ABS 204-2013 GUIDE FOR EXHAUST EMISSION ABATEMENT.pdf

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1、 Guide for Exhaust Emission Abatement GUIDE FOR EXHAUST EMISSION ABATEMENT OCTOBER 2013 American Bureau of Shipping Incorporated by Act of Legislature of the State of New York 1862 Copyright 2013 American Bureau of Shipping ABS Plaza 16855 Northchase Drive Houston, TX 77060 USA ii ABSGUIDE FOR EXHAU

2、ST EMISSION ABATEMENT .2013 Foreword Foreword International, regional, national and local air emissions legislation is driving the development of primary machinery technologies to reduce exhaust emissions, together with the use of alternative cleaner fuels, such as LNG, and secondary exhaust emissio

3、ns aftertreatment systems. For the ABS requirements for gas fueled ships, other than those covered by the IMO IGC Code, utilizing LNG or CNG as fuel, see the ABS Guide for Propulsion and Auxiliary Systems for Gas Fueled Ships. Key amongst these emissions drivers are the gaseous exhaust emissions leg

4、islated through IMO Annex VI Regulations 13 and 14 for nitrogen oxide emissions from diesel engines and sulfur oxide emissions from all fuel burning equipment onboard. A number of techniques and design features are utilized by diesel engine manufacturers to reduce the primary exhaust NOx emissions,

5、but to achieve compliance with the IMO Tier III limit (that is to be effective in NOx emission control areas from 1 January 2016), it is anticipated that the use of exhaust gas recirculation or selective catalytic reduction systems will be predominantly used. The IMO limits SOxemissions by regulatin

6、g the sulfur content of marine fuels, and it is anticipated that the reductions in the emission control area and global sulfur limits to 0.1% and 0.5%, that will be effective from 1 January 2015 and 1 January 2020 (subject to review in 2018) respectively, will promote increasing use of exhaust gas c

7、leaning systems, such as SOx scrubbers. In all cases, the air emissions performance testing, statutory certification, and statutory survey aspects are regulated through Annex VI with any proposed alternative means of compliance, such as exhaust gas cleaning systems, permitted through Regulation 4 in

8、 association with any applicable IMO Guidelines. At the time of issuance of this Guide, the applicable Guidelines for Selective Catalytic Reduction (SCR) and SOxexhaust gas cleaning systems are IMO Resolution MEPC.198(62) 2011 Guidelines Addressing Additional Aspects to the NOxTechnical Code 2008 Wi

9、th Regard to Particular Requirements Related to Marine Diesel Engines Fitted With Selective Catalytic Reduction (SCR) Systems, adopted 15 July 2011 and IMO Resolution 184.(59) 2009 Guidelines for Exhaust Gas Cleaning Systems, adopted 17 July 2009. Acceptance of an exhaust emission abatement system a

10、s an alternative under MARPOL Annex VI is subject to approval by the flag Administration of the vessel. In addition, safety and reliability aspects that fall within the scope of traditional Classification requirements are also included in this Guide. Accordingly, this Guide has been developed in ord

11、er to provide guidance for the design and construction of exhaust emission abatement systems, focusing on SOxscrubbers, SCR systems, and Exhaust Gas Recirculation (EGR) arrangements, and may be applied to all vessel types. An exhaust emission abatement system is considered approved upon verification

12、 of compliance with both the ABS requirements and the applicable IMO Regulations and Guidelines. Whilst compliance with the applicable IMO Regulations and Guidelines is a pre-requisite for ABS approval and notation, this Guide covers only the Classification approval aspects and statutory approval wo

13、uld be made by ABS as a separate parallel process in the capacity of a Recognized Organization for the vast majority of flag Administrations. The applicable edition of the ABS Rules for Building and Classing Steel Vessels (Steel Vessel Rules) is to be used in association with this Guide. This Guide

14、becomes effective on the first day of the month of publication. Users are advised to periodically check the ABS website at www.eagle.org to verify the most current and applicable version of this Guide. We welcome your feedback. Comments or suggestions can be sent electronically by email to rsdeagle.

15、org. ABSGUIDE FOR EXHAUST EMISSION ABATEMENT .2013 iii Table of Contents GUIDE FOR EXHAUST EMISSION ABATEMENT CONTENTS SECTION 1 General 1 1 Scope and Application 1 3 General . 1 5 Objectives . 2 7 Definitions and Abbreviations . 3 7.1 CO . 3 7.3 CO23 7.5 EGC 3 7.7 EGR 3 7.9 EEMS 3 7.11 Fuel Oil Com

16、bustion Unit. 3 7.13 HC . 3 7.15 MARPOL . 3 7.17 MSDS 3 7.19 NOx3 7.21 O23 7.23 PM . 3 7.25 Recognized Organization (RO) . 4 7.27 Recognized Standard 4 7.29 Rules . 4 7.31 SCR . 4 7.33 SOx4 7.35 Urea 4 9 Classification Notations . 4 9.1 General 4 9.3 EGC- SOxScrubbers . 4 9.5 EGC SCR Systems 4 9.7 E

17、GC EGR Systems 4 9.9 Exhaust Emission Monitoring Systems . 5 11 Operating and Maintenance Instruction Manuals . 5 13 Alternatives . 5 15 Certification . 5 iv ABSGUIDE FOR EXHAUST EMISSION ABATEMENT .2013 SECTION 2 EGC SOx Scrubbers 6 1 General . 6 3 Plans and Data to be Submitted . 6 5 EGC-SOxSystem

18、 Operation and Maintenance Manuals . 7 7 EGC-SOx System Configuration and Vessel Integration 7 7.1 General 7 7.3 Compatibility with Fuel Oil Combustion Units 7 7.5 Redundancy 8 7.7 Essential Services . 8 7.9 Exhaust Bypass/Dry Running of Scrubbers . 8 7.11 Prevention of Fuel Oil Combustion Unit Floo

19、ding 8 7.13 Inclinations . 8 7.15 Vessel Stability 8 7.17 Inspection and Maintenance 9 9 EGC-SOxSystem Equipment . 9 9.1 Pumps/Fans 9 9.3 Exhaust Plume Heaters . 9 9.5 Chemical Treatment System . 9 9.7 Dry Scrubber Consumable Handling Equipment . 9 9.9 Electrical System . 9 11 EGC-SOxSystem Piping .

20、 10 11.1 Exhaust Gas Piping Systems 10 11.3 Washwater Piping 11 11.5 Chemical Treatment Piping Systems . 12 11.7 Residue System. 14 13 Control, Alarm, and Monitoring System 15 13.1 General 15 13.3 Control and Monitoring System . 15 13.5 Safety Shutdown System . 15 15 FMEA Integration Test 16 17 Surv

21、eys During Construction 16 17.1 General 16 17.3 Surveys at Manufacturers Facility . 16 17.5 Surveys During Installation 16 17.7 Surveys During Trials 16 TABLE 1 Monitoring and Safety System Functions for EGC-SOxScrubber Systems . 17 TABLE 2 Certification of EGC-SOxScrubber Systems at the Manufacture

22、rs Facility 18 SECTION 3 EGC Selective Catalytic Reduction Systems 19 1 General . 19 3 Plans and Data to be Submitted . 19 5 SCR Operation and Maintenance Manuals 20 ABSGUIDE FOR EXHAUST EMISSION ABATEMENT .2013 v 7 SCR System Configuration and Vessel Integration 20 7.1 General 20 7.3 Compatibility

23、with the Engine 21 7.5 Redundancy 21 7.7 Essential Services . 21 7.9 Inclinations 21 7.11 Inspection and Maintenance 21 9 SCR System Equipment . 22 9.1 Pumps/Fans 22 9.3 Heat Exchangers . 22 9.5 SCR Reductant System . 22 9.7 SCR Reaction Chamber 22 9.9 Pneumatic Systems . 23 9.11 Electrical System .

24、 23 11 SCR System Piping 24 11.1 Exhaust Gas Piping Systems 24 11.3 Reductant Piping Systems Urea Solution . 25 13 Control, Monitoring, and Safety Systems . 26 13.1 General 26 13.3 Control and Monitoring System . 26 13.5 Safety Shutdown System 27 15 FMEA Integration Test 27 17 Surveys During Constru

25、ction 27 17.1 General 27 17.3 Surveys at Manufacturers Facility . 27 17.5 Surveys During Installation 28 17.7 Surveys During Trials 28 TABLE 1 Monitoring and Safety System Functions for SCR Systems 29 TABLE 2 Certification of SCR Systems at the Manufacturers Facility . 30 SECTION 4 EGC Exhaust Gas R

26、ecirculation Systems 31 1 General . 31 3 Plans and Data to be Submitted . 31 5 EGR Operation and Maintenance Manuals 32 7 EGR System Configuration and Vessel Integration 32 7.1 General 32 7.3 Compatibility with the Engine 32 7.5 Redundancy 33 7.7 Essential Services . 33 7.9 Prevention of Flooding 33

27、 7.11 Inclinations 33 9 EGR System Equipment . 33 9.1 Pumps/Blowers . 33 9.3 Heat Exchangers/EGR Exhaust Gas Coolers . 34 vi ABSGUIDE FOR EXHAUST EMISSION ABATEMENT .2013 9.5 Chemical Treatment System . 34 9.7 Electrical System . 34 11 EGR System Piping 34 11.1 Exhaust Gas Piping Systems 34 11.3 Was

28、hwater Piping 35 11.5 Chemical Treatment Piping Systems . 36 11.7 Residue System. 38 13 Control, Alarm, and Monitoring System 39 13.1 General 39 13.3 Control and Monitoring System . 39 13.5 Safety Shutdown System . 40 15 FMEA Integration Test 40 17 Surveys During Construction 40 17.1 General 40 17.3

29、 Surveys at Manufacturers Facility . 40 17.5 Surveys During Installation 40 17.7 Surveys During Trials 40 TABLE 1 Monitoring and Safety System Functions for EGR Systems 41 TABLE 2 Certification of EGR Equipment and Systems at the Manufacturers Facility 42 SECTION 5 Exhaust Emission Monitoring System

30、s . 43 1 General . 43 3 Plans and Data to be Submitted . 43 5 EEMS Operation and Maintenance Manuals 44 7 Exhaust Emission Monitoring Systems . 44 7.1 General 44 7.3 Inclinations . 44 9 EEMS Equipment 44 9.1 General 44 9.3 Sample Probes for Gaseous Emissions 44 9.5 Sample Handling . 45 9.7 Analyzer

31、Specifications and Calibration . 45 9.9 Data Recording and Processing Device 45 9.11 Pneumatic Systems . 45 11 Monitoring System 46 11.1 General 46 11.3 Monitoring System . 46 13 Surveys During Construction 46 13.1 General 46 13.3 Surveys During Installation 46 13.5 Surveys During Trials 46 TABLE 1

32、Monitoring System Functions for EEMS Systems 47 ABSGUIDE FOR EXHAUST EMISSION ABATEMENT .2013 vii SECTION 6 Surveys After Construction and Maintenance of Class 48 1 General . 48 1.1 Definitions 48 1.3 Modifications . 48 3 Survey Intervals 48 3.1 Annual Survey . 48 3.3 Special Periodical Survey 48 3.

33、5 Continuous Survey Program . 49 3.7 Survey Based upon Preventative Maintenance Techniques . 49 5 Surveys . 49 5.1 Annual Surveys . 49 5.3 Special Periodical Survey 51 7 Alternative Surveys . 52 viii ABSGUIDE FOR EXHAUST EMISSION ABATEMENT .2013 This Page Intentionally Left Blank ABSGUIDE FOR EXHAUS

34、T EMISSION ABATEMENT .2013 1 Section 1: General SECTION 1 General 1 Scope and Application This Guide is to be applied to exhaust emission abatement systems fitted to ABS classed vessels primarily covering SOxscrubbers, SCR systems, Exhaust Gas Recirculation (EGR) arrangements, and to Exhaust Emissio

35、ns Monitoring Systems (EEMS) associated with the aforementioned emission abatement systems, or EEMS installed as an alternative Onboard NOxVerification Procedure in accordance with the Direct Measurement and Monitoring Method of the NOxTechnical Code. The applicable notation will be assigned to a ve

36、ssel with an exhaust emission abatement system upon verification of compliance with both the ABS requirements and the applicable IMO Regulations and Guidelines. 3 General This Guide focuses on the safety and reliability aspects of exhaust emission abatement equipment that fall within the scope of tr

37、aditional Classification requirements and is to be applied to those Exhaust Gas Cleaning (EGC) systems covering SOxscrubbers, SCR systems, and EGR arrangements. SOxscrubbers and SCR units are generally installed downstream of the Fuel Oil Combustion Unit (FOCU) and are considered secondary aftertrea

38、tment systems. Compatibility of these EGC systems with the FOCU is to be verified as part of the approval process preferably in consideration of, the FOCU equipment manufacturer. In the case of EGR systems, or SCR systems fitted before the turbocharging system, these are considered primary exhaust e

39、mission reduction techniques forming part of the total engine design and as such are to be integrated by, or under authorization of, the engine designer. Those applicable requirements for EGR systems contained within this Guide are supplementary to, and to be applied in association with, the require

40、ments for diesel engines under Section 4-2-1 of the ABS Rules for Building and Classing Steel Vessels (Steel Vessel Rules). This Guide is focused on those systems designed to reduce gaseous exhaust emissions species legislated through the International Maritime Organization (IMO) Annex VI Regulation

41、s 13 and 14 for nitrogen oxide (NOx) emissions from diesel engines and sulfur oxide (SOx) emissions from all fuel burning equipment on board. Acceptance of an exhaust emission abatement system under MARPOL Annex VI, as an alternative means of compliance through Regulation 4, is subject to approval b

42、y the flag Administration of the vessel. The regulatory aspects of approving these exhaust emission abatement systems, covering the air emissions performance, testing, statutory certification, and statutory survey aspects are regulated through Annex VI in association with any applicable IMO Guidelin

43、es. At the time of issuance of this Guide, the applicable Guidelines for Selective Catalytic Reduction (SCR) and SOxexhaust gas cleaning systems are IMO Resolution MEPC.198(62) 2011 Guidelines Addressing Additional Aspects to the NOxTechnical Code 2008 With Regard to Particular Requirements Related

44、to Marine Diesel Engines Fitted With Selective Catalytic Reduction (SCR) Systems, adopted 15 July 2011 and IMO Resolution 184.(59) 2009 Guidelines for Exhaust Gas Cleaning Systems, adopted 17 July 2009. Compliance with the applicable IMO Regulations is a pre-requisite for ABS notation in accordance

45、with Subsection 1/9 of this Guide. However, this Guide is intended to cover only the Classification aspects, and the statutory approval would be made by ABS as a separate parallel process in the capacity of a Recognized Organization (RO) for the vast majority of flag Administrations. Section 1 Gener

46、al 2 ABSGUIDE FOR EXHAUST EMISSION ABATEMENT .2013 Individual flag Administrations may have in place additional requirements pertaining to the operation of EGC systems for vessels operating in their territorial waters, in particular with respect to those systems producing a washwater discharge assoc

47、iated with the exhaust gas cleaning process. These requirements may necessitate additional vessel features, performance standards, equipment, reporting and record keeping, or operational practices that are not covered by the IMO regulations or this Guide. Accordingly, any party selecting an exhaust

48、emission abatement system for a particular vessel is encouraged to verify if any additional or specific arrangements are needed to meet the requirements of the vessel, or operational port(s) Administrations. 5 Objectives The objective of this Guide is to provide criteria for the design, construction

49、, installation, survey, and operation of machinery and equipment associated with exhaust emission abatement systems in order to minimize risks to the vessel, crew, and the environment. The intent is that these requirements supplement the statutory emissions performance testing, survey, and certification requirements of the aforementioned IMO Regulations and Guidelines. Detailed requirements are provided in each of the Sections of this Guide to achieve this objective in accordance with the following key principles and requirements: Installation and operation of a