maintaining the balance ballast water treatment systems brochure

7/31/2019 Maintaining the Balance Ballast Water Treatment Systems Brochure

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Maintaining the balanceBallast water treatment systems

PureBallast 2.0 and PureBallast 2.0 EX


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Maintaining the balanceBallast water treatment systems

PureBallast 2.0 and PureBallast 2.0 EX


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Essential protectionMarine ecosystems are important, not only to

the environment, but also to our own health and

livelihood. This is why protecting the balance of

species through ballast water treatment is a key

aspect of Alfa Lavals Pure Thinking.

Our approach to ballast water treatment is

determined not only by the legislation

surrounding it, but also by the important

demands of shipyards, ship owners and shipoperators. Now in its second generation, our

PureBallast system incorporates the full

spectrum of installation and operational needs,

as well as lessons learned in years of full-scale,

real-life operation at sea.

This means that PureBallast maintains not only

the balance of species, but also the balance

between onboard and global considerations.

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ContentsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

EX version . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 34

Shipyards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

CD . . . . . . . . . . . . . . . . . . inside back cover

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OnboardperformanceThe global regulations that govern ballast water treatment are

designed to stop a devastating wave of marine biologicalinvasions. However, they affect far more than the organisms in

ballast water.

They also affect you.

While the problem of invasive species is universal, the means

of solving it has to be carried on individual vessels. You as a

shipyard, ship owner or ship operator face tough demands

when it comes to ensuring compliance, but you also have your

own demands on size, economy, ease of use and

compatibility with onboard operations.

To meet these demands, you need a mature treatment system

that handles the rigors of business at sea. Specically, you

need one that is as well adapted to life on board as it is to the

requirements of international law, and one that has proven its

merits under real-life operating conditions.

Fortunately, PureBallast is just such a system.

I N T R O D U C T I O N6


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WorldwideexperienceBy choosing PureBallast from Alfa Laval, you choose both the

right solution for your onboard needs and a proven solutionwith global backing. In addition, you choose the worlds most

experienced supplier in ballast water treatment.

Having worked with ballast water treatment for years, we

understand not only the theoretical issues, but also the

practical realities. PureBallast 2.0, Alfa Lavals second

generation of the PureBallast system, builds on thousands of

hours spent working with actual installations on site at

shipyards, as well as in full operation at sea.

Backing up that experience is Alfa Lavals network of harbour

support, which can be found in ports all over the globe. Our

far-reaching resources give you access to parts, service and

advice worldwide, in ballast water treatment and beyond.

Wherever you sail, Alfa Laval is there to bring you true

peace of mind.

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Sailing on aheadPureBallast is a clear and comfortable choice, having quickly

established itself as the commercial leader in ballast watertreatment since its launch in 2006. The system has been

chosen for more vessels than any other ballast water

treatment system, as well as for the greatest range of vessel

types. These include everything from container vessels and

tankers to offshore supply ships and naval vessels.

Moreover, PureBallast has been installed at major shipyards

all over the world.

Behind the success of PureBallast is its unique combination

of advantages. In addition to type-approved ballast water

treatment, PureBallast offers:

Easy installation in a compact space

Automated, reliable and chemical-free operation

Full integration with existing ballast water systems

Low maintenance requirements and lifecycle cost

O V E R V I E W 8


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O V E R V I E W 9


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The next generation of leadershipThe latest version of the PureBallast system, PureBallast 2.0,

incorporates a range of advances that further simplify

installation and operation. These full the needs and wishesexpressed by shipyards, ship owners and ship operators

during the course of our extensive cooperation.

PureBallast 2.0 highlightsAmong the many developments in PureBallast 2.0, the

following are especially noteworthy:

40% lower power consumption

A simplied electrical system

The ability to pause operation

The ability to stop individual AOT units

Automatic ow control

An easy-to-use graphical interface

Bus communication for

remote control

O V E R V I EW

PureBallast 2.0 offers a large

number of improvementsthat simplify both installation

and operation.

Now only a single cabinet is

needed for each AOT unit.

All control and distribution functions are

now integrated in a single cabinet.

The ow meter and control valve are

integrated for automatic ow control.

A smaller and more

effective lter is used.

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PureBallast 2.0 EXhighlightsAs part of the PureBallast 2.0 upgrade,

there is also an Ex version of the system,

PureBallast 2.0 EX, for installation in

potentially explosive environments.

Features include:

Zone 1, IIC and T4 compatibility

Reinforced AOT units

AOT temperature and uid-level

protection

Ventilated and pressure-controlled

lamp drive cabinets

Control cabinet placement outside

the Ex zone

More on PureBallast 2.0 EX can be

found on pages 30-33.

O V E R V I E W

PureBallast 2.0 EX features

reinforced AOT units.

Temperature sensors, level

sensors and a non-return valve

prevent ignition conditions from

arising within the units.

The most signicant change in PureBallast

2.0 is the reduction of the systems power

consumption by a full 40% compared to its

predecessor.

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An end to costly invasioPureBallast is an optimized answer to one of todays most

critical environmental issues: the introduction of marinespecies into foreign environments via ballast water.

While ballast water is cheap and simple to pump aboard, it

carries with it eggs, larvae and even adult organisms that are

small enough to pass through the intakes and pumps. If these

organisms survive to reach the deballasting site, they are

sometimes capable of devastating local ecosystems. The

resulting invasions cause billions of dollars in damage and may

endanger human health, which has led IMO to identify them

as one of the four greatest threats to our oceans today.

The International Convention for the Control and Management

of Ships Ballast Water and Sediments, adopted in February

2004, is designed to stop such invasions by setting

requirements for ballast water treatment.

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Regulating ballast waterThe International Convention for the Control and Management

of Ships Ballast Water and Sediments is in fact one of many

pieces of legislation designed to address the ballast waterproblem. In the United States, for example, where billions of

dollars have been spent to clear the Great Lakes and other

waterways of invasive zebra mussels, legislation is being

developed at the federal level. In addition, individual states are

considering stricter regulations of their own.

At the time of printing, these and other national regulations are

still taking shape. Thus, while Alfa Laval intends to meet all

possible treatment requirements and stays well abreast of

legislative developments, it is the IMO convention that has

formed the basis for PureBallast and other ballast water

treatment solutions.

Entering into forceThe IMO convention will become international law as soon as

it is ratied by thirty states representing a combined 35 % ofthe worlds gross tonnage in merchant shipping. As an

increasing number of treatment systems appear and a

growing number of shipping nations choose to sign, the

ratication process is gaining speed.

When the requirements take effect, the treatment systems

employed will have to be not only effective, but also safe and

practicable for both ships and their crews. The complexity of

this balance is reected in the complex process of type

approval.

R E G U L A T I O N S14 R E G U L A T I O N S


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The path to IMO approvalTo receive Ballast Water Type Approval, a treatment system

must reduce the number of organisms to within IMO limits.

Organisms larger than 50 m must be reduced by more than99.99%, which is a decrease from at least 100 000 organisms

to less than 10 organisms per cubic metre. Even bacteria

must be treated effectively.

The approval process involves biological performance tests on

land, which are conducted with water of varying composition

and a minimum ballast water capacity of 200 m3/h, as well as

six months of full-scale testing at sea. In addition, there is a

two-step procedure known as Active Substance Approval,

which certies that the solution is safe and non-toxic.

Treatment or exchange?Once ratied, the IMO convention will introduce ballast water

treatment requirements in phases (see right). Though not all

vessels will have to perform ballast water treatment directly, all

vessels without a type-approved treatment system will berequired to perform ballast water exchange. This involves

ushing out the ballast tanks at sea, which may reduce the

chances of organisms surviving within them.

The effectiveness of ballast water exchange is in dispute, as

it may actually supply organisms with fresh oxygen and

nutrients. Moreover, the procedure is a time-consuming

process that can compromise stability and put a vessel at risk

in heavy weather. As such, many ship owners and operators

will want to avoid it by installing a treatment system before

they are required to do so.

IMO limits for type approval are given in individuals per

cubic metre or colony-forming units per 100 ml.

Organism type IMO requirement

Organisms > 50 m 10 ind/m3

Organisms 50 m 10 ind/m3

E-coli bacteria 250 cfu/100 ml

Implementation of requirements

Newbuilds (constructed 2010 or later)

Treatment required from 2010 for BWC >5000 m3

Treatment required aboard all vessels from 2012

Existing vessels (constructed prior to 2010)

Treatment required from 2014 for BWC 1500-5000 m3

Treatment required aboard all vessels from 2016

When the convention has entered into force, all vessels

without a ballast water treatment system must perform

ballast water exchange in open waters.

Vessels constructed in 2009 with BWC


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The true green solutionCompact and exible, PureBallast was among the rst ballast

water treatment systems to receive Ballast Water TypeApproval. Having operated at full scale under real-life

conditions since 2003, it is also without a doubt the most

extensively tested.

PureBallast provides ballast water treatment that is 100%

chemical-free, in contrast to chemical-free systems that

actually produce chemicals during the treatment process.

Despite its high biological efciency, PureBallast requires no

chemical additives and generates no chemicals in operation,

which means its self-contained process is harmless to the

ballast water tanks and crew.

The avoidance of chemicals also makes PureBallast easy and

affordable to operate. With no additives to stock on board or

arrange for in port, the system is a sound investment not

only in environmental terms, but also in terms of operating

economy.

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T E C H N O L O G Y 17


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18 T E C H N O L O G Y


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Uniquely effectiveThe PureBallast treatment process is based on a patented

form of advanced oxidation technology (AOT), developed in

cooperation with Wallenius Water. Related technologies canbe found in many of todays smart products, such as the

self-cleaning windows of skyscrapers and cars, which

prevent the growth of organisms through an AOT reaction

that occurs when sunlight strikes titanium dioxide.

Within the PureBallast system, treatment occurs in a closed

chamber known as a Wallenius AOT unit, in which radicals

are generated. These radicals are potent yet exist for only a

few milliseconds, which means they neutralize

microorganisms but are incapable of leaving the treatment

system.

Radical advantagesIn addition to being safe for the ballast water tanks and the

vessels crew, the use of radicals has advantages over other

prominent treatment technologies. For example, the spreadof radicals is not affected by the presence of particles, which

means treatment is still effective when the water has high

sediment content.

Even more importantly, the radicals actually break down

cellular membranes, which effectively destroys the

microorganisms rather than rendering them unable to

reproduce. As a result, the potential for them to do damage

at the deballasting site is completely eliminated.

PureBallast neutralizes the living threat in ballast water with

the help of radicals, which disrupt the cell membranes of

microorganisms. After passing through the PureBallast

system, the dinoagellate above has lost its chlorophyll.

Before After

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Keeping it compact

PureBallast is a perfect match for the cramped

engine room. Built to t where every bit of space

is worth saving, it is as compact as it is effective.

PureBallast is constructed from a series of block

components, which gives the overall system

exceptional exibility. Each component is

optimized for a minimum footprint, and with

planning, components can actually be installedbetween existing pipes.

Depending on the needs of the vessel, a single

PureBallast system can handle ow rates of

250-3000 m3/h. If more capacity is required,

even higher ow rates can be achieved by

installing multiple systems in parallel.

I N S T A L L A T I O N

Wallenius AOT unit (2)

Control system (5)

Flow meter(4)

Filter(1)

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I N S T A L L A T I O N

1. Filter

A 40 m mesh lter is used during ballasting operations. This

not only blocks the intake of larger organisms, but also

reduces the amount of sediment in the ballast water tanks.

This lter is bypassed during deballasting and is cleaned via

automatic backushing.

2. Wallenius AOT unit(s)

One or more Wallenius AOT units comprise the active stage of

PureBallast treatment, in which radicals are generated toneutralize microorganisms and other organic matter. The

number of AOT units is determined by the systems ow rate,

with individual units handling a ow of 250 m3/h. The AOT units

can be placed in a number of congurations, including the

linear conguration shown here.

3. CIP unit

The performance of the AOT units is safeguarded by an

automatic Cleaning-in-Place (CIP) system, which circulates a

biodegradable solution to prevent seawater scaling within the

AOT units. This solution is reusable and is replaced only once

per year or when its pH level has become too high. The

cleaning cycle, which takes 15 minutes per unit, is automatic

and occurs after each ballasting or deballasting operation.

4. Flow meter

A ow meter coupled with a control valve automatically

ensures that the system does not exceed its certied ow rate.

This meter also provides the main control system with valuabledata regarding the amount of ballast that has been taken in or

discharged.

5. Control system

PureBallast can be operated either automatically or manually,

as well as by optional remote control. The intuitive control

panel provides a graphical overview of every aspect of the

control system, including monitoring and log functions.CIP unit (3)

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Because PureBallast is exibly constructed to suit the engine

room, no single illustration can provide a complete overview.

The sample layout here, in which the AOT units are arranged in

a linear fashion, is designed for a ow rate of 1000 m3/h.


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22 I N S T A L L A T I O N


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Designed to capacityThe vertical reaction chambers in which treatment occurs,

known as Wallenius AOT units, make up the bulk of a

PureBallast system. Each of these units handles a ow rate of

250 m3/h, and with the introduction of PureBallast 2.0, they

consume 40% less power than their predecessors.

Up to twelve AOT units can be connected within a single

system. If ow rates greater than 3000 m3/h are required, two

or even three PureBallast systems can be installed, each with

its own lter, Cleaning-in-Place (CIP) unit and control system.

The AOT units are installed such that the ow and pressure ofthe water is equally distributed between them. Although the

units are often arranged in a linear fashion, they can also be

arranged in blocks or other congurations to suit the engine

room layout.

Integrated benetsWith its exible design and ability to t between existing pipes,

PureBallast adapts easily to existing engine room conditions.

PureBallast 2.0 is even simpler to install than the previous

generation of the system, thanks to a high level of integration

that eliminates a remote interface cabinet, a control cabinet

and one breaker cabinet per AOT unit.

In addition, PureBallast is as integrated with ballast operations

as it is with the space on board. PureBallast utilizes the ballast

pumps that are already installed and requires no extra holdingtime in the ballast water tanks, so there are no additional

procedures and no delays when ballasting or deballasting.

This makes PureBallast as suitable for retrots as it is for

newbuilds.

PureBallasts modular components allow for truly exible

installation. With planning, components can even be

installed between existing pipes.

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Making operation easyThough ballast water treatment is a complicated process,

there is no reason why it should complicate life on board.

PureBallast makes it easy to meet global treatment standards,

since it provides IMO-compliant results while requiring little

from the crew.

Functioning unnoticed in the background, PureBallast is fully

automated and integrated with the vessels other ballast water

equipment. This means there are no extra procedures and no

sources of interference, and it ensures that no delays are

experienced during ballasting and deballasting.

As illustrated on the following pages, ballast operations with

PureBallast occur almost exactly as they do today.

O P E R A T I O N


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O P E R A T I O N 25O P E R A T I O N


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Deballasting operationsThe deballasting process is essentially the same as the

ballasting process. However, the lter is bypassed during

deballasting since the water has already been ltered.

After leaving the ballast water tanks, the outgoing ballast

water passes through the Wallenius AOT units to eliminate

any regrowth of microorganisms that may have occurred in

transit. Having thus been treated to the limits set by IMO, it

is then discharged into the receiving water at the

deballasting site.

The same startup and shutdown sequence is employed

during both ballasting and deballasting (see left).

O P E R A T I O N


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28 O P E R A T I O N


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Simplicity at a glancePureBallast can be operated either automatically or manually.

The main control panel, which takes the form of a durable,

full-colour graphical touchscreen in PureBallast 2.0, provides

access to every aspect of the system, including its monitoring

and log functions. Even PureBallast manuals are directly

viewable from the control panel.

In addition, PureBallast can be steered by optional remote

control. Each PureBallast system can be complemented with

a maximum of four remote control panels, which allow it to be

started, stopped and monitored from any location on board.

Modbus communication can also be used to integrate

PureBallast with other automation systems, providing access

to all PureBallast functions through the vessels standard

interface.

Operational advancesIn addition to the visual and intuitive control panel, PureBallast

2.0 offers a number of operational improvements over its

predecessor. These include a connection between the ow

meter and control vent for fully automatic ow control.

The startup and shutdown sequences, which are faster in

PureBallast 2.0, are bypassed in a new pause function, which

allows operation to be suspended for short intervals. This can

be done during heeling, for example, to facilitate the

redistribution of ballast water without having to restart the

ballast water treatment system.

Finally, users now have the option of shutting down individual

AOT units while the system is still running. This allows

changes in ow rate as well as the exchange of AOT lamps

without interrupting treatment.

PureBallast is fully automated and offers ample possibilities

for remote control. Modbus communication ensures easy

integration with the vessels general automation systems.

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Always on guardVessels like crude tankers and product tankers, which carry

volatile cargo and thus have potentially explosive areas on

board, are not exempted from ballast water treatment

requirements. However, until now there has been a lack of

treatment systems adapted to their needs.

Today, as a part of PureBallast 2.0, Alfa Laval can supply an

Ex version of the PureBallast system. Designed for Zone 1,

group IIC and temperature class T4, PureBallast 2.0 EX is

suitable for installation aboard most types of tankers that carry

ignition-sensitive cargo.

Since PureBallast 2.0 EX is a specialized version of our

second-generation system, it naturally also features most of

the improvements found elsewhere in PureBallast 2.0,

including reduced power consumption and the ability to pause

operation.

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E X V E R S I O N 31


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E X V E R S I O N32

Thoroughly preparedThe creation of PureBallast 2.0 EX has been a comprehensive

undertaking. Because of the extreme hazards that exist when

working with oil and chemicals, it has been necessary to take

every possible safety concern into account.

For this reason, Alfa Laval has looked beyond mere

regulations. Working closely with shipyards and shipping

companies that deal with volatile cargo, we have designed

PureBallast 2.0 EX to incorporate their suggestions and

insights.

PureBallast 2.0 EX requirementsIn general, PureBallast 2.0 EX has the same installation

characteristics as the standard version of the PureBallast

system. The only major difference is the placement of the

control cabinet outside the Ex zone. All non-specialized

equipment, such as the electric motor that drives the lter, is

standard and Ex-certied.

The only additional requirement with PureBallast 2.0 EX is theavailability of compressed oil-free air, also referred to as

instrument air. At startup, instrument air is used to ventilate

the drive cabinet for the AOT lamps, which contains

electronics and warm surfaces that cannot come into contact

with explosive gas.

During operation, an atmosphere of instrument air is

maintained in the lamp drive cabinet through an overpressureof two millibar. This keeps volatile gases from leaking in, while

a lock on the cabinet door prevents accidental opening

directly after shutdown.


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Protection of AOT unitsThe most difcult aspect of creating an explosion-proof ballast

water treatment system is eliminating the risk where treatment

actually occurs. In the case of PureBallast, this means

protecting the Wallenius AOT units inside and out.

At all times, the AOT units must be completely lled with liquid.

This removes the possibility of ignition, even if a leak from the

product tanks should contaminate the ballast water ow and

enter the treatment system. To ensure the presence of liquid,

the AOT units of PureBallast 2.0 EX are tted with a non-return

valve, which ensures that nothing can drain from the bottom

of the unit.

The AOT lamps themselves, which reach operating

temperatures of up to 900C, are surrounded by tough

quartz-glass shielding. As well as physically protecting the

lamps, this shielding acts as a heat barrier, never getting hotter

than the ballast water itself.

An extra level sensor and a temperature sensor, independent

from the rest of the control system, provide additional

insurance of safety margins.

Finally, the external housing of the AOT units is reinforced,

allowing it to withstand substantial forces. With this protection,

an AOT unit can absorb the explosion that would occur if

gases entered the area between the quartz-glass shielding

and an AOT lamp itself.

E X V E R S I O N

Internal and external modications of the

Wallenius AOT units eliminate explosion risk.

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Full speed aheadBecause PureBallast is chemical-free and has no moving

parts, it involves few consumables and poses no service

hazards for the crew. In fact, there is little maintenance to be

performed at all.

The crews obligations are limited to a just a few maintenance

checkpoints:

Inspection of the lter cartridge once per year

Inspection of the sacricial anode once per year

CIP uid replacement once per year, or when the pH value

reaches 3.0

Cleaning of the ow meters electrodes once per year

Replacement of AOT lamps when broken (life expectancy

1500 hours)

M A I N T E N A N C E


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35M A I N T E N A N C E

Economical easePureBallasts limited maintenance can be handled without

special tools and poses no difculty for a mechanical engineer

using the manual as a guide. This means the system can be

serviced even by inexperienced crewmembers.

For convenience and economy, the necessary maintenance

items have been organized into kits, which contain all the

instructions and tips for the relevant maintenance checkpoints.

In fact, the maintenance costs for PureBallast amount to just a

few dozen euro per thousand cubic metres of processed

ballast water.


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D i i


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37 S H I P Y A R D S

Drawing on experiencePureBallast has always been appreciated as a well-

documented system with comprehensive manuals.

PureBallast 2.0 further gears that documentation toward the

specic needs of shipyards.

With the new documentations simplied drawings and more

installation-oriented descriptions, it is easier not only to plan a

PureBallast installation, but also to place it on board within the

set timeframe for vessel construction.

On hand and on taskOf course, no amount of documentation can replace expert

advice and on-site cooperation. Alfa Laval has a strong

presence in all shipbuilding countries, complete with

technically competent personnel and engineers who speak the

local language. Having already helped to install PureBallast on

a wide range of vessel types, we meet with shipyards every

day to discuss new possibilities.

After installation is complete, we also offer a broad rangeof commissioning and technical services to aid in

starting up the system. Moreover, we can support the

buyer with valuable advice about PureBallast

operation and maintenance as well as onboard

training for the crew if desired.


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A world of supportPureBallast builds on a 100% chemical-free technology, which

means there are no chemical additives to be kept in stock.

Likewise, the system has no moving parts to wear or break,

so there is little maintenance that has to be performed.

In other words, PureBallast offers long-term self-sufciency.

Nonetheless, PureBallast comes with the backing of a truly

global supplier. Alfa Laval has a full equipment portfolio and

century of experience meeting the needs of maritime industry

as well as a worldwide network of harbour support.

Wherever your ship sails with PureBallast, you will nd access

to our dedicated team of peace-of-mind specialists. As a

result, technical assistance, onboard service and genuine

spare parts are never out of reach.

38 S U P P O R T


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39S U P P O R T


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Greater depthLift the ap for a CD with multimedia content and

additional information about PureBallast 2.0 and

PureBallast 2.0 EX.


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The attached CD containsthe following items:Invaders from the sea (excerpt)This short film, taken from the BBC Worldwide/IMO production Invaders from the

sea, presents some of the shocking consequences of the transport of organisms

via ballast water.

Turning the tide: PureBallastThis film explores the key benefits of PureBallast and shows the PureBallast

installation aboard the Wallenius car carrier Aniara.

Overview animationThis brief animation serves as an introduction to the basic principles of

PureBallast operation.

Technical data lea et

These leaets provide more specific technical details about the PureBallast 2.0and PureBallast 2.0 EX systems, including detailed capacity and maintenance

information.


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maintaining the balance ballast water treatment systems brochure

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