Alfa Laval PureBallast Technical Manual.pdf

NOAA Ship Ronald H. Brown BWMS Technical Manual

Produced By:

2 0 2 P A C I F I C A V E . , B R E M E R T O N , W A , 9 8 3 3 7

N O A A S H I P R O N A L D H B R O W N B W M S T E C H M A N U A L

Table of Contents System Manual – PureBallast 3.1 Compact ............................................................................ Section 1

Estimated Operating Expenses ............................................................................................... Section 2

System As-Built Drawings ....................................................................................................... Section 3

- PureBallast 3.1 Compact

TECHNICAL MANUAL - SECTION 1

1 PureBallast 3.1 System manual

The PureBallast 3.1 is available in several sizes, defined by the system’s max treatment rated capacity (TRC). The TRC is included in the system name and the title of each system manual.

The basic document describing the system is the connection list, and the therein stated flow chart.

Those documents are included in the system manual, chapter 6, Installation description and drawings.

The tables in this document lists the PureBallast systems with reference to the system manual describing them and the connection list and flow chart defining them.

There are two versions of PureBallast. The USCG version use flow control to be compliant with USCG legislation. The USCG HP (high performance) have double reactor capacity which allows treatment at full capacity at all time.

1.1 Manual compilation

PureBallst system Manual no. Connection list Flowchart 85 Compact USCG 9028175 02 9018539 9015279 135 Compact USCG 9028177 02 9025974 9015279 170 Compact USCG 9028179 02 9018541 9015279 250 Compact USCG 9028180 02 9023101 9021414 300 Compact USCG 9027450 02 9023102 9021414

PureBallst system Manual no. Connection list Flowchart 85 Compact USCG HP 9028176 02 9025973 9015279 150 Compact USCG HP 9028178 02 9025975 9021414

Book No.9028495 02, rev 0 1

1.2 Main component makers 1 PureBallast 3.1 System manual

1.2 Main component makers

Reference is made to flow chart 9015279 and 9021414.

Flowchart legend Component Manufacturer Model (Size according to connection list)

Filter:

Automatic self-cleaning filter

Filtrex ACB-xx-yy, 20 µm mesh (xx=935 – 9200, yy= DN200 - DN600)

UV reactor UV reactor, 170 or, UV reactor Wallenius Water UV reactor, 300

UV lamp Wallenius Water Medium pressure UV lamp, 3 kW Lamp sleeve Wallenius Water Synthetic Quartz 9000738 02

QT201-50 UV sensor

UV-TECHNIK,

IL Metronic Sensortechnik GmbH

SUV 20.2 Y2 C 40° 1000 W/m²

TS201-60 Temperature, switch JUMO Bimetal Temp. Switch 60.8301

TT201-33 Thermometer, resistance JUMO Dtrans Temp. probe 90.2815

LS201-29 Vibration limit switch PEPPERL+FUCHS Vibracon LVL-A7

Valves:

-Siemens SIPART PS2, Positioner

- Air Torque Spa AT range, ActuatorV201-8 Flow control valve

- ARI Armaturen ARI –GESA, Lugged valve

- PEPPERL+FUCHS NBN3…, Inductive pos. sensor Air Torque Spa AT range, ActuatorV201-3, -9, -19 & -32

Filter inlet, outlet, by-pass, & Start up cooling valve - ARI Armaturen ARI –GESA, Lugged valve

- Air Torque Spa AT range, Actuator V309-1 Filter backflush valve - ARI Armaturen ARI –GESA, Lugged valve

- Rotech ALB ACR3.., Pos. switch box

- Air Torque Spa AT range, Actuator

- Rotork ILG-D series, Handwheel

V212-31 By-pass valve

- ARI Armaturen ARI –GESA, Lugged valve Flow meter:

FIT201-1 Flow transmitter Endress+Hauser Promag 50W1F System and diff.

pressure Transmit-ter:

Flowchart legend Component Manufacturer Model

PT201-15

& -72

Pressure transmitter JUMO MIDAS S07

Cleaning in Place (CIP) components

2 Book No.9028495 02, rev 0

1 PureBallast 3.1 System manual 1.2 Main component makers

Flowchart legend Component Manufacturer Model (Size according to connection list)

V310-1, V320-2, V460-1, -2, -3, -4, -5 & V571-1

Valve SMC VNB

P460 Pump Tapflo T50, Pneumatic pump P320-1 Pump SMC PB1013A, Pneumatic dosing pump LS320-3 Level sensor PEPPERL+FUCHS CBN10.., Capacitive sensor

T320 CIP cleaning liquid Alfa Laval Alpacon Descalant Offshore

Electrical cabinet

(EC):

Electrical cabinet Alfa Laval EC 3.1

Book No.9028495 02, rev 0 3

Table of Contents

Safety 1

System Description 2

Operating Instructions and Control System Description

Parameters 4

Alarms and Faultfinding 5

Installation and Drawings 6

Service Manual 7

Spare Parts Catalogue 8

PureBallast: Ballast Water Treatment System

Only foreseeable conditions have been taken into consideration. No warnings are given for situations arising from unintended usage of the system components and tools.

Marine & Diesel Equipment

Printed 2018

Alfa Laval reserves the right to make changes at any time without prior notice.

Any comments regarding possible errors and omissions or suggestions for improvement of this publication would be gratefully appreciated.

Copies of this publication can be ordered from your local AlfaLaval company.

Published by: : Alfa Laval Tumba AB SE-147 80 Tumba, Sweden Telephone: +46 8 530 650 00 Telefax: +46 8 530 310 40

© Alfa Laval Tumba AB

Chapter: 1. Safety System manual — PureBallast 3.1 85 Compact

USCG

Book No. 9028175 02, rev. 3

Published By:

Alfa Laval Tumba AB SE-147 80 Tumba, Sweden

Telephone: +46 8 530 650 00

Telefax: +46 8 530 310 40

This publication or any part there of may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Tumba AB.

Contents

1 Safety information 5

1.1 Introduction 5

1.2 General safety information 5

1.3 Specific safety information 5

1.4 Personnel requirements 7

1.5 Warning signs used in the manual 7

2 Environmental issues 9

2.1 Unpacking 9

2.2 Other materials 9

1 Safety information

This chapter contains general safety and environmental information, personnel requirements and explanations of symbols used for the PureBallast system.

1.1 Introduction

This section contains safety information. This information must be read and understood before the system is installed, operated and maintained.

1.2 General safety information

The following general safety information apply:

• The PureBallast system is not Ex proofed and must not be installed in areas where an explosive atmosphere may occur.

• Use the equipment only for the purpose and parameter range specified by Alfa Laval.

• Use only Alfa Laval genuine spare parts.

• Always read and follow the documentation that is included in shipment of components and spare parts regarding handling, safety and disposal.

• Mobile cell phones must not be switched on within an area of 1 meter from an open cabinet door.

• Before installation, read applicable sections in chapter 6. Installation instruction and drawings.

• Before operation, read the Preparations and conditions section for applicable instructions in chapter 3. Operating instructions and control system description.

1.3 Specific safety information

The following safety information apply for the areas and components below. This information is also stated in the Preparations and conditions section for applicable instructions.

Maintenance safety items

• Before maintenance, read the Preparations and conditions section for applicable instructions in chapter 7. Service manual. Essential safety information is stated before instruction to routines that might involve any danger.

• Before maintaining the PureBallast system, the following valves must be locked in closed position: V201-3 and V201-8.

Book No.9028175 02 5

1.3 Specific safety information 1 Safety information

• The skid and components (if detatched) must be lifted using correct lifting tools (such as a fork-lift truck, a crane) and tackle with a load capacity greater than the weight of the component.

See the Technical data section on page for information about weight. Any complementary lifting instructions must be followed.

• Always disconnect the PureBallast system from the power supply before disassembling, and secure it from being switched on.

UV reactor safety items

• UV lamps and quartz sleeves are fragile and can easily become damaged. Exercise great care when handling them. Do not apply vibrations or shock to the UV lamp. This can cause breakage and shorten lamp life. Broken glass/quartz can also cause severe cuts. Always use protective eye glasses and clean cotton gloves when handling UV lamps and quartz glass sleeves. See Material data sheet / UV lamp in chapter 6.

• UV lamps are stored according to local regulations.

• Before installation, check that the UV lamps and quartz sleeves are not broken.

• Depressurize UV reactor and allow equipment to cool down completely before disassembling.

Hot water may escape from the reactor when removing the drain plug.

• Never handle UV lamps before they are completely cooled down. A hot UV lamp is under high internal pressure, and the risk of bursting exists. A hot lamp could also cause a burn if it is touched.

• The reactor must not be under pressure when dismounting the UV lamps.

• UV lamps radiate ultraviolet radiation when lit. Only operate the UV lamp when correctly installed inside the reactor with end caps properly closed.

• UV lamps contain a small amount of mercury (less than 0.2 grams per lamp) and must be handled and disposed of with care. Used lamps UV can be handled and disposed of in the same way as fluorescent lamps. Please refer to national regulations. If a UV lamp has accidentally been broken, mercury could be spilt. Remove mercury with a special tool such as a syringe (or use pure sulphure to bind the mercury for easy collection).

• Do not allow mercury to come in contact with your eyes or skin. Do not inhale mercury fumes.

• Free mercury must be kept in an airtight bottle, and must be disposed of according to national regulations.

• In case of having inhaled mercury fumes, consult a doctor and follow medical instructions.

• Operation and/or manual start of the UV lamps is only allowed when there is water in the reactor (indicated by level switch LS201-29), and the water temperature is below 60 °C. Improper operation could seriously damage the equipment and injure personnel.

• Manual operation of LPS, may only be performed after cable connection. If not hazardous situation may arise which, if not avoided, will result in death or serious injury.

• Before maintenance of the electrical cabinet: Switch off the PureBallast system and disconnect it from the power supply. The electrical cabinet contains a fan, which can cause injury if in operation.

Flow meter safety items

• Potential hazard / Grounding: The flow meter must be earthed.

6 Book No.9028175 02

1 Safety information 1.5 Warning signs used in the manual

Valve safety items

• Actuators must not be pressurized at any time during installation as it may result in injury.

• Lock valve in closed position before maintenance.

CIP safety items

• CIP liquid: Risk for eye and skin irritation. Avoid contact with eyes and wear protective gloves. Follow general rules when handling of cleaning agents regarding ventilation, personal protection etc.

• Always wear protective eye glasses and gloves while working on the pump.

• See Safety data sheet / CIP liquid in chapter 6.

Ancillary component safety items

• Control panels may only be cleaned when set in wipe mode. This is to prevent unintended functions from being triggered by buttons pressed during cleaning.

• Temperature switch, temperature transmitter and level switch. The external surface may be hot.

Care must be taken to avoid possible burns.

1.4 Personnel requirements

The PureBallast system must be operated, installed, maintained and repaired by persons trained for respective type of work. All persons using and working with the system must know the emergency stopping procedures.

Personnel installing, maintaining or repairing components must be of one of the following categories:

• Skilled person: A person with technical knowledge or sufficient experience to perform the tasks at hand and to enable him or her to perceive risks and to avoid hazards which electricity/mechanics can create.

• Instructed person: A person adequately advised or supervised by a skilled person to enable him or her to perceive risks and to avoid hazards which electricity/mechanics can create.

• Alfa Laval service engineer: A person with knowledge about the PureBallast system. Alfa Laval service engineer can set parameters and repair intrinsically safe apparatuses.

In some cases special skilled personnel may need to be hired, like electricians and others. In some of these cases the personnel has to be certified according to local regulations with experience of similar types of work.

1.5 Warning signs used in the manual

D! ANGER

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Book No.9028175 02 7

1.5 Warning signs used in the manual 1 Safety information

! WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

! CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTE

NOTE indicates a potentially hazardous situation which, if not avoided, may result in property damage.

8 Book No.9028175 02

2 Environmental issues

This section contains general rules regarding environmental issues. However, local rules and regulations should be consulted for detailed handling of each material.

2.1 Unpacking

• Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps.

• Wood and cardboard boxes can be reused, recycled or used for energy recovery.

• Plastics should be recycled or burnt at a licensed waste incineration plant.

• Metal straps should be sent for material recycling.

2.2 Other materials

• Rubber and plastics should be burnt at a licensed waste incineration plant. If not available they should be disposed to a suitable licensed land fill site.

• Metal parts should be sent to a licensed handler for material recycling.

• Seal rings should be disposed of in a licensed land fill site. Check the local regulations.

• Worn out or defected electronic components should be sent to a licensed handler for material recycling.

• The operator panel contain the following components with substances that might be hazardous to health and the environment: lithium battery, electrolytic capacitor and display. They shall be recycled according to local regulations.

• Used lithium batteries from the control unit are considered hazardous waste and should be disposed of accordingly.

• Used UV lamps can be handled and disposed of in the same way as fluorescent lamps. Please refer to national regulations.

• Used quarts sleeves should be disposed of as ordinary glass.

Book No.9028175 02 9

Chapter: 2. System description

USCG

SE-147 80 Tumba, Sweden

Telephone: +46 8 530 650 00

Telefax: +46 8 530 310 40

This publication or any part there of may not be reproduced or transmitted by any process or means without prior written permission of Alfa

1 Introduction 5

1.1 System overview 5

1.2 Components overview 6

1.2.1 Item numbers 7

1.3 Abbreviations 7

2 Process overview 9

2.1 IMO and USCG mode 9

2.1.1 When to use the different modes 9

2.1.2 Flow control and power optimization 9

2.2 Start-up 12

2.3 Ballasting 13

2.3.1 Backflush 14

2.3.2 CIP process 15

2.4 Deballasting 16

2.4.1 CIP process 16

2.5 Tank stripping 17

2.5.1 Stripping after-treatment (CIP) 17

2.6 Ballast water handling in the event of

malfunction 18

3 System components description 19

3.1 UV reactor 19

3.1.1 UV reactor working principle 19

3.1.2 UV reactor description 19

3.2 Filter 21

3.2.1 Filter working principle 21

3.2.2 Filter description 21

3.2.3 Backflushing for different dirt loads 23

3.3 CIP components 25

3.3.1 CIP working principle 25

3.3.2 CIP components 25

3.4 Electrical cabinet 26

3.5 Control system 27

3.5.1 Main control panel 28

3.5.2 Remote control panel (optional) 28

3.5.3 Remote interface (optional) 29

3.5.4 Power management (optional) 29

3.6 Main valves 29

3.7 Flow meter 30

3.8 Pressure transmitter 30

3.9 Sampling devices 30

1 Introduction

This contains general information about the PureBallast system and its components.

1.1 System overview

The PureBallast system is an integral part of the vessel’s ballast water system, on the discharge side of the vessel’s ballast water pumps. During ballast operation, the water is led through the filter, which removes larger particles and organisms, and then to the UV reactor, where the water is treated with UV light. During deballast, the water is led the same way, but the filter is bypassed.

Flow is monitored by the flow meter and regulated by the control valve. Note that full treatment requires treatment both during ballast and deballast.

After operation, the UV reactor is cleaned by a CIP (cleaning-in-place) process.

The complete system and ongoing processes is controlled and monitored from the electrical cabinet. Control can also be performed from remote control panels and the ship’s ISCS, via the remote interface if connected.

The bypass valve makes it possible to bypass the entire system, for example to secure ballast operation if the system is not functioning. The valve is controlled from the ISCS (integrated ship control system). When opened, an alarm is issued and an event is written to the event log in the control system, and the system is prevented from starting or shut down if opened during process.

It is allowed to open the bypass valve during a heeling process (if a heeling signal is sent to PureBallast) without the system being shut down. In that case, a heeling event is also written to the event log explaining why the bypass valve was opened.

Book No.9028175 02 5

1.2 Components overview 1 Introduction

1.2 Components overview

The key components in PureBallast are shown below.

2 Overview

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: Bypass valve, sampling devices and backflush pump (optional)

6 Book No.9028175 02

1 Introduction 1.3 Abbreviations

1.2.1 Item numbers

System components are identified by unique item numbers, for example “FT201–1” for the flow meter.

1.3 Abbreviations

The table below is a list of abbreviations used in this manual.

Abbreviation Explanation

AOT reactor Previous name for UV reactor. AOT stands for Advanced oxidation technology.

CIP Cleaning in place

I/O Input/output (Describes a program or device handling data)

ISCS Integrated ship control system

IMO International Maritime Organization

LPS Lamp power supply

MCB Motor circuit breaker

PLC Programmable logical controller (PureBallast control system)

UV Ultra violet

UV reactor The main component, where the water is treated using UV light.

UVR UV reactor

1.3 Abbreviations 1 Introduction

2 Process overview

This section gives an overview of the main processes performed by PureBallast. Each process is illustrated using the control system overview page, with relevant pipes marked.

2.1 IMO and USCG mode

The PureBallast have two process modes: IMO mode and USCG mode. These different modes set the system to run to be compliant with regulations in USA (USCG mode) or the rest of the world (IMO mode).

Before starting a process, the operator must choose if the operation shall be run in IMO or USCG mode, depending on location and destination. Mode is set using a function button in the control system.

2.1.1 When to use the different modes

2.1.1.1 IMO

IMO mode is used for

• ballast when the destination is outside US waters.

• deballast outside US waters.

IMO mode can also be used if the vessel has an AMS and is operating under an extended compliance date authorized by USCG.

2.1.1.2 USCG

USCG mode is used for

• ballast when the destination port is within US waters, regardless of starting point.

• deballast within US waters.

2.1.2 Flow control and power optimization

To ensure full treatment of the water, allowed flow and power to the lamps are controlled depending on how clean the water is. Clean water (high UV intensity) allows high flow and low lamp power, and dirty water requires lower flow and higher lamp power to treat the water according to requirements.

The illustration below show flow control and power optimization depending on the UV intensity, together with the compliant limit.

2.1 IMO and USCG mode 2 Process overview

IMO mode

UVI_IMO300

USCG mode

UVI_USCG300

10 Book No.9028175 02

2 Process overview 2.1 IMO and USCG mode

Compliant limit: When UVI falls below compliant limit, the operation continues but does not fulfill the type approval certificate. A warning and a common alarm is issued and a log is written to the event log. The operator must take action according to the ballast water plan to stop the operation or to continue operation and not comply with type approval certificate.

2.1.2.1 Flow control

In USCG mode, the flow is regulated to be as high as possible to fully treat the water. Between UVI value a and b, the flow is regulated be between 50 % and 100 % of full flow capacity. The higher UVI value (cleaner water) the the higher flow.

In IMO mode, the flow is always 100 % above compliant limit. But when UVI falls below the compliant limit, the flow is decreased to maximum 50 %.

2.1.2.2 Power optimization

The purpose is to save power by dimming the lamps to minimum power required to fully treat the water. Power is regulated when the UVI in the water is between c and d (see graph above). The power output is regulated between 50 % and 100 % of full power.

2.1.2.3 Power optimization during special

conditions

• Start-up and the first two minutes of ballast/deballast: The UV lamps are lit to 100 % to ensure treatment before values from the UV sensor are stable.

• Stop: UV lamps are lit to 100 % for 10 seconds before they are stopped. This will prolong the life of the lamps.

• Stripping: The lamps are lit to 100 % during the complete stripping process. This to have an efficient treatment of the deballast water when it is mixed with the driving water, which has not been treated at ballast.

• Low UV intensity: See Flow control above.

• Broken UV lamp: See Operation with broken UV lamp below.

2.1.2.4 Operation with broken UV lamp

If a UV lamp breaks, the ongoing process continues but does not fulfill the type approval certificate.

The flow is decreased to 65 % in IMO mode or 50 % in USCG mode of max flow and the UV lamps are lit to 100 %. This is done so that the treatment shall correspond to the type approval requirements. A warning and an additional common alarm is issued and a log is written to the event log.

If a lamp breaks during operation, the operator will have to decide to stop the operation or to continue operation and not comply with type approval certificate. After process is finished, it will not be allowed to start a new process.

Book No.9028175 02 11

2.2 Start-up 2 Process overview

2.2 Start-up

Ballasting and deballasting begins with a start-up phase. During start-up, the UV lamps are warmed up for 90 seconds.

The temperature transmitter and level switch secure that there is water in the UV reactor and that the UV lamps are sufficiently cooled. If the temperature in the UV reactor reach 45 °C, cooling water (technical water / potable water) is pumped through the UV reactor to secure that the UV lamps are not overheated. If that occurs, an alarm is issued and the system is shut down.

2 startup 170

Ballast and deballast start-up

12 Book No.9028175 02

2 Process overview 2.3 Ballasting

2.3 Ballasting

After the start-up, when the lamps are ready, the operator is requested to start the ballast pump.

The ballast water is pumped from the sea chest to the filter, that removes larger particles and organisms. This also reduces the amount of sediment build-up in the ballast water tanks. The organisms and sediments caught in the filter are flushed overboard via regular filter backflush operations. The water is finally led to the UV reactor, which produces radicals and UV light that breaks down and neutralize the organisms.

2 Ballast 170

Ballasting

Book No.9028175 02 13

2.3 Ballasting 2 Process overview

2.3.1 Backflush

To keep the filter clean, it is automatically backflushed. The backflush is performed during ongoing process without interrupting the ballasting process. When a ballast operation is stopped, a backflush is performed before the system comes to a full stop. The water used for backflushing is returned to the sea directly at the ballasting site.

2 backflush 170

Filter backflush

14 Book No.9028175 02

2 Process overview 2.3 Ballasting

2.3.2 CIP process

After a ballast operation, a CIP (cleaning-in-place) process is performed to clean the UV reactor.

This process can either be performed immediately after a ballast operation or started within 30 hours counted from when the process was started. Note, that it is possible to perform new processes during these 30 hours.

We recommend that a CIP process is performed within the same ecological zone or in international waters (200 nautical miles from the base line). This will avoid untreated water from the UV reactor and the filter to enter a different ecological zones.

The UV reactor and filter are rinsed with technical water / potable water. Then, the UV reactor is filled with biodegradable CIP liquid, which is circulated for 2 minutes every 15 minutes during the 6 hours CIP process to remove seawater scaling from the quartz sleeves and UV sensor glass.

After the cleaning is finished, the UV reactor is filled with technical water / potable water to prevent scaling, algae growth etc.

2 CIP 170

CIP circulation during CIP process.

Book No.9028175 02 15

2.4 Deballasting 2 Process overview

2.4 Deballasting

Deballast use the same start-up process as during ballast. After the start-up, when the lamps are ready, the operator is requested to start the ballast pump. The water passes through the UV reactor, but the filter is bypassed since the water has already been filtered during ballasting. The reason for treating the water a second time during deballasting is to secure that the treatment is fully effective. The minor part of the organisms, which were only injured during ballast, will be rendered totally harmless during the deballast.

The flow control and power optimization functions the same way as during ballasting.

2 deballast 170

Deballasting

2.4.1 CIP process

As after ballasting, a CIP process is performed after a deballast operation. If only deballast operations has been performed since the last CIP process, the filter is not filled with technical water / potable water during the CIP cycle, since the filter has not been used.

16 Book No.9028175 02

2 Process overview 2.5 Tank stripping

2.5 Tank stripping

Stripping can be performed to empty the ballast tanks.

After the start-up, when the lamps are ready, the operator is requested to start a stripping pump.

Pump used can either be a dedicated stripping pump or a ballast water pump. The flow controll is controlled to be 1/3 of certified flow but power optimization is not active. Number of UV reactors used during stripping is set in a parameter, to adapt to lower flow during stripping.

If a stripping eductor (not part of Alfa Laval’s scope of supply) is used it must be installed before the PureBallast system. Minium flow for deballast water includes the driving water.

Also, the water used in the stripping process, must be filtered from particles larger than approximately 5 mm. The sieve is not part of Alfa Laval’s scope of supply. Procedures to dispose of sediments from the sieve must be included in the vessel’s ballast water management plan. See also chapter 3. Operating instructions and control system description, section Stripping.

2 deballast 170

Stripping

2.5.1 Stripping after-treatment (CIP)

After stripping operation, a cleaning cycle is performed to clean the UV reactor. It is performed in the same way as described for the ballasting process. If only stripping operations has been performed since the last CIP process, the filter does not need to be filled with technical water / potable water at the end of the cycle, since the filter has not been used.

Book No.9028175 02 17

2.6 Ballast water handling in the event of

malfunction

2 Process overview

2.6 Ballast water handling in the event of malfunction

PureBallast is equipped with a bypass valve. The valve can be used in case of emergency to secure the ship, by allowing ballast water operations (ballast, deballast and heeling) without involving the ballast water treatment system. The valve is controlled by the ISCS, not PureBallast’s control system, but all bypass valve activities are logged in the event log. Such valve is required by the International Convention for the Control and Management of Ship’s Ballast Water and Sediments 2004.

If the system malfunction in connection with general cargo operation, ballast and deballast operations should be avoided.

The procedures concerning emergency and malfunction of the ballast water treatment system should be implemented in the ships Ballast water management plan.

18 Book No.9028175 02

3 System components description

This section gives an introduction to the most important PureBallast system components and their functions in the system.

3.1 UV reactor

The main part of PureBallast is the UV reactor

3.1.1 UV reactor working principle

The main treatment process take place inside the UV reactor, where the micoro organisms in the water is exposed to UV light, which renders them completely harmless.

The UV light breaks the DNA chain resulting in an internal connection (T+T) making it impossible for the micro organisms to reproduce.

2 UVtreatment

Destruction of DNA

There are no chemical substances added to the process, and there are no toxic residuals created.

Since the water is not affected chemically there are no environmental impact, and the process does not influence corrosion in any way.

3.1.2 UV reactor description

The UV reactor consist of the reactor, sensors and valves for technical water / potable water and CIP liquid, as shown in the illustration below. The UV reactor accommodates 6 medium-pressure UV lamps (3 kW each). The UV lamps are enclosed in individual quartz sleeves.

Book No.9028175 02 19

3.1 UV reactor 3 System components description

The UV lamps get very warm, so they must be cooled whenever they are lit. To secure that there is water in the reactor when the lamps are lit, the reactor is equipped with a level switch. The level switch also secures that enough CIP liquid is pumped into the reactor during the CIP process. To secure that the lamps are adequately cooled by the ballast water, each UV reactor has a threefold heat protection:

• The temperature transmitter sends information to the control systemat. The UV reactor is shut down at 60 °C.

• The temperature transmitter sends information to a safety relay in the LDC. The UV reactor is shut down at 62.5 °C.

• The temperature switch automatically shuts down the UV reactor at 65 °C.

A UV sensor monitors the UV lamp efficiency in relation to the water transmittance inside the UV reactor. Based on this input, the power to the UV lamps are regulated between 50 and 100 % of full capacity. To save power, the UV lamps will be dimmed to lowest possible level, where they are still effective.

Note, that the lamps are always lit with full effect during start-up and the first two minutes of full ballast to secure full efficiency before the UV sensor have a stable reading of water transmittance.

The lamps are also turned up to full effect for 10 seconds before stop and normal shut down.

This method will prolong the UV lamp life time.

The illustration below show the UV reactor with its main components.

2 AOT

UV reactor with UV lamps

1. Sea water outlet

2. Temperature transmitter

3. UV lamps

4. Sea water inlet

5. UV sensor

6. Level switch

7. CIP pipe

20 Book No.9028175 02

3 System components description 3.2 Filter

3.2 Filter

3.2.1 Filter working principle

The filter is a fully automatic self-rinsing component, equipped with a filter element to remove particles and organisms from the ballast water flow. An optional backflush pump can be mounted to secure correct flow in the backflush pipe 309.

3.2.2 Filter description

2 FilterFiltrex

1. Geared motor

2. Relief valve

3. Backlflush outlet

4. Backflush pump

5. Drain plug

6. Ballast water inlet

7. Adaptor plate to change flange standard and/or diameter (in some systems)

8. Junction box (Not included in the skid version of PureBallast)

9. Ballast water outlet

Book No.9028175 02 21

3.2 Filter 3 System components description

To secure efficient filtration, the filter performs a self-rinsing backflush operation at time set intervals or when triggered by indication of dirt in the filter. Pressure drop over the filter is monitored by pressure transmitters before and after the filter. Dirt is detected by an increased differential pressure drop caused by particles in the filter. When the differential pressure reaches a parameter set value, an automatic backflush operation starts.

The backflushing does not interrupt the filtration process, since only a part of the filter element area is cleaned. The areas that are not cleaned at a specific time continues the filtration of the ballast water. It is also possible to start backflush manually from the control system.

Step 1: Filtration The water enters from the inlet flange (A) and flows through a pre-filter and then through the filter element (1) from the inside to the outside. The filtered dirt is trapped on the inside of the filter element. The filtered water passes the chamber (D) and out from the filter through the outlet flange (B) and is lead to the UV reactor.

During filtration, the filter operates as a static filter, there are no moving parts and the motor (2) is not running and the nozzle (3) is standing still.

A. Inlet B. Outlet D. Chamber

1. Filter element

2. Motor

3. Nozzle (standing still during filtration)

2 FilterFiltrationFtrx

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3 System components description 3.2 Filter

Step 2: Backflush At backflush, the motor (2) starts to drives the nozzle (3). At the same time, the backflush valve (6) opens.

The nozzle rotates inside the filter element. The dirt on the inside of the filter element (1) is cleaned by a high-efficacy backflush flow in front of the nozzle. The backflush flow uses filtered water from the chamber (D) to clean the filter from the outside to the inside.

The water, together with the dirt, is lead via the nozzle through the duct (5) and out via the backflush valve (6).

All areas of the filter element that is not in front of the nozzle are filtering the water as in step 1: The water flows from the inlet (A) through the filter element and out through the outlet (B).

When the backflush is done (after approximately 20 seconds), the motor stops and the backflush valve is closed. The filter then goes back filtration with full flow to the ballast tank (no flow used for backflushing.

If a new backflush is triggered within time set in parameter p302, the filter will perform a continuous backflush for time set in parameter p303.

A. Inlet B. Outlet D. Chamber

1. Filter element

2. Motor

3. Nozzle seen from the side (rotating during backflush)

6. Backflush valve

2 FilterBackflushFtrx

3.2.3 Backflushing for different dirt loads

Below, the filter pressure drop over time (pfilter) is illustrated for different dirt load situations in the filter. Different dirtload depends on the water condition, which means that “normal” condition regarding filter backflush depends on the water conditions.

3.2.3.1 Low dirt load

In water with low dirt load, the backflush cycle is started by the time trigger (default: every 30 minutes). As long as the pressure is below the differential pressure trigger (0.50 bar), there is no need for the pressure triggered backflush. See examples below.

6 Dirtload1 Filtrex

Book No.9028175 02 23

3.2 Filter 3 System components description

6 Dirtload2 Filtrex

3.2.3.2 Medium dirt load

In more dirty waters the backflush cycle will be triggered when pfilter reaches 0.50 bar, which indicates dirt in the filter.

After each backflush, the backflush timer is reset. The filter will be backflushed again after 30 minutes or when ∆pfilter reaches 0.50 bar, whichever comes first.

In the example below, three backflushes are triggered due to high differential pressure over the filter.

After that, there is not so much dirt build up, so the next backflush is performed after 30 minutes.

6 Dirtload3 Filtrex

3.2.3.3 Heavy dirt load

In conditions with heavy dirt load, the system can perform continuous backflushes to keep the filter clean. If the filter preforms one backflush, and the differential pressure trigger a new backflush within a parameter set time, the filter will perform continuous backflushes for a parameter set time to clean the filter thoroughly. After the continuous backflush time, a check is made to make sure that the differential pressure is below 80 % of the backflush trigger pressure. If not, the backflush continues until this is true.

Also, the 0.50 limit might be exceeded. In this case the self rinsing cycle will run continuously until the problem is solved and the pressure has returned below 0.50 bar. It is OK that the flow momentarily fluctuates in an irregular curve, but it is important that the curve stabilizes.

In the example below, a series of backflushes are performed (approx. every 4 minute). After that the pressure rises above 0.50 where the filter is backflushed constantly. After that, the normal control is resumed, where the filter backflush is triggered by pressure (2 times) or by time (last backflush in the example.

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3 System components description 3.3 CIP components

6 Dirtload4 Filtrex

3.2.3.4 Long term dirt build-up

Over time, the filter element will undergo a long term build-up of particles that are not removed by backflushing. One effect of this is that “normal” pressure will increase over time. Therefore, the maintenance schedule state that the element shall be inspected and manually cleaned once a year.

The extent of the long term dirt build-up is dependent on the water conditions. In the great majority of cases this will not cause any problems – cleaning once a year is enough. But in exceptional cases (vessels trading very muddy waters) it might be necessary to clean the filter element more often. If the pressure triggered backflushing is performed with short intervals, we suggest that the filter element is manually cleaned more often than once year.

3.3 CIP components

3.3.1 CIP working principle

The purpose of the CIP (cleaning-in-place) process is to clean the quartz sleeves covering the UV lamps and the UV sensor. This will ensure that the UV light will treat the water efficiently and that the flow control and power optimization functions, based on correct input from the UV sensor.

After the UV reactor (and filter after ballast) is drained from sea water, the UV reactor and filter is filled with technical water / potable water. The UV reactor is filled with 0.3 l concentrated CIP liquid to the UV reactor. The low-pH CIP liquid removes scaling, calcium chlorides, metal ion build-up and chemical fouling on the lamps’ quartz glass sleeves. The mixed CIP liquid is left in the UV reactor for 6 hours. Every 15 minutes, the CIP liquid is circulated for 2 minutes to improve the cleaning efficiency. As a last step, the UV reactor is filled with technical water / potable water to prevent scaling, algae growth etc.

3.3.2 CIP components

The following components are involved in the CIP process.

• T320: A can with concentrated CIP liquid.

• Pump P320–1: Pumps concentrated CIP liquid to the UV reactor.

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3.4 Electrical cabinet 3 System components description

• CIP Pump P460: Drains UV reactor and filter reactor and circulates the CIP liquid in the UV reactor during CIP process.

• Valve V320–2: Leads the CIP liquid to the UV reactor.

• LS320–3: Level switch to give a warning when the CIP liquid level is low.

3.4 Electrical cabinet

The electrical cabinet is equipped with the control panel, which is used to control and monitor the system. The cabinet is equipped with an emergency stop button, an audible and visible alarm indication and USB ports for software upload and log file export. Lamps on the cabinet indicates if power is on, UV lamps are lit and if the cabinet needs to be reset after a shutdown or power off.

The electrical cabinet contains all electrical equipment needed for the system. The electrical cabinet is also fitted with three lamp power supplies (LPS), which are feeding power to the UV lamps. One LPS feeds power to two UV lamps. The LPS also monitors the function of each UV lamp and takes action if a fault occurs.

The electrical cabinet functions as a single point of contact for signal cables to all components and installed options: remote interface, remote control panels and power management system (PMS).

Also integration with other external components (not part of Alfa Laval’s scope of supply), such as GPS and ballast water pump, are done to the electrical cabinet.

The electrical cabinet is equipped with a cooling fan. The fan is regulated based on heat inside the cabinet. When the temperature reaches 30°, the fan starts to regulated between 30 % and 100 % (at 45°), according to parameter settings based on input from the temperature transmitter in the cabinet. When temperature reaches 27° the fan stops.

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3 System components description 3.5 Control system

2 Elcabinet

Electrical cabinet with main control panel.

3.5 Control system

The control system is used to set parameters, operate and monitor PureBallast. The control system continuously monitor PureBallast, both during operation and in standby mode. Any deviation is either communicated to the operator or handled automatically, based on parameter settings. Safety risks are always handled automatically.

The control system store all alarms and relevant events for at least 24 months. The memory has a vast safety margin but when it is full, data will be deleted starting with the oldest logs. Logged information can be exported to a USB memory stick.

There are three alternative ways to monitor and control PureBallast: Main panel, remote control panel (optional) and remote interface (optional). It is only possible to operate PureBallast from one place at a time.

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3.5 Control system 3 System components description

3.5.1 Main control panel

The main control panel in mounted in the electrical cabinet, and it is included in the standard installation of PureBallast. The main control panel handles every aspect of the control system. It allows the operator to monitor the system, to operate it manually and automatically, and to set parameters. Please note that some of the operations are password-protected.

2 EC

Electrical cabinet with main control panel

3.5.2 Remote control panel (optional)

As an option, it is possible to install one or two additional panels to be placed in locations from where ballast operations are performed. The remote control panel functions in the same way as the main control panel, and it allows same operations.

2 RCP Integration

PureBallast integrated with two remote control panels.

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3 System components description 3.6 Main valves

3.5.3 Remote interface (optional)

As an option, the control system can be integrated with the vessel’s ISCS via modbus. This allows monitoring and operation of PureBallast from the ISCS’s graphical user interface.

Note that Alfa Laval does not supply the graphical user interface to handle PureBallast in the ISCS, only the means to enable the integration.

2 RI Integration

PureBallast integrated with the ISCS. The interface is only an example.

3.5.4 Power management (optional)

PMS integration will allow automatic verification that there is enough power to run an operation.

Integration is done by hard wire or via remote interface, if installed.

If not integrated, the operator must verify this manually.

3.6 Main valves

The main valves in the system are:

• Inlet valve: (V201–3) Inlet from the vessel’s ballast water system during ballast. The water is directed via the filter to the UV reactor.

• Inlet valve: (V201-9) Inlet from the vessel’s ballast water system during deballast. The water is directed to the UV reactor, but bypasses the filter, since the water was filtered during ballasting.

• Filter outlet (V201–19): The valve directs the water flow from the filter to the UV reactor during ballast. The valve is also used to drain the UV reactor and for filter preservation during CIP process to lead technical water / potable water from the UV reactor to the filter.

• Backfllush valve (V309–1): The valve directs the dirty backflush water flow from the filter over board during backflush operation.

Book No.9028175 02 29

3.9 Sampling devices 3 System components description

• Control valve (V201–8): The valve have the following functions:

- Automatic regulation to maintain flow during operation so it does not exceed selected certified maximum flow. Regulation is based on input from the flow meter.

- Automatic regulation to maintain pressure needed to perform backflush of the filter.

Regulation is based on input from the pressure transmitter.

- Outlet valve from the PureBallast system to the vessel’s ballast water system after treatment.

• Technical water / potable water valve (V310-1): The valve have the following functions:

- Supplies cooling water to the reactor to secure cooling of the lamps if temperature exceed 45 °C during process.

- Supplies water to the UV reactor and filter during CIP process.

• Bypass valve (V212–31): Makes it possible to completely bypass the PureBallast system. The valve is solely operated from the ISCS, but the valve status is (and must be) indicated in the PureBallast control system. When PureBallast is bypassed, an event is written to the event log.

The component (optional in Alfa Laval’s scope of supply) is not included in the skid. The valve is equipped with a hand wheel for manual operation.

3.7 Flow meter

The flow meter (FT201–1) monitors the process flow during operation. The main function is to monitor the flow within the PureBallast system, to secure that certified flow is not exceeded. If so, a warning is issued. The flow meter also send valuable data to the PureBallast control system, where it is displayed. Example of information: Current flow and data about total amount of treated ballast water.

The flow meter consists of two main parts: A flow sensor, which is a pipe with electrodes detecting the flow. On top of the pipe, the flow transmitter is mounted, sending data to the control system.

3.8 Pressure transmitter

Two pressure transmitters monitor the pressure in the system:

• PT201-16: System pressure before filter. The control system use the information to take actions accordingly, for example issue warnings, shut down the system and adjusting the control valve to obtain optimal pressure during filter backflush.

• PT201-72: System pressure after filter. Use to calculate differential pressure over the filter to indicate dirty filter element.

3.9 Sampling devices

The two sampling devices (Q201.1 and Q201.2) make it possible to take water samples to test the water. The component (optional in Alfa Laval’s scope of supply) is not included in the skid.

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3 System components description 3.9 Sampling devices

One sampling device is installed before the water is treated and one after the water is treated.

This enables comparative tests of treated and untreated water. The component is optional to be included in Alfa Laval’s scope of supply.

Book No.9028175 02 31

Chapter: 3. Operating instructions and control system description

USCG

SE-147 80 Tumba, Sweden

Telephone: +46 8 530 650 00

Telefax: +46 8 530 310 40

This publication or any part there of may not be reproduced or transmitted by any process or means without prior written permission of Alfa

1 Introduction 7

1.1 Preparations and conditions 7

1.1.1 Compliant / non-compliant operation 8

1.1.2 Stripping 8

1.1.3 Heeling (internal transfer) 9

1.1.4 Pipe cleaning using PureBallast 9

2 Introduction to the control system 11

2.1 Login levels 11

2.2 Control of PureBallast 12

2.2.1 Remote control panels (option) 12

2.2.2 Remote interface (option) 12

2.3 Overview of the screen 14

3 Detailed page descriptions 17

3.1 Page 1.1 – Main 17

3.1.1 Status box 17

3.1.2 Flow chart 18

3.2 Page 1.2 – Overview 19

3.2.1 Status box 19

3.2.2 Flow chart 20

3.3 Page 1.3 – Reactor 22

3.3.1 Status box 22

3.3.2 UVR information 23

3.4 Page 1.4 – Filter 24

3.4.1 Status box 24

3.4.2 Filter information 24

3.5 Page 1.5 – CIP 26

3.5.1 Status box 26

3.5.2 CIP and UVR information 27

3.6 Page 1.6 – Cabinet 28

3.6.1 Electrical cabinet status 28

3.6.2 Cabinet information 29

3.7 Page 2.1 – Alarm list 30

3.7.1 Alarm list 31

3.7.2 Function buttons 31

3.8 Page 2.2 – History 32

3.9 Page 2.3 – Audit trail 33

3.10 Page 3.1 – Trend 33

3.10.1 Diagram area 34

3.10.2 Component area 35

3.11 Page 4.1 – System 1 36

3.12 Page 4.2 – System 2 38

3.13 Page 4.3 – Timers 40

3.14 Page 4.4 – Remote 1 42

3.15 Page 4.5 – Remote 2 43

3.16 Page 4.6 – LPS 44

3.17 Page 5.1–5.6 – Parameter pages 45

4 Operating instructions 47

4.1 Log in 47

4.2 Perform ballast 47

4.3 Perform deballast 48

4.4 Perform tank stripping 49

4.5 Heel (internal transfer) 50

4.6 Backflush filter manually 50

4.7 CIP clean UV reactor after ballast /

deballast 51

4.8 Attend to alarms 51

4.9 Shut down and deactivate system 53

4.10 Operate components manually 54

4.11 Operate UV lamps manually 55

4.12 Set ship specific component ID 56

4.13 Export control system event log files 57

4.14 Backup control system settings 59

4.15 Restore control system settings 59

4.16 Set control panel IP address 60

4.17 Set remote control panel

communication 61

4.18 Set remote interface communication 64

4.19 Test remote interface communication 64

4.20 Update control system softwares 66

4.21 Calibrate the control panel’s touch

screen sensibility 66

4.22 PID calibrate system 66

4.22.1 Calibrate pressure controlled regulation 67

4.23 External feed 68

4.23.1 Calibrate external feed control (optional) 68

5 List of logged information 71

5.1 Event log 71

6 Detailed process description 73

6.1 Standby mode 73

6.2 Ballast process 74

6.2.1 Ballast start-up 74

6.2.2 Full ballast 74

6.2.3 Filter backflush 75

6.2.4 Stop ballast 75

6.3 Deballast process 77

6.3.1 Deballast start-up 77

6.3.2 Full deballast 77

6.3.3 Stop deballast 78

6.4 CIP process 79

6.4.1 Start CIP 79

6.4.2 Drain ballast water (if only…