EGCS Operator’s

Pocket Guide
ISSUE APRIL 2019
 1 Things You Need to Know
1. The maximum parameters that the Exhaust Gas Cleaning
System (EGCS) is designed to operate under are generally
85% Engine load with a 3.5% fuel sulphur content, operating
in low alkalinity (eastern Baltic) seawater. Check your approved
ETM-B for more details.
2. To keep the DeSOx Tower clean during extended periods
of dry running, wash the system 2-3 times per week for
approx. 40 minutes. This is generally performed using the
CLEANING Mode in the automation. There should be no
need for washing during high EGCS usage periods.
3. Keep the water analysis rack sensors:
4 clean as dirty probes may lead to incorrect readings
4 checked for calibration using the appropriate kit
4 wet at all times to avoid the risk of failure.
4. C
 arryover can cause discoloured water to land on open decks.
It is best avoided by using the recommended cold start and full
shutdown procedures when possible, and avoiding extended
periods with higher than needed wash-water flow rates.
5. In case of multiple EGCS units with common supply or
discharge lines: To avoid cross-flooding to another EGCS upon
start-up – ensure all overboard valves for all installed EGCSs are
open and cross-connects closed before starting the system.
6. The 4 regulatory limits that ships in ECAs must comply with are:
 the SO2/CO2 ratio of the exhaust gas
 the PAH and Turbidity differentials between Rack 2 and Rack 1
 and the pH at Rack 3 (and in some cases the pH Differential
between Rack 1 and Rack 3).

2 EGCS Operator’s Pocket Guide | April 2019

7. Minimum instruments needed for compliant operations:
4 Gas analyzer 4 Turbidity sensor at Rack 2
4 PAH sensor at Rack 2 4 pH sensor at Rack 3.
8. In US VGP waters (within 3 nm from US coast) the pH limit at
the overboard discharge (Rack 3) is 6.0, with the exception
that during manoeuvring and transit when the maximum
difference of 2.0 pH units between inlet (Rack 1) and outlet
(Rack 3) is allowed. This is different to the IMO limit which
applies in all ECAs outside VGP waters and varies ship by
ship. Both limits are listed in the ETM-B Manual.
9. Spare water analysis sensors are recommended to be kept
onboard. Alternatively, Rack 1 PAH and Turbidity sensors can
be used as spares for Rack 2; and Rack 2 pH sensor (if installed)
can be used for Rack 3. Some data reprogramming is needed.
10. The normal preferred system operating mode is the
Automatic Mode ‘SETPOINT ENGINE LOAD + SO2
CORRECTION’, with the SO2/CO2 ratio set point programmed
between 3.0–3.5.
11. If the SO2/CO2 ratio is unstable, the system can be operated in
Automatic Mode ‘SETPOINT ENGINE LOAD’ which uses the
ENGINE load as reference for the seawater supply flow rate.
12. If the buffering water flow rate is fixed, reducing the wash-
water flow rate to the Tower will cause the SO2/CO2 ratio to
increase: this could help in achieving a higher (less acidic)
pH value at the overboard discharge (Rack 3).
13. Maintenance information from the System Information
Manual (SIM) must be inserted in the ship’s maintenance
program / logs for scheduled maintenance. This is a
requirement for the system’s IMO certification.

EGCS Operator’s Pocket Guide | April 2019 3

 2 Introduction

1. Regulations limit the amount of sulphur oxides (SOx)

emissions that are allowed in exhaust gas emissions from
ships. These limits are applicable all over the world but
are stricter in Emission Control Areas (ECAs) and Sulphur
Emission Control Areas (SECAs), collectively known as
ECAs. ECA are continuously being updated and the ship’s
staff needs to familiarise themselves with the applicable
requirements both for exhaust gas emissions and wash-water
discharges.
2. As the amount of SOx in the exhaust gas depends on the fuel
being burnt, ships have two options in order to comply with
the limits:
4 Burn MGO or
4 Burn HFO and reduce the SOx in the exhaust gases with
an EGCS.
3. The regulations for emissions and discharged wash-water
stipulate allowable limits for a number of different parameters,
these are known as the Compliance Parameters. The limits,
regulatory bodies and locations are shown in the table below.

4 EGCS Operator’s Pocket Guide | April 2019

 Regulatory Body IMO & EU US EPA
Location ECAs and US VGP
EU Ports Waters
Exhaust gas emissions limits
SO2/CO2 Ratio 4.3 same as
or less IMO
Wash-water limits
PAHphe – The differential
50 µg/L (ppb)*
between the concentration at same as
or less
the DeSOx Tower Outlet and IMO
at 45 t SW/MWh
the Sea Suction
Turbidity – The differential
between the concentration at 25 NTU/FNU same as
the DeSOx Tower Outlet and or less IMO
the Sea Suction
pH – Measured at the Refer to ship’s 6.0
Overboard Discharge approved ETM-B or greater
pH – Differential between
the Sea Suction and the
NA 2.0
Overboard Discharge during
manoeuvring and transit

* Calculated by EGCS automation system.

PAH (polycyclic aromatic hydrocarbons) is a measure of the

amount of unburnt fuel in the wash-water.
Turbidity is a measure of the clarity of the wash-water.
Note: Some US states, such as Hawaii, also have stricter pH
limits which are applicable when operating in their state waters.
For information about US state specific limits contact your EGCS
shore team.

EGCS Operator’s Pocket Guide | April 2019 5

 3 System Overview

6
7
4

1 2 Outlet
5
Inlet
Inlet

Main components Additional equipment

6 EGCS Operator’s Pocket Guide | April 2019

The Ecospray EGCSs onboard the ships are wet open-loop
systems that utilise seawater to reduce the SOx in exhaust gases
from the Engines. The systems pump seawater from a sea chest
to a DeSOx Tower where the SOx are removed by mixing the
seawater with the exhaust gases. The removal of the SOx also
lowers the pH of the seawater and the water must then be mixed
with additional seawater to buffer (increase) the pH before it is
discharged back into the sea.
The major components of the EGCS are as follows:
1 SW Pump – pumps the seawater from the sea chest to the
DeSOx Tower
2 SW
 Filter – removes particles and biota from the seawater
to prevent clogging and erosion of the spray nozzles in the
DeSOx Tower, the filter also has an automatic back-flush
function which returns filtered material to the sea
3 DeSOx
 Tower – sprays the wash-water into the exhaust
stream to remove the SOx and then separates the wash-
water from the exhaust gases. The gases exit the Tower via
a Demister and continue to the funnel and the wash-water
is drained from the base
4 Static
 Mixer – mixes the wash-water and buffering water
to buffer (increase) the pH
5 Buffering
 Pump – pumps the buffering water to the Static
Mixer
On some ships the following equipment is fitted:
6 De-gas unit – removes the gas entrapped in the wash-water
to avoid bubbles effect at the overboard discharge
7 Wash-water
 Filtration System – removes particles and oils
from the wash-water discharged from the DeSOx Tower
8 Thermal
 Transient Shock Mitigation System – gradually
decreases the exhaust gas temperature prior to start the EGCS

EGCS Operator’s Pocket Guide | April 2019 7

 4 General Operating Notes
Wet and Dry Running
When the Engine is running and the EGCS is turned off it is
known as the Dry condition and when it is switched on it is
known as the Wet condition.
Start and Shutdown Scenarios
A Cold start (recommended and standard) is when the EGCS is
started before (or at the same time as) the Engine. A Hot start is
when the EGCS is started on an Engine that is already running.
Full shutdown (recommended and standard) is when the Engine
is stopped first (preferred) or the Engine and EGCS are stopped
at the same time. Partial shutdown (not recommended) is when
the EGCS is stopped and the Engine is left running.
Note: To minimize carryover in the event of a partial shutdown,
reduce the engine load as low as practical (preferably to 20–30%
but in no case above 50%), allow time for exhaust gas temperature
at Tower inlet to stabilize. Shut down the EGCS, and allow sufficient
time for the Tower to drain before increasing the engine load again.
System Cleaning
If the EGCS has not been run in the past 24 hrs, then before
starting the Engine the EGCS should be run for at least 40
minutes to wash the Tower. In addition, a CLEANING Mode
cycle should be carried out 2–3 times per week when the system
is operating in the Dry condition for extended periods. If not
available in ES automation, refer to the Operating Manual.
Note: If the Demister is fitted with Technical Water Supply, the valve
should be open during the Cleaning cycle.
Soot-blowing
Economizer soot-blowing operations should be completed
at least 4 hrs before starting the EGCS.
8 EGCS Operator’s Pocket Guide | April 2019
 5 Safety Systems
The system is fitted with four primary safety features that upon
activation will automatically shut down the EGCS in order to
prevent damage to the Engine.
The four primary safety features are:
1. DeSOx Tower level sensor
Detects a high wash-water level in the DeSOx Tower bottom.
2. DeSOx Tower discharge pressure sensors
Detect a high wash-water level in the DeSOx Tower discharge
line.
3. Hull valve position status
If the hull valves on the overboard discharge or sea chest are
closed, the corresponding EGC System will automatically
shut down.
Note: The valve should not be used to stop the system.

4. Emergency stop buttons

A number of emergency stop buttons are located in the
ECR and engine room. If pressed they will automatically
shut down the system.

Note: For vessels with multiple SW Pumps and cross-over valves

between the supply lines for the wash-water and buffering water, it is
possible to unintentionally feed water into a Tower using a SW Pump
from another system if the cross-over is left open. Cross-over valves
should therefore normally be locked closed.

EGCS Operator’s Pocket Guide | April 2019 9

 6 Continuous Monitoring

Gas Analyzer

Rack 2

Rack 3

Rack 1 Rack 4

10 EGCS Operator’s Pocket Guide | April 2019

Whenever an EGCS is being used inside an ECA, the Regulations
require that the Compliance Parameters are continuously
monitored and stored for minimum 18 months.
‘Continuously monitored’ means that the value of each
parameter must be measured and recorded with a frequency
not less than 0.0035 Hz (one registration every max. 4.7 mins).
To achieve this, compliance monitoring equipment is installed as
part of the EGCS along with a Compliance Computer.

Compliance
ECOSPRAY Compliance
Monitoring Ethernet/ Ethernet
Profibus/ PLC Computer
Equipment Modbus/
4..20 mA

The Compliance Parameters are listed in Section 2 and the

compliance equipment installed is as follows:
Gas Analyzer – measures the SO2 and CO2 content of the
exhaust gases which allows the SO2/CO2 ratio to be calculated.
Seawater Inlet (Rack 1) – measures the PAH and Turbidity
of the inlet water at the sea suction. On some systems, pH is also
measured.
DeSOx Outlet (Rack 2) – measures the PAH and Turbidity of the
wash-water at the outlet of the DeSOx Tower.
Overboard Discharge (Rack 3) – measures the pH of the wash-
water at the overboard discharge.
Discharge Tank (Rack 4) – not compliance equipment and does
not perform analysis. It collects water from Racks 2 and 3 and
pumps to the Overboard.

EGCS Operator’s Pocket Guide | April 2019 11

 7 Operating Parameters & Daily Spot Checks

In order to demonstrate that the EGCS is operating properly

the regulations stipulate that a Daily Spot Check of a number
of Operating Parameters is conducted in addition to the
continuous monitoring of the Compliance Parameters.
The Operating Parameters are as follows:
4 Engine Load, % and MW
4 Wash-water pressure and flow rate at the inlet to the DeSOx
Tower
4 Wash-water temperature at the Overboard Discharge
4 Exhaust gas pressure before the DeSOx Tower
4 Exhaust gas pressure drop across the DeSOx Tower
4 Exhaust gas temperature before and after the DeSOx Tower
In practice, all the installed EGCSs continuously monitor the
Operating Parameters and the values can be displayed in
the Process Report which is generated by the Compliance
Computer; therefore you are only required to make a Daily Spot
Check to ensure that the values for the Operating Parameters
are normal and are being recorded correctly.
The check should be recorded in the EGC Record Book, the
format of which has been approved by the ship’s Classification
Society.

12 EGCS Operator’s Pocket Guide | April 2019

 8 Periodic Sampling

The IMO and EU recommend an initial wash-water sample to

be taken as part of the final commissioning and flag approval
process. Following the initial sample, a sample should be taken
at no more than 12 month intervals.
The US EPA VGP requires two samples to be taken in the first
year of permit coverage (one of these can be the commissioning
sample) and the samples must not be collected within 14 days
of each other. Following the first year, a sample should be taken
at no more than 12 month intervals.
For each annual or renewal survey, the nitrate discharge data
and laboratory analysis certificates for wash-water samples taken
within the 3 months prior to the survey will be required to be on
board as part of the EGC Record Book and available for review
by the Authorities.
One sample from each of the three racks of the EGCS must be
taken when the ENGINE is running. The samples must then be
sent to a Laboratory who will analyse the samples and issue the
laboratory analysis certificates, which can then be logged and
recorded in the EGC Record Book. Please note, one sampling kit
is required for each rack.

EGCS Operator’s Pocket Guide | April 2019 13

 9 EGC System Records

In addition to the items already mentioned in Sections 7 and

8, there are a number of EGC System Records that need to be
recorded. Below is a full list of what needs to be recorded as
a minimum.

EGC System Record Recorded in

4 Compliance Parameters Compliance

4 Operating Parameters Computer

4 Completed component adjustments Ship’s electronic

4 Required maintenance and servicing activities maintenance
system
4 Completed maintenance and servicing activities
4 Like-for-like replacements of equipment and
components

4 Daily spot checks EGC Record

4 Nitrate discharge data and analysis certificates Book
4 Alarms and troubleshooting activities
4 Storage and disposal of sludge or residuals
4 EGC System supporting documents

All EGC System Records must be preserved onboard for at least

18 months, and must be available for inspection upon request.
The EGC System Records will be required for the annual and
renewal surveys.

14 EGCS Operator’s Pocket Guide | April 2019

 10 EGCS Compliant Operation Requirements

To operate the EGCS safely and legally within compliance as a

minimum the following items are required:
1. Gas Analyzer
2. PAH sensor on Rack 2 (see note 1)
3. Turbidity sensor on Rack 2 (see note 1)
4. pH sensor on Rack 3 (see note 2)
5. Compliance Computer
6. Equipment installed as detailed in the approved OMM and
ETM-B, and safety systems operational

This assumes that system maintenance and calibration have

been conducted and EGC System Records are kept as per the
table in section 9.

Note 1: If the PAH or Turbidity sensors on Rack 1 fail, they will default
to a zero reading; therefore it is possible to continue to operate the
EGCS within compliance as long as the PAH and Turbidity sensors on
Rack 2 are operational.

Note 2: In the event of pH sensor failure on Rack 1 (where installed),

the overboard pH limit at Rack 3 must be applied (as stated in the
ship’s ETM-B). Also, if the pH sensor on Rack 3 is out of order, it can
be replaced with the one on Rack 1.

EGCS Operator’s Pocket Guide | April 2019 15

 11 EGCS Operating Modes

Automatic Mode
When the system is in its standard automatic operating
mode the EGCS Automation system may be set for either
‘SETPOINT ENGINE LOAD + SO2 CORRECTION’ or only
‘SETPOINT ENGINE LOAD’:
4 Setpoint Engine Load – adjusts the wash-water flow rate
according to a programmed flow rate vs. Engine Load
4 SO2 Correction – make a fine adjustment of the wash-water
flow rate to maintain an SO2/CO2 ratio set point

Manoeuvring Mode
This mode overrides all other selected modes and immediately
adjusts SW flow to the Manoeuvre Set point rate set in
the Parameters Page. The default is 400m3/h but may vary
depending on Engine rating. If not available SET POINT
MANUAL Mode should be used.

Set Point Manual Mode

Set point value for SW flow is entered manually. At start-up the
SW Pump ramps to the Set point and the system will maintain
that flow rate. SO2/CO2 ratio and Engine load are not used as
control feedback.

16 EGCS Operator’s Pocket Guide | April 2019

EGCS Start Before ENGINE
An automatic function named PRE-START mode can be used
to start the system before the Engine to avoid any potential
non-compliance during Engine start. The wash-water flow rate
will be fixed until the Engine load overpasses a threshold value
(generally 30%) at which point the control system switches to
AUTOMATIC Mode.

Manual Mode
This operating mode gives the operator full control of all the major
components, e.g. SW Pump, pH Buffering Pump and SW Filter.

For more information about how to operate the EGCS, including

starting and stopping procedures and troubleshooting, refer to
the EGCS Operating Manual.

EGCS Operator’s Pocket Guide | April 2019 17

 12 EGCS Manuals and Resources

EGCS Owner’s Manuals and Documents

Operating Manual (OM)
The OM is the primary source of information on the EGCS,
and it contains:
4 A detailed system description
4 Regulations and compliance requirements
4 Operating procedures and safety systems
4 Troubleshooting and corrective actions

System Information Manual (SIM)

The SIM is focused on system maintenance and contains:
4 Maintenance requirements for each system component
4 OEM manuals and datasheets

EGCS Regulatory Manuals

There are five manuals which are required for the EGCS initial
approval and its annual surveys. These manuals detail how
to operate and maintain the system in compliance with the
regulations. Some of these manuals require class approval.
SOx Emissions Compliance Plan (SECP) Class approved
EGCS Technical Manual for Scheme B (ETM-B) Class approved
Onboard Monitoring Manual (OMM)  Class approved
EGC Record Book Class approved format
SIM Required for system approval – not class approved

18 EGCS Operator’s Pocket Guide | April 2019

 13 ECAs and EU Ports

4
3

5
1
2

The current ECAs are:

1 The North American ECA, including most of the US,

Canadian coast and Hawaii

2 The US Caribbean ECA, including Puerto Rico and

the US Virgin Islands

3 The North Sea ECA, including The English Channel

4 The Baltic Sea ECA
5 All EU Ports

Note: Starting 1st January 2020, regulations on exhaust gas

emissions will apply globally as ruled by IMO’s MEPC-70.

EGCS Operator’s Pocket Guide | April 2019 19

 14 Daily Checks
Component Maintenance Requirement
EGC System Check:
4 For leaks in ECO-SOx Tower, piping
connections, valves, sample points,
pumps/filters and water analysis racks
4 For unusual vibration or noise
4 Compliance Computer is recording properly
Observe:
4 Wash-water pressure
4 Flow rate at the inlet connection
4 Exhaust gas pressure before and drop
across the EGCS
4 Engine load
4 Exhaust gas temperature before and after
the EGCS
4 SO2 (ppm)
4 CO2 (%)
4 pH
4 PAH
4 Turbidity
4 Wash-water Temperature
Expansion 4 Visual inspection for integrity
Joints
Gas Analyzer Heated sample line
4 Check temperature by hand
4 Sample tube should be noticeably warm
at probe outlet and cabinet inlet
Air quality
4 Check air filters for cleanliness

20 EGCS Operator’s Pocket Guide | April 2019

 15 Emergency Stop Checks
Emergency Stop Event System Checks
ECO-SOx Tower Water level in Tower
High Level Sensor 4 Overboard valve open?
4 Any other valve/equipment in the
discharge line blocked?
4 Blockage of discharge (ice/quay/...)?
4 Why high pressure sensors have not
triggered?
Sensor operation (defect?)
4 Dirt (ash/soot)?
4 Cable connection?
High Pressure Water level in Tower discharge
Wash-water 4 Overboard valve open?
Discharge 4 Any other valve/equipment in the
discharge line blocked?
4 Blockage of discharge (ice/quay/...)?
Sensor operation (defect?)
4 Cable connection?
Hull Valves Position Check valve position
4 C
 ondition of actuator and control
lines to be checked
4 P
 artial closure of valve can indicate
wear of actuator
4 Limit switch for correct functioning
Emergency Stop Investigate reason for manual
intervention

EGCS Operator’s Pocket Guide | April 2019 21