Alfalaval PureBallast 3.1 Compact User guide

System Manual - PureBallast 3.1 Compact3%
PureBallast Ballast Water Treatment System
PureBallast Ballast Water Treatment System
System Manual
English

1 PureBallast 3.1 System
manual
The PureBallast 3.1 is available in several sizes, defined by the system’s max treatment rated
capacity (TRC). The TRC is included in the system name and the title of each system manual.
The basic document describing the system is the connection list, and the therein stated flow chart.
Those documents are included in the system manual, chapter 6, Installation description and
drawings.
The tables in this document lists the PureBallast systems with reference to the system manual
describing them and the connection list and flow chart defining them.
Versions. The USCG version use flow control to be compliant with USCG legislation. The USCG HP
(high performance) have double reactor capacity which allows treatment at full capacity at all time.
1.1 Manual compillation
PureBallst system Manual no. Connection list Flowchart
85 Compact USCG 9028175 02 9018539 9015279
135 Compact USCG 9028177 02 9025974 9015279
170 Compact USCG 9028179 02 9018541 9015279
250 Compact USCG 9028180 02 9023101 9021414
300 Compact USCG 9027450 02 9023102 9021414
PureBallst system Manual no. Connection list Flowchart
85 Compact USCG HP 9028176 02 9025973 9015279
150 Compact USCG HP 9028178 02 9025975 9021414
Book No.9028495 02, rev 1

1.2 Main component makers 1 PureBallast 3.1 System manual
1.2 Main component makers
Reference is made to flow chart 9015279 and 9021414.
Flowchart
legend Component Manufacturer Model (Size according to connection list)
Filter:
Automatic
self-cleaning
filter
Filtrex
ACB-xx-yy, 20 µm mesh
(xx=906 – 945,
yy= DN100 - DN200)
UV reactor
UV reactor, 170 or,
UV reactor Wallenius Water UV reactor, 300
UV lamp Wallenius Water Medium pressure UV lamp, 3 kW
Lamp sleeve Wallenius Water Synthetic Quartz 9000738 02
QT201-50 UV sensor
UV-TECHNIK,
IL Metronic
Sensortechnik GmbH
SUV 20.2 Y2 C 40° 1000 W/m²
TS201-60 Temperature,
switch JUMO Bimetal Temp. Switch 60.8301
TT201-33 Thermometer,
resistance JUMO Dtrans Temp. probe 90.2815
LS201-29 Vibration limit
switch PEPPERL+FUCHS Vibracon LVL-A7
Valves:
-Siemens SIPART PS2, Positioner
- Air Torque Spa AT range, Actuator
V201-8 Flow control
valve -ARIArmaturen ARI –GESA, Lugged valve
- PEPPERL+FUCHS NBN3…, Inductive pos. sensor
Air Torque Spa AT range, Actuator
V201-3, -9,
-19 & -32
Filter inlet, outlet,
by-pass, & Start
up cooling valve -ARIArmaturen ARI –GESA, Lugged valve
- Air Torque Spa AT range, Actuator
V309-1 Filter backflush
valve -ARIArmaturen ARI –GESA, Lugged valve
- Rotech ALB ACR3.., Pos. switch box
- Air Torque Spa AT range, Actuator
-Rotork ILG-D series, Handwheel
V212-31 By-pass valve
-ARIArmaturen ARI –GESA, Lugged valve
Flow meter:
FIT201-1 Flow transmitter Endress+Hauser Promag 50W1F
System and diff. pressure Transmitter:
PT201-15
&-72
Pressure
transmitter JUMO MIDAS S07
Cleaning in Place (CIP) components
V310-1,
V320-2,
V460-1, -2,
-3, -4, -5 &
V571-1
Valve SMC VNB
P460 Pump Tapflo T50, Pneumatic pump
P320-1 Pump SMC PB1013A, Pneumatic dosing pump
2Book No.9028495 02, rev 1

1 PureBallast 3.1 System manual 1.2 Main component makers
Flowchart
legend Component Manufacturer Model (Size according to connection list)
LS320-3 Level sensor PEPPERL+FUCHS CBN10.., Capacitive sensor
T320 CIP cleaning
liquid Alfa Laval Alpacon Descalant Offshore
Electrical cabinet (EC):
Electrical cabinet Alfa Laval EC 3.1
Book No.9028495 02, rev 1 3

PureBallast 3.1 85 Compact
USCG
Lit. Code 200000695-1-EN-GB
Manual No. 9028175 02 v. 6
System manual

Published by
Alfa Laval Tumba AB
Hans Stahles väg 7
SE-147 80 Tumba, Sweden
[phone]
The original instructions are in English
© Alfa Laval Corporate AB 2019-06
This document and its contents are subject to copyrights and other intellectual property rights owned by Alfa Laval Corporate AB. No part of this document may be copied, re-produced or
transmitted in any form or by any means, or for any purpose, without Alfa Laval Corporate AB’s prior express written permission. Information and services provided in this document are
made as a benefit and service to the user, and no representations or warranties are made about the accuracy or suitability of this information and these services for any purpose. All rights
are reserved.

Contents
1 Safety............................................................................................................................... 9
1.1 Introduction..............................................................................................................10
1.2 Safety information....................................................................................................10
1.2.1 General safety information.........................................................................10
1.2.2 Specific safety information ........................................................................10
1.2.3 Personnel requirements.............................................................................13
1.2.4 Warning signs used in the manual.............................................................13
1.3 Environmental issues ............................................................................................. 14
1.3.1 Unpacking..................................................................................................14
1.3.2 Other materials.......................................................................................... 14
2 System description................................................................................................ 15
2.1 Introduction..............................................................................................................16
2.1.1 Components overview............................................................................... 17
2.1.2 Item numbers.............................................................................................18
2.1.3 Abbreviations............................................................................................. 18
2.2 Process overview.................................................................................................... 18
2.2.1 IMO and USCG mode................................................................................19
2.2.2 Flow control and power optimization..........................................................19
2.2.3 Start-up...................................................................................................... 21
2.2.4 Ballasting................................................................................................... 22
2.2.5 Deballasting............................................................................................... 24
2.2.6 Tank stripping.............................................................................................25
2.2.7 Ballast water handling in the event of malfunction.....................................25
2.3 System components description..............................................................................26
2.3.1 UV reactor..................................................................................................26
2.3.2 Filter ..........................................................................................................27
2.3.3 CIP components........................................................................................ 32
2.3.4 Cabinets and control system......................................................................33
2.3.5 Main valves................................................................................................36
2.3.6 Flow meter................................................................................................. 37
2.3.7 Pressure monitoring...................................................................................37
2.3.8 Sampling devices.......................................................................................37
3 Operating instructions and control system description................. 39
3.1 Introduction..............................................................................................................40
3.1.1 Preparations and conditions...................................................................... 40
3.2 Introduction to the control system............................................................................43
3.2.1 Login levels................................................................................................43
3.2.2 Control of PureBallast................................................................................43

3.2.3 Overview of the screen.............................................................................. 45
3.3 Detailed page descriptions...................................................................................... 49
3.3.1 Page 1.1 – Main.........................................................................................49
3.3.2 Page 1.2 – Overview..................................................................................50
3.3.3 Page 1.3 – Reactor....................................................................................53
3.3.4 Page 1.4 – Filter.........................................................................................55
3.3.5 Page 1.5 – CIP...........................................................................................56
3.3.6 Page 1.6 – Cabinet.................................................................................... 57
3.3.7 Page 2.1 – Alarm list..................................................................................59
3.3.8 Page 2.2 – History..................................................................................... 61
3.3.9 Page 2.3 – Audit trail..................................................................................62
3.3.10 Page 3.1 – Trend....................................................................................... 63
3.3.11 Page 4.1 – System 1..................................................................................65
3.3.12 Page 4.2 – System 2..................................................................................66
3.3.13 Page 4.3 – Timers......................................................................................68
3.3.14 Page 4.4 – Remote 1.................................................................................69
3.3.15 Page 4.5 – Remote 2.................................................................................69
3.3.16 Page 4.6 – LPS..........................................................................................71
3.3.17 Page 5.1–5.6 – Parameter pages..............................................................72
3.4 Operating instructions..............................................................................................73
3.4.1 Log in......................................................................................................... 73
3.4.2 Perform ballast...........................................................................................74
3.4.3 Perform deballast.......................................................................................75
3.4.4 Perform tank stripping................................................................................76
3.4.5 Heel (internal transfer)............................................................................... 77
3.4.6 Backflush filter manually............................................................................ 78
3.4.7 CIP clean UV reactor after ballast / deballast ........................................... 79
3.4.8 Attend to alarms.........................................................................................79
3.4.9 Shut down and deactivate system............................................................. 80
3.4.10 Operate components manually..................................................................81
3.4.11 Operate UV lamps manually......................................................................82
3.4.12 Set ship specific component ID..................................................................83
3.4.13 Export control system event log files......................................................... 84
3.4.14 Backup control system settings................................................................. 85
3.4.15 Restore control system settings.................................................................86
3.4.16 Set control panel IP address......................................................................87
3.4.17 Set remote control panel communication...................................................88
3.4.18 Set remote interface communication......................................................... 89
3.4.19 Test remote interface communication........................................................ 89
3.4.20 Update control system softwares...............................................................91
3.4.21 Calibrate the control panel’s touch screen sensibility................................ 92
3.4.22 Fine tune flow and pressure control ..........................................................92
3.5 List of logged information........................................................................................ 96
3.5.1 Event log....................................................................................................96

3.6 Detailed process description................................................................................... 98
3.6.1 Standby mode............................................................................................99
3.6.2 Ballast process.........................................................................................100
3.6.3 Deballast process.................................................................................... 104
3.6.4 Stripping...................................................................................................107
3.6.5 CIP process............................................................................................. 108
3.6.6 UV reactor and filter draining................................................................... 110
3.6.7 UV reactor and filter filling........................................................................ 111
3.6.8 Manual mode........................................................................................... 112
3.7 Quick guide............................................................................................................113
3.7.1 Introduction.............................................................................................. 113
3.7.2 Ballast, deballast or strip.......................................................................... 113
3.7.3 Alarm handling......................................................................................... 114
3.7.4 CIP clean UVR......................................................................................... 114
3.7.5 Export control system log files................................................................. 114
4 Parameters............................................................................................................... 117
4.1 Introduction............................................................................................................118
4.2 Control system parameters....................................................................................118
4.2.1 Introduction to parameters and parameter settings................................. 118
4.2.2 Page 5.1 — Main parameters..................................................................120
4.2.3 Page 5.2 — UVR parameters.................................................................. 123
4.2.4 Page 5.3 — Filter parameters..................................................................124
4.2.5 Page 5.4 — CIP parameters....................................................................126
4.2.6 Page 5.5 — Remote parameters............................................................. 127
4.2.7 Page 5.6 — Installation parameters.........................................................128
4.3 Lamp power supply (LPS) parameters..................................................................130
4.3.1 DIP switch settings...................................................................................130
4.4 Fuse settings for filter motor and installed (optional) pump motors.......................131
4.5 Flow meter parameters..........................................................................................131
5 Alarms and faultfinding.....................................................................................135
5.1 Introduction............................................................................................................136
5.2 List of alarms and warnings...................................................................................136
5.2.1 Control system.........................................................................................136
5.2.2 Lamp power supply (LPS)........................................................................153
5.2.3 Flow meter............................................................................................... 154
5.2.4 Level switch............................................................................................. 156
5.2.5 I/O system and X20 modules...................................................................157
5.3 List of problems and solutions...............................................................................160
5.3.1 General problems.................................................................................... 160
5.3.2 Filter.........................................................................................................162
5.3.3 CIP...........................................................................................................163
5.3.4 Valve V201–8...........................................................................................164

6 Technical data and drawings........................................................................ 165
6.1 Introduction............................................................................................................166
6.1.1 Ship specific information..........................................................................166
6.2 Technical data........................................................................................................166
6.2.1 Flow requirements................................................................................... 166
6.2.2 Water requirements..................................................................................167
6.2.3 Power requirements.................................................................................167
6.2.4 System pressure......................................................................................168
6.2.5 Pressure requirements for filter backflush............................................... 168
6.3 Control system integration.....................................................................................168
6.4 Drawings................................................................................................................169
6.4.1 Graphic symbols used in drawings.......................................................... 170
6.4.2 General drawings.....................................................................................171
6.4.3 Dimension drawings.................................................................................184
6.4.4 Electrical drawings...................................................................................199
6.4.5 Saftey Data Sheets..................................................................................256
7 Service manual .....................................................................................................277
7.1 Introduction............................................................................................................278
7.1.1 Preparations and conditions.................................................................... 278
7.1.2 Welding requirements..............................................................................278
7.1.3 Tightening torques................................................................................... 278
7.2 Maintenance schedule.......................................................................................... 280
7.2.1 Calibration schedule................................................................................ 282
7.2.2 Recommended spare parts on board...................................................... 285
7.2.3 Serial number information........................................................................285
7.3 UV reactor............................................................................................................. 290
7.3.1 Safety information....................................................................................290
7.3.2 Replace UV lamp.....................................................................................291
7.3.3 Replace quartz sleeve............................................................................. 293
7.3.4 Dismount and mount lamp power supply.................................................295
7.3.5 Test lamp power supply installation......................................................... 296
7.4 Filter.......................................................................................................................298
7.4.1 Remove filter cover and filter element..................................................... 299
7.4.2 Mount filter element and filter cover.........................................................302
7.4.3 Clean filter element and pre-filter.............................................................302
7.5 CIP ........................................................................................................................304
7.5.1 Change CIP liquid....................................................................................304
7.6 Pumps................................................................................................................... 305
7.6.1 Operate pumps manually.........................................................................305
7.6.2 Repair drain pump................................................................................... 305
7.6.3 Test pumps ..............................................................................................308
7.7 Valve block ........................................................................................................... 309

7.7.1 Change valve body.................................................................................. 309
7.7.2 Connect electrical cables to valve block.................................................. 310
7.7.3 Clean valve block.....................................................................................310
7.8 Valves.................................................................................................................... 311
7.8.1 Preparations and conditions.................................................................... 312
7.8.2 Open and close valves manually............................................................. 313
7.8.3 Lock valve in closed position................................................................... 313
7.8.4 Unlock valve.............................................................................................314
7.8.5 Dismount actuator....................................................................................315
7.8.6 Mount actuator.........................................................................................316
7.8.7 Adjust valve end position ........................................................................ 317
7.8.8 Calibrate positioner on V201-8................................................................ 318
7.8.9 Adjust cam position on V201-8................................................................ 320
7.8.10 Change direction of actuator for bypass valve V212–31 (optional)......... 321
7.8.11 Mount pilot valve on actuator V212–31 (optional)....................................322
7.8.12 Adjust valve traveling speed for V212–31 (optional)................................323
7.9 Flow meter.............................................................................................................324
7.9.1 Replace display and fuse.........................................................................324
7.9.2 Replace a circuit board............................................................................ 325
7.10 Level switch...........................................................................................................328
7.10.1 Mount level switch....................................................................................328
7.10.2 Dismount level switch.............................................................................. 328
7.10.3 Test level switch.......................................................................................329
7.11 Temperature switch and temperature transmitter..................................................330
7.11.1 Mount temperature switch / temperature transmitter............................... 330
7.11.2 Dismount temperature switch / temperature transmitter.......................... 330
7.12 Control panel......................................................................................................... 331
7.12.1 Clean control panel..................................................................................331
7.12.2 Replace control panel.............................................................................. 331
7.13 Remote control panel (optional)............................................................................ 332
7.13.1 Mount and connect remote control panel ................................................332
7.14 Electrical cabinet................................................................................................... 333
7.14.1 Disassemble and assemble I/O system...................................................333

1 Safety
200000695-1-EN-GB 9
EN
Safety

1.1 Introduction
This chapter contains general safety and environmental information, personnel
requirements and explanations of symbols used for the PureBallast system.
1.2 Safety information
This section contains safety information. This information must be read and
understood before the system is installed, operated and maintained.
1.2.1 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 Technical data and drawings
on page 165 and in the Design and installation guidelines.
• Before operation, read the Preparations and conditions section for
applicable instructions in Operating instructions and control system
description on page 39.
1.2.2 Specific safety information
The following safety information apply for the areas and components below.
This information is also stated in the Preparations and conditions section for
applicable instructions.
200000695-1-EN-GB10
1 SafetyEN
Safety

Maintenance safety items
• Before maintenance, read the Preparations and conditions section for
applicable instructions in Service manual on page 277. Essential safety
information is stated before instruction to routines that might involve any
danger.
•Before maintaining the PureBallast system, the following valves must be
locked in closed position: V201-3 and V201-8.
• The skid and components (if detatched) must be lifted using correct lifting
tools (such as a fork-lift truck, a crane) and tackle with a load capacity
greater than the weight of the component. See the section PureBallast
components in Introduction on page 166 for information about approximate
weight. Complementary lifting instructions in the Design and installation
guidelines must be followed.
• Always disconnect the PureBallast system from the power supply before
disassembling, and secure it from being switched on.
UV reactor safety items
• UV lamps and quartz sleeves are fragile and can easily become damaged.
Exercise great care when handling them. Do not apply vibrations or shock
to the UV lamp. This can cause breakage and shorten lamp life. Broken
glass/quartz can also cause severe cuts. Always use protective eye
glasses and clean cotton gloves when handling UV lamps and quartz glass
sleeves. See Material data sheet / UV lamp in chapter 6.
• UV lamps are stored according to local regulations.
• Before installation, check that the UV lamps and quartz sleeves are not
broken.
• Depressurize reactors and allow equipment to cool down completely before
disassembling.
• Never handle UV lamps before they are completely cooled down. A hot UV
lamp is under high internal pressure, and the risk of bursting exists. A hot
lamp could also cause a burn if it is touched.
• The reactor must not be under pressure when dismounting the UV lamps.
• UV lamps radiate ultraviolet radiation when lit. Only operate the UV lamp
when correctly installed inside the reactor with end caps properly closed.
• UV lamps contain a small amount of mercury (less than 0.2 grams per
lamp) and must be handled and disposed of with care. Used UV lamps can
be handled and disposed of in the same way as fluorescent lamps. Please
refer to national regulations. If a UV lamp has accidentally been broken,
mercury could be spilt. Remove mercury with a special tool such as a
syringe (or use pure sulphure to bind the mercury for easy collection).
• Do not allow mercury to come in contact with your eyes or skin. Do not
inhale mercury fumes.
• Free mercury must be kept in an airtight bottle, and must be disposed of
according to national regulations
• In case of having inhaled mercury fumes, consult a doctor and follow
medical instructions.
200000695-1-EN-GB 11
Safety 1 EN
Safety

• 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 EC: Switch off the PureBallast system and
disconnect it from the power supply. See section Shut down and deactivate
system on page 80. The cabinet contains a fan, which can cause injury if
in operation.
Filter safety items
• CIP liquid agent; Alpacon descalant offshore, may be used as cleaning
agent. Follow rules when handling CIP liquid agent, regarding ventilation,
personal protection etc. See Safety data sheet / CIP liquid on page 256
.
CIP safety items
• CIP liquid: Risk for eye and skin irritation. Avoid contact with eyes and wear
protective gloves and goggles. Follow rules when handling CIP liquid agent,
regarding ventilation, personal protection etc.
• If CIP liquid; Alpacon descalant offshore, comes in contact with eyes or
skin, rinse thoroughly with cold water.
• See Safety data sheet / CIP liquid on page 256
• Always wear protective eye glasses and gloves while working on the pump.
Pump
• CIP and drain pumps: Always wear protective eye glasses and gloves while
working on the pump.
Flow meter safety items
• Make sure that the power supply is switched off, before the cover of the
electronics compartment are removed. Risk of electric shock! Exposed
components carry dangerous voltages .
Valve safety items
• Lock valve in closed position before maintenance.
• Actuators must not be pressurized at any time during installation as it may
result in injury.
• Do not remove end caps or disassemble the actuator while the actuator is
pressurized.
200000695-1-EN-GB12
1 SafetyEN
Safety

• Do not disassemble individual spring elements. Disassembly may result in
personal injury.
• Valve block: Always disconnect the PureBallast system from the power and
air supply before disassembling, and secure it from being switched on
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.
Protective earth
• Components e.g. UVR, filter, flow meter, cabinetsskid, cabinet and remote
control panel (optional) must be earthed. The earth nut is indicated as “791”
or “PE bolt” in the dimension drawings.
1.2.3 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 knowledge about the
PureBallast system. Alfa Laval service engineer can set parameters and
repair intrinsically safe apparatuses.
In some cases special skilled personnel may need to be hired, like electricians
and others. In some of these cases the personnel has to be certified according
to local regulations with experience of similar types of work.
1.2.4 Warning signs used in the manual
DANGER
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.
200000695-1-EN-GB 13
Safety 1 EN
Safety

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.
1.3 Environmental issues
This section contains general rules regarding environmental issues. However,
local rules and regulations should be consulted for detailed handling of each
material.
1.3.1 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.
1.3.2 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.
200000695-1-EN-GB14
1 SafetyEN
Safety

2 System description
200000695-1-EN-GB 15
EN