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ALFALAVAL BWTP System Manual PB-750 - Rev00 PDF
ALFALAVAL BWTP System Manual PB-750 - Rev00 PDF
System Manual
English
Table of Contents
Safety
System Description
Printed 2013
Parameters
Service Manual
Alfa Laval reserves the right to make changes at any time without prior notice.
Any comments regarding possible errors and omissions or suggestions for improvement of this
publication would be gratefully appreciated.
Copies of this publication can be ordered from your local AlfaLaval company.
Published by: :
Chapter: 1. Safety
System manual PureBallast 3.0 Flow 750
Book No.
Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00
Telefax:
Contents
1
Introduction
Safety information
2.1
2.2
2.3
Personnel requirements
2.4
Environmental issues
11
3.1
Unpacking
11
3.2
Other materials
11
1 Introduction
This chapter contains general safety and environmental information, personnel requirements and
explanations of symbols used for the PureBallast system.
Introduction
2 Safety information
This section contains safety information. This information must be read and understood before the
system is installed, operated and maintained.
2.1
The PureBallast system is not EX proofed and must not be installed in areas where an
explosive atmosphere may occur.
Use the equipment only for the purpose and parameter range specified by Alfa Laval.
Always read and follow the documentation that is included in shipment of components and
spare parts regarding handling, safety and disposal.
Mobile cell phones must not be switched on within an area of 1 meter from an open cabinet door.
Before installation, read applicable sections in chapter 6. Installation instruction and drawings.
Before operation, read the Preparations and conditions section for applicable instructions in
chapter 3. Operating instructions and control system description.
2.2
The following safety information apply for the areas and components below. This information is also
stated in the Preparations and conditions section for applicable instructions.
Maintenance safety items
Before maintenance, read the Preparations and conditions section for applicable instructions in
chapter 7. Service manual. Essential safety information is stated before instruction to routines
that might involve any danger.
Before maintaining the PureBallast system, the following valves must be locked in closed
position: V201-3, V201-9, and V201-8.
Components must be lifted using correct lifting tools (such as a fork-lift truck, a crane) and tackle
with a load capacity greater than the weight of the component. See the Technical data section
on page for information about weight. Any complementary lifting instructions must be followed.
Always disconnect the PureBallast system from the power supply before disassembling, and
secure it from being switched on.
Cut hazards: Sharp edges on broken UV lamps and quartz sleeves can cause cuts. Exercise
great care when handling them.
Before installation, check that the UV lamps and quartz sleeves are not broken.
2.2
Safety information
Depressurize reactors and allow equipment to cool down completely before disassembling. Hot
water may escape from the reactor when removing the drain plug.
Never handle UV lamps before they are completely cooled down. A hot UV lamp is under
high internal pressure, and the risk of bursting exists. A hot lamp could also cause a burn
if it is touched.
The reactor must not be under pressure when dismounting the UV lamps.
UV lamps radiate ultraviolet radiation when lit. Only operate the UV lamp when correctly
installed inside the reactor with end caps properly closed.
UV lamps contain a small amount of mercury (less than 0.2 grams per lamp) and must be
handled with care. Please refer to national regulations regarding disposal of used lamps. If
a UV lamp is broken, mercury could be spilt. Remove mercury with a special tool such as a
syringe (or use pure sulphure to bind the mercury for easy collection).
-
Do not inhale mercury fumes. In case of having inhaled mercury fumes, consult a doctor
and follow medical instructions.
Free mercury must be kept in an airtight bottle, and must be disposed of according to
national regulations.
Operation and/or manual start of the UV lamps is only allowed when there is water in the reactor
(indicated by level switch LS201-29), and the water temperature is below 60 C. Improper
operation could seriously damage the equipment and injure personnel.
Manual operation of LPS, may only be performed after cable connection. If not hazardous
situation may arise which, if not avoided, will result in death or serious injury.
Before maintenance of the LDC: Switch off the PureBallast system and disconnect it from the
power supply. The LDC contains a fan, which can cause injury if in operation.
Potential hazards / Grounding: The mains protective grounding wire must be connected to the
terminals in accordance with the diagram (class 1 power supply).
Actuators must not be pressurized at any time during installation as it may result in injury.
CIP liquid: Risk for eye and skin irritation. Avoid contact with eyes and wear protective
gloves. Follow general rules when handling of cleaning agents regarding ventilation, personal
protection etc.
Before disassembling the pump, the pneumatic hoses must be disconnected, and the extension
pipe must be removed and blocked.
Always wear protective eye glasses and gloves while working on the pump.
Control panels may only be cleaned when set in wipe mode. This is to prevent unintended
functions from being triggered by buttons pressed during cleaning.
Temperature switch, temperature transmitter and level switch. The external surface may be hot.
Care must be taken to avoid possible burns.
Safety information
2.3
2.4
Personnel requirements
The PureBallast system must be operated, installed, maintained and repaired by persons trained for
respective type of work. All persons using and working with the system must know the emergency
stopping procedures.
Personnel installing, maintaining or repairing components must be of one of the following categories:
Alfa Laval service engineer: A person with vast knowledge about the PureBallast system.
Alfa Laval service engineer can set parameters and repair intrinsically safe apparatuses. The
person must have experience of similar types of work and be certified in accordance with
local regulations.
In some cases special skilled personnel may need to be hired, like electricians and others. In some
of these cases the personnel has to be certified according to local regulations with experience of
similar types of work.
2.4
ANGER
D
!
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
NG
WARNI
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
ON
CAUTI
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
NOTE
NOTE indicates a potentially hazardous situation which, if not avoided, may result in property damage.
2.4
Safety information
3 Environmental issues
This section contains general rules regarding environmental issues. However, local rules and
regulations should be consulted for detailed handling of each material.
3.1
Unpacking
Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps.
Wood and cardboard boxes can be reused, recycled or used for energy recovery.
3.2
Other materials
Rubber and plastics should be burnt at a licensed waste incineration plant. If not available they
should be disposed to a suitable licensed land fill site.
Seal rings should be disposed of in a licensed land fill site. Check the local regulations.
Worn out or defected electronic components should be sent to a licensed handler for material
recycling.
The operator panel contain the following components with substances that might be hazardous
to health and the environment: lithium battery, electrolytic capacitor and display. They shall
be recycled according to local regulations.
Used lithium batteries from the control unit are considered hazardous waste and should be
disposed of accordingly.
Used UV lamps can be handled and disposed of in the same way as fluorescent lamps. Please
refer to national regulations.
11
Book No.
Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00
Telefax:
Contents
1
Introduction
1.1
Abbreviations
1.2
System overview
1.3
Components overview
1.3.1
Item numbers
Process overview
2.1
Start-up
10
2.2
Ballasting
11
2.2.1
2.2.2
2.2.3
Power optimization
Backflush
Ballast after-treatment (CIP)
11
12
14
2.3
Deballasting
15
2.3.1
15
2.4
16
2.5
17
19
3.1
AOT reactor
19
3.1.1
3.1.2
19
20
3.2
21
3.2.1
3.2.2
21
22
3.3
Filter
23
3.3.1
3.3.2
3.3.3
23
24
26
3.4
28
3.4.1
3.4.2
28
28
3.5
29
3.5.1
3.5.2
3.5.3
3.5.4
Control system
Main control panel
Remote control panel (optional)
Remote interface (optional)
30
30
30
32
3.6
Main valves
32
3.7
Flow meter
33
3.8
33
3.9
Sampling devices
33
1 Introduction
This contains general information about the PureBallast system and its components.
1.1
Abbreviations
Explanation
AOT
AOT reactor
Atex
CIP
Cleaning in place
CIP module
DIN
EN
EX
Explosion-proof
I/O
IACS
ISCS
IMO
JIS
LED
LDC
LPS
MCB
1.2
System overview
Introduction
Abbreviation
Explanation
PLC
UV
Ultra violet
1.2
System overview
The PureBallast system is an integral part of the vessels ballast water system, on the discharge
side of the vessels ballast water pumps. During ballast operation, the water is led through the filter,
which removes larger particles and organisms, and then to the AOT reactor, where the water is
treated with UV light and advanced oxidation technology (AOT). During deballast, the water is
led the same way, but the filter is bypassed.
The UV lamps are powered by the LDC (via LPSs, lamp power supplies). The AOT reactor has
one dedicated LDC.
Flow is monitored by the flow meter and regulated by the control valve. The control valve also
regulates pressure during back-flushing of the filter.
The AOT reactors are cleaned using the CIP (cleaning-in-place) module, which first rinse the AOT
reactor with fresh water, and then circulates CIP liquid through the AOT. At the end of the process
the AOT reactor and the filter (filter preservation) is filled with fresh water from the CIP.
The complete system and ongoing processes is controlled and monitored from the control cabinet.
Control can also be performed from remote control panels and the ships ISCS, via the remote
interface.
The by-pass valve makes it possible to by-pass the entire system, for example to secure ballast
operation if the system is not functioning. The valve is controlled from the ISCS (integrated ship
control system).
Introduction
1.3
1.3
Components overview
Components overview
The key components in PureBallast are shown below. Note that the filter is just an example of
a filter unit; others may be chosen.
2 SystemOverview
Not in illustration:
1.3.1
Item numbers
System components are identified by unique item numbers, for example FIT201-1 for the flow
transmitter installed before the AOT reactor.
Book No.9010182 02, rev. 0
1.3
Components overview
Introduction
2 Process overview
This section gives an overview of the main processes performed by PureBallast. In the flow chart
illustrations, involved pipes are marked in bold.
2.1
2.1
Start-up
Process overview
Start-up
Ballasting and deballasting begins with a start-up phase. There must be available power for
the system. If power management is integrated, this will be confirmed automatically. If power
management is not integrated, this is confirmed manually.
During start-up, the UV lamps are warmed up for 90 seconds. Cooling water is pumped through the
AOT reactor to secure that the UV lamps are not overheated. The flow is monitored by the flow
meter to secure that there is enough flow to cool the UV lamps. If flow deviates from parameter set
values, an alarm is issued and the system is shut down.
2 Startup
10
Process overview
2.2
2.2
Ballasting
Ballasting
After the start-up, when the lamps are ready, the operator is requested to start the ballast pump.
The ballast water is pumped from the sea chest to the filter, that removes larger particles and
organisms. This also reduces the amount of sediment build-up in the ballast water tanks. The
organisms and sediments caught in the filter are flushed overboard via regular filter backflush
operations. The water is finally led to the AOT reactor, which produces radicals and UV light
that breaks down and neutralize the organisms.
2 FullBallast
Ballasting
2.2.1
Power optimization
It is possible to activate power optimization (parameter p237). During ballast and deballast, the lamp
power is adjusted according to the value from the UV intensity sensor, which constantly measure
the water transmittance. In clear water with good transmittance, the lamps are automatically
dimmed, to lower the power consumption. This means that the lamps are lit to the degree needed
for full treatment, but not more.
The purpose is to save power by dimming the lamps to minimum power required to fully treat the
water. The UV lamps are regulated individual on all AOT reactors between 50 % and 100 % of
full effect.
Power optimization during special conditions.
During start-up and the first two minutes of ballast/deballast, the UV lamps are lit to 100 % to
ensure treatment befor values from the UV sensor are stable.
Pause: UV lamps are dimmed to 50 % during pause and lit to 100 % for 2 minutes when
process is resumed.
11
2.2
Ballasting
Process overview
Stop: UV lamps are lit to 100 % for 10 seconds before they are stoped. This will prolong
the life of the lamps.
2.2.1.1
If the UV intensity falls below minimum (defined in parameter p221) for one AOT reactor, a warning
is issued, but process continnues. When UV intensity falls below limit defined in the type certificate,
a new warning is issued and a log is written to the event log. The operation continues but does
not fullfill the type approval certificate. However, the flow is decreased so that the treatment shall
correspond to the type approval requirements. The operator will have do decide to continnue
or stop the operation.
2.2.1.2
If a UV lamp breakes a warning is issued and a log is written to the event log. The operation
continues but does not fullfill the type approval certificate. However, the flow is decreased to 80 %
of current flow for all AOT reactors and the UV lamps are lit to 100 %. These actions are taken so
that the treatment shall correspond to the type approval requirements.
The operator will have do choose one alternative:
2.2.2
Backflush
To keep the filter clean, it is automatically backflushed. The backflush is performed during ongoing
process without interrupting the ballasting process. When a ballast operation is stopped, a
backflush is performed before the system comes to a full stop. The water used for backflushing is
returned to the sea directly at the ballasting site.
12
Process overview
2.2
Ballasting
2 Back-flush
Filter backflush
13
2.2
Ballasting
2.2.3
Process overview
After a ballast operation, a cleaning-in-place (CIP) process is performed to clean the AOT reactor.
This process can either be performed immediately after a ballast operation or within 30 hours after.
Note, that it is possible to perform new processes during these 30 hours. A CIP process takes
about 25 minutes per AOT reactor, if default parameters are used.
The AOT reactors are cleaned one at a time. First, the AOT reactor is rinsed with fresh water. Then
the cleaning-in-place (CIP) module circulates a biodegradable solution through the AOT reactor to
remove seawater scaling. After the cleaning is finished, the AOT reactor is filled with fresh water to
preserve the filter and prevent scaling, algae growth etc. Then the system continues with the same
procedure for the next AOT reactor. Finally, the filter is filled with fresh water to prevent scaling and
algea growth. The cleaning liquid is reused between the cleaning operations.
2 CIP
CIP process
14
Process overview
2.3
2.3
Deballasting
Deballasting
After the start-up, when the lamps are ready, the operator is requested to start the ballast pump.
The water passes through the AOT reactor, but the the filter is bypassed since the water has
already been filtered during ballasting. The reason for treating the water a second time during
deballasting is to secure that the treatment is fully effective. The minor part of the organisms, which
were only injured during ballast, will be rendered totally harmless during the deballast.
The process flow and power optimization are controlled in the same way as during ballasting.
2 FullDeballast
Deballasting
2.3.1
After deballast operation, a cleaning cycle is performed to clean the AOT reactor. It is performed
in the same way as described for the ballasting process. If only deballast operations has been
performed since the last CIP process, the filter does not need to be filled with fresh water at the end
of the cycle, since the filter has not been used.
15
2.4
2.4
Process overview
Stripping can be performed to achieve total emptying of the ballast tanks via a stripping eductor.
To use PureBallast during a stripping process an eductor must be installed before the PureBallast
system.
The water used in the stripping process, must be filtered from particles larger than approximately 5
mm. The water passes through the PureBallast system as a regular deballasting process (with
the filter by-passed). The water is finally pumped into the sea.
Note the following:
Procedures to dispose of sediments from the sieve must be included in the vessels ballast
water management plan.
16
Process overview
2.5
2.5
PureBallast is equipped with a by-pass valve. The valve can be used in case of emergency to
secure the ship, by allowing ballast water operations (ballast, deballast and internal transfers)
without involving the ballast water treatment system. The valve is controlled by the ISCS, not
PureBallasts control system, but all by-pass valve activities are logged in the event log. Such valve
is required by the International Convention for the Control and Management of Ships Ballast
Water and Sediments 2004.
If the system malfunction in connection with general cargo operation, ballast and deballast
operations should be avoided. In case untreated water is pumped to a ballast tank, this water shall
be discharged on open sea (according to regulations) and exchanged for treated water. Note that
full treatment requires treatment both during ballast and deballast.
The procedures concerning emergency and malfunction of the ballast water treatment system
should be implemented in the ships Ballast water management plan.
17
Process overview
3 System components
description
This section gives an introduction to the most important PureBallast system components and
their functions in the system.
3.1
AOT reactor
The main part of PureBallast is the AOT reactor in combination with a lamp drive cabinet (LDC)
giving power to the UV lamps in the AOT reactor. The LDC does not need to be placed in close
relation to the AOT reactor.
3.1.1
The main treatment process take place inside the AOT reactor, where the UV light inactivates the
cell DNA to prevent regrowth of organisms. The UV light also generates radicals. The radicals are
extremely reactive and react instantaneously with micro organisms and other organic contaminants
destructing their membranes. The radicals are extremely short-lived and exist only for some
milliseconds. This means that they will only exist inside the AOT reactor. The quantity of radicals
produced in the reactor is sufficient to treat the water as it passes through the reactor.
2 10_2_1_1 Cell
19
3.1
AOT reactor
There are no chemical substances added to the process, and there are no toxic residuals created.
Since the water is not affected chemically there are no environmental impact, and the process does
not influence corrosion in any way.
3.1.2
The AOT reactor consist of the reactor, sensors and valves for ballast water, fresh water and CIP
liquid, as shown in the illustration below. The AOT reactor accommodates 16 medium-pressure
UV lamps (6 kW each) powered from the lamp drive cabinet (LDC). The UV lamps are enclosed
in individual quartz-glass sleeves.
The UV lamps get very warm, so they must be cooled whenever they are lit. To secure that there is
water in the reactor when the lamps are lit, each reactor is equipped with a level switch. The level
switch also secures that enough CIP liquid is pumped into the reactor during the CIP process. To
secure that the lamps are adequately cooled by the ballast water, each reactor is equipped with
a temperature transmitter, monitored by the control system. If the temperature deviates from
parameter set values, the AOT reactor will shut down. The temperature transmitter is completed
with a temperature switch that automatically shuts down the reactor at 65 C.
A UV sensor monitors the UV lamp efficiency in relation to the water transmittance inside the AOT
reactor. Based on this input, the power to the UV lamps are regulated between 50 and 100 % of full
capacity. The UV lamps will be dimmed to lowest possible level, where they are still effective.
Note, that the lamps are always lit with full effect during start-up and the first two minutes of full
ballast to secure full efficiency independent of transmittance. The lamps are also turned up to full
effect for 10 seconds before stop and normal shut down. This method will prolong the UV lamp life
time.
The illustration below show the main components for the AOT reactor.
20
3.2
AOT reactor
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
3.2
3.2.1
Each AOT reactor is connected to a lamp drive cabinet (LDC) containing 16 lamp power supplies
(LPS), each feeding one lamp with power. The LPS also monitors the function of each UV lamp and
Book No.9010182 02, rev. 0
21
3.2
takes action if a fault occurs. Lamps on the cabinet indicates if power is on, UV lamps are lit and
if the cabinet needs to be reset after a shutdown or power off.
3.2.2
LDC description
The LDC is equipped with a cooling system to maintain correct operating temperature in the LDC,
using low-temperature cooling water. The cooling water flow is constant, but the fan only runs
when needed. When the temperature reaches 40, the fan starts at 15 % of full effect. After
that, the fan speed is regulated between 15 % and 100 %, based on input from the temperature
transmitter in the LDC.
The humidity in the cabinet is monitored by a liquid sensor. If a leakage from the heat exchanger
is detected, a warning is issued, the reactor is shut down and the cooling water inlet valve to
the LDC is shut.
The LDC can be placed up to 150 meters (cable length) from the AOT reactor. The main breaker
cut the power to the LDC and the AOT reactor.
22
3.3
Filter
2 LDC
Fan
Heat exchanger
16 LPS
Fuses
Cooling water inlet and outlet
Main breaker
Status lights and reset button
3.3
Filter
3.3.1
The filter is a fully automatic self-rinsing component, equipped with filter elements to remove
particles and organisms from the ballast water flow. The ballast water is lead through the filter, and
filtered particles are trapped in the filter element.
23
3.3
Filter
3.3.2
Filter description
2 FilterHydac
1.
2.
3.
4.
5.
6.
7.
8.
Geared motor
Water outlet
Pressure transmitter, outlet
Filter control cabinet. Only used for connections.
The filter is entirely controlled from the
PureBallast control system.
Pressure transmitter, backflush line
Backflush outlet
Pressure transmitter, inlet
Water inlet
To secure efficient filtration, the filter performs a self-rinsing backflush operation at time set intervals
or when triggered by indication of dirt in the filter. Pressure drop over the filter is monitored by
pressure transmitters on the filter inlet and outlet. Dirt is detected by an increased differential
pressure drop caused by particles in the filter candles. When the differential pressure reaches a
parameter set value, an automatic backflush operation starts. The backflushing does not interrupt
the filtration process, since the filter candles are cleaned one by one. The other filter candles
continue the filtration of the ballast water. It is also possible to start backflush manually from the
control system.
24
3.3
Filter
2 BackFlush1
2 BackFlush2
25
3.3
Filter
3.3.3
Below, the filter pressure drop over time (pfilter) is illustrated for different dirt load situations in the
filter. Different dirtload depends on the water condition, which means that normal condition
regarding filter backflush depends on the water conditions.
3.3.3.1
In water with low dirt load, the backflush cycle is started by the time trigger (default: every 30
minutes). As long as the pressure is below 0.5 bar (0.05 MPa), there is no need for the pressure
triggered backflush. See examples below.
6 Dirtload1 Hydac
6 Dirtload2 Hydac
3.3.3.2
In more dirty waters the backflush cycle will be triggered when pfilter reaches 0.5 bar, which indicates
dirt in the filter candles.
After each backflush, the backflush timer is reset. The filter will be backflushed again after 30
minutes or when pfilterreaches 0.5 bar, whichever comes first.
In the example below, three backflushes are triggered due to high differential pressure over the filter.
After that, there is not so much dirt build up, so the next backflush is performed after 30 minutes.
26
3.3
Filter
6 Dirtload3 Hydac
3.3.3.3
In conditions with heavy dirtload, the system will perform more frequent backflushes to keep the
filter clean.
Also, the 0.5 limit might be exceeded. In this case the self rinsing cycle will run continuously
until the problem is solved and the pressure has returned below 0.5 bar. It is OK that the flow
momentarily fluctuates in an irregular curve, but it is important that the curve stabilizes.
In the example below, a series of backflushes are performed (approx. every 4 minute). After that
the pressure rises above 0.5 where the filter is backflushed constantly. After that, the normal
control is resumed, where the filter backflush is triggered by pressure (2 times) or by time (last
backflush in the example.
6 Dirtload4 Hydac
3.3.3.4
Over time, the filter candles will undergo a long term build-up of particles that are not removed by
backflushing. One effect of this is that normal pressure will increase over time. Therefore, the
maintenance schedule state that the candles shall be inspected and manually cleaned once a year.
The extent of the long term dirt build-up is dependent on the water conditions. In the great majority
of cases this will not cause any problems cleaning once a year is enough. But in exceptional
cases (vessels trading very muddy waters) it might be necessary to clean the filter candles more
often. If the pressure triggered backflushing is performed with short intervals, we suggest that the
filter candles are manually cleaned more often than once year.
27
3.4
3.4
3.4.1
To ensure full performance in PureBallast, an automatic cleaning cycle is performed after ballast
and deballast operation. The purpose is to keep the quartz sleeves covering the UV lamps and the
UV sensor clean, to maximize the effect of the UV lamps, and thereby treatment efficiency.
During a cleaning cycle, the CIP module rinse the reactor with fresh water and circulates a CIP
liquid through the AOT reactor. The low-pH CIP liquid removes scaling, calcium chlorides, metal ion
build-up and chemical fouling on the lamps quartz glass sleeves. After finished cycle, the liquid
is returned to the CIP module tank; the CIP liquid is reusable for a great number of cycles. The
sequence is finalized by filling the AOT reactor with fresh water.
3.4.2
The CIP module consists of a tank where the CIP liquid is stored between usage. The pumps and
valves integrated in the CIP module are controlled by the valve block.
To secure that there is enough CIP liquid for the process, the level switch in the reactor indicates
when it is filled with CIP liquid. To prevent intrusion of water in the fresh water system, a backflow
preventer is used in the CIP module.
The CIP module is equipped with two membrane pumps:
Pump P320-1 circulates the CIP liquid in the AOT reactor and fills it with fresh water.
Pump P321-5 drains water (sea and fresh water) overboard from the reactor, via the drain line.
28
3.5
2 CIP module
CIP module
1.
2.
3.
4.
5.
6.
7.
Deaeration valve
Valve block
Regulator
Pump (CIP liquid)
Backflow preventer
Pump (reactor drain)
Tank for CIP liquid
3.5
The control cabinet is used to control and monitor the entire system, via the built in main control
panel. It is also used to communicate with the the vessels systems and components, if integrated.
The control cabinet functions as a signle point of contact for signal cables to and from the vessel.
Examples of integration: Remote interface integration and power management system (PMS).
Remote interface will allow control of PureBallast from the vessels ISCS and PMS integration will
allow automatic verification that there is enough power to run an operation. If not integrated, the
operator must verify this manually. Also integration with other external components (not part of Alfa
Lavals scope of supply), such as GPS or booster pumps, are done to the control cabinet.
29
3.5
3.5.1
Control system
The control system is used to set parameters, operate and monitor the PureBallast system. The
control system continuously monitor PureBallast (sensors, communication and PLC status), both
during operation and in standby mode. Any deviation is either communicated to the operator or
handled automatically, based on parameter settings. Safety risks are always handled automatically.
The control system store all alarms and relevant events for at least 24 months. The memory has
a vast safety margin but when it is full, data will be deleted starting with the oldest logs. Logged
information can be exported to a USB memory stick.
There are three alternative ways to monitor and control PureBallast: Main panel, remote control
panel (optional) and remote interface (optional).
If two PureBallast systems are installed on a vessel, two control systems are needed.
3.5.2
The main control panel in mounted in the control cabinet, and it is included in the standard
installation of PureBallast. It is installed in the engine room. The main control panel handles
every aspect of the control system. It allows the operator to monitor the system, to operate it
manually and automatically, and to set parameters. Please note that some of the operations are
password-protected.
2ControlPanel
3.5.3
30
3.5
2RemotePanels
31
3.6
Main valves
3.5.4
As an option, the control system can be integrated with the vessels ISCS via modbus. This allows
monitoring and operation of PureBallast from the ISCSs graphical user interface.
Note that Alfa Laval does not supply the graphical user interface to handle PureBallast in the
ISCS, only the means to enable the integration.
2RemoteInterface
PureBallast control systems main control panel integrated with the ISCS. The interface is only an example.
3.6
Main valves
Inlet valves: The inlet valves directs the water flow from the vessels ballast water system into
the PureBallast system. Different valves are used during ballast and deballast.
-
System and filter inlet valve (2013): Inlet valve to PureBallast during ballast. The valve
directs the water flow through the PureBallast filter.
Filter outlet valve (V20132): The valve directs the water flow from the filter to the AOT
reactor during ballast.
Inlet valve (2019): Inlet valve to PureBallast during deballast. The valve directs the water
to PureBallast, but bypass the filter, since the water was filtered during ballasting.
Automatic regulation to maintain flow during operation so it does not exceed selected
certified maximum flow. Regulation is based on input from the flow meter.
Outlet valve from the PureBallast system to the vessels ballast water system after treatment.
PureBallast bypass valve (V21231): Makes it possible to completely bypass the PureBallast
system. The valve is solely operated from the ISCS, but the valve positioning is (and must be)
indicated in the PureBallast control system. When PureBallast is bypassed, an event is written
to the event log. The component is optional to be included in Alfa Lavals scope of supply.
Cooling water inlet valve (V403-35): Supplies cooling water to the reactor to secure cooling of
the lamps and prevent overheating during start-up.
32
3.7
3.9
Sampling devices
Flow meter
The flow meter (FIT2011) monitors the process-flow during operation. It has two main functions:
It monitor that the flow within the PureBallast system does not exceed its certified flow. If the
certified flow is exceeded a warning is issued.
Via the flow transmitter, mounted on the flow meter, it sends valuable data to the PureBallast
control system, where it is displayed. Example of information: Current flow and data about
total amount of treated ballast water.
The flow meter consists of two main parts: A flow sensor, which is a pipe with four electrodes
detecting the flow. On top of the pipe, there is a terminal box, where the flow transmitter is
mounted. The flow transmitter monitors the flow and transmits the information to the PureBallast
control system.
3.8
The pressure monitoring device is a manifold that includes the following components to monitor
and handle pressure in the system:
Pressure transmitter(PT201-16): Send current pressure information to the control system. The
control system use the information to take actions accordingly, for example issue warnings, shut
down the system or adjusting the control valve to obtain optimal pressure during filter backflush.
3.9
Sampling devices
The two sampling devices (Q201.1 and Q201.1) make it possible to take water samples to test the
water. One sampling device is installed before the water is treated and one after the water is
treated. This enables comparative tests of treated and untreated water. The component is optional
to be included in Alfa Lavals scope of supply.
33
Book No.
Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00
Telefax:
Contents
1
Introduction
1.1
1.1.1
1.1.2
1.1.3
1.1.4
Stripping
Heeling (internal transfer)
Ballast water handling in the event of malfunction
Pipe cleaning using PureBallast
7
8
8
9
11
2.1
Login levels
11
2.2
Control of PureBallast
12
2.3
12
2.3.1
13
14
19
3.1
19
3.1.1
3.1.2
Status box
Flow chart
20
21
3.2
23
3.2.1
3.2.2
3.2.3
Flow selection
AOT selection
Status
23
24
24
3.3
25
3.3.1
3.3.2
3.3.3
CIP status
AOT information
CIP module information
26
26
27
3.4
28
3.4.1
3.4.2
3.4.3
28
30
30
3.5
31
3.5.1
3.5.2
Alarm list
Function buttons
32
32
3.6
33
3.7
34
3.7.1
3.7.2
3.7.3
Diagram area
Component area
Function buttons
35
35
36
2.4
3.8
37
3.9
37
3.10
37
3.11
37
3.12
38
3.13
41
3.14
42
3.15
44
3.16
45
3.17
46
3.18
47
3.19
48
3.20
50
3.21
52
3.22
53
3.23
Popup windows
53
53
59
Operating instructions
61
4.1
Log in
61
4.2
Perform ballast
61
4.2.1
Start ballasting
62
4.3
Perform deballast
62
4.4
64
4.5
64
4.6
65
4.7
65
4.8
Attend to alarms
66
4.9
67
4.10
68
4.11
68
4.12
70
4.13
71
4.14
72
74
4.15
74
4.16
76
4.17
77
4.18
77
4.19
79
4.20
80
4.21
80
4.22
81
4.23
82
4.24
83
4.25
84
4.26
84
4.27
85
4.28
86
86
89
5.1
89
Event log
95
6.1
Standby mode
95
6.2
Ballast process
96
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
Ballast start-up
Full ballast
Filter backflush
Pause ballast (Heeling mode)
Stop ballast
96
97
97
98
99
6.3
Deballast process
6.3.1
6.3.2
6.3.3
6.3.4
Deballast start-up
Full deballast
Pause deballast (Heeling)
Stop deballast
6.4
CIP process
6.4.1
6.4.2
6.4.3
6.4.4
6.4.5
6.4.6
6.4.7
6.4.8
6.4.9
Start CIP
Drain ballast water
Fresh water filling
Fresh water draining
CIP cleaning
CIP draining
Fresh water filling
Repeat
Filter preservation
6.5
Manual mode
100
100
101
101
102
103
104
104
105
105
105
106
106
106
106
107
1 Introduction
The control system is used to operate and monitor the PureBallast system. It also contains
functions for setting parameters, saving log files etc.
This chapter describes the control system. It includes general description of the control system
pages, step-by-step instructions and a process description with detailed information about the
components (valves, motors, pumps etc) involved in each step of respective process.
The following control system related information is given in other chapters of the manual:
Alarms and warnings including information about faultfinding and how to solve problems is
described in chapter 5. Alarms and faultfinding.
Information about integrating the control system with the vessels ISCS and power management
is described in chapter 6. Installation description and drawings.
1.1
Make sure all documentation is available, read and understood before start.
Make sure that the flow is within defined flow range during operation:
Ballast (m3/h): 190 300190 600190 750
Deballast (m3/h): 100 1000
During process, the control system requests that vessel valves are opened/closed. The
valves are outside the PureBallast system control. But the control system needs feedback
(opened/closed) during process. Status can either be confirmed manually in a popup or
automatically, if feedback signals are integrated via the remote interface option or via hard wire.
Please note:
When overboard valves are requested to be opened/closed, this means that all valves
leading the flow from the PureBallast via one of the following pipes must be opened/closed:
201, 309 and 403 and 404. During CIP process, 460.1 must be opened.
Such water as described above does not need to be transported overboard. For example,
the flow can be lead to the bilge tank. In such cases, all relevant valves leading the water
from the PureBallast system shall be opened.
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.
1.1.1
Stripping
1.1
Introduction
If stripping is performed with a low flow for a long period of time, we recommend that stripping is
performed from the ballast tanks to a collection tank. After that it is possible pump the water from
this tank with full flow using the ballast pump, and finally empty it by stripping.
This will reduce the power consumption and UV lamp runtime. If all tanks are stripped (with a low
flow) the power consumption per treated cubic meter will be unnecessary high, since the power
consumption will be high in relation to the low flow.
Example: If a process is run with a flow of 100 m3/h for 10 hours, it will give a power consumption
of 1000 kwh, not including the ballast water pump. But if the same amount of water is collected
and then processed with a flow of 1000 m3/h using the ballast water pump, the power consumption
will be 100 kwh.
1.1.2
Internal transfer of ballast water between tanks, for example during heeling procedures, does not
require the use of the PureBallast system. It is possible to perform heeling when PureBallast
is in standby mode.
If external component signal for heeling mode is integrated between PureBallast and the vessels
ISCS, any ongoing process will be paused and resumed automatically. The user is notified of
started and stopped heeling via a message in the control system, and the event is logged.
If no external signal is integrated, the ongoing process must be paused manually. During pause,
cooling water is flushed through the AOT reactor to cool the UV lamps. After completed heeling,
the operator must resume the paused process. Warning W82 will appear in the alarm list. See
instruction Pause ballast / deballast on page 64.
1.1.3
If the ballast water treatment system malfunctions, follow the procedures stated in the ships ballast
water management plan. This is valid both if the system malfunctions, for example mechanical
problems, or if full treatment cannot be guaranteed, for example a lamp failure or low UV intensity.
General recommendations are given blow.
PureBallast is equipped with a by-pass valve. The valve can be used in case of emergency to
secure the ship, by allowing ballast water operations (ballast, deballast and internal transfers)
without involving the ballast water treatment system. The valve is controlled by the ISCS, not
PureBallasts control system, but all valve activities are logged in the event log. Such valve is
required by the International convention for the control and management of ships ballast water
and sediments 2004.
If the system malfunction in connection with general cargo operation, ballast and deballast
operations should be avoided. Note that the system requires treatment both during ballast and
deballast.
If untreated water is pumped to a ballast tank, this water shall primarily be discharged to a reception
facility. When this is not possible, other discharge possibilities must be agreed with the port state
responsible for the waters where the ship is sailing and most importantly be agreed with the flag
state administration of the ship; the procedures concerning emergency and malfunction of the
ballast water treatment system should be implemented in the ships Ballast Water Management
Plan which must be approved by the flag state administration.
Introduction
1.1.4
1.1
In some vessels, the applicable class society may require means and procedure for flushing
ballast pipes with treated water, to clean them from untreated water. This procedure should be
implemented in the ships Ballast water management plan.
In PureBallast, a deballast process is run with the vessels ballast valves positioned so that the
pump takes water from a ballast water tank with treated water and
Run the process for enough time so all water in the piping is treated. Time for this depends on pipe
size and length on board.
1.1
Introduction
2.1
Login levels
Different login level controls which information that is displayed and changeable. As an example,
pages used for commissioning purposes are hidden for normal operators.
Login level
Password
Authority
Guest
N/A
Operator
Advanced
operator
AlfaLaval
aot
2007
N/A
As Guest.
As level Operator.
Full access to page 4.3 Operation timers and 4.4 Operation timers
AOT.
Full access to make settings for remote control panels and remote
interface in page 4.1 System info and 4.5/4.6 Remote interfaces 1
and 2.
11
2.3
2.2
Control of PureBallast
PureBallast can be monitored and controlled in three ways: Main control panel, remote control
panel (optional) and remote interface (optional). The system can only be controlled from one
place at a time.
The information below is only valid if remote control panels and/or remote interface is installed.
Remote control panels. It is possible to log in on one panel, even if a user is logged on another
panel. This requires that the new operator log in with the same login level or higher. The new
operator will get a popup message saying that another user is logged in. The popup gives the
alternative to cancel or to continue. If continue is chosen, the first operator will get a popup
message and is then logged out.
On each control panel it is possible to see which panel that is active and which login level that is
used. This is visible in the upper right corner of the system according to syntax: login level@control
panel.
Login level can be: Guest, Operator, Advanced operator or AlfaLaval.
Control panel can be:
Note: A panel alias can be entered to clarify where the panel is installed, for example pump room,
bridge etc. See instruction Set remote control panel communication.
Remote interface: The buttons Local and Remote are used to select which system that shall
be in command. A green light is lit under the button that corresponds to the system currently in
command. It is only possible to change between local and remote using these buttons.
2.3
If the remote interface option is used, PureBallast can be controlled from the vessels ISCS. It is
possible to access the same pages and perform the same operations from the remote interface as
for login level Operator (if allowed by the ISCS).
When the remote interface is used, the panel(s) cannot be used to operate the system; it is only
possible to monitor the system and to export log files. It is possible to turn of the remote interface,
and thus activate the panels when logged in as Operator or higher.
The PureBallast system manual does not give any information about how to run PureBallast from
the remote interface. This is due to the fact that the remote interface is custom-made. Please
refer to the vessel specific manual.
12
2.3.1
2.3
PureBallast can be operated from ISCS when the conditions below are met:
Installation and settings
Remote interface must be activated (parameter p132) and communication settings must be
correct (parameter p700 p704).
Remote operation must be in online mode. Check that the Test mode button is deactivated (no
checkmark on the button) in control system page 4.5 Remote interface 1.
Remote mode must be activated. Check that the green lamp is lit under the Remote button
on the control panel. If not, press the button. The system must be in Standby mode to toggle
between local and remote operation.
Operation
Heartbeat is updating. See that address +006 +077 are updating in control system page 4.5
Remote interface 1.
There must be no active alarms for the AOT reactors to be used during operation. Always check
the alarm list (page 2.1 Alarm list in the control system) before operation.
13
2.4
2.4
This section describes the PureBallast control system screen layout and navigation.
The control system use a touch screen, where you tap the screen to click or drag objects. Do not
use sharp objects to touch the screen. When the screen is left idle it will go to screensaving mode.
Time is set in page 4.1 System info. The screen is activated again by touching it once. The touch
will not activate any button that might be placed where you touch.
The illustration below shows the main areas and function buttons on the screen.
3 1.1
2.4
Popup windows: Are used to display or enter detailed information. It is possible to move a popup
by touching the name bar and drag it. A popup is closed either by touching confirming entered
information by touching a function button (OK, Confirm, etc.) or the X icon in the top right corner
(data is not saved).
Data entry fields: A white field indicates that it is possible to enter data. When the field is touched,
a keyboard is displayed, which is used to enter information. Enter data is confirmed by touching the
Enter button. To close the keyboard without saving data, touch the Esc button.
Tables: Individual table rows, for example an alarm, can be selected by pressing them. Column
widths can be adjusted. Press the column border in the head area and hold the finger on the screen.
Function buttons: Function buttons are used for main processes and control of the system. They
are placed att the bootom of the screenare and are always visible, but only available when colored
dark blue. Some buttons are dependent on parameters. For example, the Remote and Local
buttons are only visible if remote interface is activated.
Status indication Button color: The buttons appear in different colors, indicating status:
Blue
Blue with
checkmark
Grey
The function is disabled, for example if higher login level is required for the
function.
Status indication Button light: After a function button is pressed, a light under the button is lit
to indicate status for the activated function:
Green
Command is active.
Yellow
Yellow, blinking
Command is paused.
Description
Start ballast process.
Resumes paused process.
3Ballast
15
2.4
Button
Description
Stop current process.
3StopButtonBlue
3Pause
Pause ballast or deballast process. This is only possible during full ballast
or full deballast. The button can be hidden, using parameter p137. Allowed
length of a pause is parameter set (p138). After defined time, the paused
process is stopped.
To resume a paused process, press the function Ballast or Deballast
depending on which process that was paused.
Start CIP process.
3CIP
Activate operation from control panels, instead of remote interface (if option
is used). The button is only enabled in standby mode.
2 LocalButton
3 EnableManual
Sets the control system in manual mode, which enables manual operation
of the system and its components. When activated, the light flashes yellow.
The button is displayed for login level Advanced operator or higher. For
detailed information see Manual mode on page 107.
Disable the touch screen function for 10 seconds to make it possible to
clean the screen without the risk of starting a process or changing a setting.
3Wipe
Activate night light for the panel. Night light makes the panel less bright.
Toggles between night light and day light.
3 Night
Degree of brightness, is set in the Night light level field in page 4.1 System
info.
Contains calculator, Notepad and print function.
To print a screen image to USB: Insert a USB memory in USB panel
port on the cabinet door. Press Utilities, and then Print to save a screen
image to USB.
3 Utilities
2.4
Alarms and warnings for components are displayed in the flow chart and popups:
Active alarm.
3Alarm
Active warning.
2 Warning
17
2.4
3.1
The page displays an overview of the system, overall status and detailed information regarding
the components.
The main areas are the Status box and the Flow chart.
3 1.1
19
3.1
3.1.1
Status box
The status box display current status for the PureBallast system. The information is updated
continuously. To see accumulated operation runtime for the components, see page 4.3 Operation
timers.
The following status information is displayed:
Status information (unit)
Description
Time
Flow selection
Flow (m3/h) selected for operation. Flow is set using the arrow
buttons. Flow selection depends on parameter p131 Automatic
AOT selection:
20
3.1.2
3.1
Flow chart
The flow chart display a schematic overview of the PureBallast system and its components.
Relevant information regarding ongoing process and component status can be monitored directly
in the flow chart. Flow in pipes is indicated by coloring of the pipes and component status are
displayed by color indications. Pressure, flow and control valve opening percentage are displayed
directly on component.
Detailed information about components can be monitored in popups (by tapping the component):
AOT reactor see page 53; filter see page 59. CIP open page 1.3 CIP status, see page 25). The
popup contain status for sub components, for example valves, motors and UV lamps in the AOT
reactor.
Booster pump for AOT reactor (P4031) and LDC (P4011) are only displayed if these components
are used and activated in the parameter pages.
In manual mode (login level Advanced operator or higher) it is also possible to operate components
manually: If a component is pressed, a popup window is displayed from which the component
can be operated.
Status indication Component color:
Component status is indicated by a colored frame:
Pipes
Valves and
pumps
Status indication
Green, blinking = Travelling / starting
Green = Open / running
Grey = Closed / not running.
Red, flashing = Active alarm for the component.
It is also possible to enter ship specific ID for a component. The ID will be
visible in page 1.1 Overview and popups for the components. See instruction
Set ship specific component ID on page 71
21
3.1
Status indication for balast water pump (not part of Alfa Lavals scope of
supply).
3 PumpReq
Status indication
Green, blinking = Request sent. Popup message message Confirm ballast
pump started is displayed. (The popup is not displayed if the component
feedback is integrated with the control system.)
Green = Feed back that pump is running, either via hard wired feedback,
remote interface or the confirmation popup.
Grey = No request sent (not running).
Status indication for overboard valve(s), and other relevant valves for the
process (not part of Alfa Lavals scope of supply).
3 OBvalveReq
Status indication
Green, blinking = Request sent. Popup message message Confirm overboard
valve open is displayed. (The popup is not displayed if the component
feedback is integrated with the control system.)
Green = Feed back that valve is open, either via hard wired feedback, remote
interface or the confirmation popup.
Grey = Closed.
Status information for bypass valve(s) V21231 and external bypass valves
(not part of Alfa Lavals scope of supply). These valves are operated from the
ISCS, due to safety reasons.
External bypass is only visible if parameters (p163p165) for external bypass
valves are activated.
22
3.2
3.2
The page is used to select AOT reactors or flow for ballast and deballast and to increase/decrease
flow during ongoing operation. It is also possible to select specific AOT reactors to be used during
process, or to change AOT reactor during an ongoing process.
This page is only relevant if more than one AOT reactor is installed.
Note, that if parameter p131 Automatic AOT selection is activated, it is only possible to change
flow during operation, not in standby mode.
Normally, flow is handled from page 1.1 Overview, and this page is used during commissioning and
faultfinding when it is necessary to start individual AOT reactors.
The main areas of the page are the Flow selection, AOT selection and Status.
3 1.2
3.2.1
Flow selection
23
3.2
3.2.2
AOT selection
The area displays a table with installed AOT reactors with status information. It is possible to
choose individual AOT reactor for process in standby (if parameter p131 is disabled) or during
process (regardless of p131 setting).
The following information is displayed:
Elements
Description
Modify button
AOT 1, 2, 3 button
One row for respective installed AOT reactor with current status indicated
in the columns.
AOT n button: Press the button to select or deselect. A checkmark on the
button indicates selected. The flow setpoint for the number of AOT reactors
selected are updated in the Flow selection area. The field is updated with
m3/h for each selected AOT reactor.
Status indication:
Selected: Grey = Not selected. Green = Selected.
Ready: Grey = Not ready. Green = Ready for process.
Alarm: Grey = No alarm. Red = Active alarm.
Apply button
3.2.3
Status
Description
Current flow
Certified flow
24
3.3
3.3
The page is used to display CIP status for all AOT reactors and status for the valves and motors in
the CIP unit. The page can either be opened by selecting the tab or by tapping the CIP module in
page 1.1 Overview.
The page also display time remaining for ongoing CIP process. If no CIP required process has been
started after a ballast or deballast operation, the time remaining before CIP must be performed is
displayed.
3 1.3
25
3.3
3.3.1
CIP status
Content
3.3.2
Sub process: Sub steps of ongoing process, for example Start-up during
Ballast process.
AOT information
The area displays CIP status for respective installed AOT reactor:
Row
Content
AOT
Each row display CIP status for every installed AOT reactor
Filter preservation This row indicate status and time for the filter preservation process, that
starts after completed CIP. During filter preservation, the CIP fills the filter
with fresh water for preservation purpose.
Total
Total estimated time for a complete CIP process including filter preservation.
Column
Content
CIP error
Red square: Indicates that there is an active alarm for the component.
Check alarms on page 2.1 Alarm list.
CIP
Status
26
3.3
Column
Content
Estimated time
Time remaining CIP time. If CIP process has not been started, total time is
displayed. During CIP process, the time is counting down continuously.
The CIP process takes about 25 minutes per AOT reactor, if default
parameters are used.
Required CIP
countdown
3.3.3
The area displays a schematic illustration of the CIP module, with status for for the valves and
motors. For status indications, see Status indication Component color in section Flow chart
on page 21.
27
3.4
3.4
The page is used to handle power management. The page have two functions: Display power
status and test power management signals.
3 1.4
3.4.1
If the control system is set in normal mode, the page is used to display power management status.
Column
Content
Max power
consumption
28
Sub process: Sub steps of ongoing process, for example Start-up during
Ballast process.
3.4
Column
Content
Measured power
consumption
Power consumption during process. Value is either exact value for all
AOT reactors in use (including LDC cabinets), or calculated value based
on number of used AOT reactors and UV lamp dimming. This is set in
parameter p239.
Power status
Column
Content
Power
Request
(Output signal from
PureBallast)
Granted
(Input signal to
PureBallast)
Status
(Output signal from
PureBallast)
Calculated power
consumption
29
3.4
Column
Content
If Common power has been selected, the value is 100 kW.
3.4.2
If the control system is set in manual mode, the page is used to simulate output from PureBallast to
the power management system during commissioning preparation.
The page can also be used to troubleshoot the power management system integration by sending
and checking each signal.
3.4.3
Function buttons
The following function buttons are available and displayed when manual mode is activated:
Buttons
Content
3Manual1
Request
Set run
Press to manually simulate run signal for a power step. The button is
displayed for login level Advanced operator or higher.
30
3.5
3.5
The page display active alarms and warnings. When an alarm/warning is inactive and
acknowledged, it is moved to page 2.2 Alarm history.
Alarm type can be of two types:
-
A = Alarms stop the ongoing process, which can be restarted after the problem has been
attended to.
W = Warnings are notification of a status change, request for action or a problem that must be
attended to. Warnings allow the process to continue.
For detailed information about alarms and warnings see chapter 5. Alarms and faultfinding.
3 2.1
The main areas of the page are the Alarm list and the Function buttons:
31
3.5
3.5.1
Alarm list
Content
Text
Active time
Acknowledged time
Alarm = active
Pink
Orange
Warning = active
Yellow
3.5.2
Function buttons
Function
Ack selected
Acknowledge selected alarm (row). Press a row to indicate it, and press the
button to acknowledge it.
Ack all
32
3.6
3.6
3 2.2
Content
Text
Active time
Acknowledged
time
Normal time
The time the value that caused the alarm returned to normal.
33
3.7
3.7
The page is used to display trend curves for basic data in the system. This page display trends with
a update frequency (sample time) of 1 second. This page is useful for analyzing processes, for
example backflushes.
3 3.1
Trends can be plotted for the following components (identified by item number) and key values:
Component /
Key value
Unit
Description
Bar
V2018
PT201-16
Bar
V309-1
Status
FIT 201-1
m3 h
34
3.7.1
3.7
Diagram area
In the diagram area, trend curves are displayed for one or more components. Components
available for plotting is displayed at the bottom of the screen. Trend curves can be activated or
inactivated for respective component.
The scale of the diagram:
X axis: The time interval is always 15 minutes.
Y axis: The scale and unit used for the Y axis is set in the Settings popup for respective component.
For details, see the Component area section below.
3.7.2
Component area
The following fields and buttons are available for each component in the component area:
Column
Content / Function
Settings
button
Press the button to make settings for the components curve. Settings is
done in a popup.
3 TrendCurveSet1Nr
1: Press (not slide) the button to display or hide trend curve in the diagram.
An I indicate displayed, and an O indicates inactive.
2: Press the entry field to change start and stop value for the components Y
axis scale (when this components scale setting is used.
3: Press this button to use this components scale setting in the diagram.
4. Press the entry field and increase or decrease the number of decimals in
the component area.
35
3.7
Status
indication
3 TrendActive
3 TrendScale
Component
Value
Current value for the component is displayed in the gray field. (This
corresponds to the diagram.)
If history mode is selected, historic value is displayed.
3.7.3
Function buttons
Content
Export data to
USB
Export trend curve history as a csv file. The file can be sent to Alfa Laval for
advanced trouble shooting.
Insert a USB memory in USB panel port on the cabinet door. Press Export
data to USB button. Wait for the message Exporting database table to
disappear. The file has been downloaded to the USB memory, in a folder
named DatabaseExport.
History mode
3 TrendCurveTime
Press one time unit (year, moth, day etc) and then press or + to set time.
Real time
36
3.8
3.11
The page is used to display trend curves for basic data in the system. This page display trends with
a update frequency (sample time) of 30 seconds.
See page 3.1 Trend (15 min.) for information about function, fields and buttons.
3.9
The page is used to display trend curves for water temperature in the AOT reactor, indicated by
temperature transmitter TT20133. This page display trends with a update frequency (sample
time) of 30 seconds.
See page 3.1 Trend (15 min.) for information about function, fields and buttons.
AOT UV setpoint: The UV intensity the system is aiming to attain by increasing or decreasing
power effect to the LPS controlling the dimming of the UV lamps. The setpoint is based on
actual transmittance and is updated every 15 seconds.
Power output: Actual LPS power to UV lamps. The power is adjusted to attain the setpoint for
UV intensity based on measured water transmittance. Output is adjusted based on input from
UV sensor QT20150. Power can be 50100 %.
37
3.12
3 4.1
Description
HMI info
38
Section on page
3.12
Description
Program version: Version of HMI software.
IP settings: Display current IP address.
Setup button: Opens popup to set IP address for the main panel and
the remote control panels (optional). Requires login level AlfaLaval
HMI Backlight
PLC Info
Settings for trend pages, e.g. min and max values for different
components. Saved in file ValueTrendLegend.xml.
39
3.12
Section on page
Description
Parameters: Restore manually changed parameter to default
values.
Set default button: Set all parameter values to the default values.
Requires login level Advanced operator.
History to USB panel: Export information to the USB panel port
on the cabinet door
Backup button: The following information is saved in a folder named
PureBallast Export:
Settings for trend pages, e.g. min and max values for different
components. Saved in file ValueTrendLegend.xml.
Export: Opens the Export log files popup to export (copy) event
log and alarm list as a set of files in a folder named PureBallast.
For specific information about logged events, see section List of
logged information, Event log on page 89.
Set: Open a popup used for setting IP addresses for remote control
panels (optional). See instruction Set control panel IP address on
page 74.
Requires login level Advanced operator.
40
3.13
41
3.14
3 4.3
Unit
m3 processed
m3 processed
Runtime in hours
Runtime in hours
42
3.14
Row
Unit
Runtime in hours
Reset button: Reset to 0. If this is done each time the CIP liquid
is changed, it is possible to build up experience on how many
AOT reactors it is possible to CIP before it is time to change CIP
liquid. Requires login level Advanced operator or higher.
43
3.15
3 4.4
Total
Lap time
AOT 13:
Lamps on
44
3.16
3 4.5
Function buttons
Description
Test mode
45
3.17
3 4.6
46
3.18
3 4.7
Content
Vessel ID
Position
47
3.19
Column
Content
Position: For each valve, it is possible to connect two signals to log feedback
on open, closed or both. If signal Closed is used for a valve, the event log
will make a record each time the valve is detected closed, and each time it is
detected not closed.
Status
Logging
Two parameters per valve defines if opened and/or closed signals are
connected for respective position (valve). If parameter is set to Active,
activities for the component is logged in the event log.
Alternatives: Activated or Not used.
48
3.19
3 4.8
49
3.20
3 4.9Obe
Column
Content
LPS number
Power
Lamp on
Reignite
LPS OK
Lamp OK
Status: Green = UV lamp lit and LPS is OK. Red = LPS in fault state.
Voltage fault
System fault
50
3.20
Column
Content
Heatsink fault
Fan fault
51
3.21
3 4.10
Column
Content
AOT
Each row indicate status for the LDC for each AOT reactor.
Current
Voltage
Power total
Total effect at LDC main breaker Q1. Presented as active, reactive and
apparent values.
Freq.
L, S and I
Read button
Press the button to update data for the row. (The data is not uppdated
continuously.)
52
3.23
Popup windows
53
3.23
Popup windows
Description
UV lamps
Status indication:
Grey = Off.
Yellow = Starting.
Green = Started.
Sensor
indications
54
Component
3.23
Popup windows
Description
QT20150: UV sensor QT20150 indicates UV intensity from the UV lamps
in the AOT reactor. When transmittance falls below value set in parameter
p221 a warning is issued.
TT20133: Temperature indicator TT201-33 indicates current temperature
in the AOT reactor.
Valves
Water flow
LDC status
Component
3 LPSctlrbut
Description
Open the LPS control popup, which enables manual operation of individual
UV lamps. Requires login level Advanced operator to see the button and
manual mode open the popup. See LPS control popup and instruction
Operate UV lamps manually on page 70.
Open the LPS status popup, which gives an overview of status for UV
lamps and LPSs.
3 LPS StatusBut
Fan rotation in percent of full effect. Fan effect is based on need for cooling.
Heat exchanger
valve
TT4011
TT4012
Power
55
3.23
Popup windows
NGE
! DA
Manual start of the UV lamps is only allowed (and possible) when there is water in the AOT
reactor (indicated by level switch LS201-29), and the water temperature is below 60 C. All
necessary items cooling water flow, water temperature, and power management must be
supervised and verified by the authorized trained personnel operating the system. Improper
operation of this function could seriously damage the equipment and injure personnel.
Description
AOT number
Information is displayed for the AOT reactor selected in the AOT number
field.
Enables manual operation of the LPSs to light the UV lamps. The button is
displayed for login level Advanced operator or higher. The button enables
manual lcontrol of UV lamps.
3 ManModeBut
56
3.23
Popup windows
Component
Description
LPS 116
Press one button (116) to start or stop UV lamp 116 manually, controlled
by the LPS.
Status indication:
Blue with checkmark = Lit
Blue without checkmark = Off
Grey = Not selectable.
Start all LPS, and thereby all lamps for the AOT reactor. Requires that the
Manual mode button is pressed.
3 StartLPSBut
Stops all LPS, and thereby all lamps for the AOT reactor.
3 StopLPSBut
57
3.23
Popup windows
3 LPS popObe
Description
AOT
Information is displayed for the AOT reactor selected in the AOT number
field.
Fail safe
Displays if LPSs is active and powered on. UV lamps can only be lit if an
LPS is active. When a critical alarm (e.g. no water in the AOT reactor) is
issued, the fail safe function inactivates the LPSs and cut the power.
Status indication: Green = Active. Grey = Not active.
58
3.23
Popup windows
Component
Description
LPS 116
Power optimization
Component
Description
Setpoint
Measured
Power output
Control mode
Manual power
output
Manually set effect to LPS. Requires that the system is set in manual
mode.
59
3.23
Popup windows
Description
Mode
Filter status:
- Idle (No backflush or preservation)
- Backflush preparation
- Backflush ongoing
- Filter preservation.
Diff. pressure
Pressure
Current pressure:
PT20171: Inlet pressure.
PT20172: Outlet pressure.
PT3092: Backflush pressure.
Start backflush
60
4 Operating instructions
This section contains step-by-step instructions for operating the PureBallast system. Please read
and follow the preparations and conditions carefully, as well as any danger or warning notes.
Preparations and conditions
For reference information, see the following sections i this chapter:
Control system pages used in the instructions: See section Control system Detailed page
descriptions.
Login levels required for different procedures: See section Login levels on page 11.
Detailed information about components (valves, motors, pumps etc) involved in each step the
process. See section Detailed process description.
4.1
Log in
Press the expand button on the Log in tab in the top right corner of the screen.
Result: The log in menu is displayed.
2.
Press the expand button on the left drop down menu to display available users. Press desired
user.
Result: A keyboard is displayed.
3.
Enter password and press Enter. (See section Login levels on page 11.)
4.2
Perform ballast
The Alarm list (page 2.1) must be controlled to verify that there are no alarms needing attention.
All ballast system valves outside the PureBallast system must be set in the correct positions
for ballasting. The valve after the ballast pump must be closed (not part of Alfa Lavals scope
of supply).
61
4.3
Perform deballast
Operating instructions
Flow must have been selected before a process can be started. If parameter p131 is activated
maximum flow is automatically selected, and flow can only be changed during process
according to instruction Change ballast / deballast flow on page . If parameter p131 is
deactivated last selected flow is used. Otherwise, flow is selected on page 1.1 Overview or
1.2 AOT and flow selection.
There must be available power for the system. If power management is integrated, this will
be handled automatically. If power management is not integrated, confirm available power
manually.
4.2.1
Start ballasting
2.
Wait for the message Open valves .... Open relevant valves and then press the button in the
popup to confirm the action. Note! These valves are outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
Result: Ballast start-up starts, with cooling water cooling the lamps during warm-up.
3.
Wait for the message Confirm ballast pump started. Start the pump and then press the
button in the popup to confirm the action. Note! This component is outside the PureBallast
system control. (The popup is not displayed if the component feedback is integrated with
the control system.)
Result: Cooling stops and ballasting starts.
4.
When desired amount of water has been processed, press the function button Stop.
Result: Ongoing process is stopped and the lamps are switched off. An automatic filter
backflush is performed.
5.
Wait for the message Close valves .... Close relevant valves and then press the button in
the popup to confirm the action. Note! These valves are outside outside the PureBallast
system control. (The popup is not displayed if the component feedback is integrated with
the control system.)
6.
Wait for the message Stop ballast water pump. Stop the pump and then press the button in the
popup to confirm the action. Note! This component is outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
NOTE
A CIP cleaning process must be performed after ballasting. It can be done immediately or within 30 hours. When
time is about to elaps, a warning is issued. If no action is taken within the time limit, an entry is made in the control
systems log as a deviation from a correct handling of the system. Note, that it is possible to perform processes
during these 30 hours. Complete status information regarding CIP is displayed in page 1.3 CIP status. A CIP
process is started manually according to instruction CIP clean AOT after ballast / deballast on page 65.
4.3
Perform deballast
Operating instructions
4.3
Perform deballast
The Alarm list (page 2.1) must be controlled to verify that there are no alarms needing attention.
All ballast system valves outside the PureBallast system must be set in the correct positions
for ballasting. The valve after the ballast pump must be closed (not part of Alfa Lavals scope
of supply).
Flow must have been selected before a process can be started. If parameter p131 is activated
maximum flow is automatically selected, and flow can only be changed during process
according to instruction Change ballast / deballast flow on page . If parameter p131 is
deactivated last selected flow is used. Otherwise, flow is selected on page 1.1 Overview or
1.2 AOT and flow selection.
There must be available power for the system. If power management is integrated, this will
be handled automatically. If power management is not integrated, confirm available power
manually.
2.
Wait for the message Open valves .... Open relevant valves and then press the button in the
popup to confirm the action. Note! These valves are outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
Result: Deballast start-up starts, with cooling water cooling the lamps during warm-up.
3.
Wait for the message Confirm ballast pump started. Start the pump and then press the
button in the popup to confirm the action. Note! This component is outside the PureBallast
system control. (The popup is not displayed if the component feedback is integrated with
the control system.)
Result: Cooling stops and deballasting starts.
4.
When desired amount of water has been processed, press the function button Stop.
Result: Ongoing process is stopped and the lamps are switched off.
5.
Wait for the message Stop ballast water pump. Stop the pump and then press the button in the
popup to confirm the action. Note! This component is outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
6.
Wait for the message Close valves .... Close relevant valves and then press the button in the
popup to confirm the action. Note! These valves are outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
NOTE
A CIP cleaning process must be performed after deballasting. It can be done immediately or within 30 hours.
When time is about to elaps, a warning is issued. If no action is taken within the time limit, an entry is made
in the control systems log as a deviation from a correct handling of the system. Note, that it is possible to
perform processes during these 30 hours. Complete status information regarding CIP is displayed in page 1.3
CIP status. A CIP process is started manually according to instruction CIP clean AOT after ballast /
deballast on page 65.
63
4.5
4.4
Operating instructions
Follow this instruction to pause an ongoing ballast or deballast process. This instruction is also
used before heeling (internal transfer), if no external signal for heeling mode is integrated between
PureBallast and the vessels ISCS.
Preparations and conditions
This is only possible in sub process full ballast or full deballast. This is indicated by the lit
Pause button.
Allowed length of a pause is parameter set (p138). After defined time, the paused process
is stopped.
2.
Wait for the message Stop ballast water pump. Stop the pump and then press the button in the
popup to confirm the action. Note! This component is outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
Note: If you pause to perform heeling (internal transfer) you confirm the request without
stopping the ballast water pump.
Result: Ongoing process is paused. The UV lamps remains on at reduced power and cooling
water is run through the AOT reactor to cool the lamps. Pause mode is indicated by yellow light
under the Pause button and blinking yellow under the function button Ballast or Deballast.
3.
To resume the paused process, press the function button Ballast or Deballast.
4.
Wait for the message Confirm ballast pump started. Start the pump and press the button in the
popup to confirm the action. Note! This component is outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
Result: The process is resumed.
4.5
2.
3.
64
Operating instructions
4.6
4.7
Follow this instruction to clean the AOT reactor(s) using the cleaning in place (CIP) process.
If system shut down is activated during the CIP process, the CIP liquid is drained to the CIP tank.
Water in the AOT reactors is drained overboard.
Preparations and conditions
The system must be in standby mode. This means that this operation cannot be executed
during ballast or deballast.
Complete status information regarding CIP is displayed in page 1.4 CIP status. The page
displays remaining time for ongoing CIP cycles, remaining time before individual AOT reactors
are required to be CIP:ed etc.
If a ballast operation has been performed since the last CIP process, the process is completed
with a filter preservation, where the filter is filled up with fresh water.
2.
Wait for the message Open valves .... Open relevant valves and then press button in the
popup to confirm the action. Note! These valves are outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
Result: The automatic CIP process starts. The CIP process takes about 25 minutes per
AOT reactor, if default parameters are used.
3.
Wait for the message Close valves .... Close relevant valves and then press button in the
popup to confirm the action. Note! These valves are outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
4.7
Follow this instruction to stop an ongoing ballasting or deballasting operation. Each ballast and
deballast operation must be stopped manually.
Follow the steps below:
1.
When desired amount of water has been processed, press the function button Stop.
To get a smooth stop, the flow from the ballast pump can be reduced, but not more than 50 %.
Result: Ongoing process is stopped and the lamps are switched off. If ballasting, an automatic
backflush is performed before the system is stopped.
2.
Wait for the message Stop ballast water pump. Stop the pump and then press the button in the
popup to confirm the action. Note! This component is outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
3.
Wait for the message Close valves .... Close relevant valves and then press the button in the
popup to confirm the action. Note! These valves are outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
65
4.8
Attend to alarms
Operating instructions
NOTE
A CIP cleaning process must be performed after ballasting and deballasting. It can be done immediately or
within a 30 hours. When time is about to elaps, a warning is issued. If no action is taken within the time
limit, an entry is made in the control systems log as a deviation from a correct handling of the system. Note,
that it is possible to perform processes during these 30 hours. Complete status information regarding CIP is
displayed in page 1.3 CIP status.
4.8
Attend to alarms
Follow this instruction to attend to alarms and warnings. For descriptions of alarms and trouble
shooting, see chapter 5. Alarms and faultfinding.
An alarm or warning is indicated by a audible signal and by a blinking alarm icon:
Warning: Warnings are notification of a status change or a problem. Warnings
allow the process to continue.
2 Warning
Alarm: Alarms stop the ongoing process, which can be restarted after the
problem has been attended to.
3Alarm
If the alarm is caused by a faulty AOT reactor, the AOT reactor will shut down but the process
will continue with remaining AOT reactors.
NG
WARNI
Never reset an alarm without first finding and attending to the problem.
2.
If the process have stopped: Take action to eliminate what has caused the alarm.
3.
If the process continues: Consider if the process shall be terminated. Take action to eliminate
what has caused the alarm.
4.
After the problem has been dealt with Press the Ack all button to acknowledge all alarms, or
press the alarm row and press Ack selected button to acknowledge only this alarm.
Result: The alarm will change color to indicate change of status. See section Page 2.1 Alarm
list in this chapter. The acknowledge time is updated, and the Normal time will be updated
when the problem is resolved.
66
Operating instructions
4.9
4.9
Follow this instruction to quickly stop any ongoing operation in the PureBallast system, for example,
when a critical fault has been detected, or to make the system deactivated (currentless).
Lamp drive cabinet
Control cabinet
3 Emergency stop
Method
Stop ongoing
process
3StopButtonBlue
Shut down
67
4.11
Operating instructions
Action
Method
Deactivate
PureBallast to
make it completely
deactivated
(currentless).
Operating instructions
UV lamp effect.
4.11
It is not possible to run any processes in manual mode. Only individual components can be
operated.
When operating valves, the positioning screw on the valve must be in position 0: Closed
(default position).
2.
3.
3 PopValve
4.
Press (not slide) the Hand button icon to enable manual operation of the component.
Result: The open and closed buttons turn blue for operation. A hand icon is also displayed on
the component in the popup and the flow chart to indicate that it is manually operated.
5.
Operate the component using the open/run (left) and closed/not running (right) buttons in
the popup.
69
4.12
Operating instructions
6.
Press Hand button to stop manual mode for the component and the X button to close the popup.
or
Press the X button to close the popup and let the component remain in manually set status.
The popup is closed, and a hand icon is displayed by the component to indicate it is manually
operated.
7.
NGE
! DA
Manual start of the UV lamps is only allowed (and possible) when there is water in the AOT
reactor (indicated by level switch LS201-29), and the water temperature is below 60 C. All
necessary items cooling water flow, water temperature, and power management must be
supervised and verified by the authorized trained personnel operating the system. Inappropriate
operation of this function could seriously damage the equipment and injure personnel.
Go to page 1.1 Overview. Press the Manual function button to activate manual mode.
2.
3.
Select which AOT reactor to operate in the AOT number entry field.
4.
Open, in stated order, the following valves to fill the AOT reactor with water: 201-19, 404-36
and 403-35.
Result: The AOT reactor is now filled with water through the cooling water line 403.
5.
Wait until the AOT reactor is filled with water, indicated by the level switch (LS20129) turning
green.
70
6.
Operating instructions
4.13
7.
Press the Manual mode button to enable manual operation of the UV lamps.
8.
9.
If desired, the UV lamps can be dimmed manually: Press the LPS status button in the AOT
reactor popup. Press the Manual output filed, and enter desired percentage between 50
and 100 %. The LPS will give the entered percentage of full effect to the UV lamps. This is
indicated in the Power output field.
71
4.14
Operating instructions
IDs are only displayed in the control panel it is entered. If desired the settings can be entered in
remote control panels (optional).
2.
3 ShipIDComp
3.
4.
72
Operating instructions
4.14
Information to be
exported
Description
Event log
The event log includes all important events in the PureBallast system. The
log also include components connected via the log box. Intended to be
used mainly by service technicians.
Alarm history
A list of all alarms and warnings that has been issued from the control
system. Intended to be used mainly by service technicians.
For specific information about logged events, see section List of logged information on page 89.
Preparations and conditions
Events are only copied, hence they will remain in the control system.
Required USB memory capacity is indicated in the Export PLC events popup.
The easiest way of reading the log file is to use the program Visualog, but the file can also be
read in Exel. See Read event log in Excel below.
2.
3 ExportLog
3.
Wait for message: Insert USB in PLC. Insert a USB memory in USB PLC port on the cabinet
door.
73
4.15
4.
Operating instructions
Chose one of the following alternatives to decide time interval for the information to be copied:
Accept suggested default time interval in the Start and End fields. Default start date is the
oldest file in the system, and default end date is todays date.
Select the Specify time interval box, and enter desired interval in the Start and End fields.
5.
Press one of the following function buttons: Events, Cert events or Alarms.
Result: The information is copied to the USB memory indicated by a green checkmark on
the button during copying.
6.
Wait for the message "Export OK" to appear. If desired, export next category of events using
the function buttons.
Result: A folder named PureBallast has been saved to the USB. It contains three sub folders:
Alarm, Cert and Event. The folder corresponding to your export choices contains a CSV file.
7.
2.
Add two new columns to the furthers left. (They will become new column A and B.)
3.
4.
5.
Write =C2/(60*60*24)+$H$1 in cell A2. (It is important that all characters are correct, so it is
better to type the formula rather than copying this text.)
6.
74
Operating instructions
4.15
Port 1 must be used for the Ethernet cable at the backside of the panel. It is marked with the
symbol below.
3 USB
2.
3.
3 IPaddress
4.
3 IPaddress
Press OK.
6.
Repeat this instruction for all installed control panels, both main and remote control panels, if
installed.
75
4.16
7.
Operating instructions
Follow the instruction Set remote control panel communication to activate remote control panel.
IP addresses must have been set according to instruction Set control panel IP address.
Main control panel and remote control panel 1 (192.168.0.11) are added as default . If no
remote control panelse is used, address 192.168.0.11 shall be removed.
All remote control panels must be on and connected with an Ethernet cable.
On the main panel in the control cabinet: Go to page 4.1 System info.
2.
3 RCP communication
3.
4.
76
Operating instructions
4.18
5.
Press the Panel alias field for the new control panel. Use the keyboard to enter a name, for
example the location it is placed.
Note: Panel alias for all control panels shall be entered (with the same wording) in all panels
to be displayed in a correct way.
6.
7.
8.
2.
Set parameters to match ISCSs RTU server data according to the information in chapter 4.
Parameters, section 5.7 Remote interface.
Go to page 4.5 Remote interface 1. Make sure that the system is not in test mode (no
checkmark on the button). If not, press the Test mode button to deactivate it. Make sure that
Local operation is activated. If not, press the Local function button.
77
4.18
2.
Operating instructions
Check that the heartbeat signal is updated in both systems (+006 and +077). Also check
that values are read from the PureBallast system, for example temperature (address +116
and +117).
This will confirm that the systems communicate.
2.
Enter actual values in the in the input field for the address to send simulated information to
the ISCS. Information in decimal form, for example processed volume, is written as actual
values. Information in binary form, for example command status, is written as a bit pattern.
The key for the bit pattern is found in chapter 6. Installation description and drawings, section
System interfaces.
3.
Make sure that values and status information is displayed correspondingly in the ISCS.
4.
2.
Make sure that the command is received in page 4.5. Use the directory of addresses to see
that the bit pattern is updated correctly.
78
3.
Operating instructions
4.19
In the control panel, restore all changed values after the communication test. If not, commands
might be executed involuntarily, when the system is set to online again. Most important is that
address 001 displays 00000000.
Enter the desired bit pattern in the input field for the address.
2.
3.
If common alarm and warnings are used, make sure that address +070:7 and +070:8 are
updated. It is only necessary to check this for the first alarm.
4.
5.
6.
Press the Test mode button to set the system in online mode (no check mark on the button).
Press the Remote function button if you want to activate remote control.
79
4.21
Operating instructions
2.
Press the hand button in the Request column for a row with power step for desired number of
AOT reactors. For details, see description of page 1.4 Power request.
3.
Press the Request button for the row to simulate power request signal.
Result: Status is updated to Requested in the Request column.
4.
5.
6.
7.
Press the Set run button to deactivate the simulate running signal.
8.
2.
3.
Take a backup according to instruction Export control system log files on page 72. The files
are required to be saved for at least 24 months. The log files are erased when the software is
updated.
Take a backup according to instruction Backup control system settings. Note that this backup is
not used to reload settings, it is only a safety backup.
We recommend that a screen dump is taken for all parameter pages. (To do that: Insert a USB
memory in USB panel port on the cabinet door and press function button Utilities, and Print for
all pages.) Alternatively, take a photo. This will facilitate resetting of the parameters.
80
Operating instructions
4.22
The release notes must have been read for the version to be installed.
Shut off the power to the control cabinet using the main breaker on the side of the cabinet.
2.
Pull out the Ethernet cable from port IF2 ETH in the PLC module.
3.
Turn on the power to the control cabinet and wait for the panel to restart. Let the power to
the control cabinet remain on. Ignore the message Disconnected from remote alarm server,
it is due to the unconnected Ethernet cable. It is reconnected at the end of the Update HMI
software instruction.
4.
Next step is to install TA150 firmware, if needed. If not, next step is to install the HMI software.
At the rear side of the main control panel: Pull out the power cable from the 24V DC port.
Open the small cover on the rear side. Turn DIP switch 1 to position ON.
7BeijerMODE
2.
Insert a USB memory with the TA150 firmware in USB panel port on the cabinet door.
Reconnect the power.
3.
Wait for requests to update and delete project. Answer Yes to both. (If you dont get the
question, set DIP switch to OFF, and try again. Or copy the files to another type of USB
memory.)
Result: The new software is updated to the panel.
4.
Wait for message: Remove USB memory to continue. Remove the USB.
81
4.23
Operating instructions
5.
Wait for message: Please reboot panel to complete update. Pull out the power cable and
reconnect it to restart the panel.
(If the reboot request does not appear on the screen (some older panels freeze), pull out the
power cable and reconnect it to restart. When the panel restarts, the reboot request will not
appear, since the panel was already restarted.)
6.
When the panel has restarted, tap the screen within 10 seconds. Press Touch calibrate:
Follow the instructions on screen.
7.
In the menu displayed: Press IP settings, and set according to instruction Set control panel
IP address on page 74. (This must be done, since the older IP setting was deleted during
installation of the new TA150 firmware.) . The firmware is now installed.
8.
Let the panel remain with the menu displayed and the DIP switch in position ON.
9.
USB with correct version of the software. Note that the same version must be used for the HMI
and PLC software (same version number).
At the rear side of the main control panel: Pull out the power cable from the 24V DC port.
Open the small cover on the rear side. Turn DIP switch 1 to position ON.
7BeijerMODE
2.
Re-connect the power cable and wait for the panel to restart. (If the system requests a touch
calibration, perform it.)
3.
82
Operating instructions
4.24
4.
Press Erase project in the menu. Answer Yes in the popup. Wait for the popup to close.
5.
At the rear side: Pull out the power cable from the control panel, turn DIP switch 1 to position
OFF.
6.
Insert a USB memory with the HMI software in USB Panel port on the cabinet door. Reconnect
the power.
7.
Wait for the message Copy project from USB. Press Yes.
8.
Wait until the program is started and page 1.1 Overview is displayed. Ignore the message
Disconnected from remote alarm server, it is due to the unconnected Ethernet cable.
9.
10. If remote control panels are installed, repeat this instruction for all remote control panels. Do
not forget to update TA150 firmware if needed.
11. Make sure that the CF light on the PLC module is green. (It takes approximately 10 minutes
from the PLC software is loaded.)
12. Insert the Ethernet cable in port IF2 ETH in the PLC module.
13. Restart the system: Shut off the power to the control cabinet using the breaker at the side,
and then turn it on again.
Pull out the power cable from the 24V DC port on the rear side of the control panel.
2.
Open the small cover on the rear side. Turn DIP switch 1 to position ON.
7BeijerMODE
83
4.26
Operating instructions
3.
Re-connect the power cable. Wait for a cross is displayed on the screen.
4.
Press the cross until it changes position. Repeat until the menu is displayed again.
Result: Calibration is ready.
5.
6.
7.
Audit trail (tracking of actions in the control system, e.g. acknowledged alarms, changed
parameter values). Saved in file AuditTrail.sdf.
Parameters. It is only possible to restore parameters to the same version of the PLC software
as the back-up was taken from.
Settings for trend pages, e.g. min and max values for different components. Saved in file
ValueTrendLegend.xml.
2.
3.
Press the Backup button in page section Backup and restore, Settings to/from HMI USB.
Result: A popup is displayed and the process is started. All activities are displayed as the occur.
Read the final line of list before closing the popup: Important information might be displayed.
4.
Wait for the OK / Close button to turn blue again. If the backup was successful, the last line
shall state "Backup done".
Result: A folder named PureBallast backup has been downloaded containing the backup files.
5.
Operating instructions
4.27
Parameters can only be restored to the same version of the PLC software.
A USB memory with backup files. When the files where backuped, the backup files where
saved in a folder named PureBallast Backup. For information about backup files, see section
Backup and restore in the page description for 4.1 System info, section on page 38.
This method shall not be used to restore parameter settings after software update. Instead,
follow instruction Update PLC software using a flash card.
If you do not wish to update a certain type of setting, remove the specific file from the USB
memory before inserting the USB memory in the USB panel port on the cabinet door.
2.
3.
Press the Restore button in page section Backup and restore, Settings to/from HMI USB.
Result: A popup is displayed and the process is started. All activities are displayed as the occur.
4.
5.
Read the final line of list before closing the popup: Important information might be displayed. If
the restore was successful, the last line shall state "Restore done".
6.
Press the OK button on the popup and remove the USB memory.
7.
The control panel must be rebooted. At the rear side of the control panel: Pull out the power
cable from the 24V DC port, and insert it again.
Database, including alarm history, trend history etc. Saved in file Database.sdf.
Audit trail (tracking of actions in the control system, e.g. acknowledged alarms, changed
parameter values). Saved in file AuditTrail.sdf.
Settings for trend pages, e.g. min and max values for different components. Saved in file
ValueTrendLegend.xml.
2.
85
4.28
Operating instructions
3.
Press the Backup button in page section Backup and restore, History to HMI USB.
Result: A popup is displayed and the process is started. All activities are displayed as the
occur. Be sure to read the final line of list before closing the popup: Important information
might be displayed.
4.
When the message Export done is displayed, press the OK button on the popup.
Result: A folder called PureBallast Export is created on the USB memory.
5.
All components on page 3.1 Trend (15 min) shall be selected for plotting, and FIT201-1 shall be
used for Y axis selection.
86
Operating instructions
4.28
5. See if the time between backflush initiation and backflush can be shortened . If possible, adjust
parameter p310. See parameter p310 in the example below.
Example
In this example, five backflushes are performed. After the first four backflushes, the PID parameters
where changed for pressure regulation to adjust the movement of the control valve V201-8 before
the backflush.
The illustration is taken from page 3.1 Trend (15 min). Backflush is indicated by the movement
of the backflush valve 309-1 (pink line) and the movement of control valve V201-8 is indicated
by the blue line.
1st backflush
Parameter p166 is set to 0.30. But it takes too long time for V201-8 to get into
position to create desired pressure (1). The curve slops downwards in a long bend,
which means that it takes time for V201-8 to find correct position.
2nd backflush Parameter p166 was adjusted to 0.6. This made the valve movement much faster
in the beginning, shown by the steep curve at the beginning. But then a more slow
regulation starts, shown by the soft slope (2). This was a change for the better, but
not enough.
3rd backflush Parameter p166 was increased to 1.2 which resulted in a satisfactory valve
movement (3): A fast movement, followed by a minor adjustment. A small
overcompensation can be noted (curve goes too low), that might be adjusted by
decreasing the value to 1.1.
4th backflush During the first backflushes, parameter p310 was set to 60 seconds. The parameter
defines time between a backflush is triggered and it actually starts. But now, when
V201-8 is calibrated, this time can be shortened. Before the fourth backflush
parameter p310 is set to 15 seconds. The shortened time span is indicated by
the braces in the illustration.
5th backflush No parameter was changed. This backflush is only showed to confirm that the
parameter setting is OK and that the curve (5) for V201-8 is basically the same as
for backflush three and four (3 and 4).
87
4.28
Operating instructions
3 CalibExample
88
5.1
Event log
The table below shows which information that is saved in the log file.
The GPS stamp column indicates if the event is stamped with GPS position (Y=yes, N=no).
Event
code
Description
GPS
stamp
89
5.1
Event log
Event
code
90
Description
GPS
stamp
N
Book No.9010182 02, rev. 0
Event
code
Description
5.1
Event log
GPS
stamp
1153
5011 Log box: Valve V01 position change: [X]. 1=Open. 0=Not open.
5020 Log box: Valve V02 position change: [X]. 1=Closed. 0=Not closed.
5021 Log box: Valve V02 position change: [X]. 1=Open. 0=Not open.
5030 Log box: Valve V03 position change: [X]. 1=Closed. 0=Not closed.
91
5.1
Event log
Event
code
Description
GPS
stamp
5031 Log box: Valve V03 position change: [X]. 1=Open. 0=Not open.
5040 Log box: Valve V04 position change: [X]. 1=Closed. 0=Not closed.
5041 Log box: Valve V04 position change: [X]. 1=Open. 0=Not open.
5050 Log box: Valve V05 position change: [X]. 1=Closed. 0=Not closed.
5051 Log box: Valve V05 position change: [X]. 1=Open. 0=Not open.
5060 Log box: Valve V06 position change: [X]. 1=Closed. 0=Not closed.
5061 Log box: Valve V06 position change: [X]. 1=Open. 0=Not open.
5070 Log box: Valve V07 position change: [X]. 1=Closed. 0=Not closed.
5071 Log box: Valve V071 position change: [X]. 1=Open. 0=Not open.
5080 Log box: Valve V08 position change: [X]. 1=Closed. 0=Not closed.
5081 Log box: Valve V08 position change: [X]. 1=Open. 0=Not open.
5090 Log box: Valve V09 position change: [X]. 1=Closed. 0=Not closed.
5091 Log box: Valve V09 position change: [X]. 1=Open. 0=Not open.
5100 Log box: Valve V10 position change: [X]. 1=Closed. 0=Not closed.
5101 Log box: Valve V10 position change: [X]. 1=Open. 0=Not open.
5110 Log box: Valve V11 position change: [X]. 1=Closed. 0=Not closed.
5111 Log box: Valve V11 position change: [X]. 1=Open. 0=Not open.
5120 Log box: Valve V12 position change: [X]. 1=Closed. 0=Not closed.
5121 Log box: Valve V12 position change: [X]. 1=Open. 0=Not open.
5130 Log box: Valve V13 position change: [X]. 1=Closed. 0=Not closed.
5131 Log box: Valve V13 position change: [X]. 1=Open. 0=Not open.
5140 Log box: Valve V14 position change: [X]. 1=Closed. 0=Not closed.
5141 Log box: Valve V14 position change: [X]. 1=Open. 0=Not open.
5150 Log box: Valve V15 position change: [X]. 1=Closed. 0=Not closed.
5151 Log box: Valve V15 position change: [X]. 1=Open. 0=Not open.
5160 Log box: Valve V16 position change: [X]. 1=Closed. 0=Not closed.
5161 Log box: Valve V16 position change: [X]. 1=Open. 0=Not open.
92
Event
code
Description
5.1
GPS
stamp
5170 Log box: Valve V17 position change: [X]. 1=Closed. 0=Not closed.
5171 Log box: Valve V17 position change: [X]. 1=Open. 0=Not open.
5180 Log box: Valve V18 position change: [X]. 1=Closed. 0=Not closed.
5181 Log box: Valve V18 position change: [X]. 1=Open. 0=Not open.
Event log
93
5.1
Event log
6.1
Standby mode
Standby mode is the starting point of PureBallast. Standby mode is active at system start-up or
when no other process is active. From Standby mode, the following processes and sub processes
can be started.
Ballast
Deballast
CIP
Deactivate system
Manual mode.
95
6.2
Ballast process
6.2
Ballast process
The ballast process and sub processes are illustrated and described below. Note that the process
can be stopped at any time.
3 BallastProcess
6.2.1
Ballast start-up
2.
Request from control system to open overboard (outside PureBallast system). (Handled
automatic, if external component signal is enabled.)
3.
Overboard valve opened by operator and confirmed in control system. (Handled automatic, if
external component signal is enabled.)
Component activities:
4.
96
- Start P401-1 (booster pump for LDC cooling water) (if used)
- Open V403-35 (cooling water inlet)
- Open V201-32 (filter outlet)
Start P403-1 (booster pump for reactor cooling water) (if used).
Power management
Automatic power request from PureBallast to vessels power management system (if
integrated).
5.
6.2
Ballast process
UV lamp warming
Component activities:
6.
Cooling water fills the AOT reactors. When filled, indicated by LS201-29:
7.
Request from control system to start ballast water pump (outside PureBallast system).
(Handled automatic, if external component signal is enabled.)
8.
9.
6.2.2
Full ballast
After 2 minutes in full ballast: Start power optimization based on input from UV sensor
QT20150.
6.2.3
Filter backflush
Purpose: To clean the filter when clogged. This sub process is either triggered by too high
differential pressure or by time set interval. It can also be started manually. It is normally repeated
several times during a ballast process.
1. Filter backflush triggered by high differential pressure over filter.
Component activities:
Start automatic control of control valve (V201-8) based on input from the pressure transmitter
Open V309-1
Start M709-42.
97
6.2
Ballast process
Stop M709-42
Close V309-1
Start automatic control of control valve (V201-8) based on input from the flow meter.
6.2.4
Purpose: To pause the ballast process temporarily. During pause, the lamps are cooled with
cooling water, sea-to-sea. This mode is also used during heeling (internal transfer).
1. Operator pause the ballast process manually. Pause can also be initiated by an external signal,
for example when heeling is initiated from the ISCS. In this case, the process is resumed
automatically when the heeling signal is deactivated.
2. Set V201-8 (control valve) to parameter (p113) set opening percent.
3. Request from control system to stop ballast water pump (outside PureBallast system). (Handled
automatic, if external component signal is enabled.)
4. BW pump stopped by operator and confirmed in control system. Component activities:
- Open V404-36 (AOT reactor outlet, cooling water) on running AOT reactors
- Stop counter: Accumulated water
- Open V403-35 (cooling water inlet)
Start P403-1 (booster pump for reactor cooling water) (if used)
- Close V201-3 (filter inlet)
- Close V201-20 (reactor outlet) on running AOT reactors
- UV lamps dimmed to 50 %
Resume ballasting
Operator resumes the ballast process manually.
Component activities:
7. Request from control system to start ballast water pump (outside PureBallast system).
(Handled automatic, if external component signal is enabled.)
8. BW pump started by operator and confirmed in control system. (Handled automatic, if external
component signal is enabled.)
98
6.2
Ballast process
6.2.5
Stop ballast
Stop P401-1 (booster pump for LDC cooling water) (if used)
Stop P403-1 (booster pump for reactor cooling water) (if used), only needed if stop from
pause mode
- Close V403-35 (cooling water inlet), only needed if stop from pause mode
- Set V201-8 (control valve) to parameter set opening percent.
- Close V201-32 (filter outlet) Delay: the longes time between of p146 and p119.
2. Filter backflush
Backflushing of filter starts, including the following activities:
- Start automatic control of control valve (V201-8) based on input from the pressure
transmitter
- Open V309-1
- Start M709-42.
- Stop M709-42
- Close V309-1.
4. Request from control system to stop ballast water pump (outside PureBallast system). (Handled
automatic, if external component signal is enabled.)
5. BW pump stopped by operator and confirmed in control system.
6. Request from control system to close overboard. (Handled automatic, if external component
signal is enabled.)
99
6.3
Deballast process
6.3
Deballast process
The deballast process and sub processes are illustrated and described below. Note that the
process can be stopped at any time.
3 DeBallastProcess
6.3.1
Deballast start-up
- Start P401-1 (booster pump for LDC cooling water) (if used)
- Open V403-35 (cooling water inlet)
Start P403-1 (booster pump for reactor cooling water) (if used).
4. Power management
Automatic power request from PureBallast to vessels power management system (if integrated).
100
6.3
Deballast process
5. UV lamp warming
Component activities when power has been granted:
8. Request from control system to start ballast water pump (outside PureBallast system). (Handled
automatic, if external component signal is enabled.)
9. BW pump started by operator and confirmed in control system.
Component activities:
6.3.2
Full deballast
After 2 minutes in full ballast: Start power optimization based on input from UV sensor
QT20150.
6.3.3
Purpose: To pause the deballast process temporarily. During pause, the lamps are cooled with
cooling water, sea-to-sea. This mode is also used during heeling (internal transfer).
101
6.3
Deballast process
1. Operator pause the deballast process manually. Pause can also be initiated by an external
signal, for example when heeling is initiated from the ISCS. In this case, the process is resumed
automatically when the heeling signal is deactivated.
Component activities:
- Start P403-1 (booster pump for reactor cooling water) (if used)
- Open V404-36 (AOT reactor outlet, cooling water) on running AOT reactors.
2. Request from control system to stop ballast water pump (outside the PureBallast system
control). (Handled automatic, if external component signal is enabled.)
Component activities:
5. Request from control system to start ballast water pump (outside PureBallast system).
(Handled automatic, if external component signal is enabled.)
6. BW pump started by operator and confirmed in control system.
Component activities:
6.3.4
Stop deballast
102
6.4
CIP process
Stop P401-1 (booster pump for LDC cooling water) (if used)
Stop P403-1 (booster pump for reactor cooling water) (if used), only needed if stop from
pause mode
Close V403-35 (cooling water inlet), only needed if stop from pause mode
Close V201-9 (main inlet valve) Wait for feed back closed or delay according to p 115.
2. Request from control system stop ballast water pump (outside PureBallast system). (Handled
automatic, if external component signal is enabled.)
3. BW pump stopped by operator and confirmed in control system.
Close V201-8
4. Request from control system to close overboard. (Handled automatic, if external component
signal is enabled.)
6.4
CIP process
The CIP process is run to remove seawater scaling from the AOT reactor after ballast and deballast.
The process is performed for used AOT reactor in sequence. The process can start directly
after ballast or deballast process, or be delayed. A CIP process is started manually according
to instruction CIP clean AOT after ballast / debalalst on page 65. Note that the process can be
stopped at any time.
103
6.4
CIP process
3 CIPprocess
6.4.1
Start CIP
6.4.2
1.
104
6.4
CIP process
6.4.3
1.
Stop P321-5
Close V571-1 (CIP, deaeration valve)
Close V460-2 (CIP, drain valve)
Close V3212 (AOT reactor, upper CIP return valve)
Close V3204 (AOT reactor, lower CIP return valve).
Component activities:
6.4.4
1. Component activities:
2. Component activities when AOT reactor is empty, indicated by LS201-29 + drain time (p200):
6.4.5
CIP cleaning
1. Component activities:
2. When AOT reactors are filled, indicated by LS201-29, CIP liquid is circulated for 15 minutes.
Book No.9010182 02, rev. 0
105
6.4
CIP process
6.4.6
CIP draining
1. Component activities:
2. Component activities, when AOT reactor is empty, indicated by LS201-29 + drain time (p200):
6.4.7
1.
Component activities:
6.4.8
Repeat
When CIP process is done for the first AOT reactor, the remaining AOT reactors with status CIP
required are processed in the same way.
6.4.9
Filter preservation
Only performed if ballast has been performed since last filter preservation.
106
1.
6.5
Manual mode
- Open V310-1
- Open V309-1
- Start M709-42.
- Stop M709-42
- Close V309-1
- Close V310-1.
3. Request from control system to close overboard valve (outside PureBallast system). (Handled
automatic, if external component signal is enabled.)
4. Overboard valve closed by operator and confirmed in control system.
6.5
Manual mode
PureBallast can be set in manual mode, which enables the operator to operate components
manually and to set digital outputs.
The following can be performed in manual mode:
Operate components from the flow chart. Tap a component to operate it from the displayed
popup window. The following components can be operated: valves, motors, UV lamps etc,
digital output signals.
Requires login level 2. The Manual mode button is only displayed for login level 2.
To activate: Press the Manual mode button in page 1.1 Flow chart and follow the instructions
Operate UV components manually and Operate UV lamps manually.
To deactivate: Press the Manual mode button again in page 1.1 Flow chart or log out. All forced
outputs and manual changes are reset and the system goes to Standby mode.
107
Introduction
This is a quick guide to the most common routines performed in the PureBallast control system.
More detailed instructions are found in the PureBallast manual.
This guide covers the following routines:
The Alarm list (page 2.1) must be controlled to verify that there are no alarms needing attention.
Flow must have been selected before a process can be started. If parameter p131 is activated
maximum flow is automatically selected, and flow can only be changed during process
according to instruction Change ballast / deballast flow on page . If parameter p131 is
deactivated last selected flow is used. Otherwise, flow is selected on page 1.1 Overview or
1.2 AOT and flow selection.
There must be available power for the system. If power management is integrated, this will be
done automatically. If power management is not integrated, confirm this manually.
1.2
2.
3.
Wait for the message Open valves .... Open relevant valves and then press the button in
the popup to confirm the action. (The popup is not displayed if the component feedback is
integrated with the control system.)
4.
Wait for the message Confirm ballast pump started. Start the pump and then press the button
in the popup to confirm the action. (The popup is not displayed if the component feedback is
integrated with the control system.)
5.
When desired amount of water has been processed, press the function button Stop to end
the process.
rev. 0
1.4
6.
Wait for the message Close valves ... and Stop ballast water pump. Handle accordingly.
(The popups are not displayed if the component feedback is integrated with the control system.)
7.
Perform a CIP process if no operation is planned soon. A CIP process must be performed
within 30 hours after operation.
1.3
Alarm handling
Follow this instruction to attend to alarms and to acknowledge them afterwards. For descriptions of
alarms and trouble shooting, see chapter 5. Alarms and fault finding.
An alarm is indicated by a audible signal and by a blinking warning icon in the control panel.
Preparations and conditions
Never reset an alarm without first finding and attending to the problem.
2.
3.
If the process have stopped: Take action to eliminate what has caused the alarm.
4.
If the alarm is caused by a faulty AOT module, the ballast/deballast process has to be restarted
with another AOT according to the Perform ballast instruction.
5.
If the process continues: Consider if the process shall be terminated. Take action to eliminate
what has caused the alarm.
Press the Ack selected or Ack all button after the problem has been dealt with.
1.4
The system must be in standby mode. This means that this operation cannot be executed
during ballast or deballast.
Complete status information regarding CIP is displayed in page 1.4 CIP status. The page
displays remaining time for ongoing CIP cycles, remaining time before individual AOTs are
required to be CIP:ed etc.
2.
3.
Wait for the message Open valves .... Open relevant valves and then press button in the
popup to confirm the action.
Result: The automatic CIP cycle starts. The CIP cycle takes about 25 minutes per AOT.
Book No.9010182 02
, rev. 0
4.
1.5
Wait for the message Confirm overboard valve closed. Close the valve and then press button
in the popup to confirm the action.
1.5
Follow this instruction to copy control system information as text files to a USB memory.
Preparations and conditions
2.
3.
Wait for message: Insert USB in PLC. Insert a USB memory in USB PLC port on the cabinet
door.
4.
Chose one of the following alternatives to decide time interval for the information to be copied:
Accept suggested default time interval in the Start and End fields. Default start date is the
oldest file in the system, and default end date is todays date.
Select the Specify time interval box, and enter desired interval in the Start and End fields.
5.
Press one of the following function buttons: Events, Cert events or Alarms.
Result: The information is copied to the USB memory indicated by a green checkmark on
the button during copying.
6.
Wait for the message "Export OK" to appear. If desired, export next category of events using
the function buttons.
Result: A folder named PureBallast has been downloaded. It contains three sub folders:
Alarm, Cert and Event. The folder corresponding to your export choice contains a CSV file.
7.
rev. 0
Chapter: 4. Parameters
System manual PureBallast 3.0 Flow 750
Book No.
Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00
Telefax:
Contents
1
Introduction
2.1
Setting parameters
2.2
2.3
Set parameters
2.4
10
2.5
14
2.6
18
2.7
22
2.8
25
2.9
26
2.10
29
31
3.1
32
35
4.1
35
4.2
36
1 Introduction
This chapter contains information about parameters in the control system and flow transmitter.
It covers:
Parameter lists including information about setting range, default values etc.
Introduction
Only authorized trained personnel must set parameters in the control system both manual
operations and parameter settings. The PureBallast equipment or connected equipment can be
irreparably damaged if set or handled incorrectly.
NOTE
To change system parameters, at least login level 2 Advanced operator is required. To get
full access, login level 3 AlfaLava is required.
The parameter settings can be exported to a USB memory for safety backup, and be restored
from a backup. See chapter 3. Operating instructions and control system description for
instructions.
Parameters are valid for PLC software version V3.0.2.
2.1
Setting parameters
General (non-installation specific) parameters are preset to function for all systems. They must only
be adjusted, by Alfa Laval (or authorized trained personnel), if required by performance reasons
or similar.
The installation specific parameters are set to reflect the specific installation and shall normally only
be checked and adjusted at first start up, during preparations for commissioning.
The installation specific parameters are found in the pages listed below:
p200, p201, p208 and p216: Time-out parameters for draining and filling AOT reactor.
These parameter are evaluated during the commissioning preparation test and adjusted if
necessary.
2.3
Set parameters
p306: Filter preservation time. This parameter is evaluated during the commissioning
preparation test and adjusted if necessary.
2.2
This section describes the principles for the control system parameters and the parameter pages.
Parameters are roughly sorted by area, for example AOT reactor, filter and remote interface,
but the sorting is not strict.
Key to parameter numbers
Control system parameters are identified by item numbers with the following syntax: pX00.
p
00
2.3
Set parameters
These instructions require login level 2 or 3. Level 2 gives access to set parameters, with
exception from crucial parameters, which requires level 3.
2.
2.3
Set parameters
To see allowed range (maximum and minimum values) and change setting, press the blue
button (with the parameter ID). A button pair is displayed.
4 ParaIntervalSet
Press the sign to display range. Entered parameter value must be within defined setting
range.
4 MinMax
3.
4.
Enter the setting and confirm by touching the Enter button. To close the keyboard without
saving data, touch the Esc button.
If the parameter is set with a drop down menu, select desired choice by touching the value.
Result: The setting is saved directly, it is now safe to leave the page.
2.4
2.4
This section describes the main system parameters set in page 5.1 Main parameters 1.
4 5.1
Parameter
p100
High pressure,
shutdown trigger
(PT201-16)
Default
value
MinMax
Unit
Description
7.00
110
bar
p101
10
High pressure,
warning trigger
(PT201-16)
6.00
010
bar
2.4
ID
Parameter
Default
value
MinMax
Unit
Description
p103
Low pressure,
warning trigger
(PT20116)
0,0
-12
bar
p105
Transition trigger,
ballast flow
established
(FIT201-1)
p111
Undershoot
certified flow
p113
10
500
m3/h
080
20
10100 %
p115
Maximum travel
time for valves
10
230
sec
p116
10
1090
p117
024
hrs
p118
030
day
p119
Valve travelling
time for 201-8
110
sec
11
2.4
ID
Parameter
p120
V2018 PID
proportional gain
Default
value
0.30
MinMax
Unit
Description
0.00
10.00
N/A
p121
V2018 PID
integral time
7.00
0100
sec
p122
V2018 PID
derivative gain
0.0
0.0100.0N/A
p126
LDC after-cooling.
(Stop delay for
401-1, if installed)
060
min
p138
Timeout: Time
in Pause before
going to Stop
130
min
p140
Timeout:
Request "Confirm
overboard valve
open"
130
min
p141
Timeout: Request
"Confirm ballast
pump started"
130
min
12
ID
Parameter
p143
Timeout: Power
granted signal not
received
2.4
Default
value
60
MinMax
Unit
Description
1300
sec
60
30300 sec
p144
Timeout: Start-up
ballast flow
established
p145
Sequence step
delay
05
sec
p146
System valve
close delay
015
sec
p149
Timeout: Time in
Auto pause before
going to stop
10300 sec
45
13
2.5
2.5
This section describes the main system parameters set in page 5.2 Main parameters 2.
4 5.2
Parameter
Default
value
MinMax
Unit
Description
p127
Power
management
Not
used
N/A
Drop
list
14
Alternatives:
Not used
Hardwire ranged
Hardwire fixed
2.5
ID
Parameter
Default
value
MinMax
Unit
p128
Max time
communication
loss PLC/remote
interface
60
15240 Sec
Description
p129
Booster pump
(P401-1) for LDC
cooling water
Not
used
N/A
Drop
list
p130
Booster pump
(P403-1) for
reactor cooling
water
Not
used
N/A
Drop
list
p132
Remote interface
via modubus
Not
used
N/A
Drop
list
p135
External shut
down signal
Not
used
N/A
Drop
list
p137
Hide Pause
button
Not
used
N/A
Drop
list
15
2.5
ID
Parameter
Default
value
MinMax
Unit
Description
p160
GPS
Not
used
N/A
Drop
list
p161
1.0
0.1
60.0
Min.
p162
1.0
0.1
60.0
Min.
p163
Additional
by-pass signal
1
N/A
Drop
list
Not
used
Additional
by-pass signal
2
Not
used
N/A
Drop
list
p165
Additional
by-pass signal
3
Not
used
N/A
Drop
list
p166
Pressure PID
proportional gain
0.60
0.00
10.00
N/A
16
2.5
ID
Parameter
Default
value
MinMax
Unit
Description
p167
Pressure PID
integral time
7.0
0.0
100.0
sec
p168
Pressure PID
derivate gain
0.0
0.0
100.0
N/A
17
2.6
2.6
This section describes parameters controlling the AOT reactor set in page 5.3 AOT parameters.
4 5.3
Parameter
p200
Timeout: AOT
draining
p201
Timeout: Reactor
cooling water
(LS201-29)
18
Default
value
2
MinMax
Unit
Comment
15
min
110
min
2.6
Unit
ID
Parameter
Default
value
MinMax
p202
High temp,
alarm trigger
(TT201-33)
60
10100 C
p204
Low temp,
alarm trigger
(TT201-33)
040
p206
010
sec
p208
115
min
p210
UV lamp warm-up
time
90
090
sec
p211
UV lamp cooling
time
120
30300 sec
p212
Timeout: UV
lamp ignition
200
10200 sec
p214
High temp,
warning trigger
in LDC (TT401-1)
45
20100 C
Comment
010
sec
p216
Timeout: Fluid
fill-up time AOT
210
min
19
2.6
ID
Parameter
Default
value
MinMax
Unit
Comment
p220
UV intensity
sensor
Not
used
N/A
Drop
list
p221
Low UV intensity
warning trigger
550.0
0.0
500.0
p230
Cabinet
temperature
hysteresis
(TT401-2)
2.0
1.05.0 C
p231
Cabinet
temperature
low threshold
(TT401-2)
40.0
20.0
60.0
p232
Cabinet
temperature
high threshold
(TT401-2)
45.0
20.0
60.0
p234
UV control
proportional gain
0.10
0.00
100.00
N/A
p235
UV control
integral time
15
0100
sec
p236
UV control
derivative time
0100
sec
20
2.6
ID
Parameter
Default
value
MinMax
Unit
Comment
p237
Power
optimization
Activated
N/A
Drop
list
p238
p239
High
temperature,
warning trigger
in LDC (TT401-2)
50.0
Enable circuit
breaker data
Not
used
20.0
100.0
N/A
Drop
list
21
2.7
2.7
This section describes parameters controlling the filter module set in page 8.4 Filter parameters.
4 5.4
Parameter
p301
p304
22
Default
value
MinMax
Unit Comment
High filter
differential
pressure,
warning trigger
(PT201-27)
0.50
0.00
0.1
bar
Required
pressure to
start backflush
(PT201-16)
2.50
1.00
5.00
bar
ID
Parameter
2.7
Default
value
MinMax
Unit Comment
Backflush trigger,
differential
pressure
(PT201-27)
0.5
0.00
1.00
bar
130
min
Backflush cycle
time
20
1
100
sec
p309
Time controlled
backflush interval
30
1
120
min
p310
Backflush initial
delay
10
060
sec
p311
Backflush delay
(p305 during x
sec).
2.0
0.0
10.0
sec
p312
V201-8 min
position during
backflush
20
1550
p306
Filter
preservation time
p308
23
2.7
ID
Parameter
p313
Differential
pressure
measurement
filter
Default
value
MinMax
Unit Comment
030
sec
p314
Filter type
Type
1
N/A
p315
Filter size
6000
100
6000
24
2.8
2.8
This section describes parameters controlling the CIP module set in page 5.5 CIP parameters.
4 5.5
Parameter
p400
Default
value
MinMax
Unit
Comment
15
160
min
25
2.9
2.9
This section describes the installation specific system parameters set in page 5.6 Installation
parameters.
4 5.6
Parameter
p106
No of AOT
reactors installed
26
Default
value
1
MinMax
Unit
Comment
16
p112
Maximum flow
(FIT201-1)
2.9
1200
0
10000
m3/h
p131
Automatic AOT
selection
Not
used
N/A
Drop
list
p213
p217
Allowed no. of
failed UV lamps
per AOT reactor
01
No.
300
N/A
Drop
list
27
2.9
p218
Estimated UV
lamp lifetime
p150
EX proof system
3 000
Not
used
0
20000
hrs
N/A
Drop
list
p500
Log box
Not
used
N/A
Drop
list
28
2.10
4 5.7
Parameter
Default
value
MinMax
Unit
Comment
p700
Interface type
RS485
N/A
Drop
list
29
2.10
p701
Baud rate
9600
N/A
Drop
list
p702
Parity
No
parity
N/A
Drop
list
Defines parity.
The parameter can be changed, but
it is not recommended. Note, that the
information must be the same in ISCS
and PureBallast control system.
Alternatives: None, Odd, Even, High,
Low.
p703
p704
30
Data bits
Stop bits
N/A
N/A
Drop
list
Drop
list
Alternatives: 7 or 8.
Alternatives: 1 or 2.
4FTPanel
Buttons used:
4FTLock
4FTChange
4FTBack
4FTFwd
4FTSelect
Padlock
Change
Back
Forward
Select
4FT_Topup
Top up
31
3.1
3.1
Follow this instruction to check and set parameters in the flow meter.
1.
2.
To enter password (1000): Press Padlock. (A line appears under the first zero.)
- Press Change to change the first 0 to 1.
- Press Padlock to set the value.
- Result: The Basic settings menu appears after two seconds.
3.
4.
Press Forward until Qmax is displayed. Check that the parameter is set according to pipe
dimension for the flow meter pipe:
Pipe - Qmax (m3/h)
100 300
150 300
200 700
250 1200
300 1200
350 1700
400 2200
150 2200
500 2200
600 2200
- To change: Press Padlock.
- Press Select to select digit to change (A line is placed under the changeable digit).
- Press Change to change (toggle) the digit.
- Press Padlock to set the value.
Set Empty pipe
5.
Press Forward until Empty pipe is displayed. Check that the parameter is set to On.
- To change: Press Padlock.
- Press Change to change (toggle) the setting.
- Press Padlock to set the value.
Set Empty pipe (Activates alarm when flow meter is empty.)
6.
7.
8.
Press Padlock to display the setting. Check that the parameter is set to On.
- To change: Press Padlock.
- Press Change to change (toggle) setting.
- Press Padlock to set the value.
Set Current output 4-20 mA
32
9.
3.1
Press Forward until Current output (mA setting) is displayed. Check that the parameter is
set to 4-20 mA.
- To change: Press Padlock.
- Press Change to change (toggle) setting.
- Press Padlock to set the value.
33
3.1
4.1
The table below show the correct settings for respective LPS.
Switch 1-3 shall always be in position off. Switch 4-8 is set to identify the individual LPS according
to the table below. Only position ON is indicated. For empty cells in the table, the switch shall
be in position off.
LPS nr.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
SW 4
SW 5
SW 6
SW 7
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
SW 8
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
Example
In the illustration, the DIP switches is set for LPS no. 5.
35
4.2
7 LPSdipEx
4.2
Follow this instruction to change the DIP switch settings for an LPS. Note that the DIP switch
settings for LPS shall only be changed if faulty, indicated by all LEDs lit in LPS in combination with
alarm A130 in the control system.
Preparations and conditions
ANGER
D
!
Switch off the main breaker on the LDC door. The LPS has high voltage/power (600 V) inside
and on the lamp power connector, even when UV lamps are not lit.
Unscrew the plastic lid (1) over the DIP switches on the fron of the LPS.
7 LPSdip
2.
36
Use a small screw driver to change position of the swithces according to the table under
instruction DIP switch settings.
3.
4.
4.2
37
Book No.
Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00
Telefax:
Contents
1
Introduction
2.1
Control system
2.1.1
2.1.2
2.1.3
Alarm indication
Key to the table of alarms and warnings
List of alarms and warnings
7
7
8
2.2
49
2.2.1
49
2.3
Flow meter
50
2.3.1
2.3.2
2.3.3
50
51
51
2.4
Level switch
54
2.5
56
2.5.1
57
63
3.1
General problems
63
3.2
Filter
66
3.3
CIP
68
3.4
Valve V2018
71
1 Introduction
This chapter covers information about alarms and warnings, together with information about how
to solve the problems causing the alarms to trip. The chapter also contains a list of solutions for
problems that may occur, but that is not indicated by any system.
The chapter contains lists of alarms indicated by:
control system
See chapter 3. Operating instructions and control system description to find information about
the alarm pages and how to attend to alarms.
Introduction
2.1
Control system
This sub section lists all alarms and warnings in the PureBallast control system. The alarms are
sorted in a strict numerical order.
2.1.1
Alarm indication
An alarm is indicated by a audible signal and by a blinking warning icon in the control panel.
3Alarm
2 Warning
All alarms are displayed in the control panels page 2.1 Alarm list and are sorted in order of
occurrence; most recent alarm at the top of the list.
2.1.2
The table below explains the information given in the alarms list table. The table contains the
following columns and information:
Column in
table
Description
Alarm ID
Identification number of the alarm. The number is also indicated in the control
system alarm list.
Alarm ID:s are composed of the following elements: L100
A = Alarms stop the ongoing process, which can be restarted after the
problem has been attended to.
2.1
Control system
Alarm text /
Problem
1: If the alarm contains three digits, the first digit indicates component
according to: 1=AOT reactor and 2 =Filter. If the alarm contains two digits,
the alarm is general and is not connected to a specific component.
The text displayed in the control system. Note that AOT reactor number is
indicated by x in the table, instead of the actual AOT reactor number. In the
control system alarm text, the actual AOT reactor number is stated for the AOT
reactor concerned.
For problems not indicated by an alarm, the text gives a general explanation
of a problem that can occur.
Trigger /
Parameter
Trigger: Source of the alarm or warning, identified by the input sensors item
number or equivalent.
Parameter: The parameter controlling the alarm, when applicable.
Description
Possible
cause
What to do?
2.1.3
The table below explains alarms triggered by and displayed in the control system.
See next page.
A01
Trigger / Parameter
Trigger: PT201-16
Process
Parameter: p100
pressure too
high (PT201-16).
Automatic stop.
Comment: Pressure
transmitter PT201-16
indicates pressure
higher than set in
parameter p100.
Delay: 2 sec.
Description
Material is stocked
after pressure
transmitter PT201-16
(i.e. in an AOT
reactor).
Pressure transmitter
PT201-16 is faulty.
What to do?
Possible cause
2
2.1
Control system
Trigger / Parameter
Trigger: PT201-16
Process
pressure
signal missing
(PT201-16).
Automatic stop.
Trigger: PT201-16
Process
Parameter: p101
pressure too
high (PT201-16).
A03
10
W04
Comment: Pressure
higher than parameter
set limit.
See A01.
What to do?
Signal missing
or pressure
transmitter PT201-16
malfunction.
Possible cause
Control system
Delay: 2 sec.
Comment: Error
in system pressure
sensor. Indication of
pressure -1.0 bar (-0.1
MPa) is not an error.
Delay: 2 sec.
Description
2.1
List of alarms and warnings
Trigger: FIT201-1.
Parameter: N/A
A10
Process flow
signal missing
(FIT201-1).
Trigger / Parameter
Comment: Error in
system flow sensor.
Delay: 5 sec.
Description
What to do?
Flow meter
malfunction.
Flow transmitter
FIT201-1 malfunction
(no text on the
transmitter display,
message error)
Possible cause
2
2.1
Control system
11
12
Trigger: FIT2011
Parameter: N/A
Process
flow higher
than certified
(FIT201-1).
Reduce flow!
W12
A13
Trigger: FIT2011
Parameter: p116
Trigger / Parameter
Comment: If flow
is less than set in
parameter p116, the
system is shut down.
Delay: 20 sec.
Delay: 30 sec.
Description
Flow sensor
malfunctions.
Flow sensor
malfunctions.
Increase flow.
Control system
Wrong setting in
FIT201-1.
Wrong setting in
FIT201-1.
What to do?
Possible cause
2.1
List of alarms and warnings
Trigger: FIT201-1
Parameter: p105
A14
Process
flow too low
during start-up
(FIT201-1).
Automatic stop.
Trigger / Parameter
Delay: Set in
parameter p144.
Description
What to do?
Ballast water
pump stopped or
malfunctions
Valves in ballast
system closed.
Possible cause
2
List of alarms and warnings
2.1
Control system
13
14
A17
Valve error
(V201-3).
Trigger / Parameter
Comment: Error on
valve V2013.
Delay: 15 sec.
Description
What to do?
Control system
Position sensor
mounted upside
down.
Position sensor is
not in correct position
to sense indicator
screws. Position
screws are in wrong
position.
Fuse tripped.
Possible cause
2.1
List of alarms and warnings
A23
Comment: Error on
valve V2019.
Delay: 15 sec.
Description
Valve cannot
open/close due to
obstruction.
Too long
opening/closing time
(valve travel time)
1. Check cables.
Position sensor or
cables to position
sensor malfunction.
2. Replace position sensor if
faulty.
What to do?
Possible cause
Valve error
(V201-9).
Trigger / Parameter
2
2.1
Control system
15
16
A29
Valve error
(V201-8).
Trigger / Parameter
Comment: Error on
control valve V2018.
Delay: 15 sec.
Description
What to do?
Control system
Positioner is not
correcly set or
calibrated.
Sensor error.
Shows open all
the time.
Possible cause
2.1
List of alarms and warnings
Bypass valve is
open (V212-31).
Valve error
(V212-31).
Process
pressure too low
(PT201-16).
A33
A35
W40
Trigger: Pressure
transmitter:
PT201-16.
Parameter: p103.
Trigger / Parameter
Delay: 2 sec.
Comment: Shutdown
of all steps except CIP.
The alarm does not
prevent completion or
start of CIP process.
Delay: 15 sec.
Comment: If valve
V212-31 is in open
position, ballast or
deballast is cancelled.
The bypass valve is
not controlled by the
PureBallast system.
Delay: 15 sec.
Description
What to do?
Pressure transmitter
PT201-16 is faulty.
Possible cause
2
2.1
Control system
17
18
Trigger: Shutdown
button on control
cabinet
Parameter: N/A
Shutdown
activated
(Shutdown
button).
Shutdown
activated during
CIP (Shutdown
button).
Shutdown
activated
(External
system).
Shutdown
activated during
CIP (External
system).
A48
A49
A50
A51
Trigger: External
shut down signal.
Parameter: p135
Trigger: External
shut down signal.
Parameter: p135
Trigger: Shutdown
button on control
cabinet
Parameter: N/A
Trigger / Parameter
Delay: None.
Delay: None.
See A50.
Manual shutdown
from the ISCS
(integrated ship
control system).
See A48.
Delay: None.
Delay: None
Possible cause
Description
NOTE
NOTE
What to do?
2.1
Control system
2
List of alarms and warnings
Trigger: Control
cabinet.
Parameter: N/A
Fuse tripped in
control cabinet.
Additional
bypass valve
1 is open.
Additional
bypass valve
2 is open.
Additional
bypass valve
3 is open.
W58
A66
A67
A68
Trigger: External
system.
Parameter: p165
Trigger: External
system.
Parameter: p164
Trigger: External
system.
Parameter: p163
Trigger / Parameter
Delay: 5 sec.
Delay: 5 sec.
Delay: 5 sec.
Delay: None.
Description
overheated fuse
See A66.
See A66.
short circuit
Possible reasons:
overload
Possible cause
What to do?
2
List of alarms and warnings
2.1
Control system
19
20
Trigger: Control
system timer.
Parameter: p141.
Ballast water
pump is
not running.
Automatic stop.
Overboard valve
is not open.
Automatic stop.
Error on all
operating
AOT:s.
Automatic stop.
A71
A75
A77
If remote interface
(optinal) is used:
Communication
between PureBallast
and ISCS is wrong.
What to do?
Faulty connection of
signal cable.
Possible cause
Comment: All
AOT reactors are
deactivated.
Delay: None
Comment: Feedback
overboard valve is
OPEN.
Delay: Set in
parameter p140.
Delay: Set in
parameter p141.
Description
Control system
Trigger: AOT
reactors
Parameter: N/A
Trigger: Control
system timer.
Parameter: p140
Trigger / Parameter
2.1
List of alarms and warnings
Trigger: Control
system timer.
Parameter: p127.
Power is
not granted.
Automatic stop.
Power is not
fully granted.
Flow capacity
reduced.
W79
W80
Comment: No
power steps have
been granted within
parameter set time.
Delay: Set in
parameter p143.
Description
Trigger: Power
Delay: None.
management system.
Comment: Not all
Parameter: p127.
requested power steps
are granted. Triggered
if number or requested
power steps does
not match number of
granted power steps.
Trigger / Parameter
What to do?
Power management
master system not
granting power for
one or more AOT
reactors.
Possible cause
2
List of alarms and warnings
2.1
Control system
21
22
Trigger: Heeling
(internal transfer)
requested in control
system.
Parameter: N/A
Heeling mode
requested
by operator.
Automatic
pause.
Heeling mode
cancelled
by operator.
Process
resumed.
PLC lost
communication
with all control
panels.
W82
W83
A91
Trigger: Control
system PLC.
Parameter: N/A
Trigger: Heeling
(internal transfer) not
requested in control
system.
Parameter: N/A
Trigger / Parameter
Possible cause
Comment: After
60 seconds of lost
communication,
ongoing process is
stopped in a controlled
way and the system
is shut down. This
message is visible in
the control panels and
saved in the log after
the communication is
restored. But, W92 will
be visible in the master
control panel.
Delay: 60 sec.
Comment: Process
is resumed after being
phased during heeling.
Delay: None.
Wrong network
setting
Control system
2
3. Replace if faulty.
What to do?
Wrong software
version
Delay: 2 sec.
Description
2.1
List of alarms and warnings
Trigger / Parameter
Trigger: Control
system PLC.
Parameter: N/A
Master control
panel lost
communication
with the PLC.
W92
A93
See A91.
Faulty cable
connection.
See A91.
Faulty cable
connection.
Master panel is
switched off or faulty.
What to do?
Possible cause
2.1
Comment: After
1. Set the system to Local mode: Press the Local button
on the control panel.
communication is
lost between ISCS
2. Run the system from the control panel. Note that you
and PLC, ongoing
will need to confirm two messages from the control
process is stopped in a
panel during operation: "Confirm ballast pump started"
controlled way and the
and "Confirm overboard valve open".
system is shut down.
3. Restore these settings when the communication is
The Heartbeat field
working.
in page 4.5 Remote
4. Make sure that the system is not in test mode in page
interface, indicates
4.5 Remote interface (no check mark on the Test
communication.
mode button).
Delay: Set in
parameter p128.
Comment: After
communication is lost,
ongoing process is
stopped in a controlled
way and the system
is shut down. This
message is visible
in the master control
panel.
Delay: 30 sec.
Description
2
Control system
23
Trigger / Parameter
Description
24
What to do?
Control system
Faulty cable
connection.
Faulty settings.
Possible cause
2.1
List of alarms and warnings
Trigger: Control
system PLC.
Parameter: N/A
PLC error in
control cabinet.
W95
W96
W97
Trigger: N/A
Parameter: N/A
Trigger: Control
system PLC.
Parameter: p160
Trigger / Parameter
Delay: 2 sec.
Delay: 5 sec.
Delay: 10 sec.
Description
Faulty electrical
connection.
Error in module.
Faulty electrical
connection.
ISCS is faulty.
The voltage in the
battery in the control
system PLC is too
low.
See W92.
What to do?
Communication
between PLC and
master control panel
is lost.
Possible cause
2
Control system
25
26
What to do?
High temperature
due to obstacles or
error in one or more
components involved.
Possible cause
Check/change parameter in
control system page 5.3 AOT
parameters.
Replace transmitter TT20133
according to instruction in
chapter 7. Service manual
section Temperature switch and
temperature transmitter.
TT201-33.x
malfunction.
Control system
Trigger: AOT
Delay: Set in
temperature
parameter p206.
transmitter TT201-33.
Comment: If
Parameter: p202
temperature rises
above parameter set
value, the AOT reactor
will shutdown.
W100
Description
Trigger / Parameter
2.1
List of alarms and warnings
Parameter: N/A.
What to do?
2.1
Possible cause
AOT [x]:
AOT temp
signal missing
(TT201-33).
AOT shutdown.
W102
Trigger: AOT
temperature
transmitter TT201-33
error.
Trigger: AOT
Delay: Set in
temperature
parameter p206.
transmitter TT201-33.
Parameter: p204.
W101
Description
Trigger / Parameter
2
Control system
27
28
Trigger: LDC
temperature
transmitter TT401.
Parameter: p214
AOT [x]:
LDC cabinet
temp missing
(TT4011).
W107
W109
Trigger: LDC
temperature
transmitter TT4011.
Parameter: N/A
Trigger / Parameter
Incoming cooling
water too warm.
Delay: 5 sec.
No cooling water to
the heat exchanger.
Signal missing or
transmitter TT401
malfunction.
Control system
Incoming cooling
Check and attend to.
water valve V4011
and/or outgoing valve
blocked or closed.
What to do?
Possible cause
Description
2.1
List of alarms and warnings
Trigger:
Temperature
transmitter TT4012.
Parameter: p238
W111
LDC air
temperature too
high (TT4012)
Trigger / Parameter
Delay: 15 sec.
Description
LDC faulty.
Faulty fan.
What to do?
Faulty connection to
X20 module.
Possible cause
2
List of alarms and warnings
2.1
Control system
29
30
Trigger:
Temperature
transmitter TT4012.
Parameter: N/A
W113
LDC cabinet
temperature
missing
(TT4012)
Trigger / Parameter
Description
What to do?
Control system
Possible cause
2.1
List of alarms and warnings
W116
Description
Trigger / Parameter
Possible cause
What to do?
2
2.1
Control system
31
32
No fluid in AOT
reactor x.
LS201-29.x is
indicating dry
condition.
W118
Possible cause
A117
Description
Trigger / Parameter
Control system
2.
What to do?
2.1
2
List of alarms and warnings
AOT [x]: No
freshwater
filling in AOT
(LS201-29).
A119
Description
Trigger / Parameter
What to do?
No liquid in
AOT reactor x.
LS201-29.x is
indicating dry
condition.
Possible cause
2
List of alarms and warnings
2.1
Control system
33
34
W120
Description
Trigger / Parameter
What to do?
See W116.
Control system
Possible cause
2.1
List of alarms and warnings
W122
W126
Trigger / Parameter
Comment:
MCB=Motor circuit
breaker. AOT reactor
is deactivated.
Delay: 1 sec.
Delay: 1 sec.
Description
Possible cause
What to do?
2
2.1
Control system
35
36
Q117.
W128
W129
Trigger: Water
sensor LS below
heat exchanger in
LDC.
Parameter: N/A
Trigger / Parameter
Delay: 5 sec.
Delay: 5 sec.
Description
Faulty electrical
connection.
See above.
Control system
Condensation in the
cabinet.
Repair.
Faulty fan.
Leakage in cooling
water piping.
What to do?
Possible cause
2.1
2
List of alarms and warnings
Trigger: Lamp
power supply in AOT
reactors LDC.
Parameter: N/A
AOT [x]: UV
system failure.
Too many failed
lamps.
Estimated UV
lamp lifetime
exceeded.
A130
W131
W132
Delay: 2 sec.
Description
Delay: 1 sec.
Trigger / Parameter
Lifetime for UV
lamps are too
exceed according
to estimated lifetime
in parameter.
What to do?
LPS malfunction.
UV lamp OK signal
malfunction.
Possible cause
2
List of alarms and warnings
2.1
Control system
37
38
Trigger: TS201-60
Parameter: N/A
A137
Trigger / Parameter
Comment: AOT
reactor is deactivated.
Delay: 1 sec.
Description
Check components.
Control that valves and pumps are
functioning.
The LDC needs to be reset, see
above in this alarm description.
Check that the signal wiring
is according to electrical
drawings.
Check that all electrical
connections are OK and that
the electrical wiring is not
damaged.
Reset LDC
See W100.
What to do?
No flow in AOT
reactor or too low
flow.
Possible cause
2.1
Control system
2
List of alarms and warnings
CIP schedule
timer elapsed
Start CIP!
A138
W140
W150
Delay: Set in
parameter p117 and
p118.
Comment: AOT
reactor is deactivated.
Delay: 2 sec.
Description
Trigger: UV sensor
Delay: 20 sec.
QT201-50.
Parameter: p220 and Comment: The
warning is issued if
p221.
the UV intensity falls
below value set in
parameter p221.
Trigger: Control
system timer.
Parameter: N/A.
Trigger / Parameter
Old UV lamps.
Low UV intensity in
AOT reactor.
Error in module.
Possible cause
Check water.
What to do?
2
List of alarms and warnings
2.1
Control system
39
40
Trigger: UV sensor
QT201-50.
Parameter: p220.
W151
AOT [x]:
UV intensity
signal missing
(QT201-50)
Trigger / Parameter
See W150.
Transmitter
QT201-50.x
malfunction.
Control system
What to do?
Possible cause
Comment: The
Signal missing.
warning is issued if
the UV intensity falls
below 484 w/m2. Power
is set to 100% for the
AOT reactor and the
flow is reduced.
Delay: 20 sec.
Description
2.1
List of alarms and warnings
W161
Trigger: LPS
Parameter: N/A
Faulty LPS.
Faulty connection of
electricity or signal
cable.
Delay: 1 sec.
AOT [x]: No
response from
LDC. AOT
shutdown.
W160
Delay: 1 sec.
W153
Trigger: N/A.
Parameter: N/A
Delay: None.
Trigger: UV sensor
QT201-50.
Parameter: p221
and p237
What to do?
AOT [x]: UV
intensity low.
System flow
reduced.
Possible cause
W152
Description
Trigger / Parameter
2
List of alarms and warnings
2.1
Control system
41
42
Trigger: None.
Parameter: p239
AOT [x]:
Circuit breaker
communication
error.
W162
W163
W164
W165
Warning is active
if parameter p239
Enable circuit breaker
data is activated.
Delay: None.
Description
Faulty modubus
signal cable.
Possible cause
Driver fault
Fan fault
Heat sink fault
System fault
Voltage fault
Faulty LPS.
Replace.
What to do?
Control system
Trigger / Parameter
2.1
List of alarms and warnings
Valve error
(V20119)
Valve error
(V20120)
LDC ring
redundancy
error
Filter: Sum
alarm.
W170
W171
W180
W300
Trigger: Filter.
Parameter: N/A
Parameter: N/A
Parameter: N/A
Parameter: N/A
Trigger / Parameter
Comment: The
feedback signal Filter
SUM alarm is not
detected.
Delay: 1 sec.
Delay: None.
Delay: 15 sec.
Delay: 15 sec.
Description
Broken UV lamp
Motor problem.
What to do?
Faulty connection of
signal cable
Possible cause
2
Control system
43
44
Trigger: Pressure
transmitter PT201-27
on Boll filter.
Parameter: p314.
W304
Filter pressure
signal missing
(PT201-27).
Trigger / Parameter
Comment: Error in
pressure transmitter.
Indication of pressure
-1.0 bar (-0.1 MPa) is
not an error.
Delay: 2 sec.
Description
What to do?
Control system
Filter candle is
jammed, preventing
the flushing arm to
rotate.
Possible cause
2.1
List of alarms and warnings
Trigger: Pressure
transmitter PT201-27
on Boll filter.
Parameter: p301,
p314.
W306
Filter differential
pressure
too high
(PT-20127)
Trigger / Parameter
Delay: 2 sec.
Description
Pressure transmitter
PT201-27 does not
work correctly.
Valves connected
to filter differential
pressure transmitter
closed.
What to do?
Filter is clogged.
Relative pressure in
filter is below 0 bar.
Possible cause
2
Control system
45
Trigger: Pressure
transmitter PT201-71
on Hydac filter.
Parameter: p314.
W308
46
Signal missing
or component
malfunction.
Possible cause
2. Use the circuit diagram to
check the fuse setting, adjust
according to figures in circuit
diagram if necessary and reset
fuse.
What to do?
Delay: 2 sec.
Description
Control system
Filter pressure
signal missing
(PT201-71)
Trigger / Parameter
2.1
List of alarms and warnings
W314
Filter pressure
signal missing
(PT309-2)
W312
Trigger: Pressure
transmitter on filter.
Parameter: N/A.
Delay: 15 sec.
Delay: 2 sec.
Delay: 2 sec.
Description
See W306.
See W308.
See W308.
See W308.
Possible cause
What to do?
W315
Trigger: Pressure
transmitter PT201-72
on Hydac filter.
Parameter: p314.
Filter pressure
signal missing
(PT201-72)
W310
Trigger: Pressure
transmitter PT309-2
on Hydac filter.
Parameter: p314.
Trigger / Parameter
2
2.1
Control system
47
48
W500
Trigger / Parameter
Description
Check connections and cable for
power cable (W10) and Ehternet
cable (W104) between Control
cabinet and Log box.
Check fuse F02 and F03 in the log
box.
Check the LED error indication for
the electronic modules in the log
box. See section I/O system and
X20 modules on page 56.
What to do?
Faulty cable
connection.
Possible cause
2.1
Control system
2
List of alarms and warnings
2.2
2.2
This section explains alarms triggered by and displayed on the lamp power supply (LPS) in the
lamp drive cabinet (LDC). LPS alarms are indicated in the control system by alarm A130 Sum
alarm LPS unit.
2.2.1
The table below explains alarms triggered by and displayed in the LPS.
LED indication key
The LPS is equipped whit four light indications:
LPS on and communication is functioning.
5 LPSledG
5 LPSledG2
5 LPSledY
Broken UV lamp.
5 LPSledB2
Faulty DIP switch setting on one or more LPS. This fault occur after a 10 seconds
delay after start.
49
2.3
Flow meter
2.3
Flow meter
This section explains alarms triggered by and displayed in the flow transmitter, mounted on the flow
meter (FIT201-1). An alarm is indicated by two flashing triangles on the flow transmitter. During
normal conditions, all relevant alarms are displayed in the PureBallast control panel.
4FlowT_Alarm
Alarm time is displayed as time elapsed since the error occurred, and is showed as days, minutes
and hours.
Alarms and status are displayed in two lists, accessible from the Service mode screen in the flow
transmitter:
Status log list. All errors are stored in the log for 180 days.
2.3.1
1.
2.
Connection board
4.
5.
50
6.
2.3
Flow meter
Connection board
The transmitter is OK. Check the following: Settings, application, installation, sensor, earthing,
connections etc.
8.
The transmitter still not OK? Change settings according to chapter 4. Parameters, section
Flow transmitter parameters.
9.
If the problem cannot be detected or corrected, the transmitter must be replaced according to
the instruction Mount flow transmitter. Note that it is not necessary to reset parameters in the
new transmitter. The settings are stored in the Sensorprom unit. When the new transmitter is
replaced, settings are downloaded automatically.
2.3.2
Follow this instruction to check the error list in the flow meter.
Buttons used:
4FT_Topup
Top up
4FTLock
4FTChange
4FTFwd
4FTBack
Padlock
Change
Forward
Back
1.
2.
To enter password (1000): Press Padlock. (A line appears under the first zero.)
- Press Change to change the first 0 to 1.
- Press Padlock to set the value.
- Result: The Basic settings menu appears after two seconds.
3.
4.
Press Padlock, and then Forward until the Error pending menu appears.
5.
6.
2.3.3
The table below explains alarms triggered by and displayed in the flow transmitter.
51
2.3
Flow meter
Problem ID
Description
Output
signals
7A
Empty
display
Minimum
N/A.
7B
Undefined
7C
52
N/A.
What to do?
No power supply
Power supply
Check flow transmitter for
bended pins on the connector
Flow transmitter
defective
Current output
disabled
Digital output
disabled
Reverse flow
direction
Change direction
F70
W31
F60
Internal error
P42
Transmitter
defective
P41
Initializing error
N/A.
Measuring flow
sensor (pipe)
empty
Electrode
connection
missing/electrode
cable is
Problem ID
Description
Output
signals
2.3
Flow meter
What to do?
insufficiently
screened
7D
Unstable flow
signal
Unstable N/A.
Pulsating flow
Conductivity of
medium too low
Electrical noise
potential between
medium and
sensor
Air bubbles in
medium
Measuring
error
Undefined
Maximum
N/A.
Incorrect
installation
Check installation
P40
No Sensorprom
unit
P44
CT Sensorprom
unit
F61
Deficient
Sensorprom unit
F62
Wrong type of
Sensorprom unit
F63
Deficient
Sensorprom unit
F71
Loss of internal
data
Replace transmitter
W30
Flow exceeds
100% of Qmax.
W21
Pulse overflow
53
2.4
Level switch
Problem ID
Description
Output
signals
What to do?
N/A.
Missing one
electrode
connection
Check cables
7F
Measuring
approx. 50%
7G
Loss of
totalizer data
OK
W20
Initializing error
7H
Signs in
display:
#####
OK
N/A.
7I
N/A.
Clogged sensor
electrodes in
sensor tube
7J
Negative flow
is indicated
N/A.
Flow meter is
mounted the
wrong way round.
Parameter Flow
direction is
incorrectly set.
2.4
Level switch
This section explains the different status indications on the level switch LS201-29 in the AOT
reactor. Alarms and status are indicated by LED:s on the module.
Color
State
Description
Green
Steady
Green
Off
No power supply.
Yellow
Steady
Wet condition.
54
What to do?
2.4
Level switch
Red
Blinking
Red
Steady
55
2.5
2.5
This section explains the different status indications on the X20 modules. Alarms and status are
indicated by LED:s on the module.
All modules are identified on the front, for example X20 DO 6529 in the illustration below. To the
right, the stat indication LEDs are visible, for example r, e, X, I in the illustration below.
5X20
56
2.5
Function
Installed in cabinet
CP3485-1
Control cabinet
DO6529
DO module, 6 x relay
Control cabinet
IF1082-2
Control cabinet
PS2100
Control cabinet
AO4622
Analogue output
Control cabinet
Lamp drive cabinet
DIF371
Digital input
Control cabinet
Lamp drive cabinet
DO6529
Digital output
Control cabinet
Lamp drive cabinet
DO9322
Control cabinet
Lamp drive cabinet
AI4622
Analogue input
AT4222
BC0083
CS1030
Interface module
IF1030
S9400
2.5.1
Below, alarm and status indications displayed on the modules are explained.
NOTE
Note that all status indications are not valid for all modules.
The meaning of a status indication might vary for some modules. These variations are specified
in the Description column.
Module BC083, CP3485-1 and IF1082-2 are described in separate tables below the generic
table.
57
2.5
Light
Color
State
Description
Light
Color
State
Description
Green
Red
Off
Single flashes
Blinking
On
Off
Single flashes
Double flashes
r+e
X
I
On
Red/Green Red - steady /
Green - single
flashes
Off
Orange
On
Red
Off
Yellow
16
Orange
18
Green
112
Orange
112
Green
116
Green
On
Off
On
On
58
2.5
Light
Color
State
Description
12
Green
Off
Blinking
On
14
Orange
Status
RxD
Green
Red
Yellow
Off
On
On
On
On
TxD
Yellow
On
Tx
Yellow
On
Rx
Yellow
On
Yellow
On
Module BC0083
Light
L/A IF1 Green
L/A IF2
S/E
Red
Color
Description
On
Blinking
On
Blinking
Green
Off
Green
Green
59
2.5
Light
Color
Green
Green
Green
Green
Single flash
(approx. 1 Hz)
Double flash
(approx. 1 Hz)
Triple flash
(approx. 1 Hz)
Blinking
(approx. 2.5
Hz)
Description
Module CP3485-1
R/E
RD/F
60
Green
Red
Yellow
Red
On
On
On
On
Application is running.
Service mode.
Service or boot mode.
Over-temperature.
S/E
Green
/Red
Green
on
Green
off
Red
off
Red
on
Blinking
alternately
Green
off
EPL
Green
ETH
Green
CF
Yellow
Green
Yellow
Red
DC
OK
Red
blinking
On
Blinking
On
Blinking
On
On
On
On
2.5
Powerlink OK.
Fatal and irreparable system error. See control
system for alarm or warning. This status can only
be changed by resetting the module.
The powerlink managing node failed. This error
code can only occur in controlled node operation.
This means that the set station number lies within
the range $01 - $FD.
System failure according to blinking pattern:
Pause Pause: RAM error.
Pause Pause: Hardware error.
Link to powerlink remote station is established.
On and Ethernet activity present on the bus.
Link to Ethernet remote station is established.
On and Ethernet activity present on the bus.
Flash card OK.
Flash card active.
CPU power supply OK.
Backup battery is empty.
Module IF1082-2
The status/error light is a green/red dual LED. The interface can be operated in two moedes: Either
in Powerlink V mode or as an Ethernet TCP/IP interface. Status light depends on mode. For
TCP/IP mode, only SE green is valid.
Light
L/A X1
L/A X2
S/E
Green
Green
On
Off
Color
Red
On
Blinking
Off
On
Blinking alternately
Off
Red blinking
Description
Link to the remote station is established.
On and Ethernet activity present on the bus.
TCP/IP mode: Powerlink interface is operated purely as
an Ethernet TCP/EP interface.
Powerlink mode: Powerlinkt station is running, no errors.
Fatal and irreparable system error. See control system
for alarm or warning. This status can only be changed by
resetting the module.
The powerlink managing node failed. This error code can
only occur in controlled node operation. This means that
the set station number lies within the range $01 - $FD.
System failure according to blinking pattern:
Pause Pause: RAM error.
Pause Pause: Hardware error.
61
2.5
Module DIF371
Light
S
Green Red
Description
Off
Single
flash
Blinking
On
Off
Off
Off
Prepoerational mode.
Off
Off
On
Run mode.
Module not supplied or everything is OK.
Invalid firmware
Single
flash
62
3.1
General problems
63
Description
Problem
ID
1A
64
General problems
What to do?
Possible cause
3.1
List of problems and solutions
1D
Communication is broken
If control panels are used: See the What to do column
between remote control panel for alarm A91.
and PLC.
If control panels are not used: Remove IP address for
Remote control panel 1 according to instruction is set
for the remote control panel. See chapter 3. Operating
instructions and control system description, section Set
remote control panel communication.
5 PanelCommunicationError
1C
Check that the HMI and PLC software have the save
program version. This is visible in control system page
4.1 System info .
Abnormal operating
condition.
1B
What to do?
Possible cause
Description
Problem
ID
3
General problems
65
3.2
3.2
66
Filter
Filter
5B
5A
Differential pressure
transmitter PT20127 (Boll)
may be faulty.
Dirty water
3
List of problems and solutions
3.2
Filter
67
3.3
3.3
68
CIP
CIP
6A
6B
6C
6D
Pipe blockage
Broken valve.
Leakage in the CIP tank, CIP Locate leakage and attend to.
pump, pipes or AOT reactor.
3
List of problems and solutions
3.3
CIP
69
6E
6F
70
6G
6H
6I
Change diaphragm.
Diaphragm breakdown
CIP
Muffler is blocked
Diaphragm breakdown
Suction connection
blocked or not tight.
3.3
List of problems and solutions
3.4
3.4
Valve V2018
Valve V2018
71
72
8C
Inaccurate positioning.
Input signal fluctuates.
Faulty signal
8B
8A
3.4
Valve V2018
3
List of problems and solutions
Book No.
Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00
Telefax:
Contents
1
Introduction
Technical data
11
3.1
PureBallast system
11
3.2
PureBallast components
12
3.3
14
3.3.1
14
14
3.3.2
Installation guidelines
17
4.1
17
4.1.1
4.1.2
4.1.3
Safety information
General installation requirements
Installation of components supplied by shipyard
17
17
18
4.2
AOT reactor
18
4.3
Filter
19
4.4
CIP module
20
4.5
20
4.6
Flow meter
21
4.7
22
4.8
22
4.9
Air supply
23
System interfaces
25
5.1
25
5.2
27
5.2.1
27
28
5.2.2
5.3
45
5.3.1
5.3.2
5.3.3
46
46
47
5.4
48
5.4.1
50
5.5
50
Start-up procedures
53
Drawings
55
7.1
56
7.2
General drawings
57
7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
7.2.7
Flow chart
Connection list
Electrical system layout
Air distribution
Quality specification / Compressed air
Quality specification / Water
Quality specification / CIP liquid
57
58
64
65
66
67
68
7.3
69
7.3.1
7.3.2
7.3.3
7.3.4
7.3.5
7.3.6
7.3.7
7.3.8
7.3.9
7.3.10
7.3.11
7.3.12
7.3.13
69
70
71
73
74
75
76
77
78
79
82
83
85
7.4
Electrical drawings
7.4.1
7.4.2
7.4.3
7.4.4
7.4.5
7.4.6
7.4.7
7.4.8
7.4.9
87
87
95
115
116
118
132
133
135
138
139
8.1
Decommissioning
139
8.2
Protection
140
8.3
140
8.4
141
143
9.1
143
9.2
Lifting instructions
143
9.2.1
9.2.2
9.2.3
9.2.4
AOT reactor
Filter
CIP module
Cabinets
144
145
147
147
1 Introduction
This chapter contains information about how the PureBallast system is to be installed and drawings.
The information is presented as installation guidelines per component, relevant standards and
drawings. The chapter is opened with a summary of the main technical data.
Introduction
Value
Flange standard
Dimension: ________________
Dimension: ________________
Dimension: ________________
Location: __________________
Dimension: ________________
3 Technical data
This section states technical data for the complete PureBallast system and for individual
components. In some cases references are given to data in drawings included in this chapter.
3.1
PureBallast system
The table below states conditions, limit values etc. for the PureBallast system.
Type of data
Value
Water requirements
Sea water: Used for cooling UV lamps in the AOT reactor during
start-up.
LT (low temperature) fresh water: Used for cooling the lamp drive
cabinet (LDC) during operation.
Fresh water: Used for flushing and filling up of AOT reactors after
treatment.
Ambient air
temperature
055 C.
Relative humidity
Max. 90 %.
System flow
Power consumption
Based on maximum:
Compressed air
requirements
100 kW
1 kW (Control system including PLC, 24 V feeding, CIP motor
supply, filter motor supply)
11
3.2
PureBallast components
Technical data
Type of data
Value
Piping connections
Working pressure
PureBallast system
Working pressure
compressed air
Power: Nominal
voltage/Frequency
IP raiting
3.2
PureBallast components
The table below states conditions, limit values etc. for the individual component in the PureBallast
system. Dimensions are given in dimension drawings including technical data in the Drawings
section.
Component
Type of data
Value
AOT reactor
Pressure drop
Weight (empty)
330 kg.
Volume
Filter
12
Weight, empty
with adaptor plates
on flanges (kg)
825
Volume (dm3)
304
Technical data
3.2
PureBallast components
Weight, empty
(kg)
155 kg
Tank volume
Flow transmitter
Measures, weight
etc.
Valves
Measures, weight
etc.
Type
Connection type
EN or JIS.
Electrical cabinets
Measures, weight
etc.
Dimensions
CIP module
13
3.3
3.3
Technical data
This section gives a description of working pressure and pressure drops in the system.
3.3.1
During ballast operation, the ballast water flow goes through the filter and AOT reactor which
gives an approximate maximum pressure drop of 0.70 bar at maximum flow rate. Note that piping
outside the PureBallast system is not included. The pressure drop over the filter fluctuates between
approximately 0.20.5 bar depending on dirt load in the filter. The differential pressure over the
filter is monitored by one pressure transmitters on the filter inlet 201 and one on the filter outlet 201.
When the differential pressure reaches a parameter set limit (default is 0.5 bar), a backflush
operation is started automatically. To secure sufficient backflush flow, the pressure at Pfilter inlet
p309 (pressure loss in the backflush line). For detailed information
201 must be at least 1.0 bar +
about backflush, see chapter 2. System description, section Filter.
6 Working_Pressure_Hydac
3.3.2
Pressure calculation
The information below is used when the ballast water system is dimensioned.
14
Technical data
3.3
0.50 bar
AOT
reactor
0.20 bar
Total
0.70 bar
1.0 bar
P309
Calculated
The pressure drop for pipe 309 is installation specific and must
be calculated.
The connection list specifies required flow in pipe 309 to be
in range 60120 m3/h.
Use this flow to calculate the pressure drop in P309. Note
that P309 includes both static pressure and dynamic pressure
(pipe length, bends, valves etc) for pipe 309.
Total
pressure
drop
Calculated
15
3.3
Technical data
Enter this value in parameter p304 (Required pressure to start backflush) in the control system page
5.4 Filter parameters. The parameter defines pressure needed to start a backflush operation.
The parameter is also the setpoint for the pressure that the control valve (V201-8) will maintain
during backflush.
16
4 Installation guidelines
This section covers requirements for installing different components of the system.
4.1
4.1.1
Safety information
Earth connection must be made before any welding is done. The ground cable must have a
cross-section large enough in relation to the supply cables from the vessel. Otherwise the
equipment might be damaged during welding.
Instructions on how to mount and install components are given in chapter 7. Service manual.
NG
WARNI
4.1.2
Installation requirements given in the dimension drawings must be followed. See section
Drawings in this chapter.
There must be sufficient access to maintain the components. Access area is defined in the
dimension drawings.
All piping connected to the PureBallast components (AOT reactor, filter and CiP module shall be
propperly self supported. No load shall be transferred to or from any major components.
17
4.2
AOT reactor
Installation guidelines
All components must be installed and marked as specified in dimension drawings, flow charts
and other drawings included in this manual.
-
General drawings overall and principle information for system layout (pipes, components,
electricity, air and water).
Electrical drawings detailed electric information (circuit diagrams, cable lists etc).
4.1.3
Additional equipment, not part of Alfa Lavals scope of supply (for example cables, pipes) must
be installed according to the following sections of the manual:
Connection list
Installation guidelines
Electrical drawings
4.2
AOT reactor
18
Installation guidelines
4.3
Filter
The AOT 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.
6 AOT installation
Prepare the inlet piping first. Then mount the AOT reactor onto the inlet flange and secure it.
Finally install the outlet piping onto the top of the AOT 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.
The AOT reactor must be earthed. The earth nut is indicated as 791 in the dimension drawing.
4.3
Filter
The component must be placed on a firm level surface. The legs of the component can be
bolted or welded in place on a steady foundation.
Pipe 309 (filter back flush overboard line), with its valve, must be correctly connected.
The component must be earthed. The earth nut is indicated as 791 in the dimension drawing.
19
4.5
4.4
Installation guidelines
CIP module
The electrical cable is connected from the control cabinet to the CIP valve block. See chapter 7.
Service manual, section Connect electrical cables to valve block.
The component must be earthed. The earth nut is indicated as PE bolt in the dimension
drawing.
The component must be placed on a firm level surface. The legs of the component can be
bolted or welded in place on a steady foundation.
Connections to the flanges must be made so that the connection is not exposed to any moment
or load. This is particularly important when connecting the plastic flanges.
4.5
System interfaces (optional) must be integrated according to section System interfaces on page :
-
remote interface
power management
GPS integration
Cabinets General
Cabinets must be earthed. The earth nut is indicated as 791 in the dimension drawing.
LDC cabinet
The cabinets maximum distance (cable length) to the AOT reactor: 150 meters.
The component must be placed on a firm level surface. The legs of the component can be
bolted or welded in place on a steady foundation. It is possible to detach the cabinet from the
bottom frame to facilitate installation. The cabinet shall also be attached to the bulkhead using
the attachment bolts on the top of the cabinet.
It is possible to dismount the doors during installation: Slide the red catch on the hinge
backwards and release the locking mechanism.
Cables can be lead to the cabinet either from the floor or from the side of of the cabinet,
depending on which is most convenient. If needed, the location of the cable gland cassette
and the cover is exchanged. Power cable W201.1 to be connected to LDC: Max Icu 50 KA.
(Fixed breaker setting: 200 amp).
20
Installation guidelines
4.6
Flow meter
Signal cables W210A and B to be connected from X1 in LDC to junction box on the AOT reactor.
Cables from junction box to components are pre-assembled.
Lamp power cables W211A-D (included in scope of supply) shall be connected from X2 in
LDC to the (B side) junction box on the AOT reactor. Cables from junction box to lamps are
pre-assembled.
Control cabinet
One power link cable shall be connected from the control cabinet (X6) to LDC1 (X5). Another
power link cable shall be connected from X6 back to A1.1 in the control cabinet.
Cables General
Recommendation: Make notes of the actual connections made to the vessels systems with part
number and cable number in the electrical drawings. The drawings are prepared with indicated,
empty squared for this purpose. The electrical diagrams are found in the Drawings section.
These notes can be used to make notes of the exact connections done during installation to
simplify future faultfinding.
Electrical cables must be properly routed and supported according to applicable regulations.
Cable entries to cabinets must be sealed, using the built in cable glands. See instruction
Cable glands in chapter 7. Service manual.
Cabling shall be done according to specification in Electrical system layout on page 64, 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 nut holding the cable must be in
contact with the screen bar.
4.6
Flow meter
The ballast water flow direction must be according to the arrow on the flow sensor.
The flow transmitter must be mounted on the flow sensor pipe. It is not pre-assembled from
factory. See chapter 7. Service manual for instructions.
21
4.8
4.7
Installation guidelines
A drain solution (not part of Alfa Lavals scope of supply) must be attached to safety valve
RV201. The valve shall be drained to a scupper, with a solution which always allows water to
be drained from the valve. See Pressure monitoring device / Dimension drawing.
4.8
Inlet and outlet pipes must be correctly connected. They must also 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.
Pipes shall be designed to carry the weight of the component and media.
A bypass valve (optional part of Alfa Lavals scope of supply) must be installed. The bypass
valve (V212-31) shall be connected to the the vessels ISCS, to enable control of the valve, and
PureBallast control system to indicate valve position. See Control cabinet / Interconnection
diagram on page 87.
If PureBallast can be bypassed using other valves (apart from V212-31), status signals from
them must be connected to the control cabinet. All bypass cases must be logged.
Three additional by-pass valves can be handled, identified as additional bypass valve 1, 2 and
3. If more valves are used, they must be connected in series, which means that they are
handled as one regarding alarms and logging in PureBallast.
Signal cables for additional bypass valves are installed according to section External component
signal integration.
The yellow position indicator on actuators must be in line with the valve throttle. For pipes with
dimension 400, the red position indicator on the actuator coupling (see drawing) must also be in
line with the thottle. The position indicator must be in line with the pipe when the valve is open.
If not correct, change according to instruction in chapter 7. Service manual for instructions.
Valves shall be opened when installed. This is important to avoid that the rubber gaskets are
squeezed and damaged during installation.
Valve actuators pneumatic lines must be correctly connected and supported. See chapter
7. Service manual for instructions.
22
If delivered by Alfa Laval: Must be mounted with the pin pointing in the flow direction (see
drawing on page 79).
Flanges for connecting the sampling devices must be installed before the pipe is coated.
Installation guidelines
4.9
4.9
Air supply
Air supply
Components shall be connected to air supply that meets the requirements or the Quality
specification / Compressed air 66. Air shall always be connected.
23
4.9
Air supply
Installation guidelines
5 System interfaces
This section covers guidelines for how to install and integrate the following, if used:
external components
GPS integration
5.1
The PureBallast system can, as an option, be equipped with up to four remote control panels.
Remote control panel integration requires the following:
Communication cable (W501) between the switch (X13) in the control cabinet and the remote
control panel can be either Ethernet or fiber.
-
Ethernet cable Type: Cat 5e (or better). Max length: 100 meters. One free Ethernet
connection point (X13) in the switch in the control cabinet.
Fiber cable Type: Multi-mode fiber cable with LC connector. Max length: 500 meters.
Ports: Two free ports in the switch in the control cabinet.
If fiber is used, a network switch must be used, since the cable to the panel must be of
Ethernet type. One network switch and a 1.5 meter Ethernet cable is delivered with each
remote control panel.
If more remote control panels are to be installed than there are free fiber ports in the control
cabinet, one of the delivered network switches can be used for connection. From this switch,
it is possible to connect more panels using the free ports. Keep in mind that the cable to the
panel must be of Ethernet type. The extra switch shall be placed close to the first remote
control panel so the 1.5 meter Ethernet cable can be used.
External network switch including a terminal to handle the communication, placed near the
remote control panel. We recommend to use the external network switch close to the remote
control panel, even if it is not necessarey (if there are free ports in the control cabinet).
Network switch in control cabinet. It is installed if remote control panels have been ordered, but
can also be installed at a later stage.
A signal device must be installed according information in section Cabinets and cables on page
20. Not part of Alfa Lavals scope of supply.
Switches and cables are installed according to instructions in chapter 7. Service manual, section
Remote control panel (optional).
25
5.1
System interfaces
26
System interfaces
5.2
5.2
The PureBallast system can, as an option, be integrated with the ISCS. This will allow operation
and monitoring of the system from the ISCS. This section presents guidelines for how to connect
and implement the integration via the remote interface.
PureBallasts PLC communicate with the vessels ISCS via the remote interface. Data is sent to
and from dedicated addresses via modbus. Data can be commands, values (sum of bits), alarms
and status information. The data is then presented in the ISCS according to the vessels graphical
standard. It is possible to present all information (all addresses) or a selection. Data is sent as
binary code, with exception for time, which is sent as hexadecimal code.
Remote interface integration requires the following:
Cable W602 to be connected from connection terminal (X15) in control cabinet to ISCS.
Modbus connection from ISCS to PureBallast connection terminal X15 in the control cabinet.
Connection standard: RS485 (or RS422, not described in electrical drawings) according to
Control cabinet / Interconnection diagram. Recommended max length: 500 meters.
Implementation of remote interface signals in the ISCS according to the guidelines in this section.
After installation and integration, the function of the remote interface must be verified according
to chapter 3. Operating instructions and control system description, section Test remote
interface communication.
A signal device must be installed according to information in section Cabinets and cables on
page 20. Not part of Alfa Lavals scope of supply.
Reference information about the logical flow of the PureBallast processes can be found in chapter
3. Operating instructions and control system description, section Detailed process description.
5.2.1
This section describes all addresses in the remote interface, to handle the communication. These
addresses are displayed in the control system page 5.5 Remote interface 1 and 5.6 Remote interface
2, described in chapter 3. Operating instructions and control system description. Page 4.5 and 4.6
are used to verify that the integration functions and that correct information is displayed in the ISCS.
Modbus settings
The ISCS modbus RTU server data shall be set according to the table below:
Area
Value
Interface type
Baud rate
Parity
Databits
Stop bits
Modbus
Parameter option
Set in parameter p700 p704 in page
4.7 Remote interface. See chapter 4
Parameters for detailed information.
RTU
N/A
27
5.2
Communication
meth,od
Serial
N/A
Slave ID
10
N/A
System interfaces
PureBallast
is slave
and ISCS is
master.
5.2.2
Directory of addresses
This section list all addresses for the information sent between the systems.
The following terms are used to explain the signals in the tables below:
Address:Bit
The start address is 40000. Individual address and bit for each signal (data), is
written as Address:Bit, for example +073:14. Values for an address is written
as Address=Value, for example 015=125.
Bits are the Signal reference number. Bits are right aligned in the table.
Function
Name of the function. The name corresponds to the text used in the
PureBallast control system HMI. Parenthesis gives reference to the control
system page where the information is used/displayed. For further information
about respective piece of information, see chapter 3. Operating instructions
and control system description.
Description
Additional information, for example specific conditions that must be met before
a command can be sent.
28
System interfaces
5.2.2.1
5.2
The addresses below are used to send commands and status information from ISCS to PureBallast.
Example of data: Command to start a ballast process and feedback that the ballast water pump
is running.
Address:
40000 +
Function
Description
+001
Commands
Condition: All signals for +001 must be high until PureBallast return an
accept or reject signal (see +140).
Bit 0
Start ballast
Bit 1
Start deballast
Command: Deballast
Bit 2
Start CIP
Bit 3
Stop
Bit 4
Pause/Heeling
Bit 5
Bit 6
Bit 7
Manual backflush
(Filter popup)
29
5.2
Address:
40000 +
Function
+002
Feedback
Bit 0
Bit 1
+003
System interfaces
Description
Overboard valve
status (1.1)
30
System interfaces
5.2
Address:
40000 +
Function
Description
+004
By-pass (1.1)
Bit 015
+005
Bit 04
+006
Heartbeat (4.5)
5.2.2.2
Data to ISCS
The addresses below are used to send data from PureBallast to ISCS.
Example of data: System flow and pressure.
Book No.9010182 02, rev. 0
31
5.2
System interfaces
Address:
40000 +
Function
Description
+050
+051
+052
System pressure
PT20116 (1.1)
+053
+054
+055
32
System interfaces
5.2
Address:
40000 +
Function
Description
+056
+057
+058
+059
+060
+061
+062
33
5.2
System interfaces
Address:
40000 +
Function
Description
+063
+064
+065
+066
+067
5.2.2.3
The addresses below are used to send commands and status information from PureBallast to ISCS.
Example of data: Process mode (standby, ballast, CIP), acceptance of command from ISCS, and
request to ISCS to start ballast pump.
34
System interfaces
Address:
40000 +
Function
5.2
Description
/ Bit
+070
Command status
Bit 0
Bit 1
Bit 2
Bit 3
Stop accepted
Bit 4
Pause/Heeling accepted
Bit 5
Bit 6
Command rejected
35
5.2
Address:
40000 +
Bit 7
System interfaces
Function
Description
Sum alarm
Bit 8
Sum warning
Bit 9
Bit 10
+071
36
Commands
Bit 0
Bit 1
System interfaces
5.2
Address:
40000 +
Function
Description
+072
+073
+074
Filter mode
+075
37
5.2
Address:
40000 +
Bit 04
System interfaces
Function
Description
+076
Bit 04
+077
5.2.2.4
The addresses below are used to send status information for components to ISCS.
Example of data: Status for valves and pumps.
Address:
40000+
Function
Description
/ Bit
+080
38
Main valve status (1.1, 1.3 and popups for AOT reactor and filter)
Bit 0
V403-35
Bit 1
V201-9
System interfaces
5.2
Bit 2
V201-3
Bit 3
V201-8
Bit 4
V201-32
+081
Bit 0
P401-1
Bit 1
P403-1
+082
Bit 0
V212-31
Bit 1
Bit 2
Bit 3
+083
Bit 0
V571-1
Bit 1
V321-4
Bit 2
V321-1
Bit 3
V460-2
Bit 4
V320-2
Bit 5
V310-1
Bit 6
V310-6
Bit 7
P320-1
39
5.2
Bit 8
P321-5
System interfaces
+084
Bit 0
V309-1
Bit 1
M709-42
5.2.2.5
Alarms to ISCS
The tables below lists all alarms and warnings sent from PureBallast to the ISCS. Each alarm is
defined as a specific bit. The bit is set to 1 when the alarm is activated. The alarm IDs refer to alarms
described in chapter 5. Alarms and faultfinding, where texts to be displayed in ISCS can be found.
Example: If data at address 40902 is 000010000000100, this means that alarm W04 and warning
A33 are active (bit 2 and 10).
Empty fields are not used.
General alarms and warnings
Common alarms and common warnings (+900 and +901) indicate that there exist a common alarm
for the area or component specified.
Example of alarms and warnings: Process flow too high, valve error, component signals missing.
Address
40000 +
Common
alarms
+900
Common
warnings
+901
Main 1
+902
Main 2
+903
Main 3
+904
Filter
+905
Sum
Sum
A01
A51
W96
W300
Main
Main
A03
W58
W97
W304
AOT
AOT
W04
A66
A98 1
W306
CIP
CIP
A10
A67
A99 1
W308
Filter
Filter
W12
A68
W310
Power
Power
A13
A71
W312
Logbox
Logbox
A14
A75
W314
A17
A77
A315
A23
W79
A29
W80
Bit
40
W500
System interfaces
Address
40000 +
5.2
Main 1
+902
Main 2
+903
10
A33
W82
11
A35
W83
12
W40
A91
13
A48
W92
14
A49
A93
15
A50
W95
Common
alarms
+900
Common
warnings
+901
Main 3
+904
Filter
+905
Note 1: These alarms are only relevant for PureBallast 3.0 EX.
41
5.2
5.2.2.6
System interfaces
The addresses below are used to send status information, alarms and warning for AOT reactors
and LDC to ISCS.
Status information
Addresses for data regarding AOT reactor and respective LDC are separated in number series to
distinguish information for individual AOT reactor/LDC, if more than one.
Function
Description
/ Bit
+110 / +120
/ +130
Bit 0
Bit 1
Bit 2
42
Bit 3
Bit 4
Bit 5
System interfaces
5.2
Bit 6
Bit 7
Bit 8
Bit 9
+111 /
+121/
+131
Bit 0
LS201-29
Bit 1
TS201-60
Bit 2
V201-19
Bit 3
V201-20
Bit 4
V404-36
Bit 5
V321-2
Bit 6
Status: :
1=Open. 0=Closed.
+112 / +122
/
+132
Bit 015
+113/
+123/
+133
Bit 015
43
5.2
+114/
+124/
+134
System interfaces
+115/
125/
135
+116 / +126
/ +136
+117 / +127
/ +137
+118 / +128
/ +138
Alarms /
warnings 1
+910 / +913 /
+916
Alarms /
warnings
+911 / +914 /
+917
Alarms /
warnings
+912 / +915 /
+918
Bit
0
W100
W130
W170
W101
W131
W171
44
System interfaces
5.3
Address
40000 +
Alarms /
warnings 1
W102
W132
W107
W137
W109
A138
W111
W113
W140
W116
W150
W117
W151
W118
W160
10
W119
W161
11
A120
W162
12
W122
W163
13
W126
W164
14
W128
W165
15
W129
5.3
+910 / +913 /
+916
Alarms /
warnings
+911 / +914 /
+917
Alarms /
warnings
+912 / +915 /
+918
It is possible to connect the PureBallast control system to the vessels power management system
or ISCS. The purpose is to automatically handle power request from PureBallast to secure that
enough power is available for each ballast and deballast process. A process can only start after
acceptance from the ISCS.
The communication is either handled by the remote interface (if the option is integrated) or via hard
wires between the vessels ISCS and PureBallasts control cabinet. It is also possible to use
hard wire, even if remote interface is integrated.
Power management requires the following:
Integration and connection of signals must be done according to the guidelines in this section.
45
5.3
5.3.1
System interfaces
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 ballast or deballast process is started from the PureBallast control system.
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 power management reserves the requested power for PureBallast and
then send power granted to the control system. If the vessel cannot provide the requested
power, less power might be granted. The exact granted power is always visible in the field
Calculated power consumption in control system page 1.5 Power request or 1.1 Overview.
4. The ballast/deballast continues the start-up process and the UV lamps are lit. The control
system confirms this by sending back a power running signal to confirm that the power is used.
5. When the process is stopped from the control system, the power running signal is deactivated.
5.3.2
The power management system is based on defined power steps, defining the power needed for
1-3 AOT reactors: Step 1 extend to one AOT reactor and step 2 extend to three AOT reactors. .
Signals are defined to handle all combinations of power step (amount of power) and function
(request, grant and run). More than one signal can be sent (or received) at the same time to
achieve, for example step 1 and 2 to request power for 3 AOT reactors.
As an alternative, it is possible to use power step 4 (common) that always will be used, regardless
of the number of AOT reactors used for a specific process. The common power is defined as the
number of installed AOT reactor times the defined power consumption for one AOT reactor.
Function signal
No. of
AOT
reactor:s
Signal to
terminal
Power
(kW)
Request, step 1
Terminal strip X2
Terminal 41/42.
33
Terminal strip X2
Terminal 43/44.
65
Terminal strip X2
Terminal 47/48.
33-97
Relay module
X12. Relay K5.
Connection point
BB and A1.
33
Request, step 2
Request, step 4
(common)
1-3
Granted, step 1
46
101
201
101-401
101
System interfaces
5.3
Function signal
No. of
AOT
reactor:s
Signal to
terminal
Power
(kW)
Granted, step 2
Relay module
X12. Relay K6.
Connection point
BB and A1.
65
Relay module
X12. Relay K8.
Connection point
BB and A1.
33-97
Terminal strip X3
Terminal 49/50.
33
Terminal strip X3
Terminal 51/52.
65
Terminal strip X3
Terminal 55/56.
33-97
Granted, step 4
(common)
1-3
Running, step 1
Running, step 2
Running, step 4
(common)
5.3.3
1-3
201
101-401
101
201
101-401
The signals are hard wired and shall be connected to corresponding terminals (same ID) in the
control cabinet according to Control cabinet / Interconnection diagram on page 87. Note that the
drawing indicate a Step 4, which is not used.
Note that It is only necessary to connect enough signals to cover the number of AOT reactors
installed on the vessel. If one AOT reactor is installed it is only necessary to connect step 1 for
request, granted and running.
After installation, the signals need to be tested. This is done by simulating signals from the control
system, page 1.4 Power request. See chapter 3. Operating instructions and control system
description, instruction Simulate power request.
47
5.4
5.4
System interfaces
The following components and functions (not part of Alfa Lavals scope of supply) can be integrated
with the control system. The communication is either handled by the remote interface (if the option
is integrated) or via hard wires.
Each signal that is used must be activated in the control system page 5.2 Main parameters 2.
Output indicates signal from PureBallast and Input indicates signal from ISCS.
Signal
Control
cabinet
Explanation
Output
Common warning
Output
Input
Input
Additional bypass 1 is
open
Additional bypass 2 is
open
Additional bypass 3 is
open
Input
48
System interfaces
Signal
5.4
Control
cabinet
Explanation
Output
Input
Request Open
overboard valves
Output
Input
Output
49
5.5
System interfaces
Signal
Control
cabinet
Explanation
Output
PureBallast running
Output
5.4.1
The input and output signal cables must be connected according to the drawing Control cabinet /
Interconnection diagram on page 87. This section gives additional information to the drawing on
how to connect the cables.
Input signals
Chosen input signals must be connected from the control cabinet according to Control cabinet /
Interconnection diagram on page 87.
Output signals
Chosen output signals must be connected from the control cabinet according to Control cabinet /
Interconnection diagram on page 87. Output signals are connected via potential free relays.
5.5
This section describes the installation of GPS position signal to PureBallast. This installation is
optional. If used, the GPS position is used to stamp events in the event log.
The GPS must be connected to the module X20IF1030 in the control cabinet, using an NMEA
(RS422) serial interface with the following settings:
Parity: None
Bits/characters: 8
Stop bits: 1
50
System interfaces
5.5
6 GPS
51
5.5
System interfaces
6 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 AOT 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
AOT 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.
53
Start-up procedures
7 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).
Electrical drawings detailed electric information (circuit diagrams, cable lists etc).
See the Contents section at the beginning of this chapter to get an overview of included drawings.
55
7.1
7.1
Drawings
Symbols used in drawings are according to ISO 14617. Below, a guiding extract is shown.
573644
56
Drawings
7.2
General drawings
7.2.1
Flow chart
7.2
9007243
General drawings
57
7.2
General drawings
7.2.2
Drawings
Connection list
Connection list for Ballast water treatment system according to flow chart 9007243.
Item /
Connection
Description
Requirements/limits
Main components
201
Ballast water
Inlet/Outlet
Flow range
deballast (m3/h):
100 1000
Sea water
Sampling device
Valve
(optional)
As above.
Q201.2
V201-25
V201-3
Main valves
V201-9
V20132
V212-31
V201-8
IP201-7
IP converter
S201-7
Strainer
58
Drawings
7.2
General drawings
Item /
Connection
Description
Requirements/limits
403
Sea water
V403-35
Valve
FIT201-1
Flow transmitter
V201-15
PI201-18
RV201
PT201-16
Needle valve
Pressure gauge
Safety valve
Pressure transmitter
309
Backflush water
Sea water
V309-1
Reject valve
310.2
Flushing
miscellaneous
Flanged, blanked
460
Drain Filter
Inlet / outlet
404
Cooling water
Reactor outlet
Over board
59
7.2
General drawings
Item /
Connection
Description
Requirements/limits
V320-4
CIP / Drain
V321-2
Reactor outlet
V404-36
Cooling water
Drawings
401
Temperature: 0 38 C
Cooling capacity: 5 kW
SV401-51
Valve
402
CV402
Valve
60
Drawings
7.2
General drawings
Item /
Connection
Description
Requirements/limits
310.1
310.2
Flushing
miscellaneous
Volume:
380 L/ rinsing & preservation (2 cycles x 1 reactor x
190 L)
.
V310-1
Valve
V310-3
Backflow preventer
V310-6
V310-8
Valve
CV310-7
Strainer
320
Flushing
miscellaneous, reactor
module
V320-2
V320-11
Valve
P320-1
Pump
321
Flushing
miscellaneous, reactor
modue
CIP liquid
Pump
Normally no flow
P321-5
V321-1
V321-4
Valve
460.1
Drain Reactor
V460-2
Valve
CV460-4
Check valve
61
7.2
General drawings
Item /
Connection
Description
Requirements/limits
460.2
By gravity
Normally no flow
Volume: 300 L
Drawings
V460-3
Valve
571
De-aeration
AOT reactor / CIP
Air
V571-1
Valve
Instrument air
Max consumption:
62
Drawings
7.2
General drawings
6 Working_Pressure_Hydac
pfilter
pAOT
pfilter inlet
p309
63
7.2
General drawings
7.2.3
Drawings
9005353
64
Drawings
7.2.4
7.2
General drawings
Air distribution
585828
65
7.2
General drawings
7.2.5
Drawings
553407
66
Drawings
7.2.6
7.2
General drawings
590773
67
7.2
General drawings
7.2.7
68
594956
Drawings
Drawings
7.3
7.3
7.3.1
69
7.3.2
70
9006982
Drawings
Drawings
7.3.3
7.3
71
Drawings
9004714_p2
72
Drawings
7.3.4
7.3
586502
73
7.3.5
Drawings
74
Drawings
7.3.6
7.3
9007182
75
7.3.7
76
Drawings
9007178
Drawings
7.3.8
7.3
9007180
77
7.3.9
78
Drawings
9007176
Drawings
7.3
590066 1
79
Drawings
590066 2
80
Drawings
7.3
590066 3
81
Drawings
9005331
82
Drawings
7.3
9005261_p1
83
Drawings
9005261_p2
84
Drawings
7.3
595261_p1
85
Drawings
595261_p2
86
Drawings
7.4
Electrical drawings
7.4
Electrical drawings
7.4.1
87
7.4
Electrical drawings
Drawings
9005343_Page_22
88
Drawings
7.4
Electrical drawings
9005343_Page_23
89
7.4
Electrical drawings
Drawings
9005343_Page_24
90
Drawings
7.4
Electrical drawings
9005343_Page_25
91
7.4
Electrical drawings
Drawings
9005343_Page_26
92
Drawings
7.4
Electrical drawings
9005343_Page_27
93
7.4
Electrical drawings
Drawings
9005343_Page_28
94
Drawings
7.4.2
7.4
Electrical drawings
9005343_Page_01
95
7.4
Electrical drawings
Drawings
9005343_Page_02
96
Drawings
7.4
Electrical drawings
9005343_Page_03
97
7.4
Electrical drawings
Drawings
9005343_Page_04
98
Drawings
7.4
Electrical drawings
9005343_Page_05
99
7.4
Electrical drawings
Drawings
9005343_Page_06
100
Drawings
7.4
Electrical drawings
9005343_Page_07
101
7.4
Electrical drawings
Drawings
9005343_Page_08
102
Drawings
7.4
Electrical drawings
9005343_Page_09
103
7.4
Electrical drawings
Drawings
9005343_Page_10
104
Drawings
7.4
Electrical drawings
9005343_Page_11
105
7.4
Electrical drawings
Drawings
9005343_Page_12
106
Drawings
7.4
Electrical drawings
9005343_Page_13
107
7.4
Electrical drawings
Drawings
9005343_Page_14
108
Drawings
7.4
Electrical drawings
9005343_Page_15
109
7.4
Electrical drawings
Drawings
9005343_Page_16
110
Drawings
7.4
Electrical drawings
9005343_Page_17
111
7.4
Electrical drawings
Drawings
9005343_Page_18
112
Drawings
7.4
Electrical drawings
9005343_Page_19
113
7.4
Electrical drawings
Drawings
9005343_Page_20
114
Drawings
7.4.3
7.4
Electrical drawings
9005343_Page_29
115
7.4
Electrical drawings
7.4.4
116
Drawings
9005345_Page_16
Drawings
7.4
Electrical drawings
9005345_Page_17
117
7.4
Electrical drawings
7.4.5
118
9005345_Page_01
Drawings
Drawings
7.4
Electrical drawings
9005345_Page_02
119
7.4
Electrical drawings
Drawings
9005345_Page_03
120
Drawings
7.4
Electrical drawings
9005345_Page_04
121
7.4
Electrical drawings
Drawings
9005345_Page_05
122
Drawings
7.4
Electrical drawings
9005345_Page_06
123
7.4
Electrical drawings
Drawings
9005345_Page_07
124
Drawings
7.4
Electrical drawings
9005345_Page_08
125
7.4
Electrical drawings
Drawings
9005345_Page_09
126
Drawings
7.4
Electrical drawings
9005345_Page_10
127
7.4
Electrical drawings
Drawings
9005345_Page_11
128
Drawings
7.4
Electrical drawings
9005345_Page_12
129
7.4
Electrical drawings
Drawings
9005345_Page_13
130
Drawings
7.4
Electrical drawings
9005345_Page_14
131
7.4
Electrical drawings
7.4.6
Drawings
9005345_Page_18
132
Drawings
7.4.7
7.4
Electrical drawings
9005379_Page_5
133
7.4
Electrical drawings
Drawings
9005379_Page_6
134
Drawings
7.4.8
7.4
Electrical drawings
9005379_Page_1
135
7.4
Electrical drawings
Drawings
9005379_Page_2
136
Drawings
7.4
Electrical drawings
9005379_Page_3
137
7.4
Electrical drawings
7.4.9
Drawings
9005379_Page_7
138
8.1
Decommissioning
Follow the process below to decommission the PureBallast system. Note that if there is a freeze
risk, the system must be completely emptied of water.
1. Run the back flush sequence for the filter three times.
2. Drain all water from the filter. Leave the drain open afterwards.
3. Run the CIP process twice.
4. Drain all liquid from the AOT reactors. Leave the drains open. (Use the drain plug at the
bottom of the AOT reactor.)
5. Shut off the main valves for the start-up cooling system. Drain the system afterwards.
6. Isolate the start-up cooling system: Close installed service valve, or use a blind flange, to
prevent fluid to enter the section. (Pipe connection 403, 404.)
7. Drain all water from the LDC heatexchangers. Leave the drains open afterwards (disconnect
hoses). Shut off the main valves for the cooling system (pipe connection 401).
8. Clean the CIP module with fresh water. Rinse the tank. Drain all water/liquid from the CIP
system and leave the drains open afterwards.
9. Isolate the system: Close installed service valves, or use a blind flange, to prevent fluid to
enter the section. (Pipe connection 310, 460.)
10. Drain water from the pipe systems between the main inlet valve (V201-3, V201-9) and control
valve (V201-8). Leave any open drains open afterwards.
11. Isolate the system: Close installed service valve, or use a blind flange, to prevent fluid to enter
the section. (Pipe connection 201.)
12. Drain all water from the filter back flush line. Leave the drain flange in the bottom of the filter
open afterwards.
13. Isolate the system: Close installed service valve, or use a blind flange, to prevent fluid to enter
the section. (Pipe connection 309.)
14. Shut off the breakers on the control cabinet and the lamp drive cabinet. Lock them in that
position. Label them to avoid connection by mistake.
139
8.3
8.2
Protection
Protect all electrical cabinets from humidity with Silica gel or similar.
Protect all metal surfaces from corrosion attacks with anti-rust oil. The oil must have long
lasting effective treatment for external surfaces.
Disconnect the air supply to the CIP module. Use service valve if possible, otherwise plug
the air supply inlet.
Disconnect and drain the membrane pumps (P320-1, P321-5 or P460-7). Rinse with fresh
water and reconnect the pump.
Articles made of rubber or plastics (for example seals) must not be treated with antirust oil.
Protect pressure monitoring device etc. from mechanical damages. The following components
are recommended to be removed and stored safely: PT201-27, PT201-16, and PI201-18.
Protect the flow sensor with silica gel or similar. Protect the sensor with the supplied plastic
cover.
Change the battery in the control panel. If not, the stored log information can be lost during
storage.
Every 3 months, operate each valve by close/open exercise. This will keep the valves and
actuators in best condition.
Note that control valve V201-8 must be exercised manually at the same time as the IP201-7 is
removed. Use a wrench to apply appropriate torque.
8.3
If there is a risk for condensation of water during storage, the equipment must be protected
by ventilation and heating above dew point.
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, all articles made of rubber and elastomer
(gaskets, O-rings etc) must be changed before the system is put in service. Such articles are
found in the following components: UV lamps, quartz sleeves and catalytic candles in the
AOT reactors and the filter candles.
140
8.4
8.4
Follow the overhaul process below to star-up the PureBallast system after decommission.
1. Locate the decommissioning report stored inside the control cabinet. Use this report to the
re-commissioning of the PureBallast system.
2. Clean away the anti-rust oil with a solvent, for example, white spirit.
3. Assemble items that have been disassembled.
4. If applicable: Remove the silica gel bags from all units.
5. Before the system can be activated, it must be checked according to the commissioning
checklist.
141
8.4
9.1
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.
If the PureBallast system is stored before installation, make sure to store the components
according to the Shutdown and storage section.
9.2
Lifting instructions
NG
WARNI
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 stated in the section below.
The AOT reactor, filter, CIP and control cabinet must be lifted according to the instructions
in the following sections.
143
9.2
Lifting instructions
9.2.1
AOT reactor
6 AOT Lift
144
9.2.2
9.2
Lifting instructions
Filter
Weight of filter (empty with adaptor plates on flanges): 825 kg. A=98 cm.
6 FilterLift
9.2.2.1
Follow the instruction to raise the filter to standing position and to lift it for transportation.
1.
When the filter is resting in the bottom of the wooden case: Attach a 2 string-round sling to
the two upper lifting bolts.
145
9.2
Lifting instructions
6 FilterLift Hydac2
2.
Use a lifting gear to raise the filter to upright position. Use the bottom filter legs as turning point.
3.
When the filter is in upright position: Attach a 3 string-round sling to all three lifting bolts.
6 FilterLift Hydac
4.
146
9.2.3
9.2
Lifting instructions
CIP module
9.2.4
Cabinets
147
9.2
Lifting instructions
XXXXX
6 CabinetLift
148
Book No.
Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00
Telefax:
Contents
1
2
Introduction
1.1
Maintenance schedule
2.1
Calibration schedule
11
2.2
12
2.2.1
2.2.2
12
13
2.3
14
19
3.1
19
3.2
19
3.3
20
3.4
Unlock valve
21
AOT reactor
23
4.1
Safety information
23
4.2
24
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
Disassemble UV lamp
Disassemble quartz sleeve
Assemble quartz sleeve
Check for leaks after quartz sleeve assembly
Assemble UV lamp
24
27
27
28
28
4.3
29
4.3.1
29
4.4
31
4.5
32
Filter
35
5.1
37
5.2
37
5.3
38
5.4
39
5.5
39
5.6
40
CIP module
41
6.1
41
6.1.1
6.1.2
43
43
6.2
44
6.2.1
6.2.2
6.2.3
45
45
46
6.3
47
6.4
47
6.5
47
6.5.1
6.5.2
6.5.3
6.5.4
48
48
49
49
Flow meter
51
7.1
51
7.2
53
7.3
54
7.4
56
Valve actuator
57
8.1
58
8.1.1
58
8.2
Dismount actuator
59
8.3
59
8.4
61
62
8.6
62
8.7
64
8.8
64
8.9
65
8.10
66
8.11
68
8.5
Ball valve
71
9.1
71
10 Level switch
73
10.1
73
10.2
74
10.3
74
75
11.1
75
11.2
76
12 Control panel
77
12.1
77
12.2
77
77
78
81
13.2
83
81
85
14.1
85
14.2
87
1 Introduction
This chapter contains information and instructions about how to service the PureBallast system.
Instructions are sorted per component. The chapter is opened with a maintenance schedule
covering checks and services that must be performed with specified intervals.
1.1
NGE
! DA
Before maintaining the PureBallast system, the power supply must be switched off, to avoid
accidental starts. See instruction Abort operation and deactivate the system in chapter 3.
Operating instructions and control system description.
NOTE
All maintenance of the PureBallast system must be logged in the vessels maintenance log.
Always read and follow the documentation that are included in shipment of components and
spare parts regarding handling, safety and disposal.
Before maintaining the PureBallast system, the following valves must be locked in closed
position: V201-3, V201-9, and V201-8. See instruction Lock valve in closed position on page 20.
Follow general rules when handling of Alpacon descalant offshore cleaning agent, regarding
ventilation, personal protection etc.
Point of contact: To order service or spare parts, contact your local Alfa Laval office. For
more information, see www.alfalaval.com.
1.1
Introduction
2 Maintenance schedule
Follow this maintenance schedule to secure performance, safety and durability of the system and
its components. The schedule is sorted per component. The table refers to instructions usable
when performing the respective action.
Component
Action
Time interval
General
Inspect for
corrosion and
erosion damage.
Once a year.
General
Calibration of
sensors
According to
Calibration
schedule
See Calibration
schedule
AOT reactor
Outer inspection
of seals for
leakage.
Once a year.
If necessary,
change according
to Open AOT
reactor.
Check UV lamps
for leakage.
Once a year.
See Disassemble
quartz sleeve.
Replacement of
UV lamps.
Recommended to
change all lamps
after 3000 hours of
operation.
See Replace UV
lamp and quartz
sleeve.
Inspection and
cleaning of filter
insert, including
filter candles.
Once a year.
Replace filter
candles, if
damaged.
Outer inspection
of seals for
leakage.
Once a year.
Check sacrificial
anode.
Once a year.
Filter
Instructions
Notes
Change if needed
or every five years.
If necessary,
change faulty seals.
See Change
sacrificial anode.
Change if the
anode has lost
approximately 80
% of the zinc mass.
Maintenance schedule
pH value check.
Before each
filling-up or once
every 3 months,
whichever comes
first.
Rule of thumb:
See Change CIP
Once every 3
liquid or Refill CIP
months.
liquid.
Depending
on number of
AOT reactor
and ballasting
frequency, the liquid
check might have to
be performed more
regularly.
Replacement.
Control of stored
CIP liquid.
Visual inspection
after three years.
See Preparations
and conditions
under Change and
refill CIP liquid
instruction.
Valve block on
CIP module
Once a year.
See chapter 7.
Service manual,
section Connect
electrical cables to
valve block.
Flow meter
Once a year.
Control system
Cleaning of
display.
Displays should be
cleaned at regular
intervals or when
dirty.
Battery check
(PLC module).
Automatically every
when turned on and
every 24 hours.
CIP liquid
Battery
When alarm PLC
replacement (PLC battery low is
module).
indicated in the
control system.
or:
10
Maintenance schedule
2.1
Calibration schedule
After 5 years.
or:
Before storage for
longer periods.
2.1
Calibration schedule
Follow this calibration schedule to secure performance of the system and its components. The
schedule is sorted per component.
Interval: Once a year, if nothing else is stated.
Component
Informatoin / instruction
Flow meter
Pressure
transmitters
11
2.2
Maintenance schedule
AOT reactor
components
1. Depressurize and drain the reactor: Remove the drain plug at the bottom
of the AOT reactor.
Temperature
transmitter
(TT201-33)
TT20133
Temperature
switch (TS20160)
Level switch
(LS201-29)
UV sensor in
AOT reactor
(QT201-50)
Temperature
transmitter in
LDC (TT401)
2.2
Order a exchange sensor from your local Alfa Laval office (parts and service)
to be installed and used during the time the sensor is calibration at factory.
This section describes where the serial number plate is placed on the PureBallast system
components.
Serial numbers shall be used at error reporting and other contacts where a specific component is
discussed.
2.2.1
Serial number for the complete PureBallast system. See label on the side of the control cabinet.
Serial number for the component in question. If the component is installed on, or in, another
component, the number for the mother component shall be stated.
Item number for the component. The item number identifies a unique component in the system.
It begins with a letter abbreviation indicating the component type, for example: LS (level switch),
P (pump) and PI (pressure gauge). A complete list of abbreviations is found in chapter 6.
Installation description and drawings, section Connection list.
12
Maintenance schedule
2.2.2
2.2
Example
Level switch serial number and the serial number for the AOT reactor on which the level switch
is installed.
13
2.3
2.3
Maintenance schedule
The table below indicates the position of the serial number plate per component.
PureBallast water treatment system
Serial number for the complete PureBallast
system.
Placing: On the right-hand side gable of the
control cabinet.
7 PB 591098_SerialNo
AOT reactor
At the side of the AOT reactor, as indicated in
the illustration.
7 AOT Snr
14
Maintenance schedule
2.3
Filter
Placing: At the side of the filter, as indicated
in the illustration.
7 FilterSnr Hydac
Control cabinet
7 CC Sernr 591773#1
15
2.3
Maintenance schedule
7 LDC sernr
16
Maintenance schedule
2.3
Flow meter
(Including flow transmitter and flow sensor)
Placing: At the side of the pipe, as indicated
in the illustration.
NOTE
The flow transmitter and flow sensor have individual
serial numbers. But it is sufficient to state the flow
meter serial number.
7 FM snr 576179_manual 2
17
2.3
Maintenance schedule
3.1
Follow this instruction to manually operate the valves installed in the CIP module: V571-1, V321-4,
V321-1, V460-2, V320-2 and V310-6. Note that the orange diode on the valve body will not light
during manual operation.
Follow the steps below
1.
Identify which button (illustrated on page 47) on the valve block that controls the valve. The
lower button operates the inner hose under the valve block, and vice versa. Also see the
sticker under the valve block.
2.
Press the button on the valve body with a screw driver to operate the valve.
3.2
Follow this instruction to manually operate valves V201-3, V201-8 and V201-9.
Valves can be operated using the position screw on the pilot valve.
Position 0
Position 1
Closed (default position). If the position screw is in position 0 and the valve is
closed, it can be manually opened. But if the position screw is in position 0 and
the valve is opened, it cannot be manually closed.
Opened.
If there is limited access to the screw, it is possible to remove the DIN connector.
2.
19
3.3
3.
4.
When done, turn back the screw to position 0. If the DIN connector was removed, connect it
again.
3.3
Follow this instruction to lock valves V201-3, V201-9, V201-8 and 212-31 in closed position. These
valves are locked mechanically with two bolts on the actuator.
Preparations and conditions
Note that the end positions of the end stop bolts are factory adjusted and must not be readjusted.
Set the valve to closed position from the control system. Control the position indicator, to make
sure. The yellow position indicator is in line with the valve throttle (indicating open when
the position indicator is in line with the pipe).
2.
Disconnect power and compressed air. Verify that the valve is not under pressure.
3.
Open the padlock (2) on the actuator and remove the safety cover (1) from the bolts (3, 4).
7 576075_lock_manual
4.
Measure exactly how far out the end stop bolt (4) is from a reference surface, for example the
actuator house. Make a note of the distance. This information is needed when unlocking
the valve.
5.
Open the locking bolt (3) and turn them a couple of turns.
6.
Screw the end stop bolt (4) to its bottom position and tighten the locking bolt.
7.
20
3.4
Unlock valve
8.
Slide the safety cover over the end bolts and lock the safety cover with the pad lock.
9.
3.4
Unlock valve
Follow this instruction to unlock valves V201-3, V201-9, V201-8 and 212-31 from closed position.
Preparations and conditions
Note that the end positions of the end stop bolts are factory adjusted and must not be readjusted.
Disconnect all power and compressed air. Verify that the valve is not under pressure.
2.
Open the padlock (2) on the actuator and remove the safety cover (1) from the bolts (3, 4).
7 576075_lock_manual
3.
4.
Adjust the end stop bolt (4) to the same position (distance from reference surface) as before
locking the valve, according to the notes made during locking.
NOTE
It is important to adjust the ends stop bolt to the correct position. Otherwise the actuator
may be damaged.
5.
6.
21
3.4
7.
22
Unlock valve
Slide the safety cover in position over the end stop bolts. Lock the safety cover with the pad
lock.
4 AOT reactor
This section covers instruction for service of the AOT reactor.
4.1
Safety information
NGE
! DA
Always disconnect the PureBallast system from the power supply before disassembling, and
secure it from being switched on.
UV lamps radiate ultraviolet radiation when lit. Only operate the UV lamp when correctly
installed inside the AOT reactor with end caps properly closed.
Never dismount or handle UV lamps before they are completely cooled down. A hot UV lamp is
under high internal pressure, and the risk of bursting exists. A hot lamp could also cause a
burn if it is touched.
ON
CAUTI
Before installation, check that the UV lamps and quartz sleeves are not broken.
UV lamps and quartz sleeves are fragile and can easily become damaged. Exercise great care
when handling them. Do not apply vibrations or shock to the UV lamp. This can cause breakage
and shorten lamp life. Broken glass/quartz can also cause severe cuts. Always use protective
eye glasses and clean cotton gloves when handling UV lamps and quartz glass sleeves.
UV lamps contain a small amount of mercury (less than 0.2 grams per lamp) and must be
handled and disposed of with care. Used lamps UV can be handled and disposed of in the same
way as fluorescent lamps. Please refer to national regulations. If a UV lamp has accidentally
been broken, mercury could be spilt. Remove mercury with a special tool such as a syringe
(or use pure sulphure to bind the mercury for easy collection).
Do not allow mercury to come in contact with your eyes or skin. Do not inhale mercury fumes.
Free mercury must be kept in an airtight bottle, and must be disposed of according to
national regulations.
In case of having inhaled mercury fumes, consult a doctor and follow medical instructions.
When performing these routines, consider the need for service kits for UV and quartz sleeves,
containing O-rings, lamps, quartz sleeves etc. See Spare parts catalogue.
Do not touch the glass of the UV lamp. Wear gloves and hold the lamp by the ceramic end
parts only. If a lamp is stained on its surface, wipe off the glass with a clean soft piece of cloth
soaked with alcohol. If not, it could cause breakage and shorten lamp life.
23
4.2
AOT reactor
Keep the UV lamp in its original protective cover and case when transporting, storing and
disposing of the lamp. Otherwise it could cause injury if the lamp breaks. Do not dispose of
original protective cover and case for the UV lamp, as they should be re-used for storage
and disposal. Mark cases with used UV lamps accordingly, so that they will not be mistaken
for new lamps.
4.2
7 AOTexploded2
Cap
Cap nut
Bush
O-ring (inside bush)
Cable connector
Allen screw
Glass socket
O-ring
UV lamp
Quartz sleeve
4.2.1
Disassemble UV lamp
24
The PureBallast system must be turned off, and the power disconnected.
Book No.9010182 02, rev. 0
AOT reactor
After UV lamps have been changed, the runtime must be reset in page control system page 4.4
Operation timers AOT 13. Requires login level Advanced operator.
Wait at least 10 minutes after completed ballast or deballast process, to allow the AOT reactor
to cool down to ambient temperature. If the UV lamps are hot they are under internal positive
pressure and may burst if broken.
NG
WARNI
The AOT reactor must not be under pressure when dismounting the UV lamps.
4.2
NG
WARNI
Unscrew the nut (2) holding the caps (1). There is one nut on each side of the AOT reactor per
UV lamp. If required, use a screwdriver on the nut, gently tapping with a hammer to release.
2.
Carefully disconnect the two cable connectors (5) in both ends of the UV lamp (9).
7UVlampConnection
3.
Carefully draw out the UV lamp and one of its bushes (3) with the electric cable, by holding the
electric cables in both ends. If required, use a screwdriver to press on the ceramic end of the
lamp inside the bush on the other side whilst carefully pulling the electric cable at the other end.
25
4.2
AOT reactor
7UVBushScrewdriver
4.
Hold the UV lamp by the ceramic ends after the bushes have been removed. Immediately after
removal, place the lamp in its protective cover.
5.
6.
If no quartz sleeves are broken, mount new UV lamps according to the instruction Assemble
UV lamp on page 28. If broken see the Preparations and conditions section above.
26
AOT reactor
4.2.2
4.2
NG
WARNI
Hot water may escape from the AOT reactor when removing the drain plug.
Close the AOT reactor inlet (V201-19.n) and outlet (V201-20.n) valves from the main panel.
2.
Depressurize and drain the AOT reactor: Remove the drain plug at the bottom of the AOT
reactor.
3.
4.
Disassemble the UV lamp according to the instruction Disassemble UV lamp on page 24.
5.
Unscrew the three Allen screws (6) of the glass socket (7), just a few turns to release the
sockets on both sides.
6.
7.
Carefully remove the glass sockets and the quartz sleeve (10).
8.
Remove the O-rings (8) on both sides. The O-rings are firmly stuck in their seat, and will be
damaged during removal, but shall be replaced at assembly. Use an angled or hooked O-ring
tool to loosen and remove the O-ring. Be careful to avoid to break the glass.
If the O-ring is hard to remove, try the following:
Moisten the O-ring with acetone or denatured alcohol.
Loose the O-ring in a couple of places before removing it.
Perforate the O-ring to get a good grip.
9.
10. Carefully clean the surface and remove any small parts, for example glass or rubber.
4.2.3
Follow the instruction below to assemble quartz sleeve and check for leaks.
Preparations and conditions
Two new O-rings for each glass socket (7) might be needed.
Glass sockets and bushes must be dry and clean before mounting.
27
4.2
AOT reactor
2.
Wet the O-rings (8) with water and slip them over respective side of the quartz sleeve. Check
that the O-ring is correctly placed, or they may be damaged and cause leaks.
3.
Check the condition of the glass socket O-rings . If needed, replace them with new O-rings.
4.
Adjust the quartz sleeve, so it is placed in the middle of the AOT reactor.
Adjust the O-rings, so they are placed equally on both sides of the quartz sleeve.
5.
Carefully mount the first glass socket on the quartz sleeve with three Allen screws evenly, but
do not tighten the screws. Note that the waxed screws must be used to avoid seizing.
7QuartzSleeve
6.
Once the Allen screws (6) are evenly entered, carefully tighten them evenly to a torque of 7 Nm.
7.
8.
4.2.4
Follow the instruction below to secure that there are no leaks that may damage the UV lamps.
Follow the steps below
1.
Pressurize the AOT reactor with water to between 2 and 4 bar (0.2 and 0.4 MPa).
2.
4.2.5
Assemble UV lamp
A leakage check must have been performed according to the instruction Check for leaks after
quartz sleeve assembly.
28
AOT reactor
4.3
New heat resistant O-rings must be used in the two bushes. Always replace used O-rings.
Keep the UV lamp in its protective cover as long as possible. Do not touch the glass of the
lamp; hold the lamp by its ceramic end parts.
Glass sockets and bushes must be dry and clean before mounting.
2.
3.
4.
Insert the other bush in the opposite side of the AOT reactor.
5.
Make sure that the connection is clean to ensure good electric connection (no rust, burning or
fading on the connectors). Reconnect the two cable connectors for the UV lamp.
7UVlampConnection
6.
Mount the UV lamp caps and tighten three Allen screws at both ends of the UV lamp, by hand
only. Make sure that the electric cable is is not squeezed between the cap and the bush when
the cap is mounted. Slack can be pushed into the bush.
7.
Re-fit the drain plugs at the bottom of the AOT reactor and/or at the flanges under the AOT
reactor.
8.
Make sure there is no UV lamp failure when the lamp power supply is on.
4.3
4.3.1
Follow this instruction to open the AOT reactor for internal inspection and cleaning.
29
4.3
AOT reactor
7 OpenAOT
1. Access hatch
NGE
! DA
Always disconnect the PureBallast system from the power supply before disassembling, and
make sure it remains switched off during service.
2.
Inspect the bottom of the AOT reactor to see if there are any dirt or larger particles. If so,
remove.
Note: Be careful not to break the quartz sleeves.
3.
4.
30
AOT reactor
4.4
4.4
Follow this instruction to replace a lamp power supply inside a lamp drive cabinet (LDC).
Preparations and conditions
NG
WARNI
Switch off the main breaker on the LDC door. The LPS has high voltage/power (600 V)
inside and on the lamp power connector, even when UV lamps are not lit.
7 LPSmaint
1.
Dismount LPS
Release two power connectors at the bottom of the LPS and the signal cable connector
at the top.
2.
Loosen the nuts at the bottom (1) and the top (2) of the two rods holding the LPS. If necessary,
loosen nuts for adjacent LPS.
NOTE
Make sure not to drop the washer into the LPS. It may cause short circuit.
3.
31
4.5
4.
AOT reactor
Mount LPS
Set the DIP switches on the LPS according to chapter 5. Parameters, section Lamp power
supply (LPS) parameters.
5.
6.
Reconnect the three connectors. Make sure the connectors sit tight.
7.
8.
9.
Switch on the main breaker on the LDC door and check that both LPS:s function correctly
according to instruction Test LPS installation below.
4.5
Follow this instruction to make sure that the installation is OK and safe to use.
Preparations and conditions
NG
WARNI
This instruction must be performed after cable connection. If not hazardous situation may arise
which, if not avoided, will result in death or serious injury.
NGE
! DA
Before operating the AOT reactor, make sure that there is water in the AOT reactor.
2.
Check that there is water in the AOT reactor(s) (LS201-29). Check the LED on the level switch:
Steady yellow light indicates that there is water in the AOT reactor.
3.
Switch on the main breaker on the LDC door. Switch on the power to the AOT reactor using
the switches on the breaker cabinet(s).
4.
Start UV lamps one by one from the control system (set to manual mode). Make sure that the
UV lamps are lit. This is checked in the AOT reactor popup and on the LPS.
Note: It can take up to 150 seconds for the lamp to start.
5.
Check LEDs on the LPS and the alarm list in the control system. Make sure that no alarms
have been triggered by the LPS.
32
6.
AOT reactor
4.5
33
4.5
AOT reactor
5 Filter
This section covers the instructions for service of the filter.
Preparations and conditions
These preparations and conditions are valid for all instructions.
Disconnect the power to the filter, using the main switch on the filter cabinet.
35
Filter
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
36
Filter
5.1
5.2
Follow the instruction below to disconnect the power supply to the filter and to secure it from being
switched on.
7 FilterLock
2.
3.
Take the separate safety lock (illustrated above) and slide the plastic part backwards, to
reveal the wire legs.
4.
Put the end of the wire leg into the hole under the switch knob.
5.
Compress the legs and put the other steel wire leg into the slot to the right of the knob.
6.
Slide the plastic part back to cover the wire legs. It is now possible to lock the safety lock with
a padlock, inserted in the loop at the top of the safety lock.
5.2
Follow this instruction to remove the filter cover and filter candles.
Preparations and conditions
Disconnect the power to the filter, using the main switch on the filter cabinet.
37
5.3
1.
Motor (1)
Protective hood (4) fasten with four of the filter cover bolts (1)
Galvanic protection between the filter cover, retaining plate and housing.
2.
Remove the filter cover (2) by lifting it using the ring bolts.
3.
4.
Lift the retaining plate. Four threaded holes that can be used to attach lifting devices.
Filter
NOTE
The plate must be level when lifted, to avoid damaging the gasket and filter candle O-rings.
It is important not to turn the shaft, after the retaining plate has been removed. If the
rotation is changed, this will make the mounting much more complicated.
5.
6.
5.3
Gaskets for the retaining plate and O-rings for the filter candle must be in good condition.
Make sure that the filter candle O-rings are in position in their groove.
2.
Carefully insert the filter candles (11). Make sure that they are fitted in the hole in the lower
retaining plate and that they they snap into position.
3.
Place the gasket (10) on the filter housing. Make sure that the hole (12) for the locking pin
(9) is not covered by the gasket.
4.
Before re-fitting the retaining plate (8), note that the locking pin shall fit into the hole in the
retaining plate.
38
5.
Filter
5.5
The candles must be guided into the holes in the retaining plate.
6.
Place the gasket (7) on the retaining plate. Make sure to fit the gasket to the locking pin.
7.
Carefully lower the filter cover (2) onto the retaining plate.
NOTE
8.
The drive shaft (6) must fit the shaft in the filter housing. If not: Lift the retaining plate, turn
the shaft in the filter housing and try again.
Protective hood (4) fasten with four of the filter cover bolts (1)
Motor (1)
Galvanic protection between the filter cover, retaining plate and housing
5.4
To replace filter candles, follow the Remove filter candles instruction on page 37, and simply
replace damaged elements.
5.5
39
5.6
Filter
1.
Follow the instruction Remove filter cover and filter candles on page 0 to remove the filter
candles.
2.
If there is scaling on the filter candles: Soak the filter candles in the cleaning agent and leave
them to soak for 13 hours. Read the Preparations and conditions section for instruction
Change and refill CIP liquid.
3.
4.
Spray the filter candles with water from the outside. Start at a distance of 100 cm and reduce
to 50 cm, which is the minimum distance. The water must not be warmer than 60 C. Note: If a
high-pressure cleaner is used, the pressure must not exceed 100 bar (10.0 MPa). Minimum:
20 bar. If a cleaner with higher capacity than 100 bar is used, compensate by increasing the
distance.
5.6
2.
3.
4.
Inspect the anode. Change if the anode has lost approximately 80 % of the zinc mass.
5.
6.
Fasten the lid on the filter and restore the valves in their original positions.
40
6 CIP module
This section covers instruction for service of the CIP module.
6.1
Alpacon descalant is used as cleaning agent in the CIP module. Alpacon descalant offshore
contains no solvents and no inorganic acids. It is non-flammable and non-hazardous.
Preparations and conditions
ON
CAUTI
Risk for eye and skin irritation. Avoid contact with eyes and wear protective gloves. Follow
general rules when handling of cleaning agents regarding ventilation, personal protection etc.
ON
CAUTI
If Alpacon descalant offshore comes in contact with eyes or skin, rinse thoroughly with cold
water.
Before usage, Alpacon descalant offshore must be visually checked. It shall be transparent
light pink in color.
The instructions requires pH test equipment (paper indicator or pH meter). This is not a part of
Alfa Lavals scope of supply.
The pH value should be between 2.0 and 3.0. From the beginning, the pH value is approximately
2.0. When the pH value rises to 3.0 the cleaning liquid must be changed.
Mixing ratio for Alpacon descalant offshore is 1 part concentrated Alpacon descalant offshore to
20 parts fresh water. Follow this mixing ratio, regardless of recommendation on label.
The CIP tank shall be filled with maximum 250 liters. Min and max filling of CIP liquid can
be read on the CIP tank.
Store the CIP liquid according to the instructions on the bottle. General guidelines are:
-
The Alpacon descalant offshore can be frozen and thawed without impairing performance.
Used CIP liquid may contain residues from the cleaning process that can potentially have an
impact on the environment, although this impact is regarded as very small. There are no
transport restrictions.
Used CIP liquid is drained to one of the following: bilge tank, drain tank, sludge tank or bilge well.
When performing these routines, consider the need for service kits. See Spare parts catalogue.
41
6.1
CIP module
7 CIP 589741_description
CIP module
1.
2.
3.
4.
42
CIP module
6.1.1
6.1
Follow this instruction to change CIP liquid, when necessary according to the Maintenance schedule.
Follow the steps below
1.
If the drain valve (2) is connected to the bilge tank, follow the sub steps below. Otherwise, go
to step 2.
1. Open the drain valve V460-3 (2) under the CIP tank.
2. Wait for the tank to be totally drained. Then close the drain valve (2).
2.
If the drain valve is not connected to the bilge tank, the steps below can be followed. This
operation requires login level Advanced operator or higher.
1. Open valves V320-2 and V460-2 from the control valve, and V23011 manually. Start
pump P321-5 (4) and P320-1 (4).
2. Wait for the tank to be totally drained. Then stop the pumps and close the valves in
reversed order. Go to step 3.
3.
Open the cap (1) on top of the CIP tank and pour 12 liters of CIP cleaning agent into the tank.
4.
Fill the tank with fresh water to the Max indication on the tank.
5.
Measure the pH value in the tank to secure that it is approximately 2.0. If not, adjust the
proportions: If the pH value is too high, add more CIP cleaning agent. Measure again.
6.
Go to control system page 4.3 Operation timers. Make a note of the number of AOT reactors
that has been CIPed since last time the CIP liquid was changed. Press the Reset button for
Total number CIP:ed reactors. Requires login level Advanced operator. If this is done each
time the CIP liquid is changed, it is possible to build up experience on how many AOT reactors
it is possible to CIP before it is time to change CIP liquid.
6.1.2
Follow this instruction to refill CIP the CIP tank when there is low liquid level in the tank.
Follow the steps below
1.
Measure the pH value in the tank. Based on the pH value, estimation must be done regarding
the proportions between Alpacon descalant offshore and water. Note that the mixing ratio is
stated under Preparations and conditions above.
2.
Mix the cleaning agent with water separately. The result will get better than if mixed mix in
the tank.
3.
Pour the mixed CIP liquid into the tank. Do not fill over Max indication on the tank.
4.
Measure the pH value in the tank to secure that it is approximately 2.0. If not, adjust the
proportions: If the pH value is still too high, the CIP liquid must be changed. See the Change
CIP liquid instruction in this chapter.
43
6.2
6.2
CIP module
ON
CAUTI
Always wear protective eye glasses and gloves while working on the pump.
NG
WARNI
Always disconnect the PureBallast system from the power supply before disassembling, and
secure it from being switched on.
Before disassembling the pump, the pneumatic hoses must be disconnected, and the extension
pipe must be removed and blocked.
7 CIP pump
44
CIP module
6.2.1
6.2
2.
6.2.2
6.2.2.1
Remove the CIP pump from the CIP module and place it on a work bench.
2.
3.
Place the pump on the side that still has the nuts (the pump lays on the nuts) on a stable ground.
4.
5.
Carefully lift up the suction and discharge connections (13). You have the centre block (12)
and one of the housings with pin screws (14) left.
6.
Upend the pump and carefully pull out the pin screws (14). Be careful not to damage the
diaphragms (15).
6.2.2.2
Put the house wall with the flat side down on a plane surface.
2.
Put one of the pin screws in the hole on the spacer sleeve and turn it until it lays upside
down (180) compared to the starting position. Pull the spacer sleeve carefully against
the lower valve seat (21) until it is free and can be put out.
3.
Stick a something not pointed into the hole for the discharge connection and gently press out
the upper valve seat (20).
4.
Place one of the pin screws on the inside (behind) the valve ball stopper on the lower valve
seat (21). Carefully pull out the valve seat in the housing.
45
6.2
5.
CIP module
Remove the valve ball (23) from the valve seat, buy using a pin screw: Press out the valve ball
stopper (22), which will release the valve ball.
6.2.2.3
Have backup spares of the sealing (36) and backup O-ring (47). There is a risk that these parts
get damaged during this operation.
Press the diaphragms (15) to their neutral position (both have the same distance to the
centre block).
2.
Hold one of the diaphragms (15) and unscrew the other. Then pull out the remaining diaphragm
with the diaphragm shaft (16).
3.
Disassemble the circlips (27) which keep the air valve (61) on its place.
4.
Press out the air valve. A wood shaft of a hammer can be used. Be careful not to damage the
sealing edges towards the diaphragm or the air valve.
5.
If the shaft sealings (36) seem to be worn out, carefully remove them with a pointed tool.
6.2.3
6.2.3.1
2.
Apply some soft soap solution on the air valve O-rings (30).
3.
Push the air valve (61) into the housing. Make sure that the O-rings (30) remain in the right
position. Put the circlip (27) on the other side.
4.
Put the diaphragm (15) with shaft (16) into the centre block. Screw the next diaphragm (15)
onto the shaft (16) and fix the holes.
6.2.3.2
Make sure that the O-rings (18) are placed on the in/outlet (13) before assembling of pump.
2.
46
CIP module
6.5
3.
Make sure all pin screws (14) have one nut (37) and one washer (38) each. Nut should only be
put on one or two threads.
4.
Put all the pin screws through the housing and then turn the housing so it rests on the nuts.
5.
Put the centre block (12) to the housing with screws through the centre block. Be careful not to
damage the diaphragms.
6.
Place suction and discharge connections (13) in their positions in the housing. Be careful not
to damage the O-rings (18).
7.
Put the second housing (11) onto the pin screws (14). Make sure that suction/discharge
connections are in right direction. Be careful with the O-rings.
8.
Fasten the nuts (37) crosswise by hand, with or without washers depending on how much of
the thread comes out. Turn the nuts gently with a tool to close the pump. If some of the nuts
were fastened without washer, unscrew those and put washers underneath. After a few weeks
operation a follow up draft of the nuts is recommended.
6.3
Follow the instruction below to verify that the CIP motor is functioning.
1.
Open valves V320-2 and V460-2 from the control system, and V23011 manually. Start
pump P321-5 (4) and P320-1 (4).
2.
Observe if the motors sound and functions OK. If not, check installation and connections and
attend to and test again.
3.
6.4
Read the conditions below before reparing the junction box or valve blocks.
6.5
Follow this instruction to repair the valve block, mounted on the CIP module.
Preparations and conditions
The valve bodies does not have individual placing, they can be placed in any order.
NGE
! DA
Always disconnect the PureBallast system from the power and air supply before disassembling,
and secure it from being switched on.
47
6.5
CIP module
7 Valve block
Valve block
1.
2.
3.
4.
5.
6.5.1
Remove the scresw holding the valve bodies (2) and the signal plate (4).
2.
3.
4.
Attach a new sealing on the new valve body and fasten the valve body to the valve block.
6.5.2
Follow this instruction to connect the electrical cable from the control cabinet to the CIP valve block.
Follow the steps below
48
CIP module
6.5
1.
2.
Attach the cables according to electrical drawing Control cabinet / interconnection diagram in
chapter 6. Installation description and drawings.
3.
4.
6.5.3
Follow this instruction to clean the valve block house from dirt.
Follow the steps below
1.
2.
Operate the service air according to instruction Open and close valves manually (CIP valves)
on page 19 to blow out the dust.
3.
6.5.4
Follow this instruction to connect pneumatic hoses to the valve block, if they have been
disconnected.
Follow the steps below
1.
Connect the hoses according to the signal plate (4) on the valve block.
49
6.5
CIP module
7 Flow meter
The flow meter consists of two main parts.
Flow sensor: A pipe with four electrodes detecting the flow. On top of the pipe, there is a
terminal box, where the flow transmitter is mounted.
Flow transmitter: Monitors and transmits information to the PureBallast control system. The
flow transmitter is also used to set parameters for the flow meter. A Sensorprom in the flow
transmitter contains the data.
If the flow meter is replaced, settings must be checked according to chapter 4. Parameters,
section Flow transmitter parameters.
7.1
Follow the steps below to mount the flow transmitter on the flow sensor. The flow transmitter is not
factory mounted, to avoid damage during installation of the flow sensor.
Preparation and conditions
See chapter 6. Installation description and drawings, section Control cabinet / Interconnection
diagram for detailed information.
NG
WARNI
Potential hazards / Grounding: The mains protective grounding wire must be connected to the
terminals in accordance with the diagram (class 1 power supply).
Remove and discard the lid from the terminal box on the flow sensor.
51
7.1
Flow meter
7 FM Lid
2.
Fit PG13.5 cable gland for the power and signal cable.
3.
Connect power and grounding to the following terminal positions marked on the circuit board:
1=+
2=
Grounding.
4.
Connect current output signals to the following terminal positions marked on the circuit board:
31 = +
32 =
5.
6.
Mount the flow transmitter on the terminal box using the two screws. If other direction of the
flow transmitter is desired, please follow the instruction Change direction of flow transmitter on
page 53.
7 FM MountTM
52
Flow meter
7.2
7.2
The flow transmitter can be mounted in different directions in relation to the flow sensor. It can
be directed in steps of 90.
Follow the steps below
1.
7 FM MountTM
2.
Disconnect the power supply (terminal positions 1, 2 and grounding) and output signal cables
(terminal positions 31 and 32) from the circuit board.
3.
Remove the coil plug (1) from terminal positions 85 and 86. Remove the plug (2) from terminal
positions 82, 0 and 83.
4.
Unscrew the two screws (indicated below) holding the circuit board to the terminal box and lift
up the circuit board.
Note that the sensorprom is mounted on the underside of circuit board; be careful not to loose
it. Sometimes, the sensorprom remains in its seat on the terminal box.
7 FM ScrewCricuit
53
6.
Flow meter
Disconnect the grounding wire holding the circuit board to the terminal box.
If the flow transmitter shall be turned 180: Move the sensorprom (1 in the illustration
below) to the position on the opposite side of the circuit board and refit in reversed order.
If the flow transmitter shall be turned 90: Continue with next step.
Unscrew the four screws (2) on the terminal box to loosen it from the flow sensor.
7 FM LooseTB
7.
Turn the terminal box to 90 and fasten it with the four screws.
8.
7.3
The control pad of the flow transmitter can be mounted in different directions in relation to the
transmitter. It can be directed in steps of 90.
Follow the steps below
1.
7 FM LoosFrame
54
2.
Flow meter
7.3
7 FMScrewPad
3.
7 FM TurnPad
4.
7 FMScrewPad
55
7.4
5.
Flow meter
Snap-lock (a click is heard) the outer frame onto the control pad.
7 FM FastCover
7.4
2.
Close the main valves connecting the PureBallast pipe net to the vessels ballast pipe net and
secure it from being switched on. See instruction Lock valve in closed position on page 20.
3.
Remove all the flange bolts on the flow meter, except one on each flange. Note that the
remaining bolts on each side must be in the same position on respective flange.
4.
Loosen the nuts on the remaining bolts. Swing the flow meter outside the pipe.
5.
6.
56
8 Valve actuator
This section contain instructions for the valve actuator.
Valve actuator with switch box for position feedback to control system
1.
2.
3.
4.
5.
6.
Switch box
Bracket
Actuator
57
8.1
Valve actuator
7 Actuator
Safety cover
Pad lock
Lower position for indicator screw
Upper position for indicator screw with screw
Position indicator
Center screw
Bracket
Puck
Locking bolt
End stop bolt.
8.1
Do not operate the actuator over pressure limits. It will damage internal parts as well as cause
damage to the housing.
Do not disassemble individual spring elements. Disassembly may result in personal injury.
Do not remove end caps or disassemble the actuator while the actuator is pressurized.
The actuator must not be lubricated. It is factory lubricated for the life of the actuator during
normal working conditions. The standard lubricant is suitable for use from 20 C (4 F)
to +80 C (+176 F).
If a valve actuator is removed, check for loose spindle-bushing. Then make sure the loose
bushing is refitted to avoid play between the actuator and the valve spindle.
Actuator are mounted together with the valve body and pilot valve at delivery. Valve and actuator
mounting are sealed to guarantee correct position indication in relation to throttle position.
8.1.1
58
Valve actuator
M5
M6
M8
M10
M12
M14
M16
M20
8.2
8.3
0506
1011
2325
4852
8286
132138
200210
390410
Dismount actuator
Remove the DIN connector to disconnect the power. Let the air connection remain.
Result: Valve goes to closed position (due to the air connection). The yellow indicators on the
puck shows position of valve: closed. The yellow position indicators are in line with the valve
throttle (indicating closed when the position indicators are in opposite line with the pipe).
2.
Disconnect the air hose to the pilot valve. Verify that the actuator is not pressurized. Always
use caution and double-check that ports 2 and 4 are vented and are free from any accessory
and/or device.
3.
If the actuator have a switch box at the top: Loosen the four screws holding the switch box to
the actuator. Remove the switch box together with its bracket.
4.
Loosen the four hexagonal screws holding the actuator to the valve.
5.
If the actuator is mounted on the valve with a bracket and coupling (dimension 400): Loosen
the screws holding the bracket to the valve. Make sure not to loose the coupling between the
valve and actuator when lifting the actuator.
6.
8.3
59
8.3
Valve actuator
ON
CAUTI
The actuator must not be pressurized at any time during installation as it may result in injury.
The utmost cleanliness is required during air supply connection to the actuator, that is, the
connecting pipe thread, fittings and seals must be clean and dirt-free.
Before fitting onto the valve, make sure the actuator/valve is correctly orientated, depending on
which direction of rotation is required.
Note the position of the groove (2) of the valve stem (3). It indicates the position of the valve
throttle. The illustration shows a square variant, but octagonal versions exist.
7 ValveStem
1.
2.
3.
5.
2.
Make sure that the lock pin (inside the valve stem) only travels in the allowed sector (1) and
that it does not pass the opening (5).
3.
If the actuator is mounted on the valve with a bracket and coupling (dimension 400): First fit
the coupling on the valve stem. Make sure that the red position indicator on the coupling is in
line with the pipe when the valve is open.
4.
Fit the actuator onto the valve stem (or the coupling). The actuator may only be positioned in
even 90 intervals in relation to the valve. It is not allowed to adjust the position by turning the
actuator by hand after it is fitted on the valve stem.
5.
Mount the actuator on the valve with the four hexagonal screws. For each screw, one washer
and one spring washer shall be used. Tighten with torque according to the table Tightening
torques for actuators on page 58.
60
Valve actuator
6.
If the actuator have a switch box at the top: Make sure that the yellow position indicator under
the switch box is in line with the throttle (according to the groove in the valve stem). The yellow
position indicator shall be in line with the valve throttle (indicating open when the position
indicator is in line with the pipe). If not, remove the position indicator, turn it 90 and refit it.
Mount the switch box with the bracket on the actuator, using the four bolts.
7.
8.
Operate the valve to make sure it operates in the desired direction of rotation.
8.4
Follow this instruction to turn an actuator without position sensors on the AOT reactor.
Preparations and conditions
2.
3.
Note the position of the groove of the valve stem. It indicates the position of the valve throttle.
4.
5.
Unscrew the center screw (4) holding the puck (6) and a bracket (5).
7 ActDirectWithout
6.
Lift the puck (6), rotate it 90 and fasten it with the center screw (4) and bracket (5).
61
Valve actuator
7.
Make sure that the yellow position indicators (3) is in line with the throttle (according to the
groove in the valve stem). The yellow position indicators shall be in line with the valve throttle
(indicating open when the position indicator is in line with the pipe). If not, remove the position
indicators, turn them 90 and refit.
8.
8.5
The valve must be mounted and connected to air and power before adjustment.
2.
3.
Before mounting the switch box, change the position of the yellow position indicator, so it
is in line with the throttle.
4.
8.6
Follow this instruction to turn an actuator with a position sensor, if necessary due to lack of space.
Note that the actuator normally should not be altered.
This instruction is valid for the following valves: V201-19 and V201-20 on the AOT reactor.
Preparations and conditions
The valve must be mounted and connected to air and power before adjustment.
62
Dismount the actuator from the valve according to instruction Dismount actuator on page 59.
Put the actuator on a work bench.
2.
Valve actuator
8.6
Disconnect the DIN connector (2) from the coil: First loosen the screw (1), and then pull up
the connector.
7 DisconDINcon
3.
Unscrew the center screw (6) holding the puck (8) and a bracket (7).
7 DirActPosSnsr
4.
Lift the puck (8), rotate it 90 so that one position indicator (5) with a screw is in contact with the
position sensor. Fasten the puck with the center screw (6) and bracket (7).
5.
Move the screw on yellow position indicator to the top position and move the screw on black
position indicator to the bottom position.
6.
Make sure that the position sensor have a maximum distance of 1 mm from the puck (7). The
position sensor and the position indicator screws must be close to give a signal. If not, loosen
the screws and adjust the position. Tighten the screws to fixate the position.
7.
Fit the actuator onto the valve stem in its new position according to instruction Mount actuator
on valve on page 59.
63
8.8
Valve actuator
8.
Make sure that the yellow indicator (5) in line with the valve throttle according to the groove in
the valve stem.
9.
8.7
Follow this instruction to turn the actuator on control valve 2018, if necessary due to lack of space.
Note that the actuator normally should not be altered.
Preparations and conditions
Dismount the actuator from the valve according to instruction Dismount actuator on page 59.
2.
Fit the actuator onto the valve stem in its new position and mount it on the valve with the four
hexagonal screws. For each screw, one washer and one spring washer shall be used. Tighten
with torque according to the table Tightening torques for actuators on page 58.
3.
The position indicator scale shall be correct, but make sure that the scale still indicates correct
opening percent according to the valve throttle position. If not, loosen the four bolts to the
bracket holding the switch box. Lift it and turn the scale so it is correct.
4.
Refit the switch box. Make sure that the peg on the scale fits to the carrier on the puck
mounted on the actuator.
8.8
Follow this instruction to mount a pilot valve on actuator and connect them.
Preparations and conditions
Air and power must be disconnected. The valve position must not be adjusted during the routine.
64
Valve actuator
8.9
7 MountPilote
Check that the O-rings are fitted on the pilot valve, on the side facing the actuator.
2.
Fit the pilot valve on in the actuator, so that the pin on the actuator fits the hole on the pilot
valve. The throttle valves (2 and 4) shall be directed downwards.
3.
Mount the pilot valve with two Allen screws in the holes (1).
4.
5.
Fit the DIN connector (5) on the coil, including gasket. Then fasten the connector with the
screw (6).
8.9
Follow this instruction to tune the open and closed end positions for a valve. This is done if the
valve tends to get stuck in the end position or not close completely.
65
8.10
Valve actuator
7 576075_lock_manual
Note the exact position of the position indicator for reference after adjustment.
2.
Open the padlock (2) on the actuator and remove the safety cover (1).
Result: Two sets of bolts are displayed. The right set adjusts closing position and the left
set adjusts open position.
3.
4.
Adjust end position by turning the end stop blot (4) with small turns.
Clockwise decrease the end position.
Counterclockwise increase the end position.
NOTE
5.
Operate the valve. Compare the new position of the position indicator to see the result on the
adjustment. If needed, adjust again.
6.
Tighten the locking bolt (3) to fixate the position of the end stop bolt (4).
66
Valve actuator
8.10
7 AdjustTravel
Operate the valve manually to check traveling speed according to the instruction in the Operate
valves manually on page 19.
2.
3.
67
8.11
Valve actuator
7 201-8Positioner4
1.
2.
3.
4.
5.
6.
Do not adjust the cam wheel: 2 grey wheels above the adjustment wheel (5).
7 201-8Positioner
Make sure that the transmission ratio selector (6) is set to 90 according to sticker on the
component. If not: Adjust by pressing the bar with a screw driver.
2.
Make sure that the Arrestor device wheel (1) is set to 90. If not: Adjust by turning.
3.
If the positioner display is empty (no power): Open V201-8 manually (approximately 1-5) from
control system to supply power to the positioner.
Result: Menu 1 and turn should be displayed. If not: Press button until it is displayed.
4.
68
Valve actuator
8.11
5.
6.
Go to step 8.
7.
8.
9.
7 201-8Positioner2
Use a screw driver to loosen the yellow locking wheel (counter clockwise).
Turn the adjustment wheel (5) by hand until a 0 is displayed between the d and the U as
shown in the illustration. Normally this is when the value in the screen is close to 0.
7 201-8Positioner3
2.
69
8.11
Valve actuator
9 Ball valve
This section contains maintenance information for the ball valve.
9.1
7 BallV
Max. torque of
body bolts (8)
25 = 1 inch
1316 Nm
14.3 Nm
32 = 1
inches
2025 Nm
14.3 Nm
50 = 2 inches
3540 Nm
19.4 Nm
71
9.1
Ball valve
2.
With the valve in the open position (lever to be parallel to the axis of the pipe), remove all the
body bolts (19) except one.
3.
Loosen the nut (20) on the remaining bolt. Swing the body outside the pipe.
4.
5.
Replace seals (5, 6, 7, 9, 10, and 24). They are available in a spare parts kit for the ball valve.
6.
Mount in reverse order. The body bolts of the valve should be tightened evenly. Tighten
one-side snugly, then the one diagonally across. Repeat for the other bolts, bringing them all
down tightly in sequence. Make sure the maximum tightening torque is observed according
to the table above:
7.
8.
72
10 Level switch
This section contains information about the level switch LS201-29 installed in the AOT reactor. For
information about status indications, see chapter 5. Alarms and faultfinding, section Level switch.
7LS Component
Level switch
2.
Seal the level switch with lock tight or equivalent pipe seal.
3.
4.
Identify the sensor align mark () on the component. Make sure that it is positioned on the
upper side of the level switch.
73
10.3
5.
10
Level switch
Complete the seal carefully by tightening the component with a spanner. Use the spanner on
the hexagon flats, but not on the level switch body.
The external surface may be hot. Care must be taken to avoid possible burns.
2.
Loosen the component with a spanner. Use the spanner on the hexagon flats, but not on
the level switch body.
3.
Remove the level switch and remove the old seal from the threads.
Make sure that the component i powered (the green LED shall be lit).
2.
Hold a magnet to the test point indicated on the on the level switch, indicated below.
7LS Test
3.
74
Make sure the level switch reacts to the magnet. The component is OK if the green and
yellow LED is lit.
7 TS and TT
Seal the components threads using lock tight or equivalent pipe seal.
2.
3.
Tighten the component with a spanner. Use the spanner on the hexagon flats, but not on
the components body.
4.
75
11
The external surface may be hot. Care must be taken to avoid possible burns.
2.
Loosen the component with a spanner. Use the spanner on the hexagon flats, but not on
the components body.
3.
Remove the level switch and remove the old seal from the threads.
76
12 Control panel
This section covers instructions for service of the control system.
Control panels may only be cleaned when set in wipe mode. This is to prevent unintended
functions from being triggered by buttons pressed during cleaning.
Never use aggressive solvents, chemicals, scouring agents, pressurized air or steam jet.
2.
Clean the display and surrounding front cover with a soft cloth and mild detergent. Do not
spray detergent directly on the control panel.
When the panel is mounted, software must be updated and settings performed accroding to
last step of the instruction.
2.
77
12.2
3.
12
Control panel
7BeijerScrews
4.
Hold the panel on the outside so it does not fall out. At the same time: Slide the brackets
and remove them. Then remove the panel.
7BeijerBracket
2.
Hold the panel on the outside so it does not fall out. At the same time: Attach the brackets on
the inside by sliding them into place.
7BeijerBracket
78
12
Control panel
3.
12.2
7BeijerScrews
4.
Open the small cover on the rear side. Make sure that all DIP switches are in position OFF.
7BeijerMODE
5.
6.
7.
Remove the laminated film, to avoid static electricity that could damage the terminal.
8.
Make sure that the control panel is brought to ambient temperature before it is started. If
condensation forms, ensure that the operator panel is dry before connecting it to the power
outlet. Ensure that the voltage and polarity of the power source is correct.
9.
Load new software to the panel according to instruction Update PLC software and Install
TA150 firmware in chapter 3. Operating instruction and control system description. Also
set communication according to Set control panel IP address and Set remote control panel
communication.
79
12.2
12
Control panel
7 594060 RCP
81
13
7 RemotPanelCon
If used, a network switch (3) is installed at a location of your choice, near the position of the
remote control panel.
24 VDC cables are not included in scope of supply. Use a cable with minimum cross section of
0.75 mm2, preferably halogen free and flexible.
The remote control panel must have been mounted on a location of your choice. See Remote
control panel (optional) / Dimensional drawing in chapter 6. Installation description and drawings.
Two wires are mounted between terminal and switch power contact (2) no 1=DC, no 2=DC+,
cables are marked + and .
Prerequisites for cable length and cable types are stated in chapter 6. Installation description
and drawings, section Remote control panel integration (optional). Ethernet and fiber cable can
be used. This instruction is written for Ethernet, but if fiber is used use fiber cable and connect
them to the fiber ports instead of Ethernet ports.
Switch off the PureBallast system and disconnect it from the power supply.
At the back of the remote control panel, fasten the Ethernet cable in Ethernet port 1. Fasten
the other end of the cable in the network switchs Ethernet port number 1 (1).
2.
Connect an Ethernet cable from the network switch near the remote control panel to the
network switch in the control cabinet (see position 1 in illustration on page 83). Also see cable
W501 in Control cabinet / Interconnection diagram.
3.
If more than one remote control panel is installed, connect an Ethernet cable from Ethernet
port number 2 (1) in the network switch (near the remote control panel) to the second remote
control panel (or via a second network switch, if used).
4.
Connect a 3 core cable from network switch terminals 4 (+), 5 () and 6 (GND) to the remote
control panels 24 VDC port (2).
5.
82
13
13.2
7 591773 RI
Loosen the right end stop on the DIN rail at position (1).
2.
3.
Fasten the end stop to fixate the network switch at position (1).
4.
On the PLC, disconnect the Ethernet cable (coming from the main control panel) from port IF2
and connect it to the network switch port: 1.
5.
Connect an Ethernet cable in the IF2 on the PLC and connect the other cable end to the
network switch port: 2.
6.
Connect wire 400 (DC) to terminal 400 (3) and to network switch (1) terminal no: 1.
7.
Connect wire 402 (DC+) to PLC terminal 15 (2) and to network switch (1) terminal no: 2.
8.
Follow instruction Mount and connect network switch for remote control panel to connect
remote control panel.
83
13
Hold down the plastic clip on the top of the terminal block and pivot the block towards you.
7IO1_X025002A
2.
3.
Hold down the triangle on the top of the I/O board and loosen the board.
7IO2_X025003A
85
14.1
4.
14
Pull the board straight out (otherwise it can fasten in one of its guides).
7IO3_X025004A
5.
Compare the part number of the new I/O board to the old board, to make sure it is correct.
6.
If changing more than one board at a time, check with the electrical diagram to ensure that
the boards are mounted in the right places.
7.
Mount the new I/O board by pressing it straight into place. Make sure the board is firmly in
place, otherwise it will be impossible to mount the cable terminal.
7IO4_X025005A
8.
Remount the terminal block. Make sure the clip on the bottom of the block fastens properly in
place on the axel on the bus holder.
7IO5_X025007A
86
14.2
Pivot the terminal block on the axel until the clip on the terminal block top fastens into place in
the I/O board.
7IO6_X025006A
Lubricate the inside surfaces of the frame with Roxtec Assembly Gel or equivalent, specially
in the corners.
7 Cable1
2.
3.
4.
Peel off layers until you achieve a 0.1-1.0 mm gap between the two module halves when
held against the cable.
87
14.2
14
7 Cable2
7 Cable3
5.
Lubricate all modules thoroughly, both on the inside and the outside surfaces.
7 Cable4
6.
Insert the modules from the back of the frame opening. If possible, start with the largest
modules.
7 Cable5
88
14.2
Tighten the compression unit firmly to seal the frame. Maximum 10 Nm. A good indication is
when the lubrication is squeezed out between the modules.
7 Cable6
89
Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone:
Telefax:
Contents
1
Important information
Control Cabinet
2.1 Cabinet
10
12
14
16
3.1 Cabinet
18
AOT reactor
34
38
40
42
44
4.5 Valve
46
Filter, RF10-30
48
54
56
58
60
62
64
11 CIP module
66
70
11.2Valve
72
11.3Valve block
74
11.4Air distribution
76
78
80
82
Important information
1 Important information
State number of ordered parts. Note that the quantity in the tables do not states number of parts
delivered (only the how many of that parts that are included in the mother component).
It is only possible to order parts included in the tables.
Safeguard your commitment to quality by always using genuine Alfa Laval spare parts.
Remember, Alfa Laval cannot accept responsibility for the failure of separator equipped with
non-original spare parts. We guarantee the quality and reliability of our products.
When ordering, refer to part number listed in this catalogue and serial number, described in
chapter 7. Service manual, section Serial number information.
Book No.
2 Control Cabinet
Machine unit number or
Subassembly description
Ref
Part No
Description
1
3
4
5
6
7
8
8.1
9
10
10.1
11
12
13
14
14.1
15
16
16.1
17
18
19
20
21
22
23
24
24.1
24.2
9006237 80
9006852 01
595670 80
9006804 01
9006805 01
9006806 01
221891 04
223101 47
582212 148
591103 60
591103 10
591103 45
582212 125
9004299 04
582212 67
582212 60
582212 63
591103 38
591103 81
221701 03
9005006 80
582212 91
582212 147
582212 104
582212 102
582212 105
582212 104
582212 171
582212 167
Cabinet
Software, panel
Panel
DIN-rail 35x15
DIN-rail 35x15
DIN-rail 35x15
Lock nut
Washer
End stop (clip fix)
Over current prot. Relay
Auxiliary contact
Breaker handles
Power supply unit
Fuse
Terminal, PIT 2,5-3PV
Bus bar blue
Terminal D-PIT 2,5-3L
Contactor
Relay, over current prot.
Screw
I/O module
VIP-2, D 9SUB
Patch panel
Terminal PITTB 2,5
Terminal PITTB 2,5 PE
End plate D-PITTB
Terminal PITTB 2,5
Busbar 1/3/5-5, red
Busbar 20-5 Blue
25
26
26.1
26.2
27
28
29
29.1
29.2
30
31
32
33
34
36
37
38
39
41
42
44
45
46
47
48
49
51.1
51.2
52
52A
582212 105
582212 67
582212 60
582212 03
582212 63
582212 168
582212 123
582212 86
582212 87
9002362 81
582221 90
582212 15
593724 03
594009 03
583556 16
583556 17
9003522 07
9003522 06
591922 01
595361 01
223101 47
221803 02
582221 89
582356 18
582212 155
591103 36
596894 01
596894 01
9009695 80
9006853 01
-80
1
1
1
1
2
1
13
13
13
1
1
1
1
4
6
1
1
1
1
4
1
2
2
3
1
1
40
1
1
1
4
1
1
1
2
1
1
1
3
1
1
7
5
2
1
2
1
1
1
2
2
1
1
2
1
1
1
1
1
9004429Quantity
Notes
See page 10
See page 12
Connected: 11,15,19
Short end 15 pin, connected:
12,18,32,34,36,38,40
155mm
155mm
See page 14
245mm
500mm
Book No.
Control Cabinet
2690A
Book No.
Ref
Part No
Description
52B
53
55
68
69
70
Z
Z0.1
9009688 01
9009696 80
595673 01
9008672 80
582212 122
582212 13
597330 01
597331 01
Filter
Air outlet
Ethernet cable
Cable set
Terminal block
End plate
Cable seal
Cable seal
-80
9004429Quantity
Notes
1
1
1
3
3
Book No.
Control Cabinet
2690A
Book No.
2.1 Cabinet
Machine unit number or
Subassembly description
Ref
Part No
2
3
4
5
6
7
8
10
11
12
13
15
16
19
22
23
24
25
26
27
28
29
30
31
32
33
34
35
9006246
594009
26556
9006761
70915
221891
221716
579385
9003013
593991
9003024
223107
221891
593254
221711
593282
221803
223101
593239
581688
594488
221711
223101
221891
587276
70560
221891
544465
10
Description
01 Door
01 Screw
Spring washer
80 Mounting plate
Spring washer
05 Hexagon lock nut
01 Screw
01 T-handle
01 Rod Guide
01 Latch
02 Rod for latching
34 Spring washer
04 Lock nut
01 Retaining ring
19 Screw
01 Washer
02 Nut
73 Washer
01 Nut
01 Bracket
01 Washer
16 Screw
47 Washer
04 Lock nut
02 Washer
Washer
05 Hexagon lock nut
04 Locking liquid
-80
1
6
6
1
16
12
4
1
2
1
2
4
4
1
1
1
2
1
1
4
4
8
8
8
6
6
6
1
9006237Quantity
Notes
MRX-Z5x6 fzb
FBB 5,1 fzb
M6M 8 fzb
Book No.
Cabinet
Control Cabinet
2718A
2.1
Book No.
11
Ref
Part No
1
1.1
1.2
1.3
2
3
4
5
6
7
8
9
10
12
580986
597033
580986
580986
580986
580986
580986
580986
580986
580986
580986
580986
580986
580986
12
67
18
76
76
17
30
51
08
33
32
59
06
16
55
Description
PLC unit
Interface module
Communication module
Communication module
Bus module
Supply Bus Module
12 Digital Input
4 Analogue input
Output Module
Supply Module
12 Digital Output
6 Relay output
Terminal block 12-pin
Compact flash card
-80
1
1
1
1
11
1
3
2
1
1
1
4
12
1
9005006Quantity
Notes
Incl. locking plate.
Book No.
I/O module
Control Cabinet
2772A
2.2
Book No.
13
Ref
1
2
3
Z
14
Part No
Description
582212
582212
582212
582212
119
120
186
172
-81
8
1
1
9002362Quantity
Notes
Book No.
Relay module
Control Cabinet
2692A
2.3
Book No.
15
Ref
1
19
16
Part No
Description
9011549 80 Cabinet
9005496 01 Lamp Power Supply
-80
1
16
9004480Quantity
Notes
See page 18
Book No.
2774A
Book No.
17
3.1 Cabinet
Machine unit number or
Subassembly description
Ref
Part No
Description
1
2
3
4
5
6
7
9
9.2
10
11
12
13
14
15
19.1
19.2
19.3
20
21
22
23
24
25
26
26.1
27
28
29
30
31
32
33
34
35
36
37
37.1
38
39
40
41
42
43
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
9003628 80
9004211 01
9004212 01
9004213 01
9004506 80
9004214 01
590624 03
9004254 01
595558 01
523127 04
9004426 01
582356 30
582356 26
582356 28
582356 27
582212 164
582212 163
582212 165
582221 90
9006677 01
9004313 80
9005494 01
591103 46
591103 60
591103 54
591103 10
591103 66
591103 64
591103 61
582212 125
9004299 04
9004299 01
9004299 02
9004299 03
9006326 01
582212 146
9004174 80
594728 01
9004507 80
9004329 80
9004303 02
582212 147
9004508 80
582212 148
9004299 07
582212 141
70560
221030 10
221803 02
221803 03
221891 01
221891 02
221891 04
221891 05
223101 03
223101 16
223101 17
223101 47
587276 02
Cabinet
Centrifugal fan
Inlet duct
Protection
Terminal block
Heat exchanger
Temperature sensor
Check valve
Wire
Hexagon nipple
Hose
Lamp green, compl.
Signal lamp, White
Button ill. blue, compl.
Sign holder
Phoenix Contact
Phoenix Contact
Phoenix Contact
PE Connection bar
Filter
Main breaker
Transmitted handle kit
Breaker door seal
Over current prot. Relay
Over current prot. Relay
Auxiliary contact
Bus bar
Connection
Self-res. short-circ. lim
Power supply unit
Fuse
Relay safety
Relay safety
Relay safety
Temperature relay
Interface relay, 24V
I/O module
Temperature sensor
Terminal block
Liquid leakage amplifier
Sensor, liquid
Patch panel
Terminal block
End stop (clip fix)
Terminal
Cable holder
Washer
Screw
Nut
Nut
Lock nut
Nut
Lock nut
Hexagon lock nut
Washer
Washer
Washer
Washer
Washer
18
-80
1
1
1
1
1
1
1
1
1
2
2
1
1
1
3
16
16
16
1
1
1
1
1
2
16
16
6
3
3
1
3
1
1
1
1
1
1
1
1
1
1
2
1
13
3
2
3
12
5
1
2
4
4
3
2
4
1
21
3
9011549Quantity
Notes
See page 22
830mm
See page 26
See page 28
See page 30
Book No.
Cabinet
2775A
3.1
Book No.
19
Ref
61
62
63
64
66
67
69
73
74
75
76
20
Part No
Description
593724 03
594009 02
594009 03
594009 04
594009 07
9005626 01
582212 181
9008374 01
9008382 80
582212 122
582212 13
Distance screw
Screw
Screw
Screw
Screw
Self-tapping screw
Sc clamp SK 35 D
Igniter
Cable set
Terminal block
End plate
-80
6
4
3
2
2
5
2
2
1
1
1
9011549Quantity
Notes
See page 32
Book No.
Cabinet
2775A
3.1
Book No.
21
3.1.1 Cabinet
Machine unit number or
Subassembly description
Ref
Part No
Description
1
1A
1B
1C
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
27
28
29
30
31
33
34
35
42
42.1
58
59
60
62
63
64
66
67
69
70
72
73
74
76
77
79
80
82
83
88
89
9005142
591874
591874
9003031
9005143
9005144
221803
223101
9005145
9008903
221891
9003089
223101
221726
9003394
587276
221891
221716
9003390
223101
221030
9003401
223101
221030
9003186
9003410
223101
221030
593287
9003113
9003114
9002947
9002942
223101
221030
221891
221891
223101
587276
221851
591889
593780
9003186
9006316
221030
223101
9006322
9006519
221891
223101
9008424
221851
587276
221891
223101
223101
221891
587276
221851
Cabinet
Seal
Seal
Condensation outlet
Door, RH
Door, LH
Nut
Washer
Stand
Washer
Hexagon lock nut
Vibration damper
Washer 13x24x2,5
Screw
Mounting plate
Washer
Hexagon lock nut
Screw
Bracket, fan
Washer
Screw
Sheet, heat exchanger
Washer
Screw
Plug
Sheet, heat exchanger
Washer
Screw
Pop rivet, multi grip
Cable seal
Cable gland
Yoke
Stud bolt
Washer
Screw
Lock nut
Lock nut
Washer
Washer
Cap nut
Cable tie mount
Key
Plug
Cover, fan
Screw
Washer
Sheet
Cover
Nut
Washer, 4,3x9x0,8
Protection
Cap nut
Washer
Lock nut
Washer
Washer
Lock nut
Washer
Cap nut
22
80
04
05
01
80
80
02
47
80
05
05
02
49
10
01
02
05
01
01
47
10
01
47
10
01
01
47
10
01
01
02
01
01
47
02
04
04
47
01
05
01
01
02
01
10
47
01
01
02
41
01
05
01
04
47
47
04
01
05
-80
1
1
1
2
1
1
12
12
1
12
12
2
2
2
1
15
12
3
1
6
6
1
3
3
1
1
9
9
3
1
2
18
36
72
36
36
17
17
8
8
3
1
2
1
3
3
2
1
20
20
3
5
5
2
2
7
7
17
17
9003628Quantity
Notes
Upper LPS rack, left
Upper LPS rack, right
Cabinet floor and heat exchanger floor
Book No.
Cabinet
2700A
3.1
Book No.
23
Ref
Part No
Description
90
91
92
Z
Z0.1
9009714
221891
223101
597330
597331
Sheet
Lock nut
Washer
Cable seal
Cable seal
24
01
04
47
01
01
-80
1
1
1
9003628Quantity
Notes
Book No.
Cabinet
2700A
3.1
Book No.
25
Ref
Part No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
580986
580986
580986
580986
580986
597033
580986
580986
580986
580986
580986
580986
580986
597033
26
64
17
62
63
72
19
59
08
53
61
16
19
20
20
Description
Bus Module
Bus module
Interface Module
Bus Supply
Communication module
16 Digital input
12 Digital Output
4 Analogue input
2 Analogue Output
4 Analog Input (PT100)
Terminal block 12-pin
Locking Plate left
Locking Plate right
Terminal Block 16-pin
-80
1
6
1
1
1
1
1
1
1
1
6
0
0
1
9004174Quantity
Notes
Included in pos:1
Included in pos:1
Book No.
Cabinet
2702A
3.1
Book No.
27
Ref
1
2
3
4
5
6
7
28
Part No
Description
582212 67
582212 64
582212 65
582212 63
582212 71
582212 03
582212 148
-80
7
1
2
1
1
1
1
9004507Quantity
Notes
Book No.
Cabinet
2704A
3.1
Book No.
29
Ref
1
3
4
5
6
7
8
9
10
11
12
13
15
16
30
Part No
Description
582212 148
582212 130
582212 122
582212 88
582212 89
582212 132
582212 131
582212 156
582212 157
582212 133
582212 15
582212 15
582212 137
582212 136
-80
2
1
2
22
1
2
2
32
1
1
1
1
9
1
9004508Quantity
Notes
Cut to 294 mm
Cut to 289 mm
Cut to 431 mm
Book No.
Cabinet
2705A
3.1
Book No.
31
Ref
1
2
3
4
5
6
7
8
9
11
12
14
15
16
50
51
32
Part No
Description
-80
9008383 01
9008383 02
9008383 03
9008383 04
9008383 05
9008383 06
9008383 12
9008383 13
9008383 08
9008387 01
9008693 01
595673 04
9004439 01
9008388 01
582221 99
582221 100
Cable, 70mm
Cable, 35mm
Cable, 2,5mm
Cable, 2,5mm
Cable, 2,5mm
Cable, 2,5mm PE
Cable, 25mm PE
Cable, 6mm PE
Cable, 1,5mm
Cable, 0,75mm
Cable, 2x2x0,5mm
Ethernet cable
Cable
Cable, 2x1,5mm
Ferrite
Ferrite
5
15
20
20
20
25
1
2
6
150
6
2
1
35
2
2
9008382Quantity
Notes
on 595673 04
On incomming LAN cable
Book No.
Cabinet
2377A
3.1
Book No.
33
4 AOT reactor
Machine unit number or
Subassembly description
Ref
Part No
Description
-82
1
2
1
1
4
5
7
8
221711
223101
9001357
594412
Screw
Washer
Sensor
Valve V201-19 and V201-20
8
8
1
1
8.1
8.2
9
10
12
13
14
15
16
16.1
16.2
16.3
16.4
17
17.1
17.2
17.3
17.4
17.5
18
19
20
590667
9011365
223101
9006325
9006324
558663
594171
9005051
9005051
9005051
9005051
9005051
9005052
9005052
9005052
9005052
9005052
9005052
526350
558663
594413
08
32
03
92
01
01
64
01
01
04
01
04
07
06
08
05
01
05
07
10
09
08
05
03
80
V201-19
Hexagon head screw
Washer
Thermometer, resistance
Temperature, switch
Gasket washer
Vibration limit switch
Cable
Cable
Cable
Cable
Cable
Cable
Cable
Cable
Cable
Cable
Cable
Plug
Gasket washer
Valve
1
32
32
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
20.1
594413 80 Valve
20.2
594413 80 Valve
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
2210463
223101
1761805
597049
594707
581534
260321
592304
592304
552801
9004638
2210296
223101
221803
9006320
36
37
38
39
63
95
34
595272
558710
597044
596103
554214
03
37
01
01
02
01
25
01
02
50
01
02
33
27
80
01
02
04
01
06
Screw
Washer
Safety valve, 6 bar
Coupling, elbow 90
Pipe
Distributor
Hexagon screw
Plug
Plug, 1/4
Push-on connector
Clamp
Screw
Washer
Nut
Lamp cable
Tube, 6x1 mm
Air Hose Nipple
Cable
Screw
Cable tie
12
12
1
1
1
1
2
1
1
5
1
1
3
1
16
16
4
5
1
4
30
9002700Quantity
Notes
See page 38
A-side
See page 40
B-side
See page 42
V201-19
See page 44
V201-20
See page 44
TT201-33
TS201-60
LS201-29
V201-19
V201-20
V320-4
V404-36
V321-2
GS201-19
GS201-20
QT201-50
TS201-60
TT201-33
LS201-29
V320-4
See page 46
V321-2
See page 46
V404-36
See page 46
RV201-23
Book No.
AOT reactor
2688A
Book No.
35
Ref
Part No
Description
96
Z
ZA
ZB
Z0.1
Z0.1A
Z0.1B
544465
9009521
9007810
579380
594645
9000738
599555
Pipe-Seal
Lamp, spare set
UV lamp with contact
O-ring, 15,1x2,7
Quartz sleeve set
Quartz sleeve
O-ring
36
15
80
80
01
82
02
01
-82
1
9002700Quantity
Notes
1
2
1
2
Book No.
AOT reactor
2688A
Book No.
37
Ref
Part No
Description
-82
3
6
7
8
9
10
11
12
13
14
15
16
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
33A
34
35
36
38
39
40
41
66169
9003326
221711
9002009
9004878
9002860
9001098
9001897
221036
223101
526350
558663
9001539
221711
9003669
221040
41456
221035
70560
9003661
221035
9003662
2210295
223101
9003672
221035
9004889
9004886
221040
35120
9007794
9009416
221031
223101
221803
Drive screw
Glass socket
Screw
Lamp bush
Cap
Nut
Blind flange
O-ring
Screw
Washer
Plug
Gasket washer
Cable bracket
Screw
Bottom bracket
Screw
Washer
Screw
Washer
Stay
Screw
Plate
Screw
Washer
Upper bracket
Screw
Lifting bracket
Bracket
Screw
Nut
Cable rail
Cable rail
Screw
Washer
Nut
8
32
96
32
32
32
1
1
10
10
1
1
8
16
2
16
24
4
24
2
12
1
1
2
2
8
1
1
4
4
2
2
4
8
4
38
01
13
81
80
01
01
01
02
33
05
03
01
23
01
04
06
01
36
01
03
17
01
03
01
80
55
01
01
21
32
28
9002699Quantity
Notes
Book No.
AOT reactor
2685A
4.1
Book No.
39
Ref
1
2
3
4
5
6
7
11
12
18
19
20
22
25
40
Part No
Description
9004825 80
582212 148
582212 88
582212 122
582212 154
582212 70
582212 89
582212 151
582212 150
9003031 01
589569 21
589569 44
582356 26
582356 30
Enclosure
End stop (clip fix)
PIT 2,5
Terminal block
Busbar 5-5 Bu
Plug In Bridge, FBS 3-5
D-ST2,5
Socket
Socket
Condensation outlet
Cable Gland EMC M32
Counter nut EMC M32
Signal lamp, White
Lamp green, compl.
-80
1
2
28
3
1
1
1
6
5
1
2
2
1
1
9003748Quantity
Notes
Marked acc. to interconnection diagram.
400
402
Book No.
Junction box
AOT reactor
2679A
4.2
Book No.
41
Ref
1
2
3
4
5
6
7
8
9
10
42
Part No
Description
9004844 80
582212 148
582212 156
582212 157
9003031 01
589569 59
9004959 01
589569 45
589569 21
589569 44
Enclosure
End stop (clip fix)
Terminal, PT 6
End cover, D-PT 6
Condensation outlet
Cable gland EMC-brush M40
Insert, 8x6 mm
Counter nut EMC M40
Cable Gland EMC M32
Counter nut EMC M32
-80
1
2
32
1
1
4
4
4
4
4
9004960Quantity
Notes
Marked acc. to interconnection diagram.
Book No.
Junction box
AOT reactor
2680A
4.3
Book No.
43
Ref
Part No
Description
1
2
3
4
5
6
8
9
Z
576886
576075
576071
585976
594410
583012
9009912
595215
576075
Valve, A350
Air actuator, DA551
Pilot valve
Coil, 24 V DC
Valve connector
Throttle valve, 1/4
Sensor
Plate
Actuator spare part kit, DA/SR 551
44
26
05
01
01
01
01
01
01
65
-92
1
1
1
1
1
2
1
1
594412Quantity
Notes
Lug type
Book No.
AOT reactor
2686A
4.4
Book No.
45
4.5 Valve
Machine unit number or
Subassembly description
Ref
Part No
1
2
3
4
5
6
Z
590037
576075
576071
585976
594410
583012
576075
46
01
21
01
01
01
01
71
Description
Valve, DN32
Air actuator, SR101
Pilot valve
Coil, 24 V DC
Valve connector
Throttle valve, 1/4
Actuator spare part kit, DA/SR 101
-80
1
1
1
1
1
2
1
594413Quantity
Notes
Book No.
Valve
AOT reactor
2330A
4.5
Book No.
47
5 Filter, RF10-30
*=On request only, contact your local Alfa Laval representative
Machine unit number or
Subassembly description
Ref
Part No
Description
11
11.5
12
13
14
15
17
18
18.5
19
19.1
19.2
19.3
19.4
19.5
21
23
24
25
26
27
28
29
30
31
32
33
34
34.5
35
36
37
38
39
39.6
39.7
39.8
39.9
40
40.5
41
51
52
53
61
65
65.3
65.5
68
70
70.5
71
71.5
72
72.5
73
74
75
76
9006822
9000396
9000396
9006771
9000396
9000397
9000394
9000394
9000396
9000398
9000398
9000398
9000398
9000398
9000398
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000398
9000395
9000395
9000398
9000394
9000394
9000398
9000398
9000395
9000398
9000397
9000395
9000397
9000397
9000398
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000398
9000396
9000396
9000396
48
02
55
51
02
92
06
03
62
12
51
50
33
21
45
11
42
20
21
22
23
24
25
26
62
63
27
28
29
29
32
09
34
69
08
23
43
64
65
84
72
20
51
07
07
93
96
37
97
02
72
77
73
74
75
76
46
30
04
21
-80*
1
1
1
9
1
1
1
1
1
1
22
20
18
2
4
1
3
1
1
2
1
1
1
1
1
1
1
1
1
2
2
1
1
4
1
1
1
1
1
2
1
1
1
1
1
2
2
2
3
1
1
1
1
1
1
12
3
16
1
9006972Quantity
Notes
0,5m
1,0m
Book No.
Filter, RF10-30
2693A
Book No.
49
Ref
Part No
Description
77
81
82
83
83.5
83.6
83.7
83.8
84
85
85.5
86
86.5
87
87.5
88
88.5
88.6
89
89.1
89.2
89.3
89.6
89.8
91
92
95
112
113
113.5
114
114.5
120
120.5
121
121.5
122
126
130
140
145
155
155
155.5
155.6
155.7
156.5
157
157.5
158
160.5
161
161.5
162
162.5
163
167.5
168
168.5
169
9000396 19
9000396 13
9000396 24
9000396 63
9000398 02
9000398 40
9000398 11
9000398 59
9000398 01
9000396 52
9000398 92
9000396 57
9000396 14
9000396 58
9000396 59
9000398 20
9000398 10
9000398 42
9000396 91
9000396 50
9000396 40
9000396 54
9000396 53
9000396 34
9006769 02
9000395 39
9000395 85
9000398 03
9000398 41
9000398 02
9000398 40
9000398 11
9000395 31
9000395 81
9000398 32
9000398 07
9000395 45
9000396 29
9000394 13
9000394 123
9000394 132
9000394 91
9000394 92
9000394 94
9000398 38
9000398 91
9000394 69
9000398 18
9000398 90
9000397 22
9000396 89
9000398 77
9000398 78
9000398 67
9000397 22
9000396 85
9000396 90
9000398 97
9000398 17
9000398 90
50
-80*
8
1
10
1
4
4
4
2
8
1
2
1
1
1
1
8
8
8
1
1
1
1
1
2
1
1
3
4
4
4
4
4
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
4
4
1
1
4
4
4
1
1
2
8
8
8
9006972Quantity
Notes
3,0m
3,0m
2m
Book No.
Filter, RF10-30
2693A
Book No.
51
Ref
Part No
Description
169.5
170
171
172
173
177
178
178.1
178.2
178.5
179
180
183
184
186
188
189
189.5
190
191
191.5
192
200
200A
200B
200C
200D
200E
200F
200G
200H
200I
200J
200K
200L
200M
200N
200O
200P
200Q
203
301
302
303
Z
Z0.1
Z0.2
9000397 21
9000398 103
9000398 108
9000398 150
9000398 94
9000397 14
9000398 141
9000398 87
9000398 95
9000398 83
9000398 95
9000398 87
9000395 86
9000398 84
9000398 43
9000396 71
9000397 10
9000397 19
9007128 80
9000398 85
9000398 95
9000398 87
9007005 82
9000396 95
9007239 01
9007239 02
9007239 03
9007239 04
9007239 05
9007239 06
9007239 07
9007239 08
9007239 23
9007239 11
9007239 10
9007239 12
9007239 13
9007239 24
9007239 25
9007239 26
9007007 01
9000395 83
9000397 08
9000397 09
9007098 82
9007100 82
9007099 80
Sealing
Hex-screw
Hex-screw
Washer
Hex-nut
Sealing
Hex-screw
Washer
Hex-nut
Hex-screw
Hex-nut
Washer
Distance piece
Hex-screw
Spring ring
Fixing plate for Control
Sealing EN1514-1-IBC-DN 1
Sealing
Valve, V309-1
Hex-screw
Hex-nut
Washer
Electrical cabinet
Cabinet
Display
Main switch
Power supply
CPU
Digital output
Relay
Prot. switch
Contactor
Terminal
PE terminal
Terminal
Fuse
Sensor box
Fuse
Fuse
Fuse
Pressure transmitter
Filter element
O-ring 72.62 x 3.53*
O-ring 110.72 x 3.53*
Sealing kit
Filter element kit
Proximity switch kit
52
-80*
2
20
20
80
40
4
8
8
8
8
8
16
1
8
8
2
1
1
1
4
4
8
1
1
1
1
1
1
1
2
1
1
19
7
4
4
2
9006972Quantity
Notes
See page 54
3
9
9
9
Book No.
Filter, RF10-30
2693A
Book No.
53
Ref
Part No
Description
1
2
16
85.5
193
193.1
194
196
197
9000394 141
9000394 144
9000396 08
9000398 92
9000396 01
9000396 93
9000396 11
9000396 07
9000398 04
Butterfly valve
Actuator
Coupling M12 x 1, 5-pole,
Screw-in connector
3/2-Way valve MND310701 G
Coil
Exhaust throttle valve -G
Control plate RF3-x-EPT R
Cylinder screw ISO 4762-M
54
-80
1
1
1
1
1
1
1
1
2
9007128Quantity
Notes
Book No.
Valve, V309-1
Filter, RF10-30
2698A
5.1
Book No.
55
Ref
Part No
Description
1
2
3
5
6
7
8
19
9007167
9007166
9007185
9007192
9007193
9007196
9007186
587927
Valve, A300
Air actuator, AT 451U
Pilot valve
Throttle valve, 1/4
Actuator cable
Bracket
Switch box
Locking device, AL79 451
56
23
06
01
01
01
02
01
07
-88
1
1
1
2
1
1
1
1
9007170Quantity
Notes
Book No.
2710A
Book No.
57
Ref
Part No
Description
1
1
2
2
3
5
6
7
7
8
22
23
Z
9007167
9007167
9007166
9007166
9007185
9007192
9007193
9007196
9007196
9007186
9007198
595558
9007184
Valve, A50
Valve, A300
Air actuator, AT 101U
Air actuator, AT 451U
Pilot valve
Throttle valve, 1/4
Actuator cable
Bracket
Bracket
Switch box
Serial no. plate
Wire
Insulate plate
58
15
23
01
06
01
01
01
01
02
01
01
01
01
9007172-88 -80
1
1
1
2
1
1
1
Quantity
1
Notes
1
1
2
1
1
1
1
1
Book No.
2714A
Book No.
59
Ref
Part No
Description
1
2
3
5
6
7
8
12
13
14
15
16
17
18
19
9007167
9007166
9007185
9007192
9007193
9007196
9007186
9005789
552801
1764011
592304
569035
580758
9005792
587927
Valve, A300
Air actuator, AT 451U
Pilot valve
Throttle valve, 1/4
Actuator cable
Bracket
Switch box
Gearbox
Push-in connector
Silencer
Plug, 1/4
Flexible pipe, PA12, 8/6
Push-In Fittings
Handwheel
Locking device, AL79 451
60
23
06
01
01
01
02
01
03
02
02
02
05
06
02
07
-88
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
9007168Quantity
Notes
Book No.
2716A
Book No.
61
Ref
Part No
Description
1
2
7
9
10
13
16
19
24
27
28
30
31
Z
9007167
9007166
9007196
9007191
9007190
552801
569035
587927
552801
9007200
9007201
523127
592304
9007184
Valve, A250
Air actuator, AT 351U
Bracket
Mounting kit, Positioner
Positioner
Push-in connector
Flexible pipe, PA12, 8/6
Locking device, AL79 351
Push-in connector
Manifold
Filter
Hexagon nipple
Plug, 1/4
Insulate plate
62
22
05
02
01
01
02
05
05
02
01
01
01
02
04
-87
1
1
1
1
1
2
1
1
2
1
1
1
1
9007174Quantity
Notes
Book No.
2712A
Book No.
63
Ref
1
2
5
64
Part No
Description
-93
1
1
1
576179Quantity
Notes
Book No.
2363A
10
Book No.
65
11 CIP module
Machine unit number or
Subassembly description
Ref
Part No
1
2
3
4
5
6
7
8
9
10
11
12
15
16
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
53
54
55
56
57
58
59
60
61
62
63
9003450
590414
9004533
9002825
9003730
9002915
9003732
590313
590476
9005046
589526
526350
9003172
9004479
9003514
9004517
9002962
9002963
9004237
9003935
9002964
9002584
9002586
9003570
9003949
9002589
9003792
9002591
9003837
9004247
9002592
9003851
9003853
9003854
9003863
9003886
9003888
592649
591675
569038
592665
9003574
9005743
599223
599223
592676
592676
592790
221716
221711
221701
223101
221711
223101
587276
27345
70560
9005147
9005394
66
01
01
80
80
01
01
01
01
01
01
07
06
80
80
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
05
01
01
01
03
02
05
07
01
02
17
04
41
16
47
02
Description
Frame complete
Tank
Pump P320-1 and P321-5
Valve
Valve housing
Check valve
O-ring
Valve, angle seat
Nipple, ISO-R 3/4-1/2
Backflow preventer
U-bolt clamp, c-c 56,5
Plug
Valve block
Filter regulator
Speed controller
Reducer
Pipe #1
Pipe #2
Pipe #3
Pipe #4
Pipe #5
Pipe #6
Pipe #7
Pipe #8
Pipe #9
Pipe #10
Pipe #11
Pipe #12
Pipe #13
Pipe #14
Pipe #15
Pipe #16
Pipe #17
Pipe #18
Pipe #19
Pipe #20
Pipe #21
Nipple
Hose, 32
Hose, 32
Hose, 25
O-ring
Pipe clamp
Hose clamp 38-50
Hose clamp 32-44
Insulation sheet, 10mm
Insulation sheet, 5mm
Insulation sheet
Screw
Screw
Screw
Washer, 4,3x9x0,8
Screw
Washer
Washer
Nut, M8
Washer
01 Pipe #22
80 Air distribution
-81
1
1
2
6
3
2
6
1
1
1
1
1
1
1
2
2
1
1
1
2
1
1
2
4
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
6
5
10
3
4
7
1
2
2
4
4
16
16
2
12
19
1
1
9002547Quantity
Notes
See page 70
See page 72
See page 74
See page 76
Book No.
CIP module
2605A
11
Book No.
67
Ref
Part No
64
65
66
Z
221040
590539
548152
590414
68
53
03
03
02
Description
Screw
Clip list
Washer
Tanck screw cap
-81
5
1
5
9002547Quantity
Notes
Book No.
CIP module
2605A
11
Book No.
69
Ref
Part No
Description
1
Z
9004533 01 Pump
9004587 80 Spare part set
Z0.1
70
-80
1
9004533Quantity
Notes
Incl. O-rings, diaphragm, ball, muffler
indicated in dwg.
Incl. air valve, sealings and O-rings,
indicated in dwg.
Book No.
11
CIP module
2606A
11.1
Book No.
71
11.2 Valve
Machine unit number or
Subassembly description
Ref
Z
72
Part No
Description
9003574 01 O-ring
-80
9002825Quantity
Notes
Book No.
Valve
11
CIP module
2609A
11.2
Book No.
73
Ref
Part No
Description
1
2
3
4
5
6
7
8
9
10
11
13
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003172
74
01
02
03
04
05
06
07
08
09
10
11
12
-80
1
5
1
5
1
1
1
1
1
2
1
1
9003172Quantity
Notes
Book No.
Valve block
11
CIP module
2607A
11.3
Book No.
75
Ref
Part No
1
2
3
4
5
569035
569035
552801
558710
580758
76
05
01
50
01
06
Description
Flexible pipe, PA12, 8/6
Flexible pipe, PA12, 6/4
Push-on connector
Air Hose Nipple
Push-In Fittings
-80
1
1
6
1
2
9005394Quantity
Notes
Book No.
Air distribution
11
CIP module
2608A
11.4
Book No.
77
Ref
Part No
Description
1
2
3
4
5
6
7
8
9
9
10
10
11
14
591662
591667
1765908
2210462
221803
70490
591631
591628
2210462
2210462
590667
590667
556563
591666
Adaptor pipe
Pitot tube
Gasket
Screw
Nut, M16
Washer
Blind flange, DN50/A50
Valve, manual A50
Screw
Screw, M16x45
Q201.1
Q201.2
Wire
Rod
78
80
01
07
30
34
01
81
28
45
27
28
01
01
589745-90 -91
1
1
2
4
4
16
1
1
8
1
1
1
Quantity
1
1
2
4
4
16
1
1
8
Notes
1
1
1
Book No.
2780A
12
Book No.
79
Ref
Part No
Description
1
2
3
4
5
6
7
9
9007231
526336
9006075
9001406
543054
9006822
546600
595558
80
01
04
01
82
03
02
02
01
-80
1
3
1
1
1
1
1
4
9006076Quantity
Notes
Book No.
2709A
13
Book No.
81
14
Part No.
1761805
1764011
1765908
2210295
2210296
221030
221030
221030
221030
221030
221030
221031
221035
221035
221035
221036
221040
221040
221040
2210462
2210462
2210462
2210463
221701
221701
221711
221711
221711
221711
221711
221711
221711
221716
221716
221716
221726
221803
221803
221803
221803
221803
221803
221803
221803
221851
221851
221851
221891
221891
221891
82
01
02
07
03
02
02
10
10
10
10
10
21
03
06
36
02
04
53
55
28
30
45
03
03
04
08
13
16
16
17
19
23
01
01
02
10
02
02
02
02
03
27
28
34
05
05
05
01
02
02
Page
34
60
78
38
34
22
18
22
22
22
22
38
38
38
38
38
38
67
38
78
78
78
34
6
66
34
38
66
10
66
10
38
22
10
66
22
18
22
6
10
18
34
38
78
22
22
22
18
18
22
Ref.
Part No.
23
14
3
29
32
34
49
18
21
25
66
39
32
24
27
13
22
64
34
9
4
9
21
17
55
4
7
57
29
54
22
20
15
8
53
11
50
4
45
24
51
34
41
5
59
76
89
52
53
72
221891
221891
221891
221891
221891
221891
221891
221891
221891
221891
221891
221891
221891
221891
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223107
260321
26556
27345
35120
41456
523127
04
04
04
04
04
04
04
04
04
05
05
05
05
05
03
16
17
17
32
32
33
33
37
41
41
47
47
47
47
47
47
47
47
47
47
47
47
47
47
47
49
64
73
34
25
01
Page
18
22
22
22
22
23
6
10
10
18
22
22
10
10
18
18
18
38
34
38
34
38
34
22
66
18
22
22
22
22
22
22
22
22
22
23
6
66
6
10
22
34
10
10
34
10
66
38
38
62
Ref.
Part No.
54
35
42
79
83
91
8
16
31
55
8
14
7
34
56
57
58
30
5
40
33
14
22
73
56
59
5
17
20
24
33
42.1
67
80
82
92
44
58
8.1
30
10
10
25
15
27
4
60
35
23
30
523127
526336
526350
526350
526350
543054
544465
544465
546600
548152
552801
552801
552801
552801
552801
554214
556563
558663
558663
558663
558710
558710
569035
569035
569035
569035
569038
576071
576071
576075
576075
576075
576075
576886
579380
579385
580758
580758
580986
580986
580986
580986
580986
580986
580986
580986
580986
580986
580986
580986
04
04
05
05
06
03
04
15
02
03
02
02
02
50
50
06
01
03
03
04
01
02
01
05
05
05
05
01
01
05
21
65
71
26
01
01
06
06
06
08
08
16
16
17
17
19
20
30
32
33
Page
18
80
34
38
66
80
10
35
80
67
60
62
62
34
76
34
78
34
38
34
76
34
76
60
62
76
66
44
46
44
46
44
46
44
35
10
60
76
12
12
26
12
26
12
26
26
26
12
12
12
Ref.
10
2
18
15
12
5
35
96
7
66
13
13
24
30
3
95
11
19
16
14
4
38
2
16
16
1
43
3
3
2
2
Z
Z
1
ZB
10
17
5
9
5
8
10
11
2
2
12
13
3
7
6
Book No.
Part No.
Page
580986 51
580986 53
580986 55
580986 59
580986 59
580986 61
580986 62
580986 63
580986 64
580986 67
580986 72
580986 76
580986 76
581534 01
581688 01
582212 03
582212 03
582212 102
582212 104
582212 104
582212 105
582212 105
582212 119
582212 120
582212 122
582212 122
582212 122
582212 122
582212 123
582212 125
582212 125
582212 130
582212 131
582212 132
582212 133
582212 136
582212 137
582212 13
582212 13
582212 141
582212 146
582212 147
582212 147
582212 148
582212 148
582212 148
582212 148
582212 148
582212 148
582212 150
12
26
12
12
26
26
26
26
26
12
26
12
12
34
10
28
6
6
6
6
6
6
14
14
19
30
40
7
6
6
18
30
30
30
30
30
30
19
7
18
18
18
6
18
28
30
40
42
6
40
Book No.
Ref.
4
9
12
8
7
10
3
4
1
1
5
1.2
1.3
26
27
6
26.2
22
21
24
23
25
1
2
75
4
4
69
29
12
30
3
8
7
11
16
15
76
70
47
36
41
20
43
7
1
2
2
9
12
Part No.
Page
582212 151
582212 154
582212 155
582212 156
582212 156
582212 157
582212 157
582212 15
582212 15
582212 15
582212 163
582212 164
582212 165
582212 167
582212 168
582212 171
582212 172
582212 181
582212 186
582212 60
582212 60
582212 63
582212 63
582212 63
582212 64
582212 65
582212 67
582212 67
582212 67
582212 70
582212 71
582212 86
582212 87
582212 88
582212 88
582212 89
582212 89
582212 91
582221 100
582221 89
582221 90
582221 90
582221 99
582356 18
582356 26
582356 26
582356 27
582356 28
582356 30
582356 30
40
40
6
30
42
30
42
30
30
6
18
18
18
6
6
6
14
19
14
6
6
6
28
6
28
28
6
28
6
40
28
6
6
30
40
30
40
6
32
6
18
6
32
6
18
40
18
18
18
40
Ref.
Part No.
11
5
48
9
3
10
4
12
13
32
19.2
19.1
19.3
24.2
28
24.1
Z
69
3
14.1
26.1
15
4
27
2
3
14
1
26
6
5
29.1
29.2
5
3
6
7
19
51
46
20
31
50
47
13
22
15
14
12
25
583012
583012
583556
583556
585345
585976
585976
586907
587276
587276
587276
587276
587276
587276
587276
587927
587927
587927
589526
589569
589569
589569
589569
589569
589569
590037
590313
590414
590414
590476
590539
590624
590667
590667
590667
591103
591103
591103
591103
591103
591103
591103
591103
591103
591103
591103
591103
591103
591628
591631
01
01
16
17
61
01
01
01
01
01
01
02
02
02
02
05
07
07
07
21
21
44
44
45
59
01
01
01
02
01
03
03
01
27
28
10
10
36
38
45
46
54
60
60
61
64
66
81
81
01
Page
44
46
6
6
64
44
46
64
22
22
22
18
22
66
10
62
56
60
66
40
42
40
42
42
42
46
66
66
67
66
67
18
34
78
78
6
18
6
6
6
18
18
6
18
18
18
18
6
78
78
Ref.
6
6
36
37
1
4
4
2
58
77
88
60
13
59
32
19
19
19
11
19
9
20
10
8
6
1
8
2
Z
9
65
7
8.2
10
10
10.1
26.1
49
16
11
24
26
10
25
29
28
27
16.1
8
7
83
14
Part No.
591662
591666
591667
591675
591874
591874
591889
591922
592304
592304
592304
592304
592649
592665
592676
592676
592790
593239
593254
593282
593287
593724
593724
593780
593991
594009
594009
594009
594009
594009
594009
594171
594410
594410
594412
594412
594413
594413
594413
594488
594645
594707
594728
595215
595229
595272
595361
595558
595558
595558
84
80
01
01
01
04
05
01
01
01
02
02
02
01
01
05
07
01
01
01
01
01
03
03
01
01
01
02
03
03
04
07
01
01
01
92
92
80
80
80
01
82
02
01
01
01
01
01
01
01
01
Page
78
78
78
66
22
22
22
6
34
34
60
62
66
66
66
66
66
10
10
10
22
19
6
22
10
10
19
19
6
19
19
34
44
46
34
34
34
34
34
10
35
34
18
44
64
34
6
18
58
80
Ref.
1
14
2
42
1A
1B
60
41
28
29
15
31
41
44
49
50
51
26
19
23
27
61
33
62
12
3
62
63
34
64
66
15
5
5
8
8.1
20
20.1
20.2
28
Z0.1
25
37.1
9
5
37
42
9.2
23
9
Part No.
Page
595670 80
595673 01
595673 04
596103 01
596894 01
596894 01
597033 18
597033 19
597033 20
597044 04
597049 01
597330 01
597330 01
597331 01
597331 01
599223 02
599223 03
599555 01
66169
70490
70560
70560
70560
70560
70915
9000394 03
9000394 123
9000394 132
9000394 13
9000394 141
9000394 144
9000394 23
9000394 43
9000394 62
9000394 69
9000394 91
9000394 92
9000394 94
9000395 20
9000395 21
9000395 22
9000395 23
9000395 24
9000395 25
9000395 26
9000395 27
9000395 28
9000395 29
9000395 29
9000395 31
6
7
32
34
6
6
12
26
26
34
34
23
7
23
7
66
66
35
38
78
18
38
66
10
10
48
50
50
50
54
54
48
48
48
50
50
50
50
48
48
48
48
48
48
48
48
48
48
48
50
Ref.
4
55
14
63
51.1
51.2
1.1
6
14
39
24
Z
Z
Z0.1
Z0.1
48
47
Z0.1B
3
6
48
25
61
33
6
17
140
145
130
1
2
39.6
39.7
18
156.5
155
155
155.5
23
24
25
26
27
28
29
32
33
34
34.5
120
Part No.
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
32
34
39
42
45
51
62
63
69
81
83
84
85
86
01
02
04
07
08
11
12
13
14
19
21
24
29
30
34
37
40
50
51
52
53
54
55
57
58
59
63
71
72
73
74
75
76
77
85
89
Page
48
48
50
48
50
48
48
48
48
50
52
48
50
52
54
48
48
54
54
54
48
50
50
50
48
50
50
48
50
48
50
50
48
50
50
50
48
50
50
50
50
52
48
48
48
48
48
48
50
50
Ref.
35
37
92
21
122
51
30
31
38
120.5
301
40
95
183
193
68
75
196
16
194
18.5
81
86.5
77
76
82
126
74
89.8
65.3
89.2
89.1
12
85
89.6
89.3
11.5
86
87
87.5
83
188
70
71
71.5
72
72.5
70.5
163
160.5
Book No.
Part No.
Page
9000396 90
9000396 91
9000396 92
9000396 93
9000396 95
9000396 96
9000396 97
9000397 06
9000397 07
9000397 07
9000397 08
9000397 09
9000397 10
9000397 14
9000397 19
9000397 20
9000397 21
9000397 22
9000397 22
9000398 01
9000398 02
9000398 02
9000398 03
9000398 04
9000398 07
9000398 08
9000398 09
9000398 103
9000398 108
9000398 10
9000398 11
9000398 11
9000398 11
9000398 141
9000398 150
9000398 17
9000398 18
9000398 20
9000398 21
9000398 32
9000398 33
9000398 38
9000398 40
9000398 40
9000398 41
9000398 42
9000398 43
9000398 45
9000398 46
9000398 50
50
50
48
54
52
48
48
48
48
48
52
52
52
52
52
48
52
50
50
50
50
50
50
54
50
48
48
52
52
50
48
50
50
52
52
50
50
50
48
50
48
50
50
50
50
50
52
48
48
48
Book No.
Ref.
167.5
89
14
193.1
200A
65
65.5
15
52
53
302
303
189
177
189.5
41
169.5
158
162.5
84
83.5
113.5
112
197
121.5
39
36
170
171
88.5
19.5
83.7
114.5
178
172
168.5
157
88
19.3
121
19.2
155.6
83.6
114
113
88.6
186
19.4
73
19.1
Part No.
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000738
9001098
9001357
9001406
9001539
9001897
9002009
9002362
9002584
9002586
9002589
9002591
9002592
9002699
9002825
9002860
9002915
9002942
9002947
9002962
9002963
9002964
9003013
9003024
9003031
51
59
64
65
67
72
77
78
83
84
85
87
87
87
90
90
91
92
92
93
94
95
95
95
97
02
01
03
82
01
01
81
81
01
01
01
01
01
82
80
01
01
01
01
01
01
01
01
02
01
Page
48
50
48
48
50
48
50
50
52
52
52
52
52
52
50
50
50
50
54
48
52
52
52
52
50
35
38
34
80
38
38
38
6
66
66
66
66
66
34
66
38
66
22
22
66
66
66
10
10
22
Ref.
19
83.8
39.8
39.9
162
40.5
161
161.5
178.5
184
191
178.1
180
192
157.5
169
155.7
85.5
85.5
61
173
178.2
179
191.5
168
Z0.1A
11
7
4
19
12
8
30
25
26
29
31
34
1
4
10
6
31
30
20
21
24
11
13
1C
Part No.
9003031
9003031
9003089
9003113
9003114
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003186
9003186
9003326
9003390
9003394
9003401
9003410
9003450
9003514
9003522
9003522
9003570
9003574
9003574
9003628
9003661
9003662
9003669
9003672
9003730
9003732
9003748
9003792
9003837
9003851
9003853
9003854
9003863
9003886
9003888
9003935
9003949
01
01
02
01
02
01
02
03
04
05
06
07
08
09
10
11
12
80
01
02
01
01
01
01
01
01
01
06
07
01
01
01
80
01
01
01
01
01
01
80
01
01
01
01
01
01
01
01
01
01
Page
40
42
22
22
22
74
74
74
74
74
74
74
74
74
74
74
74
66
22
22
38
22
22
22
22
66
66
6
6
66
66
72
18
38
38
38
38
66
66
34
66
66
66
66
66
66
66
66
66
66
Ref.
18
5
9
28
29
1
2
3
4
5
6
7
8
9
10
11
13
15
22
63
6
16
12
19
23
1
18
39
38
27
45
Z
1
26
28
21
31
5
7
2
30
32
35
36
37
38
39
40
23
28
85
14
Part No.
9004174
9004211
9004212
9004213
9004214
9004237
9004247
9004254
9004299
9004299
9004299
9004299
9004299
9004299
9004303
9004313
9004329
9004426
9004439
9004479
9004506
9004507
9004508
9004517
9004533
9004533
9004587
9004588
9004638
9004825
9004844
9004878
9004886
9004889
9004959
9004960
9005006
9005046
9005051
9005051
9005051
9005051
9005051
9005052
9005052
9005052
9005052
9005052
9005052
9005142
86
80
01
01
01
01
01
01
01
01
02
03
04
04
07
02
80
80
01
01
80
80
80
80
01
01
80
80
80
01
80
80
80
80
01
01
80
80
01
04
05
06
07
08
01
05
07
08
09
10
80
Page
18
18
18
18
18
66
66
18
18
18
18
6
18
18
18
18
18
18
32
66
18
18
18
66
70
66
70
70
34
40
42
38
38
38
42
34
6
66
34
34
34
34
34
34
34
34
34
34
34
22
Ref.
Part No.
37
2
3
4
6
22
33
9
32
33
34
13
31
46
40
22
39
11
15
16
5
38
42
19
1
3
Z
Z0.1
31
1
1
9
33A
33
7
3
18
10
16
16.4
16.2
16.1
16.3
17
17.1
17.2
17.5
17.4
17.3
1
9005143
9005144
9005145
9005147
9005394
9005494
9005496
9005626
9005743
9005789
9005792
9006075
9006237
9006246
9006316
9006320
9006320
9006322
9006324
9006325
9006326
9006519
9006677
9006761
9006769
9006771
9006804
9006805
9006806
9006822
9006822
9006852
9006853
9007005
9007007
9007098
9007099
9007100
9007128
9007166
9007166
9007166
9007166
9007166
9007167
9007167
9007167
9007167
9007167
9007184
80
80
80
01
80
01
01
01
01
03
02
01
80
01
01
80
81
01
01
01
01
01
01
80
02
02
01
01
01
02
02
01
01
82
01
82
80
82
80
01
05
06
06
06
15
22
23
23
23
01
Page
22
22
22
66
66
18
16
19
66
60
60
80
6
10
22
34
34
22
34
34
18
22
18
10
50
48
6
6
6
48
80
6
6
52
52
52
52
52
52
58
62
56
58
60
58
62
56
58
60
58
Ref.
Part No.
2
3
6
62
63
23
19
67
46
12
18
3
1
2
64
35
36
69
13
12
35
70
21
5
91
13
5
6
7
11
6
3
52A
200
203
Z
Z0.2
Z0.1
190
2
2
2
2
2
1
1
1
1
1
Z
9007184
9007185
9007185
9007185
9007186
9007186
9007186
9007190
9007191
9007192
9007192
9007192
9007193
9007193
9007193
9007196
9007196
9007196
9007196
9007196
9007198
9007200
9007201
9007231
9007239
9007239
9007239
9007239
9007239
9007239
9007239
9007239
9007239
9007239
9007239
9007239
9007239
9007239
9007239
9007239
9007794
9007810
9008374
9008382
9008383
9008383
9008383
9008383
9008383
9008383
04
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
02
02
02
02
01
01
01
01
01
02
03
04
05
06
07
08
10
11
12
13
23
24
25
26
01
80
01
80
01
02
03
04
05
06
Page
62
56
58
60
56
58
60
62
62
56
58
60
56
58
60
58
56
58
60
62
58
62
62
80
52
52
52
52
52
52
52
52
52
52
52
52
52
52
52
52
38
35
19
19
32
32
32
32
32
32
Ref.
Z
3
3
3
8
8
8
10
9
5
5
5
6
6
6
7
7
7
7
7
22
27
28
1
200B
200C
200D
200E
200F
200G
200H
200I
200L
200K
200M
200N
200J
200O
200P
200Q
36
ZA
73
74
1
2
3
4
5
6
Book No.
Part No.
9008383
9008383
9008383
9008387
9008388
9008424
9008672
9008693
9008903
9009416
9009521
9009688
9009695
9009696
9009714
9009912
9011365
9011549
Book No.
08
12
13
01
01
01
80
01
05
01
80
01
80
80
01
01
01
80
Page
32
32
32
32
32
22
7
32
22
38
35
7
6
7
23
44
34
16
Ref.
9
7
8
11
16
74
68
12
7
38
Z
52B
52
53
90
8
9
1
87