MM-40 - Final - Drawing, Design & Installation Guide

Final drawing
Design and installation guide

PureBallast 3.1 / 1000 EX
IMO
MM-40
Book No. Rev 2017–09–01
Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00
Telefax: M+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.
Rev.11.3
PUREBALLAST EQUIPMENT SPECIFICATION

CUSTOMER KITANIHON SHIPBUILDING CO., LTD
HULL No/Name 655
FLAG Singapore
CLASS SOCIETY NK
Type PureBallast 3.1EX 1000 m3/h

S/N PB-01330
Set (per ship) 1
Flow rate* Ballasting 195 ～ 1000
Deballasting 100 ～ 1000
Stripping [m3/h ; per UVR] 100 ～ 333
Maximum Power 101 kw
Consumption *Include 1kw for control (required), additionally 23kw (max) is required for other options.
Power Source 440 V / 3 Phase / 60 Hz
Standard Connections Flange connection JIS
Connection Size UVR inlet/outlet valves (V201-19,20) 350A (UVR1000)
Main valves (V201-3,9,32) 350A
Control valve (V201-8) 300A
Cooling water valve (V403-35) 50A
Backflush (309) outlet connection 80A
Flow transmitter (FIT201-1) 350A
Bypass valve (V212-31 ; option) Yes 350A
Sampling device (option) Yes 2 pcs
Filter / flange direction Filtrex (opposite side ; alt)
Length of W211* 20 m (10m each ; if not specified)
Painting color Filter unit, CIP module Munsell 7.5 BG7/2
Working Pressure (UVR) 0.6 Mpa (Max)
Pressure Drop UVR ≦0.02 Mpa
See section 6.4 and 6.5 in the drawing
Filter (per unit) 0.015 - 0.05 Mpa
Temperature Sea water 0 - 40 ºC
LDC cooling water 0 - 38 ºC
Ambient 0 - 55 ºC
Air Pressure 0.55 - 0.8 Mpa
Remote Operation RCP (cabling <100 m ; IP 65) × 1
Options
(1) Air filter pcs
(2) - pcs
(3) - pcs
(4) - pcs
(5) - pcs
Note : Asbestos isn't contained in this product(s) incl. spare parts & supplies.
Common alarm from BWTS will be informed with buzzer on console in ECR, and operation
panel also can inform alarm with buzzer and indication on the panel.
Spare parts and tool for Sno.655
Items Parts No. Quantity (per ship)

UV lamp set 9009521 80 2
*Item include : UV Lamp × 1 (per set)
O-ring × 2 (per set)
Quarts sleeve set 594645 82 1

*Item include : Quartz sleeve × 1 (per set)
O-ring × 2 (per set)
CIP liquid (15 liters) 9012167 01 1

Lamp power supply 9012146 01 1
UV Sensor 9008373 02 1
pH Test Paper N/A 1
High pressure washer for filter N/A 1
Remark :
These are supplied by request of ship owner.
Contents
1 Ship specific information 7
2 Introduction 9
2.1 Safety information 9
2.2 System overview 10
3 Alfa Laval’s scope of supply 11
4 Material and equipment supplied

by installing party 15
4.1 Material selection 15
5 Mechanical installation 17
5.1 General requirements 17
5.2 Ex zones 18
5.3 UV reactor 18
5.3.1 General requirements 18
5.4 Filter 20
5.5 CIP module 21
5.6 Flow meter (FIT201-1) 22
5.7 Pressure monitoring device 25
5.8 Valves 25
5.9 Electrical cabinets 28
5.10 Ancillary equipment and functions 28
5.10.1 Sampling devices (Q201.1 and Q201.2) 28
5.10.2 Booster pumps 29
5.10.3 Tank stripping 29
3
6 Pipe design 31
6.1 Water types 31
6.2 Valves outside PureBallast 31
6.3 Pipe dimensions and material 32
6.4 Pressure and flow 34
6.5 Pressure and flow – backflush 34
6.5.1 Calculate pressure and flow for backflush 34
6.5.2 Calculate value for backflush parameter setting 35
7 Electrical design 37
7.1 Basic technical data 37
7.2 Installation requirements 38
8 Ex protection 41
8.1 Ex components 41
8.1.1 UV reactor 43
8.1.2 CIP module 44
8.1.3 Filter 44
8.1.4 Pipe net 45
8.2 Safety control system 45

8.2.1 Control circuit for UV reactor 47
8.2.2 Global emergency stop from control cabinet 52
8.2.3 Priming of the system before start 54
8.2.4 Normal stop of the system 54
9 Pneumatic design 55
10 Control system integration 57

10.1 Remote control panels 57
10.2 Remote interface 58
10.2.1 Integration process 58
10.3 Power management system integration 59

10.3.1 Overall power request process 59
10.3.2 Power steps and power signals 59
10.3.3 Power management installation 60
10.4 External feed control signal 61

10.4.1 Feed regulation during operation 61
4
10.5 External components 62
10.6 GPS 66
11 System approval 69
11.1 Alfa Laval’s responsibilities 69
11.2 Installing party’s responsibility 69
11.2.1 Approval planning 69
11.2.2 Design approval 69
11.2.3 Installation survey 70
11.3 Alfa Laval commissioning 70
12 On board installation planning 71

12.1 Delivery and transport 71
12.2 Lifting instructions 71
12.2.1 UV reactor 72
12.2.2 Filter 73
12.2.3 CIP module 74
12.2.4 Cabinets 74
13 Start-up procedures 77
14 Drawings 79
14.1 Graphic symbols used in drawings 80
14.2 General drawings 81
14.2.1 Flow chart 81
14.2.2 Technical data 82
14.2.3 Connection list 83
14.2.4 Electrical system layout (3 pages) 89
14.2.5 Instrument air distribution 92
14.2.6 Quality specification / Instrument air 93
14.2.7 Quality specification / Fresh water 94
14.2.8 Quality specification / CIP liquid 95
14.2.9 Material data sheet / UV lamp 96
14.2.10 Safety data sheet / CIP liquid 106
5
14.3 Dimension drawings including technical
data 114
14.3.1 UV reactor (previously called AOT reactor) 114
14.3.2 Filter 115
14.3.3 CIP module (2 pages) 116
14.3.4 Flow transmitter FIT201-1 118
14.3.5 Pressure monitoring device 6 bar system (Incl.
PT201-16, PI201-18, RV201 and 201-15) 119
14.3.6 Pressure monitoring device high pressure system
(Incl. PT201-16, PI201-18, RV201 and 201-15) 120
14.3.7 Valve V201-3 and V201-9 121
14.3.8 Valve V201-32 and V403-35 122
14.3.9 Valve V212-31 (Optional in scope of supply) 123
14.3.10 Control valve V201-8 125
14.3.11 Backflush valve V309-1 126
14.3.12 Check valve CV201 127
14.3.13 Sampling device Q201.1 and Q201.2 (3 pages)
(Optional in scope of supply) 128
14.3.14 Lamp drive cabinet (LDC) 131
14.3.15 Control cabinet 132
14.3.16 Remote control panel (Optional) 133
14.3.17 Transformer (Optional) 134
14.3.18 Air filter / Filter regulator (Optional) 135
14.3.19 Additional pumps (Optional) 136
14.3.20 UV reactor and LDC / Lamp power cable 139
14.4 Electrical drawings 140

14.4.1 Control cabinet / Interconnection diagram 140
14.4.2 Control cabinet / Circuit diagram 149
14.4.4 Control cabinet / Cable list 170
14.4.5 Lamp Drive Cabinet (LDC) / Interconnection
diagram 171
14.4.6 Lamp Drive Cabinet (LDC) / Circuit diagram 174
14.4.7 Lamp Drive Cabinet (LDC) / Cable list 190
14.4.8 UV reactor / Interconnection diagram 191
14.4.9 UV reactor / Circuit diagram 194
14.4.10 UV reactor / Cable list 197
14.4.11 Remote control panel (optional) / Circuit diagram 198
14.4.12 Transformer (optional) / Interconnection diagram 199
14.4.13 Transformer (optional) / Circuit diagram 200
14.4.14 Transformer (optional) / Cable list 201
14.5 Intrinsically safe circuits 202

14.5.1 Exi max multicore cable length calulation – V201–8 203
14.5.2 Exi max multicore cable length calulation – UVR
components 205
6
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
Flow range (m3/h) Ballast: 195 → 1000
Deballast: 100 → 1000
Stripping: 100 → 333 .
Number or UV reactors 1
Flange standard (EN or JIS) _________
Main valve and piping Dimension: ________________
Control valve (201-8) Dimension: ________________
Bypass valve (V212–31) Dimension: ________________
Alfa Laval’s or other
Cooling water valve (V403-35) Dimension: ________________
Cooling water valve (V401-1) Dimension: ________________
Sampling device Location Q201.1: __________________
Alfa Laval’s or other Location Q201.2: __________________
Power consumption, max _________
Remote operation (optional) Location:
Remote control panel 1: ________________
Remote control panel 2: ________________
Remote interface integration (yes/no): _____
Book No.Rev 2017–09–01 7

1 Ship specific information
2 Introduction
This document contains general guidelines for the on board design and installation planning. Alfa
Laval deliver PureBallast as a semi assembled system, with the main components, UV reactor
and control system, pre assembled and tested 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 drawing and the dimension
drawings included the Drawings section in this document. Components are identified by their ID,
for example control valve (V201-8).
Note that the function and performance of PureBallast are dependent of the installation. Therefore,
it is important that the design and installation is done according to the information given in this
document.
2.1 Safety information

• Earth connection must be made before any welding is done.
• Follow local regulations for electrical installation and earthing (grounding).
• Instructions on how to mount and install components are given in system manual, chapter
7. Service manual.
NG
WARNI
!
• Read chapter 1. Safety.
• Before installing a component, always read the Ex certificate delivered with the component.
This is especially important if the certificate number contains an “X”. Consult the overview in
section Ex protection.
• The installation must be done according to rules regarding installations in potentially explosive
environments, for example IEC 60079 series.
• Installation must be done by a fully trained professional installer.
• Damages related to transport and installation should be recorded.
Book No.Rev 2017–09–01 9

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 UV reactor are not described
individually in the list, since they are already mounted as a part of the component.
Component ID Function
Main components
UV reactor, 1 UVR 1 The main water treatment component in the system, including
pieces. reactor, valves, UV sensor, temperature sensor, temperature
switch and level switches.
Lamp drive LDC 1 Electrical cabinet feeding the UV lamps in the UV reactor with
cabinet, 1 power via lamp power supplies (LPS).
piece
Lamp power W211 Power cables between UV reactor and lamp drive cabinet. Length
cable, specified in order.
Control Control Contains the main control panel, from which PureBallast is
cabinet, 1 cabinet controlled. It also contains breaker and communication components
piece such as PLC, switches for communication with remote interface,
remote control panels etc, and terminals to connect signal cables
to components and external systems.
Filter, 1 piece Filter Mechanical filtration of the water before treatment.
CIP module, CIP Cleaning-in-place module for automatic cleaning of the UV reactor
1 piece after treatment, mainly clean the UV lamps quartz sleeves. The
CIP module is also used to drain and fill the UV reactor during CIP
process and to fill the filter with fresh water after for preservation
reasons.
Remote Extra control panels to control and monitor the PureBallast system.
control panel Number according to order.
(optional)
Valves
Book No.Rev 2017–09–01 11

Control V201-8 • Main outlet valve from the PureBallast system to the vessel’s
valve, ballast system after treatment.
1 piece
• Automatic pressure regulation to maintain needed pressure
including
during back flush.
positioner
• Automatic flow regulation during operation to secure needed
minimum flow to cool the UV lamps and secure that max flow
is not exceeded.
The positioner function as connection point for signal and power
cables to the component.
Filter inlet V201-3 Function as

valve
including • Main inlet valve to the PureBallast system during ballast, in
switch box combination with V201-32. The valve directs the water flow
through the PureBallast filter. (Closed during deballast)
The switch box function as connection point for signal and power
cables to the component.
Filter outlet V201-32 • The valve directs the water flow from the PureBallast filter to
valve the UV reactor. (Closed during deballast)
including
• The switch box function as connection point for signal and
switch box,
power cables to the component.
1 piece
Valve V201-9 • Filter bypass valve open during deballast, when the filter is not
including used. (Closed during ballast)
switch box,
1 piece
power cables to the component.
Valve, V212-31 • Bypass valve to bypass the complete PureBallast system. The
1 piece valve is solely operated from the ISCS.
including
switch box
control cables to the component.
(Optional as
part of scope
of supply)
Cooling V403–35 • Supplies cooling water to the UV reactor(s) to protect the lamps
water inlet from overheating during start-up. The valve is common for all
valve, installed UV reactor(s).
1 piece
including
control cables to the component.
switch box
Check valve, CV201 Check valve before the UV reactor to secure water in the UV
1 piece reactor.
Ancillary equipment
12 Book No.Rev 2017–09–01

Flow sensor FIT201-1 The flow meter consists of two components:
Flow sensor monitor the flow in the system. Functions together

with the flow transmitter.
Flow transmitter send flow information to the control system. It

is mounted on the flow sensor.
Pressure PT201-16 Monitor pressure and send it to the control system.

monitoring
device, 1 Manifold includes pressure transmitter (PT201-16), pressure gauge
piece (PI201–18), relief valve (RV201) and needle valve V201–15.
Sampling Q201-1 Sampling points to tap water for test of water before and after
device, 2 Q201-2 treatment.
pieces
(Optional as
part of scope
of supply)
System Information about operation, control system parameters,

manual, one faultfinding and drawings.
piece
Additional manuals or manuals as CD according to order.
Consumables
CIP liquid, 12 The liquid is used for the first filling of CIP liquid.
liters
Book No.Rev 2017–09–01 13

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:
• Support for mounting heavy components, for example extra support for the UV reactor.
• Electrical and signal cables.
• Pipes for ballast water, cooling water and CIP.
• 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.
• Booster pumps for backflus water (P309–1) and cooling water (P401 and P403), if used and not
included in scope of supply. See under heading External component signals.
• Power supply cabinet (not part of Alfa Laval’s scope of supply). Must be installed in safe zone.
• Two main breakers: To be installed in the main switch board. See section Electrical subsystem
on page .
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
• Drawings Control cabinet / Cable list and Lamp drive cabinet (LDC) / Cable list state
requirements for cables.
4.1 Material selection

Installing party is responsible for selecting material for pipes etc. 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 sea water operation; the steel should have a higher resistance to localized
corrosion than the traditional 316 or 316L steels.
Book No.Rev 2017–09–01 15

4.1 Material selection 4 Material and equipment supplied by
installing party
Used material shall be indicated in appropriate drawings.
16 Book No.Rev 2017–09–01

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. All pipes and components must be
designed to be installed as specified in the flow chart in combination with the requirements in the
Connection list. Details for components are stated on the dimension drawing, for example weight,
material, volume etc.
The relation between the components is important. Example: Cooling water inlet valve V403-35
must be installed between valve V201-9 and V201-19. The flow chart also defines where
components are to be placed in relation to pipe intersections.
Installation prerequisites:
• The PureBallast must be installed in a machinery space on the vessel (engine room, pump
room etc defined as zone 1 or 2) with
- relative humidity of max 100 %

- ambient temperature according to Technical data on page .
• 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.
Book No.Rev 2017–09–01 17

5.3 UV reactor 5 Mechanical installation
5.2 Ex zones
PureBallast Ex is classed for use in hazardous areas in accordance to the IEC 60079 series of
standards: Zone 1 , explosion group IIC and temperature class T4 (135°).
Install PureBallast components in respective locations according to the table below:
Zone 1 Safe zone

• UV reactor • Control cabinet
• Filter • Remote control panels (optional)
• CIP module • Lamp drive cabinet (LDC)
• Valves
• Flow meter
• Pressure monitoring device
5.3 UV reactor
Requirements and recommendations for UV reactor installation differs depending on if one or more
UV reactors are installed.
5.3.1 General requirements

• The flow must be within certified flow range for the system.
• Note: The rated capacity for the ballast water treatment system should not be less than the flow
rate of the largest ballast pump, according to some of the classification societies.
• The UV reactor is recommended to be placed close to the filter for best performance.
• During operation, the input flow to the PureBallast system shall be as close as possible to
the flow that has been selected for an operation. This will reduce the stress and wear of the
control valve.
• If a pipe bend is connected to the UV reactor (V201-19), the pipe should have the same
dimension as the UV reactor flange. It is not possible to use a cone to enlarge the pipe
dimension at the connection point to the UV reactor. If a cone is needed to enlarge the pipe, it
can be installed before the bend.
• The UV reactor must be mounted vertically with the water flow going upwards.
18 Book No.Rev 2017–09–01

5 Mechanical installation 5.3 UV reactor
• The UV reactor must be oriented so that the UV lamps are perpendicular (90°) to pipe 201
with flow to the UV reactor. This will result in an even distribution of the water within the UV
reactor, so that all water is treated equally. See relation between pipe 201 and position of the
UV lamps in the illustrations below.
AOT manifold2
• The UV reactor must be secured so it withstands the forces of load applied by a full UV reactor
(520 kg) at the vessel’s maximum heeling degree.
Book No.Rev 2017–09–01 19

5.4 Filter 5 Mechanical installation
• The UV reactor must be fixated at the bottom and supported at the top to carry the weight of
the component. Use the upper and lower fixing holes (1) in the support structure to fixate the
component to the steel construction of the hull. If this is not enough, completing stays has to
be made. There are four fixing holes on each side at the bottom and four at the top, after
the lifting beam has been removed.
6 AOT installation
• Prepare the inlet piping first. Then mount the UV reactor onto the inlet flange and secure it.
Finally install the outlet piping onto the top of the UV reactor.
• We recommend that the installation of the reactor is planned to be supported by its lifting point
until the units lower part is completely secured to the foundation and inlet flange.
• No fixtures should be attached to the reactor housing by welding, since this will damage or
distort the reactor, and potentially affect the biological performance of the component.
5.4 Filter
• The filter is recommended to placed close to the ballast water pump for best back flush
performance.
• When planning the location of the filter, consider the installation height and the need for a lifting
device to be used to lift the heavy cover and insert during installation and maintenance. See
basic size drawing for required installation height and access area. Filter cover and element
weight (kg): 285.
• The filter can be bolted or welded in place.
• A draining valve (not part of Alfa Laval’s scope of supply) can be installed to facilitate draining of
the filter during maintenance. See connection 460 in the filter dimension drawing.
20 Book No.Rev 2017–09–01

5 Mechanical installation 5.5 CIP module
• See section Pipe design on page for details for pipe 309.
5.5 CIP module
• The CIP shall be placed close to the UV reactor to secure that the CIP fluid (250 liter) can
circulate.
• It is recommended that the CIP module is installed below the UV reactor, or on the same level
and that the pipes to and from the UV reactor is installed according to the illustration below.
There must be no risk for additional water or air pockets in the piping. This will minimize dilution
or loss of CIP liquid and secure good pump efficiency.
- Pipe 321: Downward gradient towards both the CIP module and the UV reactor. There
must be no risk for water or air pockets inf the pipe.
- Pipe 320: Downward gradient from the UV reactor towards the CIP module. A water
lock can be created close to the CIP module, before a vertical pipe to the CIP module, as
illustrated to the left below. This is not needed if the liquid can flow by gravity to the CIP
module, as illustrated to the right below. There must be no risk for water or air pockets in
the pipe, which can affect efficiency in a negative way.
Left: CIP in level with UV reactor. Right: CIP on lower level than the UV reactor.
6 CIP_AOTrelation
• The deaeration pipe after deaeration valve V571-1 must reach approximately 2 meters
higher than valve V321-2 at the UV reactor to avoid water spillage during CIP process. It is
recommended that the deaeration pipe is led to a scupper to collect eventual (minor) water
spillage.The deaeration pipe must end in safe zone, to avoid hazardous gas to enter the UV
reactor during when valve V571–1 is opened.
• Pipe connections to the CIP must be made so that the connection is not exposed to any moment
or load. This is particularly important when connecting the plastic flanges.
• Pipe 460.2 (drain of used CIP liquid) should not be lead to bilge tank due to the low pH value.
Drain to one of the following: drain, waste or sludge tank.
• It is recommended that pipe 460.2 is connected so that used CIP liquid (250 liters) is drained to
one of the following: waist oil tank, drain tank or sludge tank. CIP liquid should be handled
according to local regulations. Note that the CIP liquid have a low pH value (approximately
3.0 when changed) and that it also contain residues from the cleaning process. See Quality
specification / CIP liquid on page .
• Max tightening torque for bolts on flanges: 20 Nm.
Book No.Rev 2017–09–01 21

5.6 Flow meter (FIT201-1) 5 Mechanical installation
5.6 Flow meter (FIT201-1)

• The flow meter should be installed after inlet valves (V403–35, V201–9 and V201–32) and
before V201–8.
• We recommend that a straight pipe is installed before and after the flow meter, with length
(L) proportional to the pipe diameter (⌀) according to the illustration below. This will secure
accurate measure.
DI Inlet and out let runs
Flow meter — Plan (Flow according to arrow)

• If there is a lack of space, it is possible to shorten the straight pipes. Note that the accuracy is
affected negatively by shorter straight pipes.
• The flow meter must always be completely filled during operation to ensure optimum flow
measurement. To achieve this, it is recommended that the flow meter is installed in a pipe with
an upward flow direction (vertical or slanting). This minimizes the risk for gas and bubbles
effecting the measurement negatively. See illustration below for examples.
DI upward flow direction
22 Book No.Rev 2017–09–01

5 Mechanical installation 5.6 Flow meter (FIT201-1)
• Do not install the flow meter at the highest point in the pipe: This result in partially filled pipes.
Do not install in a pipe with a downward flow direction: The water shall not stream by gravity.
If there is a a risk of pour measuring conditions (e.g. partially filled pipes), install a siphon
(1) downstream of the flowmeter.
DI Down pipes
Measures for installation in a down pipe.

1. Siphon
• The measuring electrode plane should be horizontal. Note that the empty pipe detection only
works correctly if the transmitter housing is facing upwards. Otherwise there is no guarantee
that empty pipe detection will respond if the measuring tube is only partially filled or empty.
DI Horizontal orientation
1. EPD electrode for empty pipe detection

2. Measuring electrodes for signal detection
3. Reference electrode for potential equalization
Book No.Rev 2017–09–01 23

5.6 Flow meter (FIT201-1) 5 Mechanical installation
• Note that the flow transmitter housing and the display can be turned. This makes the placing
of the flow meter flexible.
7 AL- field housing for Zone 1 or Class 1 Div.1
Turning the transmitter housing.
DI Turning the onsite display
Turning the onsite display
24 Book No.Rev 2017–09–01

5 Mechanical installation 5.8 Valves
5.7 Pressure monitoring device

• Pressure monitoring device must be installed vertically on a horizontal pipe. If not it will not
function.
• A solution (not part of Alfa Laval’s scope of supply) must be attached to safety valve RV201.
The valve shall be drained to a scupper, with a solution which always allows water to be drained
from the valve. See Pressure monitoring device / Dimension drawing.
5.8 Valves
The valves in PureBallast are operated by instrument air from the vessel’s instrument air system
and they are connected to the control cabinet by signal cables to give feedback.
• Valves can be installed on vertical, horizontal and sloping pipes.

• The yellow position indicator on actuators must be in line with the valve throttle. For pipes with
dimension 400, the red position indicator on the actuator coupling (see drawing) must also be
in line with the throttle. The position indicator must be in line with the pipe when the valve is
open. If not correct, change according to instruction in system manual, chapter 7. Service
manual for instructions.
• Valves shall be opened when installed. This is important to avoid that the rubber gaskets are
squeezed and damaged during installation.
• Valve actuator’s pneumatic lines must be correctly connected and supported. See system
manual, chapter 7. Service manual for instructions.
• Requirements for individual valves in the table below:
Component Guidelines
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 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
opening the valve. The reason, for example internal transfer,
must be entered in the vessel’s ballast water log book. If GPS
Book No.Rev 2017–09–01 25

5.8 Valves 5 Mechanical installation
signal is not integrated, the position must also be entered in
this log book.
Signal cables connected according to Control cabinet /

Interconnection diagram and Control cabinet / Circuit diagram.
Extra bypass valves (not part If PureBallast can be bypassed using other valves (apart from
of Alfa Laval’s scope of supply) 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.
Control valve (V201-8) Must be placed as the last component on pipe 201.
Valve dimension: 300.
If the valve dimension is different from the dimension of pipe

201, the pipe dimension must be coned up/down to fit the
valve.
Cooling water valve (V403-35) The valve must be installed between filter bypass valve
V201-9 and UV reactor inlet valve V201-19.
Check valve (CV403) (not part Optional to use. If used, it must be placed before the cooling
of Alfa Laval’s scope of supply) water valve V403–35.
Check valve (CV201) The valve must be installed before the UV reactor inlet valve
V201-19. It is recommended to be installed as close as
possible to the UV reactor.
Check valve (CV310) The valve is installed on the flange for pipe 310.1 on the CIP.
Non-return valves (not part of It is recommended to installed non-return valves at the end of
Alfa Laval’s scope of supply) the following pipes: 309, 402 and 404, as a safety precaution.
Filter bypass valve (V201–9) According to flow chart.
Filter inlet valve (V201–3) According to flow chart.
For piping dimension JIS/EN 300 and JIS 350 the valve can
NOT be mounted directly on the filter due to the adaptor plate.
For other dimensions the valve can be mounted directly on
the filter flange.
Filter outlet valve (V201–32) According to flow chart. See V201–3 regarding mounting.
26 Book No.Rev 2017–09–01

5 Mechanical installation 5.8 Valves
Filter backflush valve (V309–1) Preassembled on the filter at delivery.
Vacuum breaker vavle 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.
Air inlet to vacuum breaker valve should be retrieved from

safe zone.
VacuumBreaker
Vacuum breaker valve installation
Book No.Rev 2017–09–01 27

5.10 Ancillary equipment and functions 5 Mechanical installation
5.9 Electrical cabinets

This section covers installation guidelines for cabinets, regarding mechanical installation. For
electrical installation, see section Electrical design on page .
General requirements
• Cabinets must be firmly attached and must not amplify vibrations to or from the hull.
• Cabinets must be installed so that there is free space available to open the door.
Lamp drive cabinet (LDC)
• Maximum distance (lamp power cable length) to the UV reactor: 150 meters.
• Maximum distance (cable length) to the control cabinet: 100 meters.
• The cabinet must be placed on a firm level surface and fixated. The legs of the component can
be bolted or welded in place on a steady foundation. It is possible to detach the cabinet from
the bottom frame to facilitate installation. The cabinet shall also be attached to the bulkhead
using the attachment bolts on the top of the cabinet. The cabinet is fixed to the ships structure
via vibration dampers to minimize the effect of vibrations from the hull affecting components
inside the cabinet.
• The cooling water supply must be connected to meet the requirements in the Connection list on
page under item 401. Correct temperature and flow are crucial to secure that the LDC is cooled
in a sufficient way. The cooling water installation must be verified after a couple of hours, to
make sure that there is no leakage in the cabinet.
5.10 Ancillary equipment and functions

This section covers installation guidelines for ancillary equipment and equipment supplied by
installing party for specific functions.
5.10.1 Sampling devices (Q201.1 and Q201.2)

Sampling devices are optional part of Alfa Laval’s scope of supply. But the international ballast
water convention will require that it is possible to take water samples before and after treatment.
• One sampling device shall be installed before filter inlet valve V201-3 and the second one
as close to the overboard valve as possible. If there are several discharge lines, it might be
necessary with a sampling device on each.
• The placement of the sampling points is subject to approval by class society.
28 Book No.Rev 2017–09–01

5 Mechanical installation 5.10 Ancillary equipment and functions
• Sampling device should be installed in a straight pipe without elbows, tees or other fittings. It is
not allowed to install a connecting pipe between the control valve V201–8 and the sampling
device. No water from other sources than from PureBallast may mix with the ballast water.
Ideally, the pipe where the component is installed should be vertical and as long as possible.
The sampling device should be installed where the flow in the pipe is fully mixed and fully
developed. For full details, see standard ISO 11711-1:2013(E).
• The sampling device must be accessible for maintenance and taking samples, including the
possibility to close valve before and after, to avoid leakage during maintenance.
• Flanges for connecting the sampling devices must be installed before the pipe is coated.
• If Alfa Laval’s sampling device is used, the device must be mounted with the sampling pipe
opening pointing in the flow direction. See drawing on page 128 .
5.10.2 Booster pumps

Three booster pumps might be needed to achieve sufficient flow:
• LDC cooling water pump (P401-1): Booster pump so that cooling water flow to LDC (during
operation) shall give minimum flow according to Connection list, for Item/Connection 401.
• UV reactor cooling water pump (P403-1): Booster pump so that cooling water flow to UV
reactor (during startup and pause) shall give minimum flow according to Connection list, for
Item/Connection Item/Connection 403.
• 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.
Start and stop of the booster pumps are handled by signals sent from the control system. See
External component signals on page 62 via hardwire or remote interface.
5.10.3 Tank stripping

Stripping can be performed to empty the ballast tanks.
The stripping process is basically the same as a ballast process with the following difference: A
stripping eductor (or a stripping pump) should be used to secure minimum flow in the system.
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) fulfils 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.
Book No.Rev 2017–09–01 29

5.10 Ancillary equipment and functions 5 Mechanical installation
• 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.
30 Book No.Rev 2017–09–01

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 Water types

Below, the water types used in PureBallast are listed. For specifications, see the Connection list.
• Sea water: Used for cooling UV lamps in the UV reactor during start-up. Pipe 403 is
recommended to be connected to the vessel’s sea water cooling system or dedicated UV
cooling water pump (P403-1) for UV reactor cooling. Booster pump is not part of Alfa Laval’s
scope of supply.
• Low temperature (LT) fresh water: Used for cooling the lamp drive cabinet (LDC) during
operation. Pipe 401 and 402 can be connected as a loop to the fresh water cooling system.
The water must be taken from safe zone.
• Fresh water: Used for flushing and filling up of UV reactors after treatment.
6.2 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 canceled. Valves are to be closed when requested by popup or when the request
signal is redrawn (goes low).
Involved valves to and from PureBallast are listed below:
Ballast process
Flow to PureBallast pipes:
• 403 (UV reactor cooling water, during start-up).

• 401 (LDC cooling water, if not in closed loop)
• 201 (Ballast water)
Flow from PureBallast pipes:
Book No.Rev 2017–09–01 31

6.3 Pipe dimensions and material 6 Pipe design
• 201 (Ballast water to tanks)

• 309 (backflush water overboard)
• 402 (LDC cooling water)
• 404 (Reactor cooling water overboard, during start-up).
Deballast process
• 403 (UV reactor cooling water, during start-up).

• 201 (Ballast water)
• 201 (Ballast water overboard)

• 404 (Reactor cooling water overboard, during start-up).
CIP process
• 310.1 (Fresh water)

• 309 (Water from filter during filter preservation overboard)

• 460.1 (Drain reactor - ballast water and fresh water overboard)
6.3 Pipe dimensions and material

The follow recommendations apply to pipe and valve dimensions:
• Pipes shall be designed to carry the weight of the component and media.
• 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.
• Pipe 403 and valve V403-35 (cooling water valve, reactor): 50, 65 or 80
Dimension decided at order, smalles recommended.
• Pipe 309 (backflush): Pipe dimension MUST be increased to 150 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.
• CIP pipes: Non-corroding material is recommended for pipes used for CIP liquid, due to low pH
value: 320, 321 and 460.2.
• Penetration Ex zone dividing bulk heads is not recommended. If done, special precaution must
be taken with regards to applicable rules and classification society.
32 Book No.Rev 2017–09–01

6 Pipe design 6.3 Pipe dimensions and material
• It is not recommended to use plastic pipes for pipe 201 closer than approximately two meters
from the UV reactor. It UV light will affect the material and shorten its life time.
• Also see information in section Material selection on page 15.
Book No.Rev 2017–09–01 33

6.5 Pressure and flow – backflush 6 Pipe design
6.4 Pressure and flow

During ballasting, the ballast water flow goes through the filter and UV reactor which gives a
pressure drop of ≤ 0.70 bar at maximum flow rate, as described in the table below. Note that the
total pressure drop only includes the PureBallast components, not the vessel’s piping before the
first PureBallast component (Q201.1) or after the last (V201–8).
UV reactor ≤ 0.20 bar pUVR: 0.20 bar (0.02 MPa) including PureBallast valves.
Piping is not included, since it is installation specific.
Filter ≤ 0.50 bar pfilter: 0.15−0.50 bar (0.015–0.05 MPa).
Note that 0.50 bar is the default limit value for triggering an
automatic back flush (parameter p305). This parameter is
set by Alfa Laval during commissioning.
Total ≤ 0.70 bar ≤ 0.70 bar (0.07 MPa) not including piping.
6.5 Pressure and flow – backflush

During ballast, the differential pressure drop over the filter fluctuates between 0.15−0.50 bar,
depending on dirt load in the element. When the differential pressure over the filter, pfilter,
reaches 0.50 bar, a backflush operation is started automatically. To ensure sufficient backflush
flow pbackflush must be at least 1.0. bar.
BFpressure
6.5.1 Calculate pressure and flow for backflush

During backflush, the ballast water flow goes through the filter and UV reactor, and the backflush
discharge flow goes through filter and pipe 309.
A pressure calculation must be done to secure sufficient backflush flow in pipe 309 and to secure
that the ballast water pump can overcome pressure drop according to the table below:
34 Book No.Rev 2017–09–01

6 Pipe design 6.5 Pressure and flow – backflush
∆pFilter ≤ 0.50 bar (approximate value).
pBackflush ≥ 1.0 bar Required for efficient backflushing.
∆P309 Calculated Pressure drop for pipe 309 is installation specific

and must be calculated.
The required pbackflush (1.0 bar) gives the

required min flow in pipe 309 stated in the
connection list: 95 m3/h.
Use this flow to calculate the pressure loss in

P309.
Note that P309 shall include both static pressure

and dynamic pressure (pipe length, bends,
valves, lifting height etc) for pipe 309.
Total pressure drop Calculated Calculated value give
• total pressure drop during backflush

• minimum BW pump capacity required for
PureBallast.
If the value is greater than existing pump capacity,
steps must be taken, for example:
• Reduce the total pressure drop by reducing

p309. This can, for example, be done by
increasing the pipe diameter or by reducing
the number of bends etc in pipe 309.
• Upgrade to a pump with higher capacity.
6.5.2 Calculate value for backflush parameter setting

To ensure that pbackflush is ≥ 1.0 bar, the total pressure drop must be calculated according to the
formula below:
Filter outlet ≥ 1.0 + p309
This value will be entered in parameter p304 (Required pressure to start backflush) during
commissioning. The parameter defines pressure needed to perform an efficient backflush operation
and is the setpoint for the pressure that the control valve (V201-8) will maintain during backflush.
Book No.Rev 2017–09–01 35

6.5 Pressure and flow – backflush 6 Pipe design
7 Electrical design
This section contains information relevant for planning the electrical installation and routing.
7.1 Basic technical data

Power 400–440 VAC, 50/60 Hz 3 phase.
requirements
Max Icu 50 KA.
Power factor: 0.95.
24VDC - Remote control panel (optional).
Power Lamp drive cabinet

consumption
(kW)
100.0 Power to UV reactor.
Note: PureBallast only use power needed for treatment.

PureBallast automatically regulates the lamp power
between 50 and 100 % to secure the treatment
efficiency.
Control cabinet
1 Control cabinet including filter motor.
Control cabinet – Additional power for optional pumps
0.55 Pump P401–1 (optional) for LDC cooling water.
3.0 Pump P403–1 (optional) for UVR cooling water.
7.5 Pump P309–1 (optional) for filter backflush water.
IP rating Minimum rating: IP44. Details on respective drawing.
LDC – Heat Heat transfer from/to the LDC is depending on ambient temperature. The need
dissipation for cooling the area where the LDC is placed, is therefore dependent on ambient
temperature.
The calculations below can be used as a guide.
At an ambient temperature of
1. 10 °C, about 1200 W is transferred to the surroundings.

2. 25 °C, about 600 W is transferred to the surroundings.
Book No.Rev 2017–09–01 37

7.2 Installation requirements 7 Electrical design
3. 40 °C, no heat is transfer in either direction.

4. 45 °C, about 200 W is absorbed from the surroundings.
50 °C, about 400 W is absorbed from the surroundings.
All calculations are done with cooling water temperature of 38 °C degrees which is
worse case.
7.2 Installation requirements

PureBallast control 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 control cabinet and LDC: Requirements for cables supplied by installing party.
• Dimension drawings: Information about earth points.
38 Book No.Rev 2017–09–01

7 Electrical design 7.2 Installation requirements
Cables – General
• Dimension of cables must be within the cable gland range stated in the dimension drawings
for respective component.
• Major compoentnts (UVR, filter, CIP and cabinets) must be earthed. The earth nut is indicated
as “791” or “PE bolt” in the dimension drawings.
• Cabinets must be earthed. The earth nut is indicated as “791” in 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.
• Electrical cables must be properly suspended and supported according to applicable regulations.
• Cable entries to cabinets must be sealed, using the built in cable glands. See instruction Cable
glands in system manual, chapter 7. Service manual.
• Cabling shall be done according to specification in Electrical system layout on page 89, and
the electrical drawings. Cabling must also be done according to rules regarding installations in
potentially explosive environments, for example IEC 60079 series. This includes cable routing,
cable types and cable marking to simplify identification and fault finding.
• 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.
• EMC: Cables shall be peeled down to the cable shield. The shield must be connected to earth.
• Intrinsically safe circuits

Make sure that signal cables for intrinsically safe circuits (listed below) are verified in a the Exi
max multicore cable length calulation documents. These documents must be filled out to verify
that the cables chosen are safe to use in the specific installation. The documents for varifying
cables are available in section Intrinsically safe circuits on page 202.
The cables are:
W210.xx – Multi core cable for UVR components. Connection to lamp drive cabinet.
W201.8A – 1 x 2 cable for control valve V201-8. Connection to control cabinet.
Lamp drive cabinet
• Lamp power cable W211A-D (included in scope of supply) shall be connected from X3 in LDC to
X20:B in junction box on the UV reactor. Cables from junction box to lamps are pre-assembled.
Note: Lamp power cable dellivered from Alfa Laval must be used.
• The lamp power cable should not be winded. If it is to long, cut it before it is connected.
• Power cable W201.1 to be connected to main switch board: Max Icu 50 KA.
• Signal cables W210A and B to be connected from X1 in LDC to X20:A in junction box on the UV
reactor. Cables from junction box to components are pre-assembled.
Control cabinet
Book No.Rev 2017–09–01 39

7.2 Installation requirements 7 Electrical design
• Power cable W1 to be connected to control cabinet (Q1).

• A power link (LAN) shall be connected in a loop from the control cabinet to the LDC and
backSee Control cabinet / Interconnection diagram and LDC / Interconnection diagram.
• Signal and control cables to all components, including optional choices such as remote interface
and external component signals must be connected.
40 Book No.Rev 2017–09–01

8 Ex protection
This section describes the Ex protection of PureBallast. It covers the components that are part of
the Ex protection and a description of the electrical system, including the safety control system.
This information is necessary to get a full understanding of the Ex protection and how it is installed.
The illustration and tables below includes all components that are part of the Ex protection, sorted
on UV reactor, filter, CIP module and pipe net.
Requirements for Ex proof installation:
• Design and installation must follow a Ex standard for eliminating the risk of explosion, for
example IEC 60079 series.
• The person installing PureBallast must have knowledge about the specific Ex standard used to
eliminate the risk of explosion, for example IEC 60079 series.
• The party responsible for the installation shall carry out an inspection to verify that the
installation is correct regarding the Ex protection.
Summary
PureBallast Ex is classed for use in zone 1 hazardous areas in accordance to the IEC 60079 series
of standards, explosion group IIC and temperature class T4 (135°). It fulfills the European Directive
ATEX 2014/34/EU recommended by the IMO for use in marine applications and the IECEx certified
equipment scheme. All components in the zone are certified.
To secure that the UV lamp quartz sleeves are cooled, there must always be water in the UV
reactor when the lamps are lit. This is secured by the use of a check valve and monitored by double
sensors for fluid level and temperature. If any value deviates, or if signal is missing, the control
system (or safety control system) will shut down the UV reactor immediately. The UV reactor (Exd)
is hermetic sealed from outer atmosphere and is made flameproof (Exd). The LDC is separated
from the UV reactor and placed in safe zone.
During normal operation, the control system monitors PureBallast automatically, based on input
from sensors, to secure safe function. In addition to the control system, a safety control system
(Exi) is used. It is separate from the control system, and therefore redundant to strengthen the
protection allowing one fault tolerance. If the normal control system fails, the safety control system
will shut down the system. The safe control system is based on safety relays and is hardwired.
8.1 Ex components
All components in zone 1 have been chosen to be compliant with the Ex requirements. The
illustration and tables below list all electrical components that are part of the Ex protection, sorted
on UV reactor, filter, CIP module and pipe net.
For detailed information, see the EC certificates in the Ex binder delivered with the system.
Book No.Rev 2017–09–01 41

8.1 Ex components 8 Ex protection
6 EX components
42 Book No.Rev 2017–09–01

8 Ex protection 8.1 Ex components
8.1.1 UV reactor
All components on the UV reactor are connected to the lamp drive cabinet (LDC). The LDC is
then connected to the control cabinet.
No. Component ID Component and sub components
1 UV reactor UV reactor
– 2 Junction boxes
– Cable gland
2 LS201-29 Level switch

LS201-30 – Barrier (isolating amplifier) installed in LDC
3 TT201-33 Temperature transmitter

– Barrier (isolating amplifier) installed in LDC
4 TS201-60 Temperature switch

5 QT201-50 UV sensor
– Barrier (smart repeater) installed in LDC
6 V320-4 Valves
V321-2
V404-36 – Actuator (air driven)
– Solenoid coil
7 V201-19 UVR inlet and outlet valve

V201-20
– Actuator
– Solenoid coil
– Sensor, inductive
Book No.Rev 2017–09–01 43

8.1 Ex components 8 Ex protection
8.1.2 CIP module

All components on the CIP module net are connected to the control cabinet via the junction box.
No. Item number Component and sub components
8 CIP CIP module
– Tank
– Junction box
– Cable gland
– Fuse
9 P320-1 Drain pump

P321-5 CIP pump
10 V310-1 Valve with solenoid coil

V310-6
V320-2
V321-1
V321-4
V460-2
V571-1
8.1.3 Filter
All components on the filter are connected to the control cabinet via the junction box.
11 M709-43 Motor with gear and break

Motor with gear
– Inductive proximity switches

– Switching repeater
– Piston valve
– Switch Box Exe
– Switch Box Exi
– Cable Glands
12 PT201-71 Pressure transmitter

PT201-72 – Transmitter supply unit
PT309-2
13 V309-1 Backflush valve

– Solenoid coil
44 Book No.Rev 2017–09–01

8 Ex protection 8.2 Safety control system
8.1.4 Pipe net

All components in the pipe net are connected to the control cabinet via components own connection
or junction box.
14 FIT201-1 Flow transmitter
– Flow sensors
– Cable gland
– Barrier for transmitter
15 PT201-16 Pressure transmitter
– Junction box
– Cable gland
16 V201–8 Control valve
– Actuator
– Solenoid coil
– Switch box
– Cable gland
– Positioner
– Cable gland
– Barrier for sensor
17 V201-3 Valves
18 V201-9 – Actuator
– Solenoid coil
19 V201-32 – Switch box
– Cable gland
20 V212-31
21 V403-35
8.2 Safety control system

To control the system, three different circuits working as different layers are incorporated. As a
first layer the standard operation circuit. Second a safety control circuit, ensuring that the UV
reactors do not overheat. A global Emergency stop function is incorporated as a third layer
to handle unpredictable situations.
Book No.Rev 2017–09–01 45

8.2 Safety control system 8 Ex protection
6 EX description 2
This system is based on safety relays and is hardwired to avoid the need of a separate validation of
the software. All function in the safety system is using redundancy to ensure one fault tolerance.
46 Book No.Rev 2017–09–01

8.2.1 Control circuit for UV reactor

Each UV reactor has its own control circuit as shown below. The control circuit can be divided into
three separate sub-circuits as described in the following sections.
6 EX description 3
6 EX description 0
Book No.Rev 2017–09–01 47

8.2.1.1 Normal operation of UV reactor
Normal operation includes thermal protection through a PT1000 element connected to the PLC via
distributed I/O. This circuit will shut down the LPSs by breaking the 24V DC control voltage feeding
them via K1 if the UV reactor reach a temperature of 60°C.
Below, the circuit for temperature control under normal operation is shown in red.
6 EX description 4
8.2.1.2 Safety control circuit for UV reactor
The safe control circuit for the UV reactor will only affect the UV reactor and not the other parts of
the system (e.g. filter and CIP unit) since their safety are not depending on it.
This circuit works as a separate system outside the normal control system deploying two different
functions to control the overheating. It is based on a certified safety controller.
• Temperature limiting circuit – controls that the UV reactor does not overheat.
• Level control circuit – controls that the UV reactor does not run dry.
48 Book No.Rev 2017–09–01

8.2.1.2.1 Temperature limiting circuit
A redundant temperature limiting circuit consisting of one temperature limit switch (TS) and one
PT1000 element (TT) connected to KS01 via intrinsically safe barriers (IS). This interlocks the LPSs
and if the temperature rises above either of the sensors limits (TT level 1 = 60°C, TT level 2 = 62.5
°C and TS = 65°C) the UV reactor is shut down.
The output is redundant by breaking contactor group Q1, Q2 and Q3 together with interrupting the
24V DC feed to the LPSs.
Temperature limiting circuit: Below, the circuit is highlighted red.
6 EX description 5
Book No.Rev 2017–09–01 49

If the circuit is tripped, the Reset button S01 on the LDC door starts blinking. When the temperature
falls below 60 (the lowest value of the temperature transmitter and switch) the circuit is reinstalled
and the cabinet can be reset by pushing and releasing (negative edge) the Reset button S01.
Reset of temperature limit circuit: Below, the circuit is highlighted red.
6 EX description 6
50 Book No.Rev 2017–09–01

8.2.1.2.2 Level control circuit
A redundant level control circuit consisting of two level switches (LS201-29 and LS201-30)
connected to KS01 via intrinsically safe barriers (IS). These will shut down the LPS if the UV reactor
is empty for more than 9 seconds. The time of 9 seconds is long enough to allow air pockets in the
water, but not so long that any heat is produced.
If the circuit is tripped, an automatic reset will be performed when both level switches are activated
again and the input circuit is closed.
The output uses the same redundant structure as the temperature limit circuit. Below, the circuit is
highlighted red.
6 EX description 7
Book No.Rev 2017–09–01 51

8.2.1.3 Global emergency stop for the UV

reactor
The global emergency stop circuit is designed to handle unexpected situations. It will shut down the
UV reactor the same way as the safety control circuit without any delays.
6 EX description 8
8.2.2 Global emergency stop from control cabinet

The global emergency stop (S10) is a hardwired circuit that disconnects all LDCs in case of an
unexpected situation.
If global emergency stop is triggered, the PLC gets a high signal. This will in return execute
appropriate measures with all other actuators (e.g. filter and valves) in the system which does not
need to be safely disconnected by the emergency stop since their safety are not depending on it.
When triggered, the emergency stop is reset by pushing and releasing (negative edge) the Reset
button S11 on the control cabinet door.
52 Book No.Rev 2017–09–01

8.2.2.1 Diagnostics of power contactors in

LDC
Since the power contactors in each LDC (Q1, Q2 and Q3) are not monitored by the safety controller,
the feedback from them is connected to an input of the distributed I/O. This will indicate if one or
more contactors are erroneous, and the PLC will prohibit use of the system.
Below, the diagnostic function is shown in blue.
6 EX description 9
6 EX description 00
Book No.Rev 2017–09–01 53

8.2.3 Priming of the system before start

Since the piping of the ballast water system is classified as zone 1, at start up no ignition source are
allowed to be present. Therefore, the pipes are primed with seawater before the UV lamps can be lit.
The safety control system of the UV reactor secures that there is water in the UV reactor before
power on.
8.2.4 Normal stop of the system

When the system is stopped after process, there must be water in the UV reactor at the time the
UV lamps are powered off. This is controlled by the normal operation system, since this is not
considered as an unexpected event. It does not need to be controlled by the safety control system.
54 Book No.Rev 2017–09–01

9 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 shall be connected to the vessel’s instrument air system according to the following:
• Air distribution drawing: Layout and components requiring instrument air, including connection
dimensions.
• Connection list:
- Required pressure.
- Air consumption during operation and peak load (including time for peak load).
• Quality specification / Instrument air on page 95: The instrument air must be dry and clean
according to the quality specification. I not, components will be damaged and the system will
not work properly. If instrument air is not available, a solution must be implemented to achieve
air according to specification.
• Dimension drawings: Details and connection points.
Note:
• Instrument air shall always be connected.

• Instrument air to pre-assembled components (UV reactor, filter and CIP) is connected to an air
distributor. The air is then distributed to the valves via pre-mounted tubes.
Book No.Rev 2017–09–01 55

9 Pneumatic design
10 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.
The following optional integration is possible:
• Remote control panel

• Remote interface
• Power management
• External component signals
• GPS
Mandatory and optional integration
External bypass valves (if used) must be integrated to be logged by PureBallast event log. All other
interfaces are optional. Note that implemented options are tested during commissioning, wherefore
they shall be ready by that time.
10.1 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, provided the area is not hazardous. The
remote control panel is delivered with a mounting plate for installations in wall, worktop etc. It can
also be ordered with an IP protective back cover for installation on a stand or such.
• Remote control panel is mounted according to according to drawing Remote control panel /
Dimension drawing on page . Note the clearance area.
• Mounted at an optional location in safe zone.
Book No.Rev 2017–09–01 57

10.2 Remote interface 10 Control system integration
• Cable requirement for communication cable (W501) depends on lengt between remote control
panel and control cabinet. See below:
- Max 100 meters:

CABLE TYPE: Ethernet cable. Shielded Cat 5e (or better).
CONNECTION POINT FOR 1 RCP: From terminal X2 in remote control panels to terminal
X13 in the control cabinet.
CONNECTION POINT FOR 2 RCP: From terminal X2 in second remote control panel to
either switch SW1 in control cabinet or to switch SW1 in the first remote control panel.
- Max 500 meters:

CABLE TYPE: Fiber cable. Multi-mode fiber cable with LC connector. Max length: 500
meters. We recommend a cable with four or more cores are used to have spare cores if
one is broken.
CONNECTION POINT : From remote control panel’s switch SW1 to switch SW1 in control
cabinet.
10.2 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 Control
cabinet / Circuit diagram.
10.2.1 Integration process

It is importante 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 (this document) 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.
58 Book No.Rev 2017–09–01

10 Control system integration 10.3 Power management system integration
10.3 Power management system integration

It is possible to connect the PureBallast control system to the vessel’s power management system
or ISCS. The purpose is to automatically handle power request from PureBallast to secure that
enough power is available for each ballast and deballast process. A process can only start after
acceptance from the ISCS.
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. It is also possible to use
hardwire, even if remote interface is integrated.
Power management requires the following:
• Parameter setting must be done for parameter p127.

• Integration and connection of signals must be done according to the guidelines in this section.
10.3.1 Overall 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 ballast or deballast process is started from the PureBallast control system.

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 power management reserves the requested power for PureBallast and
then send power granted to the control system. If the vessel cannot provide the requested
power, less power might be granted. The exact granted power is always visible in the field
Calculated power consumption in control system page 1.5 Power request or 1.1 Overview.
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.
10.3.2 Power steps and power signals

The power management system is based on defined power steps, defining the power needed for 1-6
UV reactors: Step 1 extend to one UV reactor and step 2 extend to three UV reactors. Actual power
needed for process is defined under item Power consumption in section Technical data on page .
Signals are defined to handle all combinations of power step (amount of power) and function
(request, grant and run). More than one signal can be sent (or received) at the same time to
achieve, for example step 1 and 2 to request power for 3 UV reactors.
As an alternative, it is possible to use power step 4 (common) that always will be used, regardless
of the number of UV reactors used for a specific process. The common power is defined as the
number of installed UV reactor times the defined power consumption for one UV reactor.
Book No.Rev 2017–09–01 59

10.3 Power management system integration 10 Control system integration
Function signal No. of Signal to terminal

UV re-
actor:s
Request, step 1 1 Terminal strip X2

Terminal 41/42.
Request, step 2 2 Terminal strip X2

Terminal 43/44.
Request, step 4 1-3 Terminal strip X2

(common) Terminal 47/48.
Granted, step 1 1 Relay module X12.

Relay K5. Connection
point BB and A1.
Granted, step 2 2 Relay module X12.

Relay K6. Connection
point BB and A1.
Granted, step 4 1-3 Relay module X12.

(common) Relay K8. Connection
point BB and A1.
Running, step 1 1 Terminal strip X3

Terminal 49/50.
Running, step 2 2 Terminal strip X3

Terminal 51/52.
Running, step 4 1-3 Terminal strip X3

(common) Terminal 55/56.
10.3.3 Power management installation

Integration shall be done according to
• Control cabinet / Interconnection diagram

• Control cabinet / Circuit diagram
• Remote interface implementation guide, which can be required from your local Alfa Laval
sales office.
Note that It is only necessary to connect enough signals to cover the number of UV reactors
installed on the vessel. If one UV reactor is installed it is only necessary to connect step 1 for
request, granted and running.
After installation, the signals need to be tested. This is done by simulating signals from the control
system, page 1.4 Power request. See ststem manual, chapter 3. Operating instructions and control
system description, instruction Simulate power request.
60 Book No.Rev 2017–09–01

10 Control system integration 10.4 External feed control signal
10.4 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.
The purpouse of external feed is to avoid cavitation by reducing the flow before it reaches
PureBallast so that flow does not have to be reduced by PureBallast’s control valve V201-8.
Normally when the flow is high, the flow is only reduced by V201-8. If V201-8 is closed to a high
degree, there is a risk for cavitation in the system with noise, vibration and wear of V201-8 as
consequences.
When external feed is used, PureBallast controll system will request increased/decreased flow. The
signal is intended to regulate the pump speed of a frequency controlled ballast water pump, but can
also be used to regulate opening and closing of a valve installed before PureBallast. The signal can
either be sent via remote interface (optional) or by a hardwired 4-20 mA external feed signal.
10.4.1 Feed regulation during operation

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, 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.
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 V201-8 (blue line) increases slowly until it is completely open. External feed signal
(black line) increases to let the valve end in a position where it can start controlling
the flow again.
Area 2 V201-8 closes to build up pressure (yellow) for a backflush. When a backflush
is triggered, the external feed control signal remain unchanged to secure flow
for the backflush.
When the 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
Book No.Rev 2017–09–01 61

10.5 External components 10 Control system integration
pump, so that V201-8 can open. Less flow is needed after the backflush, since the
the filter is clean.
3 CalibExampleExtFeed
10.5 External components

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, except from External feed control. 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.
Installation requirements:
The signal cables are connected according to
• Control cabinet / Interconnection diagram

• Control cabinet / Circuit diagram:
62 Book No.Rev 2017–09–01

10 Control system integration 10.5 External components
• 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 Explanation
Common alarm What: Output signal from PureBallast that there is an (any) active
(mandatory to be alarm. An alarm shuts down ongoing process.
integrated)
Why: Common alarm must be 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 address 07:7.
How: 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 What: As common alarm, but for warnings. A warning is a

notification of status change or a problem.
Why: See common alarm. Alternative to alarm indication via remote

interface address 07:8.
How: See common alarm.
External bypass 1, 2, 3 What: Input signal to PureBallast that an external bypass valve (not
is open part of Alfa Laval’s scope of supply).
Why: If PureBallast can be bypassed using other valves (apart from

V212-31), status signals from them must be integrated to the control
system. All bypass cases must be logged. When any bypass valve
is opened, ongoing process is terminated and the event is logged.
All bypass cases must be logged in the event log. The event log
state the position of the bypass valve (open/close) and time for
status change, not the reason for opening 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.
Three additional bypass valves can be handled via hardwire,

identified as additional bypass valve 1, 2 and 3. If more valves are
used, they must be connected in series, which means that they are
handled as one regarding alarms and logging in PureBallast.
Book No.Rev 2017–09–01 63

10.5 External components 10 Control system integration
Signal Explanation
If remote interface is implemented, feedback signals can be

connected via the remote interface, which allows a great number
of components to be connected.
How: Open circuit = Valve open.
Request ”Open What: Output signal from PureBallast to request opening of relevant
overboard valves” valves (not operated by PureBallast). After process is stopped, the
signal goes low to request that the valve are closed.
For relevant valves, see Valves outside PureBallast on page 31. .
Used in combination with Feedback (below).
Why: If Request and Feedback signals are integrated, the operator

does not have to confirm that the OB valve is open/closed in a popup
in the control panel during operation.
How: Request = Closed circuit. No request and request withdrawal

= Open circuit.
Feedback ”Overboard What: Input signal to PureBallast to confirm that relevant valves
valves are open” are open.
Why: See Request signal above.
How: Closed circuit = Valve open.
Request ”Start BW What: Output signal from PureBallast to request start of the ballast
pump” water pump. After process is stopped, the signal goes low to request
pump to be stopped.
Used in combination with Feedback (below).

does not have to confirm that the pump is started/stopped in a popup
in the control panel during operation.

= Open circuit.
Feedback ”Ballast water What: Input signal to PureBallast to confirm that the ballast pump
pump is running” is started.
How: Closed circuit = Pump running.
64 Book No.Rev 2017–09–01

10 Control system integration 10.5 External components
Signal Explanation
Request ’’Start stripping What: Output signal from PureBallast to request start of stripping
pump’’ pump (not operated by PureBallast). After process is stopped, the
signal goes low to request that the pump is stopped.

does not have to confirm that the stripping pump is started in a
popup in the control panel during operation.
If the ballast water pump is used for stripping, it must be connected

both to the “Start BW pump” request and this request.

= Open circuit.
Feed back “Stripping What: Input signal to PureBallast to confirm that the stripping pump
pump is running’’ is started.
How: Closed circuit = Pump running.
LDC cooling water pump What: Output signal from PureBallast to request start of the LDC
(P401-1) cooling pump for line 401. Pump P401-1 is used during ballast,
deballast, pause and heeling mode.
Why: If required cooling water flow to LDC (during operation)

cannot be established with existing system, a booster pump must
be installed and connected to PureBallast. Required flow is stated
in Connection list, for Item/Connection 401.

= Open circuit.
UV reactor cooling water What: Output signal from PureBallast to request start of the UV
pump (P403-1) reactor cooling pump for line 403. Pump P403-1 is used during
start-up, ballast, deballast, pause and heeling mode.
Why: If required cooling water flow to reactor (during startup and

pause) cannot be established with existing system, a booster pump
must be installed and connected to PureBallast. Required flow is
stated in Connection list, for Item/Connection 403.

= Open circuit.
Book No.Rev 2017–09–01 65

10.6 GPS 10 Control system integration
Signal Explanation
Backflush pump What: Output signal from PureBallast to request start of the
(P309-1) backflush pump for line 309. Pump P309-1 is used during backflush
to established required flow in the pipe.
Why: If required flow in P309 can not be established, , a booster

pump must be installed and connected to PureBallast. Required
flow is stated in Connection list, for Item/Connection Filter.

= Open circuit.
Heeling mode (internal What: Input signal to PureBallast to enter heeling mode. Equal to
transfer) pushing the Pause button in control system.
Why: If integration of heeling command from ISCS is desired to

automatically pause ongoing ballast/deballast process for a healing
operation.
How: Closed circuit = Heeling mode command. Only possible

in standby, ballast or deballast. Must be connected via hardwire
(W116).
External system stop What: Input signal to PureBallast to shut down the system.
Why: If extra button (not part of AL scope of supply) to shut down

PureBallast are desired on board. The power is still on.
How: Open circuit = System stop command. Must be connected

via hardwire (W118).
PureBallast running What: Output signal from PureBallast that a process is running.
Why: If desirable to indicate that a PureBallast process is ongoing,

for example with a light or in another system.
How: PureBallast running = Closed circuit.
10.6 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 and should
be connected to module X20IF1030 in the control cabinet.
The following settings must be used:
66 Book No.Rev 2017–09–01

10 Control system integration 10.6 GPS
• 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.
Note: If RMC is used, time and date in the control system is retrieved from vessel’s GPS.
Book No.Rev 2017–09–01 67

10.6 GPS 10 Control system integration
11 System approval
Before a system is approved for usage and installation, a number of approvals are needed.
11.1 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.
11.2 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.
11.2.1 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.
11.2.2 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.
Book No.Rev 2017–09–01 69

11.3 Alfa Laval commissioning 11 System approval
11.2.2.1 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
(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.
• Ex certificates for components installed in zone 1, according to Ex certificate list, supplied
by Alfa Laval.
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.
11.2.3 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.
Note: The customer is responsible for final detailed inspection to ensure that the system is installed
according to IEC 60079 series.
11.3 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.
70 Book No.Rev 2017–09–01

12 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 system.
12.1 Delivery and transport

Preparations and conditions:
• Before installing the system, read the system manual and follow the instructions in Design and
installation guide and system manual 7. Service manual.
• Always read and follow the documentation included in shipment of components and spare
parts regarding handling, safety and disposal.
• Handle the delivery with care in order not to damage the equipment or cause personal injuries.
12.2 Lifting instructions

This section describes how to lift the heavier PureBallast components, including weights.
Preparations and conditions
NG
WARNI
!
• Components must be lifted using correct lifting tools (such as a forklift truck, a crane) and tackle
with a load capacity greater than the weight of the component.
• Any complementary lifting instructions must be followed.
• Components must be empty when lifted.
• The UV reactor, filter, CIP and control cabinet must be lifted according to the instructions in
the following sections.
Book No.Rev 2017–09–01 71

12.2 Lifting instructions 12 On board installation planning
12.2.1 UV reactor
Weight of UV reactor (empty): 560 kg. L=750 mm.
6 AOT Lift
72 Book No.Rev 2017–09–01

12 On board installation planning 12.2 Lifting instructions
12.2.2 Filter
Protect external components or remove from filter, under lifting.
Weight of filter (empty with adaptor plates on flanges): 1150 kg.
A=950 mm.
6 FilterLift
Book No.Rev 2017–09–01 73

12.2.3 CIP module
6 CIP Lift, new 9004908
12.2.4 Cabinets
Use intended lifting attachment at the top of the cabinet.
Control cabinet
Weight: 50 kg.
Center of gravity: A=500 mm. B=300 mm.
Protect the control panel screen when lifting the control cabinet.
Lamp drive cabinet
LDC weight: 430 kg.
74 Book No.Rev 2017–09–01

12 On board installation planning 12.2 Lifting instructions
Center of gravity: A=1050 mm. B=550 mm.
6 CabinetLift
Example: Control cabinet
Book No.Rev 2017–09–01 75

13 Start-up procedures
The actions below must be performed after installation, before system is put into operation. This is
important to avoid that the filter and the UV reactor is damaged by material from the ballast tanks
or remainders from the installation. These actions shall be performed both for new builds and
retrofit installations.
Before first operation
Before the system is operated the first time the actions below must be done.
NOTE
• All pipes leading to PureBallast must be well flushed to avoid that debris harm the filter and
UV reactor quartz sleeves.
• All ballast water tanks must be well cleaned before PureBallast is tested or put into operation.
This is valid both for new builds and retrofit installations.
First operation
Before first operation the actions below must be done:
• During the first operation, the filter shall be bypassed, to avoid that debris harms the filter
elements.
• We recommend that a strainer is used during the first operations, to avoid that debris harms
the system.
• The first time a tank is stripped, PureBallast must be bypassed, to avoid that debris harms
the system.
Book No.Rev 2017–09–01 77

13 Start-up procedures
14 Drawings
This section contains drawings for the PureBallast system. It is divided into three main parts:
• General drawings – overall and principle information for system layout (pipes, components,
electricity, air and water).
• Dimension drawing – detailed component information (dimensions, sizes etc).
• Electrical drawings – detailed electric information (circuit diagrams, cable lists etc).
See the Contents section at the beginning of this document to get an overview of included drawings.
Book No.Rev 2017–09–01 79

14.1 Graphic symbols used in drawings 14 Drawings
14.1 Graphic symbols used in drawings

Symbols used in drawings are according to ISO 14617. Below, a guiding extract is shown.
573644
80 Book No.Rev 2017–09–01

14 Drawings 14.2 General drawings
14.2 General drawings
14.2.1 Flow chart
(15A)
(150A)
(32A)
(350A)
(32A)
(32A)
(32A)
(32A)
(32A)
(350A)
(350A)
(32A)
(50A)
9025605
Book No.Rev 2017–09–01 81

14.2 General drawings 14 Drawings
14.2.2 Technical data
9008504
82 Book No.Rev 2017–09–01

14.2.3 Connection list
Book No.Rev 2017–09–01 83

9015785_Page_1
9015785_Page_2
84 Book No.Rev 2017–09–01

9015785_Page_3
Book No.Rev 2017–09–01 85

9015785_Page_4
86 Book No.Rev 2017–09–01

9015785_Page_5
Book No.Rev 2017–09–01 87

9015785_Page_6
88 Book No.Rev 2017–09–01

89
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9010001
92 Book No.Rev 2017–09–01

14.2.6 Quality specification / Instrument air
553407
Book No.Rev 2017–09–01 93

14.2.7 Quality specification / Fresh water
590773
94 Book No.Rev 2017–09–01

14.2.8 Quality specification / CIP liquid
Book No.Rev 2017–09–01 95
594956
14.2.9 Material data sheet / UV lamp
96 Book No.Rev 2017–09–01

Book No.Rev 2017–09–01 97

98 Book No.Rev 2017–09–01

Book No.Rev 2017–09–01 99

100 Book No.Rev 2017–09–01

Book No.Rev 2017–09–01 101

102 Book No.Rev 2017–09–01

Book No.Rev 2017–09–01 103

104 Book No.Rev 2017–09–01

Book No.Rev 2017–09–01 105

14.2.10 Safety data sheet / CIP liquid
106 Book No.Rev 2017–09–01

Book No.Rev 2017–09–01 107

108 Book No.Rev 2017–09–01

Book No.Rev 2017–09–01 109

110 Book No.Rev 2017–09–01

Book No.Rev 2017–09–01 111

112 Book No.Rev 2017–09–01

Book No.Rev 2017–09–01 113

14.3 Dimension drawings including technical 14 Drawings
data
14.3 Dimension drawings including technical data
14.3.1 UV reactor (previously called AOT reactor)
114 Book No.Rev 2017–09–01

9007161#3
14 Drawings 14.3 Dimension drawings including
technical data
14.3.2 Filter
Please also refer the page of "14.3.11 Backflush valve V309-1".

201
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Book No.Rev 2017–09–01 115

9024528
data
14.3.3 CIP module (2 pages)
116 Book No.Rev 2017–09–01
9014866_01
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9014866_02
Book No.Rev 2017–09–01 117

data
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118 Book No.Rev 2017–09–01

9024587
technical data
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PI201-18, RV201 and 201-15)

9015723
119
data
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PT201-16, PI201-18, RV201 and 201-15)
120 Book No.Rev 2017–09–01

9011098
technical data
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9007179
Book No.Rev 2017–09–01 121

data
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V201-32
V403-35
9007181
122 Book No.Rev 2017–09–01

technical data
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Note: For pipe dimension 600, see drawing 9008462.
9007177
Book No.Rev 2017–09–01 123

data
9008462
124 Book No.Rev 2017–09–01

technical data
14.3.10 Control valve V201-8
9007183
Book No.Rev 2017–09–01 125

data
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9025960
126 Book No.Rev 2017–09–01

technical data
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9004842#3
Book No.Rev 2017–09–01 127

data
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of supply)
128 590066 1
technical data
590066 2
Book No.Rev 2017–09–01 129

data
590066 3
130 Book No.Rev 2017–09–01

data
14.3.15 Control cabinet
9012102#3
132 Book No.Rev 2017–09–01

technical data
14.3.16 Remote control panel (Optional)
9012094
Book No.Rev 2017–09–01 133

data
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9029115
134 Book No.Rev 2017–09–01

technical data
14.3.18 Air filter / Filter regulator (Optional)
9018092
Book No.Rev 2017–09–01 135

data
14.3.19 Additional pumps (Optional)

LDC cooling water pump P401–1 (Optional)
9025768
136 Book No.Rev 2017–09–01

technical data
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9029122
Book No.Rev 2017–09–01 137

data
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9025772
138 Book No.Rev 2017–09–01

technical data
14.3.20 UV reactor and LDC / Lamp power cable
9007280
Book No.Rev 2017–09–01 139

14.4 Electrical drawings 14 Drawings
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14.4.1 Control cabinet / Interconnection diagram

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14.5 Intrinsically safe circuits 14 Drawings
14.5 Intrinsically safe circuits

Signals from intrinsically safe apparatus’ to the safe zone are handled as IS circuits. This section
gives necessary information about how to select and verify cables for the intrinsically safe circuits.
It also contains the Exi max multicore cable length calulation documents that shall be filled out.
Cable selection
The five IS circuit cables are not delivered by Alfa Laval, and must therefore be selected by the
party responsible for designing PureBallast. The cables must be correct for installation in the
hazardous zone, and they must match the requirements for the intrinsically safe circuits according
to the Exi max multicore cable length calulation.
Requirements for each cable (and underlying apparatuses) are described in the Exi max multicore
cable length calulation documents. The table below is an overview of the documents. After the
table, the documents are available. Each The documents are sorted in two levels:
• Example calculation: Example of standard cables and how to calculate cable specifics to
verify that the cable can be used.
• Verification fo selected/installed cable: Documents describing the basic data for the
underlaying apparatuses. This section shall be filled out according to the instruction. They can
also be used if a cable needs to be changed after installation.
Verification Reference Component

documents documents
Cable ID Intrinsically safe
apparatus ID
W210A LS201-29 Level switch
TS201-60 Temperature switch (simple apparatus)
TT201-33 Temperature transmitter (simple apparatus)
QT201-50 UV sensor
W210B LS201-30 Level switch
V201-19GS Inductive sensors, valve position
V201-20GS Inductive sensors, valve position
W2018A V201-8 Valve positioner (Simple apparatus)
Instruction for updating verification documents
Follow the instruction for each of the five verification documents for the IS circuit cables.
1. Read the example in respective document.
2. Verify that the intended cable complies with stated parameters in the document according to
section Verification of selected/installed cable.
3. Send the completed documents to ship yard / owner for storage on board the vessel.
202 Book No.Rev 2017–09–01

14 Drawings 14.5 Intrinsically safe circuits
14.5.1 Exi max multicore cable length calulation – V201–8
Book No.Rev 2017–09–01 203

204 Book No.Rev 2017–09–01
9025366_Page_2
14.5.2 Exi max multicore cable length calulation – UVR components
Book No.Rev 2017–09–01 205

206 Book No.Rev 2017–09–01
9017961_Page_2
Book No.Rev 2017–09–01 207
9017961_Page_3
208 Book No.Rev 2017–09–01
9017961_Page_4
Book No.Rev 2017–09–01 209
9017961_Page_5
210 Book No.Rev 2017–09–01
9017961_Page_6

MM-40 - Final - Drawing, Design & Installation Guide

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MM-40 - Final - Drawing, Design & Installation Guide

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Droits d'auteur :

Formats disponibles

Final drawing

Design and installation guide

Telephone: +46 8 530 650 00

Telefax: M+46 8 530 310 40

This publication or any part there of may not be

PUREBALLAST EQUIPMENT SPECIFICATION

Type PureBallast 3.1EX 1000 m3/h

Items Parts No. Quantity (per ship)

Quarts sleeve set 594645 82 1

CIP liquid (15 liters) 9012167 01 1

3 Alfa Laval’s scope of supply 11

4 Material and equipment supplied

8.2 Safety control system 45

10 Control system integration 57

10.3 Power management system integration 59

10.4 External feed control signal 61

11.3 Alfa Laval commissioning 70

12 On board installation planning 71

14.4 Electrical drawings 140

14.5 Intrinsically safe circuits 202

Flow range (m3/h) Ballast: 195 → 1000

Deballast: 100 → 1000

Stripping: 100 → 333 .

Flange standard (EN or JIS) _________

Main valve and piping Dimension: ________________

Control valve (201-8) Dimension: ________________

Bypass valve (V212–31) Dimension: ________________

Alfa Laval’s or other

Cooling water valve (V403-35) Dimension: ________________

Cooling water valve (V401-1) Dimension: ________________

Sampling device Location Q201.1: __________________

Alfa Laval’s or other Location Q201.2: __________________

Power consumption, max _________

Remote operation (optional) Location:

Remote control panel 1: ________________

Remote control panel 2: ________________

Remote interface integration (yes/no): _____

Book No.Rev 2017–09–01 7

2.1 Safety information

Book No.Rev 2017–09–01 9

Filter, 1 piece Filter Mechanical filtration of the water before treatment.

Book No.Rev 2017–09–01 11

Filter inlet V201-3 Function as

12 Book No.Rev 2017–09–01

Flow sensor FIT201-1 The flow meter consists of two components:

Flow sensor monitor the flow in the system. Functions together

Flow transmitter send flow information to the control system. It

Pressure PT201-16 Monitor pressure and send it to the control system.

System Information about operation, control system parameters,

Book No.Rev 2017–09–01 13

Examples of not included equipment:

4.1 Material selection

Book No.Rev 2017–09–01 15

Used material shall be indicated in appropriate drawings.

16 Book No.Rev 2017–09–01

5.1 General requirements

- relative humidity of max 100 %

Book No.Rev 2017–09–01 17

Install PureBallast components in respective locations according to the table below:

Zone 1 Safe zone

5.3.1 General requirements

18 Book No.Rev 2017–09–01