Alfa Laval Pureballast 3.1 85 Compact Design and Installation Guide.pdf

PureBallast 3.1 85 Compact

IMO/USCG

Lit. Code 200000407-1-EN-GB Design and installation guide

Published by Alfa Laval Tumba AB Hans Stahles väg 7 SE-147 80 Tumba, Sweden +46 8 530 650 00

The original instructions are in English

© Alfa Laval Corporate AB 2018-05

This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing intellectual property and thereto related rights. It is the responsibility of the user of this document to comply with all applicable intellectual property laws. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any form or by any means (electronic, mechanical, photocopying, recording, or otherwise), or for any purpose, without the expressed permission or authorized by Alfa Laval Corporate AB. Alfa Laval Corporate AB will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.

Table of contents

1 Ship specific information

2 Introduction

2.1 Safety information

2.2 Components overview

3 Alfa Laval’s scope of supply

4 Material and equipment supplied by installing party

4.1 Material selection

5 Mechanical installation

5.1 General requirements

5.2 Skid

5.3 Cabinets

5.4 Valves

5.4.1 Bypass valve (V212–31)

5.4.2 Vaccum breaker valve

5.5 Ancillary equipment and functions

5.5.1 Sampling devices (Q201.1 and Q201.2)

5.5.2 Booster pump

5.5.3 Tank stripping equipment

6 Pipe design

6.1 General requirements

6.2 Water requirements

6.3 Flow requirements

6.4 Pipe dimensions and material

6.5 Pipe 201

6.6 Valves outside PureBallast

6.7 System pressure

6.8 Pressure requirements for filter backflush

7 Electrical design

7.1 Power requirements

7.2 Installation requirements

7.2.1 Cables

8 Pneumatic design

9 Control system integration

9.1 Remote control panels

9.2 Remote interface

9.3 Power management system (PMS) integration

9.3.1 Power request process

9.3.2 Power management installation

9.4 External feed control signal

9.5 External components signals

9.6 GPS

10 System approval

10.1 Alfa Laval’s responsibilities

10.2 Installing party’s responsibility

10.2.1 Approval planning

10.2.2 Design approval

10.2.3 Installation survey

10.3 Alfa Laval commissioning

11 On board installation planning

11.1 Delivery and transport

11.2 Lifting instructions

11.2.1 Skid

11.2.2 Cabinets

12 Start-up procedures

13 Drawings

13.1 Graphic symbols used in drawings

13.2 General drawings

13.2.1 Flow chart

13.2.2 Connection list

13.2.3 Electrical system layout

13.2.4 Instrument air distribution

13.2.5 Quality specification / Instrument air

13.2.6 Quality specification / Technical and potable water

13.2.7 Quality specification / CIP liquid

13.3 Dimension drawings

13.3.1 Skid with backflush pump (pump is optional)

13.3.2 Skid without backflush pump (pump is optional)

13.3.3 Electrical cabinet

13.3.4 UV reactor and electrical cabinet / Lamp power cable

13.3.5 Valve V212-31 (Optional)

13.3.6 Sampling device Q201.1 and Q201.2 (Optional)

13.3.7 Remote control panel (Optional)

13.3.8 Transformer (Optional)

13.4 Electrical drawings

13.4.1 Electrical cabinet / Interconnection diagram

13.4.2 Electrical cabinet / Circuit diagram

13.4.3 Electrical cabinet / Cable list

13.4.4 Remote control panel / Circuit diagram (optional)

13.5 Saftey Data Sheets

13.5.1 Safety data sheet / CIP liquid

13.5.2 Material data sheet / UV lamp

1 Ship specific information Enter vessel specific information in the table below. This will facilitate reading information and drawings in this document, since some drawings include information for all system sizes / dimensions, and the document contains information for options only used by on some vessels. In PDF, either edit the document or add a text box.

Data Value

Flange standard (EN or JIS) ___________

Control valve (V201-8)

Bypass valve (V212–31) Alfa Laval’s or other

Dimension: ___________

Sampling device Alfa Laval’s or other

Location Q201.1: ___________ Location Q201.2: ___________

Power consumption, max (kW) ___________

Remote operation (optional)

Location:

Remote control panel 1: ___________ Remote control panel 2: ___________ Remote interface integration (yes/no):

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EN

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1 Ship specific informationEN

2 Introduction This document contains general guidelines for the on board design and installation planning. Alfa Laval deliver PureBallast as a skid with the major components preassembled, with exception for the electrical cabinet, sampling devices and bypass valve. The system is ready to be connected to the vessels associated systems according to the specifications within this document. The installing party (shipyard, installation company etc) must design the ship specific installation and supply materials for piping, power feed etc.

The purpose of this document is to facilitate the design and installation phase.

The information given should be sufficient to produce necessary documentation to update the ship specific information for installation and approval by designated classification society.

The guide gives information that is relevant for planning the installation and how to furnish the vessel with the equipment on board. It contains information about basic requirements and which calculations that must be performed to secure performance of the system. It also contain information about how to integrate the system regarding piping, feedback signals and optional remote control solutions.

Components mentioned in this document can be found in the Flow chart and the dimension drawings included in Drawings on page 45. Components are identified by their ID, for example control valve (V201-8).

Note that the function and performance of PureBallast are dependent of the design and installation. Therefore, it is important that the design and installation is done according to the information given in this document.

2.1 Safety information

WARNING

Read chapter 1. Safety in PureBallast system manual.

This is a summary of installation information. For full details, see manufacturers instruction manuals for respective component.

Installation must be done by a fully trained professional installer.

• Electrical welding requirements:

Earth connection must be done according to the below. If not, the equipment can be seriously damaged:

• Earth connection must be made before any welding is done.

• Electrical welding: Connect the welding unit’s negative lead (work lead) to the component you will weld, close to the welding area.

• Follow local regulations for electrical installation and earthing

(grounding).

• Damages related to transport and installation should be recorded.

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2.2 Components overview

The key components in PureBallast are shown below.

1. Control valve

2. Flow meter

3. Sea water outlet

4. Backflush outlet

5. Control panel

6. Electrical cabinet

7. CIP liquid can

8. Filter

9. Sea water inlet

10. UV reactor

Not in illustration:

• System bypass valve

• Sampling devices (before and after treatment)

• Backflush pump (optional)

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2 IntroductionEN

3 Alfa Laval’s scope of supply The table below is a list of all PureBallast components and consumables delivered by Alfa Laval.

The list is compiled on the top level so that integrated components are not described, because they are already mounted at delivery. For example, the valves on the UVR are not described individually in the list, since they are already mounted as a part of the component.

Component ID Function

Main components

Skid, 1 piece Skid PureBallast is delivered as a skid with the major components preassembled.

Electrical cabinet, 1 piece EC

The controlling unit. It contains the main control panel, from which PureBallast is controlled. It also contains breaker and communication components such as PLC, switches for communication with remote interface, remote control panels etc, and terminals to connect signal cables to components and external systems.

The electrical cabinet is fitted with 3 lamp power supplies

(LPS).

Lamp power cable Per UVR:

UVR 170: One piece.

W211 Power cables between UVR and EC. Length specified in order.

Remote control panel, 0-2 pieces (optional)

Extra control panels to control and monitor the PureBallast system. Number according to order.

Valves

Bypass valve, 1 piece including switch box (Optional as part of scope of supply)

V212-31 Bypass valve to bypass the complete PureBallast system.

The valve is solely operated from the ISCS.

The switch box function as connection point for signal and control cables to the component.

Ancillary equipment

Sampling device, 2 pieces (Optional as part of scope of supply)

Q201-1 Q201-2

Sampling points to tap water for test of water before and after treatment.

Transformer (optional) If voltage does not meet the requirements, a transformer must be used. The transformer is recommended to give voltage in the higher range, as close as possible to 440

VAC.

System manual, 1 piece Information about operation, control system parameters, faultfinding and drawings.

Additional manuals or manuals as CD/USB according to order.

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Component ID Function

Consumables

CIP liquid, 15 liters The liquid is used during the CIP-process.

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3 Alfa Laval’s scope of supplyEN

4 Material and equipment supplied by installing party

Additional equipment is needed to install the PureBallast system, apart from components included in Alfa Laval’s scope of supply (according to order).

These needs to be designed, supplied and installed by the party responsible for the installation.

Examples of not included equipment:

• Electrical cables and signal cables to the ship’s ISCS (integrated ship control system).

• Pipes for ballast water, cooling water and CIP unit.

• Tubings for instrument air and deareation pipe.

• Ancillary equipment, for example sieve for stripping.

• Flange for sampling devices, if the device is included in scope of supply. If not, the complete sampling device.

• Bypass valve, if not included in scope of supply.

The installing party is responsible for selecting and purchasing the equipment according to specifications in the documents below:

• Connection list

• Quality specification for water

• Quality specification for instrument air

• Cable list for Control cabinet.

4.1 Material selection

Material must be in accordance both with requirements stated in this document and with the requirements of respective classification society. For example: The classification society DNV recommends that if stainless steels are intended to be used in ballast water operation; the steel should have a higher resistance to localized corrosion than the traditional 316 or 316L steels.

Used material shall be indicated in appropriate drawings. For more information, see Pipe dimensions and material on page 21.

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4 Material and equipment supplied by installing partyEN

5 Mechanical installation This section contains information relevant for planning the installation of mechanical components and connections to water and instrument air.

5.1 General requirements

The overall layout is defined by the Flow chart drawing and details for components are stated on the dimension drawings.

Installation prerequisites:

• The PureBallast must be installed in a machinery space on the vessel (engine room, pump room etc. ) with:

• relative humidity of max 100 %

• ambient temperature of 0 to 45º C

• Components must be placed in relation to pipe intersections as defined in the flow chart.

• Components must be properly suspended and supported.

• The installation of any component should not amplify vibrations to or from the hull.

• All piping connected to the PureBallast components (UV reactor, filter and

CIP module shall be properly self supported. No load shall be transferred to or from any major components.

• Components mounted on a surface, must be placed on a firm level surface.

• There must be free space available for maintenance. Size and required access area around main components are given in the dimension drawings.

• Installation must be done by a fully trained professional installer.

Welding requirements

Earth connection must be done according to the below. If not, the equipment can be seriously damaged:

• Earth connection must be made before any welding is done.

• Electrical welding: Connect the welding unit’s negative lead (work lead) to the component you will weld close to the welding area.

• Follow local regulations for electrical installation and earthing (grounding).

5.2 Skid

Installation prerequisites regarding mechanical installation.

Location

• This version of PureBallast is not Ex proofed, and must not be installed in areas where an explosive atmosphere may occur.

• PureBallast must be installed in a machinery space on the vessel (engine room, pump room etc) with

• maximum relative humidity of max 95 %

• ambient air temperature within the range of 0 – 45 °C.

• There must be free space available for maintenance. Size and required access area around main components are given in the dimension drawing.

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Mounting

• The skid must be secured so it withstands the forces of load applied when all components and piping are filled with liquid (850 kg) at the vessel’s maximum heeling degree.

• The component must be connected to protective earth. See earth nut "791” on the dimension drawing.

• Earth cables must have a cross-section large enough in relation to the supply cables from the vessel. Otherwise the equipment might be damaged during welding.

• No external components are allowed to be mounted on the skid.

• The skid must be fixated at the bottom and supported at the top. Use the four lower fixing holes in the skid structure to fixate it to the steel construction of the hull. Use at least two upper fixing holes of the ones encircled in the illustration. Note that only holes visible in the illustration are encircled.

5.3 Cabinets

This section covers installation guidelines for cabinets, regarding mechanical installation. For electrical installation, see section Electrical design.

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5 Mechanical installationEN

• Cabinets must be installed so that there is free space available to open the door.

• To prolong the lifetime of the cabinet, we recommend to install it in the coolest possible area in the range of 0 to 45º C.

• The electrical cabinet must be bolted, using the four positions (encircled) at the bottom and at the top. If bolted use the four fixing holes at the top and six at the bottom. Delivered vibration dampers must be used.

Cable lengths

Maximum cable length between electrical cabinet and skid is 30 meters.

5.4 Valves

The valves in PureBallast are operated by instrument air from the vessel’s instrument air system. Signal cables for control and feedback are connected to the electrical cabinet.

Installation prerequisites:

• The relation between the components is important. Valves must be placed in relation to pipe joint as indicated in the flow chart. Example: Filter bypass valve V201-3 must be installed before pipe 403 is joint to pipe 201.

• Valve dimension according to section Ship specific information.

• Valves can be installed on vertical, horizontal and sloping pipes.

• Valves shall be opened when installed. This is important to avoid that the rubber gaskets are squeezed and damaged during installation.

5.4.1 Bypass valve (V212–31)

It must be possible to bypass PureBallast, using a bypass valve. The valve is optional part of Alfa Laval´s scope of supply.

The valve control for V212–31 shall be connected to and operated by the vessel´s ISCS. Signal cables to control the component shall be connected

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Mechanical installation 5 EN from the ISCS and signal cables for status information shall be connected to the PureBallast control system, This is necessary to enable logging of when PureBallast is bypassed, which is required by the Ballast water convention.

The event log state the position of the bypass valve (open/close) and time for status change, not the reason for operating the valve. The reason, for example internal transfer, must be entered in the vessel´s ballast water log book. If GPS signal is not integrated, the position must also be entered in this log book.

Signal cables connected according to Electrical cabinet / Interconnection diagram and Electrical cabinet / Circuit diagram.

Extra bypass valves (not part of Alfa Laval’s scope of supply)

If PureBallast can be bypassed using other valves (apart from V212-31), these valves (or combination of valves) must be integrated to PureBallast control system, since all bypass cases must be logged, according to the IMO convention.

Additional bypass valves can be connected via individual hardwires or remote interface. See section External component signal integration

5.4.2 Vaccum breaker valve

If the height difference between the PureBallast system and the ballast water tank is over 10 meters, a vacuum breaker valve should be considered. A vacuum breaker valve (not part of Alfa Laval’s scope of supply) eliminates the risk of cavitation in the downward going part of pipe 201 after treatment.

The vacuum breaker valve should be installed at the highest point of the piping closely after control valve V201-8. See illustration below.

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Vacuum breaker valve installation

5.5 Ancillary equipment and functions

This section covers installation guidelines for ancillary equipment and equipment supplied by installing party for specific functions.

5.5.1 Sampling devices (Q201.1 and Q201.2)

The international ballast water convention requires means of sampling ballast water to make it possible to analyze the water. Sampling devices (Q201.1 and Q201.2) are optional part of Alfa Laval’s scope of supply.

Installation prerequisites:

• Installed in pipe 201 after treatment as close as possible to the overboard valve. We recommend installation before valve V201-8 to avoid contamination by untreated water from other pipes.

• Installed so that the there is no risk that the water taken from the sampling device is contaminated by untreated water from pipe 309, 404, 460.1, 460.2 or eventual ship’s pipes. If other pipes are connected to pipe 201, a check valve must be installed to avoid that untreated water is mixed with fully treated water in pip 201 where the sampling device is installed.

• If there are several discharge lines, it might be necessary with a sampling device on each.

• Installed in a straight pipe which is at least as long as the diameter. Within that length, no components may be fitted, for example, elbows and tees.

Ideally, the pipe should be vertical and as long as possible.

• Installed so it is accessible to take samples.

• Flanges for connecting sampling device must be installed before the pipe is coated.

• The device must be mounted with the sampling pipe opening pointing in the flow direction.

• The placement of sampling point is subject to approval by class society.

• Some class societies/flag states also require that sampling device Q201.1 is installed before PureBallast to allow sampling of untreated water.

5.5.2 Booster pump

Booster pump might be needed to achieve sufficient flow. Start and stop of booster pump are handled by signals sent from the control system. See External component signals via hardwire or remote interface.

Filter backflush pump (P309-1)

Booster pump to secure enough flow in pipe 309 for sufficient filter backflush according to Connection list, for Item/Connection 309.

5.5.3 Tank stripping equipment

Stripping can be performed to empty the ballast tanks. The stripping process is basically the same as a deballast process with the following difference: A stripping eductor (or a stripping pump) should be used to secure minimum flow in the system.

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Mechanical installation 5 EN

Stripping eductor

The use of stripping eductor is approved by the Norwegian Maritime Authority, and is included in the PureBallast type approval certificate. According to MEPC 67 “there is no need to develop guidance on stripping operations using eductors as it is not recommended that ballast water sampling be performed during stripping operations” (ref MEPC 67/WP.1 - 2.32).

Note the following:

• The eductor (not part of Alfa Laval’s scope of supply) must be installed before the PureBallast system

• If an eductor is used, driving water is used to get enough flow. We recommend that the driving water alone (without the ballast water flow from the tank) fullfils the minimum flow requirement for deballast operation. This will minimize the risk of shut down due to low flow when flow of ballast water is uneven.

• The driving water used in the stripping process, must be filtered from particles larger than approximately 5 mm. Filter should be placed before eductor and/or pump.

• Procedures to dispose of sediments from the sieve must be included in the vessel’s ballast water management plan.

Stripping pump

As an alternative to an eductor, the ballast water pump or a dedicated stripping pump can be used. If the pump used for stripping is different from the normal ballast water pump, it is possible to connect specific signal cables to be used when PureBallast request the start of the stripping pump.

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6 Pipe design This section gives information about pressure drop during ballast/deballast operations, and requirements to secure efficient backflushing. The information must be considered when the ballast water system is dimensioned.

This section also contains information about calculations that must be done to secure sufficient performance.

6.1 General requirements

The installing party is responsible for that the installation is done according to the documents below, including water and instrument air supply:

• All piping connected to the PureBallast components. No load shall be transferred to or from the skid.

• Inlet and outlet pipes must be correctly connected. They must also be pressure approved by a classification society or equivalent, or be tested under supervision of a classification society and/or at the ship yards pipe shop etc.

• Connecting pipes for pipe 201, 309 and 310 must be supported on the vessel’s side so that the pipes on the skid is not exposed to any moment.

6.2 Water requirements

Ballast water Temperature: -2 to 40 °C (liquid form)

Salinity: PureBallast water treatment system can treat water with all salinities.

UVR and filter preservation Temperature: 0–38 °C.

For details, see Quality specification / Technical and potable water on page 56

6.3 Flow requirements

BW pump and other pumps must give min and max flow according to the table below:

Media Flow / consumption

Flow range – (m3/h) – Pipe 201, ballast 32 – 85 Flow range – (m3/h) – Pipe 201, deballast 17 – 170 Flow range – (m3/h) – Pipe 201, stripping 17–56

Minimum flow (m3/h) – Pipe 310: Technical water / potable water

• Startup cooling water

• UV reactor and flushing volume

0.2 l/s (max 78 l)Max flushing volume 160 l

Minimum flow (m3/h) – Pipe 309, filter backflush 15

6.4 Pipe dimensions and material

The follow recommendations apply to pipe and valve dimensions:

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• Pipes shall be designed to carry the weight of the component and media.

• Pipe 201 (ballast water): It is not recommended to use plastic pipes closer than approximately two meters from the UV reactor. It UV light will affect the material and shorten its life time.

• Pipe 201(ballast water): We strongly recommend to tailor make a spool piece to connect to the filter. Make the prefabricated pipe deliberately shorter, and measure on site to make the perfect spool piece. Also see in section Filter.

• Pipe 309 (backflush): Pipe dimension MUST be increased to65 after V309–

1. Cone is not part of Alfa Laval’s scope of supply. This is required to secure reliable backflush operation.

• Pipe 309 (backflush): It is recommended to use as few bends as possible in pipe 309, to get as low pressure resistance as possible.

• Pipe 320, 321 and 460 (CIP pipes): Non-corroding material is recommended for pipes used for CIP liquid, due to low pH value.

• Pipes must be pressure approved by a classification society or equivalent, or be tested under supervision of a classification society and/or at the ship yards pipe shop etc.

• Also see information in section Material selection.

6.5 Pipe 201

It is recommended to install a siphon in pipe 201, from skid module, to always secure a water filled flow meter.

6.6 Valves outside PureBallast

During process, the PureBallast requires that a number of valves outside of PureBallast’s control are opened to lead the flow in a correct way. A request to open the valves can either be given to the operator in a popup message in the control system or automatically, if feedback signals are integrated via the remote interface or via hardwire. PureBallast requires feedback that the valves are opened. The feedback can either be done by confirming the popup or automatically in feedback signals are integrated. Without feedback, the process is cancelled. Valves are to be closed when requested by popup or when the request signal is redrawn (goes low).

Vessel’s valves leading flow to and from the PureBallast pipes below, must be opened and closed at request:

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6 Pipe designEN

Ballast process

Flow to PureBallast pipes:

• 201 (ballast water)

• 310 (UV reactor cooling water, during start-up).

Flow from PureBallast pipes:

• 201 (ballast water to tanks)

• 309 (backflush water overboard)

Deballast process

Flow to PureBallast pipes:

• 310 (UV reactor cooling water, during start-up)

• 201 (ballast water)

Flow from PureBallast pipes:

• 201 (ballast water overboard)

CIP process

Flow to PureBallast pipes:

• 310 (fresh water)

Flow from PureBallast pipes:

• 309 (Water from UVR and filter)

6.7 System pressure

The table gives a description of system pressure range for piping and instrument air.

Pressure (bar) Comment

Piping Max pressure for standard system: 6 bar.

Max pressure for high pressure system: (Optional):

10 bar.

Instrument air Range: 5.5 – 8.0 bar to operate valves and CIP pumps.

6.8 Pressure requirements for filter backflush

Minimum required pressure at filter inlet is 1.7 bar.

This pressure will overcome pressure drop for PureBallast componets and ensure filter backflush. For details, see table below.

NOTE

Pressure requirement only includes PureBallast’s components. Piping is not included.

If a backflush pump P309 is not used, pressure drop in pipe 309 (Δp309) must be calculated and added according to the table below.

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Pipe design 6 EN

Bar Comment

Pressure drop during ballast

0.2 Pressure drop for UV reactors and

PureBallast’s valves.

0.5

Max differential pressure over the filter during ballast operation. When the differential pressure reaches 0.5 bar due to dirt in the filter, a backflush is started automatically.

Pressure needed for backflush

1.0 Required pressure to clean the filter.

Δp309

If a backflush pump P309–1 is not used, pressure drop in pipe 309 must be calculated and added. This is vessel specific and must be calculated using required flow in pipe 309:

15 m3/h.

Total The ballast pump must deliver pressure at filter inlet, covering total pressure drop over PureBallast system.

Calculate backflush parameter setting (p304)

System pressure (PT201–16) needed for backflush is set in parameter p304 (pressure setpoint during backflush). If this pressure is not fulfilled when a backflush is triggered, the control valve V201–8 will operate to build up and maintain this pressure.

The parameter setting is depending on if a backflush pump is used or not.

Without backflush pump, the setting must be calculated according to below.

With backflush pump, a fixed value is used.

Setting without backflush pump = 1.0 + Δp309 Setting with backflush pump = 1.0

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6 Pipe designEN

7 Electrical design This section contains information relevant for planning the electrical installation and routing.

7.1 Power requirements

General power requirements

Nominal voltage and frequency

• 400–440 VAC, 50/60 Hz 3 phase. If voltage does not meet the requirements, a transformer can be used. The transformer is recommended to give voltage in the higher range, as close as possible to

440 VAC.

• Max Icu 50 KA.

• Power factor: 0.95.

• 24VDC - Remote control panel (optional).

IP rating Electrical cabinet: >IP44.

Skid: ≥ IP55.

Heat dissipation (transfer) – Electrical cabinet

Heat transferred to surroundings from electrical cabinet: 1.0 kW.

Component Power consumption (kW)

Electrical cabinet Power to UV reactor, electrical cabinet and filter motor.

Note: PureBallast only use power needed for treatment. PureBallast automatically regulates the lamp power between 50 and 100 % to secure the treatment efficiency.

Pump P309–1 (optional) For filter backflush water.

1.5

7.2 Installation requirements

PureBallast electrical cabinet shall always be powered on, so that the bypass valve activities can be logged.

Power shall be connected according to the following documents:

• Electrical system layout. Overview of components and cabling.

• Interconnection diagrams: Connections and connection points.

• Circuit diagrams (excerpts included in this document): Connections and connection points.

• Cable lists for electrical cabinet : Requirements for cables supplied by installing party.

• Dimension drawings: Information about earth points.

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7.2.1 Cables

• Power cable W1 to be connected from vessel’s switch board to electrical cabinet main breaker (Q1). Max Icu 50 KA.

• Lamp power cable W20A shall be connected from X9 contact on electrical cabinet to X20:A in junction box on the UV reactor. (Cables from junction box to lamps are pre-assembled.)

Note: Lamp power cable delivered from Alfa Laval must be used.

Note: The lamp power cable should not be winded. If it is to long, cut it before it is connected.

• Signal cables W10 – W14 (W15 optional) to be connected from skid to electrical cabinet sockets X10 – X14 (W15 optional). (W10 – W15 are preconnected on the skid.)

• Signal cables to all optional choices such as remote interface and external component signals must be connected.

• Signal cable for common alarm must be connected from electrical cabinet to ISCS according to drawing Electrical cabinet / Interconnection diagram on page 70.

• Dimension of cables must be within the cable gland range stated in the dimension drawings for respective component, stated on the dimension drawing.

• Electrical cables must be properly routed and supported according to applicable regulations.

• Cable entries to cabinets must be sealed, using the built in cable glands.

• Cabling shall be done according to specification in Electrical system layout on page 52, and the electrical drawings. This includes cable routing, cable types and cable marking to simplify identification and fault finding.

• EMC: Cables shall be peeled down to the cable shield. Connect shield to protective earth / screenbar, or to the EMC cable gland.

• Power cables shall be separated from signal and bus cables. Distance between them reduces electrical noise transfer.

• If placed on a cable rack, place power and signal cables on opposite sides.

• If cables are routed in tubes due to narrow space, the power and signal cables shall be routed in separate tubes.

• Components e.g. skid, cabinet and remote control panel (optional) must be earthed. The earth nut is indicated as “791” or “PE bolt” in the dimension drawings.

• Earth cables must have a cross-section large enough in relation to the supply cables from the vessel.

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7 Electrical designEN

8 Pneumatic design This section contains information relevant for planning the installation and routing of instrument air to the components that are pneumatically operated.

Instrument air must always be connected and should be connected to the following components:

• air filter / Filter regulator on skid

• bypass valve V212–31 (if part of Alfa Laval’s scope of supply).

The following drawings are needed for pneumatic design:

• Connection list: connection 501.

Pressure requirements, air consumption during operation and peak load (including time for peak load).

• Instrument air distribution.

Air distribution layout and connection dimensions.

• Quality specification / Instrument air.

The instrument air must be according to the quality specification. If not, components will be damaged and the system will malfunction. If instrument air is not available, a solution must be implemented to achieve air according to specification.

• Dimension drawings for the components that should be connected.

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8 Pneumatic designEN

9 Control system integration This section contains information relevant for planning integration for controlling PureBallast and signals for communication between PureBallast and external components, which are not part of Alfa Laval’s scope of supply.

This integration is normally done during installation.

The following optional integration is possible:

• Remote control panel

• Remote interface

• Power management

• External component signals

• Log box

• GPS.

For remote integration, please refer to the following documents:

• Design and installation guide

• Remote interface implementation guide.

• Log box installation guide.

Mandatory and optional integration

All bypass valves status must be integrated to be logged by PureBallast event log. All other integrations are optional.

9.1 Remote control panels

If included in order, 1 or 2 remote control panels (RCP) can be mounted at an optional location, for example the bridge, cargo control room or back office. .

Installation prerequisites:

• The remote control panel is mounted at an optional location

• The remote control panel is mounted according to drawing Remote control panel / Dimension drawing. Note the clearance area.

• The remote control panel is delivered as an IP protective cabinet, for installation on a stand. It is possible to remove the back cover to use the front as a mounting plate for installations in wall, worktop etc. See Remote control panel / Dimension drawing for details.

• Power cable W502.1 must be installed according to Electrical system layout.

• Use a 24 VDC power cable with minimum cross section of 0.75 mm2, preferably halogen free and flexible.

• Connect the power cable to terminal X1 in remote control panel.

Connect one remote control panel

Two cable options are available. Choose cable depending of the distance from the electrical cabinet (EC) and the remote control panel (RCP1).

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1. Max 100 m from EC: Ethernet. Shielded Cat 5 or better.

Connect the Ethernet cable to terminal X7 in EC and to terminal X2 in

RCP1.

2. Max 500 m EC: Optical fiber. Multi-mode fiber cable with LC connector. We recommend a cable with four or more cores are used to have spare cores if one is broken.

Connect the optical cable to switch in EC and to switch in RCP1.

Connect two remote control panels

Connect the second remote control panel (RCP2) with an Ethernet cable. Two options are available:

1. Max 100 m from RCP1: Connect terminal X2 in RCP2 with terminal X2 in RCP1. If X2 is occupied by another connector, connect the cable to RJ45 in switch.

2. Max 100 m from EC: Connect terminal X2 in RCP2 with terminal X7 in EC.

If X2/X7 is occupied by another connector, connect the cable to the RJ45 in the switch.

9.2 Remote interface

If included in order, PureBallast can be integrated to the vessel’s ISCS. Alfa Laval does not supply software or graphical user interface to handle PureBallast in the ISCS, only a communication standard to use for integration.

Programming and integration shall be done according to the document Remote interface implementation guide, which can be required from your local Alfa Laval sales office and

Integration process

It is important to start the integration process at an early stage, if PureBallast’s control system is to be connected to the vessel’s ISCS via remote interface.

Follow the basic steps described below:

1. As a base for the integration, the Remote interface implementation guide should be used. It contains all necessary information for the programming.

Also chapter 2 and 3 from the system manual contains valuable supplementary information.

2. Contact the automation firm in time to plan and realize the programming.

As a standard, we recommend that the customer integrate according to the list under heading Required implementation. But consider if more functions should be implemented to get a more user friendly system. Remember that later additions are always more expensive.

3. The integration should be tested by the automation firm according to the instruction under heading Preliminary communication and signal test. This should be done before commissioning.

4. The implementation must be done at the time of the commissioning. This is necessary for Alfa Laval to be able to test run the system from the ship’s control system as a part of the commissioning.

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9 Control system integrationEN

9.3 Power management system (PMS) integration

It is possible to connect the PureBallast control system to the vessel’s ISCS.

The purpose is to automatically handle power request from PureBallast to secure that enough power is available for each process. If not integrated, the operator must ensure this manually before operation. The communication is either handled by the remote interface (if the option is integrated) or via hardwires between the vessel’s ISCS and PureBallast’s control cabinet.

Consider if power management shall be used, to be able to plan cable routing and integration.

9.3.1 Power request process

Below, the overall power request process is described. The process is based on three signals types: power request, power granted and power running.

1. A process is started.

2. Before the UV lamps are lit, a power request is sent from the PureBallast control system to the ISCS.

3. After power check, the vessel’s power management system reserves power for PureBallast and then send power granted to the control system.

4. The ballast/deballast continues the start-up process and the UV lamps are lit. The control system confirms this by sending back a power running signal to confirm that the power is used.

5. When the process is stopped from the control system, the power running signal is deactivated.

Actual power needed for process is defined in section Power requirements on page 25.

9.3.2 Power management installation

The power signals are either hardwired or connected via remote interface.

There are three power signal cables:

Signal function ID in electrical drawings Power request PMS request Power granted PMS granted Power running PMS PB running

• If hardwired, connect power signal cables according to Electrical cabinet / Interconnection diagram and Electrical cabinet / Circuit diagram.

• If connected via the remote interface, connect power signals according to Remote interface implementation guide, which can be required from your local Alfa Laval sales office.

The signals are tested during commissioning.

9.4 External feed control signal

External feed control allows PureBallast to control the flow delivered from the vessel’s ballast water system by regulating either the ballast water pump via a variable frequency driver (VFD) or a valve installed before PureBallast.

When the flow in the system is too high, PureBallast’s control valve V201-8 will close to reduce flow. If the V201-8 closes more than a parameter set degree, 200000407-1-EN-GB 31

Control system integration 9 EN the control system sends a signal requesting the ballast pump to reduce the speed (and so the flow). When the flow is reduced, V201-8 can open.

When a backflush is done, V201-8 is closed under 70 % (defined in parameter p157). The external feed control signal is lowered to request less flow from the pump, so that V201-8 can open. Less flow is needed after the backflush, since the filter is clean.

Valve V201-8 operates (open/closes) in a range between a parameter set value (p157) and 100 %, where default is 70 %. Within this range, flow is regulated by V201-8 without cavitation.

See the illustration below for an example of operation of feed control.

Area 1

Parameter p156 was set to 2 s / % when process was started.

The curves for V201-8 (blue) and external feed (black) signal are chasing each other. The reason is that the request signal changes too fast which makes V201-8 compensate, which affects the signal in return.

Area 2 Parameter p156 is raised to 6 seconds which makes the request signal change more slowly, which results in a smooth movement of V201-8 when regulating the external flow.

9.5 External components signals

PureBallast can be completed with extra components, which are not part of Alfa Laval’s scope of supply. If so, signals must be connected to the control system via the control cabinet. It is also possible to simplify operation by integrating some signals between the ISCS and PureBallast. The communication is either handled by the remote interface (if the option is integrated) or via hardwires. In some cases, hardwire is the only alternative.

Many of these component signals must be activated in the control system page 5.2 – Main parameters 2. Output indicates signal from PureBallast and Input indicates signal from ISCS.

Consider which signals that shall be used, to be able to plan cable routing and integration.

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Installation requirements:

The signal cables are connected according to:

• Control cabinet / Interconnection diagram

• Control cabinet / Circuit diagram

• The notes about “how” in the table below

• Output signals are connected via potential free relays.

NOTE

A list of integrated signals shall be available at commissioning, to facilitate parameter settings for Alfa Laval commissioning engineer.

Components and signals:

Signal What Why How Bypass valve is open Input signal to

PureBallast that the system is bypassed.

All bypass cases must be logged. When any bypass valve is opened, ongoing process is terminated and the event is logged.

Status signals from all valves must be integrated to the control system. Valves can be connected in series, which means that they are handled as one regarding alarms and logging in PureBallast.

This signal will say that one of them have been opened, but not which.

If remote interface is implemented, feedback signals can be connected via the remote interface, which allows a great number of components to be connected.

Open circuit = Valve open. Signal cables connected according to Electrical cabinet / Interconnection diagram and Electrical cabinet / Circuit diagram.

Common alarm Output signal from PureBallast that there is an (any) active alarm.

An alarm shuts down ongoing process.

Integrated to indicate alarm in stations where PureBallast is monitored and controlled. Used if remote control panels (optional) are used. If remote interface (optional) is used, this is an alternative to alarm indication via remote interface.

Active alarm = Open circuit. If an alarm is already present and a new alarm is issued, the signal will go low for three seconds, and then be re-activated as high.

Common warning As common alarm, but for warnings. A warning is a notification of status change or a problem.

See common alarm.

Alternative to alarm indication via remote interface.

See common alarm.

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Signal What Why How Request ”Start BW pump” Output signal from

PureBallast to request start of the ballast water pump (not operated by PureBallast). After process is stopped, the signal goes low to request pump to be stopped.

Used in combination with Feedback (below).

If request and feedback signals are integrated, the operator does not have to confirm that the pump is started/stopped in a popup in the control panel during operation.

Request = Closed circuit. No request and request withdrawal = Open circuit.

Feedback ”Ballast water pump is running”

Input signal to PureBallast to confirm that the ballast pump is started.

See Request signal above.

Closed circuit = Pump running.

Heeling mode (internal transfer)

Input signal to PureBallast to to enter heeling mode. If activated, ongoing process is stopped and it is prevented to start a new process.

If integration of heeling command from ISCS is desired to automatically stop ongoing ballast/ deballast process for a healing operation.

Closed circuit = Heeling mode command. Only possible in standby, ballast or deballast.

External stop Input signal to PureBallast to stop ongoing process. If extra buttons (not part of AL scope of supply) to stop PureBallast are desired on board. The power is still on.

If extra button (not part of AL scope of supply) to stop a process is desired on board. The power is still on.

Open circuit = System stop command. Must be connected via hardwire

PureBallast running Output signal from PureBallast that a process is running.

If desirable to indicate that a PureBallast process is ongoing, for example with a light or in another system.

PureBallast running = Closed circuit.

9.6 GPS

It is possible to integrate signals from the vessel’s GPS to PureBallast. It is optional, but strongly recommended to connect GPS. The information is used to stamp events in the Event log with GPS position. Note that the IMO convention requires that it must be possible to verify position for ballast water treatment activities.

The GPS is integrated according to drawing Control cabinet / Interconnection diagram and Control cabinet / Circuit diagram.

Requirements: The GPS communication must use protocol NMEA-0183, version 4.00. The following settings must be used:

• Serial: RS422

• Baud rate: 4800 bps

• Parity: None

• Bits/characters: 8

• Stop bits: 1

The position data shall be sent as messages according to RMC, GLL or GGA.

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NOTE

If RMC is used, time and date in the control system is retrieved from vessel’s GPS.

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10 System approval Before a system is approved for usage and installation, a number of approvals are needed.

10.1 Alfa Laval’s responsibilities

The International Ballast Water Convention requires that all ballast water treatment system have a type approval, issued by the flag administration of the vessel. This flag type approval shows that the treatment system meets defined requirements and standard, with respect to the treatment function. The flag type approval is supplied by Alfa Laval for the intended flag of the vessel.

Alfa Laval will also obtain class type approval for PureBallast from the major classification societies. These class type approvals shows that the system scope of supply meet respective class rule requirements.

10.2 Installing party’s responsibility

Every PureBallast installation is unique and contains vessel specific solutions regarding location, piping, materials etc. Therefore it is necessary that each individual systems is approved, both regarding on board design and installation. Approval ensures that design and installation meets the general requirements of the convention and the specific standards of the applicable classification society and flag administration.

10.2.1 Approval planning

If the system is installed in a new building, the PureBallast installation should be part of the normal system approval on the vessel.

For retrofit installations, it is recommended that contact is established as soon as possible to get the design documentation approved so that the approval process does not delay the progress of installation, and to schedule an on board visit.

10.2.2 Design approval

Applicable classification society requires to review the on board design documents before installation, to approve that the on board design is in accordance with their rules and standards, and in compliance with Alfa Laval’s class type approval.

The design documents are to be submitted by the installing party or the ship owner, and should be approved before the installation is begun. The classification society will reply in an Approval letter.

Documents to submit

Each classification society has their own requirements regarding documents and information to be submitted. Always check with the classification society in question to verify their specific requirements.

It is recommended that the vessel specific documentation refers to the main drawings for PureBallast

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(flowchart, electrical system layout etc, to clarify connections etc), or that they are attached.

The list below contains the documents normally required for approval:

• On board locations indicating

- PureBallast system, ballast water sampling points, remote control stations.

• Interconnection details to the vessel

- Piping i.e. P&I, dimensions, material etc.

- Electrical i.e. block diagram, power supply arrangement, cable types

- Control and alarm system i.e. block diagram, PureBallast externally monitored equipment.

- Pneumatic interconnection.

• Identification of by PureBallast external bypass possibilities.

• Reference to the respective class type approval issued for PureBallast.

The convention specifies that an operations and technical manual specific to the ship shall be approved by the administration (or their recognized organization) and the information above should be enough to produce such manual.

10.2.3 Installation survey

The International ballast water convention requires a survey of the complete system after installation, to confirm that the system works as designed and that it fulfills the convention’s requirements. The survey can contain both ocular inspection and running of the system.

An on board survey is also normally required by both the classification society and the flag administration. Normally, the classification societies are recognized organizations by the flag administration, wherefore the classification society cover both roles. Completed survey results in an installation approval.

This is to be done after completed installation.

10.3 Alfa Laval commissioning

After installation, a commissioning shall be performed by Alfa Laval according to the Commissioning test form. A copy of the test forms can be required from your local Alfa Laval sales office.

The commissioning can also be coordinated and used as a part of the installation survey.

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11 On board installation planning This section contains information relevant for planning the on board installation. Instructions on how to mechanically install and adjust the components are included in the system manual, delivered with the…