BWTS Installation Guide for M/V Katun
BWTS Installation Guide for M/V Katun
pro
grandengineering
GELIOS Marine
TABLE OF CONTENTS
1.INTRODUCTION .......................................................................................................................................... 3
1.1 SCOPE ...................................................................................................................................................... 3
1.2 VESSEL’S GENERAL PARTICULARS ............................................................................................ 3
3. MECHANICAL INSTALLATION ............................................................................................................. 6
3.1 GENERAL REQUIREMENTS ............................................................................................................. 6
3.1.2 WELDING REQUIREMENTS ........................................................................................................ 6
3.2 GENERAL ARRANGEMENT ............................................................................................................... 6
3.4 Module 135 ......................................................................................................................................... 10
4.1 BALLAST SYSTEM ............................................................................................................................. 12
4.2 FW SYSTEM ......................................................................................................................................... 14
4.3 COMPRESSED AIR SYSTEM .......................................................................................................... 15
5. ELECTRICAL DESING ............................................................................................................................. 16
5.1 ELECTRIC LOAD ANALISIS .......................................................................................................... 16
5.2 BALLAST WATER TREATMENT STAITION .............................................................................. 16
6. INSTALLATION OF PURE BALLAST 3.2 135 COMPACT .......................................................... 18
6.1 INSTALLATION IN ENGINE ROOM ........................................................................................... 19
6.1.1 GENERAL OVERVIEW .................................................................................................................. 19
7. APPENDIX .................................................................................................................................................. 32
1.INTRODUCTION
1.1 SCOPE
The aim of this technical report is to provide in a short form, all the technical details
regarding the retrofitting installation of “PureBallast 3.2 135 Compact”, on board of vessel
M/V “Katun”.
The present installation description is supported by the equivalent engineering study
performed by GRAND ENGINEERING GROUP LTD .
The aforementioned study was based on the technical data provided by the BWTS
maker, ALFA LAVAL
To determine the actual as-built situation a 3D laser scanner is used. Further engineering is
based on this scan.
This document is a short guide to installation the BWTS, for a more detailed description see
:
Name of document Name
ТР.941.001.001 List of design documents
ТР.941.001.002 Specification
ТР.941.001.004 List of materials, equipment and devices of the vessel, which are
objects of technical supervision of the Register
TP.941.002.001.PP Calculation of the light ship change weight
ТР.941.900.002.D2.BWMP Ballast water management plan D2
ТР.941.102.001 Installation of ballast water treatment system equipment.
Installation drawing.
ТР.941.102.001.S Installation of ballast water treatment system equipment.
Specification
ТР.941.400.005 Ballast system refitting. Diagram
ТР.941.400.006 Inlet/outlet system for technical fresh water. Diagram.
ТР.941.400.007 Compressed air system. Diagram
ТР.941.600.001 Electric load analysis
ТР.941.620.001 BWTS. Electrical Wiring Diagram
ТР.941.620.002 BWTS. Cables. Specification
Ship type
2. COMPONENT OVERVIEW
This unit is assembled into a single module for a more compact installation. The components
shown in the table are already assembled in the Module 135, except Air filter regulator,
Sampling device
Component ID Function
Main system components
UV reactor UVR .n The main water treatment component in the
(where “n” system, including reactor,
indicate valves, UV sensor, temperature sensor,
unique temperature
UV number). switch, level switch.
Electrical cabinet EC Contains the main control panel, from which
PureBallast is controlled.It also contains breaker
and communication components such as PLC,
switches for communication with remote interface,
remote control panels etc, and terminals to
connect signal cables to components and external
systems.
Filter Filter Mechanical filtration of the water before
treatment.
CIP liquid can CIP Cleaning-in-place module for automatic cleaning
of the UVR aftertreatment, mainly clean the UV
lamps quartz sleeves.The CIP module is also used
to drain and fill the UV reactor during
CIP process and to fill the filter with technical
water / potable water after, for preservation
reasons.
Valves
Control valve V201-8 Main outlet valve from the PureBallast system to
the vessel’s ballast system after treatment.
Automatic pressure regulation to maintain needed
pressure during back flush. Automatic flow
regulation during operation to secure that max
flow is not exceeded. The positioner function as
connection point for signal and power
cables to the component.
Filter inlet valve including V201-3 Main inlet valve to the PureBallast system during
switch box ballast, in combination with V201-32. The valve
directs the water flow through the PureBallast
filter. (Closed during deballast)The switch box
function as connection point for signal and power
cables to the component.
Filter outlet valve including V201-32 The valve directs the water flow from the
switch box, PureBallast filter to the UVR. (Closed during
deballast)The switch box function as connection
point for signal and power cables to the
component.
Filter bypass valve, including V201-9 Filter bypass valve open during deballast, when
switch box the filter is not used. (Closed during ballast)
The switch box function as connection point for
signal and power cables to the component.
Filter backflush valve V309–1 The valve directs the water used for filter
backflush back to the sea.
Bypass valve, including V212-31 Bypass valve to bypass the complete PureBallast
switch box system. The valve is solely operated from the
3. MECHANICAL INSTALLATION
This section contains information relevant for planning the installation of mechanical
components and connections to water and instrument air.
Installation prerequisites:
• Electrical welding: Connect the welding unit’s negative lead (work lead) to
Figure 1 General arrangement of PureBallast components
3.3 CABINET
This section covers installation guidelines for cabinets, regarding mechanical installation. For
electrical installation, see section Electrical design.
• Cabinet must be installed so that there is free space available to open the door.
• The cabinet must be placed on a firm level surface and fixated. The legs
The cabinet shall also be attached to the bulkhead using the attachments
on the cabinet backside. The cabinets are fixed to the ships structure via
vibration dampers to minimize the effect of vibrations from the hull affecting
The Module 135 installation drawings are provided in Figures 3,4 or drw ТР.941.102.001
4. PIPE DESIGN
This section contains information relevant for P&ID.
Connection of the installation and additional pipelines to the existing ship's ballast pipeline is
shown drawing TP.941.400.005 "Ballast system re-fitting".
Figure 5 Ballast system refitting
4.2 FW SYSTEM
Inlet/outlet system for technical fresh water is designed for flushing UV reactor. The
existing piping is connected to the piping for filling the CIP unit tank.
Connection of the installation and additional pipelines to the existing ship's fresh water
pipeline are provided in Figure 6 or drw TR.941.400.006
Connection of the installation and additional pipelines to the existing ship's compressed
air pipeline are provided in Figure 7 or drw TR.941.400.007
Figure 7 Compressed air system refitting
5. ELECTRICAL DESING
This section contains information relevant for planning the electrical
The EC cabinet is used to connect BWTS equipment in Skid unit: UV reactor, pump, sensors,
etc. Also, from EC connecting to GPS system, and to alarm system.
The EC are connected to the power supply network from the main switch-board by using
spare circuit breaker.
Figure 8 Electrical Wiring Diagram.
The installed system will treat the capacity of one ballast pumps with a capacity of 150 m3/h.
The following figures present the main BWTS piping arrangement and main components,
inside the steering gear room:
The following images provide a general overview of the complete BWTS installation design
with the mainballast piping inside the steering gear room.
Figure 17 Piping of ballast water treatment system
Figure 18 Existing ballast pumps pipelines (0-2 fr.). View from FWD to AFT.
Figure 19 Existing ballast pumps pipelines after the installation of the new ballast pumps
pipeline (0-2 fr.)
Figure 21 Arrangement of ballast pipelines after the installation of the new ballast pumps
pipeline
Figure 23 Existing arrangement. View from STB to the CL, (-2)-(-1) fr.
Figure 24 Arrangement after the installation of the new outlet pipeline. View from STB to
the CL, (-2)-0 fr.
Figure 25 Existing pipelines arrangement. View from STB to AFT, (-2)-0 fr.
Figure 26 Pipelines arrangement after the installation of the new outlet and back flush
pipelines. View from STB to AFT, (-2)-0 fr.
Figure 27 Existing ballast pipelines arrangement under the Alfa Laval module 135
installation area. Top view.
Figure 28 New pipelines arrangement under the Alfa Laval module 135 installation area. Top
view.
Figure 29 Existing arrangement in the Alfa Laval module 135 installation area. View from
FWD to AFT.
Figure 30 Arrangement after installation the Alfa Laval module 135. View from FWD to AFT.
Figure 31 Existing arrangement in the Alfa Laval module 135 installation area PS. View from
CL to PS
Figure 32 Arrangement after the installation of the new fresh water pipeline. View from CL
to PS
Figure 33 Existing arrangement in the PS FW tank area. View from CL to PS, 3-10 fr.
Figure 34 Arrangement after the installation of the new fresh water pipeline. View from CL
to PS, 3-12 fr.
Figure 35 Existing pipe arrangement in the PS FW tank area. View from bottom to top, 12 fr.
Figure 35 Pipe arrangement in the PS FW tank area after the installation of the new fresh
water pipeline. View from bottom to top, 12 fr.
Figure 37 Pipelines routing without 3D scan
Flanges
8 Flange 15 PN 10 EN 1092‐1 4 pcs
9 Flange 20 PN10 EN 1092‐1 16 pcs
10 Flange 65 PN10 EN 1092‐1 2 pcs
11 Flange 80 PN 16 EN 1092‐1 7 pcs
12 Flange 150 PN 16 EN 1092‐1 24 pcs
13 Flange blind 150 PN 16 EN 1092‐1 1 pcs
Valves
14 Ball valve ¾" M80524 Meson 1 pcs
15 Ball valve 2" 20‐00000147 Meson 1 pcs
Fittings
16 Flexible hose L=1100 DN20 BSP 3/4"‐BSP 3/4" 1 pcs
17 Bend DIN 2605‐1‐45‐2,3‐26.9 4 pcs
18 Bend DIN 2605‐1‐45‐2‐168.3 1 pcs
19 Bend DIN 2605‐1‐45‐4,5‐168.3 3 pcs
20 Bend DIN 2605‐1‐45‐4,5‐88.9 1 pcs
21 Bend DIN 2605‐1‐90‐2,3‐26.9 5 pcs
22 Bend DIN 2605‐1‐90‐2.9‐60.3 2 pcs
23 Bend DIN 2605‐1‐90‐4,5‐168.3 6 pcs
24 Bend DIN 2605‐1‐90‐4,5‐88.9 5 pcs
25 Reducer DIN 2616‐1‐C‐26.9‐21.3 (DN20‐DN15) 1 pcs
26 Straight screw union BSP‐BSP (unilateral soft seal) 2 pcs
27 Tee DIN 2615‐1‐168.3 2 pcs
28 Tee DIN 2615‐1‐21.3 1 pcs
29 Union EN 10242‐U12‐20‐A 1 pcs
30 Union EN 10242‐U12‐50‐A 3 pcs
31 Gasket, Flat, 15 ND, 16, DIN 2690 2 pcs
32 Gasket, Flat, 150 ND, 16, DIN 2690 17 pcs
33 Gasket, Flat, 20 ND, 16, DIN 2690 8 pcs
34 Gasket, Flat, 65 ND, 16, DIN 2690 2 pcs
35 Gasket, Flat, 80 ND, 16, DIN 2690 4 pcs
36 Bolt M12x50 5.8‐Zn DIN931 8 pcs
37 Bolt M12x55 5.8‐Zn DIN931 32 pcs
38 Bolt M16x75 5.8‐Zn DIN931 8 pcs
39 Bolt M16x80 5.8‐Zn DIN931 32 pcs
40 Bolt M24x100 5.8‐Zn DIN931 80 pcs
41 Nut M10‐Zn DIN934 40 pcs
42 Nut M12‐Zn DIN934 54 pcs
43 Nut M16‐Zn DIN934 52 pcs
44 Nut M24‐Zn DIN934 80 pcs
45 Washer 12‐Zn DIN125 80 pcs
46 Washer 16‐Zn DIN125 80 pcs
47 Washer 24‐Zn DIN125 160 pcs
48 U bolt A 30‐Zn DIN3570‐Pipe DN20 20 pcs
49 U bolt A 64‐Zn DIN3570‐Pipe DN50 1 pcs
50 U bolt A 94‐Zn DIN3570‐Pipe DN80 6 pcs
51 U bolt A 176‐Zn DIN3570‐Pipe DN150 6 pcs
52 L40x40x5 DIN1028 8,4 m
53 L70x70x5 DIN1028 3 m
54 Plate S5 EN10025 60x60 27 pcs
55 Plate S5 EN10025 90x90 6 pcs
7. APPENDIX
BDP51.DN150
CLASS III
Main deck
BDP52.DN150
CLASS III
BDV 48*
BDP44.DN150
9
CLASS III
BDP36.DN150
BDV 43*
to overbord
CLASS III
BDP45.DN150
CLASS III 13
8 14х1,8
BDV 42* 1
BDV 44* 12 1
2
9
7 11 from ZJ-DY2001-730-501_0 BDV 34*
see p.2
BDV 40*
6 1 3*
2
BDV3 9* BDV3 6* BDV35 * From AFT seachest
4
14
BDP54.DN150
BDP42.DN150 BDP39.DN150 BDP37.DN150
CLASS III
5 CLASS III CLASS III CLASS III
3 4 3
15 12 BDV3 8* FM CARGO FW PUMP
INLET
to bidge
BDV45 * 11 6 5
to overbord 2 6,9 х2, 3 * FM CARGO FW PUMP
8
BDP46.DN80 OUTLET
CLASS III BDP41.DN150
TO FI-FI SYSTEM
Main deck 2 CLASS III
FOR WATER SPRAY
BDP55.DN150
TO FI-FI SYSTEM
CLASS III
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