IG Scrubber/Dryer 8000m3h
Alfa Laval Inert Gas Systems. Alfa Laval is the market leader in inert gas generation for maritime tanker vessels. The Smit Combustion system is a low-pressure combustion-based IGS using the patented Ultramizing® technology to produce soot-free inert gas with oxygen content 2-4%. Capacity range: 1000-20,000 m³/h at 0.15-0.25 bar(g). System includes combustion generator, cooler/
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Common issues
- Scrubber tower nozzle/packing fouling with soot and scale reducing gas cooling and washing efficiency
- Deck water seal (non-return) malfunction risking gas or flame back-flow toward the scrubber
- Oxygen analyzer calibration drift giving false-safe or false-high O2 readings
- Blower bearing wear and vibration from prolonged running in a corrosive gas stream
- Scrubber effluent pH/quality issues affecting overboard discharge compliance
- Combustion chamber refractory or burner nozzle degradation affecting soot-free operation
- Pressure/vacuum breaker or mechanical non-return valve seizure
Inspection checklist
- Function-test deck seal water level, heater, and low-level alarm
- Calibrate oxygen analyzer against certified reference gas
- Inspect scrubber spray nozzles for blockage or wear
- Check blower bearings, coupling alignment, and vibration
- Test non-return/pressure-vacuum breaker for free movement
- Inspect scrubber tower internals for soot and scale build-up
- Verify IG main and distribution valves operate and seal correctly
- Check effluent pH monitoring and overboard discharge arrangement
Service intervals
| Oxygen analyzer calibration | typically monthly or per maker's schedule, and before each cargo operation requiring IG |
| Deck seal water level/heater function test | typically monthly, with a watch-level check during IG use |
| Scrubber nozzle inspection | typically every 3-6 months or at drydock, depending on fuel sulphur content and running hours |
| Blower bearing lubrication/vibration check | typically every 500-1,000 running hours per maker's schedule |
| Non-return valve/deck seal overhaul | typically annually or at drydock |
Typical wear limits
| Deck seal water level | maintain within the maker's marked working range - low level triggers alarm/trip; confirm the exact setpoint in the vessel's approved manual |
Ranges are typical for this design class. Always confirm against the manufacturer documentation for your serial number.
Critical spares
- Scrubber spray nozzles
- Deck seal non-return valve internals/gaskets
- Oxygen analyzer sensor cell
- Blower bearings
- pH probe / effluent monitoring sensor
- Burner nozzle (combustion type)
Safety
- Inert gas is an asphyxiation hazard - strict enclosed-space entry procedures required around scrubber, tank, and IG lines
- Failure of the deck seal can allow flammable cargo vapour to reach the scrubber/engine room side
- High-temperature combustion gas and hot surfaces at the scrubber inlet
- Toxic and corrosive scrubber effluent
- Loss of oxygen monitoring can mask an unsafe atmosphere being supplied to cargo tanks
Class survey
Inert gas systems are subject to specific SOLAS/class survey requirements including oxygen content verification, deck seal function test, and non-return device testing; O2 analyzer calibration and system function test records are commonly checked at annual and renewal surveys.
Components & Design
Component data being added…
Technical Data
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Common failures & inspection points
Visual inspection through scrubber manholes; check spray nozzles for blockage (impairs cooling efficiency); inspect cooling pipes, floats, sensors for corrosion or soot deposits; verify cooling water flow and demister function
Verify gauge glass is clean and water level visible; check high/low level alarm float switches operational; inspect for water leakage, corrosion; in cold weather verify heating coil function and trace heating active; confirm low-level alarm functions
Verify P/V breaker opens at preset pressure/vacuum; check sight glass and fluid level (glycol-water mixture); inspect for leakage around valve stem; test differential pressure response; replace fluid if discolored/contaminated
Calibrate analyzer ≥24 hrs before cargo operations; log calibration results; verify O2 readout 2-4% during operation; replace probe/sensor if drift >0.5%; ensure analyzer sample line clear and inlet not fouled
Observe flue gas color (should be colorless/light gray, not black); monitor fuel/air ratio; inspect burner nozzles and air registers for clogging; verify combustion oxygen ≤4%; check fuel pump pressure/flow; inspect ignition electrode condition
Confirm non-return valves at deck seal outlet prevent backflow; verify pressure differential across deck seal maintained; listen for flow disturbance; schedule valve seat/seal inspection per Condition Audit; test with pressure gauge if vessel equipped
Type-general inspection and maintenance points for this equipment category — not model-specific.
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