Guideline Nov 2004 IMO_3399078

3A Guideline to the Unified Technical FileRegulations for the Prevention of

Air Pollution from Ships

First Edition, Nov. 2004

3399078.pmd

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5Preface

This booklet is intend

ed for Licencees, ship

operators, ship

yards, and

marine engineers in general to

illustrate the Unified

Technical File designed

for all MB

D engines req

uired to m

eet the IMO

regulationfor the p

revention of air pollution.

The Unified

Technical File is a docum

ent that specifies a p

rocedure, m

ainly based

on perform

ancem

easurements, b

y which the op

erator can verify comp

liance with the IM

O N

Ox Technical C

ode to the

Flag State A

uthority (or their representative) w

hen the engine is later checked in service.

MA

N B

&W

Diesel has d

esigned this b

ooklet partly to exp

lain survey proced

ures and p

artly as a look-up

manual for IM

O d

efinitions. The first part concentrates on survey routines, from

testbed

to on board

situations (the most im

portant for the op

erator), describ

ing the survey from start to finish. The second

part exp

ands on sp

ecific subjects and

how to hand

le the most com

mon tasks on b

oard, e.g. sp

are orrecond

itioning parts covered

by the regulation.

Regard

ing general emission q

uestions or emission control of M

AN

B&

W D

iesel Two-stroke engines,

reference is given to existing material issued

by M

AN

B&

W D

iesel.

3399078.pmd

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7Contents

A.

Guid

elines for a Unified

Technical File (TF).................................................11Introd

uction............................................................................................12

Ad

vantages

............................................................................................13TF d

esign...............................................................................................14

Com

ponent changes

.............................................................................15A

djustm

ents...........................................................................................16

Sum

mary

...............................................................................................16C

oncept (engine categories).................................................................17

B.

Survey m

ethods

...........................................................................................18IM

O survey of P

arent Engines on Testb

ed............................................19

Survey of M

emb

er Engines on Testb

ed................................................22

Survey on S

ea Trial................................................................................25O

n board

survey....................................................................................27

C.

Case story

....................................................................................................31

D.

Glossary

.......................................................................................................32IM

O A

nnex VI.........................................................................................32

Engines covered

by the IM

O N

Ox regulation

........................................33Vessels covered

by the IM

O S

Ox regulation

.........................................34E

missions regulated

..............................................................................35N

Ox Lim

its..............................................................................................36

The IMO

NO

x Technical Cod

e defines three categories of engines

.....37P

erformance P

arameters

......................................................................38

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8Local Areas

............................................................................................39R

equired

IMO

NO

x comp

onent marking

...............................................40Licensees ow

n numb

ering....................................................................54

Em

issions from non-IM

O engines or for other p

urposes

......................55

E.

Descrip

tion of Docum

ents...........................................................................56

Pre-certificate

........................................................................................57TF

...........................................................................................................58O

n board

survey....................................................................................59

Engine p

arameter check m

ethod..........................................................60

Param

eter survey..................................................................................61

Survey cod

e...........................................................................................62

Record

Book of engine p

arameters

......................................................63

F.P

arameters in the d

ocument.......................................................................64

IMO

ID-num

ber......................................................................................65

Perform

ance tolerances........................................................................66

Perform

ance reference values..............................................................67

Engine setting values

.............................................................................68C

hanging of setting values....................................................................69

Influence on engines in operation

.........................................................70S

pare p

arts............................................................................................71

Major conversions

.................................................................................73S

ubstantial m

odifications

......................................................................74A

mend

ments

.........................................................................................75

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9Recond

itioning of engine parts

.............................................................76M

aintenance on an IMO

engine............................................................77

Sim

plified

measurem

ent method

..........................................................78C

ontinuous On b

oard m

onitoring..........................................................79

Is Continuous O

n board

emission m

onitoring needed

?.......................80

G.

Resp

onsibilities

............................................................................................81Licensees resp

onsibilities

.....................................................................82Yard

s responsib

ilities............................................................................83

Ow

ners responsib

ilities.........................................................................84

H.

Other............................................................................................................85

ME

engines............................................................................................86

Future regulations..................................................................................87

I.A

ssistance from M

AN

B&

W D

iesel..............................................................89

J.O

verview of S

urvey Routines

......................................................................90

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10

3399078.pmd

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11

A

In connection with the International M

aritime O

rganization (IMO

) Annex V

I of Marp

ol 73/78 Regard

ingthe P

revention of Air P

ollution from S

hips

A. Guidelines for a Unified Technical File (TF)P

urpose:

1.To ensure that M

AN

B&

W D

iesel Two-stroke engines are tested

and can b

e surveyed in

accordance w

ith IMO

Annex V

I.

2.To inform

shipow

ners and op

erators about the TF and

how to com

ply w

ith Annex V

I by using

the unified M

AN

B&

W D

iesel standard

.

Questions or com

ments regard

ing the guidelines should

be d

irected to D

ept. 2110, S

tandard

sand

Classification, see p

age 89.

3399078.pmd

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12 Introduction

The IMO

has introduced

a new A

nnex VI of M

AR

PO

L 73/78, concerning regulation for the prevention

of air pollution from

ships. A

nnex VI ap

plies to all engines d

elivered since 1 January 2000, and

entersinto enforce 19 M

ay 2005.

MA

N B

&W

Diesel has w

orked w

ith the licensees and classification societies to find

a uniform d

esignfor the TF req

uired und

er IMO

Annex V

I, in order to survey on b

oard com

pliance.

Many of the first TFs p

roduced

by the engine b

uilders varied

due to d

ifferent dem

ands m

ade b

y thed

ifferent classification societies. This happ

ened b

ecause the IMO

Annex V

I does not give sufficiently

detailed

instructions on how to d

raw-up

the TF in practice.

MA

N B

&W

Diesel has assum

ed the task of coord

inating the work to p

repare a uniform

TF, to be used

both b

y the licensees and the classification societies. The task also includ

es the necessary proced

uresfor ship

owners w

hen later engine adjustm

ents or changes of comp

onents have occurred.

3399078.pmd

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13

A

Advantages

The unified TF m

eans:

C

ertainty of market accep

tance of the TF

Satisfied

customers, w

ho can show engine com

pliance w

hen checked at sea b

y the FlagS

tate representatives

A

survey method

based

on princip

les familiar to the crew

M

ore engines can be accep

ted w

ithin the same engine G

roup, m

eaning reduced

expenses

Less m

oney spent on em

ission measurem

ents.

Parent engines can b

e shared b

etween M

AN

B&

W D

iesel and the licensees. This w

ill greatly reduce

the numb

er ofemission m

easurements and

future certification costs.

3399078.pmd

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14 TF Design

The princip

le of the MA

N B

&W

Diesel unified

concept is that the d

efined N

Ox com

ponents and

perform

ance data (m

easurement of p

max , p

comp , T

scav and p

back ) can show

that an engine comp

lies with

the NO

x limit.

Som

e licensees have, in the past, used

a comp

onent setting tolerance instead of p

erformance d

ata.H

owever, if the op

erator has adjusted

the engine, the engine might b

e out of comp

liance when the

engine is later checked b

y the Flag State for com

pliance at sea.

Only extensive tests on Testb

ed can valid

ate engine adjustm

ents when com

ponent settings tolerances

are used. It is im

portant to note that w

hen IMO

Annex V

I is ratified, the focus w

ill be on follow

-up at

sea where changes and

adjustm

ents will take p

lace.

Som

e licensees have slected to use their ow

n develop

ed TF instead

of the recomm

ended

MA

N B

&W

Diesel com

mon com

ponent ID

numb

ers. This will m

ake it much m

ore difficult for the ow

ners top

urchase spare p

arts in the future, and still stay in com

pliance w

ith the IMO

regulation.

It is pred

icted that som

e engines already d

elivered w

ill not be in com

pliance w

hen they are surveyed.

We suggest that all ow

ners who have m

ade changes to their engines contact the m

anufacturerregard

ing its status, before IM

O A

nnex VI com

es into force.

3399078.pmd

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15

A

Component Changes

This unified TF w

ill allow changes of the engines N

Ox com

ponents, w

hile maintaining com

pliance in

cases where a ship

owner changes com

ponents at sea.

Som

e owners have alread

y dem

anded

a unified system

in order to avoid

working w

ith different TFs.

3399078.pmd

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16 Adjustments

The unified TF w

ill allow all ad

justments on b

oard w

ithin the stated p

erformance p

arameters.

Summ

ary

The Unified

TF is the standard

introduced

by M

AN

B&

W D

iesel and it is accep

ted b

y the classificationsocieties head

quarters. It should

be follow

ed b

y the licensees for all future engines.

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17

A

Concept (engine categories)

The IMO

Annex V

I NO

x technical code d

efines three categories of engines:

1.Ind

ividual E

ngines2.

Engine G

roups

3.E

ngine Families

Individ

ual engine are handled

on the Testbed

, in the same w

ay as a Parent engine. H

owever, a G

roupd

efinition is not included

in the TF.

Engine G

roups and

engine Families consist of a P

arent engine and a num

ber of M

emb

er engines. All

Two-stroke engines can b

e defined

in an engine Group

, either as the Parent engine (rep

resenting theM

emb

er engines) or as a Mem

ber engine.

Most of the survey p

rocedures m

ade for the M

emb

er engines and the P

arent engine app

lication arethe sam

e. The difference for M

emb

er engines is that the emission testing is not necessary neither on

Testbed

nor at sea.

3399078.pmd

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18 B. Survey methods

The survey method

s include Testb

ed, S

ea Trial and O

n board

inspections. The flow

chart for surveym

ethods has b

een split up

into different sections to m

ake a more d

etailed d

escription. R

efer to Fig. B1,

Ap

pend

ix B in the TF.

3399078.pmd

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19

BS

urvey Start

SurveyTyp

e

Testbed

: Inspection of

PreTechnical File (E

IAP

P)

EngineTyp

e

Perform

ance andC

omp

onent app

roval

Survey Finish

Sign D

ocuments

Ad

just

Yes

No

Perfo

rmance

Check:a) measure perfo

rmance

b) measure NO

c) check fuel nozzle andECS ve

rsiond) other NO

com

ponentse) ve

rify settings x

x

NOco

mponents Check:

x

1.Pare

nt Engine

1) IMO Survey of Parent Engines on Testbed

3399078.pmd

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20 The perform

ance param

eter check is the basis of the survey m

ethods. The m

easurements involved

areused

as reference for Mem

ber engines.

Note. A

change in perform

ance usually means a change in the N

Ox level.

Perform

ance Check:

a)m

easure perform

anceb

)m

easure NO

x

NO

x comp

onent Check:

c)check fuel nozzle and

EC

S version (for M

E engine typ

es)d

)check other N

Ox com

ponents

e)verify settings

3399078.pmd

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21

Ba+

b)

Perform

ance and N

Ox m

easurements:

pm

ax , pcom

p , Tscav and

pb

ack and N

Ox m

easured (and

corrected) at the four load

points in

accordance w

ith the E2/E

3 IMO

cycle.

c)The E

lectronic Control S

ystem (E

CS

) software is im

portant for correct op

eration of the engineand

, therefore, the emission levels.

To extend the group

of engines that can be associated

with a P

arent engine, different typ

es offuel nozzles are tested

for different engine typ

es.

d)

Ap

proved

IMO

comp

liant NO

X comp

onents are listed in the engine TF (or p

re-TF).

e)The setting values are verified

for guidance only and

are not a verification of the engines actualN

Ox em

ission level. The value includes the IM

O C

hief Checksum

value on the Main O

perating

Panel for the M

E engine typ

es. The values are to be used

only as guideline ind

ications for laterad

justments after, for exam

ple, overhauls com

prising the fuel cam

or exhaust cam p

osition.

A survey cod

e is established

by d

ata gained from

the official Testbed

tests in order to ease an on

board

survey. The results, therefore, cannot be p

rinted until later together w

ith the EIA

PP

app

licationw

ith the Parent TF.

3399078.pmd

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22

Survey S

tart

SurveyTyp

e

Testbed

: Inspection of

PreTechnical File (E

IAP

P)

EngineTyp

e

Survey Finish

Perform

ance andC

omp

onent app

roval

Sign D

ocuments Ad

just

Yes No

2.Mem

ber EngineP

erfo

rma

nce


rma

nce

b) verify perfo

rma

nce

c) check fuel nozzle and ECS version

d) other NOco

mponents

e) verify settings

Print out survey code tables(with EIAPP application)

NOco

mponents Check

x

x

2) Survey of Mem

ber Engines on Testbed

3399078.pmd

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23

BThe m

ain difference b

etween surveying P

arent and M

emb

er engines is that the NO

x emission is only

being m

easured for the P

arent engine. For the Mem

ber engine, the p

erformance check verifies

comp

liance based

on the parent engine N

Ox d

ata.

Perform

ance Check:

a)m

easure perform

anceb

)verify p

erformance (Testb

ed version)

NO

x comp

onent Check:


EC

S version (for M

E engine typ

es)d

)check other N

Ox com

ponents

e)verify settings

Print out survey cod

e tables

3399078.pmd

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24 a)P

erformance m

easurements:

pm

ax , pcom

p , Tscav and

pb

ack are measured

(and corrected

) at the four E2/E

3 load p

oints.

b)

Verify perform

ance:

The survey code (Testb

ed version), w

hich is based

on the Parent engine d

ata will

automatically correct the p

erformance values and

perform

a NO

x estimate w

hen perform

ancem

easurements and

amb

ient conditions are entered

into the program

.

If the ISO

amb

ient corrected p

erformance values are w

ithin the TF specified

tolerances, theengine is in com

pliance w

ith the IMO

regulation.

c+d

)The ap

proved

IMO

NO

x comp

onents are listed in the engine TF.

e)The setting values are verified

for guidance only, and

are not a verification of the engines actualN

Ox level. The value includ

es the IMO

Chief C

hecksum value on the M

ain Op

erating Panel for

the ME

engine types. The values are to b

e used only as guid

eline indications for later

adjustm

ents after, for examp

le, overhauls comp

rising the fuel cam or exhaust cam

position.

The survey tables d

ocument the survey and

are printed

for later reference and are includ

ed in the

Mem

ber engines TF.

3399078.pmd

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25

B

Survey S

tart

SurveyTyp

e

Inspection of:

Technical File (IAP

P)

Ad

justment or

Com

ponent C

hanges

Survey Finish

Sign D

ocuments and

add

to Record

Book

No

3. Sea Trial

NOco

mponents Check

x


d) other NOco

mponents

(as considered necessary)e) ve

rify settings(as considered necessary)

Print out survey tables

x

3)Survey on Sea Trial

(without com

ponent or ad

justment changes)

3399078.pmd

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26 A NO

x comp

onent check is sufficient to verify that the engine is in comp

liance.

All d

ocumentation estab

lished so far, includ

ing the certificate, TF and eventual R

ecord B

ook (seeC

hapter E

for definition of R

ecord B

ook) should b

e inspected

and the outcom

e should b

e included

inthe IA

PP

docum

entation for later reference on board

.

NO

x comp

onent Check:


EC

S version (for M

E engine typ

es)d

)check other N

Ox com

ponents (w

hen considered

as necessary)e)

verify settings (when consid

ered as necessary)


e tables to d

ocument com

pliance.

If changes to comp

onents or settings were introd

uced,

see survey method

4 (On b

oard survey).

3399078.pmd

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27

B

Survey S

tart

SurveyTyp

e

Inspection of:

Technical File and R

ecord B

ook

Ad

justment or

Com

ponent C

hanges

Survey Finish

Sign D

ocuments and

add

to Record

Book

Ad

just

Perform

ance andC

omp

onent app

roval

Yes

Yes No

4. On b

oard S

urvey

Pe

rform

an

ce Check:

a) measure perform

an

ceb) ve

rify perform

an

ce (VIT or non-VIT)


d) other NOco

mponents

(as considered necessarye) ve



NOco

mponents Check

x

x

4)On board survey

(to be used

when ad

justments have b

een mad

e to comp

onents or settings)

3399078.pmd

2004-11-12, 12:3927

28 All established

docum

entation (EIA

PP, TF, IA

PP

and eventual R

ecord B

ook) must b

e inspected

. Theoutcom

e must b

e filed in the on b

oard R

ecord B

ook for later reference.

Perform

ance Check:

a)m

easure perform

anceb

)verify p

erformance

(onboard

VIT or non-V

IT versions)

NO

x comp

onent Check:


EC

S version (for M

E engine typ

es)d

)check other N

Ox com

ponents (w

hen considered

as necessary)e)

verify settings (when consid

ered as necessary)


e tables to d

ocument com

pliance.

3399078.pmd

2004-11-12, 12:3928

29

Ba)

Perform

ance measurem

ents:

For engines with V

IT, the 75% load

point and

one load p

oint above the V

IT break p

oint are to be

measured

. For engines without V

IT, and the M

E engine typ

es, only the 75% load

point is

measured

(the perform

ance data m

easured are as stated

above).

b)

Verify perform

ance:

The survey code (on b

oard version), w

hich is based

on the Parent engine d

ata will autom

aticallycorrect the p

erformance values and

perform

a NO

x estimate w

hen perform

ance measurem

entsand

amb

ient conditions are entered

into the program

.

If the ISO

amb

ient corrected p

erformance values are w

ithin the TF specified

tolerances, theengine is in com

pliance w

ith the IMO

regulation.

c)The fuel nozzle, b

eing the comp

onent having most influence on N

Ox , m

ust be checked

by

identification of its ID

numb

er, as well as the E

CS

version for the ME

engine types.

d)

The Flag State rep

resentative can check other NO

x comp

onents, when consid

ered as

necessary, by id

entification and com

parison w

ith the TF comp

onent ID num

bers.

3399078.pmd

2004-11-12, 12:3929

30 e)The setting values, com

prising the fuel cam

and exhaust cam

positions and

the IMO

Chief

Checksum

values on the Main O

perating P

anel (for the ME

engine types), m

ay be verified

,w

hen considered

as necessary by the Flag S

tate representative. H

owever, the values are for

guidance only.

Note. Three versions of the on b

oard survey cod

e exist dep

ending on the engine fuel p

ump

system(V

IT, non-VIT or M

E).

The survey tables d

ocument the survey and

are printed

for later reference and includ

ed in the R

ecordB

ook.

3399078.pmd

2004-11-12, 12:3930

31

C

C. Case storyA

n engine Group

was estab

lished on the b

asis of the Parent engine tested

as engine No. 1. M

emb

erengine N

o. 2 was d

elivered in agreem

ent with the estab

lished TF, b

ut for Mem

ber engine N

o. 3 it was

decid

ed to p

erform com

parison tests for a new

fuel nozzle.

1.P

arent engine2.

Mem

ber engine

3.M

emb

er engine (new fuel nozzle tests)

4.M

emb

er engine

Two d

ifferent possib

ilities exist for maintaining the engine G

roup certificates:

The new fuel nozzle can b

e add

ed to the TF w

ith an amend

ment for the nozzle, b

ut only if the newnozzle d

emonstrates a low

er NO

x value than the original fuel nozzle.

A new

engine Group

can be estab

lished on the b

asis of engine No. 3 as a new

Parent engine (if the

engine was surveyed

as a Parent engine on Testb

ed). In this case, new

Mem

ber TFs for the p

reviousM

emb

er engine need to b

e established

.

Engine N

o. 4 can be certified

to either engine Group

dep

ending on the fuel nozzle used

(provid

ed that

both nozzles are entered

in the TF).

A d

etailed d

escription of the survey m

ethods can b

e found in the TF (C

hapter 3 and

Ap

pend

ix B).

3399078.pmd

2004-11-12, 12:3931

32 D. GlossaryIM

O Annex VI

The IMO

Annex V

I is a new annex to M

AR

PO

L 73/78 the International Convention for the P

reventionof A

ir Pollution from

Ship

s and w

hich app

lies to every ship of 400 gross tons and

above.

The rules on NO

x emission are sp

ecified in C

onference Resolution 2, the N

Ox Technical C

ode.

3399078.pmd

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33

D

Engines covered by the IMO NO

x regulation

1.A

ll diesel engines w

ith an output of m

ore than 130kW and

installed in a ship

built on or after

1 January 2000.

2.A

ll engines (above 130kW

) that undergo a m

ajor conversion:

an engine rep

laced b

y a new engine b

uilt on or after 1 January 2000

any substantial m

odification, as d

efined in the N

Ox Technical C

ode, m

ade to the engine, or

the engine rating (M

CR

) is increased b

y more than 10%

Em

ergency engines and N

avy vessels are not covered b

y IMO

, and engines entirely for use in internal

State w

aters are not covered if an alternative N

Ox control m

easure is app

licable.

3399078.pmd

2004-11-12, 12:3933

34 Vessels covered by the IMO SO

x Regulation

All.

3399078.pmd

2004-11-12, 12:4034

35

D

Emissions regulated

NO

x : Regulation 13 d

escribes a sp

eed-related

IMO

NO

x limit (from

17gNO

2 /kWh to 9.8gN

O2 /kW

hd

epend

ing on rated engine sp

eed or an exhaust gas cleaning system

which p

rovides an eq

uivalentN

Ox red

uction).

SO

x : Regulation 14 d

escribes the sulp

hur limit. The sulp

hur content of the fuel shall not exceed 4.5%

.In d

efined S

Ox control areas, an H

FO fuel w

ith equal or less than 1.5%

sulphur content, or an after-

treatment system

that limits the exhaust S

Ox to eq

ual or less than 6gSO

2 /kWh are req

uired. To

docum

ent the sulphur content in the fuel, a new

bunker d

elivery note is required

, accomp

anied b

y arep

resentative samp

le of the fuel oil delivered

, as specified

in Regulation 18.

How

ever, individ

ual countries (Flag States) m

ay have special m

andatory or voluntary req

uirements

within local w

aters, and certain b

usinesses require inform

ation on different em

ission comp

onents.

3399078.pmd

2004-11-12, 12:4035

36 NOx Lim

its

The MA

N B

&W

Diesel unified

TF specifies three N

Ox values:

1.The M

CR

speed

-related IM

O N

Ox lim

it (see previous)

2.The actual P

arent engine reference NO

x value3.

The actual Parent engine N

Ox value at m

aximum

tolerance conditions.

The last value must b

e less or equal to the IM

O N

Ox lim

it to comp

ly with the IM

O A

nnex. How

ever, forO

n board

surveys, the simulated

Mem

ber engine N

Ox value m

ust be less than the P

arent enginem

aximum

value (with allow

ed tolerances).

3399078.pmd

2004-11-12, 12:4036

37

D

The IMO NO

x Technical Code defines three categories of engines

1Ind

ividual engines

2E

ngine Group

s3

Engine Fam

ilies

Engine G

roups and

Families consist of a P

arent engine and a num

ber of M

emb

er engines.

Large Two-stroke engines b

elong to either category 1 or 2 because of the necessity for ad

justments on

board

.

In princip

le, most of the survey p

rocedures m

ade for the Ind

ividual and

the Parent engine ap

plication

will b

e the same. The m

ain difference for M

emb

er engines is that the emission testing is not req

uired

neither on the Testbed

nor at sea.

The more engines that can b

e included

in the same engine G

roup, the easier and

lower the costs for

the engine build

er. Furthermore, having a U

nified TF w

ill facilitate sharing of engine Group

s among

MA

N B

&W

Diesel and

the engine build

ers, saving more costs.

3399078.pmd

2004-11-12, 12:4037

38 Performance Param

eters

Following extensive testing, M

AN

B&

W D

iesel has established

the NO

x sensitivity of different

perform

ance param

eters. This knowled

ge has been utilised

to establish the d

efined allow

ed m

aximum

IMO

tolerances. These tolerances must b

e met alw

ays, indep

endent of (or in ad

dition to) the sp

ecifiedservice tolerances in the instruction b

ooks for the engine.

3399078.pmd

2004-11-12, 12:4038

39

D

Local Areas

SO

x emission control areas (S

EC

A).

IMO

defined

area with a S

Ox lim

it of 1.5%.

Note. The B

altic Sea and

the North S

ea have been d

efined as sp

ecial restricted-S

Ox areas.

3399078.pmd

2004-11-12, 12:4039

40 Required IMO NO

x Components M

arking

MA

N B

&W

Diesel has d

efined 12 stand

ard engine com

ponents as IM

O N

Ox com

ponents that m

ightinfluence the N

Ox em

ission.

A listing of the com

ponents (includ

ing a few m

ajor sub sup

plier com

ponents: T/C

, charge-air cooler,auxiliary b

lower and

the governor) is given in Table 1.1 in the TF together w

ith the allowed

ID num

bers.

The marking p

osition on each comp

onent is describ

ed in the TFs A

pp

endix A

and is sp

ecified in a

standard

MA

N B

&W

Diesel m

arking specification.

Excep

t for the fuel nozzle, none of the defined

IMO

comp

onents are easy to replace w

ith a different

design and

, consequently, are not likely to change the N

Ox characteristics. Therefore, if the engine

perform

ance is kept w

ithin the specified

tolerances (see TF Table 1.3) the engine w

ill comp

ly with the

IMO

limit.

Only the nozzle ID

numb

er might need

verification (this is always at the d

iscretion of the surveyor). ForM

E engines, the E

lectronic Control S

ystem (E

CS

) version and the selected

engine mod

e also need to

be surveyed

.

MA

N B

&W

Diesel has d

efined the P

art Num

ber as the IM

O ID

numb

er for the comp

onent. Many of

the defined

NO

x comp

onents are already stam

ped

with the p

art numb

er.

Note. O

nly the main part num

ber is used not the revision number (see circled num

ber in TF Appendix A

.)

3399078.pmd

2004-11-12, 12:4040

41

D

PartCertified

Marking

Required Marking

NotesM

arkingInstruction

Cylinder LinerP

art

nu

mber

0742637-8Either m

an

ufacturers N

ame

Marking is on

or tradem

ark, plus Pa

rt N

o.

Camshaft side

3399078.pmd

2004-11-12, 12:4141

42 PartCertified

Marking

Required Marking

NotesM

arkingInstruction

Cylinder Cover

Part n

um

ber0742634-2

Either ma

nufa

cturers Nam

eM

arking is ono

r trademark, plus P

art

No.,

Camshaft side

Yea

r and W

eek of m

anufa

cture

3399078.pmd

2004-11-12, 12:4142

43

D

PartCertified

Marking

Required Marking

NotesM

arkingInstruction

Piston Crow

nP

art

nu

mber

0742392-0Either m

an

ufacturers N

ame

Marking is on

or tradem

ark, plus Pa

rt N

o.

Camshaft side

3399078.pmd

2004-11-12, 12:4143

44 PartCertified

Marking

Required Marking

NotesM

arkingInstruction

Fuel Pump

Part

nu

mber

0742843-8M

anufa

cturers Nam

eO

n ME engines:

Barrelo

r trademark, plus P

art

No.,

The barrel and thea

nd Engine Typeplunger are paired

3399078.pmd

2004-11-12, 12:4244

45

D

PartCertified

Marking

Required Marking

NotesM

arkingInstruction

Fuel Pump

Part

nu

mber

0742845-1M

anufa

cturers Nam

eO

n ME engines:

Plungero

r trademark, plus P

art

No.

No

ma

rking required.a

nd Engine Type

3399078.pmd

2004-11-12, 12:4245

46

3399078.pmd

2004-11-12, 12:4346

47

D

PartCertified

Marking

Required Marking

NotesM

arkingInstruction

Fuel CamP

art

nu

mber

0742636-6Either m

an

ufacturers N

ame

Marking is on

or tradem

ark, plus Pa

rt N

o.

Bearing side

Exhaust CamP

art

nu

mber

0742635-4Either m

an

ufacturers N

ame

Marking is on

or tradem

ark, plus Pa

rt N

o.

Bearing side

Inserted p

icture shows m

arking examp

le

3399078.pmd

2004-11-12, 12:4347

48 PartCertified

Marking

Required Marking

Marking

InstructionFuel N

ozzleP

art

nu

mber

0742639-1M

anufa

cturers Nam

eo

r trademark, plus P

art

No.,

and hole diam

eter (mm)

Marking Location

3399078.pmd

2004-11-12, 12:4348

49

D

PartRequired M

arkingNotes

Sca

venging-air

Man

ufacturers n

am

e, Type

,M

arking is onCooler

Contract n

um

ber,

Nam

e PlateYe

ar of m

anufacture,

Water side and Air side figures

for:

Op. Exc.

Press. (bar),

Test Exc.

Press. (bar),

Op. Te

mperature (

oC) andContent (L)

3399078.pmd

2004-11-12, 12:4349

50

3399078.pmd

2004-11-12, 12:4350

51

D

PartRequired M

arkingNotes

Turbocharger

Manufa

cturers na

me, Type

,M

arking is onSerial n

um

ber(s),N

ame Plate

Manufa

cturing date,Specification,

T/C manufa

cturer isM

ax. Cont. Speed andre

sponsible for

Max.

Cont. G

as temperature

ma

rking 4 internal

components and

issues a specific IM

Ocertificate for the T/C

3399078.pmd

2004-11-12, 12:4351

52 PartRequired M

arkingNotes

Au

xiliaryM

anufa

cturers na

me, M

odel,M

arking is onBlo

we

rCapacity

, Pressure

, Te

mp.,

Nam

e PlateD

ensity, Serial num

ber(s),Speed, P

ow

er, D

ate of build

and Electrical Source.

3399078.pmd

2004-11-12, 12:4452

53

D

PartNotes

Gove

rno

rM

anufa

cturer/Installer isre

sponsible for

ma

rking

3399078.pmd

2004-11-12, 12:4453

54 Licensees Own Num

bering

Som

e licensees have introduced

their own IM

O ID

numb

ering system. H

owever, the M

AN

B&

W D

ieselID

numb

er is always req

uired along w

ith the licensee numb

er in the TF.

The ME

engine has certain different com

ponents, b

ut the On b

oard survey exactly follow

s same

proced

ures as for the MC

engine.

3399078.pmd

2004-11-12, 12:4454

55

D

Emissions from

non-IMO engines or for other purposes

Engines that d

o not fall within the IM

O regulation (i.e. old

engines built b

efore 1 January 2000) are notreq

uired, from

the IMO

point of view

, to docum

ent the emission characteristics.

Incentives from ind

ividual states or custom

ers may urge O

wners to ob

tain actual emission values.

It is possib

le, but very d

ifficult, to measure em

issions on board

for different Flag S

tate/customer

purp

oses. The specific req

uirements (com

ponents and

accuracies) should b

e stated clearly. The ship

Ow

ners will have an ob

ligation to ensure safe access for personnel and

provid

e the equip

ment and

exhaust samp

ling gear necessary for taking the measurem

ents.

On b

oard IM

O engine certification should

only be carried

out if absolutely necessary. In ord

er to obtain

an EIA

PP

certificate after installation on board

, the engine must b

e certified either as an Ind

ividual

engine or an engine Group

. In princip

le, most of the survey p

rocedures m

ade for the Ind

ividual and

theP

arent engine app

lication will b

e the same.

The measurem

ent proced

ures must follow

normal Testb

ed p

rocedures (for m

easurements and

loadcycle) and

without any tolerance allow

ances.

For IMO

-comp

liant engines, all gaseous emission m

ust be stated

(at the four load p

oints in the E2/E

3cycle) in C

hapter 4 of the TF (for the com

mon M

AN

B&

W D

iesel TF).

3399078.pmd

2004-11-12, 12:4455

56 E. Description of documents

3399078.pmd

2004-11-12, 12:4456

57

E

Pre-certificate

The interim E

ngine International Air P

ollution Prevention C

ertificate (EIA

PP

) is the legal docum

ent thatap

proves the engine on the Testb

ed in accord

ance with the N

Ox C

ode and

Regulation 13 of A

nnex VI.

This prelim

inary or interim certificate (statem

ent of comp

liance) will only b

e issued until the

enforcement d

ate of 19 May 2005, and

will have to b

e exchanged w

ith a final EIA

PP

certificate sinceA

nnex VI has b

een ratified.

All of the original d

ocuments m

ust be availab

le on board

at all times.

3399078.pmd

2004-11-12, 12:4457

58 TFAn app

roved d

ocument that sp

ecifies the actual engines perform

ance data, the engine G

roup (a

numb

er of engines defined

by the engine w

ith the highest NO

x emission the P

arent engine), theem

ission characteristics of the Group

, and how

to survey the engine on board

for NO

x comp

liance.

MA

N B

&W

Diesel has introd

uced a U

nified TF as the stand

ard com

mon TF set-up

for all MA

N B

&W

Diesel Tw

o-stroke engines. This was d

one in order to sim

plify the IM

O A

nnex VI for O

wners and

toensure sim

ilar TFs for all MA

N B

&W

Diesel engines, ind

epend

ent of the various licensees.

To ensure comp

liance with the M

AN

B&

W D

iesel standard

, an examp

le of a Unified

TF can be

obtained

by contacting D

epartm

ent 2110.

3399078.pmd

2004-11-12, 12:4458

59

E

On board Survey

A survey of the engine, as d

efined in the TF, to verify continuous com

pliance w

ith the NO

x emission

limits of IM

O A

nnex VI.

Different survey m

ethods are sp

ecified in the IM

O N

Ox Technical C

ode d

epend

ent on the purp

ose ofthe survey (p

re-certification survey on Testbed

, initial survey on board

or, period

ical or intermed

iatesurveys on b

oard).

3399078.pmd

2004-11-12, 12:4459

60 Engine Parameter Check M

ethod

MA

N B

&W

Diesel has d

efined an E

ngine Param

eter Check M

ethod as a com

bination of a p

erformance

param

eter check and a com

ponent survey (see S

ervice Letter No. S

L03-428).

The On b

oard survey is d

escribed

in detail in TF, C

hapter 3, and

Ap

pend

ix B, Fig. B

.1. This presents an

overview of the d

ifferent mand

atory survey proced

ures.

3399078.pmd

2004-11-12, 12:4460

61

E

Parameter Survey

A m

anufacturer defined

survey proced

ure.

MA

N B

&W

Diesel has d

efined four p

erformance p

arameters for the O

n board

survey for verification ofengine com

pliance w

ith the IMO

NO

x regulation:

m

aximum

pressure

m

aximum

comp

ression pressure

scavenge air tem

perature

turb

ocharger backp

ressure.

To verify comp

liance, these param

eters (adjusted

to ISO

amb

ient conditions) m

ust stay within the

tolerances specified

in TF, Table 1.3.

The survey follows stand

ard M

AN

B&

W D

iesel proced

ures for engine perform

ance checks (see TF,A

pp

endix B

). How

ever, for scheduled

surveys, all sensors and gauges used

in the survey code m

ustb

e reliable and

calibrated

in accordance w

ith the manufacturers sp

ecifications (and the IM

O N

Ox

Technical Cod

e requirem

ents).

3399078.pmd

2004-11-12, 12:4561

62 Survey Code

A d

edicated

code for the actual engine G

roup that facilitates easy O

n board

surveys.

In connection with the O

n board

survey (see TF, Chap

ter 3 and A

pp

endix B

), MA

N B

&W

Diesel has

introduced

a small M

icrosoft Excel cod

e that, automatically, either show

s comp

liance, or points to

necessary adjustm

ents of the engine setting/perform

ance values.

When the engine is surveyed

(Testbed

or On b

oard), the setting values are m

easured in accord

ancew

ith the proced

ures in the instruction book, and

docum

ented through the survey cod

e, which is

printed

out to the Record

Book. The p

erformance p

arameter survey autom

atically app

roves the settingvalues. For M

AN

B&

W D

iesel Two-stroke engines, these are for guid

ance only (i.e. for use in casesw

here the perform

ance data can not b

e obtained

e.g. during d

ocking).

When using the M

AN

B&

W D

iesel-defined

on board

param

eter survey method

for large Two-stroke

engines, the setting values are for guidance only. For other survey m

ethods, either TF-d

efinedtolerances (b

ased on ad

ditional m

easurements for the ind

ividual settings) or am

endm

ents arenecessary.

The actual readings are registered

in the survey code for future reference.

3399078.pmd

2004-11-12, 12:4562

63

E

Record Book of engine parameters

An O

wner-estab

lished log b

ook to docum

ent any changes (including record

ed O

n board

surveys) toIM

O com

ponents or engine settings that m

ay influence NO

x emissions.

With a few

mod

ifications, the standard

on board

log book can b

e used as the R

ecord B

ook.

Together with the TF, M

AN

B&

W has introd

uced a survey cod

e that lists the necessary docum

entationfrom

the On b

oard survey to b

e included

the Record

Book.

3399078.pmd

2004-11-12, 12:4563

64 F. Parameters in the docum

ents

3399078.pmd

2004-11-12, 12:4564

65

F

IMO ID-num

ber

A m

anufacturer specified

unique num

ber for an engine com

ponent that m

ay have an influence on theengine N

Ox em

ission characteristics.

MA

N B

&W

Diesel has d

efined the P

art Num

ber as the IM

O ID

-numb

er for the comp

onent. Many of

the defined

NO

x comp

onents (MA

N B

&W

Diesel has d

efined 12 stand

ard engine com

ponents as IM

ON

Ox com

ponents) are alread

y stamp

ed w

ith the Part N

umb

er. How

ever, only the main P

art Num

ber is

used not includ

ing the revision digit (see encircled

numb

er in TF, Ap

pend

ix A).

Som

e licensees have introduced

their own IM

O ID

-numb

er system. H

owever, the M

AN

B&

W D

ieselID

-numb

er is always req

uired along w

ith the licensee numb

er in the TF. Com

ponents w

ith any one ofthe num

bers d

efined in TF, Tab

le 1.1 are valid.

Only the com

ponents m

arked w

ith an IMO

ID-num

ber and

specified

in TF, Table 1.1 (or in the

ded

icated survey cod

e for the engine Group

) are accepted

as comm

on replacem

ent spare p

arts.

New

comp

onents or mod

ified sp

are parts to rep

lace the existing comp

onent (i.e. comp

onents with a

different IM

O ID

-numb

er) must b

e amend

ed to the TF. M

AN

B&

W D

iesel are responsib

le for ensuringthat original sp

are parts can b

e used on b

oard.

Alw

ays make sure that M

AN

B&

W D

iesel ID-num

bers are ad

ded

to the licensees TF in order to ob

tainthe flexib

ility for purchasing p

arts.

3399078.pmd

2004-11-12, 12:4565

66 Performance Tolerances

The tolerances defined

in TF, Table 1.3 for the four p

erformance p

arameters that affect the engine N

Ox

emission characteristics.

Following extensive testing, M

AN

B&

W D

iesel has established

the NO

x sensitivity of different

perform

ance param

eters (maxim

um p

ressure, maxim

um com

pression p

ressure, scavenge airtem

perature and

turbocharger b

ackpressure). This know

ledge has b

een utilised to estab

lish thed

efined allow

ed m

aximum

IMO

tolerances. These tolerances must b

e met alw

ays, indep

endent of (or

in add

ition to) the specified

service tolerances in the instruction books for the engine.

3399078.pmd

2004-11-12, 12:4566

67

F

Performance Reference Values

The ideal P

arent engine perform

ance reference values is defined

in TF, Table 1.3.

When the P

arent engine is run on the Testbed

, amb

ient conditions and

, perhap

s, not precisely

adjusted

engine setting values may lead

to slightly off-perform

ance values. This is normal, therefore

to define the engine G

roup in the b

est possib

le way, a set of slightly d

ifferent values the perform

ancereference values has b

een defined

. The engine NO

x emission is now

corrected to reflect this

condition, just as the N

Ox em

ission is corrected to IS

O am

bient cond

itions.

3399078.pmd

2004-11-12, 12:4567

68 Engine Setting Values

Mechanical or electrical ad

justment features of the engine p

roviding certain engine p

erformance

characteristics.


(Testbed

or On b

oard), these values are m

easured (follow

ing thep

rocedures in the instruction b

ooks) and d

ocumented

through the survey code (and

printed

out to theR

ecord B

ook). With a few

mod

ifications, the standard

log book on b

oard can b

e used as the R

ecordB

ook. The perform

ance param

eter survey automatically ap

proves the engine setting values, w

hich forM

AN

B&

W D

iesel Two-stroke engines are for guid

ance only (i.e. for use in cases where the

perform

ance data cannot b

e obtained

, e.g. during d

ocking).

Ad

justment of the M

E engine setting values is d

one on the Engine C

ontrol System

panel and

verifiedb

y means of checksum

values. Two checksum

s are defined

for emissions, an IM

O D

esignchecksum

and an IM

O C

hief checksum. The IM

O C

hief checksum is verified

(and ap

proved

) throughthe O

n board

param

eter survey, whereas the IM

O D

esign checksum is a m

anufacturer responsib

ility,w

hich might req

uire an amend

ment to b

e in comp

liance. This amend

ment usually consists of one p

agereferring to engine G

roup, engine Typ

e, and the authorised

comp

any app

roval numb

er introducing a

new IM

O ID

-numb

er on a comp

onent.

3399078.pmd

2004-11-12, 12:4568

69

F

Changing of Setting Values

Setting values can b

e changed, d

epend

ing on the survey method

as defined

in the TF.

The actual readings are registered

in the survey code for future reference.


(Testbed

or On b

oard), these values are m

easured (follow

ing thep

rocedures in the instruction b

ooks and d

ocumented

through the survey code (and

printed

out to theR

ecord B

ook). The perform

ance param

eter survey automatically ap

proves the setting values, w

hich forM

AN

B&

W D

iesel Two-stroke engines are for guid

ance only.

3399078.pmd

2004-11-12, 12:4569

70 Influence on engines in operation

Mod

ifications to engine are allowed

within IM

O d

efined constraints.

IMO

Annex V

I uses specific d

efinitions related to engine m

odifications (sp

are parts, m

ajor conversionand

substantial m

odification).

3399078.pmd

2004-11-12, 12:4570

71

F

Spare parts

Alw

ays use spare p

arts from authorised

MA

N B

&W

Diesel sp

are part sup

pliers and

draw

ings.

Only the com

ponents m

arked w

ith an IMO

ID-num

ber and

specified

in TF, Table 1.1 (or in the

ded

icated survey cod

e for the engine Group

) are allowed

as comm

on replacem

ent spare p

arts.

New

comp

onents or mod

ified sp

are parts to rep

lace the existing comp

onents (e.g. comp

onents with a

different IM

O ID

-numb

er) must b

e amend

ed the TF. The am

endm

ent usually consists of one page

referring to an engine Group

, engine Type, and

the authorised com

pany (C

lassification Societies)

app

roval numb

er introducing a new

IMO

ID-num

ber on a com

ponent.

3399078.pmd

2004-11-12, 12:4671

72 MAN

B&

W D

iesel is responsib

le for ensuring that original spare p

arts can be used

on board

.

New

IMO

NO

x comp

onents will b

e filed b

y MA

N B

&W

Diesel w

ith the authorised com

panies w

henengine G

roups (using the unified

TF set-up) are filed

to MA

N B

&W

Diesel. This w

ill require that our

licensees report b

ack to MA

N B

&W

Diesel regard

ing introduced

engine Group

s.

Alw

ays make sure that M

AN

B&

W D

iesel ID-num

bers are ad

ded

to the licensee TF, in order to ob

tainflexib

ility when b

uying parts.

3399078.pmd

2004-11-12, 12:4672

73

F

Major conversions

As d

efined in IM

O A

nnex VI, R

egulation 13:

W

hen the engine is replaced

with a new

engine (built after 1 January 2000)

W

hen the engine undergoes a sub

stantial mod

ification

When the M

CR

rating is increased b

y more than 10%

.

In cases of a major conversion of an old

engine (an engine built b

efore 1 January 2000), this enginem

ust now fully com

ply w

ith Annex V

I, Regulation 13.

Engines that alread

y comp

ly with the R

egulation 13 might, in the w

orst case, need a new

Parent

engine, but in m

ost cases, an amend

ment w

ill be sufficient.

Engines that are d

erated (e.g. b

y more than 10%

) might have a change in their em

issioncharacteristics (p

ossibly, increased

NO

x emissions) and

, therefore, also be consid

ered as a m

ajorconversion.

3399078.pmd

2004-11-12, 12:4673

74 Substantial modifications

For IMO

comp

liant engines where the m

odification w

ill increase the NO

x emission level to exceed

theIM

O lim

it set out in Regulation 13 of A

nnex VI, and

for old engines w

here the mod

ification increasestheir existing N

Ox em

ission level beyond

the tolerances allowed

for a simp

lified m

easurement m

ethod.

Due to the d

ifficult conditions for taking m

easurements on b

oard, certain m

easurement tolerances are

allowed

in connection with this m

ethod (see N

Ox Technical C

ode 6.3.11), e.g. 10%

due to the

measurem

ent method

and 10%

due to the p

ossibility of a d

ifferent fuel, but m

aximum

of 15% in total.

For comp

liant engines, if the Parent engines m

aximum

NO

x tolerance is exceeded

, a new P

arentengine m

ust be introd

uced.

For old engines, if N

Ox increases, it w

ould req

uire major effort (if p

ossible at all) to estab

lish a TF andcertify the engine on b

oard. Fortunately, m

ost mod

ifications (introduction of new

techniques and

technologies) will red

uce emissions and

, therefore, not result in a requirem

ent for the engine to comp

lyw

ith the IMO

regulation.

3399078.pmd

2004-11-12, 12:4674

75

F

Amendm

ents

An am

endm

ent is the formal instrum

ent to introduce changes to the original IM

O com

ponents and

settings defined

in the engines TF.

The amend

ment usually consists of one p

age referring to the engine Group

, engine Type, and

the FlagS

tate representative ap

proval num

ber introd

ucing a new IM

O ID

-numb

er.

For new M

emb

ers to an existing engine Group

to which am

endm

ents have been issued

, the amend

edcom

ponent w

ill be introd

uced d

irectly into the Mem

ber TF.

3399078.pmd

2004-11-12, 12:4675

76 Reconditioning of engine parts

Engine p

arts can be recond

itioned as usual, p

rovided

the repair shop

is authorised and

uses originalM

AN

B&

W D

iesel draw

ings.

The comp

onents must b

e machined

to the same d

imensions as sp

ecified for original p

arts. If thecom

ponent ID

-numb

er is not readab

le, the numb

er must b

e re-established

in agreement w

ith thestand

ard M

AN

B&

W D

iesel marking p

rocedures.

Recond

itioning is usually perform

ed only on m

ajor large comp

onents, where the d

imensions d

o nothave the stronger influence on the em

ission characteristics.

3399078.pmd

2004-11-12, 12:4676

77

F

Maintenance on an IM

O engine

Maintenance should

be p

erformed

in accordance w

ith the engines instruction books, i.e.:

E

xchange of spare p

art as necessary

Perform

ance checks as specified

.

How

ever, attention needs to b

e kept on the tolerances sp

ecified in TF, Tab

le 1.3.

It should b

e emp

hasised that p

roper m

aintenance is required

, and that it is a p

art of keeping engine

emissions w

ithin the specified

limits. U

nless the engine is maintained

in accordance w

ith the engineinstruction b

ooks, and is com

pliant w

ith the TF specifications, the m

anufacturer bears no resp

onsibility

for the engine with regard

to IMO

comp

liance.

3399078.pmd

2004-11-12, 12:4677

78 Simplified M

easurement M

ethod

Em

ission measurem

ents for on board

confirmation tests only and

period

ical and interm

ediate surveys,

see IMO

NO

x Technical Cod

e 6.3.

The second m

ethod for O

n board

surveys as defined

in the NO

x Technical Cod

e and also the m

ethodfor verifying the em

ission status for non-comp

liant old engines w

ith back-to-b

ack measurem

ents.

Following the p

rocedures ab

ove, it is possib

le, but very d

ifficult, to measure em

issions on board

ford

ifferent Flag State/custom

er purp

oses. The specific req

uirements (com

ponents and

accuracies)should

be stated

clearly. The ship O

wners w

ill have an obligation to ensure safe access for p

ersonnel,eq

uipm

ent and the exhaust sam

pling eq

uipm

ent necessary for the measurem

ents.

Only if ab

solutely necessary should an engine b

e IMO

certified on b

oard. In ord

er to obtain an E

IAP

Pcertificate on b

oard, the engine m

ust be certified

as either an Individ

ual engine or an engine Group

, them

easurement p

rocedures m

ust follow norm

al Testbed

proced

ures (for measurem

ents and load

cycle)and

without any allow

ances.

For IMO

-comp

liant engines, all gaseous emissions are stated

(at the four load p

oints in the E2/E

3cycle) in the TF, C

hapter 4.

3399078.pmd

2004-11-12, 12:4678

79

F

Continuous On Board Monitoring

NO

x emission m

easurements (and

monitoring) ap

plied

for On b

oard p

eriodical and

intermed

iatesurveys (see IM

O N

Ox Technical C

ode 2.1.2.5) to d

emonstrate com

pliance w

ith Regulation 13 of

Annex V

I.

The third m

ethod for O

n board

surveys defined

in the NO

x Technical Cod

e (pre-certification survey on

Testbed

, initial survey on board

, or period

ical and interm

ediate surveys on b

oard).

Measurem

ents of similar q

uality to the simp

lified m

easurement m

ethod are req

uired.

A sub

-comm

ittee under the M

arine Environm

ent Protection C

omm

ittee (ME

PC

) has recently drafted

the Guid

elines for On b

oard N

Ox Verification P

rocedure D

irect Measurem

ent and M

onitoringM

ethod, D

E46/W

P.3, 17 March 2003, w

hich were ad

opted

as draft guid

elines.

It should b

e emp

hasised that continuous on b

oard m

onitoring does not im

ply continuous m

easuringd

uring the entire operation of the engine, b

ut only during d

efined seq

uences.

3399078.pmd

2004-11-12, 12:4679

80 Is Continuous On Board Emission M

onitoring needed?

No

.

As long as surveys are p

erformed

as defined

in the Unified

TF are in comp

liance with IM

O A

nnex VI,

there is no need for com

plicated

emission m

easurements on b

oard to verify com

pliance. In all cases

and at all tim

es, the engine must alw

ays be m

aintained ap

prop

riately, and p

erformance d

ata be

recorded

to ensure prop

er operation.

The continuous on board

monitoring m

ethod is an op

tion which the O

wner, w

ho will b

ear the costs,m

ust decid

e on. It will b

e difficult to estab

lish the method

without the coop

eration of the manufacturer.

3399078.pmd

2004-11-12, 12:4680

81

G

G. Responsibilities

3399078.pmd

2004-11-12, 12:4781

82 Licensees responsibilities

M

arking of comp

onents in accordance w

ith MA

N B

&W

Diesel sp

ecifications

P

erformance testing of all engines to verify com

pliance w

ith IMO

Annex V

I, and em

issiontesting of the P

arent engines on the testbed

P

reparing the TF and

app

lying for an EIA

PP

certificate

E

nsuring continuous comp

liance when engine is installed

in the vessel (See note).

All final official Testb

ed m

easurements m

ust be p

erformed

under survey cond

itions.

Note. P

rovided

that the Ow

ner maintains and

operates the engine accord

ing to MA

N B

&W

Diesel

instructions, the licensee must guarantee an IM

O com

pliant engine throughout the engine w

arrantyp

eriod (the U

S E

PA R

egulation operates w

ith a useful life warranty, w

here the useful life is defined

asthree years or 10,000 hours of op

eration).

3399078.pmd

2004-11-12, 12:4782

83

G

Yards responsibilities

A

ssist with or p

erform the initial engine survey on b

oard, d

epend

ing on the agreement w

iththe licensee

A

pp

ly for the vessel certificate (the IAP

P certificate).

Now

that the IMO

Annex V

I is ratified (enforced

from 19 M

ay 2005), the comm

on practice (and

an IMO

requirem

ent) will b

e to perform

the initial on board

survey in connection with the vessels S

ea Trial,w

here the authorised surveyor is alread

y on board

. This has not been the case so far, excep

t in certainsp

ecial cases to verify the correct adjustm

ent of the main engine.

3399078.pmd

2004-11-12, 12:4783

84 Owners responsibility

D

ecide on the unified

TF issue

M

aintain the engine in accordance w

ith the instruction books and

IMO

requirem

ents (notlim

ited to IM

O com

ponents and

perform

ance surveys)

K

eep and

upd

ate the on board

engine Record

Book

C

alibrate necessary sensors/gauges used

in the surveys

S

urvey the engines on board

and ap

ply for future certificates.

In case of emission m

easurements b

eing taken on board

, the owner takes on ad

ditional resp

onsibility.

3399078.pmd

2004-11-12, 12:4784

85

H

H. OtherC

an emissions on old

engines be red

uced?

Most likely, Yes.

Low-N

Ox nozzles and

new S

lide Fuel Valves d

esigned to im

prove H

C and

PM

emissions are availab

lefor m

any MC

engines today. H

owever, the em

ission reduction p

otential, as well as the cost, should

be

evaluated case b

y case.

The benefit for the environm

ent is unquestionab

le, but the O

wner w

ill also benefit from

imp

rovedcylind

er conditions. W

hereas the benefit from

meeting IM

O or Flag S

tate emission regulations m

ayreq

uire difficult m

easurements taken on b

oard.

3399078.pmd

2004-11-12, 12:4785

86 ME engines

The MA

N B

&W

Diesel M

E engine range has certain d

ifferent comp

onents than the 12 standard

engineM

AN

B&

W D

iesel-defined

IMO

NO

x comp

onents (a listing of the comp

onents is given in TF, Table 1.1),

but the on b

oard survey follow

s exactly same p

rocedures as for the M

C engine.

Ad

justment of the engine setting values is effected

on the Engine C

ontrol System

panel and

is verifiedb

y means of checksum

values. Two checksum

s are defined

for emissions, an IM

O D

esign checksum

and an IM

O C

hief checksum. The IM

O C

hief checksum is verified

(and ap

proved

) through the onb

oard p

arameter survey, w

hereas the IMO

Design checksum

is a manufacturer resp

onsibility, w

hichm

ay require an am

endm

ent to be in com

pliance.

3399078.pmd

2004-11-12, 12:4786

87

H

Future regulations

Today, all new

engines comp

ly with the IM

O em

ission regulation from the Testb

ed (E

IAP

P certification),

however, they lack the initial on b

oard survey (the IA

PP

certification).

Now

Annex V

I has been ratified

, all vessels must b

e surveyed to ob

tain the final IAP

P certificate. N

ewengines w

ill be surveyed

during the S

ea Trial, whereas engines introd

uced since 1st January 2000

shall be surveyed

no later than the the first dry d

ocking, but in no case later than 3 years after entry

into force.

The discussion on new

emission lim

its will start again w

ithin the IMO

. First of all, with regard

toad

ditional N

Ox red

uctions, but also other em

ission comp

onents. Theissue of the existing old

engines could surface again.

Ad

ditional Local A

reas for further SO

x control could b

e introduced

.

The work involved

in issuing the final IAP

P certificate is extensive,

first for the Ow

ners to ensure comp

liance (following the onb

oard TF

proced

ures) and, next, the A

uthorised C

omp

anies to particip

ate inthe surveys and

issue the certificates.

3399078.pmd

2004-11-12, 12:4787

88 Owners m

ight want to introd

uce new typ

e spare p

arts (e.g. the Slid

e Fuel Valve) to imp

rove enginecond

itions. Accord

ingly, MA

N B

&W

Diesel w

ill prep

are amend

ments for such cases.

Further requirem

ents for add

itional emission red

uctions, as used on som

e stationary pow

er plants, are

possib

le, but w

ill unavoidab

ly lead to increased

first cost or/and op

erational costs. For many years,

MA

N B

&W

Diesel has b

een working on d

ifferent aspects of em

ission reductions (see M

AN

B&

W D

ieselp

aper, P.333-97-04; H

ow to d

eal with E

mission C

ontrol).

The next level of emission lim

its have already b

een prop

osed b

y the leading environm

entally-activecountries and

associations (the US

, Japan and

EU

). A further N

Ox red

uction of some 25%

to 30% and

,eventually, includ

e other emission com

ponents like C

O, H

C and

soot.

The new M

E engine concep

t offers a high level of flexibility to op

timise the engine for d

ifferentem

ission regulations in Local Areas w

ithout penalising the fuel consum

ption or other em

issioncom

ponents elsew

here.

3399078.pmd

2004-11-12, 12:4788

89

I

I. Assistance from M

AN B&W Diesel

Dep

artment 2110 (C

lassifications) can inform you ab

out the proced

ures for the TF.

Dep

artment 4100 (D

iesel Service) offers the follow

ing services:

R

eview and

assistance to Ow

ners to ensure on board

comp

liance (engines with IM

Ocertificates b

efore and after the A

nnex enters into force)

G

uiding em

ission measurem

ents (for other purp

oses than IMO

certification/amend

ments).

Dep

artment 2431 (B

asic Research and

Em

issions) can, in special cases, p

erformIM

O-com

pliant em

ission measurem

ents on board

.

3399078.pmd

2004-11-12, 14:3289

90

Survey Start

SurveyType

Testbed:Inspection of

Pre-Technical File (EIAPP)

EngineType

Perfo

rmance


rmance

b) measure NO

c) check fuel nozzle andECS ve

rsiond) other NO

com

ponentse) ve

rify settings x

x

NOco

mponents Check:

xPerfo

rmance

and

Component appro

val

1.Pare

nt Engine2.M

ember Engine

NOco

mponen

x

c) check fuel nod) other NO

co(as considere

e) verify setting

(as considerePrint out survey

x

Inspection oTe

chnical Fil

Perfo

rmance


rmance

b) verify perfo

rmance


d) other NOco

mponents

e) verify settings

Print out survey code tables(with EIAPP application)

NOco

mponents Check

x

x

Survey Finish

Perfo

rmance

and

Component appro

val

Sign Documents Adjust

Adjust

Yes

Yes

No

No

3.SeaTrial

J. Overview of Survey Routines

3399078.pmd

2004-11-12, 12:4790

91J

Survey Start

SurveyType

Engine

NOco

mponents Check

x


d) other NOco

mponents

(as considered necessary)e) ve



x

Perfo

rmance


rmance

b) verify perfo

rmance

(VIT or non-VIT)


d) other NOco

mponents

(as considered necessarye) ve



NOco

mponents Check

x

x

Inspection of:Te

chnical File and Record BookInspection of:Te

chnical File (IAPP)Adjustment or

Component Changes

ce Check:

e perfo

rmance

rform

ance

el nozzle and ECS version

Oco

mponents

ttings

urvey

code tablesP

application)

onents Check

x

Survey Finish

mance

and

nent appro

val

Sign Documents and add to Record Book

Adjust

Perfo

rmance

and

Component appro

val

No

Yes

Yes No

4.On board Survey

3.SeaTrial

3399078.pmd

2004-11-12, 12:4791

92 Notes:

3399078.pmd

2004-11-12, 12:4792

93

Notes:

3399078.pmd

2004-11-12, 12:4793

94 Notes:

3399078.pmd

2004-11-12, 12:4794

95

Notes:

3399078.pmd

2004-11-12, 12:4795

96 Notes:

3399078.pmd

2004-11-12, 12:4796