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BWTS Installation Guide for M/V Katun

The document provides an installation guide for a ballast water treatment system (BWTS) onboard the vessel M/V Katun. It includes an introduction with vessel details, an overview of BWTS components, and sections covering the mechanical, piping, electrical, and commissioning aspects of installing a PureBallast 3.2 135 Compact BWTS in the vessel's engine room. Tables list relevant design documents and BWTS components. Diagrams and drawings are referenced but not included.

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0% found this document useful (0 votes)
376 views56 pages

BWTS Installation Guide for M/V Katun

The document provides an installation guide for a ballast water treatment system (BWTS) onboard the vessel M/V Katun. It includes an introduction with vessel details, an overview of BWTS components, and sections covering the mechanical, piping, electrical, and commissioning aspects of installing a PureBallast 3.2 135 Compact BWTS in the vessel's engine room. Tables list relevant design documents and BWTS components. Diagrams and drawings are referenced but not included.

Uploaded by

Ali Mohamed
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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management@grandeng.

pro

grandengineering

GELIOS Marine

Ballast Water Treatment System


Installation guide
m/v «KATUN»
( IMO 9701126 )

GRAND ENGINEERING GROUP LTD


ISTAMBUL, TURKEY 2020
BWTS INSTALLATION GUIDE m/v «Katun»

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 
 

   

GRAND ENGINEERING GROUP LTD 2 of 32 management@grandeng.pro


BWTS INSTALLATION GUIDE m/v «Katun»

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

1.2 VESSEL’S GENERAL PARTICULARS


 
Ship name Katun

Ship type

IMO number 9701126


Flag Russian Federation
Gross tonnage 2721
Net tonnage 1010
Ship dimensions
Length overall, m 72m
Breadth, m 17,2 m

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2. COMPONENT OVERVIEW

The table below is a list of PureBallast components and consumables.

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

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ISCS. The switch box function as connection point


for signal and control cables to the component.
Ancillary system equipment
Flow meter, including FIT201-1 The flow meter have two functions.
conductivity sensor QIT201–1 • Measure the flow.
• Measure conductivity. This information is used
together with
temperature to calculate salinity in the water.
The flow meter consists of three parts:
• Flow sensor monitor the flow in the system.
Functions together
with the flow transmitter.
• Flow transmitter send flow information to the
control system. It
is mounted on the flow sensor.
• The conductivity sensor measure conductivity in
the water.
Pressure monitoring device PT201-16 Monitor pressure and send it to the control
system.Manifold includes pressure transmitter
(PT201-16), pressuregauge (PI201–18), relief
valve (RV201) and needle valve V201–15.
Sampling device Q201-1 Sampling points to tap water for test of water
Q201-2 before and aftertreatment.
Air filter regulator If the requirements for instrument air are met, it
would be sufficient
to use the supplied air filter regulator, to treat
instrument air.
 

   

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BWTS INSTALLATION GUIDE m/v «Katun»

3. MECHANICAL INSTALLATION
This section contains information relevant for planning the installation of mechanical
components and connections to water and instrument air.

3.1 GENERAL REQUIREMENTS


 
The overall layout is defined by the Flow chart drawing and details for components are
stated on the dimension drawings.

Installation prerequisites:

Installation area Machinery


space on the
vessel, for
example
engine room
or pump room
Ambient air temperature: 0 – 50 °C

Relative humidity: ≤ 100 %


 

3.1.2 WELDING REQUIREMENTS


 
Earth connection must be done according to the below. If not, the equipment can be
seriously damaged:

• Earth connection must be made before any welding is done.

• Electrical welding: Connect the welding unit’s negative lead (work lead) to

the component you will weld close to the welding area.

• Follow local regulations for electrical installation and earthing (grounding).

• Installation must be done by a fully trained professional installer.

3.2 GENERAL ARRANGEMENT

General arrangement of PureBallast components are provided in Figures 1

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Figure 1 General arrangement of PureBallast components

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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

of the component can be bolted or welded in place on a steady foundation.

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

components inside the cabinet.

• To prolong the lifetime of the cabinet, we recommend to install it in the

coolest possible area in the range of 0 to 50º C.

The Cabinet installation drawings are provided in Figures 2 or drw ТР.941.102.001

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Figure 2 Electrical cabinet Installation drawing

   

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3.4 MODULE 135


 

The Module 135 installation drawings are provided in Figures 3,4 or drw ТР.941.102.001

Figure 3 Module 135 installation drawing

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BWTS INSTALLATION GUIDE m/v «Katun»

Figure 4 Module 135 installation drawing

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4. PIPE DESIGN
 
This section contains information relevant for P&ID. 

4.1 BALLAST SYSTEM


Ballast systems are designed to receive water ballast in the tanks, pump it and remove
it from the vessel in order to change the draught and stability of the vessel (ballast system),
align or create an artificial roll (roll system) and differential (differential system) in case of
loading and unloading operations, swimming in ice and in emergency situations, as well as in
connection with the consumption of fuel and water reserves. The Pure-Ballast 3.2 135
Compact ballast water treatment plant in the area of (-2)-(-1) fr is connected to the existing
pipeline by means of additional pipes. The installed pipelines are used to connect the BWTS
equipment to each other and connect the BWTS to the ship's ballast system.

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".

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Figure 5 Ballast system refitting

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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

Figure 6 FW system refitting


   

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BWTS INSTALLATION GUIDE m/v «Katun»

4.3 COMPRESSED AIR SYSTEM


The compressed air system is designed to operate PureBallast 3.2 135 Compact. It is
connected to the existing piping and fittings for connection to the setting.

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
   

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BWTS INSTALLATION GUIDE m/v «Katun»

5. ELECTRICAL DESING
 
This section contains information relevant for planning the electrical

installation and routing.

5.1 ELECTRIC LOAD ANALISIS


Since the new BWTS equipment was installed, an addition was made to the calculation of
the Electric load analysis. The calculation showed the sufficiency of the existing ship power
plant to power the newly installed BWTS equipment.

The calculation is presented in drw. ТР.941.600.001

5.2 BALLAST WATER TREATMENT STAITION


The system is supplied complete with a power/control and alarm cabinet (EC).

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.

The connection diagram provided in Figure 8 or drw. ТР.941.620.001

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Figure 8 Electrical Wiring Diagram.

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6. INSTALLATION OF PURE BALLAST 3.2 135 COMPACT


 
The selected installation area together with the installed system, is presented in the
following chapter. The selection of the installation area was performed after thorough
investigation regarding the spacea vailability inside the steering gear room.

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:

Figure 16 Steering gear floor with BWTS installation

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6.1 INSTALLATION IN STEERING GEAR


6.1.1 GENERAL OVERVIEW
The PureBallast 3.2 135 Compact ballast water treatment plant in the area of (-2)-(-1) fr The
aforementioned space was selected after a 3D laser scan survey performed by GRAND
ENGINEERING GROUP LTD.

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

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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.) 

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BWTS INSTALLATION GUIDE m/v «Katun»

Figure 20 Existing arrangement of ballast pipelines, (-2)-0 fr.

Figure 21 Arrangement of ballast pipelines after the installation of the new ballast pumps
pipeline

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BWTS INSTALLATION GUIDE m/v «Katun»

Figure 22 View on drain pipeline (under Alva Laval module 135)

 
Figure 23 Existing arrangement. View from STB to the CL, (-2)-(-1) fr.
   

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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.

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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.

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BWTS INSTALLATION GUIDE m/v «Katun»

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.

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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

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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. 

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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. 

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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 36 Pipelines routing without 3D scan

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BWTS INSTALLATION GUIDE m/v «Katun»

 
Figure 37 Pipelines routing without 3D scan

Figure 38 Pipelines routing without 3D scan

Bill of materials for piping


№  Description  Art №  Qty  Unit 
Pipes 
1  Pipe 21,3x2 EN 10220    7  m 
2  Pipe 21,3x2,3 EN 10216‐1    0,2  m 
3  Pipe 26,9x2,3 EN 10216‐1    15,7  m 
4  Pipe 60,3x3,2 EN 10216‐1    0,35  m 
5  Pipe 76,1x5 EN 10216‐1    0,3  m 
6  Pipe 88,9x4,5 EN 10216‐1    2,8  m 
7  Pipe 168,3x5 EN 10216‐1    4,4  m 

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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 

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7. APPENDIX
 

 PIPE CARDS ALBUM

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TP.941.400.001
BDV 46*
DRILL/BALLAST DECK
FILL/DISCH. AFT PORT SIDE BDP49.DN100
CLASS III

BDP51.DN150
CLASS III
Main deck

BDP52.DN150
CLASS III
BDV 48*

to ballast tank to ballast tank


BDP5.DN150 BDP31.DN150
CLASS III CLASS III
from ballast tank from ballast tank
BDP6.DN150 BDP32.DN150
CLASS III CLASS III
BDV 41*
BDP43.DN150
10 CLASS III

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

FOR WATER SPRAY TP.941.400.001


Lit. Weight Scale
DRILL/BALLAST DECK Rev Page № Drawing Sing. Date BWTS systems.
FILL/DISCH. AFT STBD BDP57.DN100 from ZJ-DY2001-581-601_0 Design. Bordakov 19.12.20 1:1
CLASS III see p.2
Summary drawing
Page 1 Pages 4
G E Grand Engineering Group LTD
BDV 49* Verif. Klymenkov 19.12.20 т \v "Katun" web: grandengineering.com.ua
G R A N D e-mail: management@grandeng.pro
Approved Mishenko 19.12.20 ENGINEERING
Copy Format A3x4
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24.02.21
24.02.21

24.02.21
24.02.21
24.02.21

24.02.21

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