Alfalaval PureBallast 3.0 Flow 1000 User guide

System Manual - PureBallast 3.0 Flow 1000PB-00479
PureBallast Ballast Water Treatment System
PureBallast Ballast Water Treatment System
System Manual
English

Table of Contents
Safety 1
System Description 2
Operating Instructions and
Control System
Description 3
Parameters 4
Alarms and Faultfinding 5
Installation and Drawings 6
Service Manual 7
Spare Parts Catalogue 8
PureBallast: Ballast Water
Treatment System
Only foreseeable conditions have been taken into
consideration. No warnings are given for
situations arising from unintended usage of the
system components and tools.
Marine & Diesel Equipment
Printed 2014

Alfa Laval reserves the right to make changes at any time without prior notice.
Any comments regarding possible errors and omissions or suggestions for improvement of this
publication would be gratefully appreciated.
Copies of this publication can be ordered from your local AlfaLaval company.
Published by: : Alfa Laval Tumba AB
E-147 80 Tumba, Schweden
Telefon: [phone]
Telefax: [phone]
© Alfa Laval Tumba AB 2014

Chapter: 1. Safety
System manual — PureBallast 3.0 Flow 1000
Book No. 9010183 02, rev. 2

Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: [phone]
Telefax: [phone]
This publication or any part there of may not be
reproduced or transmitted by any process or
means without prior written permission of Alfa
Laval Tumba AB.

Contents
1 Introduction 5
2 Safety information 7
2.1 General safety information 7
2.2 Specifc safety information 7
2.3 Personnel requirements 9
2.4 Warning signs used in the manual 9
3 Environmental issues 11
3.1 Unpacking 11
3.2 Other materials 11
3

1 Introduction
This chapter contains general safety and environmental information, personnel requirements and
explanations of symbols used for the PureBallast system.
Book No.9010183 02, rev. 2 5

1 Introduction

2 Safety information
This section contains safety information. This information must be read and understood before the
system is installed, operated and maintained.
2.1 General safety information
The following general safety information apply:
• The PureBallast system is not EX proofed and must not be installed in areas where an
explosive atmosphere may occur.
• Use the equipment only for the purpose and parameter range specified by Alfa Laval.
• Use only Alfa Laval genuine spare parts.
• Always read and follow the documentation that is included in shipment of components and
spare parts regarding handling, safety and disposal.
• Mobile cell phones must not be switched on within an area of 1 meter from an open cabinet door.
• Before installation, read applicable sections in chapter 6. Installation instruction and drawings.
• Before operation, read the Preparations and conditions section for applicable instructions in
chapter 3. Operating instructions and control system description.
2.2 Specifc safety information
The following safety information apply for the areas and components below. This information is also
stated in the Preparations and conditions section for applicable instructions.
Maintenance safety items
• Before maintenance, read the Preparations and conditions section for applicable instructions in
chapter 7. Service manual. Essential safety information is stated before instruction to routines
that might involve any danger.
• Before maintaining the PureBallast system, the following valves must be locked in closed
position: V201-3, V201-9, and V201-8.
• Components must be lifted using correct lifting tools (such as a fork-lift truck, a crane) and tackle
with a load capacity greater than the weight of the component. See the Technical data section
on page for information about weight. Any complementary lifting instructions must be followed.
• Always disconnect the PureBallast system from the power supply before disassembling, and
secure it from being switched on.
Reactor module safety items
• Cut hazards: Sharp edges on broken UV lamps and quartz sleeves can cause cuts. Exercise
great care when handling them.
• Before installation, check that the UV lamps and quartz sleeves are not broken.
Book No.9010183 02, rev. 2 7

2.2 Specific safety information 2 Safety information
• Depressurize reactors and allow equipment to cool down completely before disassembling. Hot
water may escape from the reactor when removing the drain plug.
• Never handle UV lamps before they are completely cooled down. A hot UV lamp is under
high internal pressure, and the risk of bursting exists. A hot lamp could also cause a burn
if it is touched.
• The reactor must not be under pressure when dismounting the UV lamps.
• UV lamps radiate ultraviolet radiation when lit. Only operate the UV lamp when correctly
installed inside the reactor with end caps properly closed.
• UV lamps contain a small amount of mercury (less than 0.2 grams per lamp) and must be
handled with care. Please refer to national regulations regarding disposal of used lamps. If
a UV lamp is broken, mercury could be spilt. Remove mercury with a special tool such as a
syringe (or use pure sulphure to bind the mercury for easy collection).
- Do not allow mercury to come in contact with your eyes or skin.
- Do not inhale mercury fumes. In case of having inhaled mercury fumes, consult a doctor
and follow medical instructions.
- Free mercury must be kept in an airtight bottle, and must be disposed of according to
national regulations.
• Operation and/or manual start of the UV lamps is only allowed when there is water in the reactor
(indicated by level switch LS201-29), and the water temperature is below 60 °C. Improper
operation could seriously damage the equipment and injure personnel.
• Manual operation of LPS, may only be performed after cable connection. If not hazardous
situation may arise which, if not avoided, will result in death or serious injury.
• Before maintenance of the LDC: Switch off the PureBallast system and disconnect it from the
power supply. The LDC contains a fan, which can cause injury if in operation.
Flow meter safety items
• Potential hazards / Grounding: The mains protective grounding wire must be connected to the
terminals in accordance with the diagram (class 1 power supply).
Valve safety items
• Actuators must not be pressurized at any time during installation as it may result in injury.
• Lock valve in closed position before maintenance.
CIP safety items
• CIP liquid: Risk for eye and skin irritation. Avoid contact with eyes and wear protective
gloves. Follow general rules when handling of cleaning agents regarding ventilation, personal
protection etc.
• Before disassembling the pump, the pneumatic hoses must be disconnected, and the extension
pipe must be removed and blocked.
• Always wear protective eye glasses and gloves while working on the pump.
Ancillary component safety items
• Control panels may only be cleaned when set in wipe mode. This is to prevent unintended
functions from being triggered by buttons pressed during cleaning.
• Temperature switch, temperature transmitter and level switch. The external surface may be hot.
Care must be taken to avoid possible burns.
8Book No.9010183 02, rev. 2

2 Safety information 2.4 Warning signs used in the manual
2.3 Personnel requirements
The PureBallast system must be operated, installed, maintained and repaired by persons trained for
respective type of work. All persons using and working with the system must know the emergency
stopping procedures.
Personnel installing, maintaining or repairing components must be of one of the following categories:
•Skilled person: A person with technical knowledge or sufficient experience to perform
the tasks at hand and to enable him or her to perceive risks and to avoid hazards which
electricity/mechanics can create.
•Instructed person: A person adequately advised or supervised by a skilled person to enable
him or her to perceive risks and to avoid hazards which electricity/mechanics can create.
•Alfa Laval service engineer: A person with vast knowledge about the PureBallast system.
Alfa Laval service engineer can set parameters and repair intrinsically safe apparatuses. The
person must have experience of similar types of work and be certified in accordance with
local regulations.
In some cases special skilled personnel may need to be hired, like electricians and others. In some
of these cases the personnel has to be certified according to local regulations with experience of
similar types of work.
2.4 Warning signs used in the manual
D
!ANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
!WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
!CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
NOTE
NOTE indicates a potentially hazardous situation which, if not avoided, may result in property damage.
Book No.9010183 02, rev. 2 9

2.4 Warning signs used in the manual 2 Safety information

3 Environmental issues
This section contains general rules regarding environmental issues. However, local rules and
regulations should be consulted for detailed handling of each material.
3.1 Unpacking
• Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps.
• Wood and cardboard boxes can be reused, recycled or used for energy recovery.
• Plastics should be recycled or burnt at a licensed waste incineration plant.
• Metal straps should be sent for material recycling.
3.2 Other materials
• Rubber and plastics should be burnt at a licensed waste incineration plant. If not available they
should be disposed to a suitable licensed land fill site.
• Metal parts should be sent to a licensed handler for material recycling.
• Seal rings should be disposed of in a licensed land fill site. Check the local regulations.
• Worn out or defected electronic components should be sent to a licensed handler for material
recycling.
• The operator panel contain the following components with substances that might be hazardous
to health and the environment: lithium battery, electrolytic capacitor and display. They shall
be recycled according to local regulations.
• Used lithium batteries from the control unit are considered hazardous waste and should be
disposed of accordingly.
• Used UV lamps can be handled and disposed of in the same way as fluorescent lamps. Please
refer to national regulations.
• Used quarts sleeves should be disposed of as ordinary glass.
Book No.9010183 02, rev. 2 11

Chapter: 2. System description
System manual — PureBallast 3.0 Flow 1000
Book No. 9010183 02, rev. 2

Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: [phone]
Telefax: [phone]
This publication or any part there of may not be
reproduced or transmitted by any process or
means without prior written permission of Alfa
Laval Tumba AB.

Contents
1 Introduction 5
1.1 Components overview 5
1.1.1 Item numbers 6
1.2 System overview 6
1.3 Abbreviations 6
2 Process overview 9
2.1 Start-up 10
2.2 Ballasting 11
2.2.1 Power optimization 11
2.2.2 Backflush 12
2.2.3 Ballast after-treatment (CIP) 14
2.3 Deballasting 15
2.3.1 Deballast after-treatment (CIP) 15
2.4 Stripping with eductor 16
2.5 Ballast water handling in the event of
malfunction 17
3 System components description 19
3.1 AOT reactor 19
3.1.1 AOT reactor working principle 19
3.1.2 AOT reactor description 20
3.2 Lamp drive cabinet (LDC) 21
3.2.1 LDC working principle 22
3.2.2 LDC description 22
3.3 Filter 24
3.3.1 Filter working principle 24
3.3.2 Filter description 24
3.3.3 Backflushing for different dirt loads 27
3.4 CIP (cleaning-in-place) module 29
3.4.1 CIP working principle 29
3.4.2 CIP module description 29
3.5 Control cabinet and control system 30
3.5.1 Control system 31
3.5.2 Main control panel 31
3.5.3 Remote control panel (optional) 32
3.5.4 Remote interface (optional) 33
3

3.6 Main valves 33
3.7 Flow meter 34
3.8 Pressure monitoring device 34
3.9 Sampling devices 34
4