PureBallast 3.

1 500
IMO/USCG

Lit. Code 200000085-1-EN-GB

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

The original instructions are in English

© Alfa Laval Corporate AB 2018-05

This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing intellectual property and thereto related rights. It is the responsibility of the user of
this document to comply with all applicable intellectual property laws. Without limiting any rights related to this document, no part of this document may be copied, reproduced or
transmitted in any form or by any means (electronic, mechanical, photocopying, recording, or otherwise), or for any purpose, without the expressed permission or authorized by Alfa Laval
Corporate AB. Alfa Laval Corporate AB will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.
Table of contents
1 Ship specific information........................................................................................7

2 Introduction..................................................................................................................... 9
2.1 Safety information........................................................................................................ 9
2.2 Components 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 Cabinets.....................................................................................................................17
5.3 UV reactor..................................................................................................................18
5.4 Filter........................................................................................................................... 20
5.5 CIP module................................................................................................................ 22
5.6 Flow meter ................................................................................................................ 23
5.7 Pressure monitoring device....................................................................................... 26
5.8 Valves.........................................................................................................................26
5.8.1 Bypass valve (V212–31)............................................................................... 26
5.8.2 Control valve (V201–8)................................................................................. 27
5.8.3 Check valves (CV403, CV201, CV310)........................................................ 27
5.8.4 Cooling water valve (V403–35)..................................................................... 27
5.8.5 Filter valves (V201-3, V201-32 V201-9 and V309-1).................................... 27
5.8.6 Vaccum breaker valve................................................................................... 28
5.9 Ancillary equipment and functions............................................................................. 29
5.9.1 Sampling devices (Q201.1 and Q201.2)....................................................... 29
5.9.2 Booster pumps.............................................................................................. 29
5.9.3 Tank stripping equipment.............................................................................. 30

6 Pipe design................................................................................................................... 31
6.1 Water requirements....................................................................................................31
6.2 Flow requirements..................................................................................................... 31
6.3 Pipe dimensions and material....................................................................................31
6.4 Valves outside PureBallast ........................................................................................32
 6.5 System pressure........................................................................................................ 33
6.6 Pressure requirements for filter backflush................................................................. 33

7 Electrical design........................................................................................................ 35
7.1 Power requirements...................................................................................................35
7.2 Installation requirements............................................................................................36
7.2.1 Cables........................................................................................................... 36
7.2.2 Lamp drive cabinet........................................................................................37
7.2.3 Control cabinet.............................................................................................. 37

8 Pneumatic design.....................................................................................................39

9 Control system integration..................................................................................41

9.1 Remote control panels............................................................................................... 41
9.2 Remote interface........................................................................................................42
9.3 Power management system (PMS) integration......................................................... 43
9.3.1 Power request process................................................................................. 43
9.3.2 Power management installation.................................................................... 43
9.4 External feed control signal........................................................................................44
9.5 External components signal.......................................................................................45
9.6 GPS........................................................................................................................... 47

10 System approval.....................................................................................................49
10.1 Alfa Laval’s responsibilities...................................................................................... 49
10.2 Installing party’s responsibility..................................................................................49
10.2.1 Approval planning....................................................................................... 49
10.2.2 Design approval.......................................................................................... 49
10.2.3 Installation survey....................................................................................... 50
10.3 Alfa Laval commissioning........................................................................................ 50

11 On board installation planning.......................................................................51

11.1 Delivery and transport.............................................................................................. 51
11.2 Lifting instructions.....................................................................................................51
11.2.1 UV reactor................................................................................................... 52
11.2.2 Filter.............................................................................................................53
11.2.3 Booster pumps............................................................................................ 54
11.2.4 CIP module..................................................................................................55
11.2.5 Cabinets...................................................................................................... 56
12 Start-up procedures............................................................................................. 57

13 Drawings......................................................................................................................59
13.1 Graphic symbols used in drawings.......................................................................... 60
13.2 General drawings.....................................................................................................61
13.2.1 Flow chart....................................................................................................62
13.2.2 Flow chart — Closed cooling unit, LDC (optional)...................................... 63
13.2.3 Connection list.............................................................................................64
13.2.4 Connection list — Closed cooling unit, LDC (optional)............................... 70
13.2.5 Electrical system layout...............................................................................71
13.2.6 Instrument air distribution............................................................................73
13.2.7 Quality specification / Instrument air........................................................... 74
13.2.8 Quality specification / Technical and potable water.....................................75
13.2.9 Quality specification / CIP liquid..................................................................76
13.3 Dimension drawings.................................................................................................77
13.3.1 UV reactor................................................................................................... 78
13.3.2 UV reactor and control cabinet / Lamp power cable................................... 79
13.3.3 Filter............................................................................................................ 80
13.3.4 CIP module................................................................................................. 81
13.3.5 Flow transmitter FT201-1............................................................................ 83
13.3.6 Pressure monitoring device (Incl. PT201-16, PI201-18, RV201 and
V201-15)................................................................................................................ 84
13.3.7 Valve V201-3 and V201-9........................................................................... 86
13.3.8 Valve V201-32 and V403-35....................................................................... 87
13.3.9 Valve V212-31 (Optional)............................................................................ 88
13.3.10 Control valve V201-8.................................................................................89
13.3.11 Backflush valve V309-1............................................................................. 90
13.3.12 Sampling device Q201.1 and Q201.2 (Optional)...................................... 91
13.3.13 Remote control panel (Optional)............................................................... 94
13.3.14 Log box (Optional).....................................................................................95
13.3.15 Lamp drive cabinet (LDC)......................................................................... 96
13.3.16 Control cabinet.......................................................................................... 97
13.3.17 Air filter / Filter regulator............................................................................98
13.3.18 Backflush pump P309–1 (Optional).......................................................... 99
13.3.19 LDC cooling water pump P401–1 (optional)........................................... 100
13.3.20 UVR cooling water pump P403–1 (optional)........................................... 101
13.3.21 Closed cooling unit, LDC (Optional)........................................................102
 13.3.22 Transformer (Optional)............................................................................ 103
13.4 Electrical drawings................................................................................................. 104
13.4.1 Control cabinet / Interconnection diagram................................................ 105
13.4.2 Control cabinet / Circuit diagram............................................................... 113
13.4.3 Control cabinet / Cable list........................................................................ 134
13.4.4 Lamp drive cabinet / Interconnection diagram.......................................... 135
13.4.5 Lamp drive cabinet / Circuit diagram.........................................................137
13.4.6 Lamp drive cabinet / Cable list.................................................................. 152
13.4.7 UV reactor / Interconnection diagram....................................................... 153
13.4.8 UV reactor / Circuit diagram .....................................................................155
13.4.9 UV reactor / Cable list............................................................................... 158
13.4.10 Remote control panel / Circuit diagram (optional)...................................159
13.4.11 Transformer (optional) / Interconnection diagram................................... 160
13.4.12 Transformer (optional) / Circuit diagram..................................................161
13.4.13 Transformer (optional) / Cable list........................................................... 162
13.5 Saftey Data Sheets................................................................................................ 163
13.5.1 Safety data sheet / CIP liquid....................................................................163
13.5.2 Material data sheet / UV lamp...................................................................171
 EN

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
Number of UV reactors 1

Flange standard (EN or JIS) ___________

Main valve and piping Dimension: ________________
Control valve (V201-8) Dimension: ________________

Bypass valve (V212–31)

Dimension: ___________
Alfa Laval’s or other
Cooling water valve (V403-35) Dimension: ________________
Sampling device Location Q201.1: ___________
Alfa Laval’s or other Location Q201.2: ___________

Power consumption, max (kW) ___________

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

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EN 1 Ship specific information

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 EN

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 and
the dimension drawings included in Drawings on page 59. Components are
identified by their ID, for example control valve (V201-8).
Note that the function and performance of PureBallast are dependent of the
design and installation. Therefore, it is important that the design and
installation is done according to the information given in this document.

2.1 Safety information

WARNING
Read chapter 1. Safety in PureBallast system manual.
This is a summary of installation information. For full details, see
manufacturers instruction manuals for respective component.
Installation must be done by a fully trained professional installer.

• Electrical welding requirements:

Earth connection must be done according to the below. If not, the
equipment can be seriously damaged:
• Earth connection must be made before any welding is done.
• Electrical welding: Connect the welding unit’s negative lead (work lead)
to the component you will weld, close to the welding area.
• Follow local regulations for electrical installation and earthing
(grounding).
• Damages related to transport and installation should be recorded.

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EN 2 Introduction

2.2 Components overview

The key components in PureBallast are shown below.

Example of layout with 1 UV reactor.

1. Control cabinet
2. Lamp drive cabinet (LDC)
3. CIP (cleaning-in-place) module
4. UV reactor
5. Ballast water outlet
6. Control valve
7. Flow meter
8. Sampling point
9. Filter
10. Ballast water inlet
Not in illustration:
• System bypass valve
• Pressure monitoring device

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 EN

3 Alfa Laval’s scope of supply

The table below is a list of all PureBallast components and consumables
delivered by Alfa Laval.
The list is compiled on the top level so that integrated components are not
described, because they are already mounted at delivery. For example, the
valves on the UVR are not described individually in the list, since they are
already mounted as a part of the component.
Component ID Function
Main components

The main water treatment component in the system,

UV reactor, 1 piece UVR 1 including reactor, valves, UV sensor, temperature sensor,
temperature switch, level switch and an electrically
integrated control valve, V201–8.
Contains the main control panel, from which PureBallast is
controlled. It also contains breaker and communication
Control cabinet, 1 piece CC components such as PLC, switches for communication with
remote interface, remote control panels etc, and terminals
to connect signal cables to components and external
systems.
Lamp drive cabinet, 1 LDC 1 Electrical cabinet feeding the UV lamps in the UV reactor
piece with power via lamp power supplies (LPS).

Lamp power cable

Per UVR: W211 Power cables between UVR and LDC. Length specified in
order.
UVR 600: Two pieces.

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

Cleaning-in-place module for automatic cleaning of the

UVR after treatment, mainly clean the UV lamps quartz
CIP module, sleeves.
CIP
1 piece The CIP module is also used to drain and fill the UV reactor
during CIP process and to fill the filter with technical water /
potable water after, for preservation reasons.

Remote control panel, Extra control panels to control and monitor the PureBallast
0-2 pieces (optional) system. Number according to order.

Valves

Main outlet valve from the PureBallast system to the

vessel’s ballast system after treatment.
Control valve, Automatic pressure regulation to maintain needed pressure
during back flush.
1 piece including V201-8
positioner Automatic flow regulation during operation to secure that
max flow is not exceeded.
The positioner function as connection point for signal and
power cables to the component.

Main inlet valve to the PureBallast system during ballast, in

Filter inlet valve combination with V201-32. The valve directs the water flow
including switch box, 1 V201-3 through the PureBallast filter. (Closed during deballast)
piece The switch box function as connection point for signal and
power cables to the component.

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EN 3 Alfa Laval’s scope of supply

Component ID Function

Filter outlet valve The valve directs the water flow from the PureBallast filter
including switch box, to the UVR. (Closed during deballast)
V201-32
1 piece The switch box function as connection point for signal and
power cables to the component.

Filter bypass valve Filter bypass valve open during deballast, when the filter is
including switch box, not used. (Closed during ballast)
V201-9
1 piece The switch box function as connection point for signal and
power cables to the component.

The valve directs the water used for filter backflush back to
the sea.
Filter backflush valve V309–1
If backflush pump P309–1 (optional) is installed, this valve
is premounted on the pump.

Bypass valve,
Bypass valve to bypass the complete PureBallast system.
1 piece including switch The valve is solely operated from the ISCS.
box V212-31
The switch box function as connection point for signal and
(Optional as part of control cables to the component.
scope of supply)

Supplies cooling water to the UVR to protect the lamps

Cooling water inlet valve, from overheating during start-up. The valve is common for
1 piece including switch V403–35 all installed UVRs.
box The switch box function as connection point for signal and
control cables to the component.

Check valve, 1 piece CV201 Check valve before the UV reactor to secure water in the
UV reactor.
Ancillary equipment

The flow meter consists of two components:

Flow sensor monitor the flow in the system. Functions
Flow meter, 1 piece FIT201-1 together with the flow transmitter.
Flow transmitter send flow information to the control
system. It is mounted on the flow sensor.

Monitor pressure and send it to the control system.

Pressure monitoring PT201-16 Manifold includes pressure transmitter (PT201-16),
device, 1 piece pressure gauge (PI201–18), relief valve (RV201) and
needle valve V201–15.

Sampling device, 2
pieces Q201-1 Sampling points to tap water for test of water before and
(Optional as part of Q201-2 after treatment.
scope of supply)

If one or several valves can be used as both bypass and

Log box, 1 piece heeling, a log box can be used to define different
(optional) combinations of valves and pumps, that constitutes bypass
or heeling operation.

Air filter regulator, 1 If instrument air is not available according to requirements,

piece an air filter can be installed. It filters the air to make it clean
and dry according to specification.
Filter backflush pump, 1 P309-1 Booster pump to secure enough flow in pipe 309 for
piece (optional) sufficient filter backflush.

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 Alfa Laval’s scope of supply 3 EN

Component ID Function
LDC cooling water Booster pump to secure minimum cooling water flow to
pump, 1 piece (optional) P401-1 LDC during operation.

UV reactor cooling water P403-1 Booster pump to secure minimum cooling water flow to UV
pump, 1 piece (optional) reactor during startup and pause.

If cooling water (treated cooling water / technical water) for

Closed cooling unit LDC is not available according to requirements in the
(optional) connection list, a closed cooling unit can be installed. It
circulates a closed loop of fine quality water which is
cooled with the normal sea water cooling system.

If voltage does not meet the requirements, a transformer

Transformer (optional) must be used. The transformer is recommended to give
voltage in the higher range, as close as possible to 440
VAC.

Information about operation, control system parameters,

faultfinding and drawings.
System manual, 1 piece
Additional manuals or manuals as CD/USB according to
order.

Consumables

The liquid is used during the CIP-process.

CIP liquid, 15 liters
The liquid is used for the first filling of CIP liquid.

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EN 3 Alfa Laval’s scope of supply

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 EN

4 Material and equipment supplied by

installing party
Additional equipment is needed to install the PureBallast system, apart from
components included in Alfa Laval’s scope of supply (according to order).
These needs to be designed, supplied and installed by the party responsible
for the installation.
Examples of not included equipment:
• Electrical cables and signal cables to the ship’s ISCS (integrated ship
control system).
• Pipes for ballast water, cooling water and CIP unit.
• Tubings for instrument air and deareation pipe.
• Ancillary equipment, for example sieve for stripping.
• Flange for sampling devices, if the device is included in scope of supply. If
not, the complete sampling device.
• Bypass valve, if not included in scope of supply.
• Support for mounting heavy components, for example extra support for the
UV reactor.
• Booster pumps for backflush water (P309–1) and cooling water (P401 and
P403), if used and not included in scope of supply. See External
component signals.
The installing party is responsible for selecting and purchasing the equipment
according to specifications in the documents below:
• Connection list
• Quality specification for water
• Quality specification for instrument air
• Cable list for Control cabinet and Lamp drive cabinet.

4.1 Material selection

Material must be in accordance both with requirements stated in this
document and with the requirements of respective classification society. For
example: The classification society DNV recommends that if stainless steels
are intended to be used in ballast water operation; the steel should have a
higher resistance to localized corrosion than the traditional 316 or 316L steels.
Used material shall be indicated in appropriate drawings. For more
information, see Pipe dimensions and material on page 31.

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EN 4 Material and equipment supplied by installing party

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 EN

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

5.1 General requirements

The overall layout is defined by the Flow chart drawing and details for
components are stated on the dimension drawings.
Installation prerequisites:
• The PureBallast must be installed in a machinery space on the vessel
(engine room, pump room etc. ) with:
• relative humidity of max 100 %
• ambient temperature of 0 to 50º C
• This version of PureBallast is not Ex proofed, and must not be installed in
areas where an explosive atmosphere may occur.
• Components must be placed in relation to pipe intersections as defined in
the flow chart.
• Components must be properly suspended and supported.
• The installation of any component should not amplify vibrations to or from
the hull.
• All piping connected to the PureBallast components (UV reactor, filter and
CIP module shall be properly self supported. No load shall be transferred to
or from any major components.
• Components mounted on a surface, must be placed on a firm level surface.
• There must be free space available for maintenance. Size and required
access area around main components are given in the dimension drawings.
• Installation must be done by a fully trained professional installer.
Welding requirements
Earth connection must be done according to the below. If not, the equipment
can be seriously damaged:
• Earth connection must be made before any welding is done.
• Electrical welding: Connect the welding unit’s negative lead (work lead) to
the component you will weld close to the welding area.
• Follow local regulations for electrical installation and earthing (grounding).

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

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EN 5 Mechanical installation

• Cabinets must be installed so that there is free space available to open the
door.
• The cabinets 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.
The cabinets shall also be attached to the bulkhead using the attachments
on the cabinet backside. The cabinets 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 in the LDC must be connected to meet the
requirements in the Connection list 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
• To prolong the lifetime of the cabinet, we recommend to install it in the
coolest possible area in the range of 0 to 50º C.

Cable lengths
Maximum cable length between the lamp drive cabinet and:
• the UV reactor: 150 meters (lamp power cable)
• the control cabinet: 100 meters.

5.3 UV reactor
Installation prerequisites:
• The UV reactor must be oriented so that the UV lamps are perpendicular
(90°) to pipe 201 with flow into 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.
• The UV reactor must be mounted vertically with the water flow going
upwards.
• The UV reactor is recommended to be placed close to the filter for best
performance.
• 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.
• 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.
• 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 flow must be within certified flow range for the system.

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• The UV reactor must be secured so it withstands the forces of load applied

by a full UV reactor (420 kg) at the vessel’s maximum heeling degree.
• 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.

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EN 5 Mechanical 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
Installation prerequisites:
• The filter is recommended to be 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, access area and weight.
• The filter must be bolted in place.
• If backflush pump (optional) is installed, it is recommended to be installed
directly on the filter flange (backflush outlet) for best performance. It is not
recommended to be placed further than one meter from the filter.

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 Mechanical installation 5 EN

• 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.
• See section Pipe design for details for pipe 309.

Filter flange – Alignment

Filter inlet and outlet pipe flanges should be self supported and carefully
aligned to avoid stressing the filter connections.
The pipe flanges connected to the filter flanges must be aligned with the filter
flanges according to the illustrations below:

Filter flanges – Max load

To avoid damage or stress to the filter, assure that minimum external forces or
moments are acting on the connection flanges and the filter housing. It is
important that the forces and moments do not exceed the maximum allowed
forces and moments according to the table and illustration below
Fa 150
Force (kg) Fl 150
Fc 125
Mc 75
Moments (kg x m) Ml 100
Mt 115

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EN 5 Mechanical installation

5.5 CIP module

Installation prerequisites:
• 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.

• 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.
• Pipe connections to the CIP must be made so that the connection is not
exposed to any moment or load. A pipe support should be installed on the
ship’s side of the flange connectioin to avoid that the plastic flanges or the
pipes crack.

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 Mechanical installation 5 EN

• Max tightening torque for bolts on flanges: 20 Nm.

• Pipe 460.2 (drain of used CIP liquid, 250 liters) should not be lead to bilge
tank due to the low pH value. Drain to one of the following: drain, waste or
sludge tank.
CIP liquid should be handled according to local regulations. See Quality
specification / CIP liquid on page 76.

WARNING
CIP liquid have a low pH value (approximately 3.0 when changed) and
it contain residues from the cleaning process.

5.6 Flow meter

Installation prerequisites:
• Dimension according to section Ship specific information.
• The flow meter (FIT201–1) 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. 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 should be placed with the flow transmitter facing straight
upward, when placed on a horizontal or slanting pipe. This is to make the
electrodes to be positioned to read the flow in best way, even if the pipe is
not completely full.

Flow meter horizontal orientation. Flow according to arrow (DN, Nominal

diameter).

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EN 5 Mechanical installation

• 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.

Flow meter vertical or slanting pipe. Flow according to arrow (DN, Nominal
diameter).
• 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
flow meter.

Measures for installation in a down pipe.

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 Mechanical installation 5 EN

• Seals:

Polyurethane lining — no seals are required.

Hard rubber lining — additional seals are always necessary.
Make sure that the seals do not protrude into the piping cross-section.

CAUTION
Risk of short circuit! Do not use electrically conductive sealing
compounds such as graphite.

• Transmitter connection:

1. Connection diagram inside the connection compartment cover

2. Both power supply cable and signal cable
3. Optional
4. Optional

Turn transmitter housing

The flow transmitter housing can be turned to make the placing more flexible.
Follow the illustrations below:

Turning the transmitter housing

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EN 5 Mechanical installation

Turning the onsite display

5.7 Pressure monitoring device

Installation prerequisites:
• Pressure monitoring device must be installed vertically on a horizontal pipe.
If not it will not function.
• A drain 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. Signal cables for control and feedback are connected to
the control cabinet.

Installation prerequisites:
• The relation between the components is important. Valves must be placed
in relation to pipe joint as indicated in the flow chart. Example: Filter bypass
valve V201-3 must be installed before pipe 403 is joint to pipe 201.
• Valve dimension according to section Ship specific information.
• Valves can be installed on vertical, horizontal and sloping pipes.
• 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.

5.8.1 Bypass valve (V212–31)

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

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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 operating the valve. The reason, for example
internal transfer, must be entered in the vessel´s ballast water log book. If
GPS signal is not integrated, the position must also be entered in this log
book.
Signal cables connected according to Electrical cabinet / Interconnection
diagram and Electrical cabinet / Circuit diagram.

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

If PureBallast can be bypassed using other valves (apart from V212-31), these
valves (or combination of valves) must be integrated to PureBallast control
system, since all bypass cases must be logged, according to the IMO
convention.
Additional bypass valves can be connected via individual hardwires or remote
interface. See section External component signal integration

5.8.2 Control valve (V201–8)

• The control valve must be placed according to the flow chart.
• If the valve dimension is different from the dimension of pipe 201, the pipe
dimension must be coned up/down to fit the valve.
• Maximum pipe distance from UVR is 2.5 meters.

5.8.3 Check valves (CV403, CV201, CV310)

Valve Guidelines
The valve must be installed before the UV reactor inlet valve
CV201 V201-19. It is recommended to be installed as close as possible
to the UV reactor.
CV310 The valve is installed on the flange for pipe 310.1 on the CIP.

5.8.4 Cooling water valve (V403–35)

The valve must be installed between filter bypass valve V201-9 and UV
reactor inlet valve V201-19.

5.8.5 Filter valves (V201-3, V201-32 V201-9 and V309-1)

The valves must be installed according to the flow chart. Filter backflush valve
(V309–1) is preassembled on the filter at delivery.

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EN 5 Mechanical installation

Filter valves Guidelines

Preassembled on the filter at delivery.
Filter inlet valve (V201–3) If required adapter plates are used to convert to
diferent falnge dimension or convert an EN flange
to JIS flange.

Preassembled on the filter at delivery.

Filter outlet valve (V201– If required adapter plates are used to convert to
32) diferent falnge dimension or convert an EN flange
to JIS flange.

Preassembled on the filter at delivery.

Filter backflush valve
(V309–1) If backflush pump P309–1 (optional) is
preassembled on the backflush pump.

5.8.6 Vaccum breaker valve

If the height difference between the PureBallast system and the ballast water
tank is over 10 meters, a vacuum breaker valve should be considered. A
vacuum breaker valve (not part of Alfa Laval’s scope of supply) eliminates the
risk of cavitation in the downward going part of pipe 201 after treatment.
The vacuum breaker valve should be installed at the highest point of the
piping closely after control valve V201-8. See illustration below.

Vacuum breaker valve installation

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5.9 Ancillary equipment and functions

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

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

The international ballast water convention requires means of sampling ballast
water to make it possible to analyze the water. Sampling devices (Q201.1 and
Q201.2) are optional part of Alfa Laval’s scope of supply.
Installation prerequisites:
• Installed in pipe 201 after treatment as close as possible to the overboard
valve. We recommend installation before valve V201-8 to avoid
contamination by untreated water from other pipes.
• Installed so that the there is no risk that the water taken from the sampling
device is contaminated by untreated water from pipe 309, 404, 460.1, 460.2
or eventual ship’s pipes. If other pipes are connected to pipe 201, a check
valve must be installed to avoid that untreated water is mixed with fully
treated water in pip 201 where the sampling device is installed.
• If there are several discharge lines, it might be necessary with a sampling
device on each.
• Installed in a straight pipe which is at least as long as the diameter. Within
that length, no components may be fitted, for example, elbows and tees.
Ideally, the pipe should be vertical and as long as possible.
• Installed so it is accessible to take samples.
• Flanges for connecting sampling device must be installed before the pipe is
coated.
• The device must be mounted with the sampling pipe opening pointing in the
flow direction.
• The placement of sampling point is subject to approval by class society.
• Some class societies/flag states also require that sampling device Q201.1
is installed before PureBallast to allow sampling of untreated water.

5.9.2 Booster pumps

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

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 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.

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EN 5 Mechanical installation

5.9.3 Tank stripping equipment

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

Stripping eductor
The use of stripping eductor is approved by the Norwegian Maritime Authority,
and is included in the PureBallast type approval certificate. According to
MEPC 67 “there is no need to develop guidance on stripping operations using
eductors as it is not recommended that ballast water sampling be performed
during stripping operations” (ref MEPC 67/WP.1 - 2.32).
Note the following:
• The eductor (not part of Alfa Laval’s scope of supply) must be installed
before the PureBallast system
• If an eductor is used, driving water is used to get enough flow. We
recommend that the driving water alone (without the ballast water flow from
the tank) fullfils the minimum flow requirement for deballast operation. This
will minimize the risk of shut down due to low flow when flow of ballast
water is uneven.
• The driving water used in the stripping process, must be filtered from
particles larger than approximately 5 mm. Filter should be placed before
eductor and/or pump.
• Procedures to dispose of sediments from the sieve must be included in the
vessel’s ballast water management plan.

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

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 EN

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 requirements

Ballast water Used for cooling UV lamps in the UV reactor during
start-up. Pipe 403 is recommended to be connected
to the vessel’s 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.
Temperature: -2 to 40 °C (liquid form)
Salinity: PureBallast water treatment system can
treat water with all salinities.
UVR and filter Temperature: 0–38 °C.
preservation
For details, see Quality specification / Technical and
potable water on page 75
Cooling water to Max temperature: 38 °C (± 2 °C).
LDC

6.2 Flow requirements

BW pump and other pumps must give min and max flow according to the table
below:
Media Flow /
consumption
Flow range – (m3/h) – Pipe 201, ballast 110 – 500
Flow range – (m3/h) – Pipe 201, deballast 60 – 600
Flow range – (m3/h) – Pipe 201, stripping 60–200
Minimum flow (m3/h) – Pipe 403, startup cooling water to 20
UV reactor (water sea to sea)

Minimum flow (m3/h) – Pipe 401, cooling water to LDC 1.0

(Treated cooling water / technical water)

Minimum flow (m3/h) – Pipe 309, filter backflush 50

Consumption – Pipe 310.1, technical water / potable 300

water during CIP process

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.
• Pipe 403 and valve V403-35 (cooling water valve, reactor): 50. Dimension
decided at order, smallest recommended.

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EN 6 Pipe design

• Pipe 201 (ballast water): If adaptors are mounted on the filter flanges, a
spool piece must be installed between the adaptor plate and the valves
(filter inlet valve (V201–3) and filter outlet valve (V201–32)), due to the
design of the adaptor plate.
If adaptors are NOT used, the valves can be mounted directly on the filter
flange.
• Pipe 201 (ballast water): It is not recommended to use plastic pipes closer
than approximately two meters from the UV reactor. It UV light will affect the
material and shorten its life time.
• Pipe 201(ballast water): We strongly recommend to tailor make a spool
piece to connect to the filter. Make the prefabricated pipe deliberately
shorter, and measure on site to make the perfect spool piece. Also see
Alignment and max load on filter flanges in section Filter.
• Pipe 309 (backflush): Pipe dimension MUST be increased to100 after
V309–1. Cone is not part of Alfa Laval’s scope of supply. This is required to
secure reliable backflush operation.
• Pipe 309 (backflush): It is recommended to use as few bends as possible in
pipe 309, to get as low pressure resistance as possible.
• Pipe 320, 321 and 460 (CIP pipes): Non-corroding material is
recommended for pipes used for CIP liquid, due to low pH value.
• Pipes must be pressure approved by a classification society or equivalent,
or be tested under supervision of a classification society and/or at the ship
yards pipe shop etc.
• Also see information in section Material selection.

6.4 Valves outside PureBallast

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

Ballast process
Flow to PureBallast pipes:
• 201 (ballast water)
• 401 (LDC cooling water, if not in closed loop)
• 201 (ballast water)
Flow from PureBallast pipes:
• 201 (ballast water to tanks)
• 309 (backflush water overboard)
• 402 (LDC cooling water)
• 404 (reactor cooling water overboard, during start-up)

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Deballast process
Flow to PureBallast pipes:
• 201 (ballast water)
• 403 (UV reactor cooling water, during start-up)
• 401 (LDC cooling water, if not in closed loop)
Flow from PureBallast pipes:
• 201 (ballast water overboard)
• 402 (LDC cooling water, if not in closed loop)
• 404 (reactor cooling water overboard, during start-up)

CIP process
Flow to PureBallast pipes:
• 310.1 (fresh water)
Flow from PureBallast pipes:
• 309 (Water from filter during filter preservation overboard)
• 460.1 (Drain reactor - ballast water and fresh water overboard)

6.5 System pressure

The table gives a description of system pressure range for piping and
instrument air.
Pressure (bar) Comment
Max pressure for standard system: 6 bar.
Piping Max pressure for high pressure system: (Optional): 9
bar.

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

6.6 Pressure requirements for filter backflush

Minimum required pressure at filter inlet is 1.7 bar.
This pressure will overcome pressure drop for PureBallast componets and
ensure filter backflush. For details, see table below.

NOTE
Pressure requirement only includes PureBallast’s components. Piping is
not included.
If a backflush pump P309 is not used, pressure drop in pipe 309 (Δp309)
must be calculated and added according to the table below.

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EN 6 Pipe design

Bar Comment
0.2 Pressure drop for UV reactors and
PureBallast’s valves.
Pressure drop Max differential pressure over the filter
during ballast during ballast operation. When the
0.5 differential pressure reaches 0.5 bar due to
dirt in the filter, a backflush is started
automatically.
1.0 Required pressure to clean the filter.
If a backflush pump P309–1 is not used,
Pressure needed pressure drop in pipe 309 must be calculated
for backflush Δp309 and added. This is vessel specific and must
be calculated using required flow in pipe 309:
50 m3/h.
The ballast pump must deliver pressure at
Total filter inlet, covering total pressure drop over
PureBallast system.

Calculate backflush parameter setting (p304)

System pressure (PT201–16) needed for backflush is set in parameter p304
(pressure setpoint during backflush). If this pressure is not fulfilled when a
backflush is triggered, the control valve V201–8 will operate to build up and
maintain this pressure.
The parameter setting is depending on if a backflush pump is used or not.
Without backflush pump, the setting must be calculated according to below.
With backflush pump, a fixed value is used.

Setting without backflush pump = 1.0 + Δp309

Setting with backflush pump = 1.0

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

7.1 Power requirements

General power requirements
• 400–440 VAC, 50/60 Hz 3 phase. If voltage does
not meet the requirements, a transformer can be
used. The transformer is recommended to give
Nominal voltage and voltage in the higher range, as close as possible to
frequency 440 VAC.
• Max Icu 50 KA.
• Power factor: 0.95.
• 24VDC - Remote control panel (optional).

Control cabinet: >IP44.

IP rating
Lamp drive cabinet: ≥ IP44.

Note: Heat transfer from/to the lamp drive cabinet is

depending on ambient temperature. The need for
cooling the area where the lamp drive cabinet is
placed, is therefore dependent on ambient
temperature.
The calculations below can be used as a guide.
At an ambient temperature of
Heat dissipation 1. 10 °C, about 1200 W is transferred to the
(transfer) – Lamp surroundings.
drive cabinet 2. 25 °C, about 600 W is transferred to the
surroundings.
3. 40 °C, no heat is transferred in either direction.
4. 45 °C, about 200 W is absorbed from the
surroundings.
5. 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.

Component Power consumption

(kW)
Control cabinet
1
Control cabinet including filter motor.

Lamp drive cabinet

Power to UV reactor.
Note: PureBallast only use power needed for 62.00
treatment. PureBallast automatically regulates the
lamp power between 50 and 100 % to secure the
treatment efficiency.

Pump P309–1 (optional)

4.0
For filter backflush water.

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EN 7 Electrical design

Component Power consumption

(kW)
Pump P401–1 (optional)
0.55
For LDC cooling water.

Pump P403–1 (optional)

3.0
For UVR cooling water.

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 lamp drive cabinet (LDC): Requirements
for cables supplied by installing party.
• Dimension drawings: Information about earth points.

7.2.1 Cables
• Dimension of cables must be within the cable gland range stated in the
dimension drawings for respective component.
• Components e.g. UVR, filter, CIP module, flow meter, cabinets and remote
control panel (optional) must be earthed. The earth nut is indicated as “791”
or “PE bolt” in the dimension drawings.
• Earth cables must have a cross-section large enough in relation to the
supply cables from the vessel.
• 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 gland installation in chapter 7. Service manual.
• Cabling shall be done according to specification in Electrical system layout
and the electrical drawings. 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.

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7.2.2 Lamp drive cabinet

• Lamp power cable W211A-B (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 delivered 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.

7.2.3 Control cabinet

• 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 back. See 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.

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38 200000085-1-EN-GB
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8 Pneumatic design
This section contains information relevant for planning the installation and
routing of instrument air to the components that are pneumatically operated.
Instrument air must always be connected.
The following drawings are needed for pneumatic design:
• Connection list: connection 501.
Pressure requirements, air consumption during operation and peak load
(including time for peak load).
• Instrument air distribution.
Air distribution layout and connection dimensions.
• Quality specification / Instrument air.
The instrument air must be according to the quality specification. If not,
components will be damaged and the system will malfunction. If instrument
air is not available, a solution must be implemented to achieve air
according to specification.
• Dimension drawings for the components that should be connected.

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9 Control system integration

This section contains information relevant for planning integration for
controlling PureBallast and signals for communication between PureBallast
and external components, which are not part of Alfa Laval’s scope of supply.
This integration is normally done during installation.
The following optional integration is possible:
• Remote control panel
• Remote interface
• Power management
• External component signals
• Log box
• GPS.
For remote integration, please refer to the following documents:
• Design and installation guide
• Remote interface implementation guide.
• Log box installation guide.

Mandatory and optional integration

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

9.1 Remote control panels

If included in order, 1 or 2 remote control panels (RCP) can be mounted at an
optional location, for example the bridge, cargo control room or back office. .
Installation prerequisites:
• The remote control panel is mounted at an optional location
• The remote control panel is mounted according to drawing Remote control
panel / Dimension drawing. Note the clearance area.
• The remote control panel is delivered as an IP protective cabinet, for
installation on a stand. It is possible to remove the back cover to use the
front as a mounting plate for installations in wall, worktop etc. See Remote
control panel / Dimension drawing for details.
• Power cable W502.1 (for RCP 1) and W502.2 (for RCP 2) must be installed
according to Electrical system layout.
• Use a 24 VDC power cable with minimum cross section of 0.75 mm2,
preferably halogen free and flexible.
• Connect the power cable to terminal X1 in remote control panel.

Connect one remote control panel

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

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EN 9 Control system integration

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

Connect the Ethernet cable to terminal X13 in CC and to terminal X2 in
RCP1.
2. Max 500 m CC: Optical fiber. Multi-mode fiber cable with LC connector.
We recommend a cable with four or more cores are used to have spare
cores if one is broken.
Connect the optical cable to switch in CC and to switch in RCP1.

Connect two remote control panels

Connect the second remote control panel (RCP2) with an Ethernet cable. Two
options are available:
1. Max 100 m from RCP1: Connect terminal X2 in RCP2 with terminal X2 in
RCP1. If X2 is occupied by another connector, connect the cable to RJ45
in switch.
2. Max 100 m from CC: Connect terminal X2 in RCP2 with terminal X13 in
CC. If X2/X13 is occupied by another connector, connect the cable to the
RJ45 in the switch.

9.2 Remote interface

If included in order, PureBallast can be integrated to the vessel’s ISCS. Alfa
Laval does not supply software or graphical user interface to handle
PureBallast in the ISCS, only a communication standard to use for integration.
Programming and integration shall be done according to the document
Remote interface implementation guide, which can be required from your local
Alfa Laval sales office and Control cabinet / Circuit diagram.

Integration process
It is important to start the integration process at an early stage, if PureBallast’s
control system is to be connected to the vessel’s ISCS via remote interface.
Follow the basic steps described below:
1. As a base for the integration, the Remote interface implementation guide
should be used. It contains all necessary information for the programming.
Also chapter 2 and 3 from the system manual contains valuable
supplementary information.
2. Contact the automation firm in time to plan and realize the programming.
As a standard, we recommend that the customer integrate according to the
list under heading Required implementation. But consider if more functions
should be implemented to get a more user friendly system. Remember that
later additions are always more expensive.
3. The integration should be tested by the automation firm according to the
instruction under heading Preliminary communication and signal test. This
should be done before commissioning.
4. The implementation must be done at the time of the commissioning. This is
necessary for Alfa Laval to be able to test run the system from the ship’s
control system as a part of the commissioning.

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9.3 Power management system (PMS) integration

It is possible to connect the PureBallast control system to the vessel’s ISCS.
The purpose is to automatically handle power request from PureBallast to
secure that enough power is available for each process. If not integrated, the
operator must ensure this manually before operation. The communication is
either handled by the remote interface (if the option is integrated) or via
hardwires between the vessel’s ISCS and PureBallast’s control cabinet.
Consider if power management shall be used, to be able to plan cable routing
and integration.

9.3.1 Power request process

Below, the overall power request process is described. The process is based
on three signals types: power request, power granted and power running.
1. A process is started.
2. Before the UV lamps are lit, a power request is sent from the PureBallast
control system to the ISCS.
3. After power check, the vessel’s power management system reserves
power for PureBallast and then send power granted to the control system.
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.
Actual power needed for process is defined in section Power requirements on
page 35.

9.3.2 Power management installation

Power management is activated in parameter p127 in the control system and
the options are:
• Not used
Use this option to disable power management.
• Hardwire ranged
• Hardwire fixed
• Remote interface.
• Connect power signals according to Remote interface implementation
guide, which can be requested from your local Alfa Laval sales office.

Hardwire ranged
The signal cables are arrange in a binary pattern to send and receive requests
to/from the ISCS and PureBallast control system. More than one signal can be
sent/received at the same time to request the power needed for the UV
reactors. Note that it is only necessary to connect enough signals to cover the
number of UV reactors installed on the vessel. For example, if only 1 reactor is
installed, only PMS REQ 1, PMS GRANTED:1 and PMS RUN 1 are needed.

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EN 9 Control system integration

Connect power signals according to Control cabinet / Interconnection diagram.

The table below lists the power signals and how many reactors that is
requested for each signal.
Number of UV
reactors Signal cables used Signal cables used Signal cables used
Request power Grant power Run power
(ID in electrical (ID in electrical (ID in electrical
drawings) drawings) drawings)

1 PMS REQ 1 PMS GRANTED:1 PMS RUN 1

2 PMS REQ 2 PMS GRANTED:2 PMS RUN 2
3 PMS REQ 1 + PMS REQ PMS GRANTED:1 + PMS RMS RUN 1 + PMS RUN
2 GRANTED:2 2

Note: PMS REQ 3 and PMS 3 RUN in electrical drawings are not used.
Example:
1. 3 UV reactors are requested via PMS REQ 1 and PMS REQ 2 combined.
2. The ship can only grant access to 2 UV reactors. A signal is sent via PMS
GRANTED:2 which grant power to 2 UV reactors.
3. The process starts with 2 UV reactors and the flow is reduced. A signal is
sent via PMS RUN 2.

Hardwire fixed
In this mode, only one signal cable is needed. The power management
system will always request power for all UV reactors. If the ship can not grant
the requested power, the process stops.
Connect power signals according to Control cabinet / Interconnection diagram.
Example:
1. 3 UV reactors are requested via RMS REQ 4 COMMON.
2. The ship can only grant access to 2 UV reactors. No signal is sent.
3. Process stops.
Number of UV reactors
Signal cables used
(ID in electrical drawings)

1, 2 or 3 RMS REQ 4 COMMON

1, 2 or 3 PMS GRANTED:4 COMMON
1, 2 or 3 PMS 4 RUN COMMON

9.4 External feed control signal

External feed control allows PureBallast to control the flow delivered from the
vessel’s ballast water system by regulating either the ballast water pump via a
variable frequency driver (VFD) or a valve installed before PureBallast.
When the flow in the system is too high, PureBallast’s control valve V201-8 will
close to reduce flow. If the V201-8 closes more than a parameter set degree,
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.

44 200000085-1-EN-GB
 Control system integration 9 EN

When a backflush is done, V201-8 is closed under 70 % (defined in parameter

p157). The external feed control signal is lowered to request less flow from the
pump, so that V201-8 can open. Less flow is needed after the backflush, since
the filter is clean.
Valve V201-8 operates (open/closes) in a range between a parameter set
value (p157) and 100 %, where default is 70 %. Within this range, flow is
regulated by V201-8 without cavitation.
See the illustration below for an example of operation of feed control.
Parameter p156 was set to 2 s / % when process was started.
The curves for V201-8 (blue) and external feed (black) signal
Area 1 are chasing each other. The reason is that the request signal
changes too fast which makes V201-8 compensate, which
affects the signal in return.
Parameter p156 is raised to 6 seconds which makes the
Area 2 request signal change more slowly, which results in a smooth
movement of V201-8 when regulating the external flow.

9.5 External components signal

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 electrical cabinet. It is also possible to simplify operation by
integrating some signals between the ISCS and PureBallast. The
communication is either handled by the remote interface (if the option is
integrated) or via hardwires. In some cases, hardwire is the only alternative.
Many of these component signals must be activated in the control system
page 5.2 – Main parameters 2. Output indicates signal from PureBallast and
Input indicates signal from ISCS.
Consider which signals that shall be used, to be able to plan cable routing and
integration.
Installation requirements:

200000085-1-EN-GB 45
EN 9 Control system integration

• Electrical cabinet / Interconnection diagram

• Control cabinet / Circuit diagram
• The notes about “how” in the table below
• Output signals are connected via potential free relays.

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

Components and signals:

Signal What Why How
Bypass valve is open Input signal to All bypass cases must Open circuit = Valve
PureBallast that the be logged. When any open. Signal cables
system is bypassed. bypass valve is opened, connected according to
ongoing process is Electrical cabinet /
terminated and the Interconnection
event is logged. diagram and Electrical
cabinet / Circuit
Status signals from all diagram.
valves must be
integrated to the control
system. Valves can be
connected in series,
which means that they
are handled as one
regarding alarms and
logging in PureBallast.
This signal will say that
one of them have been
opened, but not which.
If remote interface is
implemented, feedback
signals can be
connected via the
remote interface, which
allows a great number
of components to be
connected.
Common alarm Output signal from Integrated to indicate Active alarm = Open
PureBallast that there is alarm in stations where circuit. If an alarm is
an (any) active alarm. PureBallast is already present and a
An alarm shuts down monitored and new alarm is issued,
ongoing process. controlled. Used if the signal will go low for
remote control panels three seconds, and
(optional) are used. If then be re-activated as
remote interface high.
(optional) is used, this
is an alternative to
alarm indication via
remote interface.
Common warning As common alarm, but See common alarm. See common alarm.
for warnings. A warning Alternative to alarm
is a notification of status indication via remote
change or a problem. interface.

46 200000085-1-EN-GB
 Control system integration 9 EN

Signal What Why How

Request ”Start BW Output signal from If request and feedback Request = Closed
pump” PureBallast to request signals are integrated, circuit. No request and
start of the ballast water the operator does not request withdrawal =
pump (not operated by have to confirm that the Open circuit.
PureBallast). After pump is started/stopped
process is stopped, the in a popup in the control
signal goes low to panel during operation.
request pump to be
stopped.
Used in combination
with Feedback (below).
Feedback ”Ballast Input signal to See Request signal Closed circuit = Pump
water pump is running” PureBallast to confirm above. running.
that the ballast pump is
started.
Heeling mode (internal Input signal to If integration of heeling Closed circuit = Heeling
transfer) PureBallast to to enter command from ISCS is mode command. Only
heeling mode. If desired to automatically possible in standby,
activated, ongoing stop ongoing ballast/ ballast or deballast.
process is stopped and deballast process for a
it is prevented to start a healing operation.
new process.
External stop Input signal to If extra button (not part Open circuit = System
PureBallast to stop of AL scope of supply) stop command. Must be
ongoing process. If to stop a process is connected via hardwire.
extra buttons (not part desired on board. The W118.
of AL scope of supply) power is still on.
to stop PureBallast are
desired on board. The
power is still on.
PureBallast running Output signal from If desirable to indicate PureBallast running =
PureBallast that a that a PureBallast Closed circuit.
process is running. process is ongoing, for
example with a light or
in another system.

9.6 GPS
It is possible to integrate signals from the vessel’s GPS to PureBallast. It is
optional, but strongly recommended to connect GPS. The information is used
to stamp events in the Event log with GPS position. Note that the IMO
convention requires that it must be possible to verify position for ballast water
treatment activities.
The GPS is integrated according to drawing Electrical cabinet /
Interconnection diagram and Electrical cabinet / Circuit diagram.
Requirements: The GPS communication must use protocol NMEA-0183,
version 4.00. The following settings must be used:
• Serial: RS422
• Baud rate: 4800 bps
• Parity: None
• Bits/characters: 8
• Stop bits: 1
The position data shall be sent as messages according to RMC, GLL or GGA.

200000085-1-EN-GB 47
EN 9 Control system integration

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

48 200000085-1-EN-GB
 EN

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

10.1 Alfa Laval’s responsibilities

The International Ballast Water Convention requires that all ballast water
treatment system have a type approval, issued by the flag administration of
the vessel. This flag type approval shows that the treatment system meets
defined requirements and standard, with respect to the treatment function. The
flag type approval is supplied by Alfa Laval for the intended flag of the vessel.
Alfa Laval will also obtain class type approval for PureBallast from the major
classification societies. These class type approvals shows that the system
scope of supply meet respective class rule requirements.

10.2 Installing party’s responsibility

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

10.2.1 Approval planning

If the system is installed in a new building, the PureBallast installation should
be part of the normal system approval on the vessel.
For retrofit installations, it is recommended that contact is established as soon
as possible to get the design documentation approved so that the approval
process does not delay the progress of installation, and to schedule an on
board visit.

10.2.2 Design approval

Applicable classification society requires to review the on board design
documents before installation, to approve that the on board design is in
accordance with their rules and standards, and in compliance with Alfa Laval’s
class type approval.
The design documents are to be submitted by the installing party or the ship
owner, and should be approved before the installation is begun. The
classification society will reply in an Approval letter.

Documents to submit
Each classification society has their own requirements regarding documents
and information to be submitted. Always check with the classification society in
question to verify their specific requirements.
It is recommended that the vessel specific documentation refers to the main
drawings for PureBallast

200000085-1-EN-GB 49
EN 10 System approval

(flowchart, electrical system layout etc, to clarify connections etc), or that they
are attached.
The list below contains the documents normally required for approval:
• On board locations indicating
- PureBallast system, ballast water sampling points, remote control
stations.
• Interconnection details to the vessel
- Piping i.e. P&I, dimensions, material etc.
- Electrical i.e. block diagram, power supply arrangement, cable types
- Control and alarm system i.e. block diagram, PureBallast externally
monitored equipment.
- Pneumatic interconnection.
• Identification of by PureBallast external bypass possibilities.
• Reference to the respective class type approval issued for PureBallast.
The convention specifies that an operations and technical manual specific to
the ship shall be approved by the administration (or their recognized
organization) and the information above should be enough to produce such
manual.

10.2.3 Installation survey

The International ballast water convention requires a survey of the complete
system after installation, to confirm that the system works as designed and
that it fulfills the convention’s requirements. The survey can contain both
ocular inspection and running of the system.
An on board survey is also normally required by both the classification society
and the flag administration. Normally, the classification societies are
recognized organizations by the flag administration, wherefore the
classification society cover both roles. Completed survey results in an
installation approval.
This is to be done after completed installation.

10.3 Alfa Laval commissioning

After installation, a commissioning shall be performed by Alfa Laval according
to the Commissioning test form. A copy of the test forms can be required from
your local Alfa Laval sales office.
The commissioning can also be coordinated and used as a part of the
installation survey.

50 200000085-1-EN-GB
 EN

11 On board installation planning

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

11.1 Delivery and transport

Preparations and conditions:
• Before installing the system, read the system manual and follow the
instructions in chapter
Installation description and drawings and 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.

11.2 Lifting instructions

This section describes how to lift the heavier PureBallast components. For
individual component weight see dimension drawing / Dimension drawings
including technical data.
Preparations and conditions

WARNING
The 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.
The components must be empty from water when lifted.
The components must be lifted according to the instructions in the
following sections.

200000085-1-EN-GB 51
EN 11 On board installation planning

11.2.1 UV reactor
UV reactor size (m3/h) Weight, empty (kg) L (mm)
600 420 700

52 200000085-1-EN-GB
 On board installation planning 11 EN

11.2.2 Filter
Protect external components or remove from filter, under lifting.
Filter A (mm) Weight, empty with
adaptor plates on flanges
(kg)
ACB–955–250 698 680

200000085-1-EN-GB 53
EN 11 On board installation planning

11.2.3 Booster pumps

Protect external components or remove from pump, under lifting.
Pump Weight (kg) A (mm) B (mm)

UVR cooling water pump P403–

1, 90 300 165
20 m3/h

Backflush pump P309–1, 140 350 210

95 m3/h

54 200000085-1-EN-GB
 On board installation planning 11 EN

11.2.4 CIP module

Use intended lifting attachment according to the illustration below. The tank
must be empty.

200000085-1-EN-GB 55
EN 11 On board installation planning

11.2.5 Cabinets
Use intended lifting attachment at the top of the cabinet.
Protect the control panel screen when lifting the control cabinet.
Component Weight (kg) A (mm) B (mm)
Control cabinet 50 500 300
Lamp drive cabinet 150 480 400
Lamp drive cabinet 400 1050 550

56 200000085-1-EN-GB
 EN

12 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.

200000085-1-EN-GB 57
EN 12 Start-up procedures

58 200000085-1-EN-GB
 EN

13 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 table of contents to get an overview of
included drawings.

200000085-1-EN-GB 59
EN 13 Drawings

13.1 Graphic symbols used in drawings

60 200000085-1-EN-GB
 Drawings 13 EN

13.2 General drawings

This section contains the general drawings.

200000085-1-EN-GB 61
EN 13 Drawings

13.2.1 Flow chart

Note: If Closed cooling unit (optional) is used, see flow chart for Closed
cooling unit, regarding item 401 and 402.

62 200000085-1-EN-GB
 Drawings 13 EN

13.2.2 Flow chart — Closed cooling unit, LDC (optional)

200000085-1-EN-GB 63
EN 13 Drawings

13.2.3 Connection list

If closed cooling unit (optional) is used, see specific connection list.

64 200000085-1-EN-GB
 Drawings 13 EN

200000085-1-EN-GB 65
EN 13 Drawings

66 200000085-1-EN-GB
 Drawings 13 EN

200000085-1-EN-GB 67
EN 13 Drawings

68 200000085-1-EN-GB
 Drawings 13 EN

200000085-1-EN-GB 69
EN 13 Drawings

13.2.4 Connection list — Closed cooling unit, LDC (optional)

70 200000085-1-EN-GB
Drawings 13 EN

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13.2.6 Instrument air distribution

200000085-1-EN-GB 73
EN 13 Drawings

13.2.7 Quality specification / Instrument air

74 200000085-1-EN-GB
 Drawings 13 EN

13.2.8 Quality specification / Technical and potable water

200000085-1-EN-GB 75
EN 13 Drawings

13.2.9 Quality specification / CIP liquid

76 200000085-1-EN-GB
 Drawings 13 EN

13.3 Dimension drawings

This section contains the dimension drawings.

200000085-1-EN-GB 77
EN 13 Drawings

13.3.1 UV reactor

78 200000085-1-EN-GB
 Drawings 13 EN

13.3.2 UV reactor and control cabinet / Lamp power cable

200000085-1-EN-GB 79
EN 13 Drawings

13.3.3 Filter

80 200000085-1-EN-GB
 Drawings 13 EN

13.3.4 CIP module

200000085-1-EN-GB 81
EN 13 Drawings

82 200000085-1-EN-GB
 Drawings 13 EN

13.3.5 Flow transmitter FT201-1

200000085-1-EN-GB 83
EN 13 Drawings

13.3.6 Pressure monitoring device (Incl. PT201-16,

PI201-18, RV201 and V201-15)

6 bar system

84 200000085-1-EN-GB
 Drawings 13 EN

High pressure system

200000085-1-EN-GB 85
EN 13 Drawings

13.3.7 Valve V201-3 and V201-9

86 200000085-1-EN-GB
 Drawings 13 EN

13.3.8 Valve V201-32 and V403-35

200000085-1-EN-GB 87
EN 13 Drawings

13.3.9 Valve V212-31 (Optional)

88 200000085-1-EN-GB
 Drawings 13 EN

13.3.10 Control valve V201-8

200000085-1-EN-GB 89
EN 13 Drawings

13.3.11 Backflush valve V309-1

If backflush pump P309–1 (optional) is installed, this valve is premounted on
the pump.

90 200000085-1-EN-GB
 Drawings 13 EN

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

200000085-1-EN-GB 91
EN 13 Drawings

92 200000085-1-EN-GB
 Drawings 13 EN

200000085-1-EN-GB 93
EN 13 Drawings

13.3.13 Remote control panel (Optional)

94 200000085-1-EN-GB
 Drawings 13 EN

13.3.14 Log box (Optional)

200000085-1-EN-GB 95
EN 13 Drawings

13.3.15 Lamp drive cabinet (LDC)

96 200000085-1-EN-GB
 Drawings 13 EN

13.3.16 Control cabinet

200000085-1-EN-GB 97
EN 13 Drawings

13.3.17 Air filter / Filter regulator

98 200000085-1-EN-GB
 Drawings 13 EN

13.3.18 Backflush pump P309–1 (Optional)

200000085-1-EN-GB 99
EN 13 Drawings

13.3.19 LDC cooling water pump P401–1 (optional)

100 200000085-1-EN-GB
 Drawings 13 EN

13.3.20 UVR cooling water pump P403–1 (optional)

200000085-1-EN-GB 101
EN 13 Drawings

13.3.21 Closed cooling unit, LDC (Optional)

102 200000085-1-EN-GB
 Drawings 13 EN

13.3.22 Transformer (Optional)

200000085-1-EN-GB 103
EN 13 Drawings

13.4 Electrical drawings

This section contains the electrical drawings.

104 200000085-1-EN-GB
 Drawings 13 EN

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