ALPHA LAVAL FILTRATION + UV

EQUIPMENT Equipment listed in Zone 1 should have Ex-proofing

FILTER AND BACKFLUSH PUMP

UV REACTOR PROCESS DIAGRAM

CIP UNIT

LAMP DRIVE

CONTROL CABINET
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Alfa Laval
FILTRATION+UV TREATMENT
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IMPORTANT POINTS TO BE CONSIDERED DURING DESIGN FROM VENDOR MANUAL

1. CONNECTION LIST
• Ballast water treatment system
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2. CONNECTION LIST – Closed cooling unit, LDC (optional)

3. MATERIAL SELECTION:
• Material must be in accordance both with requirements stated in this document and with the requirements of respective classification society.
• Used material shall be indicated in appropriate drawings.
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4. MECHANICAL INSTALLATION

4.1. GENERAL REQUIREMENTS

• The PureBallast must be installed indoors in machinery space on the vessel (engine room, pump room etc. defined as zone 1 or 2) with:
• Relative humidity of max 100%
• Ambient temperature of 0 to 50 C
• Ex Zones
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4.2. CABINETS
• To prolong the lifetime of the cabinet, we recommend to install it in the coolest possible area in the range of 0 to 50 C.

4.3. UV Reactor
• The UV reactor must be oriented so that the UV lamps are perpendicular to pipe 201 with flow into the UV reactor.

• 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 dimensions as UVR flange. It is NOT possible to use a cone
to enlarge the pipe dimensions at the connection point of UV reactor.
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• 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.
• 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.
• 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.

4.4. Requirements for installations with more than one UV reactor

• The flow must be evenly distributed through the UV reactors and the flow must not exceed certified flow for the reactor.
• Chosen solution must be verified by a flow and pressure calculation (by installing party) to verify that the flow is evenly distributed. As a rule of
thumb, the velocity in the manifold should never exceed 3 m/s.
• UV reactors to be installed on the same level.
• Design the manifold so that the outlet flow goes in opposite direction, compared to the inlet flow.
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• The space between the UV reactors must be within the following interval: A:1000-1800.

• Increase the diameter for the inlet and outlet manifold with one standard pipe size (or more). This will result in a lower velocity, and thereby a more
even distribution of the flow.
• Strive to use as few bends and other components as possible before and after manifolds. This will result in smaller pressure drops and a more even
distribution of the flow.

4.5. Filter

• The filter is recommended to be placed close to the ballast water pump for best back flush performance.
• If backflush pump (optional) is installed, it is recommended to be installed directly on the filter flange (backflush outlet) for best performance. It is
not recommended to be placed further than one meter from the filter.
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• 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.

4.6. CIP module

• It is recommended that the CIP module is installed below the UV reactor, or on the same level and that the pipes to and from the UV reactor is
installed according to the illustration below. There must be no risk for additional water or air pockets in the piping. This will minimize dilution or loss
of CIP liquid and secure good pump efficiency.
• Pipe 321: Downward gradient towards both the CIP module and the UV reactor. There must be no risk for water or air pockets in the pipe.
• Pipe 320: Design Pipe 320 in a downward gradient from the UV reactor towards the CIP module to improve draining of UV reactor. A water
lock can be created close to the CIP module, before a vertical pipe to the CIP module, as illustrated to the left below. This is not needed if the
liquid can flow by gravity to the CIP module as illustrated.

• The deaeration pipe after deaeration valve V571-1 must reach approximately 2 meters higher than valve V321-2 on the UV reactor to avoid water
spillage during CIP process. The pipe shall be drained to a scupper, with a solution which always allows (minor) water spillage to be drained. The
deaeration pipe must end in safe zone, to avoid hazardous gas to enter the UV reactor during when valve V571–1 is opened.
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• Pipe 460.2 (drain of used CIP liquid, 250 liters) should not be lead to bilge tank due to the low pH value. Drain to one of the following: drain, waste
or sludge tank. Note that the CIP tank is drained by gravity without a pump. CIP liquid should be handled according to local regulations.

4.7. TREATMENT SPOOL UNIT

• The flow meter (FIT201-1) should be installed after inlet valves (V403-35, V201-9 and V201-32) and before V201-8.
• The flow meter should be placed with the flow transmitter dacing 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.
• 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.
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• 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.

4.8. Pressure Monitoring Device

• The component must be installed vertically on a horizontal pipe. This will result in best function and durability for the component.
• A drain solution (not part of Alfa Laval’s scope of supply) must be attached to relief valve RV201. The valve shall be drained to a scupper, with a
solution which always allows (minor) water spillage to be drained.

4.9. Valves

• Valves should be installed with the actuator on the upper half of the pipe, to minimize the risk for water entering the actuator.
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4.9.1. Bypass Valve (V212-31)

• It must be possible to bypass PureBallast, using a bypass valve.
• 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.
4.9.2. Control valve (V201-8)
• If the valve dimension is different from the dimension of pipe 201, the pipe dimension must be coned up/down to fit the valve.
4.9.3. Check valves (CV403, CV201, CV310)

4.9.4. Cooling water valve (V403-35)

• The valve must be installed between filter bypass valve V201-9 and UV reactor inlet valve V201-19.
4.9.5. Filter valves (V201-3, V201-32, V201-9 and V309-1)
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4.10. Ancillary equipment and functions

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

• 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 pipe 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.
• The device must be mounted with the sampling pipe opening pointing in the flow direction.
4.10.2 Booster pumps
• Booster pumps might be needed to achieve sufficient flow. Start and stop of booster pump are handled by signals sent from the control
system.
• LDC cooling water pump (P401-1)
Booster pump so that cooling water flow to LDC and LDCS (during operation) shall give minimum flow according to Connection list, for
Item/Connection 401.
• UV reactor cooling water pump (P403-1)
Booster pump so that cooling water flow to UV reactor (during startup and pause) shall give minimum flow according to Connection list, for
Item/Connection 403.
• Filter backflush pump (P309-1)
Booster pump to secure enough flow in pipe 309 for sufficient filter backflush according to Connection list, for Item/Connection 309.
4.10.3 Tank stripping equipments
• Stripping Eductor
▪ The eductor (not part of Alfa Laval’s scope of supply) must be installed before the PureBallast system
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▪ 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) fulfils 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.

5. Pipe Design

5.1 Water Requirements

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5.2 Flow requirements

5.3 Piping: Dimensions, connections and material

• Pipe 403 and valve V403-35 (cooling water valve, reactor): 80. Dimension decided at order, smallest recommended.
• 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 lifetime.
• Pipe with incoming stripping water should be connected to pipe 201 (ballast water) before valve V201–3 and V201–9.
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• Pipe 320, 321 and 460 (CIP pipes): Non-corroding material is recommended for pipes used for CIP liquid, due to low pH value.
• Penetration Ex zone dividing bulk heads is not recommended. If done, special precaution must be taken with regards to applicable rules and
classification society.

• Filter Pipe Connections

• Pipe 309 (backflush): Pipe dimension MUST be increased to 150 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. Adaptor plates are delivered
as loose components.
• Pipe 201 (ballast water): If adaptor plates are mounted on the filter flanges, a spool piece must be installed between the adaptor plate and
valve filter inlet valve V201–3 and filter outlet valve V201–32, due to the design of the adaptor plate. See section Spool piece below.
If adaptors are NOT used, the valves can be mounted directly on the filter flange.
• Spool Piece
• We strongly recommend to tailor make a spool piece to connect to the filter.
5.4 Installation with large height difference

• 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.
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5.5 Cavitation- Problems and solutions

• 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.
• 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.
• In PureBallast systems both pipe 201 and 309 can be affected depending on the installation and should be evaluated independently.
• Vacuum relief valves
▪ VB201: In pipe 201. Float operated vacuum relief valve providing both air release upon startup of the system and vacuum relief during
operation.
▪ VB309: In pipe 309. Only vacuum relief, without air venting function. The valve is spring loaded (normally closed) to avoid water spillage
during initiation of backflush.
• Placement of 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.
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• Placement of 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.
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• 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.
• Air inlet pipe
▪ The air inlet pipe should end in safe zone, to avoid hazardous gas to enter.
▪ The two air inlet pipes for VB201 and VB309 should not be connected to avoid the risk of contamination. They must be lead to safe zone
as two separate pipes.
▪ 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.
5.6 Air Pockets- Problems and Solutions

• It is recommended to install a de-aeration valve at points with risk for air pockets.
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5.7 System Pressure

5.8 Pressure requirements for 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.