guideline wingd-2s icer-installation

GUIDELINES for iCER Installation

Pro

d.

Cha

nge

His

tory

Rev. Creator Approver Approval Date Change ID Change Synopsis Activity Code E C

GUIDELINES

for iCER Installation

PC-Drawing

Copyright Winterthur Gas & Diesel Ltd. All rights reserved. By taking possession of the document the recipient recognizes and honours these rights. Neither the whole nor any part of this document may be used in any way for construction, fabrication, marketing or any other purpose nor copied in any way nor made accessible to third parties without the previous written consent of Winterthur Gas & Diesel Ltd.

Design Group 9726 Q-Code

A4 Document ID DAAD139643 PC

Page/s 1/15

Document ID: DAAD139643

Revision: B

Date: 24.06.2021

T_PC-Drawing_Portrait Release: 3.02 (6/22/2021)

Rev Date Made Appd Description

A 2021-03-04 CTU DST General clarifications to the exhaust gas piping

B 2021-06-24 MHU DST Addition of iCER diesel operation

Revision Reference Description

Revision: B

Date: Preliminary

4.9 Circulation water treatment system for iCER diesel operation added

4.11 Table 4-11: design temperature of valves updated from 300 °C to 380 °C

4.11 Purge valve information omitted as deliverd as engine component


Revision: B

Date: 24.06.2021

T_PC-Drawing_Portrait Release: 3.02 (6/22/2021) of 15

Table of Contents

1 Disclaimer .................................................................................................................................................................... 5

2 System Description ..................................................................................................................................................... 6

3 General Installation Aspects ....................................................................................................................................... 7

4 Components ................................................................................................................................................................ 8

4.1 Component and piping supports, and expansion compensation ................................................................ 9

4.2 Exhaust gas piping ......................................................................................................................................... 9

4.3 Water mist catcher ......................................................................................................................................... 9

4.4 Exhaust gas cooler ......................................................................................................................................... 9

4.5 Circulation tank ........................................................................................................................................... 10

4.6 Plate heat exchanger .................................................................................................................................. 10

4.7 Circulation water pump arrangement ........................................................................................................ 10

4.8 Circulation water drain arrangement for iCER gas only operation ........................................................... 10

4.9 Circulation water treatment system for iCER diesel operation ................................................................ 10

4.10 Micro economiser ....................................................................................................................................... 11

4.11 Valves .......................................................................................................................................................... 11

4.12 Purging and sealing arrangement .............................................................................................................. 14

4.12.1 Aim of purging and sealing ......................................................................................................... 14

4.12.2 Purging and sealing of exhaust gas recirculation system ......................................................... 14

5 Electrical Interface .................................................................................................................................................... 15


Revision: B

Date: 24.06.2021


List of Figures

Figure 2-1: The iCER system ............................................................................................................................................... 6 Figure 4-1: Overview of the iCER system and its components .......................................................................................... 8 Figure 4-2: Arrangement of the valves in the iCER system ............................................................................................ 11

List of Tables

Table 4-1: Description of the valves which must be installed in the iCER system........................................................ 12


Revision: B

Date: 24.06.2021


1 Disclaimer

The purpose of this document is to provide advice for the planning of the installation of the Intelligent

Control by Exhaust Recycling (iCER) system – a low pressure exhaust gas cooling and recirculation

system – into a vessel. It is arranged between the turbine of the turbocharger outlet and the

turbocharger compressor inlet.

The provided information and recommendations enable engine manufacturers, ship designers, and

shipyards to design an appropriate project specific iCER system.

If not agreed otherwise, WinGD is not responsible for the final project specific design of the iCER

system arrangement. Support structures of the exhaust gas piping system, the dimensioning of the

piping system and piping components like valves, are not within WinGD’s responsibility.

This guideline has been prepared to the best knowledge and ability of its authors. However, neither

Winterthur Gas & Diesel Ltd (WinGD) nor their employees assume any liability – under any legal

aspect whatsoever, including possible negligence – in connection with this guideline, its contents, or

modifications to it or in connection with its use.

Claims relating to any damage whatsoever or claims of other nature such as, but not limited to,

demands for additional spare supplies, service or others are expressly excluded.


Revision: B

Date: 24.06.2021


2 System Description

The iCER is a system which allows to improve the X-DF performance regarding gas and liquid fuel

consumption and environmental footprint, explicitly by reducing the emission of unburned methane.

The main component of the iCER is the Exhaust Gas Cooler (EGC) which allows recirculation of

exhaust gas to the engine. Water spray is used to cool the exhaust gas. The water circulates from the

EGC to a circulation tank from which it is pumped via a plate heat exchanger back to the EGC.

Figure 2-1: The iCER system


Revision: B

Date: 24.06.2021


3 General Installation Aspects

The Exhaust Gas Cooler (EGC) can be installed either on any platform in the engine room, close to the

engine, or as compact design next to the engine, by partly integrating it in the engine’s platforms. For

project-specific support and modification requests, please get in contact with the engine builder

and/or WinGD.

The main components of the iCER system must be purchased from a certified supplier. In the

introduction phase, Alfa Laval is available as the certified supplier to deliver the following

components:

• Exhaust Gas Cooler, see section 4.4

• Circulation tank (storing the EGC circulating process water, i.e. the circulation water), see section

4.5

• Plate heat exchanger for cooling of the circulation water, see section 4.6

• Circulation water pumps, see section 4.7

• Optional micro economiser, see section 4.8

As the components are provided by different parties, namely the following:

• Engine builder

• Certified Supplier, e.g. Alfa Laval

• Different component suppliers, e.g. valve suppliers

• Directly by the shipyard

The shipyard must take care to coordinate and to align its orders with the engine builder. Some

components might need to be initially installed in the engine builder’s testbed facility to test run the

engine.


Revision: B

Date: 24.06.2021


4 Components

The following sections describe the required components for the iCER system installation. It is

distinguished between WinGD’s recommendations which should help to install a trouble-free, long-life

system, and specifications which must be followed, as otherwise the system could not work properly.

In addition, some information is provided. For some dedicated components specific product examples

are mentioned as according to WinGD’s experience, these components provide superior performance

which supports a trouble-free introduction of the new iCER technology.

Figure 4-1: Overview of the iCER system and its components


Revision: B

Date: 24.06.2021


4.1 Component and piping supports, and expansion compensation

The common practice of the exhaust gas system installation can be followed, as the iCER system

operates at the same low exhaust gas pressure as the exhaust gas piping system to the funnel.

Proper pipe and component support to carry the component weights and to limit vibrations according

to the common practice is needed. Thermal expansions must be considered by the installation

geometry or the application of the expansion bellows.

4.2 Exhaust gas piping

The following description provides WinGD’s specification:

• Pipe diameters and bends are designed to fulfil the maximum pressure drop requirements as

defined in the Marine Installation Drawing Set (MIDS), considering in addition all other

components like valves, heat exchangers, etc.

• Pipe material:

o If a micro economiser is installed, then:

− The branch from the main exhaust gas pipe to the micro economiser must be the same

pipe and component material as for any other 2-stroke engine installation, and

− The branch from the micro economiser to EGC must consist of stainless steel

o If no micro economiser is installed, then:

− The branch from the main exhaust gas pipe to the EGC must be the same pipe and

component material as for any other 2-stroke engine installation, and

− The branch from the EGC to the TC inlet pipe connection must consist of stainless steel

• The exhaust gas pipes must be insulated:

o Upstream of the EGC, according to the general rules of exhaust gas pipe insulation (e.g.

SOLAS rules)

o Downstream of the EGC, to avoid condensation of the humid recirculating exhaust gas on

the pipe wall. The same standard must be applied as on the hot side before the cooler.

• Explosion pressure releases:

o In general, no dedicated relief devices are required in the iCER exhaust gas recirculation

line. The iCER system design pressure must not be exceeded under any circumstances.

o Relief device installation is required in the main exhaust gas piping system (the piping from

the turbocharger to the funnel) according to the project-specific calculation. One relief valve

may be located opposite to the iCER connection, if confirmed by calculation. Relief devices

must be examined and certified by the maker. Within the engine room area only self-closing

relief devices are allowed.

4.3 Water mist catcher

The following description is for information only:

• A water mist catcher is integrated on the engine before the turbocharger suction connection. This

ensures the removal of water droplets which may have formed in the piping system.

4.4 Exhaust gas cooler

In the current introduction phase of the iCER system, this component is specified to be delivered by

Alfa Laval.

The following specification will be followed by Alfa Laval and is therefore for information only:

• The required cooling capacity as defined by the GTD

• Providing the Failure Mode and Effect Analysis (FMEA) of the gas cooling system

• Integrated automation and control system according to WinGD’s interface specification


Revision: B

Date: 24.06.2021


• Material: Stainless steel, quality according to class rules and specified maximum sulphur content

of fuel (maximum 0.1%)

• Demister selection and installation, to ensure a water mist droplet size of maximum 30 microns

in diameter

4.5 Circulation tank


Alfa Laval.


• Design pressure: 0.5 bar(g)

• Instrumentation:

o A minimum and a maximum alarm level switch

o A temperature indicator

o A level switch for high water level: This activates forced water removal by circulation pumps

• A refilling connection. No refilling is usually required during normal operation.

Specification:

• The shipyard must provide the pipe connection to the hydrophore system, including the system

separation valves.

4.6 Plate heat exchanger


Alfa Laval.


• A titanium seawater-resistant heat exchanger. The maximum design pressure drop must be the

same as that of the central cooler.

4.7 Circulation water pump arrangement


Alfa Laval.

For information:

• The flow rate is selected according to the EGC size

• All valves and control functionalities are included in the arrangement

The following specifications must be considered:

• The maximum permissible pump suction and delivery heights must be acquired from the

supplier’s specifications. In cases where alternative pump specifications are required, the new

selection must be agreed upon with Alfa Laval.

4.8 Circulation water drain arrangement for iCER gas only operation

No water treatment system is required. For additional information, a drain arrangement proposal is

provided by WinGD’s installation drawings.

4.9 Circulation water treatment system for iCER diesel operation

In the current introduction phase of the iCER system, this system is specified to be designed by Alfa

Laval.

For informational purposes, the following components will be supplied by Alfa Laval and must be

installed according to Alfa Laval’s specifications:

• A water treatment system module which must be connected to the EGC control unit. This

includes:

o Centrifuges, along with pumps and valves for soot separation


Revision: B

Date: 24.06.2021


o NaOH dosing unit, including dosing pump, safety valve and control valve

o Coagulant dosing unit

• A water analyser system which must be connected to the EGC control unit. It measures the acidity

(pH) and conductivity of the water that is delivered to the EGC, by taking samples in a bypass

stream.

Following components must be provided and installed by the shipyard according to Alfa Laval’s

specification:

• Tanks, such as the NaOH tank(s) including heating, instrumentation, etc., and (heated) pipes

• Sludge tank connected to the centrifuge’s soot outlet

• Drain tank with bleed-off arrangement

4.10 Micro economiser

This is an optional component to ensure sufficient waste heat recovery, while the engine operates in

gas mode.


Alfa Laval.

The following provides information about installation considerations:

• Installed vertically or horizontally in the exhaust gas recirculation stream

• The waste heat recovery demand must be checked carefully, as in general, less steam production

power is required during gas operation. To keep this economiser compact (micro), no water drum

is included. Direct connection to the main exhaust gas boiler is required.

Specification, if installed:

• The shipyard provides the component support and the thermal expansion compensation

• The shipyard provides the pipe connection between the main economiser and the micro

economiser

4.11 Valves

Figure 4-2: Arrangement of the valves in the iCER system


Revision: B

Date: 24.06.2021


Description of the valves and accompanying equipment, along with the settings, are available in Table

4-1.

Table 4-1: Description of the valves which must be installed in the iCER system

Ro

w #

Co

de

Properties Back pressure valve Shut-off valve Flow regulating valve

1 - Valve function Back pressure control iCER shut off Shut off/control

Med

ium

2 I Fluid Exhaust gas (max. 0.5% S in

fuel) Exhaust gas (max. 0.5% S in

fuel) Exhaust gas (max. 0.1% S in

fuel)

3 S Minimum design pressure

[bar(g)] 2.5 2.5 2.5

4 S Minimum design temperature

[°C] 380

5 I Operating pressure [bar(g)] 0.12 0.5 0.5

6 S Maximum shut-off pressure under which the valve must

be operable [bar(g)] 1.0 0.5 0.5

Val

ve s

pec

ific

atio

n

7 R Valve type Butterfly valve

8 S Valve body size Engine power-related / iCER specific, considering the total system back-pressure

9 R End connections Wafer

10 R Body material

Stainless steel – Fulfilling class rules applicable to pressure class and leakage class criteria 11 R Disc material

12 R Shaft material

13 S Minimum leakage class

according to EN 60534-4/ANSI-FCI 70-2

Class I Class II Class V

14 S Local position indication Yes

15 R Actuator Double acting

16 S Fail safe Yes

17 S Manual override option Yes: Hand wheel Yes: Hand wheel Yes: Hand wheel

18 S Travel

The minimum position must be fixed during

commissioning: Full closing is not allowed

maximum 90° opening

0 – 90 degrees 0 – 90 degrees

19 S Minimum valve body

pressure class

PN2.5 PN2.5 PN2.5 20 S Minimum counterflange

pressure class

21 S Bore pattern of flanges according to EN 1092-1

based on minimum PN class

Codes: Description

I

E

R

S

= Information

= Example

= Recommendation

= Specification which must be followed


Revision: B

Date: 24.06.2021


Ro

w #

Co

de

Properties Back pressure valve Shut-off valve Flow regulating valve

Act

uat

or

22 R Type Pneumatic

23 R Minimum / maximum supply

pressure [bar(g)] 5.5 – 6.9

24 S Maximum stroking time 20 s 20 s 20 s (open) / 10 s (close)

25 S Fail position Open Close Close

26 S Emergency operator Yes

27 R Air filter regulator with

automatic drain Yes

Fail

safe

des

crip

tio

n

and

acc

esso

rie

s

28 S Fail system description If electric and/or pneumatic supply is missing, valve must move to fail save position

29 E Fail open system STI air-lock valve

AL101 1/4"

Air

tan

k

30 R Air tank size Designed for minimum 2 full strokes

31 R Air tank minimum / maximum

supply pressure [bar(g)] 5.5 – 6.9

32 R Mounting strap

Yes

33 R Safety valve G1/4"

34 R Non-return valve on inlet

35 R Ball valve for water drain

36 R Pressure gauge 1/4" 0-10 bar

37 R Manual override pressure

release valve (shortcut valve)

Po

siti

on

er e

lect

rica

l co

nn

ecti

on

an

d

equ

ipm

ent

38 R Positioner Location Directly mounted on actuator/valve

39 S Control signal 4 – 20 mA Direct

40 S Feedback signal 4 – 20 mA

41 E Manufacturer ABB

42 E Positioner model EDP300

43 S Limit switch Yes (inductive recommended)

44 S Angle detection Yes (contact free – inductive recommended)

45 S Marine approved Yes

46 I Explosion-proof design No

47 R

Valve components completely assembled,

commissioned and ready to install

Yes

Codes: Description

I

E

R

S

= Information

= Example

= Recommendation

= Specification which must be followed

Special class requirements regarding design temperature, position indicator arrangement, manual

override, and emergency operation options, must be followed.


Revision: B

Date: 24.06.2021


4.12 Purging and sealing arrangement

4.12.1 Aim of purging and sealing

• Removal of exhaust gas from the recirculation line after stopping the exhaust gas recirculation

operation

• Preventing exhaust gas ingress to the recirculation circuit while not in operation

4.12.2 Purging and sealing of exhaust gas recirculation system

Detailed arrangement is currently under development and will be provided soon through an update of

this guideline.


Revision: B

Date: 24.06.2021


5 Electrical Interface

The electrical interface specification is provided by the engine builder.

DISCLAIMER

© Copyright by Winterthur Gas & Diesel Ltd.

All rights reserved. No part of this document may be reproduced or copied in any form or by any means (electronic, mechanical, graphic, photocopying, recording, taping

or other information retrieval systems) without the prior written permission of the copyright owner.

THIS PUBLICATION IS DESIGNED TO PROVIDE AN ACCURATE AND AUTHORITATIVE INFORMATION WITH REGARD TO THE SUBJECT-MATTER COVERED AS WAS AVAILABLE

AT THE TIME OF PRINTING. HOWEVER, THE PUBLICATION DEALS WITH COMPLICATED TECHNICAL MATTERS SUITED ONLY FOR SPECIALISTS IN THE AREA, AND THE

DESIGN OF THE SUBJECT-PRODUCTS IS SUBJECT TO REGULAR IMPROVEMENTS, MODIFICATIONS AND CHANGES. CONSEQUENTLY, THE PUBLISHER AND COPYRIGHT

OWNER OF THIS PUBLICATION CAN NOT ACCEPT ANY RESPONSIBILITY OR LIABILITY FOR ANY EVENTUAL ERRORS OR OMISSIONS IN THIS BOOKLET OR FOR

DISCREPANCIES ARISING FROM THE FEATURES OF ANY ACTUAL ITEM IN THE RESPECTIVE PRODUCT BEING DIFFERENT FROM THOSE SHOWN IN THIS PUBLICATION.

THE PUBLISHER AND COPYRIGHT OWNER SHALL UNDER NO CIRCUMSTANCES BE HELD LIABLE FOR ANY FINANCIAL CONSEQUENTIAL DAMAGES OR OTHER LOSS, OR

ANY OTHER DAMAGE OR INJURY, SUFFERED BY ANY PARTY MAKING USE OF THIS PUBLICATION OR THE INFORMATION CONTAINED HEREIN.

Winterthur Gas & Diesel Ltd. Schützenstrasse 3 Tel. +41 (0)52 264 8844 www.wingd.com Winterthur Gas & Diesel AG. PO Box 414, CH-8401 Fax +41 (0)52 264 8866

Winterthur Gas & Diesel S.A. Winterthur, Switzerland

GUIDELINE_WinGD-2S_iCER-Installation

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