From: riccardo.conti@exxonmobil.com Sent: Wednesday, December 15, 2004 11:11 AM To: Bill Larch (E-mail); Bob Campbell (E-mail); Cathy Devlin (E-mail); Greg Shank (E-mail); Jim Gutzwiller (E-mail); Jim Matasic (E-mail); Jim Moritz (E-mail); Jim Wells (E-mail); Keith Selby (E-mail); Ken Goshorn (E-mail); Mark Cooper (E-mail); Michael Minotti (E-mail); Pat Fetterman (E-mail); Ron Buck (E-mail); Scott Richards (E-mail); Steve Kennedy (E-mail); Wim Van Dam (E-mail) Cc: Jeff Clark Subject: Mack T-12 TelCon, 12-15-04, 2:30pm ET: Agenda Agenda: 1. Installation Update from each Lab 2. Installation of Three EGR Coolers and Condensation Prevention in Intake Manifold Some details on item 2.: A. Installation of Three EGR coolers The attached pieces of information from Honeywell, the maker of the coolers, highlight the following: a. The 3 coolers should be installed in parallel. b. The cooling medium should be kept above 75-80 C (167-176 F) to prevent severe fouling in Phase I. Therefore the use of a dedicated loop is necessary. c. 3 coolers may develop fouling problems in Phase II due to low gas velocity. " Before I get too far along I want to confirm the temperature of the coolant going through the EGR cooler. Is it the same as the process water? If so, that is not a good thing for fouling. Fouling is dependent on a number of factors, but a couple of them are thermophoresis and condensation. Thermophoresis is a phenomenon that basically says any particles in a gas will migrate from the hotter ara to the colder area. In an EGR cooler, condensation will form a liquid film on the heat exchanger surfaces, and the soot particles will stick to this layer. That creates a kind of sponge that attracts more condensation , and also provides a sticky surface for more particulates. Anyway, the cold coolant will obviously create more condensation. We have run tests in the lab that showed fouling with cold coolant can be 5-6 times worse than normal operation. For the Mack cooler, a it could raise the gas out temperarture up to to 127C for the conditions you state ( I assume that the flow is split equally between the two cooler.) I would recommend a coolant temperature of about 75-80 C. The flow rates are not excessive for this cooler, and in fact may be a little low for Phase 2, especially if you use 3 coolers. (Another condition that can lead to higher fouling is low gas velocity.) Later this morning I can make some predictions for the flows for both. " Keith Agee Honeywell TurboTechnologies 3201 W. Lomita Blvd Torrance, CA 90505 Phone 310-517-1030 Fax 310-257-2445 (See attached file: Mack T12 ExxonMobil A.xls) B. Measures to avoid Condensation in the Intake Manifold In order of effectiveness and ease of implementation: a. Move the Venturi and Venturi By-Pass away from the engine to allow enough space length for the Venturi and Intercooler Out stream to mix properly. The dew point of the mixed stream is below Intake Manifold temperature, even in the worst case of fully saturated air feeding the engine. One additional benefit of this set-up is a streamlined arrangement on top of the engine, which will improve engine turn-around between tests. b. Limit the dew-point of the fresh air feeding the engine to 15.6 C (60 F). Achieving this condition may entail different set-ups at each lab. It may be worth exploring capabilities at each lab. c. Install a water droplet separator after the Modine Intercooler. Spirax-Sarco makes a stainless steel separator with negligible pressure drop capable of removing 100% of the water droplets carried in the gas stream. Unfortunately it's not a standard production item and we are still waiting for a quote from the manufacturer. Attache is a picture of this item: (See attached file: Water Droplet Separator.gif)