On-Board Test Procedure

BALLAST WATER MANAGEMENT SYSTEM

Project : H1018 / 19

Check By Signature
Owner
Class
Yard
Panasia
DATE

Doc. No. : PAD-OTP-000(Rev.0)

 BALLAST WATER MANAGEMENT SYSTEM

TABLE OF CONTENTS

1 OPERATING TEST ----------------------------------------------------- 2

1.1 Purge unit Check ------------------------------------------------------------------ 2
1.1.1 Purging Check ------------------------------------------------------------- 2
1.1.2 Purging complete Check ------------------------------------------------- 2

1.2 MODE OPERATING & VALVE STATUS------------------------------------ 2

1.2.1 Warming-Up Mode -------------------------------------------------------- 2
1.2.2 Ballasting Mode ------------------------------------------------------------ 3
 Unit Function Check During Ballasting----------------------------- 4
1.2.3 De-ballasting Mode -------------------------------------------------------- 6
1.2.4 Stripping Mode ------------------------------------------------------------- 8

2 ALARM TEST ----------------------------------------------------------- 11

2.1 ALARM CHECK ------------------------------------------------------------------ 11

2.2 SYSTEM TRIP TEST ------------------------------------------------------------ 14
2.2.1 Ballast Mode ---------------------------------------------------------------- 14
2.2.2 De-Ballast Mode ----------------------------------------------------------- 14

Doc. No. : PAD-OTP-000(Rev.0) 1

 BALLAST WATER MANAGEMENT SYSTEM

1 OPERATING TEST
1.1 PURGE UNIT CHECK

1.1.1 Purging Check

- Power On the Control Panel Circuit Breaker.
- Check the Power and Air Supply for Purge Unit
No. Function Result Remark
1 Purge Unit Power On
2 Purge Air Supply Above 6 kg/cm2

1.1.2 Purging Complete Check

- Check the Purging Complete Lamp On, after more than 10 minutes.
- Check the PLC & Graphic Panel Power On.
No. Function Result Remark
Purging Complete
1
Lamp On
2 PLC&GP Power On

1.2 MODE OPERATING & VALVE STATUS

1.2.1 Warming up Mode

< Fig. 1.1 Warming-Up Mode Operation >

It needs valve operation to prevent inflow and spill of untreated ballast water during
warming up. That is, warming up mode prevent flow of untreated water during warming-
up for max. 5 minutes or normal status of UV Dosage(over 300mJ/cm2). For the process, a
warming-up lamp attached on a CONTROL PANEL is put on continuously, and flickers at
the end of the process. After flickering warming up lamp, respective valve operation will
be necessary for next process. If necessary valve operation is finished, the flickering
Warming-Up Lamp will be turned off.
Warming up mode will be automatically initiated in each Ballast Mode and De-Ballast
Mode.

Doc. No. : PAD-OTP-000(Rev.0) 2

 BALLAST WATER MANAGEMENT SYSTEM

1.2.2 Ballasting Mode

< Fig. 1.2 Ballasting Mode Operation >

Operator should open the tank valve (to the tank to be ballasted) manually you want to use.
Valves which are controlled by VRC should be arranged to “warming-up mode” as per the
table below. If these valves arrangement is not done properly, mode selection Switch will be
not activated. And then operator will select the “BALLAST MODE” in the operation mode
screen of BWTS control panel, necessary valves controlled by BWTS are automatically
opened and closed as per the table below. When this operation is initiated, following will be
performed by the BWTS -

1. Warming up
-Necessary valves are opened and closed as per the mention above.
-Ballast pump is started manually by operator.

Operator should manually power on the UV Lamp of the BWTS.

-Push the “RUN” button, then UV Lamp On command is given to the BWTS.

System will run for a few minutes in this mode with lighting on warming-up lamp
and then BWTS will finish the warming-up procedure with flickering warming-up
lamp.

2. Ballasting
After warming-up finished, Operator should open the ballasting valve and close the
overboard valve.
-The ballasting valve will be opened
-The overboard valve will be closed
-Selected ballast tank will be filled with treated water.

Operator should manually open/close the tank valves if other tanks are required to be
ballasted while the system is running.

Doc. No. : PAD-OTP-000(Rev.0) 3

 BALLAST WATER MANAGEMENT SYSTEM

 UNIT FUNCTION CHECK DURING BALLASTING

A. FLOW RATE CHECK

- Check the Flow Rate on the main screen.
No. Function Unit Result Remark
#1
1 Flow Rate
#2

B. Filter UNIT CHECK

- Check the pressure value on Filter page.
No. Function Unit Result [kg/㎠] Remark

#1
1 Inlet Pressure 1.5 ~ 3.5
#2

#1
2 Outlet Pressure 1.5 ~ 3.5
#2

#1
3 Differential Pressure Below 0.5
#2

C. UV UNIT CHECK
- Check the UV dosage value on UV Unit page.
No. Function Unit Result [mJ/cm2] Remark
#1
1 Dosage Over than 250
#2

- Push the ‘Intensity Mode’ button on page of each UV unit

- When UV dosage value indicates below 290 mJ/cm2, automatic wiper cleaning
will be started.

No. Function Unit Result Remark

#1
Automatic
1
Cleaning(Intensity)
#2

Doc. No. : PAD-OTP-000(Rev.0) 4

 BALLAST WATER MANAGEMENT SYSTEM

3. Ballasting Stop
When the ballasting of tanks is done, operator should stop the system. This will begin
the stopping procedure. BWTS will do the following in sequence-
-Push the “STOP” button, then BWTS Stop Command is given to the BWTS.
-The overboard valve will be opened.
-The ballasting valve will be closed.
-UV Lamp will be turn off and cooling time(5 min.) is starting.
-In this UV Cooling Operating, all valves are arranged automatically same as
“Warming-up”
-After UV Cooling Operating was finished, all valves will be automatically arranged
to “By-pass Mode” and operator can stop the ballast pump.

Valve Status Table for Ballast Mode

MODE Warming-UP BALLAST BY-PASS
Unit No.1 No.2 No.1 No.2 No.1 No.2
Valve PUMP PUMP PUMP PUMP PUMP PUMP

Inlet Valve[PV01, PV07] OPEN OPEN OPEN OPEN CLOSE CLOSE

Intermediate Valve[PV02, PV08] OPEN OPEN OPEN OPEN CLOSE CLOSE
De-ballast Valve[PV03, PV09] CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE
Outlet Valve[PV05, PV011] OPEN OPEN OPEN OPEN CLOSE CLOSE
Bypass Valve[PV04, PV010] CLOSE CLOSE CLOSE CLOSE OPEN OPEN
SeaChest Valve[BAV26] OPEN CLOSE OPEN CLOSE OPEN CLOSE
SeaChest Valve[BAV28] CLOSE OPEN CLOSE OPEN CLOSE OPEN
Suction Valve[BAV25] CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE
Suction Valve CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE
Suction Valve[BAV27] CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE
Suction Valve CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE
Ballasting Valve[BAV23] CLOSE CLOSE CLOSE CLOSE
Open the valve you
Ballasting Valve[BAV24] CLOSE CLOSE CLOSE CLOSE
want to ballast
Ballasting Valve CLOSE CLOSE CLOSE CLOSE
Overboard Valve CLOSE CLOSE
Open the valve you Open the valve you
Port Overboard[BAV22, BAV02] CLOSE CLOSE
want to overboard want to overboard
Stbd Overboard[BAV21, BAV01] CLOSE CLOSE
Ejector suction[BAV07, BAV08] CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE
Ejector [BAV18] CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE
BAV29 CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE
CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE
CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE
CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE

 Check the above valve arrangement.

No. Warming- Up Ballast Bypass
1

Doc. No. : PAD-OTP-000(Rev.0) 5

 BALLAST WATER MANAGEMENT SYSTEM

1.2.3 De-ballasting Mode

< Fig. 1.3 De-ballasting Mode Operation >

Operator should open the tank valve (to the tank to be de-ballasted) manually you want to use.
Valves which are controlled by VRC should be arranged to “warming-up mode” as per the
table below. If these valves arrangement is not done properly, mode selection Switch will be
not activated. And then operator will select the “DE-BALLAST MODE” in the operation
mode screen of BWTS control panel, necessary valves controlled by BWTS are automatically
opened and closed as per the table below. When this operation is initiated, following will be
performed by the BWTS -

1. Warming up
-Necessary valves are opened and closed as per the mention above.
-Ballast pump is started manually by operator.

Operator should manually power on the UV Lamp of the BWTS.

-Push the “RUN” button, then UV Lamp On command is given to the BWTS.

System will run for a few minutes in this mode with lighting on warming-up lamp and then
BWTS will finish the warming-up procedure with flickering warming-up lamp.

2. De-Ballasting
After warming-up finished, Operator should open the tank suction valves and close
the sea chest valve. Then other valve arranged to de-ballast mode.
-The suction valves will be opened,
-The sea chest valve will be closed
-The De-ballast valve will be opened, and Inlet valve, Intermediate valve will be
closed automatically.
-Treated water will be discharged from selected tank.

Operator should manually open/close the tank valves if other tanks are required to be
de-ballasted while the system is running.
Doc. No. : PAD-OTP-000(Rev.0) 6
 BALLAST WATER MANAGEMENT SYSTEM

3. De-Ballasting Stop
When the de-ballasting of tanks is done, operator should stop the system. This will
begin the stopping procedure. BWTS will do the following in sequence-
-Push the “STOP” button, then BWTS Stop Command is given to the BWTS.
-The sea chest valve will be opened.
-The suction valves will be closed.
-The Inlet valve, Intermediate valve will be opened, and the De-ballast valve will be
closed automatically.
-UV Lamp will be turn off and cooling time(5 min.) is starting, and all valves are
arranged automatically same as “Warming-up”
- After UV Cooling Operating was finished, all valves will be automatically arranged
to “By-pass Mode” and operator can stop the ballast pump.

Valve Status Table for De-Ballast Mode

MODE Warming-UP DE-BALLAST BY-PASS
Unit No.1 No.2 No.1 No.2 No.1 No.2
Valve PUMP PUMP PUMP PUMP PUMP PUMP
Inlet Valve[PV01, PV07] OPEN OPEN CLOSE CLOSE CLOSE CLOSE
Intermediate Valve[PV02, PV08] OPEN OPEN CLOSE CLOSE CLOSE CLOSE
De-ballast Valve[PV03, PV09] CLOSE CLOSE OPEN OPEN CLOSE CLOSE
Outlet Valve[PV05, PV011] OPEN OPEN OPEN OPEN CLOSE CLOSE
Bypass Valve[PV04, PV010] CLOSE CLOSE CLOSE CLOSE OPEN OPEN
SeaChest Valve[BAV26] OPEN CLOSE CLOSE CLOSE OPEN CLOSE
SeaChest Valve[BAV28] CLOSE OPEN CLOSE CLOSE CLOSE OPEN
Suction Valve[BAV25] CLOSE CLOSE Open the CLOSE CLOSE CLOSE
valve
Suction Valve CLOSE CLOSE want to CLOSE CLOSE CLOSE
Suction Valve[BAV27] CLOSE CLOSE deballast
CLOSE Open the CLOSE CLOSE
valve
Suction Valve CLOSE CLOSE CLOSE want to CLOSE CLOSE
Ballasting Valve[BAV23] CLOSE CLOSE CLOSE deballast
CLOSE CLOSE CLOSE
Ballasting Valve[BAV24] CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE
Ballasting Valve CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE
Overboard Valve
Open the valve you Open the valve you Open the valve you
Port Overboard[BAV22, BAV02]
want to overboard want to overboard want to overboard
Stbd Overboard[BAV21, BAV01]
Ejector suction[BAV07, BAV08] CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE
Ejector [BAV18] CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE
BAV29 CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE
CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE
CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE
CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE

 Check the above valve arrangement.

No. Warming- Up De-Ballast Bypass
1

Doc. No. : PAD-OTP-000(Rev.0) 7

 BALLAST WATER MANAGEMENT SYSTEM

1.2.4 Stripping Mode

Stripping operation may be independently from de-ballasting operation.
Operator should open the tank valve (to the tank to be stripped) manually you want to use.
Valves which are controlled by VRC should be arranged to “warming-up mode” as per the
table below. If these valves arrangement is not done properly, mode selection Switch will be
not activated. And then operator will select the “STRIPPING MODE” in the operation mode
screen of BWTS control panel, necessary valves controlled by BWTS are automatically
opened and closed as per the table below. When this operation is initiated, following will be
performed by the BWTS in sequence-

1. Warming up

< Fig. 1.4 Stripping Warming-Up Mode Operation >

-Necessary valves are opened and closed as per the table below.
-Stripping pump is started manually by operator.

Operator should manually power on the UV Lamp of the BWTS.

-Push the “RUN” button, then UV Lamp On command is given to the BWTS.

System will run for a few minutes in this mode with lighting on warming-up lamp
and then BWTS will finish the warming-up procedure with flickering warming-up
lamp.

Doc. No. : PAD-OTP-000(Rev.0) 8

 BALLAST WATER MANAGEMENT SYSTEM

2. Stripping

< Fig. 1.5 Stripping Mode Operation >

After warming-up finished, Operator should open the Ejector suction valve.
-The ejector suction valve will be opened,
-Stripping will be started from selected tank.

Operator should manually open/close the tank valves if other tanks are required to be
stripped while the system is running.

 UNIT FUNCTION CHECK DURING STRIPPING

A. FLOW RATE CHECK

- Check the Flow Rate on the main screen.
No. Function Result Remark
1 Flow Rate

Doc. No. : PAD-OTP-000(Rev.0) 9

 BALLAST WATER MANAGEMENT SYSTEM

3. Stripping Stop
When the stripping of tanks is done, operator should stop the system. This will begin
the stopping procedure. BWTS will do the following in sequence-
-Push the “STOP” button, then BWTS Stop command is given to the BWTS.
-The ejector suction valve will be closed.
-UV Lamp will be turn off and cooling time(5 min.) is starting.
- In this UV Cooling Operating, all valves are arranged automatically same as
“Warming-up”
- After UV Cooling Operating was finished, all valves will be automatically arranged
to “By-pass Mode” and operator can stop the stripping pump.

Valve Status Table for Stripping Mode

Mode
Warming-UP STRIPPING BYPASS
Valve
Inlet Valve[PV01] CLOSE CLOSE CLOSE
Intermediate Valve[PV02] CLOSE CLOSE CLOSE
De-ballast Valve[PV03] OPEN OPEN CLOSE
Outlet Valve[PV05] OPEN OPEN CLOSE
Bypass Valve[PV04] CLOSE CLOSE OPEN
SeaChest Valve[BAV26] CLOSE CLOSE CLOSE
SeaChest Valve[BAV28] CLOSE CLOSE CLOSE
Suction Valve[BAV25] CLOSE CLOSE CLOSE
Suction Valve CLOSE CLOSE CLOSE
Suction Valve[BAV27] CLOSE CLOSE CLOSE
Suction Valve CLOSE CLOSE CLOSE
Ballasting Valve[BAV23] CLOSE CLOSE CLOSE
Ballasting Valve[BAV24] CLOSE CLOSE CLOSE
Ballasting Valve CLOSE CLOSE CLOSE
Overboard Valve Open the valve Open the valve Open the valve
Port Overboard[BAV22, BAV02] you want to you want to you want to
Stbd Overboard[BAV21, BAV01] overboard overboard overboard
Ejector suction[BAV07, BAV08] CLOSE OPEN CLOSE
Ejector [BAV18] CLOSE OPEN CLOSE
BAV29 CLOSE CLOSE CLOSE
CLOSE CLOSE CLOSE
CLOSE CLOSE CLOSE
CLOSE CLOSE CLOSE

 Check the above valve arrangement.

No. Warming- Up Stripping Bypass
1

Doc. No. : PAD-OTP-000(Rev.0) 10

 BALLAST WATER MANAGEMENT SYSTEM

2 ALARM TEST
2.1 ALARM CHECK

1) Filter Cycle Time Over: During back flushing, switch off the circuit breaker of the
back flushing motor and check the alarm.
Unit Result Set Point Delay time Remark
#1
- 53s
#2

2) Filter Inlet Pressure Sensor Fail: Disconnect the sensor cable from the terminal block
and check the alarm.
Unit Result Set Point Delay time Remark
#1
- 2s
#2

3) Filter Outlet Pressure Sensor Fail: Disconnect the sensor cable from the terminal
block and check the alarm.
Unit Result Set Point Delay time Remark
#1
- 2s
#2

4) ELCB Trip: Push the test button of ELCB and check the alarm.
Unit Result Set Point Delay time Remark
#1
- immediately
#2

Doc. No. : PAD-OTP-000(Rev.0) 11

 BALLAST WATER MANAGEMENT SYSTEM

5) UV Intensity Transmitter Fail: Disconnect the sensor cable and check the alarm.
Unit Result Set Point Delay time Remark
#1
- 2s
#2

6) UV Temperature Transmitter Fail: Disconnect the sensor cable and check the alarm.
Unit Result Set Point Delay time Remark
#1
- 2s
#2

7) Panel Inside Temp. High: Inside of ballast panel, disconnect the temperature switch’s
cable and check the alarm.
Unit Result Set Point Delay time Remark
#1
60C immediately
#2

8) Panel Inside Temp. High-High: Inside of ballast panel, disconnect the temperature
switch’s cable and check the alarm.
Unit Result Set Point Delay time Remark
#1
70°C immediately
#2

9) Flow Meter Fail: Disconnect the signal cable of the flow meter in J/B and check the
alarm.
Unit Result Set Point Delay time Remark
#1
- 2s
#2

10) Filter Operating Time Over: Set the filter differential pressure setting value under
than current value, with keeping the state during set time and check the alarm
Unit Result Set Point Delay time Remark
#1
0.45 kg/cm² 600s
#2

Doc. No. : PAD-OTP-000(Rev.0) 12

 BALLAST WATER MANAGEMENT SYSTEM

11) Filter DP High : Find out the value of the DP high in the engineer-mode, and then
enter the higher value than the reference value.
Unit Result Set Point Delay time Remark
#1
0.6 kg/cm² 60s
#2

12) UV Operating Time Over: Set the UV intensity range setting value under than current
value, with keeping the state during set time and check the alarm.
Unit Result Set Point Delay time Remark
#1
200mJ/cm² 1200s
#2

13) UV Cycle Time Over: During wiper cleaning, switch off the circuit breaker of the
wiper motor and check the alarm.
Unit Result Set Point Delay time Remark
#1
- 60 ~ 90s
#2

14) UV Dose Low: When UV dosage is lower than set value and check the alarm.
(We will adjust value by modifying program of control panel.)
Unit Result Set Point Delay time Remark
#1
50°C 5s
#2

15) UV Chamber Temp. High: When UV Chamber inside temperature is higher than and
check the alarm.
Unit Result Set Point Delay time Remark
#1
-60°C 2s
#2

Doc. No. : PAD-OTP-000(Rev.0) 13

 BALLAST WATER MANAGEMENT SYSTEM

2.2 SYSTEM TRIP TEST

1) The system must be trip, when system is trip condition during normal operation.
2) Make the trip condition on each mode, check the valve and pump state.

2.2.1 Ballast Mode

① Select ballast mode
② Start Pump running
③ Warming-up finish
④ Make the trip condition at this mode
⑤ Then, BWTS internal valve should be changed to “Bypass Mode” and pump stop.
⑥ Check the Alarm status
Alarm status Result

2.2.2 De-ballast Mode

① Select de-ballast mode
② Start Pump running
③ Warming-up finish
④ Make the trip condition at this mode
⑤ Then, BWTS internal valve should be changed to “Bypass Mode” and pump stop.
⑥ Check the Alarm status
Alarm status Result

Doc. No. : PAD-OTP-000(Rev.0) 14