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STT Emtec SCR marine Installation Manualline

Scr system for diesel engines
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This guideline describes the recommended installation procedure and maintenance for the STT SCRmarine system
STT Emtec AB (pbl)
Kontorsvägen 9
SE-852 29 SUNDSVALL
SWEDEN
Document
STT SCRmarine
Installation Guideline
Installation Guideline
Latest version available at www.sttemtec.com
Tel: +46 (0)60-64 10 40
Fax: +46 (0)60 64 10 45
e-mail: info@sttemtec.com
Internet: www.sttemtec.com
Date
Page 1
2014-08-27
Issue: 1.6
Head office: Sundsvall
Org.nr: 55 62 05 – 2927
VAT ID: SE556205292701
ISO-cetrifikat nr: 15627

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  • Page 1 Installation Guideline Installation Guideline This guideline describes the recommended installation procedure and maintenance for the STT SCRmarine system Latest version available at www.sttemtec.com STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 –...

  • Page 2: Table Of Contents

    5.1.2 Urea lines / connections 5.1.3 Flange connections 5.1.4 Injection nozzle and mixer unit 5.1.5 Mixer unit 5.1.6 DEF filter STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 –...
  • Page 3 Appendix 5 Commissioning prerequisites Appendix 6 Adblue® safety manual Appendix 7 Installing analogue sensors STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 – 2927 SE-852 29 SUNDSVALL e-mail: info@sttemtec.com...

  • Page 4: Purpose

    Note! If a POC is used in combination with SCR or as a stand alone unit, the fuel quality must fulfill EN 590. For other fuel qualities please contact Stt Emtec AB for consultation. Figure 1 on the next page is a general component location guide for the urea system.

  • Page 5: The Stt Scrmarine System

    Installation Guideline 2.1 The STT SCRmarine system Figure 1. SCR marine system configuration 1. SCR Catalyst, 2. Injection point, 3. Mixer unit, 4. Diagnostic display, 5. Urea tank, 6. Urea dosing unit, 7. Electronic control unit (ECU), 8. Urea pressure sensor, 9. Control cabinet, 10. Air pressure regulator, 11.

  • Page 6: Catalyst And Poc

    300 to 500°C. Note that this data is a guideline only and that data from the engine manufacturer are to be used for determine the proper SCR catalyst configuration. STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9...
  • Page 7 4000 5000 6000 7000 Actual Exhaust Volume Flow (M3/h) Figure 4 STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 – 2927 SE-852 29 SUNDSVALL e-mail: info@sttemtec.com...
  • Page 8 The pressure drop curves that are displayed in the graphs above are a measured value of the differential pressure over the SCR catalysts and mixer unit. It doesn’t include bends, silencers or additional piping. STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9...
  • Page 9 4000 5000 6000 7000 Actual Exhaust Volum e Flow (M3/h) Figure 8 STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 – 2927 SE-852 29 SUNDSVALL e-mail: info@sttemtec.com...

  • Page 10: Poc

    Additional brackets to support the POC assembly may be needed depending on the surroundings and support of other parts. STT Emtec recommends the use of metal resilient elements type Vibratec® or similar. Additional insulation may be used according to regulations and/or customer demands.

  • Page 11: Figure 11

    Flanges for DN125, DN150 and DN200 exhaust pipe. Maintenance: No maintenance required, check for exhaust leaks at the same time as the rest of the exhaust system. STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 –...

  • Page 12: Noise Reduction

    In a typical installation the insulation is minimum 50 mm thick. Figure 13. Catalyst assembly. The red area shows where welding is not allowed. STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 –...

  • Page 13: Thermal Expansion

    Figure 14. Figure 15. Flange pair Flange pair (exploded view) STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 – 2927 SE-852 29 SUNDSVALL e-mail: info@sttemtec.com...

  • Page 14: Mixer Assembly & Injection Nozzle

    ± 90° from the vertical plane. See figure 17 below. Figure 17. Nozzle installation, allowed angle STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 –...

  • Page 15: Replacing The Injection Nozzle

    The gasket shall always be replaced. When installing the new nozzle, check that that the nozzle tip is oriented in the same direction as the exhaust flow, see figure 16 above. STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9...

  • Page 16: Urea Dosing Unit (Uds)

    In case of heavy vibrations, additional rubber bobbins should be used (STT P/N 101793). STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9...

  • Page 17: Replacing The Urea Dosing Unit

    Note! When releasing the urea- and the electric connections, make sure no urea gets in contact with the connector receptacles! STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9...

  • Page 18: Replacing The Def Filter

    Figure 24. 108930 DEF filter unit DEF filter unit The filter unit shall be replaced every 12 mon. STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 – 2927 SE-852 29 SUNDSVALL e-mail: info@sttemtec.com...

  • Page 19: Adjusting The Main Air Pressure

    (mbar)” should read 1800±200 mbar when correct air pressure is adjusted. This reading is in absolute i.e. showing ≈ 1000±200 mbar when the air valve is “OFF” Use the locking device to secure the adjustment screw. STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9...

  • Page 20: Urea/Air Lines & Connections

    If a compressed air system is not available a separate air compressor has to be installed. Table 1 below contains STT Emtec’s recommendations of the air compressor. Table 1: Compressor data recommendations Capacities...
  • Page 21 Note! Urea is very volatile and will slip thru the slightest gap! Make sure all connections are tight! Note! Do not use copper or brass in compression fittings! STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9...
  • Page 22 When using a bulk tank to store larger amounts of urea than the service tank(-s) can hold the recommended material selection is chromium nickel or chromium nickel molybdenum steel . STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9...
  • Page 23 The standard length of the urea nozzle is 1,5 meters. If a longer urea nozzle is needed contact technical department at STT Emtec AB for evaluation. The urea nozzle tip is made of stainless steel and the urea nozzle line is made of stainless steel braided teflon tube.

  • Page 24: Urea Tank

    The urea tank provides the urea dosing unit with AdBlue®. The liquid is pumped from the tank by using the built-in diaphragm pump that is positioned inside the urea dosing unit. The urea dosing STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9...

  • Page 25: Insulation

    The insulation has to fulfil the stated regulations, e.g. surface temperature. The insulation is not within STT Emtec’s scope of supply but must be designed for easy access to the covered parts and clamps if service is needed. STT Emtec AB (pbl)

  • Page 26: Electrical And Pneumatic System

    The NOx sensor element should be installed 150 mm or more from a bend and a flange. Apply anti-seize (high temperature graphite paste) to the mounting boss and the sensor thread before assembly. Max torque 50 Nm. STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9...

  • Page 27: Exhaust Temperature Sensors

    Note! Do not tight the nut past ¾ of a turn, the thermocouple will break or wear out prematurely Note! The inside radius of the thermocouple must not be bent narrower than 15mm STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 –...

  • Page 28: Exhaust Back Pressure Sensor

    HIGH (upstream) (downstream) HIGH (upstream) Figure 40. Installed pressure sensor STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 – 2927 SE-852 29 SUNDSVALL e-mail: info@sttemtec.com...
  • Page 29 (10m) extended wiring harness for the exhaust back pressure sensor is available. Description Quantity 108365 EBP extension cable (10m) STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 – 2927 SE-852 29 SUNDSVALL e-mail: info@sttemtec.com...
  • Page 30 See Diagnostic tool manual in Appendix 4 for further information Figure 42. Example of monitoring software desktop STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 –...

  • Page 31: Stt Emtec Ab (Pbl) Kontorsvägen

    30m (to the control cabinet). • Dimensions: 117mm x 79mm x 24mm • IP classification: IP20 • Temperature range: -20ºC-+70ºC Figure 44. Discrete display STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 –...
  • Page 32 10 m. Figure 45. Control cabinet with brackets and bobbins (Option) 1. Control cabinet, 2. Rubber bobbin, 3. Bracket STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 –...
  • Page 33 Issue: 1.6 Installation Guideline Main power switch Figure 46. Control cabinet, interior layout STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 – 2927 SE-852 29 SUNDSVALL e-mail: info@sttemtec.com...
  • Page 34 More detailed description of function ECU IO This is where terminals are connected in the control unit (ECU). For information only, (pre-wired in the cabinet). STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 –...
  • Page 35 Air supply to pressure regulator 4 Nozzle Urea/air mix from pump to injection nozzle Figure 47. Wiring length and connection diagram, example only! STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 –...
  • Page 36 SUPPLY Supply voltage SCR system supply voltage (after AC/DC converter) Exhaust prs Optional extended cable for exhaust backpressure STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 – 2927 SE-852 29 SUNDSVALL e-mail: info@sttemtec.com...
  • Page 37 The complete post installation adjustments and inspection protocol can be found in appendix 3 This protocol must be completed and sent to STT Emtec AB in order to enable the product warranty and is a part of the documentation package handed over to the system operator.
  • Page 38 5.1.3 Flange connections Regular visual inspection for exhaust/soot leakage. Check that screws and bolts are securely tightened every 6 month. Replace gaskets if necessary. STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 –...
  • Page 39 The DEF filter skall be replaced every 12 mon or upon performance problems with the dosing unit; typically noticed as reoccurring trouble codes for “Dosing unit”, “Air/Urea flow” or “Dosing failure alarm”. See section 2.4.3 for a guide to replace the DEF filter. STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9...
  • Page 40 Kept as short as possible Material Teflon alt. polyamide tube (PA) or stainless steel pipe Pressure: 0 to 2 bar STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 –...
  • Page 41 Material, canning: Stainless steel AISI 316/316L, AISI 304/304L Dimensions: L=1908,5 mm (max) D=497 mm (max) STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 – 2927 SE-852 29 SUNDSVALL e-mail: info@sttemtec.com...
  • Page 42 176 to 264 VAC, 88 to 132 VAC Power consumption: 120 W Degree of protection: IP66 STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 – 2927 SE-852 29 SUNDSVALL e-mail: info@sttemtec.com...
  • Page 43 'RFXPHQW 'DWH 3DJH  677 6&5PDULQH  ,VVXH  ,QVWDOODWLRQ *XLGHOLQH $SSHQGL[  $VVHPEO\ GUDZLQJV 0HFKDQLFDO DVVHPEO\ GUDZLQJV IRU WKH PDLQ NH\ FRPSRQHQWV RI WKH 6&5 V\VWHP 7KH GUDZLQJV DUH H[DPSOHV IURP D W\SLFDO LQVWDOODWLRQ 9DULDWLRQV GXH WR WHFKQLFDO SUHUHTXLVLWHV DXWKRULW\ UHJXODWLRQV DQGRU FXVWRPHU GHPDQGV PD\ RFFXU 677 (PWHF $% SEO 7HO      +HDG RIILFH 6XQGVYDOO...
  • Page 45 Product No. Kit Pos Product No. Description Quantit Sign. Components 108233-01 OP1003 Assembly 108277-00 Can Outlet Assy, 15"--8" Flang 107722-02 Cat Assy 120+190+120x377 108160-00 Flange 15" 105060-00 Pipe Ø8x2 L=100mm 106196-00 Marking Plate, Stt logo w pn 105551 Fitting Compr. Ø3,2mm (Weld)
  • Page 47 Product No. Kit Pos Product No. Description Quantit Sign. Components 108164-01 OP1003 Assembly 108165-00 Pipe Ø8", SCR Mixer 15" 108275-00 Inlet Cone 15", Marin SCR 108167-00 Pipe Intermed, SCR Mixer 15" 108166-00 Gable Inner, SCR Mixer 15" 108195-00 Support Pipe, SCR mixer 108295-00 Support Ring, SCR mixer 108168-01...
  • Page 50 Product No. Kit Pos Product No. Description Quantit Sign. Components 107457-02 OP1003 Assembly 103854-02 Fuel Supply, Assy 107458-02 Air Supply, Assy 103868-04 Nozzle Cap 104176 Adapter 1/4BSP--3/8BSP SS2333 102259-07 Piston 102283 O-ring, 6x2 (Viton) 102270 Washer R1/4", Tredo 14...
  • Page 52 Product No. Kit Pos Product No. Description Quantit Sign. Components 107360-03 OP1003 Assembly 106665 Urea Pump Grundfos 107417-00 Manifold SCR, Assy 107196-03 Bracket UDS, Assy 107357 Filterreg/Shut-off/Manometer 107352-00 Fitting SAEJ2044 1/4, Assy 107456-00 Fitting SAEJ2044 3/8, Assy 107387-01 Hose Assy, Pump-Man. SAE 1/4" 107359 Fitting, Straight G1/4--Ø6 107361...
  • Page 56 Product No. Kit Pos Product No. Description Quantit Sign. Components 107073-00 OP1003 Assembly 107074-00 Exhaust Pipe, 8" 107337-00 Boss M20x1,5 L=15 104345-00 Boss Rp3/8" L10 106995-02 Flange (8") Ø204/285...
  • Page 58 STT SCRmarine 2014-08-27 Issue: 1.6 Installation Guideline Appendix 2 Wiring connection and length diagram (230VAC) STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 – 2927 SE-852 29 SUNDSVALL e-mail: info@sttemtec.com...
  • Page 59 STT SCRmarine 2014-08-27 Issue: 1.6 Installation Guideline Appendix 2 Wiring connection and length diagram (24VDC) STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 – 2927 SE-852 29 SUNDSVALL e-mail: info@sttemtec.com...
  • Page 60 0.5mm2 (min) (107150) ALA2 Alarm rel output ALA1 Alarm rel output 1.0mm2 (min) 230V 102918 ACT4 51x 105938 ACT3 UDS Mix ctrl 2.5mm2 (min) 1x 105939 ACT2 UDS Air ctrl (AIN1-) ACT1 8x 106121 Alarm rel c trl (AIN3-) DIG4 Databus ( single wires c an be used) UDS Air req AIN5...
  • Page 61 View from rear end (wire entry) 10 11 12 13 (460) 104366 16 17 18 19 20 21 22 CAN_LO 23 24 25 26 27 PUMP 30 31 32 33 CAN_HI 34 35 36 37 thermo-c ouple c ompensation wire 0.5mm2 (min) View from rear end 1.0mm2 (min)
  • Page 62 107737 Date: 12-Aug- 2015 Sheet File: P:\PROJEKT\Mar in_SCR_2166\Teknik\Styr system\marinSCR.ddb Drawn By: STT Emtec AB (pbl) Tel: +46 (0)60-64 10 40 Head office: Sundsvall Kontorsvägen 9 Fax: +46 (0)60 64 10 45 Org.nr: 55 62 05 – 2927 SE-852 29 SUNDSVALL e-mail: info@sttemtec.com...
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  • Page 66 < 5Ohm the terminal group B is physically connected to and the 0V reference in the engine control cabinet Note: The main electrical switch in the SCR control cabinet may have to be disabled to perform this test! STT Emtec AB...
  • Page 67 Check if any active errors occur. If any active error occurs, consult error code list, appendix 4 for corrective actions. Note. If CAN J1939 is used for obtaining engine signals, errors for engine signals can occur if engine control system is deactivated. STT Emtec AB...
  • Page 68 And that the corresponding fault code becomes active (standard default is 0°C). Reconnect the sensors and check that the fault code becomes inactive and that the reading resume the original value Repeat the procedure with T_DOC. STT Emtec AB...
  • Page 69 0 mbar ± 10 EmtecDiag corresponds to 0 mbar. mbar max. Disconnect the pressure hose to the sensor and ± 10 mbar apply a known pressure to the sensor. difference to Note: max pressure 1000 mbar. the applied pressure. STT Emtec AB...
  • Page 70 Visual inspection of all air connections and lines at No air leaks urea pump. Verify that the air pressure at the manometer at the 5,5bar FR-unit is 5.5bar and the shut-valve on the FR unit ±0.5bar is open. STT Emtec AB...
  • Page 71 In order to inspect the urea/air line from the urea pump to the nozzle (point 4 in the table below) the engine must have been run in such conditions so urea dosage has occurred (an exhaust temperature above 230°C and at various loads) STT Emtec AB...
  • Page 72 Visual inspection of urea connection and line at the No leakage urea nozzle. Check if any active error codes occurs after at least 30 minutes of engine running. If any, consult the error code list, appendix 4, for corrective actions. STT Emtec AB...
  • Page 73 Approved interval Result Signature Engine load within ± 5% of standard instrumentation Engine speed within ± 5% of standard instrumentation Boost prs within ± 5% of standard instrumentation Boost air temp within ± 5% of standard instrumentation STT Emtec AB...
  • Page 74 “Air valve” and “Mantle air valve” are “On” in EmtecDiag. Check that the value on the meter “Nozzle prs” in 1600 mbar EmtecDiag. ± 200mbar max. Check that the value on the meter “Mantle prs” in 1800 mbar EmtecDiag. ± 200mbar max. STT Emtec AB...
  • Page 75 After finalization of the post installation inspection checks, clear the error code list and disconnect the service tool. Make sure that all connectors and hoses are reinstalled properly and leave the disable switch inside the control cabinet on (enabled) and the compressed air valve open. STT Emtec AB...
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  • Page 103 Conforms to Regulation (EC) No. 1907/2006 (REACH), Annex II - United Kingdom (UK) SAFETY DATA SHEET Air1® Identification of the substance/preparation and of the company/undertaking Identification of the substance or preparation Product name Air1® Urea Solution 32.5% Synonyms Company/undertaking identification Manufacturer / Supplier Yara Industrial Immingham...
  • Page 104 Air1® Fire-fighting measures Extinguishing media In case of fire, use water spray (fog), foam, dry chemical or CO These products are Hazardous thermal carbon dioxide decomposition products carbon monoxide nitrogen oxides Ammonia. Special protective equipment Fire-fighters should wear appropriate protective equipment and self-contained breathing apparatus (SCBA) with a full face-piece operated in positive pressure mode.
  • Page 105 Air1® Physical and chemical properties Melting/freezing point -11.5°C (11.3°F) Vapour pressure 6.4 kPa (48 mm Hg) (at 40°C) 1.09 g/cm (20°C / 68°F) Density g/cm Miscible in water. Yes. Stability and reactivity Stable under recommended storage and handling conditions (see section 7). Stability Urea reacts with calcium hypochlorite or sodium hypochlorite to form the explosive nitrogen Conditions to avoid...
  • Page 106 Air1® 14. Transport information Not regulated. Not classified as hazardous material according to UN Orange Book and international transport codes e.g. ADR (road), RID (rail), ADN (inland waterways) and IMDG (sea). Regulatory information EU regulations This product is not classified according to EU legislation. Risk phrases Industrial applications.
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