HMT-1000 中航鼎衡 f

System
Ocean Guard®--BWMS
Version Date Title Project

F 2016.05.18 Drawing for Final AD0039~AD0043
Drawn Date Check Date App.ed Date Page
XY 2014.09.12 XY 2014.09.12 K,C Lu - -
Ocean Guard®--Ballast Water Management System
Drawing for Final

System
Ocean Guard®--BWMS
Version Date Title Project

F 2016.05.18 Drawing for Final AD0039~AD0043
Drawn Date Check Date App.ed Date Page
XY 2014.09.12 XY 2014.09.12 K,C Lu - -
OceanGuard ® Ballast Water Management System
BWMS Model: HMT-1000 (Ex)
Vessel Type: 25,000 DWT S.S. PRODUCT OIL & CHEMICAL TANKER
Hull Number： AD0039~AD0043 AD0039 S/N: 1500567
Class: DNV
Ship Owner: -
Ship Yard: AVIC DINGHENG SHIPBUILDING CO., LTD
Manufacturer： Headway Technology Co., Ltd.
1
DATE PAGE DESCRIPTION REV DRAWN CHECK APPROVAL
2014.09.16 - ISSUED FOR APPROVAL A
2015.02.02 - ISSUED FOR WORKING 0
2016.05.18 - ISSUED FOR FINAL F
2
TABLE OF CONTENTS
Part I General
1.1 Description of OceanGuard® Ballast Water Management System
1.2 List of Abbreviation

1.3 Technical Specification
Part 2 Scope of Supply

2.1 Scope of Headway
2.1.1 Supply scope
2.1.1Dimension and weight list
2.2 Scope of Shipbuilder (with consumption list)
Part 3 P&I Diagram for BWMS

3.1 P&I Diagram for BWMS
3.2 System Electrical diagram
3.3 Terminals Diagram for each Equipment
Part 4 Equipment Specification & Detailed Drawings

4.1 Module drawing
4.2 EUT
4.3 EUT Power Unit
4.4 Filter
4.5 Control Unit
4.6 Power Distribution Unit
4.7 Flow Meter
4.8 Monitoring Unit
4.9 Neutralization Unit
4.10 Back-flushing Pump
4.11 Remote Control Unit
4.12 Valves
4.13 Sampling Port
4.14 I/O Signal List
Part 5 List Of Spare Parts
Part 6 Commissioning Procedure
Part 7 EX-Certificates
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Part I General
1. 1Description of OceanGuard® Ballast Water Management System
OceanGuard® Ballast Water Management System is to kill organism of ship’s ballast water, aiming
at protecting maritime environment and preventing marine living things being polluted. Treated
ballast water by the System is able to meet the requirements of the Convention of Ballast Water
Management （《 Convention of International Ship’s Ballast Water and Sediment Control &
Management》）, established in 2004 by IMO(International Maritime Organization).
OceanGuard® Ballast Water Management System is the fruit of 5 years research and development
by Headway Technology Co., Ltd. It adopts advanced electro-catalysis collaborative technology
(abbr. EUT), and has achieved on-line treatment of ballast water. This method is a part of Advanced
Oxidation Process, through the combination of electro-catalysis and ultrasound technology, it is
able to highly efficiently kill the micro-organism of ship’s ballast water.
The System is characterized with simple running and easy maintenance, and it has realized local
and remote two-way automatic control, with a friendly man-machine interface, easy to operate. It
is flexible and easy for installation on small-tonnage ships while on large-tonnage ships multi units
could be installed in parallel, occupying small space.
Headway is DNV ISO9001:2008 certified and Final Approval of IMO has been granted to our
OceanGuard® Ballast Water Management System in Oct, 2010. We have received our CCS Type
Approval in Mar. 2011, and DNV Type Approval in Nov 2011, RINA Type Approval in June 2013,
and USCG-AMS certificate in Apr. 2013.
Treatment procedure contains filtering and electrocatalysis to filter and kill the organism in water,
the other components are used for control, analyze, monitoring and auto control.
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1.2 List of Abbreviation
No. Symbol Description

1 PDU Power Distribution Unit
2 CL Control Unit
3 EUT EUT Unit
4 AF Auto Filter Control Panel
5 PE EUT Power Unit
6 BP Back-flushing pump
7 MU Monitoring Unit
8 FM Flow Meter
9 B-FV Back-Flushing Valve
10 NU Neutralization Unit
11 AV Auto Control Valve
12 RCU Remote Control Unit
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1.3 Specification of HMT-1000(Ex)
Item Specification and Instructions

Type HMT-1000Ex
Rated Capacity 1000 m³/h each
Purpose Treatment of Ballast Water
Technology Filter, Electro-Catalysis
Biological Efficiency Compliance with IMO D-2 Standards
Operating Performance TRO Value ≤ 2 mg/L online
Electric Source AC 440V/ 60Hz 3Ph
Salinity Conditions (%) ＞0 Can be used in fresh water
Max. Total Pressure Loss(Total System) 0.6 bar
Working Water Temperature 0℃ ~55℃
Environment Temperature -25℃~55℃
Method of Operation Computer Operation, Auto-Control.
Equipment Color MUNSELL NO.7.5 BG7/2
Detailed Power Consumption Salinity Total Power
（PSU） Consumption When back-
flushing
0＜PSU＜3 22.3 kw 44.5 kw
3≤PSU＜20 17.5 kw 39.7 kw

≧ 20 17.5 kw 39.7 kw
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Part 2 Scope of Supply
2.1 Scope of Supply
2.1.1 Scope of Headway

1) Design and manufacture of OceanGuard® BWMS, including workshop inspection, painting,
packing and delivery.
2) System detailed drawing, electrical drawing, technical manual and operating manual.
3) BWMS Tests and Sea trial.
4) Supply of Components:
Item Component List Specification Qty (Unit) Note
1 EUT Unit HMT- 1000E 1 Exd IIB T4

2 Filter HMT- 1000F 1 Exd IIB T4
3 Filter control box HMT-AF 1 -
4 Control Unit HMT-CL 1 -
5 Power Distribution Unit HMT- 1000PDU 1 -
6 Neutralization Unit HMT-100N 1 -
7 Sampling Port - 2 -
8 Back flushing pump - 2 Ex
Remote Control Panel (Flush type)

9 - 1 -
(HMT-CR)
10 Flow Meter HMT- 300FM 2 Exd IIB T4
11 Monitoring Unit HMT-MU 1 Exd IIB T4
Cable between EUT and PE should be supplied by Headway (16× 78 M)

Where:
X: depend on shipyard actual arrangement
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2.1.2Dimension and Weight List
Dimension（mm） Unit
Qty
Item Weight
（set）
L W H （kg）
EUT Unit
2163 741 625 632 1
(HMT- 1000E-Ex)
Filter
1300 1115 2530 1950 1
(HMT-1000F-Ex)
Control Unit
560 220 830 30 1
(HMT-CL)
Power Distribution
650 320 1720 75 1
Unit(HMT- 1000PDU)
EUT Power
650 1001 1200 200 1
(HMT- 1000PE)
Flow Meter
600 565 776 126 1
(HMT- 400FM)
Neutralization Unit
500 533 1169 130 1
(HMT-100 N)
Remote Control Unit
338 443 132 11 1
(HMT-CR)
Monitoring Unit 900+15
915 245 25 1
(HMT-TRO) 8
Back-Flushing Pump 680 427 1272 339 1
Total - - - 3518 -
2.2 Scope of Shipbuilder
1) Power supply cable for BWTS, Communication cable for remote control. (All cables except the
cable between EUT and PE)
2) Cooling water supply for EUT 4m³/h with 25A pipe.
3) Flow meter and outlet 400A valve installation.
4) In and out pipe for main pipe.
5) Monitoring pipe of 15A for overboard and Neutralization unit pipe for in and out of 15A.
6) Drain pipe for components.
7) Compressed air 0.6~0.8 Mpa
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Part 3 P&I Diagram for BWMS
3.1 P&I Diagram for BWMS
3.2 System Electrical diagram
3.3 Terminals Diagram for each Equipment
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HEADWAY TECHNOLOGY CO., LTD.
BALLAST WATER MANAGEMENT SYSTEM

MK. QT. REVISION No. REVISER DATE STAGE SIZE VERSION SCALE
DRAWN X,Y WANG DATE 2014.06.18 Drawing No.
APPROVAL DRAWNING A4 2.0
CHECKED S LI DATE 2014.06.18
PAGE 5 PAGE No. 1/5
11
APPROVED K,C LU DATE 2014.06.18
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Part 4 Equipment Specification & Detailed Drawings
4.1 BWTS System
The OceanGuard® Ballast Water Management System uses the dual mechanisms of filtering and
electro-catalysis to filter and kill the organism in water. EUT Unit is the key part of the system. By
producing hydroxyl radicals of high concentration, this unit kills the planktonic creatures, bacteria
and viruses in ballast water. The technology is also called Advanced Electro-catalysis Oxidation
Processes (AEOP), which is environment-friendly, non-toxic and harmless.
Hydroxyl radicals have strong oxidability. Their oxidation capacity is next to that of fluorine.
Hydroxyl radicals can survive for a very short period of time. They react instantly with
microorganism and other organism to kill microorganism and remove other organism. Because of
their short surviving time, they won’t cause direct corrosion to pipes and other onboard parts.
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4.2 EUT Unit
4.2.1 Appearance
Please refer to the drawing below
4.2.2 Function and Principle
EUT Unit is the core of OceanGuard® BWMS. Each single unit has the treatment capacity from 100-
3300m3/h. The Electro-catalysis Unit is able to produce large numbers of hydroxyl radicals and
other highly active oxidizing substances to kill all organisms in ballast water within several
nanoseconds. The whole sterilization process is completed inside the EUT Unit.
The EUT Unit produces active substances, which is used to remove or kill the microorganism in the
medium. This unit is the core part of the system. The electro-catalysis module uses high-
performance semi-conductive catalysis materials. Water molecules are catalysised by special
materials and produce large amount of active substances such as hydroxyl radicals etc. The module
has very high current efficiency and super long service life. When water passes the Filter and the
EUT Unit, the organism contained are filtered or killed. This unit is automatic controlled by Control
unit，no operation needed when ballast.
4.2.3 Technical Data Sheet
Model HMT- 1000E-Ex

Treatment Rated Capacity 1000 m³/h
Maximum Working Pressure 6 bar
Inlet/Outlet Connection DN400 PN10 GB/T 2506-89
Maximum Working Temperature 55 ℃
Working Medium Water
Power Supply DC 0~40V, 0~2000A
Housing Material Carbon Steel(inside corrosion-proof coating)
Ex-proof grade Exd II BT4
Color Munsell NO.7.5 BG7/2
Weight Dry : 632 kg Wet: 1210 kg
Quantity 1 set
Maker Headway
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4.2.4 Cable List
Item Cable Details Quantity Note

EUT Main Power 1×95 7 FM PE
EUT Main Power 1×95 7 FM PE
Water Leakage Alarm 2×2×0.75 1 FM PE
All cables will be supplied by yard except as noted.
4.2.5 Other Information:

1).EUT unit can be installed horizontally and vertically. The subject vessel adopts which method,
and shipyard is responsible for the installation operation.
2). Details of specific repair and operation space, please check the Drawings of EUT Unit.
3).Cable length between EUT Unit and EUT power supply should not be longer than 60m. The
power consumption of cables is 150W/10m.
4).The outlet pipe of EUT Unit should be installed in a higher position than its inlet pipe for easy
maintenance.
5). Do not dismantle or do any other operations when EUT Unit is connected with power supply
and working.
6). Please refer to attached drawings:
7). The cable between EUT and PE will be supplied by Headway.
Drawing No: Drawing Title
a. HMT-1000E/201304/001 EUT Unit-Ex
b. HMT-1000E/201304/002 Construction of EUT
c. HMT-1000E/201304/003-4 Installation of EUT
※ For More Other Information, Pls Contact The Maker.
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4.3 EUT Power Unit
4.3.1 Appearance
Power switch, output voltage regulation, output current regulation, constant voltage / constant
current conversion function, start, time control, ultrasonic power switch and so on are all operated
on the panel.
(B) (A) (C) (D) (E) ⑨ ⑩

② ①
V A ① ②
H M S
(A ①
SET
V A
) (A ⑧
)
UL RUN FORWARD AUTO SLOPE CLEAR
V/A
REMOTE ⑦
UL ALARM REVERSE SET/RUN TIME PANEL
MANUAL CV
CC
UL FORWARD DISP CC START
REVERSE
POWER REVERSE SELECT CV STOP
(J) ① ② (I) ③ (H) ④ (G) ⑤ (F) ⑥

(A)
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EUT Power is exclusively used in OceanGuardTM Ballast Water Management System. It is the
power supplying system of the EUT Unit. EUT Power consists of powers of the ultrasound module
and the electro-catalysis module. The ultrasound module power is located at the upper part of
the EUT Power while the electro-catalysis module power is located at the lower part and can be
found when the cover of the EUT Power is opened. The power supply for the ultrasound module
power is AC 110/220 V; and the power supply for the electro-catalysis module power is AC
380/440 V. If the system works normally, EUT Power is automatically controlled. Instructions are
sent by the Control Unit. The EUT Power can control the operation of the EUT Unit by directly
sending related electrical parameters. The output of the EUT Power can also be controlled
manually from the panel. Working parameters are directly displayed on the panel. This power has
excellent dynamic and static output characteristics. It also has advantages including over current
protection and overvoltage protection etc. Protective responses can be quickly made toward
malfunctions.

Input Voltage AC 440V/60Hz
Output Voltage 0~40V
Output Current 0~2000A
Signal Output RS485
Cooling Type Fresh Water Cooling
Weight 200Kg/set
Ingress Protection IP44
Material of Shell Q195
Color MUNSELL 7.5 BG 7/2
Quantity 1 set
4.3.4 Cable List

EUT Power Supply 3×35 1 FM PDU
EUT Power 1×95 7 To EUT Unit
EUT Power 1×95 7 To EUT Unit
Water-Leakage Alarm 2×2×0.75 1 To EUT Unit
RS485 Communication 1×2×0.75 1 To CL
All cables will be supplied by yard. Except:
The cable between EUT and PE will be supplied by Headway.
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1).Make sure power supply is firmly vertically installed in the base; the grounding protection of
power shell must be grounded for sure.
2).Cable length between EUT Unit and EUT power supply should not be longer than 60m. The
power consumption of cables is 150W/10m.
3).The best installation position is far from places of the heat source and strong vibration. Reserve
0.5m operation space in the front side, 0.3m in the right and left side respectively.
4).After turning off air-break switch, high voltage still exists in the power supply unit. When
maintain, check or repair power supply unit, the power in filter capacitor must be released out
totally prior to opening this unit.
5).Avoid collision in the process of transportation and moving in order to avoid loss of internal
electrical elements and affect system’s normal operation.
6). Attach below security label on main power supply circuit and power case panel.
7). Please refer to attached drawings:

a. HMT1000SHIP20130422/01 Dimensional Drawing
b. HMT1000SHIP20130422/02 Installation Drawing
c. HMT1000SHIP20130422/03 Operating & Lifting
d. HMT1000SHIP20130422/04 Cooling System For PE
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4.4 Filter
4.4.1 Principle of Filter

The Filter mainly handles the impurity particles in the liquid with low viscosity. The full automatic
backflushing Filter from Headway is a mechatronics product, with features such as compact
structure, high filtering efficiency, and low consumption of water for backflushing, low operating
costs, and continuous filtration during backflushing etc. Tangent structure is adopted at the filter
inlet. It can effectively buffer the impact of water at the inlet and
reduce the resistance lose of the whole system at the Filter. The
filter element uses special structure, which can speed up the
backflushing, keep the speed equal and remove the dead areas of
backflushing, so that the efficiency of filtration and backflushing in
the equipment can be improved. This kind of filter is widely used
in the areas such as shipping, metallurgy, chemical, energy, paper
making, machine processing, public works and environmental
protection etc., with special advantages in the filtration of ships’
ballast water.
Fig. 4.4.1.1 Filter

Model HMT-1000F-Ex
Treatment Rated Capacity 1000 m3/h
Maximum Working Pressure 6 bar
Inlet/Outlet Connection DN400 PN 10 GB/T-2506-89
Filtration Precision 50 μm
Working Medium Water
Minimum Operating Pressure 1.5 bar
Housing Material Carbon Steel ( inside with corrosion-proof coating )
Material of Filter Element Super Duplex
Weight Dry: 1950 kg Wet:3050 kg
Ex-proof grade Exd II BT4
Quantity 1 set
Maker Headway
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4.4.3 Cable List

Filter Main Power 3×1.5 1 FM PDU
Back-flushing Pump Control 2×2×0.75 1 To PDU
24V-Filter Power 2×1.5 1 FM PDU
Filter Alarm 4×2×0.75 1 To CL
Filter Motor 3×1.5 1 To Filter
FV1 Control 2×2×0.75 1 To FV1
FV2 Control 2×2×0.75 1 To FV2
Pressure Difference 2×2×0.75 1 To Filter
All cables will be supplied by yard.

1).Filter must be installed vertically.
2).Details of operation and maintenance space, pls check the Drawings for Filter.
3).Keep some maintenance space (1m) left above the filter and equip necessary lifting equipment
in order to maintain the filter element easily.
4).The waste pipes between filter's back flushing outlet and outboard outlet should avoid elbows
and as simple as possible. Besides, the inlet of back flushing pump should be installed lower than
filter's waste outlet.
5).Do not dismantle or do any other electric operations when filter is connected with power
supply.
6)Please refer to attached drawings:
a. HMT-1000F/201305/001 Outline of Filter
b. HMT-1000F/201305/005 AUTO Filter box
c. HMT-1000F/201305/006 AUTO Filter Box
d. HMT-1000F/201305/007 INSTALLATION
e. HMT-1000F/201305/008 MAINTENANCE
※ For More Other Information, Pls Contact the Maker.
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1
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DN125
DN125
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4.5 Control Unit

The Control Unit controls the whole system of BWMS, including collecting and processing all
monitoring sensor signals, processing alarm signals, and automatically controlling the sequence of
starting up and shutting down the components. The Control Unit contains the control program that
is required for the operation of the system. The working status of the BWMS can be displayed on
the panel of the Control Unit, including the working status of each component, and real-time data
detected by the sensors. When the equipment breaks down, the Control Unit can send acousto-
optic alarm, switch off the power, and stop the system. The operation of the equipment can be
stored and recorded in the Control Unit. Data can be displayed as required by formal inspections.
The Control Unit collects various monitoring sensor signals in the whole system, including the
open/close status of the valves, monitoring signals such as current values, voltage values and TRO
values from the Salinity Meter, the Magnetic Flow Meter and the EUT, and voyage data of ships.
With built-in programs, the computer system of the Control Unit can calculate the current values
and voltage values based on parameters collected, so as to adjust the operation of the system until
it reaches the best operation status. In this way, BWMS can keep on working under the best status.
The Control Unit has functions of recording and storing. It can record and store the operation data
for at least 24 months. The Control Unit also has an alarm output interface, which can integrate
with other alarm signals from the engine control room. Therefore, it ensures that the alarm
information can be easily detected anywhere in the engine room.

Model HMT-CL
Input Voltage AC 220V 60Hz
Signal In/Output RS485/422
Weight 30Kg
Housing Material Structural carbon steel (Q195)
Quantity 1 set
Maker Headway
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4.5.3 Cable List
Ballast Pump Running Signal 2×2×0.75 1 FM Ballast Pump 1 Starter

Ballast Pump Running Signal 2×2×0.75 1 FM Ballast Pump 2 Starter
Filter High Pressure 2×2×0.75 1 To AMS
& Common Alarm
RS485 Communication With GPS 1×2×0.75 1 FM GPS
Power
4×2×0.75 1
On/Off/Light
Remote
Remote/EM’CY 4×2×0.75 1 FM Control Unit To Remote
Control
stop Control Room
Room
RS485 1×2×0.75 1
Communication
Feedback 1×2×0.75 1 FM FM
CL Power 2×1.5 1 FM PDU
Back-flushing Pump Running 4×2×0.75 1 To PDU
Signal
RS-485 Communication 2×2×0.75 1 FM Valve Remote Control Sys.
RS-485 Communication 1×2×0.75 1 FM PE
Filter Alarm 4×2×0.75 1 From AF
Open 1×2×0.75 1
AV1 Close 1×2×0.75 1 Inlet Valve
Status 2×2×0.75 1
Open 1×2×0.75 1
AV2 Close 1×2×0.75 1 Outlet Valve
Status 2×2×0.75 1
Open 1×2×0.75 1
AV3 Bypass Valve
Close 1×2×0.75 1
TRO/Salinity Feedback 2×2×0.75 1 FM TRO
Control Signal 4×2×0.75 1 To TRO
Fault Alarm to CL & Power FM CL 5×1.5 1 FM TRO Control Box
NU Input 4×2×0.75 1 To NU
NU Output 4×2×0.75 1 FM NU
FV1 Feedback 2×2×0.75 1 To Back-flushing Valve
FV2 Feedback 1×2×0.75 1 To Angle Valve
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1).Make sure Control Unit is firmly installed in the base; the grounding protection of power shell
must be grounded for sure.
2).Do not install the system close to the outer surface of oil tank (oil container), water tank (water
container), double bottom, etc. (If it has to, 50mm must be left between the system and such kind
of bulkhead surfaces, and add enhanced recovery board. However, resister, heater and other
electric equipment which generate high temperature in the process of work cannot be installed.)
4).Check Emergency Stop Button prior to operation, make sure the button is not running (the
button is in the lift status)
5).Please refer to attached drawings:

a. HMT-TRO-2014-04/011 Outline of Control Unit
b. HMT-TRO-2014-04/012 Components of Control Unit
c. HMT-TRO-2014-04/012 Components of Control Unit
d. HMT-TRO-2014-04/013 Operation space of Control Unit
e. HMT-TRO-2014-04/014 Monitoring Unit Control
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4.6 Power Distribution Unit

The Power Distribution Unit is the power supply control equipment of OceanGuard® Ballast
Water Management System. The input for the Power Distribution Unit is AC440V , while the
output is AC 440 V, AC 220 V and DC24V. AC 440 V is for the electrocatalysis module of the EUT
Unit, the Filter and the Back flushing Pump; AC 220 V is for the Control Unit and the TRO Meter;
DC 24 V is for the cooling of the Monitoring Unit and the Salinity Meter.

Model HMT- 1000 PDU
Input Voltage AC 440V/60Hz 3Ph & AC 110V/60Hz
Housing Material Structural carbon steel (Q195)
Colour Munsell NO.7.5 BG7/2
Quantity 1 set
Maker Headway
4.6.3 Cable List
440V System Power 3×50 1 FM Ship Power
220V System Power 2×4 1 FM Ship Power
Power 24V 2×1.5 1 To FM
Control Unit Power 2×1.5 1 To CL
Power Control / Back-flushing 4×2×0.75 1 FM CL
Pump Running Signal
EUT Power Unit Main Power 3×35 1 To PE
Filter Power 440V 3×1.5 1 To AF
Back-flushing Pump Power 2×2×0.75 1 To AF
Filter Power 24V 2×1.5 1 To AF
MU Power 2×1.5 1 To MU
NU Power 2×1.5 1 To NU
Back-flushing Pump Power 3×10 1 To BP
Back-flushing Pump Heater 2×1.5 1 To BP
Back-flushing Pump Emergency 7×1.5 1 FM EMB
Stop Button
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1).Make sure power supply is firmly vertically installed in the base; the grounding protection of
power shell must be grounded for sure.
3).The best installation position is far from places of the heat source and strong vibration. Reserve
0.5m operation space in the front side, 0.3m in the right and left side respectively.
4)Do not conduct charged operation in the process of maintenance and repair, attach below
security label on main power supply circuit and power case panel.

a. HMT-1000PDU/201304/001 Power Distribution Unit
b. HMT-1000PDU/201304/002 Components of PDU
c. HMT-1000PDU/201304/003 Installation of PDU
※ For More Other Information, Pls Contact the Maker.
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4.7 Flow Meter

The Magnetic Flow Meter can be used to detect the instantaneous flow rate in the ballast water
pipes and to measure the total amount of the ballasting and deballasting water. These are
important input parameters of the Control Unit.
After being actually calibrated with ordinary water, the Magnetic Flow Meter can be used to
measure the volumetric flow of any other conductive fluid medium, without any amendment.
Since there is no removeable part or flow-resisting parts in the measuring pipe, there is almost no
loss of pressure, and the reliability is high.

Model HMT- 400 FM
Input Voltage DC 24V
Rated Working Pressure ≤16 bars
Inlet/Outlet Connection DN400 PN10 (GB9113)
Signal In/Output 4~20 mA
Flow Rate Range 0.1-15m/s
Ingress Protection IP65; ≥Exd II CT4
Electrode Material Including molybdenum stainless steel, Titanium(Ti)
Length of Straight Pipe upstream≥ 3DN downstream≥1DN
Quantity 1 set
Maker Headway
4.7.3 Cable List
Flow Meter Main Power 2×1.5 1 FM PDU
Flow Meter Feedback 1×2×0.75 1 To CL
1).Keep the flow meter tightly fixed on piping.
2).Keep the meter horizontal. Horizontal Straight Pipe before inlet should not be less than
700~1000mm.
3).Direction of Upper Monitor can be Changed Depending on Situation.
a. HMT-400FM/201407-001 Outline of Flow Meter
b. HMT-400FM/201407-002~004 Installation of Flow Meter
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4.8 Monitoring Unit

The Monitoring Unit consists of parts such as TRO Meter, electromagnetic valve, pump, relay,
radiator and reagent bottle etc.
The Monitoring Unit is used to detect the TRO of the ballast water, which is very important
information for the performance of the BWMS. The resulting data can be uploaded to the Control
Unit. Based on the data, the Control Unit can determine the working status and modes of
equipments in the system. The performance of the Monitoring Unit will directly influence the
working status of the BWMS.
TRO means “Total Residual oxidant”. It is an important parameter for determining whether the
effective active elements in the water are sufficient or not. This instrument uses the method of
curettes to measure.
TRO Meter is used to detect the concentration of the residual oxidant in water, so as to determine
whether the quantity of the active substance in the system has reached established level. The
fluoride content in water is usually expressed in (mg/L), which is equivalent to PPM.
It is actually a simple online detecting control instrument that is easy to operate. Can be
automatically count, display reading. Its detecting ability is highly realizable and accurate. This
meter connected to the Control Unit. The operator can use the main screen of the Control Unit or
the backlit screen of the meter to read values. This meter has easy-to-operate buttons. The
operator can set the parameters visually. The meter can also be easily operated in the dark.

Input Voltage AC 220V/60Hz & DC 24V
Rated Working Pressure ≤6 bar
Operating Temperature 0-80℃
Signal In/Output RS485
Inlet/Outlet Connection DN15 GB/T 2506 Flange Type; φ8 copper pipe
Water Input Treated Water
Weight 50Kg
Material Structural carbon steel (Q195)
Install Type FLOOR STANDING TYPE
Ex-proof grade Exd II CT6
Quantity 1 set
Maker Headway
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4.8.3 Cable List
Main Power 2×1.5 1 FM PDU To TROC
Fault Alarm To CL & 24V Power FM CL 5×1.5 1 FM TROC To CL
Power To TRO 5×1.5 1 FM TORC To TRO
Inlet & Outlet Valve Control 2×2×0.75 1 FM TORC To TRO
Flow Signal To TRO Pressure Diff. FM 4×2×0.75 1 FM TORC To TRO
TRO Leakage Alarm FM TRO
TRO / Salinity Feedback 2×2×0.75 1 FM TORC To TRO
Control Signal 4×2×0.75 1 FM TORC To TRO

1).Make sure Monitoring unit is firmly installed in stand.
2).The best installation position is far from places of the heat source and strong vibration, reserve
0.5m operation space in the front side.
3).The best distance between sampling port and Monitoring unit is within 5m.
90
91
92
93
94
95
4.9 Neutralization Unit
Neutralization Unit is an optional equipment of OceanGuard® Ballast Water Management System.
If the TRO in the tank exceeds 0.2mg/l when the system discharges ballast water, the Control Unit
automatically starts the Neutralization Unit and automatically add certain amount of neutralizer
(sodium thiosulfate solution) into the pipes. The amount of the neutralizer is automatically
controlled by the Control Unit to keep the TRO in the water from the system lower than 0.2mg/l.
Fig. 4.8 Control Principle of Neutralization Unit

Neutralization Unit adds sodium thiosulfate pentahydrate into the pipes in order to remove the
TRO in the water. Please refer to the following equation:
5H2O·Na2S2O3+4Cl2=Na2SO4+H2SO4+8HCl
Sodium thiosulfate pentahydrate is white crystal powder, which is well soluble in water. It is non-
toxic and harmless, with no impact on the environment. Sodium thiosulfate pentahydrate is a
water clarifier that is often used in water-clarifying projects. In textile industry, it is used as the
antichlor for bleached cotton fabrics, the sulfur dye for dyed wool fabrics, the blush preventive
agent for indigo dye, and the antichlor for paper pulp, and so on.
Neutralization Unit Calculation
Formula:
5H2O+Na2S2O3·5H2O+4Cl2=Na2SO4+H2SO4+8HCl
248 284
Neutralization capacity=62*X*Y/71/Z (L/h)
X---TRO (mg/L)we make it 2.
Y----Flow rate（m3/h）
Z----Na2S2O3 ·5H2O in water （g/L）
If Na2S2O3 ·5H2O in water is 50g/L，Capacity is 124*Y/3550 (L/h)
When Y is 500，the capacity should be 17.5L/h
96
Model HMT-100 NU
Input Voltage AC 220V/60Hz
Control System Siemens PLC from Control unit
Capacity of Metering Pump 0~15L/h
Neutralizer Sodium Thiosulfate
Tank Capacity 100L
Weight 200 Kg
Material Structural carbon steel (Q195)
Quantity 1 set
Maker Headway
4.9.3 Cable List
Neutralization Unit Main Power 2×1.5 1 FM PDU
NU INPUT 4×2×0.75 1 FM CL
NU OUTPUT 4×2×0.75 1 FM CL
1).Make sure Neutralization Unit is firmly installed in stand.
electrical elements and effect of system’s normal operation.
3).Ensure Neutralization Unit installation place and injection port location is fixed strictly according
to Drawing supplied by maker.
a. HMT-100NU/201304/001 Overall of NU
b. HMT-100NU/201304/002 Installation dimension of NU
c. HMT-100NU/201304/003 Components of NU
d. HMT-NU100/2013-04/004 Pipe connection of NU
97
98
99
100
101
4.10 Back-Flushing Pump

1) When the Filter is filtering the ballast water, with more and more impurity particles
accumulated inside the filter element, the pressure difference between the filter outlet and inlet
becomes greater and greater.
2) When the pressure difference reaches the preset value, the backflushing process starts.
3) The Auto Filter Box controls the backflushing valve to open. The gear motor starts to work and
drives the top and bottom flushing arms, through the connecting pipe, to rotate at a constant
speed.
4) To prevent the backflushing arms from being stuck and the filter element from being blocked,
the control system is set to start the backflushing process when a certain time interval is reached,
even without the preset pressure difference being reached.
5) During the backflushing, when the joint of the flushing arm, which is connected to the
backflushing pipe, targets at a filter element, the backflushing valves has been opened already.
Under the impact of the pressure difference, the filtered clean fluid is pushed back from the
outside into the inside of the filter element. The impurity particles adhering to the surface of the
filter element is washed back into the flushing arm and then out of the backflushing pipe .
As the backflushing arms rotate at a constant speed, the filter elements are washed one by one.
During this process, other filter elements are still functioning. Therefore, the backflushing is carried
on automatically during the filtration.
Model NSL125-265B/D02
Input Voltage AC 440V 60Hz 3Phaze
Suction nominal dia DN125
Discharge nominal dia DN125
Capacity 160 m3/h
Total Head 30m
Rated power 22.2kW
Motor enclosure IP55
Ex Grade Exd II CT4
Material Carbon Steel
Quantity 1 set
Maker DESMI
102
4.10.3 Cable List
440V Power 3×10 1 FM PDU
Back flushing Pump Heater 2×1.5 1 FM PDU

1).Make sure back flushing pump is firmly installed in stand.
2).It’s better to make the intake of back flushing pump lower than the drainage outlet of filter so
as to help the filter back flush more efficiently.
3).It’s better to install the back flushing pump just after the filter back flushing outlet.
4).Clean and make sure the pipe is free from rust, welding slug and other pollutants before
connecting pump and pipe so as not to damage to the impeller when the pump is running.
103
Technical Specification
1.Backflush pump, 1 Set
General Information
Quotation No. Pos. No. 1
Pump NSL125-265B/D02
Pump Type Vertical Inline Centrifugal Pump Pump series NSL Density 1.025 kg/l
Pump Media Sea water Pump Model NSL125-265B
Pump data Motor Data

Capacity 160.00 m³/h Brand ABB
Total Man. Head 30.00 mLC Motor M2JA-H180L4A EXDIICT4
Speed 1765 rpm Power Supply El-motor 3 x 440V - 60Hz
Power Consumption 18.38 kW Construction T.E.F.C
NPSHr 3.14 mLC Insulation Cl. F-IP55
Non-Overl. Power 21.76 kW Motor Speed 1765 rpm
Eta 73.13 % Performance 25.30 kW
Delivered by DESMI A/S
Max. working pressure; being the pressure at the suction branch and the maximum generated head at zero flow. For this particular pump
in standard material: 14.5 bar ( =144.3 mLC with a density of 1.025 kg/l )
If higher working pressure is required other materials are available upon request.
Test pressure; pump approved by classification societies have been pressure tested according to the requirements of these societies, i. a
test pressure of 1,5 x working pressure.
The test pressure is stated in the test certificate and stamped on the discharge flange of the pump.
Tolerance: According to ISO 9906 grade 2
Specification:
Pump Casing Bronze
Suction/Pressure Flange 125/125 mm..
Impeller NiAlBz
Impeller Diameter 258.00 mm
Shaft Stainless Steel
Shaft Seal Mechanical seal, Stainless steel and NITRIL Ø38
Bearings Ball Bearings
Coupling Monobloc
Rotation Clockwise
Manometer MAN. -1/+5 BAR W. COCK, loose supply gauge board
Class Society Without
Max grain size 21.00
Each pump with two DIN standard DN125 counter flange.

Nameplate with English word.
With motor space heater.50W power
Terminal box 90° position, cable gland L direction.
Paint color: MUNSELL 7.5 BG7/2
(C) DESMI - WinPSP 2012 Pump Selection Program - Version 3.45 (04.01.2013) - DB: 219 (11.01.2013)
Date: 25-03-2013
104
1.Backflush pump, 1 Set
1
According to ISO 9906 grade 2
(1) NSL125-265B Speed: 1765 rpm, Imp. Dia: 258.0 mm, Density: 1.025 kg/l
105
106
4.11 Remote Control Unit

Signal In/Output RS485
Weight 11Kg
Material of Shell Stainless Steel
Installation Type Flush type
Quantity 1 set
4.11.2 Cable List
Power ON / OFF / Light 4×2×0.75 1 FM CL
Remote / EM’CY Stop 4×2×0.75 1 FM CL
RS485 Communication 1×2×0.75 1 FM CL

1).Make sure components are firmly installed in the base; the grounding protection of power shell
must be grounded for sure.
2).Do not install the system close to the outer surface of oil tank (oil container), water tank (water
container), double bottom, etc. (If it has to, 50mm must be left between the system and such kind
of bulkhead surfaces, and add enhanced recovery board. However, resister, heater and other
electric equipments which generate high temperature in the process of work cannot be installed.)
4).Check Emergency Stop Button prior to operation, make sure the button is not running (the
button is in the lift status)
a. HMT-CR/201403-001 Outline of CR
b. HMT-CR/201403-002 Components of CR
107
O CEAN
108
O CEAN
109
4.12 Pneumatic Valves

Input Voltage AC 220V / DC24V
Size 400A
Flange Standard CBM1012-81
Control System Automatic Controlled By PLC
Drive Mode Pneumatic & Manual
Pressure 5 bar
Ex-proof grade Exd II CT4 or above
Material Bronze
Maker HEADWAY
4.12.2 Cable List
HAV1 1×2×0.75 1 From CL
1×2×0.75 1 From CL
2×2×0.75 1 From CL
HAV2 1×2×0.75 1 From CL
1×2×0.75 1 From CL
2×2×0.75 1 From CL
4.12.3 Other Information

1).Make sure Valves is firmly installed in stand.
2).HAV3 shipyard supply
110
AD0039-AD0043 HMT-1000 Ex VALVE LIST
系统型号 BWMS TYPE：HMT-1000 Ex 2016/5/18
安装位置数量
序号名称/控制方式阀门编号&铭牌刻字内容法兰标准FLANGE
型号 TYPE INSTALL QUAN 材质 METERIAL 备注 NOTE
NO. NAME/CONTROL TYPE VALVE NO.&NAMEPLATE STANDARD
POSITION TITY
气动蝶阀对夹式(双电控) 阀体球墨铸铁，阀板青铜

1 AIR CONTROL BUTTERFLY 400A HAV1 BWMS INLET SYSTEM INLET 1 PN1.0MPa BODY DUCTILE CAST
WAFER TYPE (DOUBLE) IRON,PLATE BRONZE
气动蝶阀对夹式(双电控) 阀体球墨铸铁，阀板青铜

2 AIR CONTROL BUTTERFLY 400A HAV2 BWMS OUTLET SYSTEM OUTLET 1 PN1.0MPa BODY DUCTILE CAST
气动角度阀对夹式阀体球墨铸铁，阀板青铜

FV2 ANGLE CONTROL
3 AIR ANGLE CONTROL 400A FILTER OUTLET 1 PN1.0MPa BODY DUCTILE CAST
VALVE
BUTTERFLY WAFER TYPE IRON,PLATE BRONZE
手动蝶阀对夹式阀体球墨铸铁，阀板青铜

4 MANUAL BUTTERFLY 400A HMV1 EUT OUTLET VALVE EUT OUTLET 1 PN1.0MPa BODY DUCTILE CAST
WAFER TYPE IRON,PLATE BRONZE
气动蝶阀对夹式 (双电控) 阀体球墨铸铁，阀板青铜

5 AIR CONTROL BUTTERFLY 125A FV1 BACK FUSHING VALVE BACK FLUSHING 1 PN1.0MPa BODY DUCTILE CAST
HMV2 BACK FLUSHING 阀体球墨铸铁 BODY

6 手动截止阀 MANUAL VALVE 125A BACK FLUSHING 1 PN1.0MPa /
VALVE DUCTILE CAST IRON
111
AD0039-AD0043 HMT-1000 Ex VALVE LIST
系统型号 BWMS TYPE：HMT-1000 Ex 2016/5/18
安装位置数量
序号名称/控制方式阀门编号&铭牌刻字内容法兰标准FLANGE
型号 TYPE INSTALL QUAN 材质 METERIAL 备注 NOTE
NO. NAME/CONTROL TYPE VALVE NO.&NAMEPLATE STANDARD
POSITION TITY
HBV4 TRO INLET; 阀体铸钢，阀球 316L .

MONITORING
7 球阀 BALL VALVE 15A HBV5 TRO OUTLET ; 3 PN1.0MPa BODY CAST STEEL, BALL /
UNIT
HBV6 TRO INLET; 316L
阀体铸钢，阀球 316L .
HBV7 NU INLET NEUTRALIZATION
8 球阀 BALL VALVE 15A 2 PN1.0MPa BODY CAST STEEL, BALL /
HBV8 NU OUTLET; UNIT
316L
含取样接头
HBV3 SAMPLING VALVE WITH
9 球阀 BALL VALVE 50A SAMPLING 2 PN1.0MPa BODY CAST STEEL, BALL
HBV9 SAMPLING VALVE CONNECTI
316L
ON
HBV1 WATER INLETT; WITH PRESSURE
球阀 BALL VALVE ø8 2 PN1.0MPa BODY CAST STEEL, BALL
HBV2 WATER OUTLET; INDICATOR
316L
HBV10 FRESH WATER INLET 阀体铸钢，阀球 316L .

EUT POWER UNIT
10 球阀 BALL VALVE 25A HBV11 FRESH WATER 2 PN1.0MPa BODY CAST STEEL, BALL /
COOLING
OUTLET 316L
112
113
114
HBV10/HBV11
HBV3/HBV9
115
4.13 Sampling Unit
Rated Working Pressure ≤10 bars
Inlet/Outlet Connection DN50 PN5
Water Input Fresh Water and Seawater
Weight 5Kg
Material Carbon Steel
Install Type Straight Type and Bend Type
Quantity 2 sets
Scope Headway
4.13.2 Other Information
Please refer to attached drawings:
a. HMT-SP/201307/001 Sampling Port
b. HMT-SP/201307/002 Installation Instruction
116
O CEAN
117
O CEAN
118
4.14 I/O Signal List
Item Content Type Comment
Output signal Internal common alarm signal Dry contact -
Input signal GPS RS485/422 -
Ballast Pump
FM Ballast Pump Starter - -
Running Signal
119
BWMS Spare Parts List
(HMT-1000ex)
序号名称型号数量备注备件编号
number name type quantity remark (S/N)
压差表进出口接头 G1/4 外丝
1 Joint of Pressure 转￠8 不锈钢 2 1.15.07.0038
Differ Gauge 管
￠67*2.65
GB/T3452.1-
滤芯 O 型圈（上）
2 2005 硬度 10 1.12.01.0060
Elements O ring （Upper）
A60
过滤器备件
Filter spare
￠65*2.65
GB/T3452.1-
滤芯 O 型圈（下）
3 2005 硬度 10 1.12.01.0061
Elements O ring （Lower）
A60
星型圈
4 F37.47×5.33 2 1.12.03.0002
X Ring
外六角碳钢镀锌带法兰
螺栓 EUT 单元备件
5 M12x50 4 1.10.01.0003
Hex head galvanized EUT Unit spare
flange face screw
继电器 RIF-0-RPT-2
6 2 1.45.01.0016
Relay 4DC/21 控制单元备件
铜螺柱 Control Unit spare
7 M3x45 4 1.62.04.0039
Copper Bolt
G1/2 内丝转
过壁接头
8 G1/4 外丝不 2 1.15.07.0012
Connections 监测单元备件
锈钢 304
Monitoring spare
软管
9 8mm 0.5m 1.23.01.0004
Plastic pipe
-
箱体合页
10 CL209Z3A00 2 pairs 电控箱体备件 1.91.01.0004
Hinge
1 Electric Cabinet
箱体钥匙 spare
11 -- 1 1.10.19.0001
Electric Cabinet Key
1/4 双电控
双电控电磁阀气动阀门备件
24DC
12 Double Electric Solenoid 1 Pneumatic Valve 1.80.14.0008
SCG531C002
Valve spare
MS （asco）
120
序号名称型号数量备注备件编号
number name type quantity remark (S/N)
气动阀门备件
电磁线圈
13 DC24V 2 Pneumatic Valve 1.42.01.0016
Electromagnetic coils
spare
中和单元备件
硫代硫酸钠
14 4kg 5 Neutralization Unit 1.92.01.0002
Na2S2O3
spare
121
Part 6 Commissioning Procedure
122
Commissioning Instructions for OceanGuard BWMS 1
OceanGuard○R Ballast Water Management

System
Commissioning Instructions
Qingdao Headway Technology Co., Ltd.
BWMS Model: HMT-1000 Ex
Vessel Type: 25,000 DWT S.S. PRODUCT OIL & CHEMICAL TANKER
Hull Number： AD0039~AD0043
Class： DNV
Ship Yard: AVIC DINGHENG SHIPBUILDING CO., LTD
Date: 2014.06.30
123
Table of Contens
Commissioning Instructions .................................................................................................................1
1. Safety ............................................................................................................................................3
1.1 Safety Instructions ..................................................................................................................3
1.2 Symbols and Explanatory Notes .............................................................................................3
1.3 Warranty .....................................................................................................................................4
1.4 Abbreviations..............................................................................................................................4
2. Basic terms for commissioning procedure ...................................................................................5
2.1. General Scope ..........................................................................................................................5
3. Definition of Responsibilities.....................................................................................................5
3.1. Headway Deployment Period and Scope ..................................................................................5
3.2. Installation Readiness and Site Access ....................................................................................5
3.3. Job Site Coordination ..............................................................................................................5
3.4. Services Provision ...................................................................................................................5
3.5. Storage and Rest Area Provisions............................................................................................5
3.6. Installation Works and Damaged Equipment by Buyer /Shipyard ..........................................6
3.7. Delays and Compensation .......................................................................................................6
4. System Acceptance ....................................................................................................................7
4.1. Acceptance Tests and Documentation .....................................................................................7
4.2. Duration and Location of the Acceptance Test .......................................................................7
4.3. Repetition of the Acceptance Test /Minor Deficiencies ..........................................................7
4.4. Test Conditions ........................................................................................................................7
5. Detailed commissioning procedure, pneumatic equipment ......................................................7
5.1. Preliminary remarks .................................................................................................................7
5.2. Preparations and prerequisites ..................................................................................................8
5.3. Procedure steps .........................................................................................................................8
6. Detailed commissioning procedure and connection of electrodes cabling ..................................9
6.1. Preliminary remarks .................................................................................................................9
6.2. Connection of cables between EUT Unit and EUT Power ......................................................9
6.3. Pre commissioning procedure: .................................................................................................9
7. Premises for Commissioning ......................................................................................................10
8. BWMS - CHECKLIST .............................................................................................................12
9. CHECKLIST OF ALARM .......................................................................................................12
10. CHECKLIST OF BALLASTING ............................................................................................12
11. CHECKLIST OF DE-BALLASTING .....................................................................................12
12. CHECKLIST OF BYPASS MODE .........................................................................................12
13. BWMS-SHORT OPERATION MANUAL .............................................................................20
124
1. Safety
1.1 Safety Instructions
 All parts provided by the manufacturer are exclusively for OceanGuard® Ballast Water
Management System. Every part can be used only under the required conditions and environment,
being an integral part of the ballast water management system. Please don’t use the parts for other
purposes. This may lead to physical injury of the user.
 The installation and maintenance of OceanGuard® Ballast Water Management System shall be
carried on by technicians authorized by the manufacturer. Otherwise, injuries may happen to
related personnel because of the unfamiliarity with the system.
 The parameters of OceanGuard® Ballast Water Management System shall be set in the factory.
User’s modification is not allowed. In case any modification is needed, it shall be down with the
manufacturer’s permission and in the correct way. Parameters set by the user could cause system
failure, or change the safe operation environment of the system; and thus cause injuries to the
personnel.
 The structure of any equipment in the system is not allowed to be changed without the
manufacturer’s permission. Any part that does not run properly shall be replaced immediately with
parts from Headway. For parts from other manufacturers, we cannot guarantee that they are
designed and manufactured according to the design requirements and the safety standards of the
system. This may cause death or injuries of the personnel.
 To prevent safety accidents from happening, this manual uses safety symbols to provide safety tips.
Please read the related sections carefully. Failing to follow the tips and instructions of this manual
may cause equipment malfunctions or personnel injuries.
 Symbolic safety tips are put on OceanGuard® Ballast Water Management System. Please do not
tear off or scrawl over them. Please follow the instructions strictly and operate safely.
 Clients have the right to specify the material and detailed specifications of some devices of
OceanGuard® Ballast Water Management System. Please make sure your requirements meet the
ship conditions and can ensure the personnel safety.
1.2 Symbols and Explanatory Notes
 Explanatory Notes in this Manual
Danger
This symbol is a safety note. Ignorance of it may cause severe damage to human
body.
Caution
This symbol is a safety note. Ignorance of it may cause general damage to human
body.
125
Note
This symbol is a reminding note. Ignorance of it may cause damage to equipment.
Reading
This symbol is a reading note. Please follow the symbol to look for related
chapters or sections.
Information
This symbol is an information note. Please follow the instructions of this symbol.
 Safety notes on BWMS
Electric Shock Warning – Ignorance of this note may cause electrical shock hazard.
1.3 Warranty
Within 12 months after a client signs for acceptance of OceanGuard® Ballast Water Management
System, under the condition of normal operation and use, if any part does not work properly, the
manufacturer will replace or repair the part for free.
Within the warranty period, the manufacturer will charge if any of the following occurs:
 Within the warranty period, any system failure or part damage caused by an improper operation or
usage.
 Within the warranty period, damages are caused by parts from other manufacturers.
 Within the warranty period, any system failure or part damage caused by a modification of the
equipment structure.
 Within the warranty period, any system failure or part damage caused by the material or
specifications specified by the client.
1.4 Abbreviations
 AEOP: Advanced Electrocatalysis Oxidation Process
 BWMS：Ballast Water Management System
 EUT: Full name, Electrocatalysis enhanced by Ultrasonic Technology
 FCB: Filter Control Box
 IMO: International Maritime Organization
 PDU: Power Distribution Unit
 PLC: Programmable Logic Controller
 TRO: Total Residual Oxidant
126
2. Basic terms for commissioning procedure
2.1. General Scope
These Terms and Conditions shall apply to all contracts for Pre-Commissioning and Start-Up of a
OceanGuard® Ballast Water Management System.
3. Definition of Responsibilities
3.1. Headway Deployment Period and Scope
The deployment period of Headway’s specialist is restricted to a maximum of working man days as
agreed per contract. The Buyer must give a minimum notice of 2 week for Headway to deploy its specialist
to the agreed job site. The working time shall not exceed 10 hours a day and 5 days per week.
3.2. Installation Readiness and Site Access
The Buyer must arrange that the complete installation and connection of the equipment (mechanical
and electrical) has been made in accordance with Headway’s instructions and the systems are entirely
complete and ready for commissioning. The Buyer will give Headway and its representatives free and
unrestricted access to the system location and that the work can be carried out continuously and without
hindrance.
3.3. Job Site Coordination
The Buyer will appoint a Site-Manager who coordinates the commissioning activities between the
shipyard, Headway and any third parties involved.
3.4. Services Provision
The Buyer is to provide the necessary operating media and electrical power as well as compressed air
and water, heating and lighting, etc., including the required connections to the place of installation;
everything in the quality and quantity required.
3.5. Storage and Rest Area Provisions
The Buyer must arrange for the provision of suitable, dry, lockable rooms in the immediate vicinity of
the place of installation for the storage of machine parts, instruments, devices, materials, tools etc. For the
supplier's personnel the buyer shall provide appropriate work and amenity rooms equipped with adequate
sanitary installations. In order to protect the supplier's personnel and property on site, the Buyer shall make
all arrangements he himself would make to protect his own personnel and property.
127
3.6. Installation Works and Damaged Equipment by Buyer /Shipyard
If deficiencies are found during the pre / final commissioning inspection by Headway of the equipment
installation (mechanical/electrical), the Buyer shall remedy these deficiencies as soon as possible prior to
commissioning/start-up of the system. The Buyer shall also be liable for all defects or damages caused by
deficient installation work of the shipyard with respect to the systems supplied by Headway. The costs for
replacement parts by Headway that are needed short notice to rectify damaged parts due to improper handling
by the shipyard and/or any missing parts will be fully reimbursed by the Buyer to Headway.
3.7. Delays and Compensation
If an interruption of the Commissioning Services exceeds seven days, then Headway shall be entitled
after prior consultation with the Buyer to recall its specialists. Waiting time and/or the additional expenses
for lodging, travelling and any other interim cost increases shall be borne by the Buyer.
128
4. System Acceptance
4.1. Acceptance Tests and Documentation
The Acceptance Test shall demonstrate the proper performance of the Ballast Water Treatment System in
presence of the Buyer's inspector. After successful performance tests, the appropriate Acceptance Test protocols are
then signed off by the Buyer and Headway.
4.2. Duration and Location of the Acceptance Test
The performance tests (ballasting/de-ballasting) will take place directly in the harbour before the sea-trial
depending on the situation on-site. Headway will give the Buyer notice to perform the required Acceptance Tests
together with the Buyer’s inspector. These performance tests shall not take longer than 1/2 days and the Buyer shall
be obligated to accept the work performed as soon as notification of completion of the tests is received (Acceptance
Test Protocols).
4.3. Repetition of the Acceptance Test /Minor Deficiencies
If the systems failed the performance tests, then Headway shall be under the obligation of correcting the
deficiency within a reasonable period of time, unless the deficiency is considered to be immaterial to the Buyer's
interests, or if the deficiency is due to circumstances for which the Buyer or a third party bears responsibility. If the
deficiency is of minor importance, the Buyer shall not be entitled to refuse acceptance of the systems, if Headway
expressly recognizes its obligation of correcting the deficiency within a reasonable period of time.
4.4. Test Conditions
The proper performance of a system is subject to the condition that the tests will be made with sea-, brackish- or
river-water. Furthermore, the ballast water shall not contain any oils, toxic or radioactive substances, solvents,
chemical agents or wastewater.
5. Detailed commissioning procedure, pneumatic equipment
5.1. Preliminary remarks

 All of the pneumatic pipe work and tubes have to be cleaned (blow out air-cleaning) thoroughly before operation
of the pneumatic valves, otherwise serious problems during operation will occur.
 Do not use Teflon tape or liquid sealants in pneumatic systems for an airtight seal. These materials could block
the automatic valves piston.
 This procedure has to be done prior to any pneumatic leakage test.
 The below mentioned procedure has to be adhered strictly for cleaning and testing:
129
5.2. Preparations and prerequisites

 All pneumatic tubes for operation of the automatic pneumatic valves are disconnected at the intake of the
automatic valves. The tubes are bended away from the automatic valves fitting in order to prevent a pollution of
the automatic valves during air-cleaning.
 Check, that the manual override screws of the automatic valves are in “OFF” –position = not actuated
 Check, that all “NO” pneumatic butterfly valves flaps are physically in OPEN position during absence of control
air. Remove the pneumatic actuator to check the mark on the flap spindle and paint mark one of the fixing screws
after reassembly, for reference during HEADWAY commissioning. Check the “NC” valves for CLOSE position
of the flap in case, that the actuator body and the valve body are not installed in line any more
5.3. Procedure steps
5.3.1. Cleaning of pneumatic pipe work
1. Blow out the air supply pipes with maximum flow speed for at least 30s. Check that no water escapes from
the pipes during the process. The presence of water in the control air causes serious malfunction of the automatic
valves.
2. Close the pipe connection in front of the shut-off valves
3. Open the air supply line in front of the air manifolds to the air tubes.
4. Blow out the air supply pipes with maximum flow speed for at least 30s. For this purpose, Increase the set
pressure at the air controllers to the maximum value.
5. Close the air supply line in front of the air manifolds
6. Blow out the air supply tubes with maximum possible flow speed. Do an individual check for each supply
tube, that there is a relevant air discharge at the end. If not, check and remove the cause of the blockage.
7. Stop the air flow and connect all air tubes back again to the automatic valves
5.3.2. Leakage test
1. Pressurise the pneumatic system to a set value of 5 bars outlet pressure at the air controllers (lower than
intake air pressure). Check that that the controllers will keep this pressure and do not increase the outlet pressure to a
higher value. After that, increase the pressure to 7 bars at the air controllers.
2. Carry out a leakage test for the whole pneumatic system by using suitable liquids, e.g. dish- washer solution
from a spray bottle. Fix the air leakages, if present.
5.3.3. Function test
1. Check the pneumatic butterfly valves for smooth movement by using the manual override levers at the
allocated automatic valves. The valve flaps should not jump out of the seat when leaving the closed position. If this
happens, check the alignment of the valve body to the connected flanges.
The pneumatic butterfly valves are preset prior to delivery to the following opening and closing speed at the
throttle valves. Do not change the settings, but take a note for the valves which are obviously not in the required range.
HEADWAY will check these valves after arrival on site.
130
Preset opening and closing speed of pneumatic butterfly valves (for 90°rotation angle):
Nominal width: DN 200: open: 5 s close: 5 s
DN 250 open: 10 s close: 10 s
6. Detailed commissioning procedure and connection of electrodes cabling
6.1. Preliminary remarks
 EUT unit must start at inlet of the entire disinfection system, meaning that EUT Unit has the shortest distance to
water inlet point
 This procedure has to be done after EUT Unit and EUT Power are installed and completely piped
 Cable length between EUT Unit and EUT Power must not exceed 60 m
 Specified cable type, described in the wiring diagram, has to be used
 Cables have to be laid in a good manner, observing existing rules and regulations
 Suitable copper or zinc based paste has to be laid at the cable shoes, copper plates and connection bolts / nuts for
good electrical connection and corrosion protection.
6.2. Connection of cables between EUT Unit and EUT Power
EUT Unit
 Cable shoes are to be screwed tight
 Single lines have to permanently marked at both sides
 Cable must be laid stress free and fixed at a suitable position
 Cover around EUT Unit is to be remounted
EUT Power:
 Cable to be laid from the EUT Unit to the EUT Power and connected according to the wiring diagram and marks
inside of the cabinet
 EUT Unit has to be connected with corresponding EUT Power (‘+’ to ‘+’ and ‘-‘ to ’-‘)
6.3. Pre commissioning procedure:
 Check, using a suitable device, cable by cable whether they are connected tightly at both ends and the correct
connections points are used
131
7. Premises for Commissioning
PREMISES FOR COMMISSIONING

ACTIVITIES SIGNATURE
GENERAL REQUIREMENTS
BALLAST PUMPS WORK NORMALLY
BALLAST WATER PIPELINE SYSTEM WORKS NORMALLY
INSTALLATION OF PNEUMATIC VALVES PIPELINE SYSTEM AND WORK NORMALLY
ELECTRICAL CONNECTION OF WHOLE SYSTEM COMPLETE
FILTER
INSTALLATION OF FILTER
WIRING OF FILTER COMPLETE(GEAR MOTOR, DIFFERENTIAL PRESSURE GAUGE)
INSTALLATION OF FILTER MAINTENANCE LUG
INSTALLATION OF FILTER DRAINAGE PIPELINE
EUT UNIT(WITH POWER UNIT)
INSTALLATION OF EUT UNIT
WIRING TO EUT UNIT COMPLETE
INSTALLATION OF EUT COOLING WATER PIPELINE
CONTROL UNIT
INSTALLATION OF CONTROL UNIT
WIRING TO CONTROL UNIT COMPLETE
INSTALLATION OF CONTROL UNIT BOX GROUND WIRE
MONITORING UNIT
INSTALLATION OF MONITORING UNIT
WIRING TO MONITORING UNIT COMPLETE
INSTALLATION OF MONITORING UNIT BOX GROUND WIRE
132
INSTALLATION OF MONITORING UNIT SAMPLING PIPELINE
INSTALLATION OF MONITORING UNIT AIR PIPELINE
INSTALLATION OF MONITORING UNIT DRAINAGE PIPELINE
POWER DISTRIBUTION UNIT
INSTALLATION OF POWER DISTRIBUTION UNIT
WIRING TO POWER DISTRIBUTION UNIT COMPLETE
INSTALLATION OF POWER DISTRIBUTION UNIT BOX GROUND WIRE
FILTER CONTROL BOX
INSTALLATION OF FILTER CONTROL BOX
WIRING TO FILTER CONTROL BOX COMPLETE
INSTALLATION OF FILTER CONTROL BOX GROUND WIRE
NEUTRALIZATION UNIT
INSTALLATION OF NEUTRALIZATION UNIT
WIRING TO NEUTRALIZATION UNIT COMPLETE
INSTALLATION OF NEUTRALIZATION UNIT BOX GROUND WIRE
OTHERS
WIRING TO FLOW METER AND GROUND WIRE COMPLETE
WIRING TO BACKFLUSHING PUMP COMPLETE
WIRING TO PNEUMATIC VALVES COMPLETE
REMARKS:
READY FOR COMMISSIONING
COMPANY DATE NAME SIGNATURE
133
8. BWMS - CHECKLIST
CHECKLIST BWMS
ORDER REFERENCE
DATE
NAME OF SHIP
BUILDING NUMBER AD0039~43
SHIPYARD AVIC DINGHENG SHIPBUILDING CO., LTD
CONTACT PERSON
PHONE CONTACT PERSON
E-MAIL CONTACT PERSON BWMS@HEADWAYTECH.COM
MANUFACTURER QINGDAO HEADWAY TECHNOLOGY CO.,LTD.
MODEL HMT-1000 Ex
SERIAL NUMBER
SERIALNUMBER OF CONTROL UNIT
SUPPLIER HEADWAY
CHECKLIST OF INSTALLATION
COMPLETE
COMPONENTS TOPIC ITEMS
YES NO
LOCATION
LABELING FROM HEADWAY OR SHIPYARD
GENERAL WIRING ACCORDING TO DRAWING AND CORRECT LABELING

FITER
ARRANGEMENT
PIPING IS CORRECTLY INSTALLED TO BWMS SCHEME
PRESS TEST BUTTON, CHECK THE NORMAL FUNCTION OF BACK-

FLUSHING OF FILTER. (MANUAL TEST)
LOCATION

EUT UNIT & GENERAL
POWER ARRANGEMENT
WIRING ACCORDING TO DRAWING AND CORRECT LABELING
LOCATION

MONITORING GENERAL
UNIT ARRANGEMENT
VALUES ARE SHOWN ON THE DISPLAY
LOCATION
GENERAL WIRING ACCORDING TO DRAWING AND CORRECT LABELING

CONTROL UNIT
ARRANGEMENT
VALUES SHOWN ON DISPLAY MATCH WITH DATA FROM EVERY

COMPONENT
134
LOCATION

REMOTE GENERAL
CONTROL UNIT ARRANGEMENT WIRING ACCORDING TO DRAWING AND CORRECT LABELING
VALUES SHOWN ON DISPLAY MATCH WITH DATA FROM EVERY

COMPONENT
LOCATION
POWER GENERAL
LABELING FROM SHIPYARD OR HEADWAY
DISTRIBUTION ARRANGEMENT
LOCATION

NEUTRALIZATI GENERAL
ON UNIT ARRANGEMENT
LOCATION

GENERAL
FLOW METER
ARRANGEMENT
LOCATION
BACK- LABELING FROM HEADWAY OR SHIPYARD

GENERAL
FLUSHING
ARRANGEMENT
PUMP WIRING ACCORDING TO DRAWING AND CORRECT LABELING
LOCATION

GENERAL
VALVES
ARRANGEMENT PIPING IS CORRECTLY INSTALLED TO BWMS SCHEME
DIFFERENT VALVES STATUS WILL MATCH TO THE DIFFERENT

COLOR DISPLAY OF CONTOL UNIT (OPEN: WHITE, CLOSE: BLACK,
ALARM: RED, ACTIVE: GREEN.)
REMARK:
CHECKED OF INSTALLATION
135
9. CHECKLIST OF ALARM
CHECKLIST OF ALARM
COMPLETE
YES NO
CHECK THE STATUS OF START, WHEN THE CONTROL UNIT IS SWITCHED

POWER ON ON
CHECK
CHECK THE DISPLAY STATUS FOR EACH FUNCTION BUTTON
MANUALLY SHUT DOWN ONE VALVE WHICH IS OPEN, AND CHECK

WHETHER THE DISPLAY STATUS OF THIS VALVE IS CORRECT OR NOT
CHECK IF THE BROKEN-DOWN VALVE IS DISPLAYED IN RED STATE UNDER

THE PIPE STATUS
CHECK IF THERE IS ALARM, WHEN THERE IS NO SIGNAL FROM

FLOWMETER
CHECK IF THERE IS ALARM, WHEN THERE IS NO SIGNAL FROM SALINITY

METER
WHEN PRESSURE DIFFERENCE GAUGE REACH THE SET VALUE (0.5 BAR),
ALARM BACK-FLUSHING WILL START. (BACKFLUSHING USES 10% OF PUMP
BUTTON CAPACITY)
PRESSURE DIFFERENCE IS TOO HIGH (>1.5 BAR), THERE WILL BE

“OVER-PRESSURE ALARM” FROM THE FILTER
CHECK IF THERE IS ALARM, WHEN THERE IS MALFUNCTION WITH THE

ULTRASOUND MODULE OF THE EUT POWER UNIT DURING BALLASTING
CONTROL CHECK IF THERE IS ALARM, WHEN THE LOW-LIQUID LEVEL OF THE

UNIT NEUTRALIZATION UNIT IS REACHED.
CHECK IF THERE IS A “COMMON ALARM” OUTPUT IN CASE OF ALARM
(NO = NO ALARM, NC = ALARM)
CHECK WHEN THERE IS ALARM, PRESS THE KEY “MUTE”, THE AUDIBLE
ALARM IS SILENCED, LEAVING THE VISUAL ALARM UNCHANGED
CHECK WHEN THE PROBLEM IS SOLVED, THE VISUAL ALARM IS GONE

ALARM
FUNCTION
CHECK WHEN THERE IS A NEW ALARM, THE LAST ALARM INFORMATION
IS SHOWN ON TOP OF THE ALARM INFORMATION, OTHER ALARMS ARE
LISTED IN THE ORDER OF HAPPENING TIME
CHECK THE ALARM LOGGING ON THE SD-CARD
WHEN THE CONTROL UNIT IS POWER ON, PRESS THE KEY “SETTING”, CODE
IS REQUIRED TO MAKE THE SETTINGS.
INPUT THE CODE, AND CHECK WETHER THE SETTING STATE CAN BE
ENTERED
SETTING
CHECK WETHER THE SYSTEM CAN BE UPDATED
FUNCTION
(ONLY FOR HEADWAY)
CHECK IF THE INITIAL CONCENTRATION OF TRO CAN BE SET (2.0 PPM)
CHECK IF THE INITIAL CURRENT OF EUT POWER CAN BE SET
ALARM ALARM
CHECK WHEN THERE IS ALARM IT IS SHOWN ON THE IAMCS
(IAMCS) FUNCTION
REMARK
136
10. CHECKLIST OF BALLASTING
CHECKLIST OF BALLASTING
POWER ON THE SYSTEM
CHECK THE SYSTEM, MAKE SURE THERE IS NO ALARM
PRESS THE KEY “BALLAST-ON” START THE BALLASTING PROCESS
BALLASTING PROCESS: DURING THE BALLASTING PROCES, WATER IS TREATED BY THE FILTER AND EUT UNIT
DURING THE PROCES THE FLOW WILL BE AROUND 800 M3/H
WHEN THE BALLASTINGPROCESS IS FINISHED, PRESS THE KEY “BALLAST-OFF”, THE

SYSTEM
WILL STOP BALLASTING
COMPLETE
YES NO
ON.
CHECK THE DISPLAY STATUS FOR EACH FUNCTION BUTTON.

POWER ON
CHECK CHECK THE ALARM STATUS. IF THERE IS NO ALARM, ITS OK.
PRESS THE KEY “BALLAST ON” , THE SYSTEM STARTS THE BALLASTING
PROCESS
VALVE 01: BYPASS VALVE WB/087 OPEN CLOSE X
VALVE 02: FILTER INLET VLAVE HAV1 OPEN X CLOSE
VALVE 03:SYSTEM OUT LET VALVE HAV2 OPEN X CLOSE
VALVE 04: BACKFLUSH VALVE FV1 OPEN CLOSE X
VALVE VALVE 05: FILTER OUTLET VALVE FV2 OPEN X CLOSE

POSITION
IN VALVE 06: HBV 4 - TRO METER IN OPEN X CLOSE
BALLAST-ON
MODE VALVE 07: HBV 5 - TRO METER OUT OPEN X CLOSE
CHECK
VALVE 08: HBV 3 - SAMPLE PORT OPEN CLOSE X
VALVE 09: HBV 6 - TRO METER IN OPEN CLOSE X

CONTOL UNIT
VALVE 10: HBV 9- SAMPLE PORT OPEN CLOSE X
VALVE 11: HBV 8 - NU OUT OPEN X CLOSE
VALVE 12: HBV 7- NU FW IN OPEN X CLOSE
CHECK THE DISPLAY OF THE SALINITY METER
CHECK THE DISPLAY OF THE FLOW METER
SENSOR CHECK THE DISPLAY OF UTC TIME AND DATE (ZDA SIGNAL)
FUNCTION
CHECK CHECK THE DISPLAY OF GPS POSITION (GLL SIGNAL)
CHECK THE DISPLAY OF THE TRO METER
CHECK THE DISPLAY OF THE CURRENT AND VOLTAGE

CHECK IF EACH VALVE IS FUNCTIONING NORMALLY, AND THE DISPLAY
STATIS IS CORRECT
PIPE
FUNCTION PRESS THE “BALLAST-OFF” BUTTON, THEN CHECK WHETHER EACH
CHECK VALVE IS FUNCTIONING NORMALLY, AND THE DISPLAY STATUS IS
CORRECT OR NOT
ALARM CHECK IF THE POWER SUPPLY IS AUTOMATICALLY ADJUSTED WHEN

CHECK THE TRO LEVEL IS ABOVE 2.2MG/L DURING BALLASTING.
137
CHECK IF THE POWER SUPPLY IS AUTOMATICALLY ADJUSTED WHEN

THE TRO LEVEL IS BELOW 1.8MG/L DURING BALLASTING.
CHECK IF THERE IS ALARM, WHEN THERE IS NO OUTPUT FROM THE EUT

POWER DURING BALLASTING
CHECK IF THE POWER SUPPLY IS AUTOMATICALLY SHUT DOWN WHEN

THE FLOW IS LOW ( <50 M3/H ) (DELAY 120 SEC)
EMERGENCY MODE CAN BE SELECTED WHEN THERE IS A ALARM,

NORMAL BALLASTING MODE CAN ONLY BE STARTED AFTER TROUBLE
SHOOTING
CHECK IF THE OPERATION LOG IS CORRECT

FOR CORRECT LOGGING A GPS SIGNAL IS NEEDED
LOG GLL FOR POSITION, ZDA FOR DATA AND TIME (UTC TIME)
FUNCTION
CHECK CHECK IF THE ALARM LOG IS CORRECT
GLL FOR POSITION, ZDA FOR DATA AND TIME (UTC TIME)
BALLAST PUMP DATA FLOW M3/H SUCTION BAR PRESSURE BAR
REMARK
CHECKED OF BALLASTING MODE
138
11. CHECKLIST OF DE-BALLASTING
CHECKLIST OF DE-BALLASTING
POWER ON THE SYSTEM
PRESS THE KEY “DE-BALLAST-ON” START THE DE-BALLASTING PROCESS
DE-BALLASTING PROCESS: DURING THE DE-BALLASTING PROCESS, WATER GOES THROUGH THE DE-BALLAST LINE
DURING THE DE-BALLASTING PROCESS, IF THE TRO IS ABOVE 0.2MG/L, THE

NEUTRALIZATION UNIT IS STARTED AUTOMATICALLY
WHEN THE DE-BALLASTINGPROCESS IS FINISHED, PRESS THE KEY “DE-BALLAST-OFF”,
THE SYSTEM WILL STOP DE-BALLASTING
COMPLETE
YES NO
ON.
CHECK THE DISPLAY STATUS FOR EACH FUNCTION BUTTON.
POWER ON
CHECK
CHECK THE ALARM STATUS. IF THERE IS NO ALARM, ITS OK.
PRESS THE KEY “DE-BALLAST ON” , THE SYSTEM STARTS THE DE-
BALLASTING PROCESS
VALVE 01: BYPASS VALVE WB/087 OPEN CLOSE X
VALVE 02: FILTER INLET VLAVE HAV1 OPEN CLOSE X
VALVE03:SYSTEM OUT LET VALVE HAV2 OPEN CLOSE X
VALVE 04: BACKFLUSH VALVE FV1 OPEN CLOSE X
VALVE VALVE 05: FILTER OUTLET VALVE FV2 OPEN CLOSE X

POSITION
IN VALVE 06: HBV 4 - TRO METER IN OPEN CLOSE X
DE-BALLAST-
ON MODE VALVE 07: HBV 5 - TRO METER OUT OPEN X CLOSE
CHECK
VALVE 08: HBV 3 - SAMPLE PORT OPEN CLOSE X
CONTOL UNIT VALVE 09: HBV 6 - TRO METER IN OPEN X CLOSE
CHECK THE DISPLAY OF THE SALINITY METER
CHECK THE DISPLAY OF THE FLOW METER

SENSOR
FUNCTION CHECK THE DISPLAY OF UTC TIME AND DATE (ZDA SIGNAL)
CHECK
CHECK THE DISPLAY OF GPS POSITION (ZDA SIGNAL)
CHECK THE DISPLAY OF THE TRO METER

STATIS IS CORRECT
PIPE CHECK IF THE NEUTRALIZATION UNIT WILL START AUTOMATICALLY,
FUNCTION WHEN PUSH ‘DE-BALLASTING BUTTON’.
CHECK
CHECK IF THE NEUTRALIZATION UNIT WILL STOP AUTOMATICALLY,
WHEN THE TRO LEVEL IS BELOW 0.2MG/L
139
PRESS THE “DE-BALLAST-OFF” BUTTON, THEN CHECK WHETHER EACH

VALVE IS FUNCTIONING NORMALLY, AND THE DISPLAY STATUS IS
CORRECT OR NOT
EMERGENCY MODE CAN BE SELECTED WHEN THERE IS A ALARM,

NORMAL DE-BALLASTING MODE CAN ONLY BE STARTED AFTER TROUBLE
SHOOTING

FUNCTION
CHECK CHECK IF THE ALARM LOG IS CORRECT
REMARK
CHECKED OF DE-BALLASTING MODE
140
12. CHECKLIST OF BYPASS MODE
CHECKLIST OF
BYPASS MODE
POWER ON THE SYSTEM
PRESS THE KEY “BYPASS ON” , START THE BYPASS BALLASTING OR BYPASS DE-
BALLASTING PROCESS
EMERGENCY MODE PROCESS: DURING THE BYPASS BALLASTING OR BYPASS DE-BALLASTING MODE, THE WATER GOES
THROUGH THE BYPASS PIPES
WHEN THE BALLASTING OR DE-BALLASTINGPROCESS IS FINISHED, PRESS THE KEY

“BALLAST-OFF” OR “DE-BALLAST-OFF”, THE SYSTEM WILL STOP THE PROCES
COMPLETE
YES NO
ON.
POWER ON CHECK THE DISPLAY STATUS FOR EACH FUNCTION BUTTON.
CHECK
PRESS THE KEY “BYPASS ON” THE SYSTEM WILL START THE PROCES AND
WILL LOG A ALARM BECAUSE THE SYSTEM IS BYPASSED
VALVE 01: BYPASS VALVE WB/087 OPEN X CLOSE
VALVE 02: FILTER INLET VLAVE HAV1 OPEN CLOSE X
VALVE VALVE03:SYSTEM OUT LET VALVE HAV2 OPEN CLOSE X

POSITION VALVE 04: BACKFLUSH VALVE FV1 OPEN CLOSE X
IN VALVE 05: FILTER OUTLET VALVE FV2 OPEN CLOSE X
BYPASS-
BALLAST VALVE 06: HBV 4 - TRO METER IN OPEN CLOSE X
MODE VALVE 07: HBV 5 - TRO METER OUT OPEN CLOSE X
CHECK VALVE 08: HBV 3 - SAMPLE PORT OPEN CLOSE X
CONTOL UNIT VALVE 09: HBV 6 - TRO METER IN OPEN CLOSE X
SENSOR CHECK THE DISPLAY OF UTC TIME AND DATE (GLL SIGNAL)
FUNCTION
CHECK CHECK THE DISPLAY OF GPS POSITION (ZDA SIGNAL)
PIPE
FUNCTION
STATIS IS CORRECT
CHECK
ALARM
CHECK IF THERE IS ALARM, WHEN THE EMERGENCY MODE, IS STARTED
CHECK
FUNCTION
CHECK IF THE ALARM LOG IS CORRECT
CHECK
REMARK
CHECKED OF BYPASS MODE
141
13. BWMS-SHORT OPERATION MANUAL
BWMS-SHORT OPERATION
MANUAL
ORDER REFERENCE
DATE
NAME OF SHIP
BUILDING NUMBER AD0039~43
SHIPYARD AVIC DINGHENG SHIPBUILDING CO., LTD
CONTACT PERSON
PHONE CONTACT PERSON
E-MAIL CONTACT PERSON BWMS@HEADWAYTECH.COM
MANUFACTURER QINGDAO HEADWAY TECHNOLOGY CO.,LTD.
MODEL HMT-1000 Ex
SERIAL NUMBER
SERIALNUMBER OF CONTROL
UNIT
SUPPLIER HEADWAY
USING THE BWMS SHORT DESCRIPTION

IMPORTANT READ THE MANUAL THIS WILL EXPLAIN A LOT ABOUT THE SYSTEM
1 POWER ON THE SYSTEM 1 TURN ON THE POWER FROM THE POWER DISTRIBUTION
2 PUSH START ON THE CONTOL UNIT
3 PUSH START ON THE FILTERBOX
STARTING THE SYSTEM 2 CHOOSE ONE OF THE OPTIONS ( BALLAST ON, DEBALLAST (BY GRAVITY) ON,
EMERGENCY ON)
3 IF THE SYSTEM IS EMPTY SLOWLY OPEN THE VALVE TO FILL THE SYSTEM (FIRST
STARTUP)
POWER ON THE SYSTEM
PRESS THE KEY “BALLAST-ON” START THE BALLASTING PROCESS
DURING THE BALLASTING PROCES, WATER IS TREATED BY THE FILTER AND EUT
BALLASTING PROCESS: UNIT
DURING THE PROCES THE FLOW WILL BE AROUND 800M3/H
WHEN THE BALLASTINGPROCESS IS FINISHED, PRESS THE KEY “BALLAST-OFF”, THE
SYSTEM
WILL STOP BALLASTING
POWER ON THE SYSTEM
PRESS THE KEY “DE-BALLAST-ON” START THE DE-BALLASTING PROCESS
DURING THE DE-BALLASTING PROCESS, WATER GOES THROUGH THE DE-BALLAST
DE-BALLASTING PROCESS: LINE
DURING THE DE-BALLASTING PROCESS, THE NEUTRALIZATION UNIT IS STARTED
AUTOMATICALLY; IF THE TRO IS BELOW 0.2MG/L, THE NEUTRALIZATION UNIT IS
STOP AUTOMATICALLY
WHEN THE DE-BALLASTINGPROCESS IS FINISHED, PRESS THE KEY “DE-BALLAST-
OFF”, THE SYSTEM WILL STOP DE-BALLASTING
POWER ON THE SYSTEM
PRESS THE KEY “BYPASS ON” , START THE BYPASS BALLASTING OR BYPASS DE-
BALLASTING PROCESS
BYPASS MODE PROCESS: DURING THE BYPASS BALLASTING OR BYPASS DE-BALLASTING MODE, THE WATER
GOES THROUGH THE BYPASS PIPES
WHEN THE BALLASTING OR DE-BALLASTINGPROCESS IS FINISHED, PRESS THE KEY
“BALLAST-OFF” OR “DE-BALLAST-OFF”, THE SYSTEM WILL STOP THE PROCESS
FILLING THE NEUTRALISATION OPEN THE COVER, PUT IN 4 KG OF SODIUM THIOSULFATE PENTAHYDRATE, CLOSE
UNIT IF THERE IS A LEVEL THE COVER !, THE NEUTRALISATION UNIT WILL AD WATER AND MIX FOR 10
ALARM MINUTES AUTOMATICLY.
MONITOR UNIT MAINTENANCE EVERY 12 MONTHS, SEE MANUAL
SHUTTING DOWN THE SYSTEM
DRAIN THE WATER FROM THE FILTER, THE BACKFLUSHPUMP AND THE EUT.
FOR A LONGER PERIOD
142
Part 7 EX-Certificates
143
EX CERTIFICATE LIST
Ocean GuardR Ballast Water Management Sytem
CERTIFICATE
No. EQUIPMENT Model EX-PROOF GRADE Attachment name
NO.
1 EUT Unit HMT-1000E ExdⅡCT4 /DNV DNV 13 ATEX 3858X DNV_13_ATEX_3858X_1-2077ZJ3_CC_EUT UNIT
ExdⅡCT6
2 2804-2013-CE-RGC-DNV DNV ATEX FILTER ACK_EC
/DNV
3 Filter Pressure differ gauge HMT-1000F Ex ia IICT5 Gb CNEx13.1175X CNEX_FILTER DP
ExdⅡCT4
4 Three-phase motors PTB 99 ATEX 114 HEW_ATEX_Three-phase motors
/PTB
ExdⅡCT4
5 Flow Meter HMT-400FM GYJ15.1014X ABB_Electromagnetic Flowmeter_NEPSI
/NEPSI
Ex diapx IICT6
6 CE14.5019 HMT-TRO-EX-CE145019-GB
/PCEC
TRO Monitoring
7 Flow Switch HMT-TRO Ex ia IICT6 Ga CNEX,CNEx13.1106X CNEX_TRO_Flow switch
Unit
8 Pressure transmitter Exia IICT4 Ga PCEC CE13.2166X PCEC_TRO_Pressure transmitter
ExmbⅡT6
9 Solenoid valve GYJ13.1005X NEPSI_Valve solenoid
/NEPSI
FV2,HAV1,HAV2,
HAV3
ExdⅡCT6
10 Valve Limited switch GYJ14.1067X NEPSI_Limited switch
/NEPSI
ExmbⅡBT5
11 Positioner FV1 DEKRA11ATEX0017X ATEX_Valve Positioner
/ATEX
12 IS Barrier NPEXA-C511 Ex ia ga IIC CNEx14.3275 Cer. IS barrier 1（NPEXA-C511）
TRO Control Box
13 IS Barrier NPEXA-CM311 Ex ia ga IIC CNEx14.3274 Cer. IS barrier 2（NPEXA-CM311）
back flushing
14 Three-phase motors M2JA180 Exd IICT5 LCIE 04 ATEX 6101X/02 04ATEX6101-02
pump
144
[2] EQUIPMENT OR PROTECTIVE SYSTEM INTENDED FOR USE IN POTENTIALLY EXPLOSIVE ATMOSPHERES DIRECTIVE
94/9/EC
[3] EC-Type Examination Certificate Number: DNV 13 ATEX 3858X
[4] Equipment or Protective System: EUT unit
[5] Applicant – Manufacturer or Authorized representative: Qingdao Headway Technology Co.,Ltd
[6] Address: F4,#5 Building ,A Area, Huite Industrial City,#177

Zhuzhou Road,Laoshan District ,Qingdao ,China
[7] This equipment or protective system and any acceptable variation thereto is specified in the schedule to this certificate
and the documents therein referred to.
[8] DNV, notified body number 0575 in accordance with Article 9 of Council Directive 94/9/EC of 23 March 1994,
certifies that this equipment or protective system has been found to comply with the Essential Health and Safety
requirements relating to the design and construction of equipment and protective systems intended for use in
potentially explosive atmospheres given in Annex II to the Directive.
The examination and test results are recorded in confidential reports listed in section 14.
[9] Compliance with the Essential Health and Safety Requirements has been assured by compliance with:
EN 60079-0: 2009, EN 60079-1:2007 and EN60079-7:2007
[10] If the sign “X” is placed after the certificate number, it indicates that the equipment or protective system is subject to
special conditions for safe use specified in the schedule to this certificate.
[11] This EC-TYPE EXAMINATION CERTIFICATE relates only to the design and construction of the specified
equipment or protected system. If applicable, further requirements of this Directive apply to the manufacturer and
supply of this equipment or protective system.
[12] The marking of the equipment or protective system shall include the following:
II 2 G Ex d e IIC T6 Gb
Høvik, 2015-08-05
for Det Norske Veritas AS
Asle Kaastad
PROD 021
Certification Manager
145
[13] Schedule
[14] EC-TYPE EXAMINATION CERTIFICATE No.: DNV 13 ATEX 3858X
Certificate History
Revision Description Report no. Issue date
- Original certificate 2015-605867 2015-08-05
[15] Description of Equipment or Protective System

EUT Unit is designed for OceanGuardTM Ballast Water Management System as the sterilization and algae removal
device. The EUT unit is comprised of a electro catalysis unit, a ultrasonic unit , a vibrating level switch and a shell
body.
The electro catalysis unit is comprised of terminal box, copper strip and internal pillar electrode. The terminal box is
protection by increased safety “e”. The ultrasonic unit is protection by flameproof enclosures “d”. The vibrating level
switch sitrans type LVL200 obtained ATEX certificate separately (KEMA 09ATEX0014X). The entry holes are
installed with appropricate cable glands which have obtained ATEX certificates.
Type Identification
HMT - □ E □
EX:Explosion proof sign ,while non-explosion proof product ,identify vacancies

E:EUT Sign
Rate Flow : identified as nominal capacity Of EUT unit
HMT: Company Code
Electrical Data
Peak Voltage of supplier : 40V DC
Maximum Current: 100A,300A,350A,500A,750A,1000A,1350A,1700A,2000A,2500A,3400A,4200A,5000A,6000A
Ambient Temperature
-25oC to +60 oC
Degrees of protection (IP Code)

IP 56
146
Techinical Data
Series Model Maximum Maximum Peak

number explosion-proof flow Current Voltage
series (m3 / h ) (A) (V)
1 HMT-50E-Ex 50 100 40
2 HMT-100E-Ex 100 300 40
3 HMT-200E-Ex 200 350 40
4 HMT-300E-Ex 300 500 40
5 HMT-450E-Ex 450 750 40
6 HMT-600E-Ex 600 1000 40
7 HMT-800E-Ex 800 1350 40
8 HMT-1000E-Ex 1000 1700 40
9 HMT-1200E-Ex 1200 2000 40
10 HMT-1500E-Ex 1500 2500 40
11 HMT-2000E-Ex 2000 3400 40
12 HMT-2500E-Ex 2500 4200 40
13 HMT-3000E-Ex 3000 5000 40
14 HMT-4000E-Ex 4000 6000 40
[16] Project No.: PRJC-390757-2012-PRC-CHN
Descriptive Documents
Number Title Rev. Date
HMT-E-EX-ZZ001-00 Assmbly drawing of EUT for BWMS 2012-07-01
HMT-E-Ex-KT001-00 Shell body 2012-07-01
HMT-E-Ex-TB001-00 Terminal box lid 2012-07-01
HMT-E-Ex-TB002-00 Terminal box 2012-07-01
HMT-E-Ex-US001-00 Ultrasonic unit 2012-07-01
HMT-E-Ex-US001-01 Lid 2012-07-01
HMT-E-Ex-US001-02 Protective casing 2012-07-01
HMT-E-Ex-US001-03 Assembly of amplitude transformer 2012-07-01
HMT-E-Ex-06 Cooper strip 2012-07-01
HMT-E-Ex-07 Internal pillar electrode 2012-07-01
HMT-E-Ex-08 Compression plate 2012-07-01
HMT-E-Ex-09 Electrode sleeve 2012-07-01
HMT-E-Ex-10 Cone sleeve 2012-07-01
HMT-E-Ex EC002-00 Electro-catalisys unit lid 2012-07-01
HMT-E-Ex-11 Terminal plate 2012-07-01
HMT-E-Ex-12 Gasket 2012-07-01
HMT-E-Ex-13 Nameplate 2012-07-01
HMT-E-Ex-14 Warning board 2012-07-01
HMT-E-EX-JX001-00 Connection drawing of EUT for BWMS 2012-07-01
HMT/RD/BWMS2015001 Ultrasonic Unit Power / /
147
Routine test
- The enclosure for ultrasonic unit shall be subjected to a routine overpressure test according to clause 16 of EN 60079-
1, with a test pressure of minimum 0,5 MPa.
- Dielectric strength test should be carried out according to clause 7.1 of EN 60079-7
[17] Special Conditions for Safe Use

1. Repairs of the flameproof joints must be made in compliance with the structural specifications provided by
the manufacturer. Repairs must not be made on the basis of values specified in table 2 of EN 60079-1.
2. The assembly should be equipped with suitably certified cable glands with a compatible type of protection
for the intended use.
3. Confirm EUT Unit is filled with water prior to running the system. The temperature of water can not be
more than 60°C.
4. When liquid level switch detects the internal water level up to the position of liquid level switch,
meanwhile, the flow meter of BWMS detects that there is a certain flow rate of more than 30~50m3/h of
water flows through EUT Unit. Only when satisfying the above two conditions, control system will supply
power to EUT Unit.
[18] Essential Health and Safety Requirements

See part 9 of this certificate
END OF CERTIFICATE
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HMT-1000 中航鼎衡 f

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HMT-1000 中航鼎衡 f

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System

Version Date Title Project

Ocean Guard®--Ballast Water Management System

Drawing for Final

Version Date Title Project

OceanGuard ® Ballast Water Management System

BWMS Model: HMT-1000 (Ex)

Hull Number： AD0039~AD0043 AD0039 S/N: 1500567

Ship Yard: AVIC DINGHENG SHIPBUILDING CO., LTD

Manufacturer： Headway Technology Co., Ltd.

2014.09.16 - ISSUED FOR APPROVAL A

2015.02.02 - ISSUED FOR WORKING 0

2016.05.18 - ISSUED FOR FINAL F

1.1 Description of OceanGuard® Ballast Water Management System

1.2 List of Abbreviation

Part 2 Scope of Supply

Part 3 P&I Diagram for BWMS

Part 4 Equipment Specification & Detailed Drawings

Part 5 List Of Spare Parts

Part 6 Commissioning Procedure

1. 1Description of OceanGuard® Ballast Water Management System

No. Symbol Description

Item Specification and Instructions

3≤PSU＜20 17.5 kw 39.7 kw

2.1 Scope of Supply

2.1.1 Scope of Headway

Item Component List Specification Qty (Unit) Note

1 EUT Unit HMT- 1000E 1 Exd IIB T4

8 Back flushing pump - 2 Ex

Remote Control Panel (Flush type)

10 Flow Meter HMT- 300FM 2 Exd IIB T4

11 Monitoring Unit HMT-MU 1 Exd IIB T4

Cable between EUT and PE should be supplied by Headway (16× 78 M)

Back-Flushing Pump 680 427 1272 339 1

2.2 Scope of Shipbuilder

3.1 P&I Diagram for BWMS

3.2 System Electrical diagram

3.3 Terminals Diagram for each Equipment

BALLAST WATER MANAGEMENT SYSTEM

4.1 BWTS System

Please refer to the drawing below

4.2.2 Function and Principle

4.2.3 Technical Data Sheet

Model HMT- 1000E-Ex

Item Cable Details Quantity Note

4.2.5 Other Information:

※ For More Other Information, Pls Contact The Maker.

(B) (A) (C) (D) (E) ⑨ ⑩

(J) ① ② (I) ③ (H) ④ (G) ⑤ (F) ⑥

4.3.3 Technical Data Sheet

4.3.4 Cable List

7). Please refer to attached drawings:

※ For More Other Information, Pls Contact The Maker.

4.4.1 Principle of Filter

Fig. 4.4.1.1 Filter

4.4.2 Technical Data Sheet

Item Cable Details Quantity Note

4.4.4 Other Information:

※ For More Other Information, Pls Contact the Maker.

4.5.1 Function and Principle

4.5.2 Technical Data Sheet

Ballast Pump Running Signal 2×2×0.75 1 FM Ballast Pump 1 Starter

5).Please refer to attached drawings:

气动蝶阀对夹式(双电控) 阀体球墨铸铁，阀板青铜

气动蝶阀对夹式(双电控) 阀体球墨铸铁，阀板青铜

气动角度阀对夹式阀体球墨铸铁，阀板青铜

手动蝶阀对夹式阀体球墨铸铁，阀板青铜

气动蝶阀对夹式 (双电控) 阀体球墨铸铁，阀板青铜