Design

The Aalborg i-OC is a vertical and cylindrical boilerthat employs natural circulation of water

and steam. Its pressure sections are manufactured from mild steel that is able to withstand

high temperatures.

The plant is designed according to Alfa Laval’s modular Aalborg boiler concept, with a main

module that comprises two parts: an oil-fired section and an exhaust gas section that recovers

heat from the main engine.

One or two optional exhaust gas modules (Alfa Laval Aalborg Micro boilers) can be incorporated

for auxiliary engine waste heat recovery. Handling the auxiliary exhaust gas with separate but

connected modules ensures flexibility and a stress-free plant design.

• Oil-fired section

The oil-fired section of the main module comprises a furnace, a steam space and a convection

section. The convection section, through which the flue gas flows, consists of helix tubes with

a turbocleaning effect.

• The modulating-type pressure-atomizing burner (Aalborg MF PA) is fully integrated with the

convection part of the oil-fired section. The burner housing is mounted on the boiler front,

angled 15° downwards towards the furnace bottom. It optimizes the flue gas flow distribution

during combustion, which results in higher performance in the convection part and lower NOx

emissions.

• Main engine exhaust gas section

The main engine exhaust gas section comprises smoke tubes and an internal bypass damper.

The bypass consists of a plain tube welded to the lower and upper tube plates,

with the automatic damper installed in the top.

• Auxiliary engine exhaust gas boilers (optional)

The exhaust gas boiler modules for auxiliary engine waste heat recovery comprise serrated

and finned spiral tubes. Each module has its own exhaust gas bypass damper.

These smaller modules are bolted directly to the main module, with no piping or other

equipment. All boiler mountings are shared with and installed on the main module.

Benefits

• Composite design – can utilize fuel and/or exhaust gas

• Minimized footprint and weight

• Internal bypass for regulation of steam production and back pressure

• Standardized, pre-assembled and easy to install

• Optimized for high self-cleaning effect in the smoke tubes

• New burner design for easy inspection and maintenance

Maintenance

The Aalborg i-OC has adequate space for inspection and maintenance in the steam and water

sections. The boiler can easily be washed with water or mechanically cleaned through the

boiler uptakes, and the smoke tubes are also easy to clean when needed. The Aalborg

i-OC is optimized for water level control and a high gas velocity even through the smoke

tubes, which makes it effectively self-cleaning.

Servicing the burner is easy. By opening a top plate, the lance can be withdrawn to service

both the lance and nozzle. Access to the oil system and electrical components is possible

through two separate covers on the side of the burner.

Selection

All information is available immediately upon request, including layout drawings for the

design of the engine room.

The Alfa Laval Aalborg i-OC is a high-performance composite boiler, capable of generating

steam through the firing of oil and/or the recovery of waste heat from engine exhaust gas.

Its modular design comprises one oil-fired section and one–three exhaust gas sections.

One of the exhaust gas sections is connected to the main engine, while the two other

exhaust gas sections are optional and can be connected to one or two auxiliary engines.

Application

Able to work with multiple heat sources, the Aalborg i-OC offers reliable production of steam

while sailing and during port stays. As a composite boiler, it demands considerably less space

than having both oil-fired and exhaust gas boilers on board. In addition, it has a smaller

footprint and weighs less than older composite boiler designs. At its operating pressure of 

7 bar(g), the Aalborg i-OC can produce up to 2500 kg/h of steam with its oilfired section

and up to 1000 kg/h with its exhaust gas sections.

Fault finding made easy

The PLC has functional modules stored on separate I/O

cards rather than on one large circuit board. Self-diagnostic

capabilities enable faster and easier troubleshooting and

I/O replacement, if required. Should a fault occur in the

PLC system , an alarm alerts the operator and, upon opening

the cabinet door, a flashing red LED indicates the faulty

component . I/O card replacement requires less than a

minute and no tools or cables are required.

Extended service lifetime of entire separation system

EPC 60 Retrofit not only replaces the old control system

but upgrades the entire separation system. Replacing old

electronic components such as pressure switches with

modern  components extends the lifetime of the ancillary

equipment and ensures separator uptime as well as spare

part availability. Alfa Laval’s global service network and

spare parts supply chain ensures prompt delivery of parts

or service around the world.

Efficient cleaning

Utilizing the benefits with CIP (cleaning in place) secure a

clean bowl without dismantling. Regular cleaning provides

higher separation efficiency  and prevents mechanical

damage  caused by manual  cleaning or, in the worst case

scenario , by bowl imbalance resulting from an uneven

sludge discharge.

Extending separator performance

With its space-saving design, modular I/O cards and ease

of operation and maintenance, the EPC 60 Retrofit kit is

a solid choice for extending the life of older separation

systems . The kit easily mounts into the space occupied by

the old control  cabinet. Older generations of circuit boards

are upgraded with modular I/O cards, which can easily be

replaced in a matter of minutes.

One of the features is the built in P & I temperature controller.

It is always recommendable to use a P & I controller to secure

a steady and high separation temperature on the oil, making

sure the separation efficiency is as high as possible.

System components

•  EPC 60 cabinet, which has the exact same size,

mounting  requirements and cable flanges for re-use

of existing cables

• Pressure transmitter with adapters to replace existing

pressure  switches

• Surge protectors to be installed on existing solenoid

valves to protect the EPC 60 components from peak

voltages

• MT 60 water transducer board replaces all the older

boards and sensors for the  ALCAP separators

• The EPC 60 control system is ready to utilize coming

features  introduced for the EPC 60

EPC 60 Retrofit State-of-the-art control for older centrifugal separators

Background

Alfa Laval separators, such as the MAPX, MMPX, WHPX,

MOPX, FOPX, LOPX and MFPX, were developed decades

ago and are equipped with older control systems.

Unlike mechanical parts, it is difficult to assess the condition

of the electrical components of these systems. Damage to a

single component on a complex circuit board, for instance,

can affect the entire separation system and cause downtime.

Rather than wasting time to determine which electrical

component  requires replacement, it is common practice

in the marine and diesel industry to replace the entire card

often without considering other options.

Application

As a leader at the forefront of marine separator automation

and control systems, Alfa Laval offers a reliable way to

upgrade older generations of its control systems with new

state-of-the-art control technology. The Alfa Laval EPC 60

Retrofit kit is specifically designed to replace all Alfa Laval

separator electronic control systems in older separators,

including the IPC 231. EPC 30. EPC 41 and EPC 400.

Modernizing previous generations of Alfa Laval separators

and control systems with EPC 60 control technology:

• Ensures safe, reliable and efficient operation of the separator

• Makes the separator easier to operate

• Prolongs separator system lifetime

• Secures future spare parts supply