Operation Manual For BWMS

Preliminary Installation, Operation& Maintenance Manual Rev. 1.
Operation and Maintenance Manual

Hull No.:P55K-1/2/3/4
Type: BC-2500
SunRui Marine Environment Engineering Co., Ltd
2016-4
Operationand Maintenance Manual I
CONTENTS
1. INTRODUCTION ................................................................................................................................... 1
1.1 Manual Introduction ..................................................................................................................... 1
1.2 Customer Support Information ..................................................................................................... 1
1.3 Warranty........................................................................................................................................ 1
1.4 Abbreviations ................................................................................................................................ 1
1.5 Warning Sign Definitions ............................................................................................................... 3
2. SAFETY ................................................................................................................................................. 4
2.1 General .......................................................................................................................................... 4
2.2 Risk Assessment ............................................................................................................................ 4
2.2.1 Risk to safety of ship............................................................................................................... 4
2.2.1.1 Flooding ................................................................................................................... 4
2.2.1.2 Corrosion.................................................................................................................. 5
2.2.2 Risks to human health ............................................................................................................ 6
2.2.2.1 Introduction ............................................................................................................. 6
2.2.2.2 Occupational exposure (HES) and quantitative risk evaluation .............................. 6
2.2.2.3 General public/human exposure via environment .................................................. 7
2.2.3 Risks to the aquatic environment........................................................................................... 8
2.3Sodium Hypochlorite Hazards & Aid .............................................................................................. 8
2.3.1 Sodium Hypochlorite Hazards ................................................................................................ 8
2.3.2 First Aid................................................................................................................................... 9
2.4Safety Precautions of H2 ................................................................................................................. 9
2.4.1 General ................................................................................................................................. 10
2.4.2 Safety Measures ................................................................................................................... 10
2.4.2.1 Prevent of H2 Leakage ........................................................................................... 10
2.4.2.2 Emergency Measures............................................................................................. 10
2.5 Sodium Thiosulphate Hazards & Aid ........................................................................................... 10
2.5.1 Sodium ThiosulphateHazards ............................................................................................... 10
2.5.2 Aid......................................................................................................................................... 11
2.5.3Handling and Storage ............................................................................................................ 11
2.6 Electric Hazards ........................................................................................................................... 11
2.7 Emergency Hazards ..................................................................................................................... 12
Operationand Maintenance Manual II
3. GENERAL INSTRUCTIONTION ............................................................................................................ 13

3.1 System Description ...................................................................................................................... 13
3.1.1 System Working Condition ................................................................................................... 14
3.1.2 Automatic Back-flushing Filter Unit ..................................................................................... 14
3.1.3 Electrolytic Disinfection Unit ................................................................................................ 14
3.1.4 Automatic Neutralization Unit ............................................................................................. 15
3.1.5 TRO Monitoring System ....................................................................................................... 15
3.1.6 Flow Measuring System ....................................................................................................... 15
3.1.7CONTROL SYSTEM ................................................................................................................. 16
3.1.8 ADD SALT UNIT ..................................................................................................................... 16
3.2Main Equipments& Instruments Description............................................................................... 16
3.2.1 Seawater Boost Pump .......................................................................................................... 16
3.2.2 Blower .................................................................................................................................. 16
3.2.3 Cyclone ................................................................................................................................. 17
3.2.4 Metering Pump..................................................................................................................... 17
3.2.5 Gas Detection and Alarm Instrument................................................................................... 17
3.2.6 Rectifier ................................................................................................................................ 18
3.2.7 System Control Cabinet ........................................................................................................ 18
3.2.8 EDU Junction Box.................................................................................................................. 18
3.2.9 Remote Control Box ............................................................................................................. 18
3.2.10 Motor Control Cabinet ....................................................................................................... 19
3.2.11 ANU control box ................................................................................................................. 19
4. SYSTEM OPERATION .......................................................................................................................... 20
4.1 General ........................................................................................................................................ 20
4.2 Initial Startup Check .................................................................................................................... 21
4.2.1 Initial Startup Check for Ballasting Process .......................................................................... 21
4.2.2 Initial Startup Check for De-ballasting Process .................................................................... 30
4.3 Ballasting Process Operation ....................................................................................................... 34
4.3.1 Local Control of Ballasting Process ....................................................................................... 34
4.3.2 Remote Control of Ballasting Process .................................................................................. 37
4.4 De-ballasting Process Operation ................................................................................................. 39
4.4.1 Local Control of De-ballasting Process ................................................................................. 39
4.4.2 Remote Control of De-ballasting Process............................................................................. 40
4.5 Adding SALT Process Operation .................................................................................................. 41
SunRui Marine Environment Engineering Co. , Ltd
Operationand Maintenance Manual III
5. maintenance ...................................................................................................................................... 43
5.1Daily maintenance ........................................................................................................................ 43
5.1.1 AUTAMATIC BACK-FLUSHING FILTER ................................................................................... 43
5.1.2 TRO ANALYZER ..................................................................................................................... 43
5.1.3SEAWATER BOOSTER PUMP (EQ04) AND 3# SEWAGE PUMP (EQ02-3#) ............................. 48
5.1.4ELECTROLYZER ....................................................................................................................... 49
5.1.5 BLOWER ................................................................................................................................ 49
5.1.6 CYCLONE ............................................................................................................................... 49
5.1.7 METERING PUMP ................................................................................................................. 49
5.1.8 RECTIFIER .............................................................................................................................. 50
5.1.9 System Control Cabinet and Motor Control Cabinet ........................................................... 51
5.1.10 Junction Box ....................................................................................................................... 51
5.1.11 Remote Control Panel ........................................................................................................ 52
5.1.12 Sewage Pump (EQ02-1~2#) ................................................................................................ 52
5.1.13 Dosing Pump and salt pump............................................................................................... 52
5.2 PREVENTIVE MAINTENANCE ....................................................................................................... 53
5.2.1 Automatic Back-flushing Filter ............................................................................................. 53
5.2.2 TRO ....................................................................................................................................... 54
5.2.3 Ballast Water Flow meter ..................................................................................................... 54
5.2.4 Seawater Boost Pump (EQ04) AND 3# SEWAGE PUMP (EQ02-3#) ...................................... 54
5.2.5 Electrolyzer ........................................................................................................................... 55
5.2.6 Blower .................................................................................................................................. 55
5.2.7 Cyclone ................................................................................................................................. 56
5.2.8 Metering Pump..................................................................................................................... 56
5.2.9 Rectifier ................................................................................................................................ 56
5.2.10 System Control Cabinet and Motor Control Cabinet ......................................................... 57
5.2.11 Junction Box ....................................................................................................................... 57
5.2.12 Remote Control Panel ........................................................................................................ 58
5.2.13 Sewage Pump (eq02-1~2#) ................................................................................................ 61
5.2.14Dosing Pump and salt pump ............................................................................................... 61
5.3 CORRECTIVE MAINTENANCE ....................................................................................................... 63
5.3.1 Automatic Back-flushing Filter ............................................................................................. 63
5.3.2 TRO Analyzer ........................................................................................................................ 64
5.3.3 Ballast Water Flow meter ..................................................................................................... 66
Operationand Maintenance Manual IV
5.3.4 Seawater Booster Pump (eq04) and 3# sewage PUMP (eq02-3#) ....................................... 72
5.3.5 Blower .................................................................................................................................. 73
5.3.6 Metering Pump..................................................................................................................... 73
5.3.7 Rectifier ................................................................................................................................ 74
5.3.8 System Control Cabinet and Motor Control Cabinet ........................................................... 75
5.3.9 Junction Box ......................................................................................................................... 75
5.3.10 Remote control panel ......................................................................................................... 76
5.3.11 Sewage Pump (eq02-1~2#) ................................................................................................ 76
5.3.12 Dosing Pump....................................................................................................................... 78
6. SYSTEM ALARMING AND TROUBLESHOOTING ................................................................................. 80
6.1 General ........................................................................................................................................ 80
6.2 Application................................................................................................................................... 80
6.3 Alarm ........................................................................................................................................... 80
6.3.1 General ALARM AND REMEDY ............................................................................................. 80
6.3.2STOP ALARM AND REMEDY................................................................................................... 83
7. DATA SHEET AND assembly/disassembly drawing............................................................................ 85
7.1AFU ............................................................................................................................................... 85
7.1.1 DATA SHEET .......................................................................................................................... 85
7.1.2ASSEMBLY DIAGRAM ............................................................................................................. 86
7.2EDU ............................................................................................................................................... 89
7.2.1 DATA SHEET .......................................................................................................................... 89
7.3 ANU ............................................................................................................................................. 92
7.3.1 DATA SHEET .......................................................................................................................... 92
7.4 METERING PUMP (EQ09) ............................................................................................................ 94
7.4.1 DATA SHEET .......................................................................................................................... 94
7.4.2 DRIVE END—EXPLODED DRAWING ...................................................................................... 94
7.4.3 Liquid End--Exploded Drawing ............................................................................................. 97
7.5 SEWAGE PUMP (EQ02-1~2#)....................................................................................................... 99
7.5.1 DATA SHEET .......................................................................................................................... 99
7.5.2 ASSEMBLY DIAGRAM and parts list (eq02-1~2#) ............................................................... 100
7.5.3 ASSEMBLY DIAGRAM and parts list (eq02-3#) ................................................................... 103
7.6 dosing pump (EQ14) .................................................................................................................. 104
Operationand Maintenance Manual V
7.6.1 DATA SHEET ........................................................................................................................ 104

7.6.2 ASSEMBLY DIAGRAM .......................................................................................................... 104
7.7 BOOSTER PUMP......................................................................................................................... 106
7.7.1 DATA SHEET ........................................................................................................................ 106
7.7.2 ASSEMBLY DIAGRAM and parts list .................................................................................... 107
7.8Rectifier (eq08) ........................................................................................................................... 109
7.8.1 data sheet ........................................................................................................................... 109
7.9 System control cabinet (EQ08) .................................................................................................. 109
7.9.1 DATA SHEET ........................................................................................................................ 109
7.10 Remote control cabinet (EQ24) ............................................................................................... 110
7.10.1 data sheet ......................................................................................................................... 110
7.11Motor control cabinet (EQ25) .................................................................................................. 110
7.11.1 data sheet ......................................................................................................................... 110

perationand Maintenance Manual P1 / Total 110 Pages
1. INTRODUCTION
1.1 MANUAL INTRODUCTION

The purpose of this manual is to describe the ballast water treatmentsystem with all its components
and how to install, operate and maintain the system.
1.2 CUSTOMER SUPPORT INFORMATION
Contact address if assistance is required:

Address 149-1 Zhuzhou Road, Laoshan District, Qingdao, China
Telephone +86-532-68725810
Fax +86-532-68725001
Email shipd@sunrui.net
Internet website www.sunrui.net
1.3 WARRANTY
The BalClor○R Ballast Water Management System has a warranty of 12 months from commissioning
of the system.
1.4 ABBREVIATIONS
BWMS BALLAST WATER MANAGEMENT SYSTEM

E.R ENGINE ROOM
APT AFTERPEAK TANK
AFU AUTOMATIC BACKFLUSHING FILTER UNIT
EDU ELECTROLITIC DISINFECTION UNIT

ANU AUTOMATIC NEUTRALIZATION UNIT
MFU MOBILE FLUSH UNIT
H2 HYDROGEN
Cl2 CHLORINE
HMI HUMAN MACHINE INTERFACE
PLC PROGRAMMABLE LOGIC CONTROLLER

LEL LOWER EXPLOSIVE LIMIT

Operation and Maintenance Manual P2/ Total 110 Pages
EQ02 SEWEDGE PUMP

EQ03(A/B/C) ELECTROLYZER
EQ04 SEAWATER BOOSTER PUMP
EQ05(A/B) BLOWER
EQ06 CYCLONE
EQ07 RECTIFIER
EQ08 SYSTEM CONTROL CABINET
EQ09(A/B) METERING PUMP
EQ10 NEUTRALIZATION TANK
EQ11 BLENDER
EQ12 Y-TYPE STRAINER

EQ13 PRE-FITLER
EQ14 DOSING PUMP
EQ17 BUFFER TANK
EQ18 TRO SAMPLING PUMP
EQ19(A/B) PULSATION DAMPER
EQ21 AFU CONTROL CABINET

EQ22 EDU JUNCTION BOX
EQ23 ANU JUNCTION BOX
EQ24 REMOTE CONTROL BOX
EQ25 MOTOR CONTROL CABINET
EQ31 AIR FILTER AND REGULATOR
EQ32 AIR FILTER AND DRYER

EQ33 Y-TYPE STRAINER OF TRO SAMPLING PUMP
MO11 BLENDER MOTOR
PT21 PRESSURE TRANSMITTER
AP21 AIR PRESSURE SWITCH
FT FLOWMETER
TT21 TEMPERATURE SENSOR

LS21/31 LIQUID LEVEL METER
CS21 CHLORINE SENSOR

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HS01/02 HRDROGEN SENSOR

PD11 PRESSURE DIFFERENTIAL SWITCH FOR EQ01
PT11 OUTLET PRESSURE TRANSMITTER OF EQ01
TR0-XX TRO ANALYZER
CM21 CONDUCTIVITY METER

GT21/22 EQ03 INLET/OUTLET GROUND CONNECTION
1.5 WARNING SIGN DEFINITIONS

INITIONS
It indicates possibilities for immediate hazards, which will result in

fatal or severe personnel injuries and substantial property
DANGER: damage, if the required precautions are not taken.
It iindicates possibilities for hazards or unsafe practices, which

could result in fatal or severe personnel injuries or substantial
WARNING: product or property damage, if the required precautions are not
taken.
It indicates possibilities for hazards or unsafe practi

practices, which
CAUTION! could result in minor personnel injuries and/or property damage,
if the required precautions are not taken.
Itt indicates possibilities for electric shock.
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2. SAFETY
2.1 GENERAL
Under
nder normal conditions, the BalClor
BalClor® Ballast Water Management System runs safely, but incorrect
operation or maintenance may result in serious breakdown with fatal injury or damage to property.
The
he following is compulsory for safe operation:
BalClor® BWMS operators

perators should be fully trained and competent in installation, operation,
maintenance, and emergency procedures of BalClor® BWMS.
ATTENTION!
Avoid direct contact with sodium chlorite solution

solution.
Stop system immediately once leakage occurs

occurs, then check and maintain the system.
Turn off the power supply prior to maintenance or other work.
When
hen disassembling, assembling and conducting maintenance or when handling reagents, be sure to
wear safety gloves, helmet and protective shoes.
Control system
ystem is set at automatic mode during operation; manu
manual
al mode is not advised during long
personnel absence.
Confirm the electrolyzers are full of seawater before power supply.
System operating data should be collected constantly; any inefficiency should be solved with no
delay.
Normally, the BalClor®Ballast

Ballast W
Water
ater Management System is liquid tight, which means the sodium
hypochlorite (NaClO) solution and Hydrogen should not leak from the system. However,
H in the event
of leakadge,, please be extremely alert, careful, and follow the instructions in the chapter of ANU.
DANGER: Careless
areless operation of the BalClor® BWMS can create safety hazards.
Please
lease read the following information carefully and ensure that every personnel involved
in is familiar
with the precautions and first aid instructions.
2.2 RISK ASSESSMENT
2.2.1 RISK TO SAFETY OF SHIP
2.2.1.1 FLOODING
Sun
The BalClor®BWMS is connected to the ship ballast piping system by coated steel pipes, together
with a number of automatic and manual valves. The BWMS is so designed that in case of any failure
of thecomponents or function module, the system will be stopped to isolate theBWMS from the ship
ballast piping.
2.2.1.2 CORROSION
Further to the corrosion test on two kinds of low carbon steels, as reported in the application for
Basic Approval, comprehensive corrosion testing has been conducted in accordance with the
guidance provided in section 5.1 of the "Report of the eighth meeting of the GESAMP-BWWG"
contained in document MEPC 59/2/16.
The corrosion tests include two kinds of low carbon steels, i.e. stainless steel and Cu alloy
respectively, and the test on one non-metal. In addition, corrosion of marine epoxy-coated steel and
the coating properties of the specimens exposed to the treated water were also tested. The test
duration was six months. All the tests have completed except the long-term test on stainless steel
and Cu alloy. The full corrosion testing reports are provided in appendix 5 to the confidential dossier.
Based on these tests the following conclusions were obtained:
 For uncoated steel exposure, the corrosion rates of bare steels were tested using the method of
mass loss. No localized corrosion was found on the samples of 360 steel and CCS B steel both in
the treated water and in the control water. The corrosion tests show that the corrosion
morphology of the bare samples subjected to the treated water are same with those subjected
to natural seawater, i.e. all are uniform corrosion. The results of corrosion rate calculation
indicate that the corrosion rate of the bare steels in the ballast water treated by BalClor®BWMS
is at the similar level with that of the steels in nature seawater.
 Regarding coated steel, the corrosion rating of coated specimens was evaluated in accordance
with the rule of ASTM D1654-08. While the corrosion rating of the specimen exposed in natural
seawater was rating 7, the rating of the specimen in the treated seawater was rating 8. That
implies that the corrosion on the coated specimens exposed in the treated water is lighter than
that in natural seawater.
 The effect of the treated water on the epoxy painted specimens was tested, and no significant
difference was found in coating properties compared to natural seawater.
 The effect of the treated water on non-metal was evaluated, and Nitrile butadiene rubber (NBR,
gasket material) was used for testing. The results show that the main properties of NBR
immersed in treated water for six months was at the similar level to that immersed in natural
seawater.
 For steel and Cu alloy, the interim report on corrosion testing was included in the application
dossier based on the results of two months exposure. Long-term testing was still ongoing at the
time of submission for Final Approval, and the final report will be submitted as part of Type
Approval requirements.
2.2.1.3 Storage and handling of the substances

The only chemical substance carried on board is sodium thiosulfate. The substance is widely used in
dechlorination in water, such as halt bleaching in the paper-making industry. It is also used in
smelting silver ore, in producing leather goods and to set dyes in textiles. Sodium thiosulfate is also
used to fix black and white photography negatives after the developing stage.
Sodium thiosulfate is kept in a tightly closed container, stored in a cool, dry, ventilated area;
therefore, there is no any risk to the safety of ships during storage and handling.
When the sodium thiosulfate is handled and mixed by crew, it is required that the operators should
wear neoprene or rubber gloves and other protective clothing, wear safety glasses or chemical
goggles with face shield and wear respirator. Safety procedure for handling of sodium thiosulfate is
detailed in "Technical Specification and Manual", in appendix 11 of the confidential application
dossier.
2.2.2 RISKS TO HUMAN HEALTH
2.2.2.1 INTRODUCTION
®
The assessment on potential risks of ballast water treated by the BalClor BWMS was carried out by
China Classification Society (CCS) together with the applicant in accordance with the IMO
Methodology for Information gathering and conduct of work of the GESAMP-BWWG contained in
BWM.2/Circ.13.
The human health risk assessment of theBalClor ® BWMS includes assessment of risks to human
health due to potential exposure of crew, dock workers and PSC inspectors to chemicals associated
with BalClor ® BWMS during normal operation and in accident situations, as well as general public
exposure to the discharge treated ballast water. The full assessment report is provided in appendix
10 of the confidential dossier.
2.2.2.2 OCCUPATIONAL EXPOSURE (HES) AND QUANTITATIVE RISK EVALUATION

As recommended by the GESAMP-BWWG, identification/description of the unit operations
associated with BalClor ® BWMS has been carried out as a basic step to identify which individual
system component is likely to lead to human exposure to the BWMS related chemicals. Each unit was
assessed for the potential risk of human exposure to the BWMS related chemical substances.
The BalClor ® BWMS is designed to operate automatically, and under normal operating conditions,
the system is to be considered as a closed system, therefore, the crew's exposure to the treated
water is highly unlikely.
During ballasting, the air in the empty ballast tanks will gradually be vented out of the tanks as the air
is replaced by the rising water. The air can contain chemical substances found in the ballast water
that could imply a health risk if inhaled. Crew on deck can be exposed to the vented tank air. To

minimize the exposure to the vented tank air, crew should avoid staying in the area near to the vent
heads when the BWMS is operating.
Although it is considered to be highly unlikely, crew or dock workers could have contact with treated
ballast water during maintenance and sediment cleaning in ballast tanks. Ship's crew and PSC officers
could have contact with treated ballast water when sampling during discharge.
®
Following the identification of operation units in BalClor BWMS, the occupational exposure to
chemicals associated with the system was assessed for the following HES assumptions:
-carrying out work on deck near to the vent heads of ballast tanks;
-entering ballast tanks for cleaning or maintenance; and
-sampling from the BWMS at discharge.
All routes of exposure were thoroughly evaluated based on very conservative assumptions, and the
calculated results show that there is no unacceptable risk to human health, without consideration of
wearing personal protective equipment (PPE). Therefore, it is not necessary for the crew to wear PPE
as a routine when working on deck. Notwithstanding, to minimize the potential risk, PPE is
recommended when people enter empty ballast tanks for cleaning, maintenance or sampling.
Human risk in accident situations was also addressed. Though human exposure to TRO or neutralizer
due to accidental leakage is considered to be highly unlikely, safety precautions and mitigating
measures are provided to protect the crew in case of any incident (refer to the full assessment report
in the confidential dossier).
2.2.2.3 GENERAL PUBLIC/HUMAN EXPOSURE VIA ENVIRONMENT

The following two scenarios are identified as possible scenarios of exposure to the general
population through environment and food chain:
-exposure to sea bathers in surrounding areas (oral, inhalational or dermal exposure by way of
bathing in areas near the harbours); and
-Exposure to the general population through the food chain (oral intake by way of marine foods).
As worst scenarios, the calculation results for human health risk to general public via swimming near
port (oral route) and through eating marine food from the ballast water discharge areas are listed in
Tables 9-6 and 9-7.
Table 9-6: MRR values for seawater ingestion during swimming
Chemical MOS MOSref MRR(MOS/MOSref)

Tribromomethane 1.724 E+05 100 1.724 E+03
Dibromochloromethane 1.8 E+06 100 1.8 E+04
Monobromoacetic acid 3.182 E+05 100 3.182 E+03
Bromochloroacetic acid 2.51 E+05 100 2.51 E+03

Dibromoacetic acid 3.18 E+04 100 3.18 E+02

Dibromochloroacetic acid 3.23 E+06 100 3.23 E+04

Tribromoacetic acid 2.34 E+06 100 2.34 E+04
Dibromoacetonitrile 5.22 E+04 100 5.22 E+02
Sodium thiosulphate 1.206 E+05 100 1.206 E+03
Table 9-7: Calculated MRR(MOS/MOSref) values (Human health risk via eating marine food from
the ballast water discharge areas)
Chemical MOS MOSref MRR(MOS/MOSref)
Tribromomethane 2.68E+04 100 2.68 E+02
Dibromochloromethane 2.67E+06 100 2.67E+04
Monobromoacetic acid 2.15E+05 100 2.15E+03
Bromochloroacetic acid 1.71E+05 100 1.71E+03

Dibromoacetic acid 4.07E+05 100 4.07E+03
Dibromochloroacetic acid 2.225E+06 100 2.225E+04
Stribromoacetic acid 8.075E+06 100 8.075E+04
Dibromoacetonitrile 4.44E+04 100 4.44E+02
Sodium thiosulphate 8.28 E+04 100 8.28 E+02
As shown in the above tables, all MRR values are much higher than 1, it can be judged that there is
no unacceptable risk to the general public.
2.2.3 RISKS TO THE AQUATIC ENVIRONMENT
Risk to aquatic environment by chemicals in ballast water was carried out by calculating PEC/PNEC
ratio. If PEC/PNEC ratio is less than or equals to 1, the chemical is of no immediate concern. If
PEC/PNEC ratio is greater than 1, the substance should be of concern.
The PEC/PNEC calculated for chemicals are all less than 1, so the ballast water treated byBalClor®
BWMS of Sunrui Company has low potential risk for aquatic environment.
2.3SODIUM HYPOCHLORITE HAZARDS & AID

The chemical solution involved in the BalClor® BWMS that is hazards and potentially dangerous to
the operating personnel.
2.3.1 SODIUM HYPOCHLORITE HAZARDS
The sodium hypochlorite produced by EDU is a cloudy-white flocculent liquid with a faint odor of
bleach. It is corrosive and will cause harm to the health of human body.

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DANGER: Doo not contact Sodium Hypochloritesolution directly.
Skin Contact
The
he damage depends on concentration, pH, volume of solution, and duration of exposure. It may
cause redness, pain, blistering, itchy eczema and chemical burns. Sensitization
ensitization reactions are possible
in previously exposed persons. R
Repeated or long-term contact with corrosive substances may result
in dermatitis.
Inhalation
Breathing in vapors may cause severe bronchial irritation, sore throat with possible blistering,
coughing, stomachache, nausea, labored breathing, shortness of breath and pulmonary edema.
Eye Contact
The
he sodium hypochlorite product, if splashed in the eye, may cause redness, pa
pain,
in, and blurred vision.
These
hese symptoms should clear completely within a day or two after proper first aid trea
treatment has
been taken.
Ingestion
The
he ingestion of sodium hypochlorite may cause irritation and erosion of the mucous membranes,
nausea, vomiting (possibly
ossibly bloody), abdominal pain and spasms, and diarrhea.
2.3.2 FIRST AID
Eye Burns
Use copious amounts of fresh waterto irrigate the eye immediately for at least 15 minutes, while
holding the eyelids apart and rotating the eye. Then seek immediate medical treatment.
trea
Skin Burns
Apply
pply copious amounts of water to the burned area. Remove
emove the affected clothing. Do not neutralize
acid with an alkaline solution. Seek
eek immediate medical treatment.
Chemical
hemical Ingestion or Inhalation
Obtain
btain emergency medical assistance immediately. Remove
emove him from the contaminated
environment a.s.a.p.
Iff sodium hypochlorite has been swallowed, and the patient is conscious, give him milk, melted ice
cream, or raw eggs. Do
o not use emesis, gastric lavage
lavage,, or acid antidotes to treat the victim. Antacids
such as milk of magnesia or aluminum hydroxide gel are useful. Avoid
void the use of sodium bicarbonate.
2.4SAFETY
SAFETY PRECAUTIONS O
OF H2
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DANGER:
ANGER: The following safety procedures must be followed during operation and
maintenance of the system.
2.4.1 GENERAL
Hydrogen gas (H2) is the by-product

product of the EDU. Hydrogen
ydrogen is not harmful to humans. Hydrogen is
extremely flammable by small sparks, hot surfaces and open flames. When hydrogen concentration
in the air reaches 4% - 74%, it will form explosive mixtures.
To
o prevent the possibility of generating a flammable aatmosphere
osphere in the ballast tanks，
tanks the H2 is
separated and ventilated overboard during ballasting operation.
2.4.2 SAFETY MEASURES
2.4.2.1 PREVENT OF H2 LEAKAG

LEAKAGE
The safest way of handling H2 is to make sure that ventilation is sufficient, hence avoiding any
flammable H2 concentration. International
nternational standards recommend that Hydrogen is mixed in the ratio
of 1:100 with air to prevent any flammable mixes accruing.
The Hydrogen
ogen generated in the EDU is separated from the water by a cyclone (EQ06),
(EQ06) and then the
hydrogen gas is diluted to a safe level by a blower and released overboard via tight pipe. A spark
arrestor should be installed at the end of the exhaust pipe.
2.4.2.2 EMERGENCY MEASURES

Leakage of H2 into the cabinet may occur either from permeation, leakage or following a complete
system breakage. Hydrogen concentration inside the cabinet is continuously monitored by a H2
detection and alarm system. An
n alarm will be activated when H2 concentration reached 20%LEL and
the EDU will shutdown if H2 concentration reached 60%LEL.
2.5 SODIUM THIOSULPHATE HAZARDS & AID

2.5.1 SODIUM THIOSULPHATEHAZARDS
TEHAZARDS
DANGER: May
ay be harmful if swallowed or inhaled may cause irritation to skin
skin, eyes, and
respiratory tract.
Inhalation
May cause irritation to the respiratory tract. Symptoms may include coughing and shortness of
breath.
Ingestion
Low level of toxicity by ingestion. Diarrhea may occur by ingestion of large quantities.
Sun
Skin Contact
Irritation may occur from prolonged skin contact.
Eye Contact
Contact may cause mechanical irritation.
Chronic Exposure
Chronic exposure may cause skin effects.
Aggravation of Pre-existing Conditions
No information found.
2.5.2 AID
Inhalation
Remove to fresh air. Get medical attention for any breathing difficulty.
Ingestion
Induce vomiting immediately as directed by medical personnel. Never give anything by mouth to an
unconscious person. Get medical attention.
Skin Contact
Wash exposed area with soap and water. Get medical advice if irritation develops.
Eye Contact
Wash thoroughly with running water. Get medical advice if irritation develops.
2.5.3HANDLING AND STORAGE
Keep in a tightly closed container, stored in a cool, dry, ventilated area. Protect against physical
damage. Isolatefrom incompatible substances. Containers of this material may be hazardous when
empty since they retainproduct residues (dust, solids); observe all warnings and precautions listed
for the product.
2.6 ELECTRIC HAZARDS
NOTE:Configuration of this system consists of common and explosion proof products. Consideration
must be made that mechanical ventilation of pump room should be in compliance with the
requirements as below:
1. Once malfunction of ventilation occurred, duty station should be given audible and visual alarm;

2. It should be taken measures immediately to recover ventilation. Otherwise, explosion-proof

equipments or instruments should be disconnected in safety zone.
Only qualified personnel familiar with the electric system of the equipment and associated
technicians should plan orimplement the installation, start-up and subsequent maintenance of
thesystem. Failure to comply may result in personal injury and/orequipment damage.
There is dangerous voltage in the cabinets after the power wires are connected. Operators and
installers must abide by National Code and standards and local codes outline provisions for safely
installing electrical equipment. Installation must comply with specifications regarding wire types,
conductor sizes, branch circuit protection and disconnect devices. Failure to comply may result in
personal injury and/or equipment damage.
Power must be applied to the equipment to perform the start-up procedures. Some of the voltages
present are at incoming line potential. To avoid electric shock or damage to equipment, only
qualified service personnel should carry out the start-up procedures. Thoroughly read and
understand the procedure before operation. If an event does not occur complying with the
procedure in operation, Do Not Proceed. Correct the maloperationbefore continuing.
An incorrectly applied or installed system can result in component damage or a reduction in product
life. Wiring or application errors, such as, incorrect or inadequate AC supply, excessive ambient
temperatures, serious damp or water induction may result in component damage or malfuntion of
the system.
2.7 EMERGENCY HAZARDS

In most cases the control system can monitor malfunctions. Once malfunctions appear, it will raise
the alarm and/or shut down the equipment in order to avoid personal injury andequipment damage.
The control system contains two self-locking “emergency stop” switches that are separately installed
on control cabinet, remote junction box. Pressing any “emergency stop” switch can stop the whole
system and make the “start-up” switch invalid.
When some emergency hazards which are related with the equipment occur, operators should stop
the system by pressing any “emergency stop” switch. Do Not restart the system before searching out
and correcting the malfunction.
Under rare conditions special malfunctions can cause the “emergency stop” switch invalid, such as
some PLC malfunctions. In this case operators should immediately shut down the main power. All the
“emergency stop” switches must be tested after searching out and correcting all malfunctions. Do
not restart the system before testing the switches.
NOTE:The blender can only be shut down by “emergency stop” switch on the ANU junction box.
Others are of no effect.

3 GENERAL INSTRUCTIONTION
BalClor® BWMS consists of AFU, EDU, ANU, TRO monitoring system, flow measuring system, control
system etc.
3.1 SYSTEM DESCRIPTION
BalClor® BWMS technology applies a combination of filtration, disinfection and neutralization

process. BalClor® BWMS treat ballast water on board through filtrationfollowed by disinfection with
oxidantproduced by an electrolytic process duringballasting, and neutralization at de-ballasting.
When ballasting, the ballast water is firstly filtrated by an automatic back-flushing filter, which
removes large plankton and solid particles from ballast water. Then, at disinfection step, a
sidestream of seawater flows through an electrolytic unit ( electrolyzer ) to produce oxidant (sodium
hypochlorite ),which is then injected back into the main ballast pipe to the ballast tanks to kill the
residual planktons,pathogens, larva or spores.
When de-ballasting, sodium thiosulfate solution is added into the treated ballast water toneutralize
the residual oxidants. The neutralization step will always be employed prior to dischargeto ensure
that no unacceptable risk is posed to the receiving environment.
BalClor® BWMS can be consisted by automatic back-flushing filter unit, electrolytic disinfection unit,
and automatic neutralization unit components. Hereinto, flowmeter (FT01~02), seawater filter
(AFU01~02), and TRO analyzer (TR01~02) will be installed in engine room. Please find corresponding
specification of equipment or specification in Chapter 10.

3.1.1 SYSTEM WORKING CONDITION
0～90％
Humidity range (The equipment installed
in the Engine Room)
Working conditions Salt air

Air condition
(Ocean atmosphere)
Environment temperature: 0～55 ℃
Seawater temperature 5～35 ℃
Static condition all directions ≤22.5°

Slope & Swing
Dynamic condition all directions ≤22.5°
Voltage floating ±10%
Instantaneous voltage floating ±20%
Electromagnetic Frequency floating ±5%

compatibility
±10%
Instantaneous frequency floating (Recovery time is 3
second)
Power supply 440V, 60Hz, 3Φ
3.1.2 AUTOMATIC BACK-FLUSHING FILTER UNIT
The ballast filter is an automatic back-flushing filter;its flushing is done without interrupting
operation and with a minimal pressure drop. The filter has a 50 micron screen, which can effectively
remove planktons and solid particles whose size exceeds 50 micron.The automatic back-flushing
filter can continue to work even if the back-flushing process is running. The back-flushing process has
little influence to the pressure loss.
When the differential pressure of the filter screen or the working time achieves the set value, the
system will automatically start self-cleaning cycle, and the dirty water is firstly sent into sewage
system. Then, the sewage is pumped back to sea either in a separate line or through a connection to
an overboard line.
3.1.3 ELECTROLYTIC DISINFECTION UNIT
The electrolytic unit takes seawater from pre-filter (EQ13) outlet which has 0.8mm screen.

The electrolytic unit extracts about 36 m3/h seawater to electrolyzer and generates oxidant (sodium
hypochlorite) and by-product hydrogen. The electrolyzed water contains sodiumhypochlorite
solution is injected back into the main ballast pipe. The biocide reacts in the pipe with both inorganic
and organic species in the ballast water to provide effective disinfection.
The hydrogen is separated by cyclone, and then the hydrogen is diluted with air using a blower to a
safe level before it is released overboard.
3.1.4 AUTOMATIC NEUTRALIZATION UNIT
Automatic neutralization unit is used to neutralizing residual chlorite in the treated ballast water
during de-ballasting process. The amount of neutralizer is controlled and adjusted according to the
amount of flow of the ballast water in the main pipe and theTRO concentration in the ballast water
measured by the first TRO analyzer.
Na2S2O3 solution is used as the neutralizer. NaCl and Na2SO4 produced in the neutralizationreaction
are common in seawater, they will not result in marine pollution.
3.1.5 TRO MONITORING SYSTEM
TRO Monitoring system is an economical and low maintenance instrument for ballast water to
analyze total residual chlorine of main pipe by use of DPD chemical colorimetric method. The
reagents consist of two bottles. One bottle has a buffer to control the PH; the second has an
indicator that contains DPD, which produces color for chromogenic reaction. A green LED provides
the 515 nm source lamp, and colorimeter compares chroma of sample water with reference
standards to obtain measurement results.
In ballasting, TRO monitoring system measures TRO concentration of ballast water after fully mixed
with sodium hypochlorite solution and simultaneously transmits concentration signal to PLC in the
control cabinet and remote control panel. After compared with preset signal, PLC transfers result
signal to rectifier. On the basis of received signal, rectifier will regulate output current to control
amount of Sodium Hypochlorite generated by electrolytic cell to maintain TRO concentration.
In de-ballasting, sampling pump (EQ18) sucks tiny amount of ballast water to TRO analyzer to
determine the TRO level. And the control system will calculate neutralizer dosage automatically in
accordance with TRO level and flow rate.
3.1.6 FLOW MEASURING SYSTEM
Flow measuring system uses an electromagneticflowmeter to measure the flow volume of ballast
water. The electromagnetic measuring system consists of one transmitter and one sensor.

Measurement system based on Faraday law on electromagnetic induction, the flow of the seawater
can be measured by voltage caused of circulation of the water between the two internal electrode.
During ballasting process, the control system calculates the chlorine production according to TRO
level and volume flow. And during de-ballasting process, the dosing amount of sodium thiosulphate
is also determined by the two factors.
3.1.7CONTROL SYSTEM
BalClor® BWMS is designed for completely automatic operation on the basis of PLC platform. During
automatic operation, the working condition of every part in this system is automatically monitored.
In emergency cases, the system can be manually operated. When emergency occurs, PLC will send
instruction signals to adjust the working condition of the identified part.
Meanwhile, PLC will transmit the working parameters of the equipments and the alarm status to the
HMI for operating and observing.
CAUTION： The PLC will lock the BWMS when serious faults comes out, press the RESET button for
about 10 seconds after the faults settled, the system will reset again.
3.1.8 ADD SALT UNIT
Add salt unit is designed for freshwater route. When the ship sailing in water which salinity less than
10 PSU, the salt water unit would be used to supply salt water to EDU.
Salt unit is mainly composed of salt water tank, salt water pump as well as some of valve and
instrument.
3.2MAIN EQUIPMENTS& INSTRUMENTS DESCRIPTION
3.2.1 SEAWATER BOOST PUMP
Only when the ship sailing in the region of fresh water and during ballasting process, the seawater
boost pump will start to work automatically and small amount seawater in A.P.T. is pumped into the
electrolytic unit.
The seawater boost pump is vertical single-stage single-suction centrifugal type. The pump body is
straight connection with motor. The shaft seal is mechanical seal improve the efficiency of pump.
3.2.2 BLOWER

The set of two blowers is one of the most important components in BalClor○R BWMS, which directly
affects the safety and efficiency of the whole system. The main purpose of installing blowers in the
system is to dilute the electrolytic byproduct –hydrogen by at least 100 times before releasing, in
order to insure vessel operation safety.
There are two set fans, one use and one standby.
3.2.3 CYCLONE
The cyclone is simple, compact, low-cost equipment in application of cyclonic separation principle to
separate hydrogen from liquid after generated in electrolyzer.
The cyclone consists of a vertical shell with a tangential inlet and two outlets separately for gas and
liquid. The tangential flow from the inlet to the body of the cyclone causes the flow to swirl with
sufficient tangential velocity to produce centripetal forces on the entrained gas which are an order of
magnitude higher than the force of gravity. Then into a chamber containing narrowly separated
parallel corrugated plates stacked one above other to produce inertial forces on the air flow to which
make differences with movement locus of liquid-drop.
The combination of gravitational, inertial and centrifugal forces pushes the Sodium Hypochlorite
solution radially outward and downward toward the liquid exit, while the Hydrogen is driven inward
and upward toward the gas exit.
3.2.4 METERING PUMP
A metering pump is used to pump certain amount of neutralizer (sodium thiosulphate) and react
with residual oxidants to ensure TRO (Total Residual Oxidants) level do not exceed the discharge
standard for active substances issued by IMO.
The pumping rate is in accordance with TRO concentration and adjusted by the PLC (Programmable
Logic Controller), which calculates the needed amount of sodium thiosulphate according to the TRO
level and flow rate of discharging ballast water
3.2.5 GAS DETECTION AND ALARM INSTRUMENT
The Hydrogen and Chlorine detectors convert the gas concentration to 4-20mA standard signals and
transmit them to PLC in System Control Cabinet. PLC adopts separate time design for each detector.
After logic analysis, PLC responds to the received signal in the way of digital display and sound-light
alarm, while recording alarm time and concentration. In the mean time, the whole system will shut
down if the gas concentration reaches to high-high alarm.

Lower explosive limit of Hydrogen in the air is 4.0%. When H2 concentration reaches 20%LEL (high
alarm value), system control cabinet gives out sound-light alarm.EDU will shut down immediately,
when H2concentration exceeds 60%LEL (high-high alarm value). Control system can display alarm
details on HMI for ventilation in time.
Once chlorine concentration reaches 0.4ppm(high alarm value),the alarm gives out sound-light alarm
to the system control cabinet. EDU will stop working at once, when concentration exceeds
0.55ppm(high-high alarm value). Control system can display alarm details on HMI for ventilation in
time.
3.2.6 RECTIFIER
The rectifier is a type of high-frequency switch rectifying power supply to convert AC into DC and
provide DC power for the whole BWMS. The rectifier is mainly composed of power modules,
monitors and frames. Each power module works separately at average current in parallel operation.
3.2.7 SYSTEM CONTROL CABINET
The system control cabinet is the control center of the BalClor○R BWMS with steady performance and
facilitating operation. The control cabinet is composed of the cabinet, PLC; touch screen,
intermediate relays, terminals, and contactor, etc. The remote control function of the system is
realized by the remote control box.
The control cabinet supplies AC power for meters and valves. The PLC in the cabinet controls the
rectifiers, electrolyzers, and electric valves to realize the electrolysis and neutralization process. And
all the operation can be conducted on the touch screen. The control cabinet communicates with
onboard control system via RS485 or no source contacts signal.
3.2.8 EDU JUNCTION BOX
The EDU junction box acts as a bridging role between the control cabinet and the EDU. The function
includes: Supply power for meters, electric valves. Switch the electrolysis voltages into 4~20mA
signal and transmit signals to control cabinet.
3.2.9 REMOTE CONTROL BOX
The remote control panel is used to realize the remote control functionof theBalClor○
R BWMS. The
remote control panel is composed of the cabinet, and touch screen etc, The operating personnel can
through the remote operation panel control BalClor○R BWMS。

3.2.10 MOTOR CONTROL CABINET
The motor control cabinet is composed of the cabinet, intermediate relays, terminals, motor
breakers, and contactor, etc. The control cabinet supplies AC power for pumps, blowers, TRO
sampling valves, motors of filters, etc.
3.2.11 ANU CONTROL BOX
The ANU control box is a bridging role between the control cabinet and the ANU. The function
includes: Supply power for metering pump, stirring motor and electric valves. Connect the control
signal with the frequency changer to adjust the pumping rate of the metering pump.

4SYSTEM OPERATION
4.1 GENERAL
The PLC and HMI are arranged in the control cabinet and remote control panel.
CAUTION! Professional personnel are required to carry out the dismantling and servicing on the
PLC and HMI. If any error occurs, please return to company for repair or contact with SUNRUI
Company for assistance.
NOTE: If a PLC program failure occurs, Turn OFF the power to the PLC, Set pin 2 of the DIP switch to
ON.Turn ON the power to the PLC. The system files will be automatically loaded into the PLC and the
PLC will restart. Memory card PLC
Automatically TransferringMemory Card Files to theCPU Unit at Power-up

1. Install the Memory Card into the CPU Unit.
2. Set pin 2 of the DIP switch to ON.
3. Turn ON the power to the PLC.
The files will be read automatically whenthe power is turned ON.
The battery and the Memory Card replacement of PLC and HMI see 6.2.12
The communication protocol is Modbus-RTU based RS-485(2-wire) half-duplex digital interface, and
BalClor® BWMS is slave. The default baud rate is 9600, and the default setting is 8bit/1stopbit/no
parity. The communication distance is up to 500m.
The signals provided to the BalClor® BWMS are listed as follows:
No. Signal name Signal type description remarks

Whether Ballasting
1 Ballasting start reply signal Dry contact reply start power
permit
2 Ballast pump running status Dry contact
BAV13/15/22:RS485;B
Filter by-pass valves and TV020:dry contact;
3
overboard valves status
BTV003/004:4~20mA
Remember the
history operating
4 GPS information RS422
data according to
actual conditions

5 G.S. pump running status Dry contact
The signals provided by the BalClor® BWMS are listed as follows:
No. Signal Name Signal type description

Query answer for EDU
1 Start require signal when ballasting Dry contact
power when ballasting
2 Public alarm Dry contact

3 Running / stopping state Dry contact
4.2 INITIAL STARTUP CHECK
Before starting the BalClor® BWMS, take a few minutes to verify that all components of the BWMS
were intact.
Inspect unit to ensure all components are as they were originally supplied.
CAUTION! This system cannot treat the simultaneous ballasting/de-ballasting process of WBT &
APT. Fire & bilge ballast pump should be also not working with fire & general service pump
together during ballasting/de-ballasting process of APT.
Note :Inspect the reagents volume and validity in TRO analyzer. Please replace the buffer and
indicator timely when needed. For reagent preparation refer to section 7.1.2.2 Replacing and
installing the reagents
4.2.1 INITIAL STARTUP CHECK FOR BALLASTING PROCESS
Note :Components including FT01/02/03/04/05/06/07, AFU01/02/03, EQ02-1#/2#/3#, EQ04,

EQ14,ASU,EDU01/02 and TR01/02would be involved in ballasting treatment process.
1. Inspect and tighten all loose terminals and cables in DC Rectifier circuit.
2. Ensure control cabinet is CLOSED before energizing unit.
3. Diaphragm valve (HV201) in EDU01&02 could be used for regulating flowrate to electrolyzer.
4. Before starting the pump check that:
- The shaft rotates freely without jarring sounds.
- The pump casing and the suction line are filled with liquid.
Start the pump for a moment to check the direction of rotation. If the direction is correct (i.e. in
thedirection of the arrow) the pump may be started.
5. Verify following valves are positioned according to table below.

Valve Valve
NO. Valve Name Valve Location Figure
Code state
Starboard Side Of Ballasting Process
1 BAV27 O/CIND.B’FLY V/V ON Near sea chest BWMS-FD-01
2 BAV26 O/CIND.B’FLY V/V OFF Near BAF10 BWMS-FD-01
3 BAV28 O/CIND.B’FLY V/V OFF Discharge of No.1 TCP BWMS-FD-01
4 BAV25 Local control B’FLY v/v ON Suction of No.1WBP BWMS-FD-01
5 BAV36 Swing check v/v ON Discharge of No.1WBP BWMS-FD-01
6 BAV32 Local control B’FLY v/v OFF On deballast line BWMS-FD-01
7 BAV31 Local control B’FLY v/v On Before No.4 WBT BWMS-FD-01
8 BTV005 Butterfly valve On Inlet of AFU01 BWMS-FD-02
9 BTV001 Opening IND. B’FLY v/v OFF Outlet of AFU01 BWMS-FD-02
10 BTV003 O/C IND.B’FLY V/V OFF Bypass valve of AFU01 BWMS-FD-02
11 BTV408 Stop check valve ON Before EQ18-1# BWMS-FD-02
12 BTV404 Stop check valve ON Discharge of EQ18-1# BWMS-FD-02
13 BTV410 Stop check valve ON After EQ18-1# BWMS-FD-02
14 BTV207 Stop valve ON After ODU BWMS-FD-02
15 BTV201 Opening IND. B’FLY v/v ON Near ODU BWMS-FD-02
16 HV41 Butterfly valve ON Suction of EQ14 BWMS-FD-02
17 HV45 Butterfly valve ON Discharge of EQ14 BWMS-FD-02
18 BTV009 Butterfly valve ON Suction of EQ02-1# BWMS-FD-02
19 BTV012 Stop check valve ON Near overboard BWMS-FD-02
20 BTV402 Electric ball valve ON Suction of EQ18-1# BWMS-FD-02
Electric ball valve ON Inlet of electrolyzer

21 EV201 BWMS-XTT-01
(EDU)
Inlet of electrolyser
22 HV201 Diaphragm valve ON BWMS-XTT-01
(EDU)
Outlet of electrolyser
23 HV202 Butterfly valve ON BWMS-XTT-01
(EDU
Flushing inlet/Drain
24 HV203 Ball valve OFF BWMS-XTT-01
(EDU)
Flushing outlet
(EDU)
26 HV205 Three-way valve ON Inlet of PS21 (EDU) BWMS-XTT-01
27 HV206 Three-way valve ON Inlet of WP21(EDU) BWMS-XTT-01
28 HV207 Regulating valve ON Before EQ17 BWMS-XTT-01
29 HV208A/B Vent valve ON After EQ17 BWMS-XTT-01
30 HV209 Ball valve OFF Drain(EDU) BWMS-XTT-01
31 EV202 Electric ball valve ON Outlet of EDU BWMS-XTT-01

Valve Valve
Code state
32 BTV104 Stop valve ON Before EDU BWMS-FD-02
33 BTV103 Stop valve ON Before EQ13 BWMS-FD-02
34 BTV101 Stop valve ON Suction of EQ04 BWMS-FD-02
35 BTV105 Stop check valve OFF Near EDU BWMS-FD-02
PortSide Of Ballasting Process
1 BAV18 O/C IND.B’FLY V/V ON Near sea chest BWMS-FD-01
2 BAV19 O/C IND.B’FLY V/V OFF Near BAF10 BWMS-FD-01
3 BAV21 O/C IND.B’FLY V/V OFF Discharge of No.1 TCP BWMS-FD-01
6 BAV29 Local control B’FLY v/v OFF On deballast line BWMS-FD-01

(EDU)
Inlet of electrolyser
(EDU)
Outlet of electrolyser
(EDU
(EDU)
25 HV204 Ball valve OFF Flushing outlet(EDU) BWMS-XTT-01

Valve Valve
Code state
APT Ballasting Process
1 BTV021 O/C IND.B’FLY V/V ON Inlet of AFU03 BWMS-FD-03
2 BTV019 Opening IND. B’FLY v/v ON Outlet of AFU03 BWMS-FD-03

Butterfly valve (with limit
3 BTV020 OFF Bypass of AFU03 BWMS-FD-03
switch)
4 BTV023 Stop valve ON Suction of EQ02-3# BWMS-FD-03


10 BTV204 O/C IND. B’FLY v/v ON Near ODU BWMS-FD-03
14 Electric ball valve ON Inlet of electrolyzer

EV201 BWMS-XTT-01
(EDU)
15 Inlet of electrolyzer
HV201 Diaphragm valve ON BWMS-XTT-01
(EDU)
16 Outlet of electrolyzer
HV202 Butterfly valve ON BWMS-XTT-01
(EDU
17 Flushing inlet/Drain
HV203 Ball valve OFF BWMS-XTT-01
(EDU)

Valve Valve
Code state
Starboard Side Of Ballasting Process (Fresh water Route)
6 BAV32 Local control B’FLY v/v ON On deballast line BWMS-FD-01
7 BAV31 Local control B’FLY v/v OFF Before No.4 WBT BWMS-FD-01

(EDU)
Inlet of electrolyzer
(EDU)

Valve Valve
Code state
Outlet of electrolyzer
(EDU
(EDU)
Flushing outlet
(EDU)
33 BTV101 Stop valve OFF Suction of EQ04 BWMS-FD-02
36 BTV505 Stop valve ON After ASU BWMS-FD-02
37 BTV504 Opening IND. B’FLY v/v ON After ASU BWMS-FD-02
On fresh water line to
38 BTV502 Electric butterfly valve ON BWMS-FD-02
EQ51
39 BTV501 Stop check valve ON BWMS-FD-02
EQ51
40 BTV56 Butterfly valve ON Discharge of EQ15 BWMS-FD-02
42 BTV51 Butterfly valve ON Suction of EQ15 BWMS-FD-02
PortSide Of Ballasting Process (Fresh water Route)
3 BAV21 O/C IND.B’FLY V/V OFF Discharge of No.2TCP BWMS-FD-01
6 BAV29 Local control B’FLY v/v OFF On deballastline BWMS-FD-01

Valve Valve
Code state

(EDU)
Inlet of electrolyzer
(EDU)
Outlet of electrolyzer
(EDU
(EDU)
38 BTV502 Electric butterfly valve ON BWMS-FD-02
EQ51
39 BTV501 Stop check valve ON BWMS-FD-02
EQ51
42 BTV51 Butterfly valve ON Suction of EQ15 BWMS-FD-02
APT Ballasting Process (Fresh water Route)

Valve Valve
Code state
1 BTV021 O/C IND.B’FLY V/V ON Inlet of AFU03 BWMS-FD-03
2 BTV019 Opening IND. B’FLY v/v ON Outlet of AFU03 BWMS-FD-03

3 BTV020 OFF Bypass of AFU03 BWMS-FD-03
switch)
4 BTV023 Stop valve ON Suction of EQ02-3# BWMS-FD-03


10 BTV204 O/C IND. B’FLY v/v ON Near ODU BWMS-FD-03
14 Electric ball valve ON Inlet of electrolyzer

EV201 BWMS-XTT-01
(EDU)
15 Inlet of electrolyzer
HV201 Diaphragm valve ON BWMS-XTT-01
(EDU)
16 Outlet of electrolyzer
HV202 Butterfly valve ON BWMS-XTT-01
(EDU
17 Flushing inlet/Drain
HV203 Ball valve OFF BWMS-XTT-01
(EDU)

Valve Valve
Code state
32 On fresh water line to

BTV502 Electric butterfly valve ON BWMS-FD-02
EQ51
33 On fresh water line to
BTV501 Stop check valve ON BWMS-FD-02
EQ51

4.2.2 INITIAL STARTUP CHECK FOR DE-BALLASTING PROCESS
Note :Components including FT01/02/03/04/05/06/07, AFU01/02/03, EQ02-1#/2#/3#, EQ04,

EQ14,ASU,EDU01/02 and TR01/02would be involved in de-ballasting treatment process.
1. Inspect liquid level of neutralizing tank to ensure there is sufficient neutralizer before
de-ballasting. The neutralizing solution should be prepared before dosing according to the
following procedures:
a. Drain the rest neutralizing solution in the tank.
b. Switch off the ANU power, open the tank lid and add about 290 kg sodium thiosulphate crystals
(Hypo) into the tank.
c. Add some fresh water into the tank and observe the water level of the level meter, and stop
adding fresh water when the water level reaches half the total height. Turn on the ANU power and
start the mixer to stir the solution.
d. Turn off the mixer and cut off the ANU power after 30 minutes’ blending, add fresh water to the
1150 mm and then close the lid. Reconnect the power to switch on the mixer for another 20 minutes.
2. Verify following valves are positioned according to table below.
Valve Valve
Code state
Starboard Side Of Deballasting Process
1 BAV27 O/C IND.B’FLY V/V OFF Near sea chest BWMS-FD-01
2 BAV26 O/C IND.B’FLY V/V ON Near BAF10 BWMS-FD-01
8 BAV22 O/C IND.B’FLY V/V ON Near overboard BWMS-FD-01
9 BTV005 Butterfly valve OFF Inlet of AFU01 BWMS-FD-02
11 BTV003 O/C IND.B’FLY V/V ON Bypass valve of AFU01 BWMS-FD-02
15 BTV207 Stop valve OFF After ODU BWMS-FD-02
16 BTV302 Electric ball valve ON After ANU BWMS-FD-03
17 BTV306 Stop check valve ON After ANU BWMS-FD-03
18 HV301A Ball valve ON In ANU BWMS-XTT-02

Valve Valve
Code state
21 HV304 Ball valve ON In ANU BWMS-XTT-02

PortSide Of Deballasting Process
1 BAV18 O/C IND.B’FLY V/V OFF Near sea chest BWMS-FD-01
2 BAV19 O/C IND.B’FLY V/V ON Near BAF11 BWMS-FD-01
3 BAV21 O/C IND.B’FLY V/V OFF Discharge of No.2TCP BWMS-FD-01
9 BTV006 Butterfly valve OFF Inlet of AFU01 BWMS-FD-02
11 BTV004 O/C IND.B’FLY V/V ON Bypass valve of AFU01 BWMS-FD-02
15 BTV208 Stop valve OFF After ODU BWMS-FD-02
18 HV301B Ball valve ON In ANU BWMS-XTT-02

APT Deballasting Process
1 BTV021 O/C IND.B’FLY V/V OFF Inlet of AFU03 BWMS-FD-03

3 BTV020 On Bypass of AFU03 BWMS-FD-03
switch)

Valve Valve
Code state

12 25V Butterfly valve ON Overboard BWMS-FD-03
Starboard Side Of DeballastingProcessby Stripping Ejector
1 BAV20 O/C IND.B’FLY V/V OFF In pump room BWMS-FD-01
4 BAV24 O/C IND.B’FLY V/V ON In pump room BWMS-FD-01
5 BAV37 Swing check v/v ON Near stripping ejector BWMS-FD-01
6 BAV40 Stop check valve ON On fire main line BWMS-FD-01
7 BAV15 O/C IND.B’FLY V/V ON Near stripping ejector BWMS-FD-01
9 BTV32 Local control B’FLY v/v OFF On ballast main line BWMS-FD-01

PortSide Of Deballasting Process by Stripping Ejector
4 BAV24 O/C IND.B’FLY V/V ON In pump room BWMS-FD-01
5 BAV37 Swing check v/v ON Near stripping ejector BWMS-FD-01
6 BAV40 Stop check valve ON On fire main line BWMS-FD-01
7 BAV15 O/C IND.B’FLY V/V ON Near stripping ejector BWMS-FD-01

Valve Valve
Code state
9 BTV32 Local control B’FLY v/v OFF On ballast main line BWMS-FD-01


4.3 BALLASTING PROCESS OPERATION

BalClor® ballast water management system is designed based on human operation; it has two
operation manners including local control and remote control. Local control model is operation by
control system control cabinet; the operation manner is used to equipment adjacent and overhauling.
Remote control model is operating the system by controlling HMI, the HMI is on the wall of the cargo
control room, and simple operation can control the system.
The remote control is used to operating the system in normal conditions.
Note : Make sure the pipe is current and the valve of EDU is on the right status before the system is
running!
Check the quantity of the neutralization reagent and make sure the reagent is in the using date(three
months).
4.3.1 LOCAL CONTROL OF BALLASTING PROCESS
a) Starting of Ballasting Process

Connect the power source of system control cabin and enter the interface after 10 seconds as
followed.
① Click the button “AUTO” on the screen to inter automatic running model.
Note: The system has two languages. Click the button on the screen to change language, If
the system in automatic running model.

1#/2#ballasting process control interface (
1# ballasting process control interface（APT）
② Click the blank place of “Set TRO Level” to set the TRO (the default level is 7.5 ppm).

③ Click or , return ballasting process control interface
④ Click the button to start the system.
The sewage pump will start according to the differential pressure of the AFU. Or the operator can
start the sewage pump by clicking the button on ballasting process control interface.
Note:
The control system could detect the system automatically , the detecting information include of
whether power system is normal, whether power supply of AFU and H2/Cl2 detector is normal,
whether communication of TRO, blower, flowmeter is normal, whether electric valve of EDU is open.
The information of system will be displayed on the screen as “information bar”. As the system has
independent logic control process and interlock with the subproject, the screen will display the alarm
signal and happen time on “ALARM” control interface if abnormal condition appears. The system will
stop automatically until the fault is overcome. The operator can operator the BWMS when the
screen display the information of “EDU ALREADY.
Click the button on the screen to inter alarm control interface.
Alarm control interface
Click the button to eliminate the alarm sound.

Pull the reset button for 5 seconds when the system alarms and the alarm will stop.
c) Stopping of Ballasting Process
Click the button “STOP” could stop the system after the ballasting process is over.
Note: please do not shutoff the power source after stop the system.
4.3.2 REMOTE CONTROL OF BALLASTING PROCESS
Control the ballasting process remotely by operating the HMI. Make sure the pipe is unimpeded and
the power source is adequate.
a) Starting of Ballasting Process
Adjust the “LOCAL/REMOTE” switch to “REMOTE” position before the system starts. Open HMI and
inter the operating interface.
1#/2#ballast tank ballasting control plate

Ballasting control plate for APT

The buttons on the below of the screen are ”LANGUAGE”, “RECORD”, “ALARM”, “BALL(W.B.T)”,
“BALL(A.P.T)”, “DEBAL” and ”Valve Control”
Set TRO on the screen (normal 7.5ppm), the top and bottle of the screen are display two EDU control
systems.
Click “START” button could operate the system automatically and the operating data will display on
the screen. What’s more, the operator could control the filter backwashing by clicking the button
“Flush”.
Note: when ballast, the ballast pump and the APT pump cannot be used at the same time, if not,
there will be alarm information displayed on the screen and required to stop ballasting process.
b) Stopping of Ballasting Process
Click the button “STOP” to stop the system after the ballasting process is over.
Note: do not shutoff the power source after the system stop.

4.4 DE-BALLASTING PROCESS OPERATION
Note: make sure the neutralization drug in the neutralization tank is sufficient and available! Make
sure the TRO reagent is sufficient and available!
4.4.1 LOCAL CONTROL OF DE-BALLASTING PROCESS
a)Starting of De-ballasting Process

Open the system control cabin switch and adjust the “LOCAL/REMOTE” switch to “LOCAL” position,
the display as followed.
Enter automatic control interface by clicking “AUTO”, click the button “DEBAL” to enter the interface
of de-ballasting.

de-ballast automatic control interface

Choose the de-ballast way then click the different buttons of “START” to control the neutralization
unit.
At the start of de-ballast process, BalClor○R BWMS put the neutralization reagent sufficiently to the
main pipe and inject adequate reagent according to TRO and flow of main pipe.
The TRO analysis near the outlet of ballast water detect the TRO. If the TRO valve is higher than the
given value, the control panel will display alarm signal. The seaman should shutoff the ballast pump
after receive the alarm signal.
c) Stopping of De-ballasting Process
Click the button “STOP” to stop the system after the de-ballasting process is over.
d)Shutoff Power Source of Rectifier
Open the door of rectifier and shutoff the power source.
4.4.2 REMOTE CONTROL OF DE-BALLASTING PROCESS

a)Starting of De-ballasting Process
Adjust the “LOCAL/REMOTE” switch to “REMOTE” position before the system starts. Open HMI and
inter the operating interface.

Inject the neutralization reagent to B.W.T(S), B.W.T (P), and APT as needed by clicking “START”
buttons.
b) Stopping of De-ballasting Process
Stop the neutralization process by clicking “STOP” buttons as needed.
Close the HMI after operation is over.
4.5 ADDING SALT PROCESS OPERATION
Add 1000kg salt into the salt tank 3 hours Before entering the freshwater area. Fill the salt tank
with freshwater to the highest water level. Start the pump for recirculation to make the salt resolve.
After the ballasting pump starts, adjust the flow rate of the salt water pump.
Add 500kg salt to the salt tank every one hour; after adding salt, fill the tank with freshwater.
One hour before ending the ballasting process, stop adding the salt and water.
NOTE: The particle diameter of the salt should be less than 0.3mm or it will affect the salt dissolution.

Quantity of Concentration of Concentration

Quantity of salt Adding salt Adding water
time（h） water in salt in tank of salt into
in tank（Kg） after （Kg） after（m3）
tank（m3）（PSU） EDU(PSU)
0 1000 12 83 17 0 0
1- 500 6 83 17 500 6
1+ 1000 12 83 17 0 0
2- 500 6 83 17 500 6
2+ 1000 12 83 17 0 0
3- 500 6 83 17 500 6
3+ 1000 12 83 17 0 0
4- 500 6 83 17 500 6
4+ 1000 12 83 17 0 0
5- 500 6 83 17 500 6
5+ 1000 12 83 17 0 0
6- 500 6 83 17 500 6
6+ 1000 12 83 17 0 0
7- 500 6 83 17 500 6
7+ 1000 12 83 17 0 0
8- 500 6 83 17 500 6
8+ 1000 12 83 17 0 0
9- 500 6 83 17 500 6
9+ 1000 12 83 17 0 0
10- 500 6 83 17 500 6
10+ 1000 12 83 17 0 0
11- 500 6 83 17 500 6
11+ 1000 12 83 17 0 0
12- 500 6 83 17 0 0
12+ 1000 12 83 17 0 0
-means the status of no salt and fresh water adding.

+means the status of adding of salt and fresh water.

5MAINTENANCE
Periodic maintenance work is strongly recommended to prevent any accidents which may occur
during operation of the BalClor○R BMWS and to keep the system operating in a constantly smooth
state.
5.1DAILY MAINTENANCE
5.1.1 AUTAMATIC BACK-FLUSHING FILTER
In order to make sure the filter continues to operate properly, observe the following points for
maintenance:
•After finishing the filtering process of ballast water, it is recommended that the filter is flushed 3
times before shut down. Afterwards, it is strongly recommended the filter is filled up with fresh
water in order to avoid deposits to harden. Running empty or drying up of the filter must be
avoided.
• Regularly Check:
– The differential pressure,
– The leak tightness of the filter, especially all connections and seals
– The filter for corrosion and other damage and
– The condition of all screw connections and whether they are firmly tightened.
• Check the condition of the sacrificial anode (if fitted) at least 2x per year. Replace the sacrificial
anode when the zinc mass has worn in such a way that the carrier frame can be seen.
• The filter must be inspected annually for leaks.
• Check filters with an inner lining/coating check for internal corrosion and any material abrasion
caused by medium contamination each time you open the filter element or at least 1x annually. BOLL
& KIRCH Filterbau GmbH has to be consulted in event damaged surfaces have to be repaired. The
contact data for the respective national subsidiary can be found in the appendix of the operating
instructions.
• Replace all seals when overhauling the filter.
5.1.2 TRO ANALYZER
Please note that to perform these maintenance operations of TR01/02 which located in P.R. the
cabinet door must be open and the instrument in maintenance by-pass mode.
5.1.2.1 Maintenance Schedule

The recommended schedule is shown below. It is important to replace the reagents to get reliable
accurate readings from the instrument. The Buffer supplied can last for up to one year. Each mixed
indicator reagent will last for up to 90 days when kept special cooling chamber.The one year kit
includes one buffer bottle and four sets of indicator reagents. The indicator reagents in another clip
and is further held with a Velcro strap.
Each TRO analyzer is shipped with one Tubing/Cuvette kit. The kit consists of the following:
Qty Part
1 Spare Buffer Cap Assembly
1 Spare Indicator Cap Assembly
8 Pump Tubes
1 Spare Cuvette
Two replacement sets of reagent cap/tubing assemblies are supplied with the instrument; one for
the buffer and one for the indicator. It is recommended to keep one kit on hand at all times.
Generally, both pump tubes should be replaced annually. Spare cap assemblies for both the buffer
and the indicator are supplied and can be replaced when needed.
Every 90 days
1. The indicator reagent required for operating this instrument must be changed at least every 90
days. The buffer reagent can be used up to one year.
2. The internal strainer should be checked and cleaned if necessary.
3. The glass cuvette should be inspected. Check for excessive debris on the inside surface of the glass.
It is suggested to keep a spare cuvette to replace when required. The old cuvette may be cleaned, if
possible, for future replacement.
Flushing the System
Press the SERVICE button to stop the water flow. Remove old reagents and discard. Place the suction
tubes in a small container of clean water. Press SERVICE to return to operation mode, press PRIME
and then  to flush the system with water. Remove the suction tubes from the water Press PRIME
and then  to remove most of the water.
After a PRIME the instrument will perform a water calibration (WCAL). It will take a few
minutes to complete this procedure.
*The 1 year buffer and 90 day indicator reagent life is primarily used on ballast water applications.
The assumption is based on the factory default of a 2 ½ minute cycle and up to 60 hours total
operation per month.
Pump Tubing Replacement
The black pump tubes may need replacement more often due to the fact that they are subject to
wear. The inline check valves should not need to be replaced and should be saved. Please note that
the check valves are directional as shown below.
FLOW
INLETEnvironment Engineering
SunRui Marine OUTLET Co. , Ltd
CHECK VALVE DETAIL
Steps:
1 Flush the system as described above to reduce personal contact with the reagents.
2 Press SERVICE to stop the flow of sample water and drain the cuvette.
3 Remove and retain the thumb screw on top of the pump; pull the pump hammer and
spring up and out of the way. There is no need to completely remove the hammer and
spring.
4 Working on one reagent side at a time. Replace the black tubing between optics inlet and
the check valve OUTLET. Discard the old tubing.
5 Ensure the check valve is placed into its seat.
6 Repeat steps 4 & 5 for the other reagent.
7 Replace the hammer and spring back into place and secure with the thumb screw.
8 Check the drawing on the following page to ensure correct installation.
9 Return to operation as described.
Cap Assembly Replacement

When the Cap Assemblies needs to be changed follow the procedure shown below. It is
recommended that both assemblies are changed at the same time.
Steps:
1 Flush the system as described above to reduce personal contact with the reagents.
2 Press SERVICE to stop the flow of sample water and drain the cuvette.
3 Remove the buffer cap assembly from the cabinet vent and the connection at the check
valve.
4 Replace the buffer cap (blue cap) assembly. Note that the vent tube is not centered and
does not connect to the suction tube.
5 Repeat steps 3 & 4 for the indicator side (white cap).
6 Replace reagents, prime and return to service.
Cuvette Replacement
Check the condition of cuvette and change if it appears badly soiled or discolored. Follow the steps
below.
Steps:
1. Replace the two Cap Assemblies.
2. Turn the knurled top on the optics system counterclockwise (as viewed for the top) until
the cuvette just “pops” out, but do not remove the top.
3. When the cuvette “pops” out, move the retaining o-ring& remove the cuvette. You may
need a stiff wire such as a bent paper clip to grasp the cuvette. Retain this cuvette for
future use if it can be cleaned.
4. Install the new cuvette by pushing it firmly in place and turning the knurled top clockwise
until the cuvette is held securely.
5. Check the drawing on the following page to ensure correct installation.
6. Return to operation as described.

anual P
P46// Total 110
11 Pages
T-Strainer Cleaning
A T- strainer is integral to the instrument and must be checked occasionally. When necessary it must
be removed and cleaned.
Steps:
1. Press SERVICE to stop the flow of sample water and
drain the cuvette.
2. Ensure the source water is turned off.
3. The T-strainer
strainer is clamped to the intake regulator. The
removal requires the use of a flat blade screwdriver
as shown in the photo. Once the clamp is opened the
T-strainer
strainer can be removed.
4. Disconnect the T-strainer
strainer an
and regulator from the
tubing and clear of the case.
5. Clean the T-strainer
strainer screen and replace.
6. Be certain the clamp is tightened fully and the
pumping connections are complete.
7. Turn source water back on.
8. Return to normal operation.
Return to Normal Operation
Press the SERVICE button to return sample flow to the system. Check for leaks. If a leak occurs
press SERVICE again, repair leak and try again. Once the system is operating correctly, return or
replace reagents and press PRIME and then  one time to restartrt reagent flow. The system will
automatically return to normal operation.
Tubes may darken due to contact with the reagent. This condition does not
affect the performance of these parts.
5.1.2.2
.1.2.2 Replacing or Installing the Reagents
Reagent kits are available

able from HF scientific for Total Chlorine Refer to section 9.2 Replacement Parts
and Accessories for the appropriate Catalog number. There are two reagents required, for the
instrument to operate; the buffer and the indicator.
The reagents are provided “wet”
wet” and the buffer is ready to use and will last up to one year.
The smaller indicator reagent does require the addition of the DPD power to activate it. Once
activated it starts to oxidize. This process is slowed by keeping it in the cooling chamber.
Indicator
dicator Reagent Preparation
Add about 400 ml of de-ionized
ionized water into the indicator bottle. Cap tightly and shake vigorously until
the powder is dissolved. Remove the cap and add the contents of the DPD powder bottle (small
brown bottle). Cap and shake to fully dissolve the powder. When fully dissolved add enough
de-ionized
ionized water to bring the volume in the bottle up to the fill line
line.
Sun
Once mixed the indicator has an expected life of up to 90 days if kept in the
powered cooling chamber. Write the mixing date on the reagent bottle labels in
the area provided. Dispose of expired reagents correctly.
Buffer Reagent Preparation
Add about 400 ml of de-ionized water into the buffer bottle. Cap tightly and shake vigorously until
the powder is fully dissolved. When fully dissolved add enough de-ionized water to bring the volume
in the bottle up to the fill line.
To replace the reagents, press the SERVICE button; this will empty the cuvette and stop any flow of
water. Remove the cap on both bottles replace with the cap supplied with the CLX-XT. The buffer is
installed on the left and the indicator is installed in the cooling chamber. The suction tube for both
reagents will reach the bottom of the bottles.
To complete the replacement procedure, press the PRIME button and then the  button. This will
draw enough of each reagent to completely prime the tubes and replace any old solution. The
system will automatically return to normal operation after it has primed.
Use caution when changing the reagents as they are corrosive. These reagents
may stain clothing. After changing the reagents, operators should wash their
hands.

5.1.2.3 Check Valve Flushing Kit
Sometimes upon initial commissioning, the check valves stick and require manual priming. This
should not be needed after commissioning. Be careful when using this kit to use only chlorine free
water. Complete instructions are included in the kit.
5.1.2.4 Cleaning Instrument
Flush the system as mentioned in section 6.1.2.1Maintenance Schedule. When the flushing is
finished, press the SEVICE button wait until the display reads HOLd.
As a matter of safety, always disconnect any power source to the instrument prior to attempting any
cleaning. It is recommended that the source water is also shut off.
Isopropyl alcohol (rubbing alcohol) on a soft cotton cloth works very well in removing reagent stains
from plastic parts, the key pad and the display. Use care when cleaning around electrical components.
Do not use any harsh cleaning agents as these may cause damage to the instrument components.
Ensure that the system is dry prior to applying power.
5.1.3SEAWATER BOOSTER PUMP (EQ04) AND 3# SEWAGE PUMP (EQ02-3#)
(1) Appearance
 Check for oxidation or corrosion of the front casing, bracket.
 Check for leakage of pump and piping system.
(2) Operation
 Before starting you must turn the pump shaft to see if the rotor is block and rubbed.
 Check to see if the coupling place of pump and piping is loose.
 When the pump is operated for the first time after being overhauled and reassembled, open
the pump body top thread plug, then pour water into pump body. After the water is emitted,
screw the thread plug.
 Check the rotation direction of motor is correct.
 Start motor, after the outlet pressure is going up, must open discharge valve gradually until
the outlet pressure reaches specified value.
 Keep pump running within allowed flow range, which is commonly 50%~120% of the rated
flow, otherwise, easy to cause the motor overload and damage.
 Don’t keep pump running for a long period after the discharge valve has been shut.
 Close the discharge valve after pump has stopped working. If a sudden power failure during
pump running, must cut off power supply first, then close the discharge valve.
5.1.4ELECTROLYZER
Electrolyzer, the on-site generator of hypochlorite has demonstrated reliable operation in numerous
installations throughout the world. The electrolyzer in BalClor® BWMS is supplied pre-assembled and
fixed together with some other components in the EDU.
Check the bolt fastener cell if there's any loose and leak in the daily maintenance; fasten the screwif
it appears to loosen.
Tightness of All Bolted Connections
Check for tightness of all bolted connections every month or whenever the leakage occurs. If leakage
still occurs after tightening, the sealing must be replaced.
5.1.5 BLOWER
Daily inspection:
1. Ensure no dust, debris or dirt particles deposit inside the blowers regularly, prevent potential
causes of rusty.
2. Check on power connection periodically; ensure no water leakage into wire coil box.
3. Ensure ground cable connection.
4. Ensure smooth air supply.
5.1.6 CYCLONE
Daily maintenance is necessary to prevent major faults occurring which could prevent the correct
operation of your Cyclone. To ensure that major faults are prevented, carry out the followings:
1. Visually check housing welding seam for crackle and seepage.
2. Ensure that all fasteners and connections are tight and secure.
3. Visually check housing outside surface for corrosion.
5.1.7 METERING PUMP
5.1.7.1 Visual Check of Seal Integrity of MechanicalAssembly

Check for leaks in the following components.

1. Motor flange: If leaking, replace motor flange sealing gasket.
2. Strokeadjustment knob: If leaking, replace stroke adjustment seal.
5.1.7.2 Checking the Pump Capacity
Assuming the pump has been calibrated, the capacity can be checked by shutting the valve from the
supply vessel and opening the valve from the calibration column to the suction side of the liquid end.
Measure the volume of pumped liquid for a given period of time at the various settings.
5.1.7.3 Occurrence of Leak from Detection Ports
Determine whether the product collected at the detection port in the liquid end mounting assembly
is lubricating oil or the pumped fluid. If the product is pumped fluid, the diaphragm has failed. If the
product is lubricating oil, the oil seal bellows has failed.
5.1.7.4 Change lubrication oil when needed
Recommended Oil
No. Specification Amount/set Note
Manufacturer brand
Initially, change the oil in the

pump drive assembly after the
Gear
Environmental first 1000 hours of operation.
1 GMobil 600 600 mL
temperature :>-5℃ Thereafter, change drive oil on
XP220
an annual basis or after every
5000 hours of operation.
5.1.8 RECTIFIER
The BalClor○R BWMS electric control system is carefully designed simply operated to provide reliable
performance with minimal maintenance. Daily maintenance for the rectifier should follow the
national and local rules and regulations of marine electrical equipment maintenance, which include
the following:
In daily operation, the operators should often check the rectifier to make sure that the ambient
environment is under normal conditions, no mechanical damage occurs, and no water or other
objects enter into the equipment. Abnormalities must be handled immediately if found. The
equipment need to be kept dry and clean.
Visual check of the integrity of the insulation coating and check for the oxidation and rust in the
connection metal between the cable ends and equipment. If any symptoms occur, take appropriate
measures.
When the equipment is in operation, operators must keep all the doors of cabinet and boxes closed.
Do not dump objects outside ventilation opening at the back of the rectifier to ensure cooling.

When the gas cutting or electric welding is conducted near the rectifier, the outside cables of the
rectifier must be covered with incombustible blanket to avoid cable damage by flying spark. And
fireman is required to watch over the procedure.
5.1.9 SYSTEM CONTROL CABINET AND MOTOR CONTROL CABINET
performance with minimal maintenance. Daily maintenance for the control cabinet should follow the
the following:
In daily operation, the operators should often check the control cabinet to make sure that the
ambient environment is under normal conditions, no mechanical damage occurs, and no water or
other objects enter into the equipment. Abnormalities must be handled immediately if found. The
measures.
When the equipment is in operation, operators must keep all the doors of the cabinet closed.
When the gas cutting or electric welding is conducted near the System Control Cabinet and Motor
Control Cabinet, the outside cables of the Control Cabinet must be covered with incombustible
blanket to avoid cable damage by flying spark. And fireman is required to watch over the procedure.
5.1.10 JUNCTION BOX
performance with minimal maintenance. Daily maintenance for the junction box should follow the
the following:
In daily operation, the operators should often check the junction box to make sure that the ambient
environment is under normal condition
Start inquiry signal when ballasting Dry contact Query answer for EDU power when ballast
Public alarm Dry contact
Running / stopping state Dry contact
, no mechanical damage occurs, and no water or other objects enter into the equipment.
Abnormalities must be handledimmediately if found. The equipment need to be kept dry and clean.
measures.

When the gas cutting or electric welding is conducted near the Junction Box, the outside cables of
the Junction Box must be covered with incombustible blanket to avoid cable damage by flying sparks.
And fireman is required to watch over the procedure.
5.1.11 REMOTE CONTROL PANEL
performance with minimal maintenance. Daily maintenance for the remote control panel should
follow the national and local rules and regulations of marine electrical equipment maintenance,
which include the following:
In daily operation, the operators should often check the remote control panel to make sure that the
ambient environment is under normal conditions, no mechanical damage occurs, and no water or
other objects enter into the equipment. Abnormalities must be handled immediately if found. The
measures.
5.1.12 SEWAGE PUMP (EQ02-1~2#)
Daily maintenance is necessary to prevent major faults occurring. To ensure that major faults are
prevented, carry out the followings:
1. Before starting, turn the pump shaft to ensure that rotor isn’t blocked.
2. Checkwhether the pump and pipeline are well combined.
3. When the pump is operated for the first time after being overhauled and reassembled, open the
pump body top thread plug, then pour water into pump body. After the water is emitted, screw
the thread plug.
4. Check whether therotation direction of the motor and the pump is correct. After the check,
open the suction valve fully and start the motor, after the exit pressure rises, adjust the
discharge valve to the exit pressure required.
5. After the pump has stopped working, close the discharge valve. If power off occurs during the
operation, cut off the power supply first, and then close the discharge valve.
6. Never throttle the suction valve during operation, otherwise troubles may occur due to dry
operation.
7. Never operate over 15min with the discharge valve completely closed. When a centrifugal pump
is operated without discharge, most of the power changes into heat and as a result water
temperature rises to the boiling point causing seizure of the interior of the pump.
8. Check suction pressure everyday if there is no abnormalpressure drop and take record.
5.1.13 DOSING PUMP AND SALT PUMP

anual P
P53// Total 110
11 Pages
Appearance 1. Check for oxidation or corrosion of the front casing, bracket and base
plate.
2. Check
heck for lea
leakage of the pump and piping system.
3. Check
heck the pump exterior for any physical damage such as corrosion, paint
stripped off.
Operation 4. Check for irregular sounds and vibrations.
5. Check
heck any abnormal overheat on the surface of motor, threethree-phase
current is imb
imbalanced,
alanced, bearing noise, foreign material blocking the vent of
fan.
6. Check
heck the in
in-tank
tank fluid levels and inlet/outlet pressure.
7. Check
heck the current and motor loading.
8. Check
heck and test
test-run
run backup pumps regularly to ensure they can function
properly when needed.
5.2 PREVENTIVE MAINTENANCE

ENANCE
5.2.1 AUTOMATIC BACK-FLUSHING

FLUSHING FILTER
Regular inspection of the seals (once annually).

Inspection of the corrosion protection (paint, coating, rubber coating)(once annually).
Ensure that filter mesh always maintain in wet conditio
condition.
Fill the geared motor after 5000 operating hours (represents approx. 6years of filter operating time)
with new grease.
Removing the strainer insert
Put the filter out of service.
DANGER: Danger of injury throughunintentional switching of the shut

shut-off
off elements on the
filter.
Disconnect the compressed air supply.
Put the electrical control unit out of service (main switch “OFF”) and secure it againbeing switched
back on withoutauthorization.
Unscrew the motor.
Release the locking plate and groove nut.
Loosen
oosen the cover nuts and lift the cover.
Lift the strainer insert and flushing device bythe welded
welded-on
on eyelets vertically out of thefilter.
Removing the filter cartridges
Sun
Loosen the screws and lift the top flushingarm.

Loosen the screws and lift the cover plate.
Pull out the filter cartridge vertically upwards.
If necessary, release the filter cartridges with adriftapplied from belowwith light blows.
Cleaning the filter cartridges
Place the filter cartridges in a container of cleaning agent - e.g.“BOLL Clean 2000” (Appendix) and
leave to soak for 1-3hours.
Then spray them with a high-pressure cleaning appliance fromboth directions, in the last work
process spray counter to filtrationdirection.
Caution! A max. Overpressure of 85 bar and a max. temperature of70℃ must not be exceeded.
5.2.2 TRO
If the TRO analyzer is relocated or will be inactive for long periods of time, remove the reagents.
Flush the reagent system as describe in 6.1.2.1Maintenance Schedule. Place the instrument in
Service mode to drain the system then remove power by disconnecting the mains power plug. It is
usually a good idea to disconnect or shut off the source water.
5.2.3 BALLAST WATER FLOW METER
Check whether the connection cable is loose or damaged. Check the appearance and screen whether
there is a problem.
5.2.4 SEAWATER BOOST PUMP (EQ04) AND 3# SEWAGE PUMP (EQ02-3#)
The following parts should be inspected quarterly.

1. Check to see if the valve of suction piping is sealed the check valve leaks, so that the pump is not
existent were this to happen, you must stop running to avoid the pump is damaged on account of dry
operation.
2. If abnormal sound or vibration is heard during operating, stop running to check.
3. When it is not in use for long time, you must open the water discharge cock.
4. When the pump has been dismantled, check the following parts for wear and damage:
- Sealing ring/impeller: Max. clearance 0.3~0.6mm measured in radius.
-Shaft seal/shaft seal cover: Check the seat for flatness and cracks. Check the rubber parts for
elasticity.
Frost protection

Pumps which are not being used during periods of frost should bedrained to avoid damage.Drain the
pump by loosening the vent screw in the pump headand by removing the drain plug from the base.
Pay attention to the direction of the vent hole and take care to ensure that the
Caution! escaping water does not cause injury to persons or damage to the motor or other
components.
Do not tighten the vent screw and replace the drain plug until thepump is to be used
again.
5.2.5 ELECTROLYZER
5.2.5.1 Early Warning of the Exhaustion of Anode Catalytic Coating
The voltage applied to the electrolyzer in operation is measured by D.C. volts installed on the rectifier
control panel. The reading of the volts have to be periodically taken, checked and recorded as they
demonstrate the working conditions of the electrolyzer. After years of continuous operation, the
gradually rising voltage levels would be an early warning of the exhaustion of the anode coating
catalytic properties.
5.2.5.2 Electrolyzer Cleaning Operation
During the production of hypochlorite, catholic deposits consisting mainly of the hydroxides and
carbonates are formed simultaneous with the basic reactions. These deposits reduce the current
efficiency. So a cleaning operation with a large amount of fresh water which is circulated through the
electrolyzer by means of a centrifugal pump is highly recommended when a dock of the ship is taken
place.
-When cleaning, connect cleaning inlet flange with interface flange-N24 of EDU, and connect
interface flange-N25 of EDU with cleaning export flange. (Please refer to the ‘Outline Drawing of
EDU’).
-Ensure EDU is in power-off state.
-Close the valve HV202, and open HV203&204. Please refer to the ‘Flow diagram for EDU’.
-Start the cleaning pump and clean the electrolysis cell lasting for about 15min.
5.2.5.3 Tightness of All Bolted Connections
Check for tightness of all bolted connections every month or whenever the leakage occurs. If leakage
still occurs after tightening, the sealing must be replaced.
5.2.6 BLOWER
Caution! Before carrying out any servicing operation on the blower, disconnect electrical power
supply.
1. Before operation, ensure that no objects block the air intake port of the blower.

2. Clean the ventilation screen regularly to ensure sufficient ventilation and avoid overheating.
3. Check for the connection between the casings, bearing assemble and support, as well as between
the bearing black and cap. Fasten all the bolts to avoid violent vibration of the blower.
4. Fan motor has self-lubrication system; don’t need to add lubricating oil to the motor bearing in the
service life of the motor.
5.2.7 CYCLONE
In addition to the daily/prior to operation checks, carry out the following as applicable.
Check whether the unit has air leakage or not.
De-rust & repair painting of partial housing based on corrosion condition.
5.2.8 METERING PUMP
Initially, change the oil in the pump drive assembly after the first 1000 hours of operation. Thereafter,
changes drive oil on an annual basis or after every 5000 hours of operation.
5.2.8.1 Diaphragm Assembly
The diaphragm should be replaced annually or every 5000 hours of operation to avoid the possibility
of failure. More details please refer to themaker’s instructions (Milton Roy) in Section Diaphragm and
Oil Seal Bellows Replacement.
5.2.8.2 Oil Seal Bellows
The seal bellows should also be replaced annually. Oil seal bellows replacement requires the removal
of the diaphragm assembly, so it is recommended that the oil seal and diaphragm assembly be
replaced at the same time. More details please refer to themaker’s instructions (Milton Roy) in
Section Diaphragm and Oil Seal Bellows Replacement.
5.2.8.3 Check Valves
As in the case of the diaphragm, it is recommended that check valve balls, seats, gaskets, and O-rings
be replaced on an annual basis or every 5000 hours of operation. If highly corrosive material (acids,
slurries, etc.) is being pumped, more frequent replacement may be required. Complete instructions
for replacement of worn check valves are given in Section Corrective Maintenance of the maker’s
instructions (Milton Roy).
5.2.9 RECTIFIER
Periodic maintenance for the rectifier should follow the national and local rules and regulations of
marine electrical equipment maintenance. Only qualified personnel who arefamiliar with the electric
system of the equipment and associated technician can plan and undertake termly maintenance of
thesystem. Please commit termly maintenance every six months as follows:

Check the power supply of the rectifier, and make sure that the power supply is correct and has no
phase lack.
Check rectifier fans and replace the broken ones.
Check each display part, and make sure that each can work well. Check all the switches, and make
sure that they can work flexibly and reliably.
Check for the looseness, overheating and discharge of the bolts. And tighten all of bolts if necessary.
Check each shock absorber and change the damaged ones.
Clean the cabinet. Take measures to keep the integrity of the painting and no corrosion occurs .Make
sure that all the signs are complete and in position.
Test the insulation impedance including A.C. input and D.C. output impedance to enclosure, A.C.
input impedance to D.C. output according to the national and local rules and regulations of marine
electrical equipment maintenance. Overhaul the rectifier if short-circuit or insulation decrease occurs.
Correct the malfunction prior to operation.
5.2.10 SYSTEM CONTROL CABINET AND MOTOR CONTROL CABINET
Periodic maintenance for the system control cabinet should comply with the national and local rules
and regulations of marine electrical equipment maintenance. Only qualified personnel who
arefamiliar with the electric system of the equipment and associated technicians can plan and
undertake termly maintenance of thesystem. Please commit termly maintenance every six months as
follows:
Check the power supply of the control cabinet, and make sure that the power supply is correct and
has no phase lack.the battery and the Memory Card replacement of PLC and HMI see 8.2.12）
Check each display part, and make sure that each can work well. Check all the switches, contacts,
relays, buttons and make sure that they can work flexibly and reliably.
Check for the looseness or damage of the PLC, relays and other contact parts. And tighten all the
loosing parts if necessary. Inspect for amoralities of the contactors and replace the ones that have
faults.
Check the “emergency stop” button and make sure it can work well under various working
conditions.
Check for the looseness of the fixing bolts and tighten the loosing ones.
Clean the cabinet. Take measures to keep the integrity of the painting and no corrosion occurs .Make
sure that all the signs are complete and in position.
Test the insulation impedance of A.C. input. Overhaul the control cabinet if short-circuit or insulation
decrease occurs. Correct the malfunction prior to operation.
5.2.11 JUNCTION BOX

Periodic maintenance for the junction box should comply with the national and local rules and
regulations of marine electrical equipment maintenance. Only qualified personnel who arefamiliar
with the electric system of the equipment and associated technicians can plan and undertake termly
maintenance of thesystem. Please commit termly maintenance every six months as follows:
Check for the looseness of the fixing bolts and tighten the loosing ones.
Clean the junction box. Take measures to keep the integrity of the painting and no corrosion
occurs .Make sure that all the signs are complete and in position.
Test the insulation impedance of A.C. input. Overhaul the junction box if short-circuit or insulation
decrease occurs. Correct the malfunction prior to operation.
5.2.12 REMOTE CONTROL PANEL
In addition to the daily/prior to operation checks, carry out the following as applicable.
Replacing the battery of HMI
The battery service life is approximately five years at 25C. The service life will be shortenedif the
battery is used at higher temperatures. Replace the battery periodically, according tothe operating
environment.Replace within five days after the RUN indicator lights orange.
Perform the following procedure within five minutes to replace the battery:
After power to the HMI has been turned ON and at least five minutes have lapsed, turn OFF the
power.
Open the battery cover on the rear panel of the HMI.
Remove the battery that is secured inside the HMI, grasp the cable, and pull the connect or out
vertically to remove it.
Connect the new battery connector, and insert the battery into the battery holder in thebattery
cover.
Close the battery cover, being careful not to squash the battery cable.
Installing and Removing the memory card of HMI

Installing the memory card

The Memory Card is installed in the memory card interface on the side of the HMI.
Push the Memory Card firmly into the back of the slot. (The eject button will be pushed
out when the Memory Card is installed properly.)
Removing the memory card
Press the eject button.
To stop the Memory Card from springing out and falling, place your middle finger on the eject
button, and hold the Memory Card with your index finger.
Replacing the battery of PLC
At 25°C, the maximum service life for batteries is five years whether or not power is supplied to the
CPUUnit while the battery is installed. The battery's lifetime will be shorter when it is used at higher
temperaturesand when power is not supplied to the CPU Unit for long periods.
If the PLC Setup has been set to detect a low-battery error, the ERR/ALM indicator on the front of
theCPU Unit will flash when the battery is nearly discharged.
Perform the following procedure within five minutes to replace the battery:
If the CPU Unit has not been ON, turn it ON for at least five minutes and then turn it OFF.
Open the component on the upper left of the CPU Unit and carefully draw out the battery.
Installing and Removing the memory card of PLC

Installing the memory card
Pull the top end of the Memory Card cover forward and remove from the Unit.

Insert the Memory Card with the label facing to the left. (Insert with the△ on the
MemoryCardlabel and the △ on the CPU Unit facing each other.)
Push the Memory Card securely into the component. If the Memory Card is inserted correctly, the
Memory Card eject button will be pushed out.
Removing the memory card

Press the Memory Card power supply switch.
Press the Memory Card eject button after the BUSY indicator is no longer lit.The Memory Card will be
ejected from the component.
Pull out the Memory Card.

Install the Memory Card cover when a Memory Card is not being used.

5.2.13 SEWAGE PUMP (EQ02-1~2#)
The following parts should be inspected quarterly.

1. Check to see if the valve of suction piping is sealed the check valve leaks, so that the pump is not
existent were this to happen, you must stop running to avoid the pump is damaged on account of dry
operation.
2. If abnormal sound or vibration is heard during operating, stop running to check.
3. When it is not in use for long time, you must open the water discharge cock.
4. Check the shaft seal/shaft seal cover: check the seat for flatness and cracks. Check the rubber parts
for elasticity.
5. Check the impeller and seal ring coupling clearance is not too large, each 2000 hours.The
max.clearance of sealing rings/impeller is 0.4~0.5mm measured in radius.
6. Replace the bearings in case of wear and noise.
Frost protection
Pumps which are not being used during periods of frost should bedrained to avoid damage.Drain the
pump by loosening the vent screw in the pump headand by removing the drain plug from the base.
Pay attention to the direction of the vent hole and take care to ensure that the
Caution! escaping water does not cause injury to persons or damage to the motor or other
components.
Do not tighten the vent screw and replace the drain plug until thepump is to be used
again.
5.2.14DOSING PUMP AND SALT PUMP
1. The following items should be inspected quarterly referring to following table.

Part Name Inspection Item Solution
Front and rear casing 1. Cracks 1. Replace
2. Scratch marks (except when 2. Contact the distributor
pumping particle laden fluids) 3. Clean
3. Crystallization or sludge 4. Contact distributor
4. Shaft support loose or deformed

Front casing o-ring Deformed, corroded or swollen replace

Impeller and magnet 1. Scratch marks or cracks 1. Contact distributor
assembly 2. Cracked bearing or crystallization 2. Contact distributor
3. Bearing displays signs of some wear 3. Replace if worn excessively
and tear 4. Clean
4. Crystallization and other sludge 5. Remove the objects
5. Foreign objects stuck in impeller 6. Contact distributor
6. Impeller deformed
Shaft and thrust ring 1. Scratch marks 1. contact distributor
2. cracks 2. replace
Motor 1. resistance of three phases and 1. Repair or change if
insulation impedance abnormal is found.
2. check amount of lubricant when 2. Keep amount of lubricant at
using open bearing. proper level.
Maintenance and wear/tear limits

Maintenance the magnetic pumps by controlling the wearing parts like bearing, shaft, thrust ring and
wear ring.
To avoid damages at the pump, we recommend, controlling the wearing gap limit between bearing
and shaft not exceed 0.8mm, while between thrust ring and wear ring not exceed 1.0mm. You need
only to change one of parts with heavier wear and tear.
During disassembly of the magnetic pump the dimensions of following components should be
checked:
Part Dimension (mm)
New part Time to change

Shaft outer diameter 28 27.2
Bearing inner diameter 28 28.8
Thrust ring thickness 7 6

Wear ring thickness 7 6
1. AMA’s powerful permanent magnetic coupling could adversely affect

persons who are assisted by electronic devices such as pacemaker.
2. Be sure to turn the power off before performing any type of maintenance,
repair or inspection. Make special provisions so that no other operator
DANGER
mistakenly turns on the power supply while someone is working on the
pump. In a noisy or poor visibility environment, display a sign near the
power supply switch to notify others that someone is “WORKING” on the
pump. Power supply mistakenly turned on during maintenance may lead to

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personal injury.
1. When
hen handling a toxic or odorant liquid, ventilate the working area well. In
addition, the operator must wear protector gear (such as safety mask, safety
goggles, and protective gloves).
2. No remodeling
remodeling: remodeling
odeling of the pump by the user may result in serious
WARNING
injury, electric shock, or damage to the pump. Do o not attempt to remodel as
it is very dangerous.
3. Magnetic
agnetic field hazard: be careful not to get your hands or fingers pinched by
parts. Impeller
mpeller is encapsu
encapsulated strong magnet inside. While,
hile, do not let the
magnet close to the magnetic sensitive objects such as magnetic cards,
computer equipment, etc.
1. Usese the right tools for any maintenance or disassembly and assembly.
2. Bee careful with hazardous liqu
liquids:
3. Iff pumping dangerous chemicals, be sure to drain and wash well before
disassembling. A small amount of fluid may however remain in the internal
CAUTION
parts or pipe fittings.
5.3 CORRECTIVE MAINTENANCE

ENANCE
5.3.1 AUTOMATIC BACK-FLUSHING

FLUSHING FILTER
SYPTOM REMEDY
Manually trigger a backwash

To open the backwash valve turn the EMERGENCY actuation
Failure of the screw on the solenoid valve.
electricalcontrol unit Switch off the electrical control unit (main switch “OFF”
“OFF”)
Attach the crank handle supplied to the free end of the
gearedmotor’s shaft
shaft.
Blockage of the flushing Put the filter out of operation
Device Under no circumstances should you turn the geared motor
with thecrank handle.
Put the filter out of service ( Remo
Removal
val from Service) and
eliminatethe cause.
Permissible differential Open the bypass line
pressure exceeded
No reduction indifferential Open the control valve further
pressuredespitebackwashi
Sun
ng If the differential pressure cannot be reduced despite

backwashing,open the control valve further or, if necessary,
put the filter out ofoperation (Removal from Service) and clean
the filter cartridges (Maintenance).
5.3.2 TRO ANALYZER
5.3.2.1 Fault Detection
The CLX-XT performs continuous diagnostic monitoring. In the CLX-XT, there are 4 severity levels of
fault detection. Level 4, 3 & 2 will allow normal operation, but tale cares of the problems. Level 1 is
an instrument failure and the instrument will not run. Any faults are displayed in a queue form in the
bottom of the LCD.
A level 4 fault will be a screen indication that one of the alarm levels has been activated. This fault
level will not affect the 4-20 mA and will only trigger the alarm. The sample back light blinks at a rate
of once every 4 seconds.
A level 3 fault indicates a failure or a problem that usually can be corrected by the operators. Refer
to the chart below. If any of these errors occur, the instrument will still display readings and probably
run still. These faults will self-clear when the problem is corrected. If any of these faults occur, they
will affect the 4-20mA and any alarm set for fault detection (Error). The sample back light blinks at a
rate of once every 2.5 seconds.
Level 3 (Self-Clearing) fault conditions
Message Description of Fault Corrective Action
MA 4-20 mA enabled & loop open Check 4-20 mA wiring or turn off 4-20mA if
not used
CAL Calibration invalid –not accepted Recalibrate if needed
WATR No water flow Check water flow
FAST Intake water flow too fast Set flow rate
SLOW Sample cuvette filling too slowly Set flow rate
PURG Sample cuvette has slow purge Check drain lines
NPRG Sample cuvette not purging Check drain lines
ISOL Problem with intake solenoid Check wiring, check for clogged solenoid
PSOL Problem with purge solenoid Check wiring, check for clogged solenoid
RGNT Problem with reagent Check reagent and lines
GLAS Dirty cuvette Replace or clean cuvette
WCAL Water Level Calibration Invalid Clear fault
A level 2 fault indicates a severe problem that will usually require technical assistance from HF
scientific customer service. The queued display will show POST.If this fault occurs it will affect the
4-20mA and any alarm set for fault detection (Error). The sample back light blinks at rate of once
every 1 second.

A level 1 fault is a system fault. This is NOT a problem that the operator can correct, and the unit
must be returned to the factory for service. These failures consist of failures in the CPU, A/D,
EEPROM or other devices internal to the instrument. The queued display will show FAIL, the upper
display will show a four or five digit fault code.If this fault occurs, it will affect the 4-20mA and any
alarm set for fault detection (Error). The instrument will not run with this fault. The sample back light
blinks at rate of once every 0.4 seconds.
If any fault condition occurs, the message indicating the fault will be shown on the lower row of the
display.
5. 3.2.2 Setting Flow Rate
The flow rate on the CLX-XT was factory adjusted and usually should not need adjustment.
Installation variances may affect the flow. The flow is adjusted by removing regulator vinyl cap and
turning the adjustment screw on the pressure regulator. To assist in this adjustment follow the
procedure shown below:
Press the SERVICE button.
Wait for the display to read Hold, and then press Mode/ Exit.
Display will show FLOW with the number 0. Press either the  or button.
CLXB will drain, and then pulse in water while a count is displayed on the screen.
The display will show one of three messages HI, LO or Good.
The flow test determines if the flow rate is suitable for proper operation. Loosen the locking nut then
adjust the pressure regulator using a coin or a large flat blade screwdriver. Press either the  or
button while in the FLOW routine to display a new flow rate. Please note that only ¼ turn
incremental adjustments should be made to the regulator on each attempt.
If the message is LO, turn the regulator control clockwise. If the message is HI, turn the regulator
counterclockwise. If the message is good, no adjustment is required. Tighten the locking nut after
adjustment and replace the regulator vinyl cap. To return to normal operation, press the  button.
5. 3.2.3 Clearing Faults
Every time SERVICE mode is exited, all faults are cleared. If the original fault or a new fault occurs, it
will be posted.
5.3.2.4 Reagent Clogs
If reagents fail to flow (Due to a clog in either the tubing or at a check valve). To alleviate this you
may have to flush the system with Chlorine Free water, preferably deionized water.
5.3.2.5 Diagnostic Chart
Symptom Cause Cure

Lower display shows MA 4-20 mA loop open Check wiring.

Readings are erratic (1) Bubbles in solution (1) See above

(2) Debris in flow (2) Install T strainer at inlet
Readings are lower than Condensate or leaky (1) Install desiccant cartridge kit
expected measurement cuvette
(2) Replace or clean cuvette
Measurement cuvette dirty
(3) Replace reagents
(3) Reagents bad or expired
(4) Check buffer lines andcheck
(4) Buffer reagent not valves.
beingdispensed
Upper display flashes Sample Over-Range Check sample. Sample may be too
high to read.
Upper display shows nOnE No current reading displayed Wait to post a reading
while attempting to calibrate
5.3.3 BALLAST WATER FLOW METER
1) System error messages




2) Process error messages
3) Process error messages

4) Response of Outputs to errors

5.3.4 SEAWATER BOOSTER PUMP (EQ04) AND 3# SEWAGE PUMP (EQ02-3#)
Before removing the terminal box cover and before removing/dismantling the pump,
Caution! make sure that the power supply has been switched off and that it cannot be accidentally
switched on.
Fault Cause Remedies
The pump has no or 1. Wrong direction of rotation. 1. Change direction of rotation to

too low capacity 2. Piping system choked. clockwise when viewed from shaft
3. The pump is choked. end (the direction of the arrow).
4. Suction line leaks, pump takes 2. Clean or replace.
air. 3. Clean the pump.
5. Suction lift too high. 4. Find the leakage, repair the fault,
6. Pump and piping system wrongly non-return valve not submerged.
dimensioned. 5. Check data sheet Q/H curve and
NPSH or contact DESMI.

6. As 5.
The pump uses too 1. Counter-pressure too low. 1. Insert orifice plate or check
much power. 2. The liquid is heavier than water. valve/contact DESMI.
3. Foreign body in pump. 2. Contact.
4. Electric motor is running on 2 3. Dismantle the pump, remove the
phases. cause.
4. Check fuses, cable connection, and
cable.
The pump makes noise 1. Cavitation in pump. Suction lift too high/ Suction line
wrongly dimensioned./ Liquid
temperature too high.
5.3.5 BLOWER
Normal trouble shooting:

1) Vibration: many reasons can cause vibration; several aspects could be investigated as followed:
a. The friction between impeller and wind path will send out strong noise.
b. The stents has insufficient strength and not be firm which can cause strong vibration.
c. The loosen of impeller rivet, imbalance and corrosion of leaf, drop of balance piece and damage
gear can cause strong vibration.
2) Heating:Running after period of time, if the motor’s temperature is too high. The reasons may be
as followed:
a. The motor is broken. The gap is too small to conform the requirements.
b. Axis and bearing assembly skewed, two bearing’s axial are no in one degree.
c. Resistance is too large, motor operate over-load.
d. The power resource is too low.
Shut off the power before repair and maintenance, the non-relevant personnel
Caution!
prohibited benear-by.
5.3.6 METERING PUMP
Before carrying out any servicing operation on the pump or piping, disconnect
Caution! electrical power from the pump. Be sure that there is no fluid pressure in the liquid end
and piping.
5.3.6.1 Cleaning Fouled Check Valves

Check valve assemblies are designed to be self-cleaning and should seldom need servicing. Fouled
check valves can usually be cleaned by pumping a solution of mild detergent and warm water (if
compatible with liquid being pumped) for 15 minutes, followed by flushing with water.
5.3.6.2 Check Valve Replacement
General
Before beginning work on the valve assemblies, make sure the suction and discharge shut-off valves
are closed and that pressure has been bled from the pump liquid end. When replacing the valves, be
sure to replace the valve O-rings.
Preliminary Operations
1) Set the pump capacity knob to 0%. If stroke locking screw was previously tightened, slightly
loosen the locking screw.
2) Disconnect power to pump motor. Check that the equipment cannot be accidentally started.
Place a notice at the location of the power switch indicating that the pump is being serviced.
3) Disconnect the pump hydraulically by removing pipe or tubing connections to suction and
discharge check valves.
Disassembly
Unscrew the threaded connector;
Unscrew the check valve assembly from the liquid
Reassembly
Be sure to follow instructions carefully and refer to the appropriate figure when
Caution! reassembling check valves. If check valve cartridges are installed incorrectly, one of the
following willoccur:
1) Immediate and severe damage to pump will occur.
2) No pumping of fluids.
3) Reverse pumping action (fro discharge line into suction line).
5.3.7 RECTIFIER
The Power Indicator Light Abnormal

After switching on the A.C. breaker, the monitor screen and the power indicator light do not work.
Check the voltage of A.C. input. If the red light is on, check for the voltage lack or phase lack. If the
screen is on and the indicator light is not on, please measure the voltage across the light. If the
voltage remains normal, it indicates the light is broken.
DC alarming light on
Check for the status of all the error lights on the power modules. Voltage Alarming light on indicates
that the DC voltage output has exceeded the overvoltage. Please check for the flow rate of seawater

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and the block of the electrolytic cells. If they are in normal conditions, please measure the salinity of
the fluid (in a large area near
ear the sea inlet, the seawater is not suitable for electrolysis, owing to the
fact that the salinity is lower than average value.) In overvoltage, the output voltage is locked at the
overvoltage value to avoid damage to modules. The locking status continucontinues
es unless the faults are
corrected and AC power is reconnected.
Current Alarm light on indicates the output current has exceeded overcurrent value and the rectifier
will recover to normal status after AC power is reconnected.
Temperature Alarming light iss on, which indicates the overheating. Check for the ventilation and fan
failures.
WARNING: Disconnect the electrical power prior to replacement of power module.

Plugging with power on is prohibited. For the personnel safety, the own maintenance is forb
forbidden
because of the hazardous high voltage in the power module.
5.3.8 SYSTEM CONTROL CABINET AND MOTOR CO

CONTROL CABINET
No Display On The Touch Screen

Check for the power supply of control cabinet and the status of power switch. Check for the 24 V
power supply
upply for the touch screen. Make sure that the screen is not in the screen saving status.
No Response Of Buttons On The Touch Screen
Make sure that the screen is not in the locking state and that the local/remote switch and the
“Emergency Stop” buttons aree on the right position. Make sure that the PLC is in operation and work
well.
No Alarming In the Case That the Pumps Do Not Work
Check for the three phase power supply for the cabinet.
No Response of Relays or Contactors
Check for the PLC output and corresponding fuse.
Maintenance and Replacement of Spare Parts
Replace the damaged parts or parts in poor condition with spare parts with equivalent or higher
quality. We highly recommend you to use parts supplied by the manufacturer.
WARNING:Replace the damaged parts or parts in poor condition as soon as found out, or it
may cause serious personal injury or even death.
5.3.9 JUNCTION BOX
Sun
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Indicator Lights on ANU Junction Box Do Not Work

Check
heck for the voltage across the corresponding terminals and the damage of the lights.
Mixer Do Not Work
Check
heck for the voltage across the corresponding terminals.
Check
heck for the PLC and the cable connection of frequency convertor
No Display on the Hydrogen Alarm In
InEDU Junction Box and Indicator Light of Transmitter Off
Check
heck for the voltage across the corresponding terminals
5.3.10 REMOTE CONTROL

L PANEL
No Display On The Touch Screen

Check for the power supply of control cabinet and the status of power switch. Check for the 24 V
power supply for the touch screen. Make sur
suree that the screen is not in the screen saving status.
No
o Response Of Buttons On The Touch Screen
Make sure that the screen is not in the locking state and that the local/remote switch and the
“Emergency Stop” buttons are on the right position. Make sure tthat
hat the PLC is in operation and work
well.
No Alarming In the Case That the Pumps Do Not Work
Check for the three phase power supply for the cabinet.
No Response of Relays or Contactors
Check for the PLC output and corresponding fuse.
Maintenance and Replacement
acement of Spare Parts
Replace the damaged parts or parts in poor condition with spare parts with equivalent or higher
quality. We highly recommend you to use parts supplied by the manufacturer.
WARNING:Replace the damaged parts or parts in poor conditio

conditionn as soon as found out, or it
may cause serious personal injury or even death.
5.3.11 SEWAGE PUMP (EQ02--1~2#)
Before removing the terminal box cover and before removing/dismantling the pump,
Caution! make sure that the power supply has been switched off and that it cannot be accidentally
switched on.
Fault Cause Remedies
The pump has no or 1. Wrong

rong direction of rotation. 1. Change
hange direction of rotation to
Sun
too low capacity 2. Piping system choked. clockwise when viewed from shaft
3. The pump is choked. end (the direction of the arrow).
4. Suction line leaks, pump takes 2. Clean or replace.
air. 3. Clean the pump.
5. Suction lift too high. 4. Find the leakage, repair the fault,
6. Pump and piping system wrongly non-return valve not submerged.
dimensioned. 5. Check data sheet Q/H curve and
NPSH or contact DESMI.
6. As 5.
The pump uses too 1. Counter-pressure too low. 1. Insert orifice plate or check
much power. 2. The liquid is heavier than water. valve/contact DESMI.
3. Foreign body in pump. 2. Contact.
4. Electric motor is running on 2 3. Dismantle the pump, remove the
phases. cause.
4. Check fuses, cable connection, and
cable.
The pump makes noise Cavitation in pump. Suction lift too high/ Suction line
wrongly dimensioned./ Liquid
temperature too high.

5.3.12 DOSING PUMP
Malfunction Possible cause Rectification

1).Incorrect rotational 1).Change over two power lines.
direction of motor. 2).Fill again and vent.
2).Pump not sufficiently filled. 3).Check the suction line and foot valve for leaks.
3).Pump takes in two much 4).Route lines correctly to allow air to escape.
air. Position gate valve with spindle on the side.
1 Pump dose 4).Suction line contains 5).Fit a larger impeller or larger pump.
not transfer trapped air. 6).Incorrect pump size selected.Please inform us of
fluid 5).Excessive geodetic delivery the preciseconditions with respect to the
head. requiredPump.
6).Existing counter pressure is
higher than the max. pump
pressure.
1).Blockage of the suction line, 1).Flush the lines and remove theimpeller if
supply necessary.
line or impeller. 2).Change the pipework arrangement,install a vent
2).Air trapped in the pipework. valve.
3).Excessive geodetic delivery 3).Fit a larger impeller or larger pump.Please
head. inform us of the preciseconditions with respect to
4).Pipework flow resistances the requiredpump.
greaterthan assumed. 4).Use a larger pipe cross section, largerimpeller
2. Insufficient 5).Excessive suction height and/or larger pump. Pleasedo not hesitate to
pump flow (formation ofvapors in the contact us forinformation.
rate. pump during suctionprocess, 5).Clean the suction basket and suctionline, use
cavitations). larger suction line crosssection if necessary. Check
6).Excessive temperature of that thefoot valve completely opens, installthe
theconveyed fluid. pump in a lower position ifnecessary. If a
7).Fluid viscosity higher than self-priming containeris used, use a larger
originallyassumed. container ifnecessary.
6).Reduce the temperature of the fluid,install the
pump in a lower position.
7).Dilute or preheat the conveyed fluid.
Actual plant delivery head is 1).Reduce flow with pressure gate
3. Pump
lowerthan the pump delivery valvesaccordingly.
conveys too
head. 2).Fit a smaller impeller.
muchfluid.
3).Reduce rotational speed if possible.

1).Pump conveys too much 1).Refer to point 3.

fluid. 2).Check the data with respect to thedelivery of
2).Density or viscosity of the fluid, possibly install amotor with a higher
4. Motor conveyedfluid is too high. rating.
overload. 3).impeller makes contact. 3).Check the impeller mounting andtighten if
necessary.
Impeller deformed due to hightemperature,
replace impeller andeliminate cause for
excessively hightemperature.
5. Pump 1).Sliding bearings worn. 1).Fit new sliding bearings.
operation 2).Excessive suction head. 2).Refer to point 1.
is noisy 3).Insufficient suction line 3).Enlarge the line cross section.
oruneven. cross section.

6 SYSTEM ALARMING AND TROUBLESHOOTING
6.1 GENERAL
Note:Before operating BalClor® BWMS, please read Chapter 8 Alarming and Troubleshooting
carefully.
This chapter includes the solutions for most faults. In BalClor® BWMS operation, refer to alarm code
and seek for appropriate solutions if any fault alarming occurs. If the fault cannot be handled
according to the chapter, please contact Qingdao Sunrui.
6.2 APPLICATION
(1) EDU Module
(2) ANU Module
(3) AFU Module
(4) Instruments and meters including TRO Analyzer, gas detector and flowmeter etc.
6.3 ALARM
6.3.1 GENERAL ALARM AND REMEDY
BWMS alarm include of general alarm and stop alarm, all of which function as follows,
Alarm
Description Remedy
type
Check electrical connection between PLC in EDU
PLC communication error and remote control box→ repeat the procedure
and if the fault still occurs.
PLC battery low change it
turn up diaphragm valve excessively or piping
abnormalities
EDUpressureHigh
Check the piping →check the ballast pump→ turn
General down the diaphragm valve
alarm
Mis-action of sensor or leakage in channel
_H2_High≥20%LEL
Waiting the influence action stop (for example:
paintwork), Check for the leakage in wind channel
_CL2_High≥0.4ppm → recalibrate sensor and replace the sensor if
fault still occurs.
Check Rectifier in the "remote" model→ Check

Rectifier COM.fault electrical connection and contact SunRui if the fault
still occurs

Alarm
Description Remedy
type
TRO_work_error Referring to TRO analyzer manual
TRO_com_error Referring to TRO analyzer manual
Ballastpump'sflowrate>1200m3/h Rest it
Poor seawater quality or block of filter screen

In the case of poor seawater quality → in normal
AFU DP ALARM operationmaintenance is not required. Otherwise
clean the screen according to “filter maintenance
manual”
EDU_FT_Offline
Salinity_sensor_Offline
EDU_Temp_Offline
EDU_V_Offline
Fuse melt, circuit fault, cablefault, sensor fault
EDU_PI_Offline
Check electrical connection→ replace fuse→
FT_Offline check sensor
PVoffline
Blower_overload Motor power supply fault or Contactor control

circuit fuse melts or breaker protection
SewagePump_overload
Check the switch in motor control cabinet at
"AUTO" → Check motor power supply→check
motor power voltage relay →Check electrical
connection→ replace contactor control circuit fuse
AFU_overload
→switch on motor breaker→ repeat the
procedure and change the circuit parts if the fault
still occurs.
EDU_Valve_PositionFault Fuse melt, circuit fault, valve is blocked or damage

to valve mechanical component
Check electrical connection→ replace fuse→
ANU_Valve_PositionFault check for the block of valves and replace the valve
if the fault still occurs.
Motor Power Fault alarm Checkthe power line phase sequence

Alarm
Description Remedy
type
TRO is in abnormal status, Abnormal mix
Check the sampling pump,sampling solenoid,

sampling pipes of TRO→ Check TRO senor status
TRO_Exceed_Range
and reagents→ check the mix point on and in
ballasting pipe→ calibrate TRO analyzer referring
to “TRO analyzer manual”→ContactSunRui if
fault still occurs.
Neutralizer failure, TRO is in abnormal status,
Abnormal mix
Check ANU→ prepare neutralizing solution→
Check the sampling pump ,sampling solenoid,
TRO_discharge_high>0.2ppm sampling pipes of TRO→ Check TRO senor status
and reagents→ Check the flow rate in ballasting
pipe→ check the signal of flow meter on ballasting
pipe → check the mix point on and in ballasting
pipe

6.3.2STOP ALARM AND REMEDY
Alarm type Description Remedy
REMOTE_Emergency_sto
p Rest it
Local_Emergency_stop
The booster pump or pipe have faults
EDU_Flow_low<8 m3/h Check the piping→ check the ballast pump→ Turn up
diaphragm valve, replace with alternate pumps if the
fault still occurs.
Temperature transducer or electrolyzer fault or
seawater’s temperature gets to 55℃ before put into
EDU_Temp_High EDU
Check seawater’s temperature in front of EDU, Calibrate
the transducer, and contact SunRui if the fault still occurs
turn up diaphragm valve excessively or piping
abnormalities
EDU_Pressure_High_High
down the diaphragm valve
Turn up diaphragm valve excessively or piping
Stop alarm abnormalities
Electrolyzer_DP_too_high
down the diaphragm valve
Mis-action of sensor or leakage in channel
H2_High_High >60%LEL
Waiting the influence action stop (for example:
paintwork), Check for the leakage in wind channel →
CL2_High_High >0.55ppm recalibrate sensor and replace the sensor if fault still
occurs.
H2_Sensor_Offline Fuse melt, circuit fault,cable fault,sensor fault

Check electrical connection→ replace fuse→ check
Cl2_Sensor_Offline
sensor
Filter_Bypass Close it
Wind_pressure_low! Wind channel is blocked or wind pressure switch fault or
blower failure
Blower exchange Check the wind channel→auto shift to alternate blower，
repair or replace the failed one if fault still occurs.
Rectifier internal fault Check electrical connection and contact SunRui if the

Alarm type Description Remedy
fault still occurs

Salinity_low_Alarm rest it
Boosterunableget water! Motor power supply fault or Contactor control circuit

Please check valves! fuse melts or breaker protection
Check the switch in motor control cabinet at "AUTO" →
Booster_overload
Check motor power supply →check motor power
voltage relay →Check electrical connection→ replace
DosingPump_overload contactor control circuit fuse →switch on motor breaker
→ repeat the procedure and change the circuit parts if
MeterPump_overload the fault still occurs.
Refill the tank with neutralizing solution, check the
ANU_tank_level_low
floater of level meter

7DATA SHEET AND ASSEMBLY/DISASSEMBLY DRAWING
The ballast water filter is an automatic back-flushing filter;its flushing is done without interrupting
operation and with a minimal pressure drop. The filter has a 50 micron screen, which can effectively
remove planktons and solid particles whose size exceeds 50 micron.The automatic back-flushing
filter can continue to work even if the back-flushing process is running. The back-flushing process has
little influence to the pressure loss.
When the differential pressure of the filter screen or the working time achieves the set value, the
system will automatically start self-cleaning cycle, and the dirty water will be pumped overboard.
7.1AFU
7.1.1 DATA SHEET
Type 6.18.3-size 400 (AFU01/02) 6.18.3-size 200 (AFU03)

Filtration grade 50 μm wire screen 50 μm wire screen
Operation flow ; Max 1000 m3/h ;1400m3/h 320m3/h ;370m3/h
flow
Fresh water supply ~1.0 m3 per time after ballasting for ~0.13 m3 per time after ballasting
each for each
Inlet & outlet flange DN400, PN10 DN200, PN10
Flushing valve flange DN125, PN16 DN80, PN16

Allowable operating MAX 10 bar MAX 10 bar
pressure
Min flushing pressure 1.5 bar 1.5 bar
Pre-set DP value 0.5 bar 0.5 bar
Flushing quantity 168 m3/h at 1.5 bar 83 m3/h at 1.5 bar
Back-flushing time ~20s (for ref., and need adjusting) ~20s (for ref., and need adjusting)
Pressure drop 0.2 bar on clean screen at 20℃ 0.2 bar on clean screen at 20℃
Motor Electrical driven, 0.09 kw Electrical driven, 0.09 kw
Filter screen 1.4410 1.4410
Housing Carbon steel with protective coating Carbon steel with protective coating
Seal material perbunan perbunan
Power 3ph, 440V, 60 Hz 3ph, 440V, 60 Hz

Empty weight 1100kg 400kg
7.1.2ASSEMBLY DIAGRAM



7.2EDU
7.2.1 DATA SHEET
Type : BC-2500
Main power : 440V 60Hz
Treatment Capacity : 2500 m3/h
Seawater supply : 36 m3/h
Fresh water supply : ~3m3 per time
Empty Weight : ~2250 kg

Dimension (L x W x H ) : 3000mm x 1600 mm x 2760mm
Ballast water inlet N21: DN80 DIN PN 10 FLEXIBLE JOINT
Oxidant outlet N22: DN80 DIN PN 10 FLEXIBLE JOINT
Vent N23 : DN250 DIN PN6 SS304, RF
Drain/Flushing inletN24: DN40 DIN PN 10 FLEXIBLE JOINT
Flushing outletN25: DN40 DIN PN 10 FLEXIBLE JOINT

Drain N26 : DN25 DIN PN 10 FLEXIBLE JOINT

General outlook of EDU

General outlook of EDU
Equipment List
EQUIPMENT LIST
CODE Spec. CODE Spec.
EQ03 BC4000 ELECTROLYZERS EQ17 BUFFER TANK
EQ05 BLOWERS EQ22 JUNCTION BOX

EQ06 CYCLONE

7.3 ANU
7.3.1 DATA SHEET
Type : 1.0 m3
Main power : 440V 60Hz
Fresh water supply : ~1.0 m3 per time
Empty Weight : ~600 kg
Dimension (L x W x H ) : 1650 x 1300 x 1831
Inlet flange of fresh water N31 : DN40 DIN PN 10 CS lining, RF

Outlet flange of neutralizer N32 : DN15 DIN PN 10 SS316, RF
Drain N33 : DN25 DIN PN 10 SS316, RF
FRONT VIEW OF ANU

SIDE VIEW OF ANU
Equipment List
EQUIPMENT LIST
CODE Spec. Equipment CODE Spec. Equipment
EQ-09A/B 90L/h,440V,60Hz Metering pump EQ-23 - Junction box
EQ-10 1.0m³ Neutralization MO-11 440V,60Hz Stirrer motor

tank
EQ-12 DN15 Y type strainer LS-31 - Level meter
EQ-19A/B M8 Damper

7.4 METERING PUMP (EQ09)
7.4.1 DATA SHEET
Type : MB0090PN
Structure : Mechanically actuated diaphragm
Maximum flow rate : 90 L/h
Max Pressure : 7 bar
Medium : Sodium thiosulphate solution
Diaphragm material: PTFE

Power supply : 440V 60Hz
Power : 0.25 kW
Speed: 1385 rpm
Protection grade : IP 55
Power factor, cosØ: 0.735
Components : Safety valve

Back-pressure valve
Damper
Quantity : Two sets
7.4.2 DRIVE END—EXPLODED DRAWING


7.4.2.1 Parts List of Drive End
No. Specification Code. Quan.

1 IEC 71 Motor –B5-0.25KW S220001A 1
IEC 71 Motor –B5-0.37KW S220002A 1
2 M8 X 25 Bolts S5300005L 4
99 Flat gasket, 8 S550005G 4
3 Flange seal gasket, IEC 71 10110441 1
Z1(including Worm assembly,7.25:1,IEC71 101S0019 1
4,5,6,7,8)
Worm assembly,9.5:1,IEC71 101S0020 1
Worm assembly,19:1,IEC71 101S0021 1
Worm assembly,38:1,IEC71 101S0022 1

9 MB oil leveler 10110351 1
10 Rectangle seal ring 15x22x2 S150001A 1
11 MB box 10110021 1
12 MB bearing bush 10110221 1
13 MB connecting rod oil seal 10110301 1
14 Turbine , 7.25:1,IEC71 10110161 1

Turbine , 9.5:1,IEC71 10110131 1
Turbine , 19:1,IEC71 10110141 1
Turbine , 38:1,IEC71 10110151 1
15 M8X20 Bolts S530006A 1
M8X25 Bolts S530011A 1
16 MB connecting rod 10110101 1

MB connecting rod 10110102 1
17 O ring for oil plug,14x2.65 S140002A 1
18 Bolts,G3/8’’ 10110362 1
19 Bolts S530009E 1
Z2(including MB assembly , SL=4 101S0023 1
20,
MB assembly , SL=6 101S0024 1
21,22,23,24)

25 O ring 103 x 3.55, S140003A 1

26 MB side cover 10110041 1
27 Bolts, M6X16 S530002A 4
28 Plat gasket,M6 S550004D 4
29 MB Stroke bolts,6X20 10110371 1

30 O ring 4x1.8 S140001A 1
31 Nylon ball 3/16’’ S930001C 1
32 Elasticity check ring,47 S5500001F 1
33 MB stroke regulating rod 10110291 1
34 B Type oil seal, 45x62x8 S150002A 1
35 MB stroke regulating hand shank 10110341 1

36 Bolts S530010J 2
37 MB regulating hand shank mark 10110411 1
- Lubricating oil,0.7L S1100001 1
- Plate name 10110421 1
- MB ruling mark 10110401 1
- Name plate rivet S560001A 4

- MB rotate position mark 10110451 1
7.4.3 LIQUID END--EXPLODED DRAWING

7.4.3.1 Parts List of Liquid End
No. Specification Code. Quan.

Z3(including 1’’ valve assembly, PVC 101S0009 2
82,43,44,45,46,47,48,17)
1’’ valve assembly, PVDF 101S0010 2
49 MB0090~MB0250 pump head, PVC 10123061 1

50 BOLTS,M8X90 S510004A 6
51 Big gasket,8 S550007D 6
Z4 MB0090~MB0250 diaphragm assembly, PVC 101S0013 1
57 MB0090~0250 diaphragm support ring 10123101 1
73 Connecting rod 10124121 1
80 MB diaphragm support ring metal gasket 10124181 1

74 Mediate spring 10110321 1
58 Bolts,M6X30 S530004A 4
59 Spring gasket,6 S550003D 4
29 Plat gasket,6 S550004D 4
60 Mediate part 10110081 1

75 Bolts, M8 S540001D 6
7.5 SEWAGE PUMP (EQ02-1~2#)
7.5.1 DATA SHEET
Capacity : 168 m3/h

Head : 15 m
Pump Type : NSLH150-215/D02
Motor Type : M2JA-H160M4A

Housing : RG5
Shaft : STEEL AISI 329
Impeller : DS/EN1950 CC333
Shaft seal : Mechanical seal
Bearings : Ball bearings
Rotation : Clockwise
Suction flange : DN150,PN10
Discharge flange : DN150,PN10
Speed : 1752 RPM
Power supply : 440V,60Hz
Rated power : 12.7kw
NPSHr: 2.8mLC
Explosion-proof grade : Ex d IIC T4
EQ02-3
Capacity : 83 m3/h
Head : 25 m
Pump Type : ESL80-180/D12

Motor Type : 4A 132 S2-2
Housing : RG5
Impeller : DS/EN1950 CC482K


Bearings : Without bearings

Speed : ~3480 RPM
Rated power : 9kw
NPSHr: 7.02mLC
7.5.2 ASSEMBLY DIAGRAM AND PARTS LIST (EQ02-1~2#)


Part Part Part

Description Description Description
No. No No
1 Pump Casing 63 Bracket 107 Pipe pl ug
Manometer
2 Pump Plug 64 Set screw 106
cock
3 Pump Plug 67 Set screw 109 Set screw
Manometer
4 Seali ng ri ng 69 Guar d 110
fitti ng
5 Impeller 70 Coupl ing pa rt pump
Coupling part
6 Nut 71
motor
7 Spr ing colla r 72 Spacer
8 Washer 73 Pointed screw
9 Sunk Key 74 Elastomer
10 Mech. Shaft seal 76 Alle n screw
11 Water deflector 77 Alle n screw
12 Ring lock 79 Nut

13 Ball bear ing 81 Seali ng w asher
14 Support disc 84 Lubricator nipple
15 Ball bear ing 86 Pointed screw
16 Sunk key 93 Set screw

17 Sha ft 94 Base plate
18 Bearing housing 95 Lock washer
19 Alle n screw 96 Manometer
20 Sha ft seal cover 97 Reducing nipple
21 O-ring 98 Haxago n nipple

22 Alle n screw 99 T-piece
Bulk head
58 Copper pi pe 100
connection
59 Hexagon nipple 101 Screw ca p
60 Set screw 103 Copper pi pe

7.5.3 ASSEMBLY DIAGRAM AND PARTS LIST (EQ02-3#)

7.6 DOSING PUMP (EQ14)
7.6.1 DATA SHEET
Capacity : 36 m3/h
Head : 45 m
Pump Type : AMA-EP
Motor Type : M2QA-H132S2B
Medium: Sodium hypochlorite solution
Gross weight : 121kg

Housing : ETFE
Impeller : ETFE+CF
Suction flange : DN65
Discharge flange : DN50
Speed : 3405 RPM

Rated power : 8.6 kW
7.6.2 ASSEMBLY DIAGRAM

7.6.2.1 Parts List

7.7 BOOSTER PUMP
7.7.1 DATA SHEET
Capacity : 40 m3/h
Head : 28 m
Pump Type : ESL40-180/D12
Motor Type : 3D132S1-2
Housing : RG5

Impeller : DS/EN1982 CC482K


Bearings : Without bearings

Speed : 3480 RPM
Rated power : 6.6kw
NPSHr: 6.24mLC
7.7.2 ASSEMBLY DIAGRAM AND PARTS LIST


7.8RECTIFIER (EQ08)
7.8.1 DATA SHEET
Rated output DC range : 1%~100%

Accuracy: ≤±1.0%
Output DC ripple factor : ≤2% （Half load）
Ambient temperature : 0℃－55℃
Communication interface : RS485
Communication protocol: MODBUS-RTU

Enclosure protection grade : IP 44
Heater power : 150 W
Gross weight : ~900 kg
Insulation impedance
A.C. input impedance to enclosure : ≥10MΩ
A.C. input impedance to DC output : ≥10MΩ

D.C. output impedance to enclosure : ≥10MΩ
Transformer component
Input : 440V, 60Hz
Output : AC 220/440V, 60Hz
DC 75V, 450A
Quantity of EQ07 : 1 set per EDU
7.9 SYSTEM CONTROL CABINET (EQ08)
7.9.1 DATA SHEET
Cabinet material : Carbon steel, plastic sprayed

Protection Grade : IP 44
Power supply : 440VAC @60Hz

Weight : ~ 150 kg
Quantity : 1 set per EDU
7.10 REMOTE CONTROL CABINET (EQ24)
7.10.1 DATA SHEET
AC input : AC220V/60Hz/1h
Communication protocol : Controller Link

Ambienttemperature : 0℃－55℃
Enclosure protection grade : IP44
Gross weight : 5kg
Quantity : 1 set per vessel
The remote control panel is used to realize the remote control functionof theBalClor® BWMS. The
remote control panel is composed of the cabinet, PLC, and touch screen etc,The operating personnel
can through the remote operation panel control BalClor® BWMS.
7.11MOTOR CONTROL CABINET (EQ25)
7.11.1 DATA SHEET
Cabinet material : Carbon steel, plastic sprayed
Protection Grade : IP 44
Power supply : 440VAC @60Hz
Weight : ~ 150 kg
Quantity : 1 set per EDU
The motor control cabinet is composed of the cabinet, PLC;intermediate relays, terminals, motor
breakers, and contactor, etc. The control cabinet controls and supplies AC power for sludge
pump-EQ02, seawater booster pump-EQ04 and dosing pump-EQ14.

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Preliminary Installation, Operation& Maintenance Manual Rev. 1.

Operation and Maintenance Manual

SunRui Marine Environment Engineering Co., Ltd

3. GENERAL INSTRUCTIONTION ............................................................................................................ 13

7.6.1 DATA SHEET ........................................................................................................................ 104

SunRui Marine Environment Engineering Co. , Ltd

1.1 MANUAL INTRODUCTION

1.2 CUSTOMER SUPPORT INFORMATION

Contact address if assistance is required:

Internet website www.sunrui.net

BWMS BALLAST WATER MANAGEMENT SYSTEM

EDU ELECTROLITIC DISINFECTION UNIT

PLC PROGRAMMABLE LOGIC CONTROLLER

SunRui Marine Environment Engineering Co., Ltd

EQ02 SEWEDGE PUMP

EQ12 Y-TYPE STRAINER

EQ21 AFU CONTROL CABINET

EQ32 AIR FILTER AND DRYER

TT21 TEMPERATURE SENSOR

SunRui Marine Environment Engineering Co. , Ltd

HS01/02 HRDROGEN SENSOR

CM21 CONDUCTIVITY METER

1.5 WARNING SIGN DEFINITIONS

It indicates possibilities for immediate hazards, which will result in

It iindicates possibilities for hazards or unsafe practices, which

It indicates possibilities for hazards or unsafe practi

Itt indicates possibilities for electric shock.

BalClor® BWMS operators

Avoid direct contact with sodium chlorite solution

Stop system immediately once leakage occurs

Turn off the power supply prior to maintenance or other work.

Confirm the electrolyzers are full of seawater before power supply.

Normally, the BalClor®Ballast

2.2 RISK ASSESSMENT

2.2.1 RISK TO SAFETY OF SHIP

SunRui Marine Environment Engineering Co. , Ltd

2.2.2 RISKS TO HUMAN HEALTH

2.2.2.2 OCCUPATIONAL EXPOSURE (HES) AND QUANTITATIVE RISK EVALUATION

SunRui Marine Environment Engineering Co. , Ltd

2.2.2.3 GENERAL PUBLIC/HUMAN EXPOSURE VIA ENVIRONMENT

Table 9-6: MRR values for seawater ingestion during swimming

Chemical MOS MOSref MRR(MOS/MOSref)

Bromochloroacetic acid 2.51 E+05 100 2.51 E+03

SunRui Marine Environment Engineering Co. , Ltd

Dibromochloroacetic acid 3.23 E+06 100 3.23 E+04

Bromochloroacetic acid 1.71E+05 100 1.71E+03

2.2.3 RISKS TO THE AQUATIC ENVIRONMENT

2.3SODIUM HYPOCHLORITE HAZARDS & AID

2.3.1 SODIUM HYPOCHLORITE HAZARDS

SunRui Marine Environment Engineering Co. , Ltd

DANGER: Doo not contact Sodium Hypochloritesolution directly.

2.3.2 FIRST AID

Hydrogen gas (H2) is the by-product

2.4.2 SAFETY MEASURES

2.4.2.1 PREVENT OF H2 LEAKAG

2.4.2.2 EMERGENCY MEASURES

2.5 SODIUM THIOSULPHATE HAZARDS & AID

Irritation may occur from prolonged skin contact.

Contact may cause mechanical irritation.

Chronic exposure may cause skin effects.

Aggravation of Pre-existing Conditions

unconscious person. Get medical attention.

2.5.3HANDLING AND STORAGE