DG PB 3.1 500 Compact Flex Imo Uscg

PureBallast 3.
1 500 Compact Flex

IMO/USCG
Design and installation guide

Lit. Code 200000180-1-EN-GB
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 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 Ship specific information..................................................................................... 7
2 Introduction...................................................................................................................9
2.1 Safety information......................................................................................................9
2.2 Components overview.............................................................................................10
3 Component overview........................................................................................... 11
4 Material and equipment supplied by installing party.......................13

4.1 Material selection.....................................................................................................13
5 Mechanical installation........................................................................................15
5.1 General requirements..............................................................................................15
5.1.1 Welding requirements................................................................................ 15
5.1.2 Tightening torques..................................................................................... 15
5.2 Maximum distance between components............................................................... 17
5.2.1 Maximum pipe lengths............................................................................... 17
5.2.2 Maximum cable lenghts............................................................................. 17
5.3 Cabinets.................................................................................................................. 17
5.4 UV reactor............................................................................................................... 18
5.5 Filter.........................................................................................................................21
5.6 CIP module..............................................................................................................22
5.7 Flow meter ..............................................................................................................23
5.8 Pressure monitoring device.....................................................................................25
5.9 Valves...................................................................................................................... 25
5.9.1 Bypass valve (V212–31)............................................................................ 25
5.9.2 Control valve (V201–8).............................................................................. 26
5.9.3 Filter valves (V201-3, V201-32, V201-9 and V309-1)................................ 26
5.10 Ancillary equipment and functions...........................................................................26
5.10.1 Sampling devices (Q201.1 and Q201.2)....................................................27
5.10.2 Booster pump.............................................................................................27
5.10.3 Tank stripping equipment........................................................................... 27
5.10.4 Air supply................................................................................................... 28
6 Pipe design.................................................................................................................31
6.1 Water requirements................................................................................................. 31
6.2 Flow requirements...................................................................................................31
6.3 Piping: Dimensions, connections and material........................................................32
6.4 Installations with large height differences................................................................35
6.4.1 Cavitation – Problems and solutions..........................................................35
6.5 Air pockets – Problems and solutions..................................................................... 38
6.6 Valves outside PureBallast ..................................................................................... 39
6.7 System pressure......................................................................................................39
6.8 Pressure requirements for filter backflush............................................................... 41
7 Electrical design...................................................................................................... 43
7.1 Power requirements................................................................................................ 43
7.2 Installation requirements......................................................................................... 43
7.2.1 Cables........................................................................................................44
8 Pneumatic design...................................................................................................45
9 Control system integration............................................................................... 47

9.1 Remote control panels.............................................................................................47
9.2 Remote interface..................................................................................................... 48
9.3 Power management system (PMS) integration....................................................... 49
9.3.1 Power request process.............................................................................. 49
9.3.2 Power management installation.................................................................49
9.4 External feed control signal..................................................................................... 49
9.5 External component signals.................................................................................... 51
9.6 GPS.........................................................................................................................53
10 System approval..................................................................................................... 55
10.1 Alfa Laval’s responsibilities......................................................................................55
10.2 Installing party’s responsibility................................................................................. 55
10.2.1 Approval planning...................................................................................... 55
10.2.2 Design approval......................................................................................... 55
10.2.3 Installation survey...................................................................................... 56
10.3 Alfa Laval commissioning........................................................................................56
11 Compliant operation according to BWMP..............................................57
12 Transport and storage.........................................................................................61

12.1 Delivery and transport............................................................................................. 61
12.2 Lifting instructions....................................................................................................61
12.2.1 UV reactor..................................................................................................62
12.2.2 Filter........................................................................................................... 63
12.2.3 Backflush pump......................................................................................... 64
12.2.4 CIP module................................................................................................ 65
12.2.5 Cabinets.....................................................................................................66
12.3 Storage and long term decommissioning................................................................ 66
13 Start-up procedures.............................................................................................. 69
14 Drawings...................................................................................................................... 71
14.1 Graphic symbols used in drawings..........................................................................72
14.2 General drawings.................................................................................................... 73
14.2.1 Flow chart.................................................................................................. 74
14.2.2 Flow chart — Vacuum relief valve, VB201 and VB309 (optional).............. 75
14.2.3 Connection list........................................................................................... 76
14.2.4 Electrical system layout............................................................................. 81
14.2.5 Instrument air distribution...........................................................................83
14.2.6 Quality specification / Instrument air.......................................................... 85
14.2.7 Quality specification / Technical and potable water................................... 86
14.2.8 Quality specification / CIP liquid.................................................................87
14.3 Dimension drawings................................................................................................ 89
14.3.1 UV reactor..................................................................................................90
14.3.2 Electrical cabinet........................................................................................91
14.3.3 Filter........................................................................................................... 92
14.3.4 CIP module................................................................................................ 93
14.3.5 Flow transmitter FT201-1...........................................................................94
14.3.6 Pressure monitoring device (PT201-16, PI201-18, RV201, V201-17)....... 95
14.3.7 Valve V201-9 .............................................................................................96
14.3.8 Valve V212-31 (optional)............................................................................97
14.3.9 Control valve V201-8................................................................................. 98
14.3.10 Backflush valve V309-1............................................................................. 99
14.3.11 Vacuum relief valve VB201 (optional)...................................................... 100
14.3.12 Vacuum relief valve VB309 (optional)...................................................... 101
14.3.13 Sampling device Q201.1 and Q201.2 (optional)...................................... 102
14.3.14 Remote control panel (optional)...............................................................105
14.3.15 Log box (optional).................................................................................... 107
14.3.16 Lamp drive cabinet (LDC)........................................................................ 108
14.3.17 Air filter regulator......................................................................................109
14.3.18 Air preparation unit (optional)...................................................................110
14.3.19 Backflush pump P309–1 (Optional)..........................................................111
14.3.20 Transformer (optional)..............................................................................112
14.4 Electrical drawings.................................................................................................113
14.4.1 Electrical cabinet / Interconnection diagram............................................ 114
14.4.2 Electrical cabinet / Circuit diagram ..........................................................120
14.4.3 Electrical cabinet / Cable list.................................................................... 141
14.4.4 Lamp drive cabinet 1/ Interconnection diagram....................................... 142
14.4.5 Lamp drive cabinet 1 / Circuit diagram.................................................... 143
14.4.6 Lamp drive cabinet 1 Cable list................................................................146
14.4.7 UV reactor / Circuit diagram ....................................................................147
14.4.8 Remote control panel / Circuit diagram (optional)....................................148
14.5 Saftey Data Sheets................................................................................................149
14.5.1 Safety data sheet / CIP liquid...................................................................149
14.5.2 Safety data sheet / UV lamp.................................................................... 158
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
Flange standard (EN or JIS) ___________
Control valve (V201-8) 200
Bypass valve (V212–31)

Dimension: ___________
Alfa Laval’s or other
Filter module connections:

Inlet valve (V201–3) Integrated components premounted at delivery.
Outlet valve (V201-32)
UV reactor connections:
Inlet valve (V201-19)
Integrated components premounted at delivery.
CIP unit connection (V321-2)
CIP unit connection (V320-4)
CIP unit connections:

Line 460
Line 320 Dimension: ___________
Line 321
Line 310
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):
___________
200000180-1-EN-GB 7
EN 1 Ship specific information
8 200000180-1-EN-GB
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 71. 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

Read chapter 1. Safety and chapter 7. Service manual in PureBallast system
manual.
Installation must be done by a fully trained professional installer.
200000180-1-EN-GB 9
EN 2 Introduction
2.2 Components overview

The key components in PureBallast 3.1 are shown below.
1. Filter
2. Flow meter
3. UV reactor
4. CIP (cleaning-in-place) module
5. Electrical cabinet (EC)
6. Lamp drive cabinet/cabinets (LDC), not included in all system sizes
7. Control valve
Not in illustration:
• System bypass valve
• Sampling device
• Pressure monitoring device
10 200000180-1-EN-GB
EN
3 Component overview
The table below is a list of PureBallast components and consumables.
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, including

reactor, valves, UV sensor, temperature sensor, temperature
UV reactor UVR switch, level switch and an electrically integrated control valve,
V201–8.
The controlling unit. It contains the main control panel, from

which PureBallast is controlled. It also contains breaker and
communication components such as PLC, switches for
Electrical cabinet EC communication with remote interface, remote control panels etc,
and terminals to connect signal cables to components and
external systems.
The electrical cabinet is fitted with 5 lamp power supplies (LPS).
Additional lamp drive cabinet. The LDC is feeding the UV lamps

Lamp drive cabinet LDC 1 in the UVR with power. LDC 1 contains 5 LPS.
Lamp power cable delivered from Alfa Laval must be used.

Lamp power cable W211 Power cables between UVR and EC or LDC. Length specified in
order.
Filter Filter Mechanical filtration of the water before treatment.
Cleaning-in-place module for automatic cleaning of the UVR after

CIP module CIP treatment, mainly clean the UV lamps quartz sleeves.
Remote control panel Extra control panels to control and monitor the PureBallast
(optional) system. Number according to order.
Valves
Main outlet valve from the PureBallast system to the vessel’s

ballast system after treatment.
Automatic pressure regulation to maintain needed pressure
Control valve V201-8 during back flush.
Automatic flow regulation during operation to secure that max
flow is not exceeded.
Main inlet valve to the PureBallast system during ballast, in

combination with V201-32. The valve directs the water flow
Filter inlet valve V201-3 through the PureBallast filter. (Closed during deballast)
Preassembled on the filter at delivery.
The valve directs the water flow from the PureBallast filter to the
Filter outlet valve, V201-32 UVR. (Closed during deballast)
Preassembled on the filter at delivery.
Filter bypass valve open during deballast, when the filter is not
Filter bypass valve V201-9 used. (Closed during ballast)
200000180-1-EN-GB 11
EN 3 Component overview
Component ID Function
The valve directs the water used for filter backflush back to the
sea.
Filter backflush valve V309–1 Preassembled on the filter at delivery.

If backflush pump P309–1 (optional) is installed, this valve is
delivered mounted on the pump. If backflush pump is not used,
the valve is mounted on the filter.
Bypass valve, including Bypass valve to bypass the complete PureBallast system. The
switch box valve is solely operated from the ISCS.
V212-31
(Optional as part of scope The switch box function as connection point for signal and control
of supply) cables to the component.
Vacuum relief valve VB201 Vacuum relief valve to solve the problem with cavitation and
(optional) VB309 vacuum in the system.
Ancillary equipment
The flow meter consists of two components:

• Flow sensor monitor the flow in the system. Functions
Flow meter FT201-1 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 device PT201-16 Manifold includes pressure transmitter (PT201-16), pressure
gauge (PI201–18), relief valve (RV201) and needle valve V201–
17.
Sampling device Q201-1 Sampling points to tap water for test of water before and after
(optional as part of scope treatment.
Q201-2
of supply)
If one or several valves can be used as both bypass and heeling,

Log box (optional) a log box can be used to define different combinations of valves
and pumps, that constitutes bypass or heeling operation.
If instrument air is not available according to requirements, an air

Air preparation unit preparation unit can be installed. It filters the air to make it clean
(optional) and dry according to specification.
Filter backflush pump Booster pump to secure enough flow in pipe 309 for sufficient
P309-1
(optional) filter backflush.
If voltage does not meet the requirements, a transformer must be

Transformer (optional) used. The transformer is recommended to give voltage in the
higher range, as close as possible to 440 VAC.
PureBallast Connect The Alfa Laval PureBallast Connect is a connectivity platform

(optional) that allow the PureBallast system to be monitored remotely.
Information about operation, control system parameters,

System manual faultfinding and drawings.
Additional manuals or manuals as CD/USB according to order.
Consumables
CIP liquid, 15 liters The liquid is used during the CIP-process.
12 200000180-1-EN-GB
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 all medias to, from and between the PureBallast components.
• 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.
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
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 dimension and material in section Pipe design on page
31.
200000180-1-EN-GB 13
EN 4 Material and equipment supplied by installing party
14 200000180-1-EN-GB
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 indoors in a machinery space on the
vessel (engine room, pump room etc. ) with:
• relative humidity of max 100 %
• ambient temperature of 0 to 45º C
• 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 componentshould 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.
5.1.1 Welding requirements

Earth connection must be done according to the below. If not, the equipment
can be seriously damaged:
• Ensure that all solenoid valve connectors on the reactor valves (V201-19,
V320-4, V321-2) are disconnected prior to any welding on- or nearby
components of the PureBallast system.
• 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).
• Installation must be done by a fully trained professional installer.
5.1.2 Tightening torques

Use tightening torques according to the tables below for each respective
component. If no specific torques are specified for a component, see table
General tightening torques below.
200000180-1-EN-GB 15
EN 5 Mechanical installation
UV reactor
Glass socket screws – maximum 7 Nm.
CIP module
Flange bolts – maximum 20 Nm.
Filter
Thread Maximum tightening torque, Nm
M4 3
M6 7
M8 12
M10 18
M12 25
M14 35
M16 45
M18 60
M20 75
M22 90
M24 105
Actuator
Thread Tightening torque, Nm
M5 5-6
M6 10-11
M8 23-25
M10 48-52
M12 82-86
M14 132-138
M16 200-210
M20 390-410
General Tightening Torques

Thread Stainless steel Carbon steel
Maximum tightening torque, Maximum tightening torque, Nm
Nm
M6 7 10
M8 17 25
M10 33 48
M12 57 83
M16 140 204
M20 270 408
M24 470 696
M30 - -
M36 - 2500
16 200000180-1-EN-GB
Mechanical installation 5 EN
5.2 Maximum distance between components

We recommend that all components are installed close to each other.
However, limitations on pipe length and cable lengths should not be exceeded.
5.2.1 Maximum pipe lengths

Place the components according to the limitations below:
5.2.2 Maximum cable lenghts

Place the components according to the limitations below:
5.3 Cabinets
This section covers installation guidelines for cabinets, regarding mechanical
installation. For electrical installation, see section Electrical design.
200000180-1-EN-GB 17
• Cabinets (LDC, control cabinet) 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.
• To prolong the lifetime of the cabinet, we recommend to install it in the
coolest possible area in the range of 0 to 45º C.
Cable lengths
For recommended cable length see illustration Maximum cable lenghts in
section Maximum distance between components , that specify distances
between PureBallast system components.
5.4 UV reactor
• 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.
• It must be possible to de-aerate the manifold after the UV reactor to remove
air pockets in the pipe. A vacuum relief valve assembly or a manual valve
can be used.
18 200000180-1-EN-GB
• The UV reactor must be secured so it withstands the forces of load applied

by a full UV reactor (500 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.
200000180-1-EN-GB 19
• 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.
• A drain solution (not part of Alfa Laval’s scope of supply) must be attached
to relief valve RV201-23. The valve shall be drained to a scupper, with a
solution which always allows (minor) water spillage to be drained.
20 200000180-1-EN-GB
5.5 Filter
• 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.
• A drain solution (not part of Alfa Laval’s scope of supply) must be attached
to relief valve RV201-50. The valve shall be drained to a scupper, with a
solution which always allows (minor) water spillage to be drained.
• 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.
• For pipe connections, see section Piping: Dimensions, connections and
material on page 32.
200000180-1-EN-GB 21
5.6 CIP module

• The CIP shall be placed close to the UV reactor to secure that the CIP fluid
can circulate.
• It is recommended that the CIP module is installed on the same level as the
UV reactor and the filter.
• Design pipe 320 in a downward gradient from the UV reactor towards the
CIP module to improve draining of the UV reactor. A water lock can be
created close to the CIP module, before a vertical pipe to the CIP module.
This will improve the suction from the drain pump. There must be no risk for
water or air pockets in the pipe, which can affect suction in a negative way.
• If pipe 320 (to the UV reactor) and 310.1 (to the filter) are installed below
the floor, maximum lifting height between pipe and CIP is 0.75 meter.
• It is recommended that the deaeration pipe after deaeration valve V571-1

on the UVR 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. This is particularly important when
connecting the plastic flanges.
• It is recommended that pipe 460 is connected so that used CIP liquid is
drained overboard, or to one of the following: waste oil tank, drain tank or
sludge tank.
Pipe 460 (drain of used CIP liquid) should not be lead to bilge tank due to
the low pH value.
CIP liquid should be handled according to local regulations. See Quality
specification / CIP liquid on page 87.
WARNING
CIP liquid have a low pH value (approximately 3.0 when changed) and
it contain residues from the cleaning process when discharged from the
UVR.
22 200000180-1-EN-GB
5.7 Flow meter

• Dimension according to section Ship specific information.
• The flow meter (FT201–1) should be installed according to flow chart.
• The flow meter should be placed with the flow transmitter facing 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.
• The flow meter should be installed with the arrow on the plate pointing in
the flow direction.
• We recommend that a straight pipe is before and after the flow meter, with
length proportional to the pipe diameter according to the illustration below.
This will secure correct 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.
DN=Nominal diameter.
• The flow meter must always be completely filled during operation to ensure
correct 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.
DN=Nominal diameter.
200000180-1-EN-GB 23
• 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.

• 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:
The cable from the flow transmitter shall be connected to the control
cabinet. See Electrical cabinet / Interconnection diagram, in section
Electrical drawings on page 113.
• Ground the transmitter with a cable with a minimum dimension of 6 mm2.
The transmitter has to be grounded to optimize the measurement of the
transmitter sensor and to prolong the lifetime of the transmitter’s sensing
electrodes.
1. Connection diagram inside the connection compartment cover

2. Both power supply cable and signal cable
3. Optional
4. Optional
24 200000180-1-EN-GB
Turn transmitter housing and display

The flow transmitter housing and display can be turned to make the placing
more flexible.
Follow the illustrations below:
5.8 Pressure monitoring device

• Pressure monitoring device must be installed vertically on a horizontal pipe.
This will result in best function and durability for the component.
5.9 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 electrical cabinet.
• 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.
• Valves should be installed with the actuator on the upper half of the pipe, to
minimize the risk for water entering the actuator.
• Valves shall be opened when installed. This is important to avoid that the
rubber gaskets are squeezed and damaged during installation.
5.9.1 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.
200000180-1-EN-GB 25
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
5.9.2 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.
• The valve should be installed with the actuator positioned on the top 180
degrees of the pipe. This is to avoid water assembling in the positioner
ruining the electrical components inside.
• The air filter on the positioner should be turned so it points downward.
5.9.3 Filter valves (V201-3, V201-32, V201-9 and V309-1)

Filter valves Guidelines
If required adapter plates are used to convert to
Filter inlet valve (V201–3) different flange dimension or convert an EN flange to
JIS flange.
If required adapter plates are used to convert to

Filter outlet valve (V201–32) different flange dimension or convert an EN flange to
JIS flange.
If backflush pump P309–1 (optional) is installed, this

Filter backflush valve valve is delivered mounted on the pump. If backflush
(V309–1) pump is not used, the valve is mounted on the filter.
5.10 Ancillary equipment and functions

This section covers installation guidelines for ancillary equipment and
equipment supplied by installing party for specific functions.
26 200000180-1-EN-GB
5.10.1 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.
• Installed in pipe 201 after treatment as close as possible to the overboard
valve.
• 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.
• 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.
• Optimally installed in a horizontal pipe. It is possible to install the
component in a vertical pipe, if the flow is going upwards.
• 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.
5.10.2 Booster pump

Booster pump 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.
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.
5.10.3 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.
200000180-1-EN-GB 27
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.
5.10.4 Air supply

Depending on the quality of the air supplied, either an air filter regulator or an
optional air preparation unit must be installed. If the requirements set in the air
quality specification are met, it would be sufficient to use the supplied air filter
regulator. If the air quality requirements are not met; the optional air
preparation unit must be used. It ensure that the air requirements are met.
Air filter regulator
The air filter regulator should be installed vertically with the bowl in lower
position. It shall only be installed if an air preparation unit (optional) is not
installed.
Note: Only delivered if an air preparation unit (optional) is not ordered.
28 200000180-1-EN-GB
Air preparation unit (optional)

If instrument air is not available according to requirements, an air preparation
unit can be installed. It filters the air to make it clean and dry according to
specification.
Note: Only installed if an air filter regulator is not installed.
200000180-1-EN-GB 29
30 200000180-1-EN-GB
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 Temperature: -2 to 40 °C (liquid form)
Salinity: PureBallast can treat the following types of water:
• Fresh water
• Brackish water
• Marine water
Technical water / UVR and filter preservation.

potable water
Temperature: 0–38 °C.
For details, see Quality specification / Technical and
potable water on page 86
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 – Pipe 201, ballast 110 – 500 m3/h
Flow range – Pipe 201, deballast 60 – 600 m3/h
Flow range – Pipe 201, stripping 60 – 600 m3/h
Pipe 310, technical water / potable water
• Start-up cooling water flow 48 l /min (max 60 l)
• CIP process, volume 366 l
Minimum flow – Pipe 309, filter backflush 50 m3/h
200000180-1-EN-GB 31
EN 6 Pipe design
6.3 Piping: Dimensions, connections and material

The follow recommendations apply to pipe and valve dimensions:
• Pipes shall be designed to carry the weight of the pipe and the media in it.
• 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 with incoming stripping water should be connected to pipe 201 (ballast
water) before valve V201–3 and V201–9.
• 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.
Filter pipe connections

• Pipe 309 (backflush): Pipe dimension MUST be increased to 100 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 201 (ballast water): Adaptor plates are used for transition to JIS flange
standard and some pipe dimensions. Consult the filter dimension drawing
in section Dimension drawings on page 89 to see if adaptor plates, and
details if used in the specific project. Adaptor plates are delivered as loose
components.
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:
32 200000180-1-EN-GB
Pipe design 6 EN
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
200000180-1-EN-GB 33
EN 6 Pipe design
34 200000180-1-EN-GB
Pipe design 6 EN
6.4 Installations with large height differences

If the PureBallast system is placed high up in ship’s pump rooms or even on
deck in a deckhouse the fall height in the downward going pipes between the
PureBallast system and the tanks/overboard can be considerable. Whenever
the water in the pipes free fall in downward going pipes the pressure upstream
will be affected and low pressure will appear. Depending of the geometry of
the system the low pressure can be considerable and can potentially cause
cavitation and water hammering which is harmful to the PureBallast
installation.
This section gives design recommendations and requirements to deal with
those problems.
6.4.1 Cavitation – Problems and solutions

There are multiple factors that can contribute to low pressure in these
systems, but the fall height has a major contribution. Our recommendation is
to install a vacuum relief valve whenever there is a risk for considerable low
pressure. Installations with around 10 meters of fall height or above must have
a vacuum breaker installed. If the fall height is less but still considerable the
lowest pressure in the worst-case scenario should be determined. It is
recommended to install a vacuum relief valve if the absolute pressure in any
scenario is likely to be less than 0.7 bar. Major classification societies require
that measures are taken to eliminate problems caused by low pressure. In
PureBallast systems both pipe 201 and 309 can be affected depending on the
installation, and should be evaluated independently.
Note that it is the total height difference that is intended. It is not possible to
“shorten” the height difference by making two vertical segments by a short
horizontal pipe in the middle.
Vacuum relief valves

To solve the problems with cavitation and vacuum, the system should be
equipped with vacuum relief valves:
In pipe 201. Float operated vacuum relief valve providing both air
VB201 release upon startup of the system and vacuum relief during operation.
In pipe 309. Only vacuum relief, without air venting function. The valve
VB309 is spring loaded (normally closed) to avoid water spillage during
initiation of backflush.
Installation requirements
Follow the requirements below:
200000180-1-EN-GB 35
EN 6 Pipe design
Placement VB201
• At highest possible point in a horizontal part of the pipe 201, after control
valve V201-8.
• As close as possible to the bend. Installation in bend not recommended
because it reduces the functionality of the valve
• The component should be installed vertically in top of the pipe.
• See illustration and table below for requirements on dimensions and
distances for VB201.
Measure Description Min. (m) Max. (m)

H1 Length of air inlet pipe Not applicable 20
H2 Length of standpipe Not applicable 1
Distance from control

X 1.5 x D Not applicable
valve
Y Distance from bend 0 30
• If H1 ≤ 1 m:
same size as D2
Diameter of air inlet
D1 • If H1 > 1 m: one Not applicable
pipe
size larger than
D2
Diameter of standpipe Same as valve Same as pipe 201

D2 dimension. dimension.
36 200000180-1-EN-GB
Pipe design 6 EN
Placement VB309
• The component should be installed vertically in top of the pipe.
• At highest possible point in a horizontal part of the pipe 309, after V309-1.
• It is recommended to install VB309, regardless of backflush pump
(optional).
• See illustration below for an installation overview for VB309.
Mounting
• A standpipe (not in AL scope of supply) should be installed on pipe 201. It
should be as short as possible.
• If the standpipe is made as a bend to allow vertical installation of the
component, the bend radius should be as large as possible.
• A short connecting pipe should be installed between the valve and the air
inlet pipe to enable removal of the component for service. It should be
made with threads for connection to the valve and a flange for connection
to the air inlet pipe. At service, the valve must be removed together with the
connecting pipe.
200000180-1-EN-GB 37
EN 6 Pipe design
Air inlet pipe

• The CIP venting must not be connected to air inlet pipes for VB201 and
VB309 to avoid intake of air from hazardous zone.
• The air intake pipe should be at least one size larger than the valves
dimension if the air inlet pipe is longer than 1 meter.
• There is a risk for a standing water column in the air inlet pipe. For
installations where the valve is installed close to an outdoor environment
with risk for negative temperatures, the air inlet pipe should be designed to
avoid water freezing in the pipe.
• The component should be protected from incoming particles at the end of
the air inlet pipe:
• The end of the air inlet pipe should be equipped with a goose neck or a
vent cap (not part of AL scope of supply). There is a risk for water
spillage from the air inlet pipe. Make sure that eventual spillage from the
air inlet pipe does not risk to harm any components.
• A strainer (not part of AL scope of supply) should be installed at the end
of the air intake pipe. Maximum mesh size 5 mm. The strainer should
not obstruct the air flow by decreasing the inlet area.
Yard supplied components

If the vacuum relief valve is not supplied by Alfa Laval, the requirements below
should be fulfilled.
PB pipe Flow (m3/h) Min size1 (mm) Min orifice

area2 (mm2)
201 (ballast/ 85 – 1000 80 4558

deballast)
130 (all
309 (backflush) 50 1960
flows)
Note 1: Min. size: Dimension of the valve’s air inlet diameter.

Note 2: Min. orifice area: Area at the smallest cross section in the valve.
Spring loaded, or not
It is recommended that the valve VB309 is spring loaded. Opening
VB309 pressure 0.7 - 1.0 bar (absolute pressure).
VB201 Should not be spring loaded to allow release of air.
6.5 Air pockets – Problems and solutions

When a pipe contains air pockets, the effective pipe area is reduced which
creates higher flow. It is therefore important make sure that the pipe is filled
with water.
It is recommended to install a de-aeration valve at points with risk for air
pockets.
38 200000180-1-EN-GB
Pipe design 6 EN
6.6 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:
• 310 and 320 (UV reactor cooling water, during start-up).
Flow from PureBallast pipes:
• 201 (ballast water to tanks and reactor cooling water to tanks, during start-
up)
• 309 (backflush water overboard)
Deballast process
• 310 and 320 (UV reactor cooling water, during start-up).
• 201 (ballast water).
• 201 (ballast water overboard and reactor cooling water to overboard, during
start-up)
CIP process
• 310 + 320 (fresh water)
• 320 + 321 (CIP fluid circulation)
• 460 (Drain reactor and filter - ballast water and fresh water overboard).
6.7 System pressure

The table gives a description of system pressure range for piping and
instrument air.
200000180-1-EN-GB 39
EN 6 Pipe design
Pressure (bar) Comment

Max pressure for standard system: 6 bar.
Piping
Max pressure for high pressure system: 9 bar.
Instrument air Range: 5.5 – 8.0 bar to operate valves and CIP pumps.
40 200000180-1-EN-GB
Pipe design 6 EN
6.8 Pressure requirements for filter backflush

This is section presents how to calculate pressure necessary to overcome
pressure drop for PureBallast components to ensure filter backflush.
Normal minimum required pressure at filter inlet is 1.7 bar. However, this
pressure is affected by other components installed in the system. This is
presented in this section together with necessary calculations for system
pressure.
NOTE
Pressure requirement only includes PureBallast’s components. Piping is
not included.
If a backflush pump P309–1 is not used, pressure drop in pipe 309
(Δp309) must be calculated and added according to the table below.
Bar Comment
Pressure drop for UV reactors and PureBallast’s
0.2 valves.
Pressure drop during Max differential pressure over the filter during
ballast ballast operation. When the differential pressure
0.5 reaches 0.5 bar due to dirt in the filter, a
backflush is started automatically.
1.0 Required pressure to clean the filter.
Pressure needed for If a backflush pump P309–1 is not used, pressure
backflush drop in pipe 309 must be calculated and added.
Δp309 This is vessel specific and must be calculated
using required flow in pipe 309: 50 m3/h.
The ballast pump must deliver pressure at filter
Total inlet, covering total pressure drop over
PureBallast system.
Calculate backflush parameter setting (p304)

System pressure (measured by 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 the pressure set in parameter p304.
Needed pressure is dependent on if a backflush pump P309 is used or not.
Without pump Calculated value 1.0 + Δp309
With pump Fixed value 1.0
Without pump P309 = 1.0 + Δp309

Setting with pump P309= 1.0
200000180-1-EN-GB 41
EN 6 Pipe design
42 200000180-1-EN-GB
EN
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 voltage in the
higher range, as close as possible to 440 VAC.
Nominal voltage and
frequency • Max Icu 50 KA.
• Power factor: 0.95.
• 24VDC - Remote control panel (optional).
Electrical cabinet: >IP44.

IP rating Lamp drive cabinet: ≥ IP44.
Cables and connectors: ≥ 65.
Heat dissipation Heat transferred to surroundings from electrical cabinet:
(transfer) – Electrical 1.6 kW.
cabinet
Heat dissipation Heat transferred to surroundings from lamp drive cabinet:
(transfer) – Lamp drive 1.6 kW.
cabinet 1
Component Power consumption

(kW)
Electrical cabinet and Lamp drive cabinet 1
Power to UV reactor.
64
Note: PureBallast only use power needed for 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.
7.2 Installation requirements

PureBallast electrical 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 electrical cabinet and lamp drive cabinet (LDC):
Requirements for cables supplied by installing party.
• Dimension drawings: Information about earth points.
200000180-1-EN-GB 43
EN 7 Electrical design
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, 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. .
• 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.
• Power cable W1, W2, W3 (size dependent) to be connected to main switch
board: Max Icu 50 KA.
• For recommended cable length see illustration Maximum cable lenghts on
page 17.
• Signal cable W13A and signal/motor cables; W10, W11, W12, W14 are
delivered in 10 meters pieces. For cable length > 10 meters, join pre-
assembled 10 meter extensions to obtain length up to 30 meters.
44 200000180-1-EN-GB
EN
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 to the following components:
• UVR
• Filter
• CIP unit
• Bypass valve V212–31 (if part of Alfa Laval’s scope of supply).
The UVR, filter and CIP unit has pre-mounted tubes which distribute the
instrument air to the connecting valves.
Instrument air should be used, to get required stability in pressure and
required quality or the air. Service air is not sufficient.
We recommend that air to PureBallast is not taken from an air supply system
that also serves any essential systems. If it is, secure proper protection
against leak in case of fire or damage.
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.
200000180-1-EN-GB 45
EN 8 Pneumatic design
46 200000180-1-EN-GB
EN
9 Control system integration

To facilitate monitoring and control of PureBallast, it is possible to integrate the
system to communicate with other components on board the vessel, for
example GPS.
The following optional integrations are possible:
• Remote control panels
• Remote interface
• Power management
• External component signals (hardwired connection of individual
components and features)
• GPS
• Log box
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. .
• 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 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 electrical cabinet (EC) and the remote control panel (RCP1).
200000180-1-EN-GB 47
EN 9 Control system integration
1. Max 100 m from EC: Ethernet. Shielded Cat 5 or better.

Connect the Ethernet cable to terminal X7 in EC and to terminal X2 in
RCP1.
2. Max 500 m EC: 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 EC 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 EC: Connect terminal X2 in RCP2 with terminal X7 in EC.
If X2/X7 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 Electrical 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.
48 200000180-1-EN-GB
Control system integration 9 EN
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.
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 43.
9.3.2 Power management installation

The power signals are either hardwired or connected via remote interface.
There are three power signal cables:
Signal function ID in electrical drawings
Power request PMS request
Power granted PMS granted
Power running PMS PB running
• If hardwired, connect power signal cables according to Electrical cabinet /

Interconnection diagram and Electrical cabinet / Circuit diagram.
• If connected via the remote interface, connect power signals according to
Remote interface implementation guide, which can be required from your
local Alfa Laval sales office.
The signals are tested during commissioning.
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.
200000180-1-EN-GB 49
Using external feed control will ensure that flow to PureBallast is optimal for
the ongoing process. For example, the stripping flow can be significantly lower
compared to deballast. If external feed is not used, control valve V201–8 must
close to reduce flow to allowed maximum flow. This will result in wear and tear
of the control valve. There is also a probability for cavitation and noise as a
result of the partly closed control valve.
How does it work

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.
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 are chasing
Area 1 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 request
Area 2 signal change more slowly, which results in a smooth movement of
V201-8 when regulating the external flow.
Installation
Signal cable from PureBallast control cabinet should be connected to the
vessel’s control system (ISCS) and then to the VFD. The signal cable should
not be connected directly from control cabinet to the VFD.
50 200000180-1-EN-GB
9.5 External component signals

PureBallast can be completed with extra components, which are not part of
Alfa Laval’s scope of supply. If so, signals must be connected to the control
system via the control cabinet. It is also possible to simplify operation by
integrating some signals between the ISCS and PureBallast. The
communication is either handled by the remote interface (if the option is
integrated) or via hardwires. In some cases, hardwire is the only alternative.
Consider which signals that shall be used, to be able to plan cable routing and
integration. The signal cables are connected according to:
• Electrical cabinet / Interconnection diagram
• Electrical cabinet / Circuit diagram
• The notes about "how" in the table below.
NOTE
A list of integrated signals shall be available at commissioning, to facilitate
parameter settings for Alfa Laval commissioning engineer.
The table below describes available input and output signals to and from
PureBallast electrical cabinet.
Signal What Why How
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. An PureBallast is monitored already present and a
alarm shuts down ongoing and controlled. Used if new alarm is issued, the
process. remote control panels signal will go low for three
(optional) are used. If seconds, and then be re-
remote interface (optional) activated as high.
is used, this is an
alternative to alarm
indication via remote
interface address 07:7.
Common warning As common alarm, but for See common alarm. See common alarm.
warnings. A warning is a Alternative to alarm
notification of status indication via remote
change or a problem. interface address 07:8.
200000180-1-EN-GB 51
Signal What Why How

Bypass open Input signal to PureBallast If PureBallast can be If remote interface is
that an bypass valve is bypassed using other implemented, feedback
open. valves (apart from signals can be connected
V212-31), status signals via the remote interface,
from them must be which allows a great
integrated to the control number of components to
system in one electrical be connected.
(24V) loop. When any
bypass valve is opened,
ongoing process is
terminated and the event
is logged.
All bypass cases are to be
logged in the event log.
The event log state if any
valve in the loop are in
wrong position (open/
close) and time for status
change, not the reason for
opening the valve. The
reason, for example
internal transfer, must be
entered in the vessel’s
ballast water log book. If
GPS signal is not
integrated, the position
must also be entered in
this log book.
Request "Start BW pump" Output signal from If Request and Feedback Request = Closed circuit.
PureBallast to request signals are integrated, the No request and request
start of the ballast water operator does not have to withdrawal = Open circuit.
pump. After process is confirm that the pump is
stopped, the signal goes started/stopped in a
low to request pump to be popup in the control panel
stopped. during operation.
Feedback "Ballast water Input signal to PureBallast See Request signal Closed circuit = Pump
pump is running" to confirm that the ballast above. running.
pump is started.
Heeling mode (internal Input signal to PureBallast If heeling operations are Closed circuit = Heeling
transfer) to enter heeling mode. performed, this signal mode command. Only
Before entering heeling should be connected. possible in standby,
mode the system must be This signal will activate a ballast or deballast.
stopped otherwise it shuts heeling event in the event
down PureBallast. log, instead of a bypass
event.
If integration of heeling
command from ISCS is
desired to automatically
stop ongoing ballast/
deballast process for a
healing operation.
External system stop Input signal to PureBallast If extra button (not part of Open circuit = System
to shut down the system. AL scope of supply) to stop command. Must be
shut down. connected via hardwire.
PureBallast are desired
on board. The power is
still on.
PureBallast running Output signal from If desirable to indicate that PureBallast running =
PureBallast that a process a PureBallast process is Closed circuit.
is running (power ongoing, for example with
management signal or via a light or in another
remote interface). system.
52 200000180-1-EN-GB
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 Control cabinet / Interconnection
diagram and Control 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.
NOTE
If RMC is used, time and date in the control system is retrieved from
vessel’s GPS.
200000180-1-EN-GB 53
54 200000180-1-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
(flowchart, electrical system layout etc, to clarify connections etc), or that they
are attached.
200000180-1-EN-GB 55
EN 10 System approval
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.
56 200000180-1-EN-GB
EN
11 Compliant operation according to

BWMP
To manage to operate in compliance with the ballast water management
convention, the routines for ballast operations must be well defined in the
ballast water management plan (BWMP).
An operation is compliant if ballast operations are performed using the
treatment system, within stated limitations and in accordance with the system
manual.
When defining or redefining the vessel’s BWMP, there are several issues to be
taken into consideration. This section contains a checklist of issues and areas
that should be considered and defined.
All issues are not applicable for all vessels. Also note that this is a general
compilation. For each vessel it is also important to consider if there are
applicable requirements by the below, or others:
• IMO
• USCG
• EPA
• Flag state
• Classification society
Non-compliant operation
A process is not compliant in the cases described below. The BUMP must
therefore be defined to avoid these cases and define means to solve any
arisen situation.
Area Reason
PureBallast was bypassed during ballast/deballast, so the water
Bypass was not treated.
USCG/IMO
mode • Deballast operation using IMO mode within US waters.
(Only • Deballast of water that was ballasted using IMO mode. It may
applicable for therefore be necessary to keep track of if IMO or USCG mode
USCG was used for ballast for respective tank.
systems.)
Flow Operation with higher flow rate than certified.
CIP cleaning System not CIP cleaned within time.
Broken UV Operation with one or more non-functioning lamps.

lamp
200000180-1-EN-GB 57
EN 11 Compliant operation according to BWMP
UV intensity UV intensity lower than compliance limit.
The ballast water is contaminated by untreated water from other

pipes, i.e. there are living organisms in the water. Even a small
amount of water, a few hundred liters, can contaminate a ballast
tank and cause non-compliance during a compliance test. It is
therefore important that PureBallast is always used for ballast
operations.
Other reasons for contamination:
Contamination • Leaking valves, if there is untreated water present in the piping.
• Internal transfer between tanks can contaminate tanks, if
untreated water is present in the piping.
• Water standing in dead ends of the piping system.
• Sediment in tanks is a breeding ground for organisms.
Therefore, it is important to review the vessel’s ballast water
management plan regarding frequency of sediment removal.
Solution to non-compliant operation

If the ballast water is not fully treated or contaminated by untreated water, a
ballast water exchange must be performed, making sure that the tanks and
pipes are flushed and replaced with with treated water.
The exchange must be performed
• using PureBallast both at deballast and ballast.
• at a location where ballast water exchange is allowed
• minimum 200 NM from the US coast. The mid ocean is most favourable,
since UV transmittance is very high, and the biological activity is low.
NOTE There exist local regulations, for example before entering the great lakes.
It is also possible to contact the captain of the port zone, both at origin and at
destination. They will inform of what measures that can be approved in each
case.
Also to be considered
The following areas also needs to be described in the plan, in regards of if
they are allowed on the vessel. If allowed, routines frequency etc must be
defined for respective operation or task should be stated in the BWMP.
• Ballast water reporting.
• Stripping routines.
• Healing routines: Requires that a healing signal is integrated between
PureBallast and the vessels ISCS. For more information, see External
components signal in this document.
• Gravity operation (not using the ballast water pump) can only be allowed if
the following prerequisites are fulfilled:
• The requirements for flow and backflush pressure is fulfilled.
• The vessel’s flag state and classification society allow gravity operation.
• It is stated in the vessels’s approved ballast water management plan.
58 200000180-1-EN-GB
Compliant operation according to BWMP 11 EN
• Pipe emptying: Some classification societies requires that pipes before the
treatment system (valve V201-3 and V201-9) should be drained and
discharged at same location or at open sea.
• Emergency routines, if the treatment system cannot be used and ballast
operations needs to be performed.
• Pipe cleaning routines.
• Sediment handling routines.
• Vessel general permit.
200000180-1-EN-GB 59
EN 11 Compliant operation according to BWMP
60 200000180-1-EN-GB
EN
12 Transport and storage

This section contains information relevant for delivery, transport, lifting and
storage. Instructions on how to mechanically install and adjust the
components are included in the system manual, delivered
with the system.
12.1 Delivery and transport

Preparations and conditions:
• Before installing the system, read the system manual and follow the
instructions in 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.
12.2 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.
200000180-1-EN-GB 61
EN 12 Transport and storage
12.2.1 UV reactor
UV reactor size (m3/h) Weight, empty (kg) L (mm)
600 420 700
62 200000180-1-EN-GB
Transport and storage 12 EN
12.2.2 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
200000180-1-EN-GB 63
12.2.3 Backflush pump

Protect external components or remove from pump, under lifting.
Pump Weight (kg) A (mm) B (mm)
Backflush pump P309–1, 140 350 210

95 m3/h
Backflush pump P309–1
64 200000180-1-EN-GB
12.2.4 CIP module

Use intended lifting attachment according to the illustration below.
200000180-1-EN-GB 65
12.2.5 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)
Electrical cabinet 160 800 400
Lamp drive cabinet 1 (LDC 1) 150 480 400
12.3 Storage and long term decommissioning

This section describes requirements for decommissioning and storage of the
system for a long period. The rules must be followed when the system shall be
shut down for along period.
Perform the actions below to protect the system:
• All system equipment must be stored indoors at 5 – 55 °C, in anon-
condensing environment.
• If there is a risk for condensation of water during storage, the equipment
must be protected by ventilation and heating above dew point.
66 200000180-1-EN-GB
• Protect pressure monitoring device etc. from mechanical damages. The

following components are recommended to be removed and stored safely:
PT201-71, PT201 -72, 309-2, PT201-16, and PI201-18.
• Protect components equipped with circuit boards from condensation.
Recommendations:
• Remove IP201-7 and FT201–1 and store in a non condensing
environment
• All articles made of rubber / elastomer has a limited useful life time.
Therefore, the following instructions must be followed:
• If the filter or any filter candles are stored for more than 12 months, we
recommend that the seals are checked, and changed if necessary,
before the system is put in service.
• If the system is stored for more than 24 months, it is recommended to
change all articles made of rubber and elastomer (gaskets, O-rings etc)
before the system is put in service. Such articles are found in the
following components: UV lamps and quartz sleeves in the UV reactor
and the filter candles.
200000180-1-EN-GB 67
68 200000180-1-EN-GB
EN
13 Start-up procedures
The actions below must be performed after installation, before system is put
into operation. This is important to avoid that the filter and the UV reactor is
damaged by material from the ballast tanks or remainders from the
installation. These actions shall be performed both for new builds and retrofit
installations.
Before first operation
Before the system is operated the first time the actions below must be done.
NOTE
All pipes leading to PureBallast must be well flushed to avoid that debris
harm the filter and UV reactor quartz sleeves.
All ballast water tanks must be well cleaned before PureBallast is tested
or put into operation. This is valid both for new builds and retrofit
installations.
First operation
Before first operation the actions below must be done:
• During the first operation, the filter shall be bypassed, to avoid that debris
harms the filter elements.
• We recommend that a strainer is used during the first operations, to avoid
that debris harms the system.
• The first time a tank is stripped, PureBallast must be bypassed, to avoid
that debris harms the system.
200000180-1-EN-GB 69
EN 13 Start-up procedures
70 200000180-1-EN-GB
EN
14 Drawings
This section contains drawings for the PureBallast system. It is divided into
three main parts:
• General drawings – overall and principle information for system layout
(pipes, components, electricity, air and water).
• Dimension drawing – detailed component information (dimensions, sizes
etc).
• Electrical drawings – detailed electric information (circuit diagrams, cable
lists etc).
See the Contents section at the table of contents to get an overview of
included drawings.
200000180-1-EN-GB 71
EN 14 Drawings
14.1 Graphic symbols used in drawings
72 200000180-1-EN-GB
Drawings 14 EN
14.2 General drawings

This section contains the general drawings.
200000180-1-EN-GB 73
EN 14 Drawings
14.2.1 Flow chart
Note: If vacuum relief valve, VB201 and VB309 (optional) is used see
additional flow chart.
74 200000180-1-EN-GB
Drawings 14 EN
14.2.2 Flow chart — Vacuum relief valve, VB201 and VB309

(optional)
200000180-1-EN-GB 75
EN 14 Drawings
14.2.3 Connection list
76 200000180-1-EN-GB
Drawings 14 EN
200000180-1-EN-GB 77
EN 14 Drawings
78 200000180-1-EN-GB
Drawings 14 EN
200000180-1-EN-GB 79
EN 14 Drawings
80 200000180-1-EN-GB
Drawings 14 EN
14.2.4 Electrical system layout
200000180-1-EN-GB 81
EN 14 Drawings
82 200000180-1-EN-GB
Drawings 14 EN
14.2.5 Instrument air distribution
Instrument air distribution — Filter
200000180-1-EN-GB 83
EN 14 Drawings
Instrument air distribution — UVR
84 200000180-1-EN-GB
Drawings 14 EN
14.2.6 Quality specification / Instrument air
200000180-1-EN-GB 85
EN 14 Drawings
14.2.7 Quality specification / Technical and potable water
86 200000180-1-EN-GB
Drawings 14 EN
14.2.8 Quality specification / CIP liquid

Note that the information below regarding dilution is not valid for compact or
compact flex systems.
200000180-1-EN-GB 87
EN 14 Drawings
88 200000180-1-EN-GB
Drawings 14 EN
14.3 Dimension drawings

This section contains the dimension drawings.
200000180-1-EN-GB 89
EN 14 Drawings
14.3.1 UV reactor
90 200000180-1-EN-GB
Drawings 14 EN
14.3.2 Electrical cabinet
200000180-1-EN-GB 91
EN 14 Drawings
14.3.3 Filter
92 200000180-1-EN-GB
Drawings 14 EN
14.3.4 CIP module
200000180-1-EN-GB 93
EN 14 Drawings
14.3.5 Flow transmitter FT201-1
94 200000180-1-EN-GB
Drawings 14 EN
14.3.6 Pressure monitoring device (PT201-16, PI201-18,

RV201, V201-17)
200000180-1-EN-GB 95
EN 14 Drawings
14.3.7 Valve V201-9
96 200000180-1-EN-GB
Drawings 14 EN
14.3.8 Valve V212-31 (optional)
200000180-1-EN-GB 97
EN 14 Drawings
14.3.9 Control valve V201-8
98 200000180-1-EN-GB
Drawings 14 EN
14.3.10 Backflush valve V309-1
If backflush pump P309–1 (optional) is installed, this valve is delivered

mounted on the pump. If backflush pump is not used, the valve is
mounted on the filter.
200000180-1-EN-GB 99
EN 14 Drawings
14.3.11 Vacuum relief valve VB201 (optional)
100 200000180-1-EN-GB
Drawings 14 EN
14.3.12 Vacuum relief valve VB309 (optional)
200000180-1-EN-GB 101
EN 14 Drawings
14.3.13 Sampling device Q201.1 and Q201.2 (optional)
102 200000180-1-EN-GB
Drawings 14 EN
200000180-1-EN-GB 103
EN 14 Drawings
104 200000180-1-EN-GB
Drawings 14 EN
14.3.14 Remote control panel (optional)
200000180-1-EN-GB 105
EN 14 Drawings
106 200000180-1-EN-GB
Drawings 14 EN
14.3.15 Log box (optional)
200000180-1-EN-GB 107
EN 14 Drawings
14.3.16 Lamp drive cabinet (LDC)
108 200000180-1-EN-GB
Drawings 14 EN
14.3.17 Air filter regulator
200000180-1-EN-GB 109
EN 14 Drawings
14.3.18 Air preparation unit (optional)
110 200000180-1-EN-GB
Drawings 14 EN
14.3.19 Backflush pump P309–1 (Optional)
200000180-1-EN-GB 111
EN 14 Drawings
14.3.20 Transformer (optional)
112 200000180-1-EN-GB
Drawings 14 EN
14.4 Electrical drawings

This section contains the electrical drawings.
200000180-1-EN-GB 113
EN 14 Drawings
14.4.1 Electrical cabinet / Interconnection diagram
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DG PB 3.1 500 Compact Flex Imo Uscg

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DG PB 3.1 500 Compact Flex Imo Uscg

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PureBallast 3.

1 500 Compact Flex

Design and installation guide

The original instructions are in English

© Alfa Laval Corporate AB 2019-06

4 Material and equipment supplied by installing party.......................13

9 Control system integration............................................................................... 47

11 Compliant operation according to BWMP..............................................57

12 Transport and storage.........................................................................................61

1 Ship specific information

Control valve (V201-8) 200

Bypass valve (V212–31)

Filter module connections:

CIP unit connections:

Sampling device Location Q201.1: ___________

Power consumption, max (kW) ___________

2.1 Safety information

2.2 Components overview

The main water treatment component in the system, including

The controlling unit. It contains the main control panel, from

Additional lamp drive cabinet. The LDC is feeding the UV lamps

Lamp power cable delivered from Alfa Laval must be used.

Filter Filter Mechanical filtration of the water before treatment.

Cleaning-in-place module for automatic cleaning of the UVR after

Main outlet valve from the PureBallast system to the vessel’s

Main inlet valve to the PureBallast system during ballast, in

Filter backflush valve V309–1 Preassembled on the filter at delivery.

The flow meter consists of two components:

Monitor pressure and send it to the control system.

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

If instrument air is not available according to requirements, an air

If voltage does not meet the requirements, a transformer must be

PureBallast Connect The Alfa Laval PureBallast Connect is a connectivity platform

Information about operation, control system parameters,

CIP liquid, 15 liters The liquid is used during the CIP-process.

4 Material and equipment supplied by

4.1 Material selection

5.1 General requirements

5.1.1 Welding requirements

5.1.2 Tightening torques

General Tightening Torques

5.2 Maximum distance between components

5.2.1 Maximum pipe lengths

5.2.2 Maximum cable lenghts

• Cabinets (LDC, control cabinet) must be installed so that there is free

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

5.6 CIP module

• It is recommended that the deaeration pipe after deaeration valve V571-1

5.7 Flow meter

Measures for installation in a down pipe.

Polyurethane lining — no seals are required.

1. Connection diagram inside the connection compartment cover

Turn transmitter housing and display

5.8 Pressure monitoring device

5.9.1 Bypass valve (V212–31)

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

5.9.2 Control valve (V201–8)

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

If required adapter plates are used to convert to

If backflush pump P309–1 (optional) is installed, this

5.10 Ancillary equipment and functions

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

5.10.2 Booster pump