFOC Blower WHS NaOH Bleed-off Sludge

0.1/0.5% S % g/kWh kW kW l/h l/h l/h
Tier II 25% 162.0 14 8.7 3.3 154 0.7
50% 154.5 28 8.7 3.6 205 1.0
75% 152.0 44 8.7 6.2 381 1.9
85% 155.6 37 8.7 6.0 378 1.9
100% 158.0 34 8.7 6.6 421 2.0
Tier III 25% 169.0 55 8.7 1.8 278 0.7
50% 163.5 91 8.7 3.1 541 1.5
75% 159.0 94 8.7 4.7 839 2.3
85% 159.6 91 8.7 4.8 869 2.3
100% 162.0 94 8.7 5.4 990 2.5
Table 12: Output from CEAS on the specified 16.4 MW
engine

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Consumption data for EcoEGR on LS fuel

Based on the specified sailing profile in the scenario and on the output from
CEAS the consumptions of each load point are calculated. In the present
3.12 Calculation of EGR data

scenario, covering a one-year period, the data in Table 13, Page 56 are
found.

EcoEGR - LS MCR Time Fuel Blower WHS NaOH Bleed-off Sludge

0.1/0.5% S % hours ton kW kW l/h l/h l/h
Tier II 25% 270 719 4 2 0.9 41 0.2
50% 1080 2.743 30 9 3.9 221 1.1
75% 3240 8.096 143 28 20.2 1234 6.1
85% 540 1.381 20 5 3.2 204 1.0
100% 270 701 9 2 1.8 114 0.5
Tier III 25% 90 250 5 1 0.2 25 0.1
50% 180 484 16 2 0.6 97 0.3
75% 300 784 28 3 1.4 252 0.7
85% 30 79 3 0 0.1 26 0.1
100% 0 0 0 0 0.0 0 0.0
Tier II 5400 13.641 206 47 30.0 1814 8.9
Tier III 600 1.597 52 5 2.3 400 1.1
Total 6000 15.238 258 52 32.3 2214 10.0
Table 13: Consumptions and discharges according to the specified scenario on a 16.4 MW engine

Tank capacities for EcoEGR on LS fuel

The capacities of NaOH tank, sludge tank and EGR drain tank are
calculated using the tank conditions given in the scenario, i.e. a capacity of
540 + 60 hours on NaOH and sludge tank, similar to around 36 days in
service, and a 24 hours capacity for the EGR drain tank. The EGR drain
tank is designed to hold a bleed-off volume, which may accumulate when
operating in areas where discharge to sea is not possible, i.e. port,
3 EGR – Exhaust Gas Recirculation

harbours and estuaries.

A tank margin is included to compensate for variations in the sailing profile
and sailing time. The capacities for the specified scenario are presented in
Table 14, Page 56.

EcoEGR - LS Frequency hours Volume m3 Margin Min. volume

0.1/0.5% S TII TIII TII TIII Total 15% m3
NaOH tank 540 60 3.0 0.2 3.2 0.5 3.7
Sludge tank 540 60 0.9 0.1 1.0 0.1 1.1
Drain tank 0 24 0.0 16.0 16.0 2.4 18.4
Table 14: Tank capacities estimated for the specified scenario of a 16.4 MW EcoEGR engine using LS
fuel of 0.5% global and 0.1% in ECA

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Tank capacity for EcoEGR on HS fuel

In case the EcoEGR engine is configured to operate on
high sulphur fuel, the CEAS consumption data must be

3.12 Calculation of EGR data

revised. The tank capacities using fuel of 3.5% sulphur
are presented in Table 15, Page 57. Please note that the
NaOH tank and Sludge tank may be part of tanks
installed for EGCS.

EcoEGR - HS Frequency hours Volume m3 Margin Min. volume

3.5% S TII TIII TII TIII Total 15% m3
NaOH tank 540 60 17.9 4.2 22.1 3.3 25.5
Sludge tank 540 60 2.5 0.5 3.0 0.5 3.5
Drain tank 0 24 0.0 12.8 12.8 1.9 14.7
Table 15: Tank capacities estimated for a 16.4 MW EcoEGR engine using HS fuel of 3.5% S

Tank capacity for EGR on LS fuel

The tank capacities related to an EGR engine, which
only operates in EGR mode inside ECA, must relate to
operation in ECA area only. Based on the re- vised
consumption data for this situation, the tank capacities for
low sulphur EGR are presented in Table 16, Page 57.

EGR - LS Frequency hours Volume m3 Margin Min. volume

0.1% S TII TIII TII TIII Total 15% m3
NaOH tank 0 60 0.0 0.1 0.1 0.0 0.1
Sludge tank 0 60 0.0 0.2 0.2 0.0 0.2
Drain tank 0 24 0.0 15.0 15.0 2.3 17.3
Table 16: Tank capacities estimated for a 16.4 MW EGR engine using LS fuel of 0.1% in ECA

Tank capacity for EGR on HS fuel

In case the EGR engine is configured to operate on high
sulphur fuel, the con- sumption data must be revised. The
tank capacities based on fuel of 3.5% sulphur are
presented in Table 17, Page 57. Please note that the
3 EGR – Exhaust Gas Recirculation

NaOH tank and Sludge tank may be part of tanks

installed for EGCS.

EGR - HS Frequency hours Volume m3 Margin Min. volume

3.5% S TII TIII TII TIII Total 15% m3
NaOH tank* 0 60 0.0 3.8 3.8 0.6 4.3
Sludge tank* 0 60 0.0 1.5 1.5 0.2 1.8
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Drain tank 0 24 0.0 12.2 12.2 1.8 14.0
Table 17: Tank capacities estimated for a 16.4 MW EGR engine using HS fuel of 3.5% in ECA