2023 SHELL FORUM: PARTNERS

SHARING
MEGA ENGINE OPERATIONS KEY NUANCES
07.SEP.2023
MEGA ENGINE OPERATIONS
CONTENTS

 MEGA Engine
 Significance of EGR System
 Risks of EGR Failure
 Considerations for Response Measures
 Technical Issues during at the construction stage
 Operating Strategies of MEGA engine vessel
 Q&A
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A. MEGA Engine

 Advanced Otto-Cycle process

The generation of Nox is largely suppressed and comply with the Nox Tier III requirements
and to advance combustion system to reduce pre-ignition (or Knocking).

 Low Fuel Gas Pressure System

Significantly reduced pressure of fuel gas from 300bar to 10-16bar .

 Proven EGR Design for significantly lower Nox, Co2 and GHG emissions.
Lowered peak temperature of the combustion to reduce the generating of Nox
and Co2 and to prevent of further methane slip from 30% to 50% efficiency

 Revitalizing the conventional engine concept, effectively mitigated pre-ignition (or Knocking)
concerns.
Upgraded SGAV (Safety gas admission valve) installed, enhance the condition of gas admission.

 Simple pilot Fuel system for VLSFO/MGO (Source: MAN B&W)

Developed Micro Booster Injection Valve (MBIV) based on the Fuel Booster Injection Valve (FBIV)
MEGA ENGINE OPERATIONS
B. Significance of EGR

 Three different matching method for the EGR System comply on various
regional condition. Gas Tier III Mode, Diesel Tier II and III mode.

 High Efficient combustion condition

 Prevent imperfect combustion and knocking while firing.

 Mixing Scavenge air and the exhaust gas to reduce the O2 content and in
crease the CO2 before entering the combustion chamber.  Decrease N
ox 20~22%

 To comply with the Tier requirements, EGR should permanently oper

ate regardless of sailing area.

Nox Emission Control Area US/CANADA – 200 Nautical Miles

Northern Europe Baltic Sea, North Sea & English channel

Tier II Global Nautical Area

(Source: MAN B&W)

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B. Risks of EGR System Failures

 ME-GA engine is designed to operate with EGR in all normal operation situations;
Gas (covering both Tier II and Tier III operation), Diesel Tier II mode, and Diesel III mode.

EGR Running in all Modes*

Running Mode Fuel Maximu
Nox
m Load
Diesel Tier II Fuel Oil Tier II 110%
Gas Gas Tier III 100%
Diesel Tier III Fuel Oil Tier III 100%

* In case of failures on the EGR system, it will be possible to continue operation with engine loads up to 7
0% in both gas and diesel mode. Nox Certification is not applicable for such scenario

 Power limitation down to 70%, is to prevent very high turbocharger speed caused by high scavenging air pressure.

 EGR system failure not only hinders Tier III compliance but also limits operational capacity to 70% of MCR, posing risk of operational
disruption and associated losses.
* If the vessel’s schedule is planned to navigate at MCR speed.

 In case of failure of EGR, at the 70% load, gas mode could be unstable due to knocking
 No Nox Technical File is included in case of failure of EGR system
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B. Countermeasures

 Techincal operator analyze risks in operati  Machineries failures are covered under LR Rules
ng main engines with EGR failure. Part 5, Chapter 2.
 EGR System endorsed without object
 Collaboration with the Maker enhances r ions, ensuing compliance.
esponses strategies. Classification
Risk Analysis
Rules

PREPARATORY
MEASURES
 EGR failure causing Nox non-compli  Retaining steering capability at a
ance triggers emergency operation ( minimum of 7 knots is crucial (Par
70% engine load) Regulatory Preserving t 5, Ch.22, Sec.1)
 Reporting complies with MARPOL Ann Key services  Propulsion & Machinery Redunda
ex VI, Regulation 5.6. Adherence ncy standards ensure stability
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B. Concerning Issues – EGR system

 Frequent clogging due to numerous carbon clusters in processed recirculati

on water from the EGR system. Occurs approximately 18-hours interval,
leading to an increase in manpower is required.

 O2 Sensor installed on EGR system, require to replace every 2,000 Hours.

 EGR drain water tank has a capacity of 150m3, and in the event of WTS system fail
ure, EGR could not be operated due to the drain capacity.

 No redundancy solutions for above problems is prepared.

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A. Concerning Issues – Double Wall Pipe Air

 Supplying 30 Bar engine starting air pressure in Double Wall Pipe reduces 0.
5 bar, causing freezing at air spray point.

 Previous Modifications using control air line not applied for MEGA engine concept.

 Pressure reduction in air, ideal gas law PV=nRT, results in temperature decrease.

 Causing excessive air consumption on this concepts.

 This effect intensifies in winter, causing operational challenges. MAN is

underway to identify solutions, potentially involving modification.
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A. Concerning Issues – Engine parameters

 SM ALBATROSS, SM BLUEBIRD (X-DF) had difficulties on consuming the Per

u gas,
Due to high nitrogen contents. (Low LCV)

 MAN have informed that the parameter change (performance Tuning) coul
d be done with authorized personnel only.

 Expect at least 10 days to change parameter of main engine due to security.

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B. Conclusion

 Operational Efficiency Enhancement

The innovative ME-GA engine and EGR system contribute to operational efficiency enhancement.

 Operational Strategies
Formulating operational strategies accounting for the potential of EGR System failures.

 Environmental Compliance
Positive outcomes attainable through securing environmental compliance and operational stability.
Reporting and the mitigation plan should be reflected to the Routing plan of the vessel.

 Classification Acceptance
Continuously monitor and collaborate to enhance MEGA engine operations,
emphasizing technical expertise through communication, ship visits, and knowledge sharing.

 Statutory Obligations
Flag notification required due to EGR failure affecting NOx compliance.
Immediate reporting aligns with environmental standards.
Thank you for your attention