Norwegian Greentech
Ballast Water Management System
NGT BWMS user documentation Part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100 m 3 /h
Document id
OSMM
NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
Revision Log
Rev Reason for change
C
B
A
Revised for USCG
Added information on chapter 7.3 filling operation
First issue
ii
Prepared
by
KB
TG
HR
Approved
by
HG
TG
HG
Date
27.04.2021
27.01.2021
07.12.2020
NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
Contents
1
Introduction .................................................................................................................................... 1
1.1
Product documentation for the NGT BWMS .......................................................................... 1
1.2
About ballast water conventions ............................................................................................ 1
1.2.1
Background and status.................................................................................................... 1
1.2.2
Our commitment as solution provider ........................................................................... 1
1.2.3
Your obligations as a ship operator ................................................................................ 2
1.3
2
3
About the NGT BWMS ............................................................................................................ 2
1.3.1
Working logic .................................................................................................................. 2
1.3.2
Customer support guidance for operation and maintenance ........................................ 3
1.3.3
Contact information: ....................................................................................................... 3
Safety precautions .......................................................................................................................... 4
2.1
Identification of hazards and areas of special attention ........................................................ 4
2.2
Personal protective equipment .............................................................................................. 4
2.3
Requirements to operator skill and training ........................................................................... 4
2.4
Handling of broken UV lamps ................................................................................................. 5
2.5
Limitations on location and use of the BWMS........................................................................ 5
System description .......................................................................................................................... 6
3.1
Delivery condition ................................................................................................................... 6
3.2
NGT BWMS range ................................................................................................................... 8
3.3
Scope of supply ..................................................................................................................... 11
3.3.1
4
Surface finish ................................................................................................................. 11
System architecture ...................................................................................................................... 12
4.1
Process system architecture ................................................................................................. 12
4.2
Control system architecture ................................................................................................. 14
4.2.1
Vessel IAS ...................................................................................................................... 14
4.2.2
BWMS controller ........................................................................................................... 15
4.2.3
I/O node ........................................................................................................................ 15
4.2.4
UV controller ................................................................................................................. 15
4.3
Safety features ...................................................................................................................... 16
4.3.1
Design features for safety ............................................................................................. 16
4.3.2
In case of release of untreated ballast water ............................................................... 16
4.3.3
Manual bypass and shutdown of the BWMS ................................................................ 17
4.4
Performance and sensitivity to changes in environmental conditions................................. 18
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NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
4.4.1
Water quality ................................................................................................................ 18
4.4.2
Treatment settings and performance ........................................................................... 18
4.4.3
Power consumption ...................................................................................................... 18
4.5
5
Effects on vessel’s existing ballast water system .................................................................. 19
BWMS control system ................................................................................................................... 20
5.1
Graphical user interface ........................................................................................................ 20
5.1.1
Control page (home screen) ......................................................................................... 20
5.1.2
Detailed control page.................................................................................................... 23
5.1.3
Trends page ................................................................................................................... 24
5.1.4
Logs page....................................................................................................................... 25
5.1.5
Settings page ................................................................................................................. 27
5.1.6
Alarms page .................................................................................................................. 29
5.2
Recommended REMOTE user interface ................................................................................ 31
5.2.1
5.3
6
System Security ..................................................................................................................... 34
5.3.1
Tamper protection of settings and parameters............................................................ 34
5.3.2
Monitoring and logging of process control interruptions............................................. 36
Overview of BWMS operation principles ...................................................................................... 37
6.1
7
REMOTE IAS user interface ........................................................................................... 31
Control mode selection ......................................................................................................... 37
6.1.1
Service mode................................................................................................................. 39
6.1.2
Local mode .................................................................................................................... 40
6.1.3
Remote mode................................................................................................................ 40
6.2
Normal ballast water treatment operations ......................................................................... 41
6.3
Regulation of ballast water treatment.................................................................................. 41
6.3.1
Filtering ......................................................................................................................... 41
6.3.2
Monitoring of flow ........................................................................................................ 43
6.3.3
Valve settings for flow direction and pressure regulation ............................................ 44
6.3.4
Temperature monitoring .............................................................................................. 45
6.3.5
UV Treatment................................................................................................................ 45
Standard operation procedures .................................................................................................... 50
7.1
Labour burden and requirements to operator training ........................................................ 50
7.2
Selecting control mode ......................................................................................................... 50
7.2.1
REMOTE control mode .................................................................................................. 50
7.2.2
LOCAL control mode ..................................................................................................... 51
7.3
Filling operation (Ballasting) ................................................................................................. 52
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NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
7.3.1
Standard operating procedures .................................................................................... 52
7.3.2
Process parameters for filling operation ...................................................................... 54
7.3.3
Process diagrams for filling operation .......................................................................... 55
7.4
7.4.1
Standard operating procedures .................................................................................... 56
7.4.2
Operator actions on GUI for discharge operation ........................................................ 58
7.4.3
Process parameters for discharge operation ................................................................ 59
7.4.4
Process diagram for discharge operation ..................................................................... 60
7.5
Stripping of ballast water tanks ............................................................................................ 61
7.5.1
Standard operating procedures .................................................................................... 61
7.5.2
Operator actions on GUI for stripping operation ......................................................... 62
7.5.3
Process parameters for stripping operation ................................................................. 63
7.5.4
Process diagram for stripping operation ...................................................................... 64
7.6
Stop mode ............................................................................................................................. 65
7.6.1
Standard operating procedure for normal stop ........................................................... 65
7.6.2
Operator actions on GUI for stop of operations ........................................................... 66
7.6.3
Process parameters for normal stop ............................................................................ 67
7.7
Flushing ................................................................................................................................. 68
7.7.1
Standard operating procedure...................................................................................... 68
7.7.2
Operator actions on GUI for flushing operation ........................................................... 69
7.7.3
Process diagram for flushing operation ........................................................................ 70
7.8
Operating UV lamp wiper ..................................................................................................... 71
7.8.1
Standard operating procedure – manual wiper system ............................................... 71
7.8.2
Standard operating procedure – electrically actuated wiper system........................... 72
7.9
Sample taking ........................................................................................................................ 73
7.9.1
Installing the sample valve ............................................................................................ 73
7.9.2
Standard operating procedure...................................................................................... 73
7.9.3
Sampling flow adjustment for isokinetic sampling conditions ..................................... 74
7.10
8
Discharge, de-ballasting ........................................................................................................ 56
Other operations................................................................................................................... 75
Maintenance ................................................................................................................................. 76
8.1
Maintenance tasks after operation ...................................................................................... 76
8.2
Scheduled maintenance........................................................................................................ 76
8.2.1
Maintenance at weekly intervals .................................................................................. 76
8.2.2
Maintenance at monthly intervals ................................................................................ 76
8.2.3
Maintenance at 6 months intervals .............................................................................. 77
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NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
8.2.4
Maintenance at yearly intervals ................................................................................... 77
8.2.5
Maintenance at 5 year intervals ................................................................................... 77
8.2.6
Maintenance indicated by warnings ............................................................................. 78
8.3
9
Calibration and zeroing of measurement device .................................................................. 78
8.3.1
UV sensor ...................................................................................................................... 79
8.3.2
Water temperature sensor ........................................................................................... 79
8.3.3
Pressure transducers..................................................................................................... 79
8.3.4
Flowmeter ..................................................................................................................... 79
8.3.5
Conductivity sensor....................................................................................................... 79
8.4
Necessary tools ..................................................................................................................... 80
8.5
Spare parts ............................................................................................................................ 81
8.6
Repairs .................................................................................................................................. 81
8.6.1
Replacement of filter elements .................................................................................... 81
8.6.2
Replacement of UV lamps ............................................................................................. 82
8.6.3
Replacement of quartz sleeves ..................................................................................... 82
8.6.4
Replacement of pressure sensors and conductivity sensor.......................................... 82
8.6.5
Replacement of solenoid valve ..................................................................................... 83
8.6.6
Adjustment to or replacement of valve position feedback sensor............................... 84
Alarms and trouble shooting ........................................................................................................ 85
9.1
Alarm list ............................................................................................................................... 86
9.1.1
Warnings ....................................................................................................................... 87
9.1.2
Errors ............................................................................................................................. 90
9.2
Alarm handling ...................................................................................................................... 94
9.2.1
Handling of warnings .................................................................................................... 94
9.2.2
Handling of errors ......................................................................................................... 95
9.3
Self-diagnostics functionality ................................................................................................ 96
9.3.1
IO monitoring ................................................................................................................ 96
9.3.2
Backflush pump motor health monitoring.................................................................... 97
9.3.3
Particle filter motor health monitoring......................................................................... 98
9.3.4
BWMS valve status and position monitoring ................................................................ 99
9.3.5
Filter differential pressure monitoring ....................................................................... 101
9.3.6
Flow monitoring .......................................................................................................... 101
9.3.7
UV lamp health monitoring......................................................................................... 102
9.3.8
UV light sensor monitoring ......................................................................................... 103
9.3.9
UV lamp wiper motor health monitoring ................................................................... 103
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NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
9.3.10
Temperature monitoring in UV cabinets .................................................................... 105
9.3.11
Temperature monitoring in the UV chamber ............................................................. 106
9.4
Troubleshooting for filling operations ................................................................................ 107
9.5
Troubleshooting for discharge mode.................................................................................. 108
9.6
Troubleshooting for stripping mode ................................................................................... 109
9.7
Troubleshooting for stop mode .......................................................................................... 110
9.8
Troubleshooting for flushing mode .................................................................................... 110
10
Data logging ............................................................................................................................ 111
10.1
Back-up of log data ............................................................................................................. 111
10.2
Accessing the logs ............................................................................................................... 111
10.3
Contents of logs .................................................................................................................. 111
11
10.3.1
System log ................................................................................................................... 112
10.3.2
Event log...................................................................................................................... 113
10.3.3
Mode log ..................................................................................................................... 117
10.3.4
Alarm log ..................................................................................................................... 118
10.3.5
Filling and discharge .................................................................................................... 119
10.3.6
Flow and intensity logs................................................................................................ 120
10.3.7
Reading, printing and archive logs .............................................................................. 121
Appendices .............................................................................................................................. 122
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NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
List of figures
Figure 1 - BWMS operating principle ...................................................................................................... 2
Figure 2 – Identification of main components ........................................................................................ 6
Figure 3 – Physical arrangement of main components .......................................................................... 7
Figure 4 - System architecture of main process equipment ................................................................. 13
Figure 5 - Schematic layout of BWMS control system .......................................................................... 14
Figure 6 - Control page (home screen) ................................................................................................. 20
Figure 7- Detailed control page ............................................................................................................ 23
Figure 8 - Trends page Screen ............................................................................................................... 24
Figure 9 - Logs page, System log ........................................................................................................... 25
Figure 10 - Logs page: Event log ........................................................................................................... 26
Figure 11 - Settings page: Password prompt ........................................................................................ 27
Figure 12 - Settings page ....................................................................................................................... 28
Figure 13 - Alarms page: Active alarms................................................................................................. 29
Figure 14 - Recommended layout of IAS REMOTE user interface for BWMS ....................................... 31
Figure 15 - Main control page with control mode selection panel displayed ...................................... 38
Figure 16 - Status message - Remote requested .................................................................................. 39
Figure 17 - Particle filter operating principle ........................................................................................ 42
Figure 18 - Flow versus UV-I correlation ............................................................................................... 49
Figure 19 - Steps to enable REMOTE control ........................................................................................ 51
Figure 20- Steps to enable LOCAL control ............................................................................................ 51
Figure 21- Steps to start and stop filling operation .............................................................................. 53
Figure 22 - BWMS state during filling operation .................................................................................. 55
Figure 23- BWMS state during backflushing ......................................................................................... 56
Figure 24- Steps to start and stop discharge operation........................................................................ 58
Figure 25 - BWMS state during discharge operation ............................................................................ 60
Figure 26 - Steps to start and stop stripping operation ........................................................................ 62
Figure 27 - BWMS state during stripping operation ............................................................................. 64
Figure 28 - Steps to stop an operation.................................................................................................. 66
Figure 29 - Steps to start flushing operation ........................................................................................ 69
Figure 30 - BWMS state during flushing operation............................................................................... 70
Figure 31 - Operation of manual wiper system for UV lamps .............................................................. 71
Figure 32 - UV controller front panel .................................................................................................... 72
Figure 33 - Winch handle for manual operation of filter ...................................................................... 80
Figure 34 - UV-I Below Limit ................................................................................................................. 89
Figure 35 - System log tab................................................................................................................... 112
Figure 36 - Event log tab ..................................................................................................................... 113
Figure 37 - Mode log tab ..................................................................................................................... 117
Figure 38 - Alarm log tab..................................................................................................................... 118
Figure 39 - Filling log tab ..................................................................................................................... 119
Figure 40 - Discharge log tab .............................................................................................................. 119
Figure 41 - Flow log tab....................................................................................................................... 120
Figure 42 - Intensity log tab ................................................................................................................ 120
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NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
List of tables
Table 1 - BWMS filter size and capacities
Table 2 - BWMS UV size and capacities
Table 3- Example of BWMS specifications – single chamber configurations (600 m3/h shown)
Table 4 - Example of BWMS specifications – multi chamber configurations (3100 m3/h shown)
Table 5 - Surface finish
Table 6 - BWMS environmental conditions
Table 7- BWMS treatment target performance values
Table 8 - Control page GUI elements
Table 9 - List of BWMS operating states
Table 10 - Detailed control page GUI elements
Table 11 - Trends page GUI elements
Table 12 - Logs page GUI elements (system log)
Table 13 - Logs page GUI elements (Event log)
Table 14 - Settings (Log in) page GUI elements
Table 15 - Settings page GUI elements
Table 16 - Alarms page (active alarms) GUI elements
Table 17 - REMOTE user interface GUI elements
Table 18 - Summary of user configurable parameters - typical values
Table 19 - Summary of factory-set parameters
Table 20 - List of BWMS control modes
Table 21 - Control selection options
Table 22 - Pressure settings for filtering control
Table 23 - Flow monitoring parameters
Table 24 - Summary of UV system temperature limits
Table 25- Calculated power/flow set-points and alarm limits for IMO Mode. NGT BWMS DXL12BK419 is values presented
as example
Table 26 - Expected process parameter values during filling operations
Table 27 - Expected process parameter values during discharge operations
Table 28 - Expected process parameters values during stripping operations
Table 29 - Expected process parameters values during stop
Table 30 - Example of target flow values for isokinetic sampling
Table 31 - Alarms indicating a need for maintenance
Table 32 - Summary of possible alarm statuses
Table 33 - Description of BWMS alarm outcomes
Table 34 - List of BWMS warnings
Table 35 - List of BWMS errors
Table 36 - Handling of BWMS warnings
Table 37 - Handling of BWMS errors
Table 38 - Modbus communication monitoring parameters
Table 39 - Backflush motor monitoring parameters
Table 40 - Particle filter motor monitoring parameters
Table 41 - Valve monitoring parameters
Table 42 - Pressure monitoring parameters
Table 43 - Flow monitoring parameters
Table 44 - UV lamp health monitoring parameters
vii
8
8
9
9
11
18
18
21
22
23
24
25
26
27
28
29
33
34
36
37
38
43
44
45
47
54
59
63
67
74
78
85
86
88
93
94
95
96
97
98
100
101
101
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NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
Table 45 - UV light sensor monitoring parameters
Table 46 - UV lamp wiper monitoring parameters
Table 47 - UV cabinet monitoring parameters
Table 48 - UV chamber monitoring parameters
Table 49 - Summary of possible event entries in event log
Table 50 - Summary of possible control mode entries in Mode log
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103
104
105
106
116
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NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
List of abbreviations
The following abbreviations and definitions are used in the document:
Abbreviation / item
@
°C
µ (prefix)
A
ANSI
bar
BFP
Bool
BW
CMFDA
D + index
diff.
DN + number
DNA
ERP
EX
FDA
FM
GUI
HDD
HH:MM:SS
hr(s)
I
I/O (node)
IAS
IMO
Init + state
kWh
LT
M
m
m (prefix)
Definition or explanation
Shorthand for "at". Used in tables. E.g. 10 mA@7bar
Degrees Celsius. Unit for temperature
Prefix: micro- One millionth of the base unit, e.g. 1.000.000 µm = 1m
Ampere. SI unit for electrical current
American National Standards Institute
SI unit for pressure.
As used in system diagrams: Backflush pump
Boolean variable. Evaluates to true or false
Ballast water. Referring to ballast water or as prefix to identify components
belonging to ballast water system
Vital staining with 5-chloromethylfluorescein diacetate. Method of
measuring biological efficacy
Diameter
Difference / differential. Typically used with regards to differential pressure
across filter.
Description of pipe / flange size. Nominal diameter of pipe. E.g. DN300 for
pipework with nominal internal diameter of ø300 mm
The carrier structure for genetic instructions in organisms and viruses
Enterprise resource planning (system).
Classification code system for equipment placed in hazardous locations.
Vital staining with Fluorescein Diacetate. Method of measuring biological
efficacy
As used in system diagrams: Flow meter
Graphical User Interface
Hard disk drive
Time format: 2 digit hour, 2-digit minute, 2 digit second in the 24-hour
format. E.g. 14:05:59 = 2:05:59 PM
Hour(s)
Current, measured in Ampere (A)
Input / Output. Module in control system handling input and output
signals.
Integrated automation system or ballast water control system. The system
controlling the ballast water operations (BW pump, BW line valves and
BWMS bypass valve)
International Maritime Organisation
Initialising. System is in initialising or warm-up state prior to operation. E.g.
InitFilling
kiloWatt-hour. Derived unit for energy.
As used in system diagrams: Light transmitter (sensor)
As used in system diagrams: Electric motor
meter. Length
Prefix: milli- One thousandth of the base unit, e.g. 1000 mA = 1A
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NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
Abbreviation / item
m2
m3
Max.
micron
Min.
NGT BWMS
Modbus
MPN
n
n/a
NC
NO
NGT
Nom.
Ohm
OSHA
P
P&ID
PC
pdf
PF
pH
pin-code
PLC
PN(10)
POS
PPE
PSU
PT
PT100
Q + index
R
s
Super Duplex
t
Definition or explanation
Square meter. Area.
Cubic meter. A volume of 1000 L
Maximum
micro-meter.
Minimum
"Ballast Water Management System" - trade name for the Norwegian
Greentech ballast water treatment system
Industrial communication protocol. Used between control components in
the BWMS and towards the IAS.
Most Probable Number. Method of measuring biological efficacy
Running index for number. Ie. 1..n
Not applicable
Normally closed - referring to default behaviour of electrical switches or
relays. Contrasts with NO.
Normally open - referring to default behaviour of electrical switches or
relays. Contrasts with NC.
Norwegian Greentech. Company name of BWMS manufacturer. A
subsidiary of Havyard. New name for previous company name MMC Green
Technology
Nominal
SI unit for electrical resistance
Occupational Safety and Health Administration
Pressure in bar
Piping and Instrumentation Diagram
Personal computer. Referring to the computer system integrated in the
main control cabinet, running the BWMS control application
Portable Document File format. Platform independent file format by
Adobe.
As used in system diagrams: Particle filter
Measure of acidity
Passcode consisting of digits. 4-digit pin-code is used by the BWMS control
system for protection of certain settings
Programmable Logic Controller.
Pressure class. 10 bar is standard for the BWMS components
Position / sequence number on figures, drawings etc.
Personal protective equipment.
Practical Salinity Unit. Measure of salinity of ocean water using the PSS-78
scale
As used in system diagrams: Pressure transmitter (sensor)
Type of thermal sensor
Flow
Resistance in Ohms
Seconds
Stainless steel quality with high corrosion resistance
Temperature, in degrees Celsius
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NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
Abbreviation / item
TRC
TT
US
USB
USCG
UV
UV
UV-I
UVT10
V
V + index
W
YYYY-MM-DD
ø
Definition or explanation
Treatment Rated Capacity
As used in system diagrams: Temperature transmitter (sensor)
United States. In this context, every port / destination governed by US
jurisdiction.
Universal Serial Bus. Hardware interface for connection of peripheral
devices to computer systems.
United States Coast Guard
Ultra Violet (light). The NGT BWMS is based on UV light treatment.
As used in system diagrams: UV unit
UV light intensity, measured in w/m2
UV transmission index (10 mm sample)
Volt. SI unit for electrical potential
As used in system diagrams: Valve, e.g. V1
Watt. SI-unit for electrical power
Date format: 4-digit year, 2-digit month, 2 digit day. E.g. 2017.10.01 =
October first, 2017
Diameter symbol
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NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
1 Introduction
1.1 Product documentation for the NGT BWMS
The product documentation for the NGT BWMS is organised into three parts:
•
•
•
Part I covers handling, storage and installation instructions.
Part I is written primarily for the shipyard, to provide information on engineering and
installation best practices.
Part II (this document) covers operation, safety and maintenance of the BWMS during
normal operation.
Part II is written primarily for the ship’s crew, as a reference for safe and efficient operation
and maintenance of the equipment.
Part III contains all appendices referenced in Parts I & II.
Part III contains installation specific details and data, whereas Parts I & II are generic and
cover all BWMS sizes and variants.
1.2 About ballast water conventions
1.2.1 Background and status
Ballast water discharge standards are put in place to protect the oceans against the spreading of
invasive species. Non-indigenous species travel across oceans as unwanted passengers in the ballast
water of ships every day and can cause great harm if they are released into new habitats where they
have no natural enemies.
The NGT BWMS is designed and tested to fully comply with the following:
•
•
•
•
IMO Resolution MEPC.300(72) - Code for Approval of Ballast Water Management
Systems (BWMS Code)
Regulation D-2 of the International Convention for the Control and Management of
Ships' Ballast Water and Sediments, 2004
DNV GL rules for classification of ships, Part 6, Chapter 7, Section 1
Procedures and requirements for approval of ballast water management systems by the
U.S. Coast Guard Marine Safety Center in accordance with 46 CFR Subpart 162.060 Ballast Water Management Systems
DNV GL type approval certificate TAP000028V Rev.0 is valid for our system designs up to
D5XL18-BK750, with a max TRC of 1274m3/h.
USCG type approval is valid for our system designs up to
D5XL18-BK750, with a max TRC of 1274m3/h.
Ballast water convention is require all merchant ships to install systems for treatment of ballast
water in order to minimize the spreading of aquatic species.
The IMO ballast water convention first entered into force in September 2017.
1.2.2 Our commitment as solution provider
The NGT BWMS has been carefully designed and optimised to provide efficient and reliable ballast
water treatment to help our customers protect the environment.
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NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
The system is manufactured from high quality components and materials and has been tested and
qualified according to the IMO ballast water discharge standards.
We make every effort to deliver a reliable and cost effective product with the highest performance
standards.
1.2.3 Your obligations as a ship operator
Any ballast water treatment system must be correctly operated and maintained in order to provide
the necessary capability to remove harmful organisms from the ballast water.
It is your obligation as a ship operator to operate and maintain the NGT BWMS as instructed in this
manual to ensure proper function and protection of the environment.
Please follow the instructions and procedures in this manual accurately and faithfully. You are
encouraged to contact Norwegian Greentech or one of our representatives in case of questions or
need for assistance.
1.3 About the NGT BWMS
1.3.1 Working logic
The NGT BWMS is based on a combination of mechanical filtering and UV irradiation.
A particle filter with a 20 µm super duplex mesh removes all particles and organisms larger than 20
µm from the ballast water on intake.
The water then flows past several UV-lamps in a specially designed UV chamber before it reaches
the ballast water tanks. The high-energy UV light will damage the DNA of all living organisms,
bacteria and virus such that they are either killed instantly or unable to reproduce and multiply.
On ballast water discharge, the water is subjected to one more dose of UV-light to effectively kill or
render non-viable any organisms which have survived the first UV treatment.
Figure 1 - BWMS operating principle
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NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
The combined effect of filtering and two UV irradiation doses is sufficient to reduce the organism
count to well below the ballast water discharge standards set by IMO.
The BWMS is delivered with a complete control system with interface to the ship IAS such that it can
be integrated seamlessly into the ballast water operations.
The system has dedicated operation modes for ballast water intake and discharge operations.
1.3.2 Customer support guidance for operation and maintenance
Our service team is always available for technical support for questions regarding the prober
integration and installation of the NGT BWMS.
For us to be able to provide the most efficient and correct guidance, we ask that you follow the
below steps prior to contacting NGT:
•
•
•
•
Review the applicable section of this manual carefully for generic information
Check the appendices of this manual to see if your topic is addressed
Review the project specific data and drawings to see if there are any specific instructions for
your installation
Prepare a few notes for our guidance, including:
o The nature of the problem
o The affected components
o Applicable drawings, diagrams or sections of this manual
o Any other relevant information
Please contact us by e-mail or phone to obtain assistance.
The contact information for Norwegian Greentech and our worldwide agents is found below.
1.3.3 Contact information:
Main office:
NORWEGIAN GREENTECH AS
6092 FOSNAVÅG
NORWAY
TEL +47 70 08 01 40
E-MAIL: service@norwegiangt.no
Worldwide agents:
See "agents" section on web page: www.norwegiangt.no
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NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
2 Safety precautions
2.1 Identification of hazards and areas of special attention
Throughout the manual, you will see the following icons where additional precautions or attention is
required.
A red warning triangle indicates a potential danger and special precautions should be
taken to ensure the safety of personnel or vessel.
A yellow warning triangle indicates a situation or area where special attention is
required to prevent technical problems.
A green warning triangle indicates a useful piece of information, e.g. a tool tip or good
practices to help the installation work.
2.2 Personal protective equipment
The NGT BWMS utilize a fully enclosed UV lamp solution and there is no danger of UV exposure as
long as the installation and operation instructions are followed.
The BWMS does not produce any dangerous or noxious substances during operation.
Accordingly, there is no need for special protective equipment related to the UV unit or other
components of the BWMS.
Standard PPE (safety shoes, helmet, protective eyewear & clothing) as specified in the
ship operator work instructions should be worn during work on the BWMS.
2.3 Requirements to operator skill and training
All operation and maintenance work should be performed by suitably trained personnel.
The requirement is that all operators of the BWMS must receive training and familiarisation for use
of the BWMS during installation and commissioning of the system.
The description “trained personnel” is considered as personnel that has attended mandatory
training offered during installation and/or commissioning onboard vessel by NGT service engineer.
Ballast water operations can impact the stability and structural integrity of the vessel. It
is the responsibility of the vessel operator and captain to ensure that all personnel
involved has the necessary skill and certification.
Maintenance of the BWMS involves work on electrical installations and pressurised
pipelines. It is the responsibility of the vessel operator and captain to ensure that all
personnel involved has the necessary skill and certification.
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2.4 Handling of broken UV lamps
The UV lamps contain small amounts of Mercury. Mercury is considered a hazardous
substance and the lamps should be treated accordingly.
The small amount of mercury in a lamp is not possible to identify, but in case of a broken or defect
lamp it should be kept in a suitable box or container, and be delivered to an approved reception
facility.
Please consult the UV lamp handling procedure provided in Part III, Appendix C.5.
2.5 Limitations on location and use of the BWMS
The BWMS is designed for use for all IMO regulated areas on all types of vessels, with capability for
processing of freshwater, brackish and sea water. Please see section 4.4 and Table 6 for details.
Please note the following restrictions on location of the BWMS:
•
•
•
•
The BWMS is designed for location in below decks or inside ship, protected from weather
The BWMS is not designed for submersion or installation in tanks
The BWMS is not designed for installation in void spaces or other inaccessible areas
The standard certified BWMS scope of supply is not designed for (location) operation in EX
designated areas, and would need to be certified case by case.
The following limitations must be considered while operating the BWMS. Please take these into
consideration when planning ballasting/de‐ballasting operations:
•
During ballast water intake and discharge, the TRC (treated rated capacity) flow is not to be
exceeded. Refer to the technical specification in Part III, Appendix A.1, for system specifics.
•
The backflush system will not function in an optimal way if flow is below stated minimum
flow for the particle filter. Refer to the technical specification in Part III, Appendix A.1 –
minimum flow in filling and discharge
•
The minimum flow during operation of the UV unit can never be below the minimum flow
limit. Refer to the technical specification in Part III, Appendix A.1.
•
The UV lamps need a warm up time of 5 minutes before operating at full power
•
The UV lamps need a cooling down period of 10 minutes before re‐start after having been in
operation. Water flow is not needed for the cool down period, but the UV chamber must be
water filled during cool down.
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3 System description
3.1 Delivery condition
The system is typically delivered as separate components for flexible installation in a retrofit or
special purpose application. As an option, the system can be delivered as a complete, skid mounted
solution.
The system configuration comprises:
•
•
•
•
•
•
•
A particle filter
A backflush pump
Remotely controlled process valves
One or two UV chambers, with UV lamps, UV sensor and temperature sensor
One or two UV cabinets
A flow meter and pressure sensors for process monitoring and control
BWMS Control Cabinet for operation of the BWMS, with integration to the ship automation
system
The main process components of the BWMS are illustrated below.
Figure 2 – Identification of main components
The BWMS process components are identical whether delivered as separate components or as a skid
mounted system.
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The physical arrangement of the BWMS components is such that:
•
•
•
•
•
•
The filter is always placed as the first treatment component after the inlet valve
There is an arrangement of valves and piping to allow bypass of the filter during discharge
operations
The UV chamber is always placed after the filter, after the filter bypass valve/piping
arrangement
When more than one UV chamber is installed, all UV chambers are connected in parallel by
means of a pipe manifold or similar arrangement
The flow meter is normally placed upstream of the filter, but may also be located
downstream of the UV chamber(s).
If possible a sampling point should be located as close as practical to the overboard
discharge
The inlet and outlet valves define the system boundaries from a treatment and control point of view.
Figure 3 – Physical arrangement of main components
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3.2 NGT BWMS range
The NGT BWMS is configured to cover a TRC range from 30 to 3600 m3/h based on the combination
of filter, UV unit and flow meter sizes listed in tables below.
The available filter sizes with corresponding flow ratings are:
Filter
designation
273
324
356
419
521
600
750
900
1000
1100
Maximum
rated flow
(m3/hr)
62
94
204
378
518
614
1274
1384
2040
3100
Backflush
flow1
(m3/hr)
22
22
28
40
40
40
58
54
54
79
Flange connection,
main inlet & outlet
Flange connection,
Backflush outlet
DN80
DN125
DN150
DN200
DN250
DN300
DN400
DN500
DN600
DN700
DN50
DN50
DN65
DN65
DN65
DN65
DN65
DN80
DN80
DN100
Table 1 - BWMS filter size and capacities
Notes to Table 1:
1: Maximum flow through backflush line during backflushing. Main flow will be reduced by this amount during backflushing.
Stated values based 2 bar system pressure. s
The available UV sizes with corresponding flow ratings are:
UV designation
Maximum
rated flow
(m3/hr)
DL1
DL2
DL3
DL4
DXL6
DXL9
DXL12
D4XL8
D4XL10
D4XL12
D5XL14
D5XL16
D5XL18
D5XL20
D5XL22
D5XL24
30
60
90
150
200
260
350
460
600
750
1005
1180
1323
1475
1645
1815
Maximum
rated flow in
USCG Mode
(m3/hr)
30
60
90
128
200
260
350
460
600
750
1005
1180
1314
1458
1630
1788
Minimum flow1
(m3/hr)
Flange connection,
inlet & outlet
2
3
4
5
8
12
15
17
22
26
30
34
39
43
47
51
DN80
DN80
DN125
DN150
DN150
DN200
DN200
DN250
DN300
DN300
DN400
DN400
DN400
DN400
DN400
DN400
Table 2 - BWMS UV size and capacities
Notes to Table 2:
1: Minimum flow through chamber to meet UV lamp cooling requirements.
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The treatment capacity of the BWMS is determined as follows:
•
•
•
The maximum TRC of the BWMS is limited by the maximum rated flow of the filter or UV
unit, whichever is lower.
The minimum flow in filling is determined by the filter backflushing flow plus UV minimum
flow
The minimum flow during discharge and stripping is determined by the UV minimum flow
Main process control valves for ballast water are sized to match the maximum TRC.
The exact configuration and TRC of the BWMS is stated in the technical specification which is
attached as Part III, Appendix A.1
As an example of a single UV chamber configuration, the NGT BWMS D4XL10-BK600 model will be
composed of:
•
•
One filter, size 600 with a maximum rated flow of 614 m3/h
One UV unit, D4XL10 with a maximum rated flow of 600 m3/h
The resulting NGT BWMS D4XL10-BK600 specifications are:
NGT BWMS D4XL10-BK600 specifications
Value Determined from
(m3/hr)
TRC
600 Least of filter and UV max. rated flow values
Minimum flow in filling
62 Filter backflush flow + UV minimum flow
Minimum flow in discharge
≥ 22 UV minimum flow or larger
Minimum allowable flow
22 UV minimum flow
Flow parameter
Table 3- Example of BWMS specifications – single chamber configurations (600 m3/h shown)
As an example of a multi-UV chamber configuration, the NGT BWMS D5XL22x2-BK1100 model will
be composed of:
•
•
One filter, size 1100 with a maximum rated flow of 3100 m3/h
Two parallel coupled UV units, D5XL22, with a combined maximum rated flow of 3290 m3/h
and a combined minimum flow of 2 x 47 = 94m3/h
The resulting NGT BWMS D5XL22x2-BK1100 specifications are:
NGT BWMS D5XL22x2-BK1100 specifications
Flow parameter
Value Determined from
(m3/hr)
TRC
3100 Least of filter and UV max. rated flow values
Minimum flow in filling
173 Filter backflush flow + UV minimum flow
Minimum flow in discharge
≥ 94 UV minimum flow or larger
Minimum allowable flow
94 UV minimum flow
Table 4 - Example of BWMS specifications – multi chamber configurations (3100 m3/h shown)
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In cases where higher flow rate at a lower UV-T is needed, the BWMS can also be configured with a
larger UV chamber with higher TRC compared to filter TRC. Especially for USCG operation, this can
be an relevant configuration.
The exact configuration and TRC of the BWMS is stated in the technical specification which is
attached as Part III, Appendix A.1
As an example of a configuration with larger UV chamber, the NGT BWMS DL4-BK273 model will be
composed of:
•
•
One filter, size 273 with a maximum rated flow of 62 m3/h
One UV unit, DL4 with a maximum rated flow of 150 m3/h
The resulting NGT BWMS DL4-BK273 specifications are:
NGT BWMS DL4-BK273 specifications
Value Determined from
(m3/hr)
TRC
62 Limited by filter TRC
Minimum flow in filling
27 Filter backflush flow + UV minimum flow
Minimum flow in discharge
≥ 5 UV minimum flow or larger
Minimum allowable flow
5 UV minimum flow
Flow parameter
Table 51 – Example of BWMS specifications – combinations of UV and filter
Another example of such configuration, the NGT BWMS DXL12-BK356 model will be composed of:
•
•
One filter, size 356 with a maximum rated flow of 204 m3/h
One UV unit, DXL12, with a maximum rated flow of 350 m3/h
The resulting NGT BWMS DXL12-BK356 specifications are:
NGT BWMS DXL12-BK356 specifications
Value Determined from
(m3/hr)
TRC
204 Limited by filter TRC
Minimum flow in filling
43 Filter backflush flow + UV minimum flow
Minimum flow in discharge
≥15 UV minimum flow or larger
Minimum allowable flow
15 UV minimum flow
Flow parameter
Table 52 – Example of BWMS specifications – combinations of UV and filter
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3.3 Scope of supply
The BWMS system is delivered as a complete system with the following main components:
•
•
•
•
•
•
•
•
Particle filter, including valves and pump for backflushing functionality
Process valves
UV chamber(s)
Sensors: flow meter, three pressure sensors, temperature, conductivity and UV sensor
Main control cabinet
UV power & control cabinet(s)
Control system with local operating screen
Sampling valve
When delivered as a skid mounted system, the components and necessary piping is factory mounted
on a skid frame.
For models with more than one UV chamber, each additional UV chamber has its own UV control
and power cabinet.
Not included in the scope of supply is:
•
•
•
Ballast water pump, valves and piping
Cabling and power supply for cabinets
Cabling and power supply for remote operating stations
3.3.1 Surface finish
Equipment
Particle filter
Backflush pump
UV Cabinet
Flow meter
Valves
NGT Control Cabinet
UV Chamber
Piping and framework
Surface finish
Coating, RAL colour
RAL 7035
RAL 7035
RAL 7035
RAL 7035
RAL 7035
RAL 7035
N/A – Stainless steel
N/A – Stainless steel
Table 5 - Surface finish
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4 System architecture
The BWMS is composed of two sub-systems:
1. The process system, comprising all processing equipment for water treatment
2. The control system, comprising PC and PLC based controllers, I/O modules, sensors etc.
Each sub-system is described in detail below
4.1 Process system architecture
The main process equipment always includes:
•
•
•
•
•
•
•
•
•
A 20 micron particle filter (PF1, M2) with backflush pump (BFP1, M1)
Pressure transmitters (PT1, PT2, PT3)
Conductivity transmitter
Up to two UV chambers (UV1 – UV2) with:
o UV lamps
o UV light intensity sensor (LT1 – LT2)
o Temperature sensor (TT1 – TT2)
o Optional electric drive for wiper system (M4)
A flow meter (FM1)
Main process valves V1-V5. Valve V4 is electrically actuated
Valves for backflushing/flushing system V8, V9 and V10. V10 is electrically actuated.
Ball valves for freshwater V6 and V11. *
Ball valves for air evacuation V16.1 and V16.2. *
* Not illustrated in Figure 4, as these are not related to treatment process of ballast water.
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A simplified schematic layout is shown in Figure 4 below. For a complete process diagram, reference
is made to the P&ID.
Figure 4 - System architecture of main process equipment
The following equipment is not part of the BWMS scope of supply, but is included in the safety and
control mechanisms of the BWMS:
•
•
The ballast water pump, with pressure relief valve if pump is of positive displacement type
The BWMS bypass valve
The treatment process and the functionality of each component is described in section 6.3.
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4.2 Control system architecture
The control system includes a main controller, an UV controller, and an interface to the vessel IAS.
The control system architecture is illustrated in Figure 5.
Figure 5 - Schematic layout of BWMS control system
The functionality of each control system component is described in the following sections.
4.2.1 Vessel IAS
The BWMS interfaces to the vessel IAS through a Modbus interface or through hardwired signals.
NGT does not deliver components or plugins for the IAS, but the IAS provider can include a REMOTE
user interface for normal operation of the BWMS based on NGT guidelines. Please see
Recommended REMOTE user interface for details on the remote user interface.
The IAS normally controls the main ballast water pump and the BWMS bypass valve. The BWMS
controller monitors two feedback signals received from the IAS:
•
•
Ballast water pump running signal
Bypass valve status (open/closed)
The ballast water pump and bypass valve are always monitored.
The system is designed and tested on different flow rates. Therefor to be able to exploit the full
capacity of the system, measurements to regulate flow needs to be installed. For example by
integration of IAS towards a frequency converter.
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4.2.2 BWMS controller
The BWMS controller consists of a panel PC with a touch screen for the graphical user interface and
user interaction, and the BWMS control software for control of all BWMS functions.
The BWMS controller communicates with an I/O node and the UV controller PLC over a Modbus
protocol through an ethernet switch. The UV controller handles communication with all UV related
equipment, while the I/O node handles communication with the remaining process equipment. A
detailed overview of monitored equipment and signals is provided in sections 4.2.3 and 4.2.4 below.
The BWMS control system is programmed to make scheduled backups of the application and log
database to a backup HDD or memory stick if connected to a USB port in the panel PC.
4.2.3 I/O node
Input signals from sensors, valves and motors are received by the I/O node and transmitted to the
BWMS controller over the Modbus network.
The following items are monitored through the I/O node:
•
•
•
•
•
Backflush pump motor
Particle filter motor
BWMS process valve status
Filter differential pressure
Flow meter (Flow sensor signal received from flow converter)
A detailed description of monitored parameters is provided in section 9.3.
4.2.4 UV controller
Input signals from the UV equipment are received by the UV controller and transmitted to the
BWMS controller over the Modbus network.
The following items are monitored through the UV controller:
•
•
•
•
•
UV lamp status
UV light sensor
UV lamp wiper motor (if installed)
UV cabinet temperature (UV control and power cabinets)
UV chamber temperature (PT100 signal through temperature controller)
A detailed description of monitored parameters is provided in section 9.3.
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4.3 Safety features
The BWMS has a number of safety features built in through design and mechanical layout,
monitoring and diagnostics functions, and alarm functions. These are described in the following.
4.3.1 Design features for safety
Safety against bursting due to high fluid pressure in the system is provided through two main design
features:
1. The BWMS components and pipework are all rated for pressure class PN10. This means that
the system will have a considerable safety margin on the pressure capacity relative to the
head delivered by the most common types of ballast water pumps in use. (Centrifugal
pumps)
2. For systems with positive displacement pumps, the pump must have a built-in pressure relief
valve, set according to the ballast water piping pressure rating.
Safety against overheating and potential build-up of steam pressure in the UV chamber is provided
by a two-layer safety design:
1. The BWMS controller monitors flow and will stop the BWMS operation (including shut down
of UV chambers) if the flow through the UV chamber is too low to provide sufficient cooling
to keep the lamps below their maximum operating temperature.
2. The UV controller monitors water temperature in the chamber and will stop the BWMS if
the water temperature rises above the UV lamp operating temperature limit. The
temperature limit for the lamps (60°C) is well below the boiling point.
The BWMS controller and the UV controller are separate systems both capable of analysing sensor
data and shutting down the UV chamber independent of the other controller, and therefore
provides two independent layers of safety for the UV process control.
4.3.2 In case of release of untreated ballast water
If the BWMS operates in waters where treatment is insufficient to comply with set treatment limits
and/or experience any form of malfunction that reduces the treatment capacity, the BWMS will
generate a warning or error signal. BWMS will operated based on severity of error signal, and take
required measurements to avoid continued operation that can damage equipment or environment.
(See section 9.1.1 and 9.1.2)
The operator will then have to make a choice to stop operation or continue operation with UV
intensity below the limit. (See Figure 34)
If the operator opts to continue an operation with UV intensity below the limit, the UV treatment is
insufficient to ensure that the ballast water is complying with the ballast water standard.
This means that the ballast water cannot be legally discharged, and the event log will contain an
entry marked: “No or reduced treatment allowed by operator”.
Ignoring the UV intensity limit should only be done when safety considerations dictate that ballast
water operations must continue regardless of treatment status.
The officer in charge must make an entry in the ballast water log stating the date and reason for the
non-compliant operation.
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4.3.3 Manual bypass and shutdown of the BWMS
The BWMS is intentionally designed without control of the BWMS bypass valve. The design rationale
is that the decision to bypass the BWMS must be made with due consideration to both vessel safety
and environmental consequences. The responsibility to make this safety critical decision lies with the
officer in command.
In case of an emergency, the BWMS can be bypassed completely by opening the BWMS
bypass valve from the IAS, or manually on the valve, if the valve has this functionality.
Any bypass of the BWMS will trigger an alarm.
The time and duration of a bypass of the BWMS system will be logged. The officer in charge
is required to make an entry in the ship’s log stating the reason for bypassing the BWMS
and the amount of ballast water released without treatment.
The system bypass valve is monitored by the BWMS control system. Text in the BWMS log is
indicating that the bypass valve was opened and no treatment performed. Time and duration of any
bypass is logged.
The system can be configured to include “Other operations”, where ballast pump operations can
bypass the BWMS without triggering an alarm when ballast water treatment is not required. This
includes operations such as internal ballast water transfer, drill water discharge or use of the ballast
water pumps for deluge or foam systems.
Other operations is a mode selected from the IAS, which sends a signal to the BWMS not to trigger
the usual alarm if the bypass valve is opened.
The time and duration of an "Other operations" mode selection is logged in the BWMS log.
The Bypass valve is not to be opened and closed during normal operation.
See also section 7.10.
In case of a malfunction in the BWMS, it can be safely shut down by:
1. Giving the STOP order from the REMOTE user interface
2. Switching to local command mode and giving the STOP order from the local touch screen
3. Switching power off using the main power switches on the BWMS control cabinet and UV
control / power cabinets
Please note:
•
•
•
In all three scenarios, the UV lamps will be shut down immediately.
If the stop order is given, the BWMS will perform the normal stop procedure.
If power is switched off, the BWMS I/O node will close all pneumatic valves (failsafe setting).
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4.4 Performance and sensitivity to changes in environmental conditions
4.4.1 Water quality
The BWMS is designed to operate in IMO regulated waters, within water quality parameters defined
in Table 6 below.
Parameter
Water temperature at intake
Salinity
Acidity
Operational limit
-2 < t intake < 50
No limitation
7.5 < pH < 8.4
Unit
°C
PSU
pH Total
Table 6 - BWMS environmental conditions
The effect of the UV irradiation process is not affected by changes in environmental
parameters within the above ranges.
For waters with very high turbidity, the filter will be affected and more frequent
backflushing cycles can be expected. This is automatically regulated by the BWMS
controller.
4.4.2 Treatment settings and performance
The BWMS filtration and UV treatment process is designed to operate and perform with target
values as defined in Table 7.
Parameter
Minimum UV intensity
Required holding time
Target filter differential pressure
Maximum filter differential pressure
Operational target
See Part III.
Appendix A.1
No limitations
< 0.3
1.0
Unit
W/m2
Hour
Bar
Bar
Table 7- BWMS treatment target performance values
4.4.3 Power consumption
The power consumption numbers for your specific BWMS configuration are detailed in the technical
specification (Part III, Appendix A.1)
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4.5 Effects on vessel’s existing ballast water system
The BWMS is a treatment system which is placed in-line in the existing ballast water piping
arrangement.
Due to the flexible installation as separate components, the BWMS has limited effect on the
functionality and operation of the existing ballast water system. The effects of installing and
operating the BWMS can be summarised as:
•
•
•
•
•
The BWMS creates a nominal back pressure of 1.5 bar. The ballast water pump must be
dimensioned to operate with this additional back pressure
The BWMS will close the main outlet valve in case of certain malfunctions as a required
precaution against release of untreated water. This can lead to a pressure build-up in the
ballast water system. The entire ballast water system must be dimensioned to tolerate the
maximum head delivered by the ballast water pump.
A main bypass valve must be fitted and monitored, to allow complete bypass of the BWMS
in an emergency situation.
The BWMS does not consume or produce any substances during operation, and it does not
change the chemical composition of the seawater. Thus, the BWMS will not lead to any
additional corrosive or otherwise damaging effects on the existing ballast water piping and
tanks.
When operating, the BWMS can interact with the vessel IAS/Frequency Converters to
automatically regulate the ballast water flow. For more detailed information regarding flow
reduction please see section 6.3.5
A pressure relief valve must be included in the ballast water pump when positive
displacement pumps are used.
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5 BWMS control system
5.1 Graphical user interface
The BWMS control system is organised around a series of dedicated pages that provide contextual
controls and information.
The pages can be accessed on the local touch screen on the BWMS control cabinet and are used to
control the BWMS when the control mode is set to LOCAL or SERVICE mode. (See section 6.1)
If the system is in REMOTE control mode, the local touch screen displays process
information and status, but the BWMS cannot be controlled from the local touch screen.
The REMOTE user interface is different from the BWMS user interface on the local touch screen. The
REMOTE user interface only contains limited controls and process information. Please see section
5.2 and the IAS documentation for details.
5.1.1 Control page (home screen)
The control page is what is normally displayed during operation.
If the selection switch is set to remote, this page cannot be used for running the ballast treatment
system, but will still provide feedback on operational parameters and system status.
The page contains the following items:
Figure 6 - Control page (home screen)
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The GUI elements are:
Control page
Pos
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Description / functionality
Tabs for selection of displayed page. Options are:
“Control”, “Trends”, “Logs”, “Settings” and “Alarms”
Status widgets in tabs show “at a glance” information about status in tab
Maximum flow allowed for current operation
Set desired flow at startup of system, new MAX FLOW will be provided from UV controller
once warmup is finished. If calculated MAX FLOW from UV is lower than desired flow,
then MAX FLOW will override the set desired flow. If the desired flow is lower than MAX
flow from UV, the desired flow will override the MAX FLOW from UV.
Status indicators for remote operation, ballast pump running signal.
Current BWMS software version
Button to turn on / off labels on GUI elements
Pressure reading from PT1 at filter inlet
Filter dialog box with display of filter status, calculated differential pressure and button to
start backflushing cycle manually
UV unit dialog box with display of UV status, UV intensity and any error messages
Current flow through BWMS as reported by flow meter and indicator for stable flow
readings
Current setting of BWMS main outlet valve. Indicates percentage of opening
System status messages.
BWMS bypass valve and bypass line status. Normally closed during BW operations
Buttons for manually selecting operation type. Available choices are:
“Start filling”, “Start discharge”, “Start Stripping”, “Start flushing cycle” and “Stop”.
See section 6.2.
State indicator. The system can be in a number of states as defined in Table 9.
Control mode indicator and button to change control mode. Displays the current control
mode and activates control mode selection panel as described in section 6.1.
Table 8 - Control page GUI elements
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The system operating states are:
Current state
InitFilling
Filling
InitDischarge
Discharge
InitStripping
Stripping
Stopping
Flushing
Operating states
Description
System is preparing for treatment of ballast
water to be pumped from sea to ballast tanks.
Operator pumps from sea chest to overboard
until UV units are done warming up.
UV units are done warming up, operator
switches pumping from overboard to ballast
tank.
System is preparing for treatment of ballast
water to be pumped from ballast tanks to
overboard. Operator pumps from sea chest to
overboard until UV units are done warming up.
UV units are done warming up, operator
switches pumping from ballast tank to
overboard.
System is preparing for treatment of ballast
water to be stripped from ballast tanks to
overboard. Operator pumps from sea chest to
overboard using the stripping ejector until UV
units are done warming up.
UV units are done warming up, operator
switches ejector to suction from ballast tank to
overboard.
System has been stopped by operator and is
waiting for flow to cease, so that system valves
can be closed.
System is being flushed, by alternating between
blowing of air through the system and filling
system with fresh water.
Table 9 - List of BWMS operating states
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5.1.2 Detailed control page
By pressing the filter or UV dialog box the control page can be changed to a detailed view.
Depending on the control mode, the detailed view has different functionality:
•
•
If in Local or Remote mode: The detailed view displays valve status of all BWMS valves.
If in Service mode: The detailed view allows manual control of all valves.
The detailed control page contains the following items:
Figure 7- Detailed control page
The GUI elements are:
Detailed control page
Pos
1
2
3
4
5
6
7
8
9
10
11
12
13
Description / functionality
Freshwater supply valves, V6 & V11
Filter inlet valve, V2, and PT1 pressure reading
Backflush pump and backflush overboard line valve, V10
BWMS inlet valve, V1
Filter bypass valve, V3
Filter outlet valve, V5
PT2 pressure reading
Filter status differential pressure reading
Return to home screen
Outlet valve, V4, and manual/automatic valve operation toggles for V4
BWMS bypass valve and bypass line. Valve can only be monitored, not controlled
Filter drain line, PT3 and valve V8 for freshwater flushing
Filter backflush line and valve V9 & V10 for backflushing
Table 10 - Detailed control page GUI elements
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5.1.3 Trends page
The trends page show trends of selected operational data. This is helpful when monitoring BWMS
performance as any deviations in treatment performance, ballast water flow or operational
parameters can be quickly spotted and corrective actions taken before a problem occurs.
The trends page is available in all control modes but trends data are not exported to the REMOTE
user interface and must be read locally on the BWMS control panel.
Figure 8 - Trends page Screen
The GUI elements are:
Pos
1
2
3
Trends page
Description / functionality
Trends tab is selected / active
Tabs for selection of collections of graphs
Trend graphs
Table 11 - Trends page GUI elements
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5.1.4 Logs page
The data logged by the control system can be accessed through the logs page.
The logs page contains a number of different log types, organised into tabs.
The system log page is a summary page with high level information. The other tabs contain time
history data. The user can select a tab to view, print or export the associated log data for a user
selected time interval.
Figure 9 - Logs page, System log
The GUI elements are:
Logs (systems log) screen
Pos
1
2
3
4
5
Description / functionality
Logs tab is selected / active
Tabs for selection of log type (system selected). Available logs are:
“System”, “Event”, “Mode”, “Alarms”, “Filling”, “Discharge”, “Flow” and “Intensity”
System timers area. Contains running / elapsed time for selected components and
systems
Current value areas. Displays current values of flow and UV intensity
Operational data area. Contains a summary of important operational data
Table 12 - Logs page GUI elements (system log)
Time history logs can be filtered for user selected intervals and either displayed or saved. The page
for displaying user selected log data is illustrated below for the event log, but is similar for other log
types.
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Figure 10 - Logs page: Event log
The GUI elements are:
Pos
1
2
3
4
5
6
7
8
Logs (events log) screen
Description / functionality
Logs tab is selected / active
Event log is selected
Database connection. Press this button to connect to the log database. Green colour
indicates that the system is connected to the database
Date picker to set the “From” date
Date picker to set the “To” date
Button to submit request to database and update display to contain selected “From” –
“To” date interval
Button to print log data for selected interval to a pdf file. The file can be stored locally on
the controller PC or on a USB memory stick for archiving or sharing
Display area. Contains log data with timestamp information for selected time interval
Table 13 - Logs page GUI elements (Event log)
See also section 5.1.4 for a more detailed discussion of data logging.
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5.1.5 Settings page
The settings page allows a number of system parameters to be adjusted. The settings page is
password protected and the initial screen prompts the user for a 4-digit pin-code.
Only trained and authorized personnel should access the settings page and adjust
settings Consult NGT before making any changes to default settings.
Figure 11 - Settings page: Password prompt
The GUI elements are:
Pos
1
2
Settings (log-in) screen
Description / functionality
Settings tab is selected / active
Password-prompt. Contact NGT for code
Table 14 - Settings (Log in) page GUI elements
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After successful log in, the main service page is displayed:
Figure 12 - Settings page
The GUI elements are:
Settings page
Pos
1
2
3
4
5
6
Description / functionality
Settings tab is selected / active
System (settings) tab is selected / active
Filter settings area. Contains settings to adjust filter and backflush behaviour
Pressure, flow and delay settings
Treatment mode selection, IMO or USCG.
Log-out button. Press to log out of service page. (Automatic log-out after 10 min.)
Table 15 - Settings page GUI elements
The settings page only allows adjustment of parameters which do not affect the
biological treatment.
To avoid confusion, it is good practice to always log out of the settings page, return to
the control page, and set the control mode to “Local” or “Remote” after completing
any maintenance tasks. This helps avoid risk of control issues at the next ordinary
ballast water operation. Should you forget, the system automatically logs you out of
the settings page after 10 minutes of inactivity.
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5.1.6 Alarms page
The alarms page allows the operator to view and acknowledge any alarms or warnings which may
have been set.
Figure 13 - Alarms page: Active alarms
The GUI elements are:
Alarms (active alarms) page
Pos
1
2
3
4
5
6
Description / functionality
Alarms tab is selected / active
Timestamp for alarm event
Status of alarm. See below
Level of alarm. Can be:
“Error” or “Warning”
Alarm text
Button to acknowledge the selected alarms
Table 16 - Alarms page (active alarms) GUI elements
Alarms in the treatment control system are divided into two main categories, “warnings” and
“errors”. The two types of alarms are easily separated by their category classification in the “level”
column (pos 4).
Alarms can be acknowledged individually by double-clicking (tapping) anywhere on a
line.
All alarms can be acknowledged together by pressing the "Acknowledge all" button.
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Alarms can have several statuses:
•
•
•
“UNACK-SET” is an alarm that is set and has not yet been acknowledged by the operator. It
will not disappear when acknowledged, simply change its state.
“SET” is an alarm that is set, but has been acknowledged by the operator – it will disappear
once the event that caused the alarm has been remedied.
“UNACK” is an alarm that is no longer set, but has not yet been acknowledged by the
operator. It will disappear when acknowledged.
Unacknowledged alarms appear in red text.
Acknowledged alarms appear in yellow text.
5.1.6.1 Warnings
A warning is an alarm that is not necessarily disruptive to system operation, but functions more as a
notification that something might be, or soon could be, going wrong. It is also used to give general
information concerning events that hinder the system from operating, but are easily fixed (such as
the service mode warning or the UV cool down warning).
Please see section 9.1.1 and 9.1.2 for a complete list of warnings and suggested remedial actions.
5.1.6.2 Errors
An error is an alarm that is disruptive of proper operation of the treatment system. If such an error
occurs, one or more aspects of the treatment system will not work properly, or at all.
Please see section 9.1.2 and 9.2.2 for a complete list of errors and suggested remedial actions.
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5.2 Recommended REMOTE user interface
5.2.1 REMOTE IAS user interface
The manufacturer of the IAS creates the interface layout for the remote operation of the BWMS. The
functionality and layout may therefore vary between different types and makes of IAS.
The recommended layout for the REMOTE user interface is shown below. Functions and status lights
are grouped to minimise the workload for the operator and promote a clear overview of the status
of the BWMS.
The REMOTE user interface on your vessel may be different from the recommended layout.
Always consult the IAS documentation before operating a system you are not familiar with.
Figure 14 - Recommended layout of IAS REMOTE user interface for BWMS
The GUI elements of the REMOTE user interface and their interaction with the IAS are:
ID
1
SIGNAL
START FILLING
2
3
FILLING
START DISCHARGE
4
5
DISCHARGING
START STRIPPING
6
7
8
STRIPPING
STOP OPERATION
START FLUSHING CYCLE
9
10
11
FLUSHING
BW SYSTEM PRESSURE
BW SYSTEM FLOW
DESCRIPTION
Output from IAS. Start filling command to NGT BWMS
Input signal to IAS. Feedback from NGT BWMS that filling mode is
activated.
Output from IAS. Start discharge command to NGT BWMS
Input signal to IAS. Feedback from NGT BWMS that discharge mode
is activated.
Output from IAS. Start stripping command to NGT BWMS
Input signal to IAS. Feedback from NGT BWMS that stripping mode
is activated.
Output from IAS. Stop operation command to NGT BWMS
Output from IAS. Start flushing cycle command to NGT BWMS
Input signal to IAS. Feedback from NGT BWMS that flushing is
active.
Input signal to IAS. Analog signal, pressure in Bar
Input signal to IAS. Analog signal, flow in m3/h.
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ID
SIGNAL
12
CURRENT FLOW LIMIT
13
SET DESIRED FLOW
14
IMO /USCG MODE
15
16
STOP BALLAST PUMPS
BALLAST PUMP IS
RUNNING
17
UV WARMING UP
18
UV RUNNING
19
UV COOLING DOWN,
STOP PUMPS
20
REDUCED FLOW
21
FLOW LIMIT EXCEEDED
22
UV-I BELOW LIMIT
WARNING
23
UV-I BELOW LIMIT
ALARM
24
SHUTDOWN TIMER
STARTING
25
26
SHUTDOWN TIMER
CONFIRM CONTINUE
NON-COMPLIANT
DESCRIPTION
Input signal to IAS to set the upper flow limit. The IAS must adjust
BW pump or flow reduction valve to limit flow below this value.
Output from IAS. Set a lower flow to limit or increase the amount of
flow for the system. Can be adjusted during operation.
Input signal to IAS. Feedback from NGT BWMS that USCG mode is
activated. Indicators to be arranged (lit) such that OFF = IMO mode
and ON = USCG mode.
Input signal to IAS. BWMS requesting IAS to please stop the ballast
pumps when system is stopping and flow has stopped. System will
not go into stop mode until pumps has been stopped.
Input signal to IAS. Feedback from pumps that one or more pumps
are running.
Input signal to IAS. Feedback from NGT BWMS that system is not
ready for treatment. As long as this signal is active, pumping shall
only be from sea to sea, not to or from ballast water tanks.
Normally achieved through operation procedures (consult Ballast
Water Management Plan for more information).
Input signal to IAS. Feedback from NGT BWMS that system is ready
for treatment and pumping to and from tanks can be performed.
Input signal to IAS. Feedback from NGT BWMS that UV has stopped,
treatment is no longer performed. Ballast water pumps can be
stopped.
Input signal to IAS. Signals that the flow is reduced below nominal
TRC to new limit displayed at Pos 12. Applicable in USCG flow
reduction and stripping modes.
Input signal to IAS. Feedback from NGT BWMS that flow limit has
been exceeded and operator must reduce flow. If in USCG mode:
Automatic flow adjustment has failed to reduce flow below limit.
Operator must investigate and adjust flow manually to continue
operation.
Input signal to IAS. Feedback from NGT BWMS that UV-I is below
current UV-I limit. If flow is not reduced according to current UVI
the UV-I error will occur.
Input signal to IAS. Feedback from NGT BWMS that UV-I is below
current UV-I limit. Operator must make a choice within 60 seconds:
Stop operation or continue with non-compliant treatment.
Input signal to IAS. Signal to indicate that shutdown timer will start
counting down. Timer count down from 60 s which starts when
insufficient treatment is detected.
Input signal to IAS. Timer for shutdown that shows remaining time
before BWMS will initiate stop after UV-I Treatment Out of spec is
set. This signal is only sent by modbus, if the IAS has only hardwired
signals from BWMS, then this timer must be created in the IAS and
its starting signal is sent from the Shutdown Timer Starting signal.
Operator has to confirm to continue non-compliant within time to
avoid shutdown.
Output from IAS. Confirm continue command to NGT BWMS.
Confirms (Acknowledges) that operation should continue even if
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ID
SIGNAL
27
RELEASE CONTROL
30
REQUEST REMOTE
CONTROL
CONFIRM REMOTE
CONTROL
REMOTE CONTROL
ENABLED
31
REMOTE CONTROL
ACCEPTED
32
OTHER OPERATIONS
(OUTPUT)
28
29
33
34
BYPASS VALVE IS OPEN
OTHER OPERATIONS
(IS ACTIVE - INPUT)
38
SYSTEM IS BEING
BYPASSED
RESET ALARMS
ALARM (COMMON
MAJOR ERROR)
WARNING (COMMON
MINOR WARNING)
39
ILLEGAL VALVE(S)
35
36
37
DESCRIPTION
treatment is not compliant due to low UV-I value. NGT BWMS
records acknowledgement in event log.
Signal from IAS to BWMS that transfer of control from REMOTE to
LOCAL control station is acknowledged.
Signal from IAS to BWMS that transfer of control from LOCAL to
REMOTE control station is requested. Must be acknowledged on
LOCAL control station before control is transferred.
Signal from IAS to confirm that remote (IAS) still wants control after
BWMS local station has released control.
Input signal to IAS. Feedback from NGT BWMS that control is given
to a Remote Control System (IAS)
Input signal to IAS. Feedback from NGT BWMS that control is
released, and Remote Control System (IAS) can now send Confirm
Remote Control signal to get control.
Output from IAS. Other operation command to NGT BWMS. This
function is to be used when the ballast water system/pump is used
for other operations then pumping of ballast water, or internal
transfer. This button/signal has a toggle function. When ON “Bypass
Valve Open Alarm” will not be set in NGT BWMS. The button/signal
shall not be possible to activate when FILLING STARTED or
DISCHARGE STARTED is active. When this signal is active it is
common to interlock so that it is not possible to pump over board
(consult Ballast Water Management Plan for the ship for more
information)
Output from IAS. Since IAS controls the Bypass valve, this will be a
signal to BWMS Control system that indicates that the bypass valve
has been opened. NGT BWMS is bypassed because bypass valve is
open. This can be achieved in two ways: Bypass valve closed signal
is given from IAS to NGT BWMS. NGT BWMS gives an alarm if this
signal goes low. Logic is made in IAS so that a signal is given when
the Bypass valve is NOT closed. NGT BWMS gives an alarm if this
signal goes high. NGT BWMS gives an alarm on this signal and
creates a record in BWMS log.
Input signal to IAS. Feedback from NGT BWMS that other operations
mode is activated and bypass valve alarms are supressed.
Output from IAS. Feedback from NGT BWMS that bypass valve has
been opened by IAS, and that the BWMS is now bypassed, an entry
in the log will be made.
Output from IAS. Reset alarms command to NGT BWMS
Input signal to IAS. Feedback from NGT BWMS active alarm. This
shall give visible and acoustic alarm in IAS
Input signal to IAS. Feedback from NGT BWMS active warning. This
shall give visible warning in IAS
Optional output signal to IAS for indicating that one or more illegal
valve(s) in combinations has been opened.
Table 17 - REMOTE user interface GUI elements
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5.3 System Security
5.3.1 Tamper protection of settings and parameters
The BWMS uses a combination of factory-set and user configurable parameters to control treatment
and define behaviour.
•
•
•
•
The user configurable parameters are available on the password protected settings page and
allow the user to adjust the general behaviour of the BWMS
The user configurable parameters do not affect the biological treatment
The factory-set parameters are used to adapt the generic BWMS control software to the
specific BWMS size and affects treatment process limits such as sensor ranges, flow limits
and warning/error limits
The factory-set parameters are not available for the user to view or change once they are set
during production
The user configurable parameters are summarised in Table 18. Their values are normally identical
across the range of BWMS, except for the parameter value “MinimumFlowDischarge” which
depends on the size of the BWMS.
The user configurable parameters can only be set within the indicated range.
Parameter name
FlushingTime
MinimumInterval
PressureCheckpoint
Settings
group
Filter
Filter
Filter
PressureCheckTimer
BackflushPressCheckpoint
Filter
Filter
MinimumFlowDischarge
StableFlowDelay
FillingPressCheckpoint
DischargePressCheckpoint
Monitoring
Monitoring
Monitoring
Monitoring
LowDiffPressCheckpoint
WarnDiffPressCheckpoint
Monitoring
Monitoring
Settings page name
Backflush time
Minimum interval
Diff. Pressure
checkpoint
Pressure check delay
Power flush back
pressure
Min discharge flow
Flow check delay
Filling; System pressure
Discharge; System
pressure
Low diff. Pressure alarm
High diff. Pressure
warning
Default
Value
20 s
10 s
0.3 bar
0 – 0.3
3s
0–3
2 bar
0 – 10
XX m3/h**
60 s
1.5 bar
2 – 102*
30 – 120
0 – 10
1 bar
0 – 10
-3 bar
-10 – 0
0.7 bar
0–1
Table 18 - Summary of user configurable parameters - typical values
*
**
For complete overview please see section 3.2
For system specific values please see Appendix A.1
34
Range
Min - Max
20 – 120
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The effect of adjustments to the various parameters can be summarised as:
Parameters in the Filter settings group affect the triggering of automatic backflushing cycles:
•
•
•
•
•
FlushingTime defines the time the filter motor runs during each backflushing. A full cycle
takes 20 s to complete. Setting a higher value will cause the backflushing to continue after a
full cycle is completed.
MinimumInterval is the minimum time interval the system will wait before triggering the
next automatic backflush cycle.
PressureCheckPoint is the differential pressure across the filter which will trigger an
automatic backflushing.
PressureCheckTimer is a delay before a high differential pressure measurement is confirmed
and triggers an automatic backflushing
BackflushPressCheckpoint is the target pressure used for control of the main outlet valve
when "power backflushing" is enabled. This function closes the outlet valve partially during a
backflushing cycle to increase the differential pressure across the filter and increase the
efficiency of the backflushing.
Parameters in the Monitoring settings group affect the triggering of warnings during filling and
discharge operations:
•
•
•
•
•
MinimumFlowDischarge defines the minimum allowed flow during discharge and stripping
operations. This can be set lower than the minimum flow during filling to help avoid
repeated stops due to marginal flow during stripping. The value can never be lower than the
system minimum flow defined by MinimumSystemFlow (Table 18)
StableFlowDelay defines the time span before the flow values reported flow meter begins. If
the ballast piping layout results in air pockets or otherwise leads to unstable flow at the start
of ballast operations, the flow meter can be forced to wait for a user determined time span
before measurements begin. The UV unit(s) will remain in “Init” state until a stable flow is
reported.
FillingPressCheckpoint and DischargePressCheckpoint are the target pressures used for
control of the main outlet valve during normal operation. The outlet valve is automatically
throttled to build a slight back pressure across the BWMS to ensure proper operation. The
value during filling is slightly higher to ensure efficient backflushing of the filter.
LowDiffPressCheckpoint is a value used to evaluate if pressure sensors perform correctly.
The BWMS evaluates the difference in pressure before and after the filter. Normally, the
sensor after the filter should report a lower value than the one before. A negative difference
is an indication of a sensor malfunction.
WarnDiffPressCheckpoint defines the differential pressure value triggering a warning that
the filter is becoming clogged.
The parameters “MinimumFlowDischarge” and “StableFlowDelay” are the only flow-related
parameters accessible to the user. Neither of these influence the biological treatment efficacy, but
they are available to allow the user to tune the BWMS for more stable operation during stripping
operations where the flow into the BWMS may contain significant amounts of air.
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The factory-set parameters are summarised in Table 19. Their actual values vary with the size of the
BWMS and are found in BWMS Technical specification Part III, Appendix A.1.
Parameter name
AI_CurrentFlow
BaseRatedTreatmentFlow
HighDiffPressCheckpoint
MinimumFlowFilling
MinimumFlowForUV
MinimumSystemFlow
UVIntensityRequirement
Description
Scaling values for input signal from
flowmeter. See the BWMS Technical
specification in Part III, Appendix A.1
for max flow value at 20mA.
The treatment flow that this unit is
rated for when fully operational
High diff. Pressure error (indicates
clogged filter)
Minimum flow during filling.
Determined by filter backflush
requirements
Minimum flow for safe UV operation.
Minimum flow for system, stop if flow
is below this
Intensity requirement for upholding
rated treatment
Value
4 mA = 0 m3/h
20 mA = XXXX,X m3/h
XXX m3/h
1.0 bar
XX m3/h
XX m3/h
XX m3/h
XXXX W/m2
Table 19 - Summary of factory-set parameters
Never attempt to change protected settings unless you have specific training.
Never attempt to access configuration files. Changing system configuration voids the
type approval and your ballast water operations will be illegal.
5.3.2 Monitoring and logging of process control interruptions
All sensors relevant for the treatment process are monitored in such a way that both sensor
malfunction and cable breakages will be detected. Such malfunctions will result in warnings or errors
which will be logged to the alarm log database.
The BWMS control system will continue to log events and alarms as long as the BWMS control
cabinet is powered and the BWMS control system is running, even in the event of a bypass.
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6 Overview of BWMS operation principles
6.1 Control mode selection
There are two options for control stations:
1. LOCAL control from the BWMS control cabinet touch screen. This is the primary control
station with all system functionality available, developed and provided by NGT.
2. REMOTE control from a mimic screen provided as part of the ship IAS. This option contains a
subset of functionality and is provided by the automation system manufacturer. NGT
provides only recommendations on remote screen layout and functionality.
NGT can also supply a remote mimic screen for remote control of the BWMS system. This
option is for where Remote Control is needed, but integration towards IAS is not possible.
The BWMS can be operated in one of three control modes.
The available control modes are:
Mode
Service
Local
Remote
Control modes
Description
All automatic functions are disabled; system must be manually operated via
the LOCAL control station "Detailed control" page. See section 5.1.2
All manual functions are disabled; system must be operated using the function
buttons on the LOCAL control station "Control page" See section 5.1.1
All manual functions are disabled; system must be operated from remote
system.
Table 20 - List of BWMS control modes
The following rules apply for control transfer between control modes:
•
•
•
Control can be transferred from LOCAL to REMOTE stations while an operation is ongoing.
The ongoing operation will continue.
Control can be transferred from REMOTE stations to the LOCAL screen while an operation is
ongoing. The ongoing operation will continue.
The service mode can only be entered while the system is in standby/stopped state. It is not
possible to enter service mode while an operation is ongoing.
The control mode is selected via a control mode selection panel on the main control page of the
BWMS control system.
The control selection panel is normally hidden, but can be displayed by pressing / tapping
the button “ CHANGE CONTROL MODE” next to the “STOP” button.
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Figure 15 - Main control page with control mode selection panel displayed
The control selection options are:
Pos
1
2
3
4
5
Control page - Control selection panel
Description
Press this button to show control selection panel
When control is requested from an IAS REMOTE control station,
this button must be pressed to acknowledge transfer of control
to the REMOTE control station
Take control locally
When this button is pressed, the BWMS forces LOCAL control,
i.e. control is immediately transferred to the LOCAL control
screen without waiting for acknowledgement on a REMOTE
control station. This is a safety feature to ensure that full LOCAL
control can be achieved in an emergency situation.
Service mode
When this button is pressed, the BWMS enters service mode –
see description in section 6.1.1
Cancel / Close button
Press this button to close control selection panel (if present in
current version)
Option / Button
Change control mode
Release control
Table 21 - Control selection options
Control can be transferred between REMOTE and LOCAL stations while an operation is
ongoing. The service mode can only be entered while the system is in standby/stopped.
When REMOTE control has been requested, a status message “Remote Requested” will be displayed
on the BWMS main control page to alert the operator that a control transfer is requested. To release
control, the operator must activate/display the control selection panel (press "CONTROL MODE”,
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pos 1) and press the “Release control” button, pos 2. Then the Remote station must send a Confirm
signal to get remote control, this must be sent within 60 seconds.
Figure 16 - Status message - Remote requested
6.1.1 Service mode
In “service” mode, the BWMS is operated from the local touch panel on the main control cabinet. It
is possible to manually operate valves from the detailed control page menu as described in section
5.1.2.
“Service” mode is only used for maintenance, fault finding or system tuning and should
never be selected when performing routine ballast water operations.
All alarms for warnings and errors are active while in service mode.
Because valves and UV unit can be operated separately in service mode, it is possible to
open all valves even when the UV lamps are off. To prevent release of untreated water,
the BWMS control system monitors valve positions and UV status to detect possible
discharge of water during service mode. If valve positions indicate discharging, this will
be logged as an event in the event log: "Possible service mode discharging detected".
The operator must always verify that no overboard discharge of untreated water takes
place during service mode, either by stopping the ballast water pump (if running),
ensuring that UV unit(s) are operating, or directing water to a holding tank for future
treatment.
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6.1.2 Local mode
In “local” mode, the BWMS can only be operated from the local touch panel on the main control
cabinet.
The control system home page displays system status and values of key parameters. The filling,
discharge, stop and flushing operations can be selected from the control home page.
While in local mode, more detailed process information can be accessed by pressing the various
component symbols. E.g., if the filter / UV dialog box is pressed, an expanded view with valve status
and more parameter values is presented.
Alarm messages can be accessed and acknowledged from the alarm menu. Alarms are also passed to
the IAS.
6.1.3 Remote mode
In “remote” mode, the BWMS is controlled from the REMOTE user interface in the IAS. The BWMS
receives control signals from the ship IAS. The recommended REMOTE user interface contains
buttons to select the filling, discharge, stripping, stop and flushing operations. In addition, flow and
pressure readings are displayed. The REMOTE user interface also contains status lights for key
functionality:
•
•
•
•
•
•
•
Filling, discharge, stripping or flushing operation started
Flow reduction active
Active warning or alarm
Bypass valve open
Remote operation active
UV status (warming up, running, cooling down)
Warnings about flow and UV limit violation and a button to override stop at low UV-I
readings
The recommended REMOTE user interface functionality is explained in section 5.2.
Please also refer to the IAS or ballast water control system documentation for details.
In remote mode, the local touch panel displays process information but cannot be used to control
the BWMS functions.
Alarms from the BWMS are handled on the IAS alarm display along with all other alarms onboard.
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6.2 Normal ballast water treatment operations
The process steps for a complete ballast water treatment include:
1. Ballast water filling
a. Pump ballast water from sea
b. Filter ballast water
c. Apply first UV treatment
d. Pump treated water to ballast tank
2. Holding time in ballast water tank
a. Hold treated water in tank during voyage
3. Ballast water discharge
a. Pump treated water from ballast water tank
b. Apply second UV treatment
c. Discharge ballast water to sea
The BWMS automatically manages the filtering process and the settings for the UV treatments to
meet the IMO ballast water discharge standards for both filling and discharge operations.
The BWMS also includes an automated operating mode for stripping of ballast water tanks using an
ejector pump. The stripping mode is similar to the discharge mode, but the treatment capacity is
reduced to account for possible effects of particles in the ejector driving water.
The treatment process and ballast water operations are identical for skid mounted and separate
component units.
6.3 Regulation of ballast water treatment
The treatment processes are regulated by the BWMS controller and the UV controller. The BWMS
controller handles:
•
•
•
Filtering
Valve settings for flow and pressure regulation
Flow monitoring
The UV controller regulates:
•
UV treatment
6.3.1 Filtering
The filter is composed of a basket and an internal flushing device.
During normal filtering (left side of Figure 17), the water is forced through the mesh into the clean
side of the filter, and then exits the filter through the filter outlet.
The particle filter needs to be backflushed at intervals to clear deposits and fouling from the filter
mesh. During a backflushing, the flow across the filter mesh is temporarily reversed and any fouling
on the mesh is flushed out through the backflush overboard line.
A pump is installed to increase the efficiency of backflushing cycles. The pump starts and stops
automatically.
During a backflushing operation, the main flow may decrease slightly depending on the type of
ballast pump.
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Figure 17 - Particle filter operating principle
During a backflush cycle(right side of Figure 17), a moveable backflush outlet is moved by the motor
on filter top.
The pressure in the backflush discharge pipe is much lower than in the clean side of the filter and
water is now forced backwards through the mesh, dislodging particles from the mesh. In addition,
the pressure difference between filter inlet and the backflush discharge creates a strong axial flow
through the filter mesh which flushes all dislodged particles out through the backflush discharge.
The backflush discharge is lead via the backflush pipe and overboard. It is worth nothing that
although this water is untreated, it is released at the location of ballast water intake, and contains
only species that are indigenous to that location.
The need for a backflushing operation is governed by the quality of the intake water. A higher
concentration of suspended matter will lead to more frequent backflushing cycles because more
particles are caught by the filter mesh and needs to be cleared off.
The pressure differential across the filter is calculated by the BWMS control system based on the
readings from the two pressure transducers PT1 and PT2.
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The control system evaluates the pressure difference against a threshold and an upper limit to
determine the state of the filter and initiate automatic backflush cycles:
•
•
•
•
If the pressure difference is above the threshold, a backflush cycle is initiated
If the pressure difference is above the warning limit, a warning about possibly clogged filter
is issued
If the pressure difference is above the upper limit, the filter is likely clogged and the BWMS
must stop to protect the filter from damage. The BWMS enters the protect filter - stop mode
to protect filter mesh.
The operator must decide whether to stop the ballast operation and clear the filter, or
bypass the BWMS and continue the ballast operation.
Log entries are made for each backflush cycle, and in the event of a warning or alarm about high
pressure differential.
Parameter
Threshold
Value
0.3 bar
Upper
limit
1.0 bar
Delay
5s
Action
Initiate backflush cycle.
Log entry.
Warning at 0.7 bar, log entry.
Alarm and filter protection – stop
mode at upper limit, log entry
Comment
Normal operation.
System automatically increases
backflushing frequency with increasing
pressure difference.
Before triggering warning and alarm
action.
Table 22 - Pressure settings for filtering control
When stopping the BWMS after a ballast water intake operation, a full backflushing cycle is
automatically completed to ensure that all contamination is removed from the filter and not carried
over to the next location for ballast water intake.
6.3.2 Monitoring of flow
The flow meter readings are continuously evaluated by the BWMS control system to ensure that:
•
•
There is a minimum flow past the UV chamber(s) to avoid overheating
The flow through the system is within the treatment capacity of the BWMS
If the measured flow is continuously below the minimum limit, the UV lamps will not ignite, or, if
running, they will power off and initiate the cool-down sequence to avoid overheating. An entry will
be made in the log system that the UV units were stopped due to lack of flow.
The measured flow is compared to the applicable TRC limit to ensure that flow is within the
treatable range.
If flow is above the TRC, the UV treatment will not be sufficient to meet the ballast water discharge
standards. Notifications, warnings and errors are triggered when the TRC is exceeded by margins as
defined below. This is to alert the operator that flow must be reduced, and eventually stop the
BWMS if flow continuously exceeds the TRC by a margin of more than 5%.
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The flow monitoring parameters are:
Parameter
Minimum
limit
Value
25 –139 m3/h
Notification Current TRC
limit
Action
Error: Misc_5: Flow too
low to run UV unit(s) and
stop if below limit, log
entry.
Notification: Misc_17:
Flow above system rating
detected, log entry
Warning
limit
Current TRC
+ 2.5%
Warning: Misc_18: Flow
above system rating
detected, log entry
Error limit
Current TRC
+ 5%
Error: Misc_7: Flow
above system rating
detected, stop, log entry.
Delay
10 s if below
limit
60 s if above
limit
Comment
Depending on BWMS model.
Refer to Table 2 and the technical
specification in Part III, Appendix A.1
for minimum flow limits
Applies to the current flow limit, either
full TRC or flow reduction settings.
Refer to Part III, Appendix A.1 for
determination of maximum TRC
Applies to the current flow limit, either
full TRC or flow reduction settings.
Refer to Part III, Appendix A.1 for
determination of maximum TRC
Applies to the current flow limit, either
full TRC or flow reduction settings.
Refer to Part III, Appendix A.1 for
determination of maximum TRC
Notification, warning or error is set
immediately, stop after indicated delay
Table 23 - Flow monitoring parameters
The outcome of a flow above TRC event is:
•
•
•
The system is set up to regulate the flow based on flow limits and readings from the
flowmeter.
If the regulation fails, the operator is given 60 seconds to adjust flow below limit. The
operator must override IAS pump settings or stop the system to investigate the cause.
If flow is still above limit after 60 seconds, the system will perform a stop.
Log entries will be made when the maximum treatment flow is exceeded, for both notifications,
warnings and errors.
6.3.3 Valve settings for flow direction and pressure regulation
The BWMS valves are adjusted automatically for each operating mode.
The process control valves V1, V2, V3 and V5, and the backflush overboard valve V10 are either fully
open or fully closed, to direct the flow through or past the filter, and to allow discharge of the
backflush discharge water.
The outlet valve V4 is normally 100% open during ballasting and de-ballasting operation.
In backflush sequence valve V4 is adjusted to achieve the correct back pressure across the BWMS to
ensure good backflushing performance. To avoid pressure build-up, the valve never closes beyond
30% during these operations.
The flow through the BWMS must be adjusted by changing the ballast water pump settings or
operating a flow regulation valve external to the BWMS.
See Section 7.3 and 7.4 for lists of valve positions and system states in filling and discharge modes.
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6.3.4 Temperature monitoring
The UV controller monitors the water temperature in the UV chamber and the UV power cabinet to
prevent overheating of UV lamps and power supply components.
The temperature measurements are not used to regulate UV treatment. Warnings and errors are
issued if temperatures exceed thresholds and limits. The temperature limit values are summarised in
Table 24 below.
Location
UV chamber
Value
Threshold = 50°C
UV chamber
Limit = 60°C
UV power
cabinet
Threshold = 50°C
UV power
cabinet
Limit = 60°C
Delay
10 s
Action
If above threshold:
Warning UV1_04:
UVUnit 1: Water getting
warm, log entry.
If above limit:
Error UV1_10:
UVUnit 1: Water too
hot, stop, log entry.
If above threshold:
Warning UV1_05:
UVUnit 1: Cabinet
getting warm, log entry.
If above limit:
Error UV1_11
UVUnit 1:Cabinet too
hot, stop, log entry.
Comment
The operator should attempt to
increase flow to increase cooling.
UV lamps must be shut down to avoid
overheating and potential damage to
lamps
The crew should check that cooling
fans are running and that air filters are
clean.
UV power supply must be shut down
to prevent overheating.
Before triggering designated action.
Table 24 - Summary of UV system temperature limits
6.3.5 UV Treatment
The BWMS has two control modes, IMO Mode or USCG Mode. IMO Mode is used for ballasting and
de-ballasting operations outside US waters. For any ballasting or de-ballasting operation in US
waters, the USCG Mode must be activated. USCG Mode must also be activated before treating any
ballast water that is planned discharged in US waters.
The operator must make a choice of operation mode, based on planned ballasting operations.
Description of mode selection is found in Chapter 5.1.5.
The UV treatment is controlled by the UV controller based on readings from the UV light intensity
sensor.
The regulation is based on measurement of the UV intensity at the UV light sensor, inside of the UV
chamber. The measured UV intensity depends on the UV transmission of the water, fouling on
quarts sleeves and UV lamp efficacy.
For a given flow, a set minimum UV intensity is necessary to treat the water and achieve the
required biological efficacy. The UV controller monitors the measured UV intensity and adjusts UV
power to achieve the required UV intensity according to actual flow in the most efficient way.
When UV-intensity changes because of changes in UV transmission, the UV power and flow is
adjusted automatically in the following order:
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1. The UV controller always attempts to run at maximum flow and reduce power in steps, in an
attempt to save energy
2. The UV controller always start at 100% power
3. If UV-intensity allow it, step-wise power reduction is initiated
4. If UV-intensity decreases due to decreasing UV transmission, the UV power is increased in
steps, until UV is operating at maximum power
5. If power is at maximum and UV-intensity continues to decrease, the UV controller requests a
reduction in flow
UV power is adjusted in fixed steps between:
•
•
60% (minimum power setting)
100% (maximum power setting)
The quantity of power steps will vary depending on system size and power supply.
UV systems with ballast controlled UV lamps will operate with four power steps, UV systems with
transformer controlled UV lamps will operate with three power steps. (For system specific data
please see Part III, Appendix A.1)
The operator can set a desired flow in GUI control page. This desired flow will be target flow during
UV-warming up. Once warming up is completed, based on the measured UV-I, a max flow setpoint
will be calculated. If this setpoint is lower than the Desired flow, the UV Max Flow will override the
desired flow. If the Desired flow is set lower than the UV Max Flow, the Desired flow will override
the UV Max flow.
The BWMS is equipped with a conductivity sensor that detects if the salinity in the BWMS inlet water
is < 1 PSU (fresh water). If fresh water is detected, the BWMS will calculate max flow setpoint
according to fresh water control curve. This is only valid in IMO Mode. See figure 18.
The BWMS is designed to operate with active flow control, but can also operate without active flow
control. The UV controller continuously monitors flow versus UV-I, calculates a max flow set point,
and generates a warning signal if UV-I is nearing minimum, and an error signal if minimum UVI I is
reached.
If the BWMS operates without active flow control, then the BWMS will be limited to UV-I value
according Figure 18 at pump capacity. If the UV-I value measured is deemed insufficient, BWMS will
generate warning and error alarms and the operator would need to make decision to stop operation
or continue in non-compliance operation. See Figure 34
Operation during active flow control :
•
The BWMS controller then calculates a new flow target based on the above mentioned max
flow setpoint and warning limit, the ballast pump will adjust the flow to this flow target.
All actions and measurements related to flow and power stepping is based on the systems UV-I
limits. Please refer to appendix Part III, A1 for system specific values.
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The table below shows as an example, the UV-I limits for NGT BWMS DXL12-BK419 in IMO Mode.
UV-I limit at max TRC:
Min. UV-I limit:
19945W/m2
6209 W/m2
Action
Based on
UV-I value
(for NGT BWMS
DXL12-BK419)
W/m2
Power step-down
Power step-up
limit + 35%
23 638
Only at max TRC.
120s
Power step-up
UV-I limit + 10%
17 510
Only for full TRC,
and not max
power step
30s
Warning and error
limits /Flow
regulation
Flow UV-I limit
Between
6 209 – 15 919
Regulated based
on max flow signal
from UV controller
<120s
Warning limit (*)
Min. UV-I limit +10%
6 830
Error limit (*)
Min. UV-I limit
6 209
Comment
Delay
If active flow
regulation
If active flow
regulation
N/A
60s
Table 25- Calculated power/flow set-points and alarm limits for IMO Mode. NGT BWMS DXL12-BK419 is values presented
as example
* If no or defect flow regulation, warning and error limits will occur on higher values calculated from the UV-Controller
The table below shows as an example, the UV-I limits for NGT BWMS DXL12-BK419 in USCG Mode.
UV-I limit at max TRC:
Min. UV-I limit:
29524W/m2
6209 W/m2
Action
Based on
UV-I value
(for NGT BWMS
DXL12-BK419)
W/m2
Warning and error
limits /Flow
regulation
Flow UV-I limit
Between
6 209 – 29 524
Warning limit (*)
Min. UV-I limit +10%
6 830
Error limit (*)
Min. UV-I limit
6 209
Comment
Delay
Regulated based
on max flow signal
from UV controller
<120s
If active flow
regulation
If active flow
regulation
N/A
60s
Table 53- Calculated power/flow set-points and alarm limits for USCG Mode. NGT BWMS DXL12-BK419 is values presented
as example
* If no or defect flow regulation, warning and error limits will occur on higher values calculated from the UV-Controller
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The detailed steps in the controller logic are summarised below:
•
•
•
•
•
•
•
•
•
If measured UV intensity is above the power step-down setpoint, the UV controller will
attempt to step down in power. (When USCG Mode is selected, there is no power stepping,
and the system always operates at 100% power)
If measured UV intensity is below the power step-up setpoint, the UV controller will attempt
to step up in power if possible.
If measured UV intensity is below the flow reduction setpoint for the actual flow, and the
power is at 100%, the UV controller will calculate a new max flow set point. The BWMS
controller then calculates a new flow target based on the above mentioned max flow
setpoint, the ballast pump will adjust the flow to this flow target.
The UV controller continuously calculate a max flow set point, and also provides a warning
signal if UV-I is nearing minimum, and an error signal if minimum UVI I is reached.
When the UV controller is in flow reduction mode, the system operates at 100% UV power
and power stepping is not performed.
If UV intensity increases, the flow can be stepped up again.
If UV intensity reaches warning setpoint for lowest UV-I, no further flow reduction is
possible and system is operating at lowest capacity
If UV intensity drops to error setpoint for the actual flow or gets below error limit for lowest
UV-I, the UV controller will set an error and a dialog box will inform the operator to: Stop
operation or continue outside the claimed performance
If the operator opts to continue, a log entry (Table 49, event “No or reduced treatment
allowed by operator”) will be made.
The detailed steps in the controller logic without active flow control are summarised below:
•
•
•
•
•
If measured UV intensity is above the power step-down setpoint, the UV controller will
attempt to step down in power
If measured UV intensity is below the power step-up setpoint, the UV controller will attempt
to step up in power if possible
If measured UV intensity is below warning setpoint, and the power is at 100%, the BWMS
will generate warning alarm
If measured UV intensity is below error setpoint, the BWMS will generate error alarm and
the operator would need to make decision to stop operation or continue in non-compliance
operation
If the operator opts to continue, a log entry (Table 49, event “No or reduced treatment
allowed by operator”) will be made If UV intensity increases above the error limit during the
60 second timer, the error will be reset and normal operation is resumed. A new log entry
will be made to indicate that treatment was restored.
USCG Mode
When the USCG Mode is active, the BWMS will ensure to treat the water and achieve the required
biological efficacy, as required by USCG. The functionality and control logic is the same when USCG
Mode is active, as described earlier in chapter 6.3.5, but in USCG Mode, the system will always
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operate with 100% UV power. UV design limits for BWMS operation is lower in USCG Mode
compared to IMO Mode. See figure 18 below.
If the operator opts to continue an operation with UV intensity below the limit, the UV
treatment is insufficient to ensure that the ballast water is complying with the ballast
water standard.
This means that the ballast water cannot be legally discharged, and the event log will
contain an entry marked: “No or reduced treatment allowed by operator”.
Ignoring the UV intensity limit should only be done when safety considerations dictate
that ballast water operations must continue regardless of treatment status.
The officer in charge must make an entry in the ballast water log stating the date and
reason for the non-compliant operation.
The USCG mode shall be activated before treating any ballast water that is planned to
be discharged in US waters. The USCG mode must be used for both treatment at ballast
water uptake (even if outside of US waters) and treatment at discharge.
To illustrate the correlation between different UV-I measures towards flow, see Figure 18.
Flow vs. UVI
Flow Marine/brakish water
Flow Fresh water (<1 PSU)
Flow USCG Mode
300
Flow [m3/h]
250
200
150
100
50
0
0
5000
10000
15000
20000
UVI [W/m2]
Figure 18 - Flow versus UV-I correlation
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30000
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BWMS capacity range 30-3100
7 Standard operation procedures
The BWMS provides automated process control for 5 main operations which are performed
regularly:
1.
2.
3.
4.
5.
Filling operations
Discharge operations
Stripping operations
Normal stop sequence
Flushing of the BWMS with fresh water after operation
7.1 Labour burden and requirements to operator training
Personnel operating the BWMS must have received basic familiarisation training for the BWMS and
must be familiar with the vessel ballast water management plan and ballast water control systems.
The BWMS can be operated in any of the 5 main operating modes by a single person.
The BWMS requires only simple pushbutton orders and adds little or no time to the ballast water
operations, apart from the necessary waiting time for initialising and valve settings required to
redirect ballast water flow during initialising.
7.2 Selecting control mode
The five main operations can all be controlled from the REMOTE user interface or from the local
touch screen on the BWMS control cabinet. You must select a control mode by selecting the control
mode as described in section6.1.
During normal vessel operations, you will probably prefer to operate the system in
remote control mode for convenience.
The USCG mode shall be activated before treating any ballast water that is planned to
be discharged in US waters. The USCG mode must be used for both treatment at
ballast water uptake (even if outside of US waters) and treatment at discharge.
7.2.1 REMOTE control mode
To enable remote control, the system must be in the following state:
•
•
•
•
•
Power switches on BWMS and UV cabinets activated
Outlet valve (pos. 10) on NGT detailed control home page set to Auto (See Figure 7)
“REMOTE” operation requested from IAS, BWMS LOCAL screen has released control, and IAS
has acknowledged control with confirm signal. (See Figure 19)
"REMOTE CONTROL ENABLED" status light (pos. 5) on LOCAL control screen is green
(See Figure 6)
“REMOTE ENABLED” status light (pos. 26) on REMOTE user interface is green (See Figure 14)
The BWMS can now be operated remotely from the REMOTE user interface in the IAS.
The REMOTE user interface on your vessel may be different from the recommended
layout. Always consult the IAS documentation before operating a system you are not
familiar with.
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Figure 19 - Steps to enable REMOTE control
7.2.2 LOCAL control mode
To enable local operation, the system must be in the following state:
•
•
•
•
Power switches on BWMS and UV cabinets activated
LOCAL control forced from BWMS LOCAL screen
Control mode status (pos. 17) on the control home page shows “LocalControl” (See Figure 6)
Outlet valve (pos. 10) on NGT detailed control home page set to Auto (See Figure 7)
The BWMS can now be operated from the local touch screen on the BWMS controller.
Figure 20- Steps to enable LOCAL control
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7.3 Filling operation (Ballasting)
The filling mode is used when taking on ballast water. During filling, the system can be in one of two
states:
1. InitFilling: Waiting for valves to be set, feedback signal from ballast water pump and flow to
stabilise above the minimum limit. Warming up UV lamps for 5 minutes.
2. Filling: Once the UV lamps are running and all parameters are within expected intervals, the
BWMS will enter the Filling state.
7.3.1 Standard operating procedures
The standard operating procedure is:
1. Open any valves in the backflush overboard line (other than the BWMS V10)
2. Set the ballast water (BW) valves to suction from sea chest, via BWMS and overboard
3. Select “Start filling” operation from LOCAL control screen or REMOTE user interface. (See
Figure 21) The BWMS enters the "InitFilling" state.
4. Start the ballast pump and check that flow is above minimum level (See Table 26).
5. The UV lamps will automatically ignite and start warming up when the flow is stable. The
warm up time is 5 minutes.
6. When the UV lamps are warmed up, the system enters the "Filling" state.
7. When the system status reads "Filling", you can set BW valves to fill the desired tank(s) and
close the overboard valve.
8. When all planned filling is complete, it is recommended to pump a quantity of treated water
from one of the ballast tanks, via actual pipe lines and back overboard. This ensures that no
untreated sea water remains in the BW pipelines. It is recommended to run the pump for
approximately 1 minute.
9. Select "Stop" to shut down the system. See separate procedure in Stripping of ballast water
tanks.
10. Close valves in the backflush overboard line.
Please note:
•
•
•
•
During the InitFilling state, the UV lamps need a warm-up time of 5 minutes before they are
operational.
During the warm-up time, the UV intensity is not sufficient for proper treatment and you
must set the ballast water valves to pump from sea, through the BWMS and back overboard
(Step 1). This ensures that there is flow through the system but discharges the insufficiently
treated water back overboard.
After 5 minutes, the UV lamps are warmed up and the UV intensity is sufficient for
treatment. You can now switch to pumping from sea to ballast tanks. (Step 6)
On installations were the backflush line is connected to the main overboard line, an extra
valve is to be mounted upstream of the connection point for the backflush line. This due to
in this case the overboard valve need to be open all time during filling to allow backflush.
The new valve to be closed after end of warming up time, and valves for inlet to ballast tanks
are opened.
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Make sure that all valves in the backflush overboard line are open during filling, such
that the BWMS can be backflushed. Only valve V10 is controlled by the BWMS, all
other valves must be manually set to open during filling, and manually closed when
filling is completed.
See Troubleshooting for filling operations for information on troubleshooting for
"Filling" operations.
Figure 21- Steps to start and stop filling operation
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7.3.2 Process parameters for filling operation
The expected range of process parameters in filling mode is:
Parameter
Valve V1
Valve V2
Valve V3
Valve V5
Valve V4
Value
Open
Open
Closed
Open
Open valve to 100%.
Then automatic: >30% open
Flow
> minimum limit for filling
(24 – 181m3/h)
Pressure @ P1
P1 ≈ P2+0.15 bar
Pressure @ P2
P2 = 1.5 bar
System state
"Filling"
"Start filling" button
UV status
Flashing green, then
Solid green
"Running"
UV intensity
> xxxxx W/m2
Water temperature in UV
chamber
Filter status
< 60°C
"Monitoring"
"Backflushing" as needed
Comment
Automatically adjusted to achieve
correct pressure reading at P2 if
backflushing operation. Valve never
closes to less than 30% open during
operation.
Varies with BWMS model. See Part III,
Appendix A.1 for specific value for
your installation
Pressure drop across filter must be
less than 1 bar. Normal pressure drop
across clean filter is about 0.1 bar.
Target minimum value for optimum
backflushing function, varies with
pump type and ballast system layout.
After 5 min. warm-up in InitFilling
state
In InitFilling
In Filling
All UV lamps are lit. Expect 5 min.
warm-up time with status "Warming
up"
Lower error limit.
Actual intensity will vary with UV
power and UV transmission index.
See Part III, Appendix A.1 for specific
value for your installation
Upper error limit. Expect values below
50°C during normal operation.
Filter is running. Pressure difference is
being monitored.
Backflushing occurs when pressure
difference exceeds 0.3 bar.
Table 26 - Expected process parameter values during filling operations
If the flow drops below the minimum level at any time during the filling, the BWMS will
enter the stop mode to prevent overheating. Refer to the technical specification in
Appendix A.1 for allowable minimum flow levels in filling and set your ballast pump
accordingly.
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If the UV is shut down due to lack of flow, a cooling period of 10 minutes is required before the
system can be restarted.
7.3.3 Process diagrams for filling operation
The state of the BWMS during a filling operation is illustrated in Figure 22 below.
Figure 22 - BWMS state during filling operation
When a backflush operation is in progress, the following components are activated:
•
•
•
•
The backflush filter outlet valve V9 opens
The backflush overboard line valve V10 opens
The backflush pump BFP1 with motor M1 starts
The filter motor M2 starts and directs backflush flow across the filter basket
The state of the BWMS while backflushing during a filling operation is illustrated in Figure 23- BWMS
state during backflushingbelow.
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Figure 23- BWMS state during backflushing
When the backflush operation is completed, the components in the backflush system returns to
standby mode, with the overboard line valve V10 closed.
7.4 Discharge, de-ballasting
The discharge mode is used when releasing ballast water to sea. During discharge, the system can be
in one of two states:
1. InitDischarge: Waiting for valves to be set, feedback signal from ballast water pump and flow
to stabilise above the minimum limit. Warming up UV lamps for 5 minutes.
2. Discharge: Once the UV lamps are running and all parameters are within expected intervals,
the BWMS will enter the Discharge state.
7.4.1 Standard operating procedures
The standard operating procedure is:
1. Set the ballast water (BW) valves to suction from sea chest, via BWMS and overboard
2. Select “Start discharge" operation from NGT touch screen or REMOTE user interface. The
BWMS enters the "InitDischarge" state. The "Start discharge" button flashes green.
3. Start the ballast pump and check that flow is above minimum level (see Table 27)
4. The UV lamps will automatically ignite and start warming up when the flow is stable. The
warm up time is 5 minutes.
5. When the UV lamps are warmed up, the system enters the "Discharge" state. The "Start
discharge" button becomes solid green.
6. When the system status reads "Discharge", you can set BW valves to pump from the desired
tank(s) and close the suction from sea chest.
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7. When a tank is empty, select the next tank before the current tank is emptied completely.
8. When all planned discharge is completed, select "Stop" to shut down the system. See
separate procedure.
Please note:
•
•
•
During the InitDischarge state, the UV lamps need a warm-up time of 5 minutes before they
are operational.
During the warm-up time, the UV intensity is not sufficient for proper treatment and you
must set the ballast water valves to pump from sea, through the BWMS and back overboard
(Step 1). This ensures that there is flow through the system but discharges the insufficiently
treated water back overboard.
After 5 minutes, the UV lamps are warmed up and the UV intensity is sufficient for
treatment. You can now switch to pumping from sea to ballast tanks. (Step 6)
See section 9.4 for information on troubleshooting for "Filling" operations.
The discharge operation must be monitored closely. Switch to suction from a different
tank or stop the BWMS system and ballast water pump when the ballast tank is empty.
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7.4.2 Operator actions on GUI for discharge operation
Figure 24- Steps to start and stop discharge operation
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7.4.3 Process parameters for discharge operation
The expected range of process parameters in discharge mode is:
Parameter
Valve V1
Valve V2
Valve V3
Valve V5
Valve V4
Flow
Value
Open
Closed
Open
Closed
Open valve to 100%.
> minimum limit
(2-102 m3/h)
Pressure @ P1
n/a
Pressure @ P2
System state
P2 = 1 bar
"Discharge"
"Start discharge" button
UV status
Flashing green, then
Solid green
"Running"
UV intensity
> xxxx W/m2
Water temperature in UV
chamber
Filter status
< 60°C
Idle
Comment
Filter is bypassed during discharge
Varies with BWMS model. See Part III,
Appendix A.1 for specific value for
your installation
Filter is bypassed during discharge.
Inlet pressure is not used for
regulation.
Target minimum value
After 5 min. warm-up in InitDischarge
state
In InitDischarge
In Discharge
All UV lamps are lit. Expect 5 min.
warm-up time with status "Warming
up"
Lower error limit.
Actual intensity will vary with UV
power and UV transmission index.
See Part III, Appendix A.1 for specific
value for your installation
Upper error limit. Expect values below
50°C during normal operation.
Filter is bypassed during discharge.
Table 27 - Expected process parameter values during discharge operations
If the flow drops below the minimum level at any time during the discharge, the BWMS
will enter the stop mode to prevent overheating. Refer to the technical specification in
Appendix A.1 for allowable minimum flow levels in discharge and set your ballast pump
accordingly.
If the UV is shut down due to lack of flow, a cooling period of 10 minutes is required before the
system can be restarted.
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7.4.4 Process diagram for discharge operation
The state of the BWMS during a discharge operation is illustrated in Figure 25 below.
Figure 25 - BWMS state during discharge operation
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7.5 Stripping of ballast water tanks
The BWMS has a dedicated operating mode for stripping of near empty ballast water tanks.
The stripping mode is based on the use of an ejector, with local driving water filtered through a
strainer at intake. To compensate for any shadowing effects of particles in the driving water, the
maximum flow limit is set to ⅓ of the nominal TRC during stripping. Otherwise, the process and
functionality is identical to the discharge mode.
7.5.1 Standard operating procedures
The standard operating procedure is:
1. Open valves in pipeline from stripping ejector to BWMS and overboard
2. Select "Start Stripping" from LOCAL screen or REMOTE user interface. The BWMS enters the
"InitStripping" state. (See Figure 21 )
3. Start the stripping ejector pump and check that flow is above the minimum flow limit (See
Figure 22)
4. The UV lamps will automatically ignite and start warming up when the flow is stable. The
warm up time is 5 minutes.
5. When the UV lamps are warmed up, the system enters the "Stripping" state.
6. When the system status reads "Stripping", you can set BW valves to open suction from the
desired tank(s).
7. When a tank is empty, select the next tank.
8. When all planned stripping is completed, select "Stop" to shut down the system.
Please note. The stripping operation is largely identical to a discharge operation and the same
limitations apply:
•
•
During the InitStripping state, the UV lamps need a warm-up time of 5 minutes before they
are operational.
During the warm-up time, the UV intensity is not sufficient for proper treatment and valves
from ballast tank not to be open until warming up is finished. After 5 minutes, the UV lamps
are warmed up and the UV intensity is sufficient for treatment.
See section 9.6 for information on troubleshooting for Stripping operations.
Because of the increased risk of large air bubbles and unsteady flow during stripping
operations, you must monitor the stripping operation closely.
When the tank is empty, or in case of large fluctuations in flow (indication that air is
present in the flow), the operation must be stopped immediately.
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7.5.2 Operator actions on GUI for stripping operation
Figure 26 - Steps to start and stop stripping operation
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7.5.3 Process parameters for stripping operation
The expected range of process parameters in stripping mode is:
Parameter
Valve V1
Valve V2
Valve V3
Valve V5
Valve V4
Flow
Pressure @ P1
Value
Open
Closed
Open
Closed
Open valve to 100%.
< ⅓ TRC
> minimum limit
(2-126 m3/h)
n/a
Pressure @ P2
System state
P2 = 1 bar
"Stripping"
"Start stripping" button
UV status
Flashing green, then
Solid green
"Running"
UV intensity
> xxxx W/m2
Water temperature in UV
chamber
Filter status
< 60°C
Idle
Comment
Filter is bypassed during stripping
Varies with BWMS model. See Part III,
Appendix A.1 for specific value for
your installation
Filter is bypassed during stripping.
Inlet pressure is not used for
regulation.
Target minimum value
After 5 min. warm-up in InitStripping
state
In InitStripping
In Stripping
All UV lamps are lit. Expect 5 min.
warm-up time with status "Warming
up"
Lower error limit.
Actual intensity will vary with UV
power and UV transmission index.
See Part III, Appendix A.1 for specific
value for your installation
Upper error limit. Expect values below
50°C during normal operation.
Filter is bypassed during stripping.
Table 28 - Expected process parameters values during stripping operations
If the flow drops below the minimum level at any time during the stripping, the BWMS
will enter the stop mode to prevent overheating. The minimum flow during stripping is
identical to the minimum flow in discharge. Refer to the technical specification in
Appendix A.1 for allowable minimum flow levels in discharge and set your ballast pump
accordingly.
If the UV is shut down due to lack of flow, a cooling period of 10 minutes is required before the
system can be restarted.
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7.5.4 Process diagram for stripping operation
The state of the BWMS during a stripping operation is illustrated in Figure 27 below.
Figure 27 - BWMS state during stripping operation
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7.6 Stop mode
The stop mode is an automated shutdown procedure to ensure that the system is safely shut down
after a ballast water filling or discharge operation. The behaviour depends on the type of operation
that was carried out prior to the stop order:
Before performing Stop from Filling mode the operator must open overboard valve
and closing tank inlet valve(s). This to prevent untreated water entering the tank(s).
•
•
When a stop is ordered from Filling mode, the BWMS performs a backflushing and the UV
lamps are powered off. When the backflushing is completed, you can shut down the ballast
water pump. The BWMS controller waits for the flow to cease, then closes the inlet and
outlet valve.
When a stop is ordered from Discharge mode, the backflushing is omitted. The UV lamps are
powered off, you can shut down the ballast water pump and the BWMS controller will close
the inlet and outlet valves when the flow has ceased.
7.6.1 Standard operating procedure for normal stop
To perform a normal stop from "Filling" mode, the standard procedure is:
1. Select "Stop" on the local NGT touch screen or REMOTE user interface. (See Figure 28)
2. The UV lamps will shut down and the UV unit displays the status "Cooling down".
3. The filter begins a backflushing cycle and the filter status indicates "Backflushing" for
approximately 20 seconds.
4. When a message appears: "Please stop ballast pump", you must stop the ballast water
pump.
5. When the flow has ceased, the inlet valve V1 and outlet valve V4 are closed, and valves V2,
V3 and V5 are opened.
To perform a normal stop from "Discharge" and "Stripping" mode, the standard procedure is:
1. Select "Stop" on the local NGT touch screen or REMOTE user interface.
2. When a message appears: "Please stop ballast pump", you must stop the ballast water
pump.
3. The UV lamps will shut down and the UV unit displays the status "Cooling down".
4. When the flow has ceased, the inlet valve V1 and outlet valve V4 are closed, and valves V2,
V3 and V5 are opened.
The time for the UV to cool down is 10 minutes. The BWMS cannot be restarted before the cooling
completes.
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7.6.2 Operator actions on GUI for stop of operations
Figure 28 - Steps to stop an operation
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7.6.3 Process parameters for normal stop
The expected range of process parameters are:
Parameter
Valve V1
Valve V2
Valve V3
Valve V5
Valve V4
Flow
Value
Closing
Open
Open
Open
Closing (fully)
Decreasing to 0
Pressure @ P1
Decreasing to 0
Pressure @ P2
Decreasing to 0
System state
"Stopping" then
"Waiting for commands"
"Cooling down" then "Off"
UV status
UV intensity
Filter status
Comment
After flow has ceased
After flow has ceased
After operator shuts down ballast
water pump
After operator shuts down ballast
water pump
After operator shuts down ballast
water pump
Decreasing to 0
"Backflushing" or "Idle",
then "Filter bypassed"
UV lamps power off, UV enters off
after cooling down
After UV lamps power off
"Backflushing" if from Filling mode,
"Idle" if from Discharge mode.
Valve V3 opens after flow ceases,
causes filter to be bypassed.
Table 29 - Expected process parameters values during stop
After a ballast water intake or discharge operation, the BWMS enters standby mode automatically
and listens for new orders from the REMOTE user interface or the local touch screen, depending on
the selected control mode.
The UV lamps need a cooling down period of 10 minutes before re‐start after having
been in operation. Please take this into consideration when planning ballasting or de‐
ballasting operations.
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7.7 Flushing
The NGT BWMS is primarily manufactured from corrosion protected components to ensure superior
corrosion resistance. However, if seawater remains in the system for extended periods of time, the
seawater will start “eating” the oxygen from the protecting oxide layer of the stainless steel and very
soon pitting corrosion will occur and result in leaking.
It is very important to ensure that the system is flushed by fresh water after each
operation – both ballast water intake and discharge.
The flushing mode is a maintenance operation used for automated freshwater flushing of the system
after filling or discharge operations. It is used after each filling or discharge operation to evacuate
seawater and preserve the BWMS with freshwater.
When a flushing is ordered, the following events occur:
•
•
•
•
•
•
Valves V16.1 and V16.2 open allow air to enter the system.
The filter drain valve V8 opens to drain the filter from the lowest point.
The backflush valve V10 opens partially, to let seawater evacuate from the system.
The backflush pump is started to pump out all seawater from the system.
The PT3 pressure transducer monitors pressure to determine when the system is fully
drained, then the backflush pump is stopped and filter drain valve V8 and the backflush
valve V10 is closed.
Valves V6 and V11 opens to fill the system with fresh water from the ship's freshwater
system.
7.7.1 Standard operating procedure
The flushing operation is fully automated. The operator orders the flushing to start and system is
drained and refilled with fresh water automatically. The standard operating procedure to perform a
flushing is:
1. Open any valves in the backflush overboard line (other than the BWMS V10)
2. Select "Start flushing cycle" from local NGT touch screen or REMOTE user interface.
(See Figure 29)
3. You must wait for the system to complete the flushing cycle, then confirm that the system
enters the standby state and all air and freshwater valves are returned to closed position.
4. Close valves in the backflush overboard line.
* If the system not to be utilized over a longer period of time, a second flushing sequence is
recommended.
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7.7.2 Operator actions on GUI for flushing operation
Figure 29 - Steps to start flushing operation
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7.7.3 Process diagram for flushing operation
The state of the BWMS during a flushing operation is illustrated in Figure 30 below.
Figure 30 - BWMS state during flushing operation
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7.8 Operating UV lamp wiper
The UV lamps in the UV chamber are protected by quartz glass sleeves. The sleeves become fouled
by impurities in the water and to help remove this fouling, the sleeves are equipped with a wiper
system.
The wipers for the quartz sleeves are to be operated during the filling, depending on the quality of
the water. In polluted waters, the quartz sleeves may need to be operated several times during a
filling cycle.
•
•
On systems with electrically actuated wipers, the wiping occurs automatically.
On systems with manual wipers, the wipers must be manually operated.
7.8.1 Standard operating procedure – manual wiper system
The wipers should be operated at the following times:
1. Before a filling or discharge operation
2. During filling or discharge operation: If the warning UV1_25: "UVUnit1: UVUnit 1: UV
intensity nearing minimum for current flow " occurs. (Note: Similar alarms for UV2 when
more than one UV chamber is installed)
3. During filling or discharge operation: When a reduction in intensity occurs.
4. After each filling or discharge operation is completed
Figure 31 - Operation of manual wiper system for UV lamps
When operating the manual anti-fouling mechanism be careful when removing the
retaining pin. The water pressure will push the wiper rod out of the unit! Always apply
counter pressure when removing the retaining pin.
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To operate the manual wiper and clean the UV lamp quartz sleeves:
1. Locate the wiper handle on the UV chamber (see Figure 31 above)
2. Use one hand to apply counter pressure to the handle
3. Remove the retaining pin and gently allow the water pressure to push the wiper handle out
of the chamber.
4. When the handle is fully extended, gently push it back into the chamber.
5. Insert the retaining pin to hold the handle in the retracted position. Never leave the handle
extended or unsecured.
7.8.2 Standard operating procedure – electrically actuated wiper system
The electrically actuated wiper system will automatically operate when the UV controller determines
a need based on UV intensity readings from the UV light sensor. You do not need to manually
operate the wipers during normal operations.
As part of the scheduled maintenance, the wipers should be operated before the system is flushed
with freshwater. For this purpose, the electric actuated wipers can be started from the UV
controller.
Figure 32 - UV controller front panel
To manually operate the electrically actuated wipers:
1. Press button 4 (
) on the numeric keypad
2. The wipers will automatically perform one complete wipe cycle
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7.9 Sample taking
Port state authorities may request samples of treated ballast water to examine if ballast water can
be legally discharged.
Samples of treated ballast water is taken from an isokinetic sample point, which is normally located
at, or close to the main ballast overboard discharge.
The samples are taken through a special sample valve mounted at the sample point. The sample
valve consists of a bent tube mounted inside the ballast water pipe, a ball valve and a hose barb for
attaching sample taking equipment.
The design of the sample valve, with sample tube, is important to ensure that a valid
sample can be taken in a safe way. Do not use any other device for sample taking at
the BWMS sampling points.
7.9.1 Installing the sample valve
The sample valve is normally not mounted at delivery. A blind flange is installed at the sample point
and the sample valve is attached adjacent to the sample point with one of the blind flange bolts.
The procedure to install the sampling valve is found in the sample taking procedure in Part III,
Appendix H.3.
7.9.2 Standard operating procedure
The ballast water system can be pressurised up to 10 bar during operation and
sampling. Open sampling valve carefully and gradually, and never attempt to move the
sampling valve to a different sampling point while the system is pressurised.
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The sample taking is normally conducted by an appointed laboratory. The laboratory will perform
the sampling by connecting their sampling equipment to the sample valve.
The recommended procedure for sampling is:
1.
2.
3.
4.
5.
Install the sample valve as described in the sample taking procedure in Part III, Appendix
H.3.
Attach the sample taking equipment to the hose barb of the sample valve. If necessary, a
short length of hose with suitable fittings can be inserted between sample valve and
sampling equipment to adapt to the sample equipment dimensions.
When sampling equipment is ready, the ball valve is opened fully.
Flow must be adjusted using the flow meter and flow adjustment valves on the sampling
equipment. Do not throttle the ball valve to reduce flow.
To ensure isokinetic sampling conditions, adjust the sample flow to match the target
sample flow. The target sample flow depends on pipe diameter and ballast water flow,
as indicated in the example Table 30 below. Recommended sample flow values for
specific BWMS sizes are found in the sample taking procedure in Part III, Appendix H.3.
7.9.3 Sampling flow adjustment for isokinetic sampling conditions
To obtain a correct and representative sample, the sample flow must be adjusted to match the
target sample flow which is calculated for specific combinations of pipe dimensions and ballast
water flow values. This ensures that isokinetic flow conditions exist in the sample tube.
The correct target sample flows for your specific installation are found in the sample taking
procedure in Part III, Appendix H.3.
The target sample flows are calculated from the ballast water flow, the main pipe diameter and the
diameter of the sample tube as follows:
𝑄𝑠𝑎𝑚𝑝𝑙𝑒 = 𝑄𝑚𝑎𝑖𝑛 ∗ (
𝐷𝑠𝑎𝑚𝑝𝑙𝑒 2
)
𝐷𝑚𝑎𝑖𝑛
Dsample is either ø12 or ø25, depending on the diameter of the main pipe.
The target sample flows are specified for three values of Qmain:
1. The nominal TRCs
2. ⅔ of TRC
3. ⅓ of TRC
Dmain (mm)
Corresponds to DN
flange size of outlet
valve
Dsample (mm)
12 or 25 mm
depending on BWMS
model
Qmain (m3/h)
TRC
⅔ TRC
⅓ TRC
Qsample (m3/h)
QTRC
QFlow ⅔TRC
QFlow ⅓TRC
Table 30 - Example of target flow values for isokinetic sampling
Correct sample flows for other ballast water flow values can be calculated from the formula above.
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7.10 Other operations
The ballast water pump(s) might be used for operations that do not require treatment, such as
internal transfer, drill water discharge, water to foam system, etc.
In systems where such operations are required, there will be a function (button) marked “Other
operations” to activate a signal to the BWMS, so that no alarm will be given when the bypass valve is
opened.
The IAS system must be programmed to close the main overboard valve while the BWMS bypass
valve is open in order to avoid illegal dumping of untreated water.
The system will be automatically reset to normal when the bypass valve is closed and “other
operations” cancelled after the end of that operation.
Time and duration for the operation will be logged in the BWMS control system.
Never activate “Other operations” while the system is in operation. Complete or stop
the ongoing operation before switching to “Other operations” mode.
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8 Maintenance
To ensure optimum performance it is important to follow the recommendations below, regarding
proper operation and maintenance routines.
All maintenance activities are to be noted in the maintenance log.
8.1 Maintenance tasks after operation
After completion of all ballast water operations before or after a voyage, the system must be flushed
with freshwater to prevent corrosion.
The flushing operation is described in section 7.7.
Failure to perform the freshwater flushing increases the risk of corrosion and promotes
fouling of internal components. Always perform freshwater flushing after operation.
It is good practice to operate the UV chamber wipers when shutting down the BWMS to ensure that
the UV lamp quartz tubes are clean and free from fouling. Manual wipers should be operated as
instructed in section 7.8.1. Electrical wipers are operated automatically by the control system.
The estimated labour burden and required training for the freshwater flushing is:
•
•
No special training required
The flushing operation is automatic and requires only a single press on a button to activate.
8.2 Scheduled maintenance
Maintenance of the BWMS should be planned and managed through the vessel maintenance
planning system. All scheduled maintenance should be logged through the vessel maintenance
planning system.
The necessary scheduled maintenance activities are detailed below.
8.2.1 Maintenance at weekly intervals
Perform a visual inspection of all parts of the BWMS:
•
•
Check freshwater and air pipe connections for leakage.
Check main pipework for leaks at flange connections to components
The estimated labour burden and required training for the weekly maintenance is:
•
•
•
The inspection can be carried out by a single person
The person performing the inspection must be familiar with the P&ID and have a basic
knowledge of shipboard piping installation.
The inspection can be carried out in less than 30 minutes.
8.2.2 Maintenance at monthly intervals
•
•
Check operation of valves by selecting the Service menu at the local panel, open and close
one valve at the time.
Operate the wiper mechanism on the UV chamber to clear away any accumulated fouling
from the UV lamps. See section 7.8 for operation of the wiper system
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•
•
Run a flushing sequence for refreshing the freshwater.
Check the function of the cooling fan in cabinet doors. Change or clean air filters in cooling
fans if dirty.
The estimated labour burden and required training for the monthly maintenance is:
•
•
•
The maintenance operations can be carried out by a single person.
The person performing the maintenance must be familiar with the P&ID and be trained in
the operation of the BWMS.
The maintenance can be carried out in less than 60 minutes.
8.2.3 Maintenance at 6 months intervals
Perform all of the scheduled maintenance activities listed above, and in addition:
•
Perform a thorough check of electrical connections, earth connections and fastening of
cabinets, piping connections and clamping, retighten as required.
The estimated labour burden and required training for the bi-annual maintenance is:
•
•
•
The maintenance operations can be carried out by a single person.
The person performing the maintenance must be familiar with the P&ID and be trained in
the operation of the BWMS, and in addition be certified for work on electrical installations.
The maintenance can be carried out in less than 2 hours.
8.2.4 Maintenance at yearly intervals
Perform all of the scheduled maintenance activities listed above, and in addition:
•
•
•
Check filter body and UV chamber for leaks and signs of corrosion or damage.
Open the particle filter and inspect for corrosion, wear and damage.
Check all internal surfaces for signs of corrosion, wear and damage.
(See Part III, Appendix D.1 section 8.5)
Check the condition of the sacrificial anodes on the filter. Replace the anode if worn. See
Part III, Appendix D.1 section 8.6 for details and note that the filter manufacturers
recommended 6 month inspection interval is extended to 12 months because the system is
preserved with freshwater between operations.
The estimated labour burden and required training for the yearly maintenance is:
•
•
•
The maintenance operations is preferably carried out by two persons.
The persons performing the maintenance must be familiar with the P&ID and be trained in
work on ship systems and pipework.
The maintenance can be carried out in less than 2 hours (4 manhours).
8.2.5 Maintenance at 5 year intervals
Perform all of the scheduled maintenance activities listed above, and in addition:
•
•
Clean the filter basket if fouling or deposits have accumulated.
See Part III, Appendix D.1 section 8.5
Replace the filter anode unless replaced during previous yearly maintenance.
The estimated labour burden and required training for the 5 year maintenance is:
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•
•
•
The maintenance operations is preferably carried out by two persons.
The persons performing the maintenance must be familiar with the P&ID and be trained in
work on ship systems and pipework.
The maintenance can be carried out in less than 4 hours (8 manhours).
8.2.6 Maintenance indicated by warnings
In addition to the regularly scheduled maintenance, the BWMS control system will generate
warnings when maintenance is required based on accumulated operating hours.
This includes the UV lamps, which should routinely be replaced after approximately 3000 running
hours to ensure optimum efficiency and UV light intensity.
The relevant warnings and corrective actions are summarised in Table 31 below.
ID
Misc_2
Alarm text
Too long since last automatic
backflush
Misc_15
Increasing difference pressure
detected across filter
UV1_6
UVUnit 1: Wiper request
maintenance
UV1_16
UVUnit 1: Lamps request
maintenance
UV1_24
UVUnit 1: Replace battery
Recommended action
Initiate a backflush cycle manually.
If condition persists: Check condition of filter insert. Lack of automatic
backflushing is due to low pressure build-up in filter, something which
may indicate a damaged filter insert.
See Part III, Appendix D.1, section 8.5
Estimated labor burden to inspect filter insert: 4 hours.
Filter insert is partly clogged. Rinse filter insert as recommended by
manufacturer. See Part III, Appendix D.1 section 8.5
Estimated labour burden to rinse filter insert: 6 hours
The wiper rings in the automatic wiper mechanism have reached their
lifetime limit and should be replaced. Replace wiper rings and shaft seal
at earliest opportunity.
See Part III, Appendix C.1 section 6.2.3
Estimated labour burden to replace wiper rings: 3 hours
The UV lamps have reached their default/safe lifetime limit and should be
replaced. Schedule replacement at earliest opportunity.
See Part III, Appendix C.1 section 8.
Estimated labour burden to replace UV lamps: 2 hours
The UV controller uses an internal battery for internal backup. The
battery voltage is dropping and the battery should be replaced to avoid a
loss of UV controller settings stored in memory. Schedule replacement of
battery at earliest opportunity.
Please contact NGT for guidance.
Table 31 - Alarms indicating a need for maintenance
Please note that the efficiency of the UV lamps will decline with time. If the system
constantly operates at full UV power and/or near the lower UV intensity limit, it may
be an indication that the lamps are nearing the end of their useful lifetime, regardless
of the accumulated running hours.
8.3 Calibration and zeroing of measurement device
The BWMS is equipped with sensors for monitoring of UV light intensity, water temperature,
pressure and flow, as described in section 4.1.
The sensors are all factory calibrated and no re-calibration is necessary or possible under normal
operating conditions.
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Calibration of sensors requires specialist tools and knowledge.
If you suspect erroneous measurements from a sensor, you must first replace the
sensor to restore correct operation. Contact NGT for advice on correct replacement
parts and how to repair or recalibrate the faulty sensor for future re-use.
The zero point for each sensor can be checked as described below.
8.3.1 UV sensor
Check the zero point for the UV sensor by reading the UV intensity in the UV unit dialog box (pos 10
on Figure 6) on the BWMS main control screen.
When the UV unit is OFF, the UV intensity reading must be 0 w/m2.
8.3.2 Water temperature sensor
The water temperature in the UV chamber is monitored by means of a PT100 temperature sensor.
The measurements of the PT100 must be checked against an independent measurement of the
water temperature. The suggested procedure is:
1. Remove the PT100 sensor from the UV chamber
2. Expose the sensor to a source with a known temperature and check the readings on the
LOCAL control screen.
8.3.3 Pressure transducers
Check the zero point for the pressure transducers by reading the pressure at the filter inlet and filter
outlet (pos 2, pos 7 and pos 12 on Figure 7) on the BWMS detailed control screen.
When the BWMS is in standby state (pos 16 on Figure 6), PT1 and PT2 readings must be 0 bar.
8.3.4 Flowmeter
Check the zero point for the flow meter by reading the flow (pos 11 on Figure 6) on the BWMS main
control screen.
When the BWMS is in standby state (pos 16 on Figure 6), and the outlet valve is fully closed (pos 12
on Figure 6), the flow reading must be 0 m3/h.
8.3.5 Conductivity sensor
The conductivity sensor is factory calibrated and not subject for any recalibration after installation.
If frequent alarms related to measured conductivity occurs, please contact NGT for further support.
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8.4 Necessary tools
A special winch handle for manual actuation of the filter backflushing mechanism is delivered with
the filter for use in case of a fault in the automatic backflushing system.
The winch handle is illustrated in below:
Figure 33 - Winch handle for manual operation of filter
When handling the UV quartz glasses, UV lamps and UV sensor, it is imperative that
clean cotton gloves or similar is used to avoid touching the UV components directly.
Other necessary tools include only hand- and electric tools which are normally found in well assorted
on-board workshops:
•
•
•
•
•
•
•
•
Multimeter
Measurement equipment (caliper, thickness gauges etc).
Assorted metric screwdrivers (flat head, Philips)
Metric Allen wrench for socket head screws
Metric wrench and socket set for hex-head screws
Adjustable torque wrenches for controlled tightening, covering 0-600 Nm range
Rubber and nylon head mallet
High pressure washer equipment with adjustable pressure for cleaning of filter basket
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8.5 Spare parts
In order to comply with the Type Approval, only OEM spare parts can be used and obtained through
official NGT channels.
See section 1.3.2 for contact information for NGT aftermarket services and local agents.
When presenting an inquiry for spare parts, please present the Project and Serial No. stated on the
BWMS identification plate on the spare parts order.
Please see table 51 for recommended spare parts to have during installation and operation of
BWMS.
Qty
1
1
1
1
1
Part Description
UV- Chamber Lamp
UV-Chamber Quartz sleeve with O-rings
Filter Gasket Set, Filter House
Filter Gasket set, Filter Insert
Solenoid valve, Namur ¼» 24VDC
Table 51 – Recommended spare parts
8.6 Repairs
Certain repairs, listed in this section, can be made by the ship’s crew or by yard personnel using
original spare parts provided by NGT.
Repairs on internal components in the control cabinets, the UV chambers, or major overhauls of the
filter should be left to qualified service personnel from, or appointed by, NGT.
Safe and correct function and compliance with the ballast water convention cannot be
guaranteed if unauthorized repairs are made.
8.6.1 Replacement of filter elements
It is recommended to inspect the filter insert every year, to visually observe the condition and
specially look for defects or damaged areas in the filter mesh.
The following alarms / warnings calls for filter element inspection:
Misc_2: Too long since last automatic backflush:
•
•
Indicates that the differential pressure over the filter element has been bellow threshold for
backflushing for a long time, more than 50 hours of operation.
This can be an indication of damages in the filter mesh, preventing differential pressure to
build up.
Misc_3: High difference pressure detected across filter
•
Filter element may be clogged and backflush piping may not open correctly.
The procedure for opening of filter housing and replacement of filter element is described in Part III,
Appendix D.1 chapter 8 with special attention to chapter 8.5.
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8.6.2 Replacement of UV lamps
The following alarms / warnings calls for UV lamp replacement:
UV1_16: UVUnit 1: Lamps request maintenance
•
This warning indicates that lamp life time has passed standard threshold (3000 hours). It is
recommended to replace lamps. This is a warning and if ignored, next level will be alarm that
intensity gets too low.
UV1_25: UVUnit1: UVUnit 1: UV intensity nearing minimum for current flow & UV1_2:UVUnit 1:
Intensity below minimum
•
These alarms occur when UV intensity drops below warning and alarm limits and full power
has been applied. If wiping has been performed as normal and water quality (UVtransmission) is not too low, this is an indication that lamp efficiency is declining and that
lamps should be replaced.
UV1_18-23: UVUnit 1: Lamp group 1..n failure
•
Each lamp group consist of two or three lamps. This alarm indicates that there is no current
going through the two lamps coupled in series. If electric circuits are intact, this is an
indication that one of the lamps are defect.
UV1_9: UVUnit 1: All lamps failure
•
This alarm indicates that there is no current going through any of the lamp groups. If electric
circuits are intact, this is an indication that several lamps are defect.
Procedure for opening of UV chamber and replacement of UV lamps is described in Part III, Appendix
C.1 chapter 8 with special attention to chapter 8.1 and 8.3.
8.6.3 Replacement of quartz sleeves
Broken quartz sleeves will in most situations result in water leakage from the UV chamber.
Procedure for opening of UV chamber and replacement of UV quartz sleeves is described in Part III,
Appendix C.1 chapter 8 with special attention to chapter 8.2.
8.6.4 Replacement of pressure sensors and conductivity sensor
The following alarms / warnings calls for pressure sensor replacement:
Misc_4: Low difference pressure detected across filter - check sensors
•
This warning is related to the unlikely measurement that pressure before filter is lower than
pressure after filter. It should be investigated if there can be a practical reason for this to
happen, if not it may be the result of a defective pressure sensor.
Sensor_1: Possible fault for Pressure sensor filter outlet
•
This alarm indicates that the analog signal from pressure sensor is outside of the 4-20 mA
measurement range. Faulty electric circuits may be a reason for this alarm, or it may be the
result of a defective pressure sensor.
Sensor_2: Possible fault for Pressure sensor filter inlet
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BWMS capacity range 30-3100
•
This alarm indicates that the analog signal from pressure sensor is outside of the 4-20 mA
measurement range. Faulty electric circuits may be a reason for this alarm, or it may be the
result of a defective pressure sensor.
Sensor_3: Possible fault for Pressure sensor freshwater flushing
•
This alarm indicates that the analog signal from pressure sensor is outside of the 4-20 mA
measurement range. Faulty electric circuits may be a reason for this alarm, or it may be the
result of a defective pressure sensor.
Sensor_5: Possible fault for Conductivity sensor
•
This alarm indicates that the analog signal from conductivity sensor is outside of the 4-20 mA
measurement range. Faulty electric circuits may be a reason for this alarm, or it may be the
result of a defective sensor.
The procedure for replacement of sensors is as follows:
1. BWMS must be in stop state. Then secure that system cannot be started by setting system
to local mode and switching of power switches.
2. BWMS must be depressurized and emptied of water.
3. Disconnect electric connection to sensor.
4. Dismount sensor by use of proper wrench key.
5. Mount new sensor by use of proper wrench key.
6. Reconnect electric connection to sensor.
7. Refill BWMS with water again, e.g. by use of automatic flushing.
8. Reset BWMS by switching on power switches and setting desired mode.
8.6.5 Replacement of solenoid valve
The following alarms / warnings calls for solenoid valve inspection / replacement:
Valve1..n: Missing feedback on Valve 1.. n
•
This alarm indicates that the feedback signal from the corresponding valve is not correct.
Check electric circuits and position feedback sensor. Check connected instrument air and
pressure of this. If these are ok, check the solenoid valve.
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BWMS capacity range 30-3100
Procedure for replacement of solenoid valve is as follows:
1. BWMS must be in stop state. Then secure that system cannot be started by setting system
to local mode and switching of power switches.
2. Isolate and depressurise system air supply, secure from accidental opening.
3. Disconnect electric plug on solenoid valve.
4. Dismount solenoid valve by use of proper Allen Wrench.
5. Mount new solenoid valve by use of proper Allen Wrench.
6. Connect electric plug to solenoid valve.
7. Reset BWMS by switching on power switches and setting desired mode.
8. Open supply of system air again
8.6.6 Adjustment to or replacement of valve position feedback sensor
The following alarms / warnings calls for valve position feedback sensor inspection / replacement:
Valve_1..n: Missing feedback on Valve 1.. n
•
This alarm indicates that feedback signal from corresponding valve is not correct. Check
electric circuits and solenoid valve. Check connected instrument air and pressure of this. If
these are ok investigate further the position feedback sensor.
The procedure for adjustment of feedback sensor is as follows:
1. BWMS must be in stop state. Then secure that system cannot be started by setting system
to local mode and switching of power switches.
2. Set valve to open or close position
3. Check that corresponding sensor (micro switch) is activated. If not turn on wheel for
adjustment of cam activating the sensor.
4. Set valve to opposite position (open/close).
5. Check that corresponding sensor (micro switch) is activated. If not turn on wheel for
adjustment of cam activating the sensor.
6. Close feedback sensor box by use of proper tools wrench- / Allen Wrench.
7. Reset BWMS by switching on power switches and setting desired mode.
The procedure for replacement of feedback sensor is as follows:
1. BWMS must be in stop state. Then secure that system cannot be started by setting system
to local mode and switching of power switches.
2. Disconnect electric wiring to feedback sensor.
3. Dismount feedback sensor by use of proper tools wrench- / Allen Wrench.
4. Mount new feedback sensor by use of proper wrench- / Allen Wrench.
5. Connect electric wiring to feedback sensor.
6. Reset BWMS by switching on power switches and setting desired mode.
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BWMS capacity range 30-3100
9 Alarms and trouble shooting
All alarms are displayed locally on the BWMS touch screen.
When the BWMS to IAS communication is hardwired, alarms from the BWMS can be treated as
common warning/alarms in the IAS.
When the BWMS to IAS communication is through Modbus, important alarms, with text and status,
are passed to the IAS.
Alarms in the treatment control system are divided into two main categories, “warnings” and
“errors”. The two types of alarms are easily separated by their "LEVEL" category in the alarm list.
•
•
A warning is an alarm that is not necessarily disruptive to system operation, but functions as
a notification that an unwanted condition is about to occur. It is also used to give general
information concerning events that hinder the system from operating, but are easily
remedied.
An error is an alarm that is disruptive of proper operation of the treatment system. If such
an error occurs, one or more aspects of the treatment system will not work properly, or at
all. Errors can also occur if the system has not been properly monitored – and some physical
variable (for instance too low flow for too long) has caused a malfunction in the treatment
system.
Alarms can have several statuses:
Status
“UNACK-SET”
“SET”
“UNACK”
"OK"
Description
“UNACK-SET” is an alarm that is set and has not yet been acknowledged
by the operator. It will not disappear when acknowledged, simply change
its state.
“SET” is an alarm that is set, but has been acknowledged by the operator –
it will disappear once the event that caused the alarm has been remedied.
“UNACK” is an alarm that is no longer set, but has not yet been
acknowledged by the operator. It will disappear when acknowledged.
Alarms which are both acknowledged and not set (i.e. the alarm condition
is no longer existing) will be given the status "OK" in the log and disappear
from the active alarm list on the alarms page.
Table 32 - Summary of possible alarm statuses
•
•
Unacknowledged alarms appear in red text.
Acknowledged alarms appear in yellow text.
On the BWMS LOCAL screen, the alarms can be acknowledged in two ways:
•
•
Alarms can be acknowledged individually by double-clicking (tapping) anywhere on a line.
Several alarms can be acknowledged together by selecting several alarms and pressing the
"Acknowledge selected" button (pos. 6 on Figure 13)
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9.1 Alarm list
The outcome of BWMS warnings or errors depends on the criticality level of the condition.
In general:
•
•
•
•
Warnings are typically assigned the "Minor" criticality
Errors are assigned the "Major" category
With a minor warning, the operator need not take any action but is warned that an unusual
situation has occurred.
With a major error, operator action is required. The BWMS will normally be allowed to
continue and complete the current operation, but will not be able to start a new operation
until the error is corrected
The complete list of outcomes is:
Outcome
Continue
Continue w. alarm
Continue – No start
Stop
Filter protection –
Stop
Description
Current operation continues without interruption.
Current operation continues but an alarm is set. The cause should be
investigated and corrected at first opportunity.
Current operation can be completed but the BWMS will not be able to
start a new operation until the cause is found and corrected. Typically
applies to feedback signal failures.
The BWMS will perform an ordinary stop sequence and request that the
ballast water pump is stopped. Typically applies when an error occurs
during initialisation before an operation and there is no risk of discharge
of untreated water.
The BWMS will open filter bypass valve (V3), to protect filter mesh from
any damages related to high pressure.
The BWMS will perform an ordinary stop sequence and request that the
ballast water pump is stopped. Typically applies when an error occurs
during initialisation before an operation and there is no risk of discharge
of untreated water.
Table 33 - Description of BWMS alarm outcomes
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BWMS capacity range 30-3100
9.1.1 Warnings
The list of warnings (minor criticality) for the BWMS control system is:
ID
Alarm / Warning text
Criticality
Outcome
Set point
Delay
[s]
Misc_1
Operation could not
start, check if a ballast
pump is running
Minor
Stop
Bool
0
Arming
delay
[s]
0
Misc_2
Too long since last
automatic backflush
No or reduced
treatment detected
Minor
Continue
30 min.
0
0
Minor
Continue
if confirm
Bool
60
0
Service/Maintenance
mode active
Flow below minimum
recommended for
backflushing
Flow below minimum
recommended for
discharging
Operation inhibited
condition detected
Minor
Continue
Bool
0
0
Minor
Continue
12-452
m3/h
0
0
Minor
Continue
5-126
m3/h
0
0
Depends on BWMS size. See
Part III, appendix A.1
Minor
Continue
– No start
Bool
0
0
Misc_15
Increasing difference
pressure detected
across filter
Minor
Continue
0.75 bar
3
0
Misc_17
Flow above system
rating detected
Minor
(Notificati
on)
Continue
Current
TRC
0
0
General warning which is set
when one or more alarms of
category "Continue – No start"
has occurred.
Increasing pressure difference
indicates a partially clogged
filter mesh. Risk of exceeding
filter maximum pressure.
Notification only: System is
operating at maximum TRC.
Misc_18
Flow above system
rating detected
Minor
Continue
0
0
System is operating above
maximum TRC (2.5 %).
Misc_19
Backflush pump has
reached the
recommended running
time for a replacement
Backflush pump has
reached the
recommended running
time for a service check
Minor
Continue
Current
TRC +
2.5%
Bool
0
0
Minor
(Notificati
on)
Continue
Bool
0
0
Boll filter motor has
reached the
recommended running
time for a replacement
Boll filter motor has
reached the
recommended running
time for a service check
Minor
Continue
Bool
0
0
Minor
(Notificati
on)
Continue
Bool
0
0
Transfer of control is
detected
Minor
Continue
Bool
0
0
Backflush pump has reached
running time and needs
replacement (usually after
5000 hours)
Notification that backflush
pump has reached
recommended running time
and needs service check
(usually after 500 hours)
Boll filter motor has reached
recommended running time
and needs replacement
(usually after 5000 hours)
Notification that boll filter
motor has reached
recommended running time
and needs service check
(usually after 500 hours)
Control was transferred to
Remote or to Local station.
Misc_6
Misc_9
Misc_10
Misc_11
Misc_13
Misc_20
Misc_21
Misc_22
Misc_23
87
Cause / comment
A ballast pump is already
running before BWMS is
started. BWMS will remain in
InitFilling/InitDischarge state
until pump is stopped and restarted.
Pre-set time interval between
backflushing was exceeded
Warning which is set if the
operator selects to continue
filling or discharge with UV
intensity below limit. (Dialog
box on error UV1_2)
Control mode selection is set
to "Service"
Depends on BWMS size. See
Part III, appendix A.1
NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
ID
Alarm / Warning text
Criticality
Outcome
Set point
Delay
[s]
Misc_24
Control transfer in
progress
Minor
Continue
Bool
0
Arming
delay
[s]
0
Misc_25
Freshwater is detected
Minor
(Notificati
on)
Continue
Bool
0
0
Flow_1
Waiting for stable flow
or ballast pump running
confirmation
UVUnit 1: Water getting
warm
Minor
(Notificati
on)
Minor
Continue
Bool
0
0
Continue
Bool
(50° C)
0
0
UV1_5
UVUnit 1: Cabinet
getting warm
Minor
Continue
Bool
(50° C)
0
0
UV1_6
UVUnit 1: Wiper
requires maintenance
Minor
Continue
0
0
UV1_16
UVUnit 1: UV Lamps
requires maintenance
UVUnit 1: UV intensity
nearing minimum for
current flow
UVUnit1: UV Lamp or
Group n Fault
Minor
Continue
0
0
Minor
Continue
Bool
(8000
cycles)
Bool
(3000 h)
Bool
(variable)
0
0
Minor
Continue
Bool
0
0
UVUnit1: All UV lamps
failure
UVUnit1: UV Sensor
failure
UVUnit1: UV Dose
warning
UVUnit1: Lost heartbeat
to modbus master
UVUnit1: Ethernet
connection lost
Minor
Continue
Bool
0
0
Minor
Continue
Bool
0
0
Minor
Continue
Bool
0
0
Minor
Continue
Bool
0
0
Minor
Continue
Bool
0
0
UV1_69
UVUnit1: Wiper
initialization failed
Minor
Continue
Bool
0
0
UV1_70
UVUnit1: Wiper motor
is jammed
UVUnit1: Wiper cannot
reach park pos.
UVUnit1: Wiper cannot
reach motorside pos.
Ballast pump 1 Frequency converter is
in LOCAL operation
Minor
Continue
Bool
0
0
Minor
Continue
Bool
0
0
Minor
Continue
Bool
0
0
Minor
Continue
Bool
0
0
Ballast pump 1 - Alarm
from frequency
converter
Ballast pump 2 Frequency converter is
in LOCAL operation
Minor
Continue
Bool
0
0
Minor
Continue
Bool
0
0
Ballast pump 2 - Alarm
from frequency
converter
Minor
Continue
Bool
0
0
UV1_4
UV1_25
UV1_32 ..
63
UV1_64
UV1_65
UV1_66
UV1_67
UV1_68
UV1_71
UV1_72
BPump1_
1
BPump1_
2
BPump2_
1
BPump2_
2
Table 34 - List of BWMS warnings
88
Cause / comment
Control of control is in
progress. For transferring to
Remote, confirm with message
on remote station within 60s
to transfer control.
Conductivity sensor detected
salinity above 1000 that
indicate that water in system is
fresh water
Notification only: Waiting for
stable flow or ballast pump
running confirmation
Water in UV chamber
approaching temperature
limit.
Air temperature in cabinet
approaching temperature
limit.
Pre-set / default maximum
wiper cycle count
Pre-set / default lamp life
setting
Set point is current UV-I limit
+10%. Depends on TRC and/or
flow reduction step
Warning of possible lamp or
lamp group failure. Check
lamps.
Warning of possible fail for all
UV lamps. Check lamps
Warning of possible failure of
UV sensor. Check sensor
Warning of UV dose is too low
according to current flow
Warning of possible loss of
communication heartbeat
Warning of possible loss of
ethernet communication
connection
Warning of possible fail of
wiper initialization. Check
wiper
Warning of possible jamming
of wiper motor. Check wiper
Warning of possible wiper
position failure. Check wiper
Warning of possible wiper
position failure. Check wiper
Frequency Converter 1 has
been set to local operation.
For automatic flow control set
it to auto control
Frequency Converter 1 has
alarm. For details see alarm on
local panel
Frequency Converter 2 has
been set to local operation.
For automatic flow control set
it to auto control
Frequency Converter 2 has
alarm. For details see alarm on
local panel
NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
The set points defined as "Bool" are Boolean values passed to the BWMS controller from either the
UV controller or the IAS. They evaluate to either 0 (false / un-set) or 1 (true / set).
Variable set points are used for the flow and UV intensity limits which are varied. The current flow
value is passed to the UV controller and the appropriate set point value is set.
Figure 34 - UV-I Below Limit
If the operator opts to continue an operation with UV intensity below the limit, the UV
treatment is insufficient to ensure that the ballast water is complying with the ballast
water standard.
This means that the ballast water cannot be legally discharged, and the event log will
contain an entry marked: “No or reduced treatment allowed by operator”.
Ignoring the UV intensity limit should only be done when safety considerations dictate
that ballast water operations must continue regardless of treatment status.
The officer in charge must make an entry in the ballast water log stating the date and
reason for the non-compliant operation.
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BWMS capacity range 30-3100
9.1.2 Errors
The list of errors for the BWMS control system is:
ID
Alarm text
Criticality
Outcome
Set point
Delay
[s]
BFMotorOverload
Boll filter motor:
overload detected
Major
Continue No start
0V
0
Arming
delay
[s]
0
BFMotorRunning
Boll filter motor:
missing running
signal
Backflush pump:
overload detected
Major
Continue No start
0V
5
0
Major
Continue No start
0V
0
0
Backflush pump:
missing running
signal
Communication
error with IO
node 1
Communication
error with UV
Unit 1
Communication
error with
frequency
converter for
ballast pump 1
Communication
error with
frequency
converter for
ballast pump 2
Ballast pump 1 Emergency stop
motor
Ballast pump 1 –
Frequency
converter fault
Major
Continue No start
0V
5
0
Major
Stop
5s
0
0
Major
Stop
5s
0
0
Timeout limit for Modbus
signal
Major
Stop
0
0
0
Communication error for
frequency converter 1. Check
power and network cable.
Major
Stop
0
0
0
Communication error for
frequency converter 2. Check
power and network cable.
Major
Stop
0
0
0
Major
Stop
0
0
0
Emergency stop alarm from
frequency converter for ballast
pump 1
Frequency converter fault for
ballast pump 1. Check
frequency converter.
Ballast pump 1 Missing running
signal from
frequency
converter.
Ballast pump 1 Lost permission
from PMS
Ballast pump 1 Pump stopped
because
conditions are not
ready.
Ballast pump 1 Communication
error with
frequency
converter
Major
Stop
0
0
0
Frequency converter fault for
ballast pump 1. Check
frequency converter.
Major
Stop
0
0
0
Major
Stop
0
0
0
Frequency converter fault for
ballast pump 1. Check
frequency converter.
Frequency converter fault for
ballast pump 1. Check
frequency converter.
Major
Stop
0
0
0
BFPumpOverload
BFPumpRunning
IO_1
IO_2
IO_3
IO_4
BPump1_3
BPump1_4
BPump1_5
BPump1_6
BPump1_7
BPump1_8
90
Cause / comment
Motor protection relay has
tripped due to high current
through relay. May be caused
by too high load on motor or
damages in electric motor
windings.
Motor starter relay is not
energized. May be caused by a
fault in power supply.
Motor protection relay has
tripped due to high current
through relay. May be caused
by too high load on motor or
damages in electric motor
windings.
Motor starter relay is not
energized. May be caused by a
fault in power supply.
Timeout limit for Modbus
signal
Frequency converter fault for
ballast pump 1. Check
frequency converter.
NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
BPump2_3
BPump2_4
BPump2_5
BPump2_6
BPump2_7
BPump2_8
Misc_3
Misc_4
Misc_5
Misc_7
Misc_8
Misc_14
Misc_16
Misc_26
Misc_27
Flow_2
Sensor_1
Ballast pump 2 Emergency stop
motor
Ballast pump 2 –
Frequency
converter fault
Ballast pump 2 Missing running
signal from
frequency
converter.
Ballast pump 2 Lost permission
from PMS
Ballast pump 2 Pump stopped
because
conditions are not
ready.
Ballast pump 2 Communication
error with
frequency
converter
High difference
pressure detected
across filter
Low difference
pressure detected
across filter check sensors
Flow too low to
run UV unit(s)
Flow above
system rating
detected (5%)
Major
Stop
0
0
0
Major
Stop
0
0
0
Major
Stop
0
0
0
Major
Stop
0
0
0
Major
Stop
0
0
0
Major
Stop
0
0
0
Frequency converter fault for
ballast pump 2. Check
frequency converter.
Major
Filter
protection
- stop
Continue
w. alarm
1.0 bar
0
0
Filter insert are clogged. Risk of
damage to filter
-3 bar
0
0
Unexpected pressure
difference value. May indicate
a sensor error
Major
Stop
10
0
Major
Stop
2-102
m3/h
Current
TRC + 5%
<120
0
System is being
bypassed
Illegal ballast
valve
combination
detected
Major
Stop
Bool
0
0
Depends on BWMS size. See
Part III, appendix A.1
Depends on BWMS size. See
Part III, appendix A.1
Nominal TRC or flow reduction
step.
BWMS bypass valve is open.
Major
Stop
Bool
0
0
Heartbeat loss
detected for UV
Unit 1
communication
Treatment out of
spec – insufficient
treatment
Major
Stop
15 s
0
0
Major
Stop
Bool
0
0
Critical stop
condition
detected
Flow below
minimum safe
flow
Possible
underrange fault
for Pressure
sensor on filter
inlet (PT1)
Major
Stop
Bool
0
0
Major
Stop
Bool
0
0
Flow is no longer stable, check
if ballastpump is running.
Major
Stop
3,8 mA
0
0
Sensor or cable failure.
Major
91
Emergency stop alarm from
frequency converter for ballast
pump 2
Frequency converter fault for
ballast pump 2. Check
frequency converter.
Frequency converter fault for
ballast pump 2. Check
frequency converter.
Frequency converter fault for
ballast pump 2. Check
frequency converter.
Frequency converter fault for
ballast pump 2. Check
frequency converter.
An illegal combination of valve
positions for monitored valves
was detected.
Illegal combinations are vessel
specific and defined by class
authority on project level.
BWMS control system lost
heartbeat from UV controller.
Treatment out of spec
according the UVI for current
flow. Reduce flow if the
automatic reduction is not
sufficient, or confirm to
continue with treatment not
according to regulations.
Critical stop condition detected
NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
Sensor_2
Possible
underrange fault
for Pressure
sensor on filter
outlet (PT2)
Possible
underrange fault
for flowmeter
Possible
underrange fault
for Valve 4
position feedback
signal
Possible
underrange fault
for conductivity
sensor
Possible
underrange fault
for Pressure
sensor on
backflush pipe
(PT3)
Possible
overrange fault
for conductivity
sensor
Possible
overrange fault
for Pressure
sensor on filter
outlet (PT2)
Possible
overrange fault
for Pressure
sensor on filter
inlet (PT1)
Possible
overrange fault
for flowmeter
Possible
overrange fault
for Valve 4
position feedback
signal
Major
Stop
3,8 mA
0
0
Sensor or cable failure.
Major
Stop
3,8 mA
0
0
Sensor or cable failure.
Major
Continue No start
3,8 mA
60
0
Sensor or cable failure.
Major
Continue No start
3,8 mA
60
0
Sensor or cable failure.
Major
Continue No start
3,8 mA
60
0
Sensor or cable failure.
Major
Stop
3.8 mA
0
0
Sensor or cable failure
Major
Stop
3.8 mA
0
0
Sensor or cable failure
Major
Stop
3.8 mA
0
0
Sensor or cable failure
Major
Stop
3.8 mA
0
0
Sensor or cable failure
Major
Stop
3.8 mA
0
0
Sensor or cable failure
Possible
overrange fault
for Pressure
sensor on
backflush pipe
(PT3)
UVUnit1: UV
sensor failure
UVUnit1:
Intensity below
minimum
UVUnit1: All
lamps failure
UVUnit1: Water
too hot
Major
Stop
3,8 mA
0
0
Sensor or cable failure.
Major
Stop
0
0
Sensor or cable failure.
Major
Continue
w/ alarm
Bool
(3,8 mA)
Bool
(variable)
0
0
Major
Stop
Bool
0
0
Major
Stop
Bool
(60° C)
0
0
UV1_11
UVUnit1: Cabinet
to hot
Major
Stop
Bool
(60° C)
0
0
UV1_12
UVUnit1: Start
relay failure
Major
Stop
Bool
0
0
Stop after 60s from error signal
if no action is taken, see
section 6.3.5
All lamps in UV chamber 1 has
failed
Water in UV chamber is above
temperature limit. UV must be
shut down to avoid
overheating and boiling.
Air temperature in cabinet
above limit. Risk of damage to
power supply.
Can only occur at startup, in
InitFilling or InitDischarge
Sensor_3
Sensor_4
Sensor_5
Sensor_6
Sensor_7
Sensor_8
Sensor_9
Sensor_10
Sensor_11
Sensor_12
UV1_1
UV1_2
UV1_9
UV1_10
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NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
UV1_15
UVUnit1: Wiper
initialization fail
Major
Stop
Bool
0
0
UV1_17
UVUnit1: missing
running signal
UVUnit1: UV
Lamp or Group n
Fault
UVUnit1:
Temperature
sensor failure
UVUnit1: UV dose
alarm
UVUnit1: Lost
heartbeat to
modbus master
Major
Stop
Bool
60
0
Major
Stop
Bool
0
0
Major
Stop
Bool
(3,8 mA)
0
0
Major
Stop
Bool
0
0
Major
Stop
Bool
0
0
UVUnit1: Wiper
motor is jammed
UVUnit1: Wiper
cannot reach park
pos.
UVUnit1: Wiper
cannot reach
motorside pos.
UVUnit1: UV
stopped by failure
UVUnit1: Lambda
5 Ethernet
communication
error
Missing feedback
on Valve 1
Missing feedback
on Valve 2
Missing feedback
on Valve 3
Position deviation
on Valve 4
Major
Stop
Bool
0
0
Major
Stop
Bool
0
0
Major
Stop
Bool
0
0
Wiper position failure. Check
wiper.
Major
Stop
Bool
0
0
Major
Stop
Bool
0
0
UV Unit 1 stopped due to
failure. Check UV alarms.
Error communicating over
Modbus
Major
Continue No start
Continue No start
Continue No start
Continue No start
0V
0
0
0V
0
0
0V
0
0
5%
60
0
Missing feedback
on Valve 5
Missing feedback
on Valve 6
Missing feedback
on Valve 8
Missing feedback
on Valve 9
Position deviation
on Valve 10
Major
Continue No start
Continue No start
Continue No start
Continue No start
Continue No start
0V
0
0
0V
0
0
0V
0
0
0V
0
0
5%
60
0
Missing feedback
on Valve 11
Missing feedback
on Valve 16
Major
Continue No start
Continue No start
0V
0
0
0V
0
0
UV1_18 .. 49
UV1_26
UV1_50
UV1_51
UV1_52
UV1_53
UV1_54
UV1_59
UV1_60
Valve1_FB
Valve2_FB
Valve3_FB
Valve4_FB
Valve5_FB
Valve6_FB
Valve8_FB
Valve9_FB
Valve10_FB
Valve11_FB
Valve16_FB
Major
Major
Major
Major
Major
Major
Major
Major
Evaluated by UV controller.
Based on position feedback
signal.
UV controller missing running
signal from UV chamber
Lamps on group n have failed.
Up to 6 groups of up to 3
lamps.
Temperature sensor in UV
chamber has failed.
UV dose to low according to
UVI for current flow.
Last heartbeat was received
too long ago. Check Lamda5
power, ethernet cable and IP
address.
Wiper motor failure. Check
wiper.
Wiper position failure. Check
wiper.
Expected position feedback for
valve not registered.
Expected position feedback for
valve not registered.
Expected position feedback for
valve not registered.
Difference between ordered
and actual valve position is
above defined limit. Actuator
may be malfunctioning.
Expected position feedback for
valve not registered.
Expected position feedback for
valve not registered.
Expected position feedback for
valve not registered.
Expected position feedback for
valve not registered.
Difference between ordered
and actual valve position is
above defined limit. Actuator
may be malfunctioning.
Expected position feedback for
valve not registered.
Expected position feedback for
air relief valve not registered.
Table 35 - List of BWMS errors
The set points defined as "Bool" are Boolean values passed to the BWMS controller from either the
UV controller or the IAS. They evaluate to either 0 (false / un-set) or 1 (true / set).
Variable set points are used for the flow and UV intensity limits which are varied. The current flow
step value is passed to the UV controller and the appropriate set point value is set.
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NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
9.2 Alarm handling
When a warning or alarm occurs, the operator must respond by:
•
•
•
Interpreting the alarm based on the tables below
Rectify the alarm cause
Acknowledge the alarm on the alarm page of the BWMS control system or in the IAS
Restart the BWMS if applicable
9.2.1 Handling of warnings
The recommended actions in case of warnings are:
ID
Misc_1
Alarm / Warning text
Operation could not start, check if a
ballast pump is running
Misc_2
Too long since last automatic
backflush
Misc_6
No or reduced treatment detected
Misc_9
Misc_10
Service/Maintenance mode active
Flow below minimum recommended
for backflushing
Misc_11
Flow below minimum recommended
for discharging
Misc_13
Operation inhibited condition
detected
Misc_14
Illegal ballast valve combination
detected
Misc_15
Increasing difference pressure
detected across filter
Misc_17
Flow above system rating detected
Misc_18
Flow above system rating detected
UV1_4
UV1_5
UVUnit 1: Water getting warm
UVUnit 1: Cabinet getting warm
UV1_6
UVUnit 1: Wiper request
maintenance
UVUnit 1: Lamps request
maintenance
UVUnit 1: Replace battery
UVUnit 1: UV intensity nearing
minimum for current flow
UV1_16
UV1_24
UV1_25
Recommended action
The BWMS "Start filling" or "Start discharge" order must be given before ballast
water pump(s) are started. If a pump is already running when the start order is
given, the BWMS will not initialise correctly. Stop any ballast water pumps, then
start the desired BWMS operation. When the BWMS is in "InitFilling" or
"InitDischarge", the ballast water pump can be started.
Inspect filter elements for damage. Long intervals between backflushing can
indicate a leak across the filter mesh, which prevents pressure from building even
with a clogged filter.
Warning is set if operator selects "continue" option in UV1_2 error dialog box.
This warning indicates that operator has acknowledged to continue operation
with an insufficient UV intensity.
Check home screen on BWMS controller to see if "Service mode" is enabled.
The current flow is too low to allow efficient backflushing. Flow should be
increased above "Minimum flow in filling" limit indicated in the technical
specification in Part III, Appendix A.1
Flow is below the minimum recommended limit for discharging. The operation
can continue as long as the flow is above the absolute minimum limit indicated in
the technical specification in Part III, Appendix A.1. To clear warning, increase
flow above the recommended "Minimum flow in discharge" limit indicated in the
technical specification in Part III, Appendix A.1.
One or more errors with outcome "Continue – No start" is set. Check the alarms
page for set alarms and correct the cause of any errors. Then acknowledge errors
and this warning.
The BWMS monitors a number of valves in the ballast water system based on
class requirements. The list of monitored valves is vessel specific and defined by
the class society on a case by case basis. The warning indicates that an illegal
combination of ballast system valves was detected. Check and correct valve
settings according to the approved ballast water management plan.
The difference pressure across the filter is approaching the upper limit. Initiate
backflushing cycle to attempt to clear filter mesh. If problem persists, consider
stopping operation to inspect and/or clean filter manually.
The system is operating at the maximum TRC. This is a notification only to the
operator, no immediate action is necessary.
The system is operating above the maximum TRC. This is a warning to the
operator that the flow will need to be reduced to the TRC or below.
Manually check if UV-chamber is hot. Check flow through UV-chamber.
Manually check if cabinet is hot. Check if cooling fans running and condition of
inlet filter.
The wiper rings and shaft seal should be replaced.
Be aware that more than 75% of lamp expected life time is passed. Plan
replacement of UV lamps.
The back-up battery in the UV controller is low. Contact NGT for advice.
The measured UV intensity is nearing the limit for the current flow setting. The
BWMS will automatically attempt to increase power or reduce flow depending on
operation mode. No operator interaction is required.
Table 36 - Handling of BWMS warnings
94
NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
9.2.2 Handling of errors
The recommended actions in case of errors are:
ID
BFMotorOverloa
d
BFMotorRunnin
g
BFPumpOverloa
d
BFPumpRunning
Alarm text
Boll filter motor: overload detected
Recommended action
Check if motor is ok. Reset motor protection relay.
Boll filter motor: missing running signal
Check el. supply to motor. Check signal cable and relay on main motor
contactor.
Check if motor is ok. Reset motor protection relay.
IO_1
IO_2
Misc_3
Misc_5
Misc_7
Communication error with IO node 1
Communication error with UV Unit 1
High difference pressure detected across
filter
Low difference pressure detected across
filter - check sensors
Flow too low to run UV unit(s)
Flow above system rating detected
Misc_8
System is being bypassed
Misc_16
UV1_1
UV1_2
Heartbeat loss detected for UV Unit 1
communication
Possible fault for Pressure sensor filter inlet
Possible fault for Pressure sensor filter outlet
Possible fault for flowmeter
Possible fault for Valve 4 position feedback
signal
Possible fault for conductivity sensor
Possible fault for Pressure sensor backflush
pipe
UVUnit 1: UV sensor fail
UVUnit 1: Intensity near minimum
UV1_9
UV1_10
UVUnit 1: All lamps failure
UVUnit 1: Water too hot
UV1_11
UVUnit 1: Cabinet to hot
UV1_12
UV1_15
UV1_17
UV1_18, 19, 20,
21, 22, 23
UV1_26
UVUnit 1: Start relay failure
UVUnit 1: Wiper failure
UVUnit1: Missing running signal
UVUnit1: Lamp group n failure
UV1_27
UV1_31
UVUnit 1: Lamda 5 Ethernet communication
error
UVUnit 1: Lamda 5 Ethernet card not
installed
UVUnit 1: Lamda 5 Ethernet cable
disconnected
UVUnit 1: Lamda 5 Ethernet socket 2 not
connected
UVUnit 1: Lamda 5 Missing heartbeat
Valve1_FB
Valve10_FB
Valve2_FB
Valve3_FB
Valve4_FB
Valve5_FB
Valve9_FB
Missing feedback on Valve 1
Position deviation on Valve 10
Missing feedback on Valve 2
Missing feedback on Valve 3
Position deviation on Valve 4
Missing feedback on Valve 5
Missing feedback on Valve 9
Misc_4
Sensor_1
Sensor_2
Sensor_3
Sensor_4
Sensor_5
Sensor_6
UV1_28
UV1_29
UV1_30
Backflush pump: overload detected
Backflush pump: missing running signal
UVUnit 1: Temperature sensor failure
Check el. supply to motor. Check signal cable and relay on main motor
contactor.
Check fuse and network cabling
Check fuse and network cabling
Check pressure sensor reading. If ok, inspect filter elements.
Check pressure sensors
Check if ballast pump is running
Check setting of ballast water pump. Reduce flow to be below current
allowable limit as indicated on LOCAL and/or REMOTE user interface.
If this is not expected, visual inspect bypass valve and position feedback
sensors.
Check signal cable between UV controller and IO node. Check status of UV
controller. Power cycle UV unit to attempt to restore communication.
Check PT1 sensor, wiring and signal input module.
Check PT2 sensor, wiring and signal input module.
Check sensor, wiring and signal input module.
Check sensor, wiring and signal input module.
Check CT1 sensor, wiring and signal input module.
Check PT3 sensor, wiring and signal input module.
Check sensor, wiring and signal input module.
Perform wiping if manual wiper system is installed. If electrical wiper
system: check UV-wiping function.
Check power supply for all lamps. Check all UV lamps
Use an IR thermometer or similar to manually check if UV-chamber is hot.
Check flow through UV-chamber.
Use an IR thermometer or similar to manually check if cabinet is hot. Check
if cooling fans running and condition of inlet filter.
Check condition of UV-lamp start relay.
Check UV wiper motor
Check power supply and cable for UV power cabinet.
Check power supply and cable for group n. Check UV lamps on group n
Check status of temperature controller in UV control cabinet. See section
9.3.10 for diagnostics. Replace cable or sensor as applicable.
Check signal cable between UV controller and IO node.
Power cycle UV unit to restart UV controller and Ethernet card should be
detected. If problem persists, contact NGT.
Check signal cable between UV controller and IO node.
Power cycle UV unit to attempt to restore Ethernet communication. If
problem persists, contact NGT.
Check signal cable between UV controller and IO node. Restart entire
system to attempt to restore normal communication.
Check valve position. Check position feedback sensor.
Check valve position. Check position feedback sensor.
Check valve position. Check position feedback sensor.
Check valve position. Check position feedback sensor.
Check valve position. Check position feedback sensor.
Check valve position. Check position feedback sensor.
Check valve position. Check position feedback sensor.
Table 37 - Handling of BWMS errors
95
NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
9.3 Self-diagnostics functionality
The BWMS contains a number of sensors for self-diagnostics and process monitoring. All are linked
to warning or error alarms to alert the operator if a malfunction is imminent or has occurred. All
sensor data is received through either the I/O node or the UV controller before it is evaluated by the
BWMS controller and routed to alarms in the IAS if needed.
9.3.1 IO monitoring
The BWMS controller monitors the Modbus communication and raises an alarm if communication is
lost. In addition, the BWMS control system and the UV controller exchanges heartbeat signals to
detect if either side has stopped responding. The heartbeat monitoring works as follows:
•
•
•
•
The BWMS control system sends a signal to the UV controller and listens for a reply
The UV controller sends a reply to the BWMS controller and listens for a reply to that
The two sides keep replying and listening for each other’s replies
If either side fails to reply within a timeout limit, the other side will trigger an error
The parameters for Modbus communication monitoring are tabulated below. Note that IO_2 and
prefix UV1 refers to errors for UVUnit1. Similar alarms for UVUnit2 when installed.
Parameter
I/O node signal
timeout
UVUnit1…n signal
timeout
UV Unit1 Ethernet
com. error
UV Unit1 Ethernet
card error
UV Unit1 Ethernet
cable error
UV Unit1 Ethernet
socket error
BWMS heartbeat
timeout
UV Unit 1 heartbeat
timeout
Delay
Value
5s
5s
Bool
Bool
Bool
Bool
15 s
15 s
Action
If timeout:
Error: IO_1, Log entry
If timeout:
Error: IO_2, Log entry
If true:
Error: UV1_27, Log Entry
If true:
Error: UV1_28, Log Entry
If true:
Error: UV1_29, Log Entry
If true:
Error: UV1_30, Log Entry
If timeout:
Error: UV1_31, Log Entry
If timeout:
Error: Misc_16, Log Entry
Comment
BWMS enters “Stop” mode
BWMS enters “Stop” mode
BWMS enters “Stop” mode
BWMS enters “Stop” mode
BWMS enters “Stop” mode
BWMS enters “Stop” mode
BWMS enters “Stop” mode
BWMS enters “Stop” mode
0s
Table 38 - Modbus communication monitoring parameters
Referring to Figure 5, the diagnostics functions handled through the I/O node are:
1.
2.
3.
4.
5.
Backflush pump motor health monitoring
Particle filter motor health monitoring
BWMS valves status and position monitoring
Filter differential pressure monitoring
Flow monitoring
The I/O node converts signals from hardwired sensor input signals to data transmitted to the BWMS
controller over the Modbus network. All evaluation of data and triggering of warnings and alarms is
performed by the BWMS control software.
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NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
The diagnostics functions handled through the UV controller are:
6.
7.
8.
9.
10.
UV lamp health monitoring
UV light sensor monitoring
UV lamp wiper motor health (when an electric wiper system is installed)
Temperature monitoring in UV (control and power) cabinets
Temperature monitoring in UV chamber
The UV controller interprets signals from the sensors and transmit alarm triggers to the BWMS
controller. The BWMS controller does not evaluate any signals from the UV equipment monitoring, it
only transmits and logs alarms from the UV controller.
If values outside allowable parameter ranges are measured, or an UV alarm trigger is received, the
BWMS controller will raise a warning or error to the IAS and log it to the BWMS log.
9.3.2 Backflush pump motor health monitoring
The necessary flow for backflushing is provided by a separate pump driven by an electric motor. The
motor for the backflush pump is monitored for:
•
•
Motor running feedback signal
Motor overload feedback signal
The BWMS controller expects a feedback signal from the pump motor starter when a backflush cycle
is initiated and raises an alarm if there is no feedback signal.
The main motor contactor has a signal switch (NO type) which provides a 0-24 V signal to indicate if
the contactor is open or closed.
A separate thermal-magnetic circuit breaker is installed for protection of the motor. The motor
protection circuit breaker is set corresponding to the rated motor current and breaks the circuit if
the current is exceeded by more than 25%.
A signal switch (NC type) is mounted on the motor protection circuit breaker and provides a 0-24 V
signal to indicate if the motor protection circuit breaker is tripped.
Parameter
M1 running
signal
M1 overload
signal
Delay
Value
Closed = 24 V:
running
Open = 0 V: not
running
Closed = 24 V:
motor ok
Open = 0 V: Motor
overload
Action
If not running (0 V)
then
Error: BFPumpRunning,
Log entry
If overload (0 V)
then
Error:
BFPumpOverload, Log
entry
Comment
BWMS continues operation but
will not restart after a stop.
BWMS continues operation but
will not restart after a stop.
Motor running: 5 s
Overload: 0 s
Table 39 - Backflush motor monitoring parameters
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NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
9.3.3 Particle filter motor health monitoring
The filter comprises a filter insert, where water flows through the filter mesh from inside to outside.
Particles are collected on the inside.
The backflushing of the filter is performed by directing water flow through inside of the filter insert,
such that all particles are flushed off the filter mesh and out the backflush outlet. A motor turns a
flushing arm which directs the flow through the filter insert. This to ensure minimum impact on the
main flow during backflushing operation.
The health of the filter motor is monitored through the following parameters:
•
•
Motor running feedback signal
Motor overload feedback signal
The BWMS controller expects a feedback signal from the filter motor when a backflush cycle is
initiated and raises an alarm if there is no feedback signal.
The main motor contactor has a signal switch (NO type) which provides a 0-24 V signal to indicate if
the contactor is open or closed.
A separate thermal-magnetic circuit breaker is installed for protection of the motor. The motor
protection circuit breaker is set corresponding to the rated motor current and breaks the circuit if
the current is exceeded by more than 25%.
A signal switch (NC type) is mounted on the motor protection circuit breaker and provides a 0-24 V
signal to indicate if the motor protection circuit breaker is tripped.
Parameter
M2 running
signal
M2 overload
signal
Delay
Value
Closed = 24 V:
running
Open = 0 V: not
running
Closed = 24 V:
motor ok
Open = 0 V: Motor
overload
Action
If not running
then
Error: BFMotorRunning,
Log entry
If overload
then
Error:
BFMotorOverload, Log
entry
Comment
BWMS continues operation but
will not restart after a stop.
BWMS continues operation but
will not restart after a stop.
Motor running: 5 s
Overload: 0 s
Table 40 - Particle filter motor monitoring parameters
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NGT Ballast Water Management System – User documentation part II:
Operation, Safety & Maintenance manual
BWMS capacity range 30-3100
9.3.4 BWMS valve status and position monitoring
The BWMS controller is monitoring valve feedback signals for the main process valves V1, V2, V3 &
V5 in the form of a 0-24 V signal from two switches on each valve actuator. Both switches are NOtypes.
Switch 1 is closed when the valve is open, switch 2 is closed when the valve is closed. This results in
two separate 24V signals to be monitored, one for open valve, one for closed valve. When the
BWMS controller orders a valve to open or close, it expects the corresponding feedback signal to
occur.
Valve position signal for the outlet valve V4 and backflush valve V10 is a 4-20 mA signal covering 0 to
100% opening of the valve. The BWMS controller compares the reported position to the ordered
position and calculates a deviation.
If the valve position signal is missing, or if there is an unacceptable deviation between expected and
actual position of V4 or V10, an alarm is raised.
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Parameter
V1
position
Value
Switch 1 = 24 V and
Switch 2 = 0 V: Open valve
Switch 1 = 0 V &
Switch 2 = 24 V: Closed valve
V2
position
Switch 1 = 24 V and
Switch 2 = 0 V: Open valve
Switch 1 = 0 V &
Switch 2 = 24 V: Closed valve
V3
position
Switch 1 = 24 V and
Switch 2 = 0 V: Open valve
Switch 1 = 0 V &
Switch 2 = 24 V: Closed valve
V5
position
Switch 1 = 24 V and
Switch 2 = 0 V: Open valve
Switch 1 = 0 V &
Switch 2 = 24 V: Closed valve
V10
position
Switch 1 = 24 V and
Switch 2 = 0 V: Open valve
Switch 1 = 0 V &
Switch 2 = 24 V: Closed valve
V4
position
<3.8 mA = sensor failure
4 mA = 0% (closed)
20 mA = 100% (open)
Delay
Missing signal: 0 s
Position deviation: 60 s
Action
If order = “Valve open” and
switch 1 = 0 V
or
If Valve closed &
switch 2 = 0 V
then
Error: Valve1FB, Log entry
If order = “Valve open” and
switch 1 = 0 V
or
If Valve closed &
switch 2 = 0 V
then
Error: Valve1FB, Log entry
If order = “Valve open” and
switch 1 = 0 V
or
If Valve closed &
switch 2 = 0 V
then
Error: Valve1FB, Log entry
Comment
BWMS continues
operation but will not
restart after a stop.
If order = “Valve open” and
switch 1 = 0 V
or
If Valve closed &
switch 2 = 0 V
then
Error: Valve1FB, Log entry
BWMS continues
operation but will not
restart after a stop.
If order = “Valve open” and
switch 1 = 0 V
or
If Valve closed &
switch 2 = 0 V
then
Error: Valve1FB, Log entry
BWMS continues
operation but will not
restart after a stop.
If sensor failure
then
Error: Sensor_4, Log entry
If deviation > 5%
then
Error: Valve4_FB, Log entry
BWMS continues
operation but will not
restart after a stop.
Table 41 - Valve monitoring parameters
100
BWMS continues
operation but will not
restart after a stop.
BWMS continues
operation but will not
restart after a stop.
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9.3.5 Filter differential pressure monitoring
Two pressure transducers are installed.
1. PT1 is located at the filter intake
2. PT2 is located between filter and UV unit, after the filter bypass valve
The signals from the PT1 and PT2 are 4-20 mA signals and are used to calculate the pressure
differential across the particle filter and trigger automatic backflushing cycles.
Please see section 6.3 for an overview of pressure regulation settings.
If pressure transducer signals are outside the expected range or missing, an alarm is raised.
Parameter Value
PT1 signal <3.8 mA = sensor failure
4 mA = 0 bar
20 mA = 10 bar
Action
Comment
If sensor failure
BWMS enters “Stop” mode.
then
Error: Sensor_1, Log entry
PT2 signal
<3.8 mA = sensor failure If sensor failure
BWMS enters “Stop” mode.
4 mA = 0 bar
then
20 mA = 10 bar
Error: Sensor_2, Log entry
Delay
0s
Table 42 - Pressure monitoring parameters
9.3.6 Flow monitoring
The flow through the BWMS is measured using a magnetic flowmeter. The flowmeter consists of a
flow sensor built into a pipe section and a flow converter which converts the raw flow sensor signal
to a 4-20 mA signal.
If flowmeter signals are outside the expected range or missing, an alarm is raised.
Parameter Value
FM1 signal <3.8 mA = sensor failure
4 mA = 0 m3/h
20 mA = TRC m3/h
Delay
Action
Comment
If sensor failure
BWMS enters “Stop” mode.
then
Error: Sensor_3 Log entry
0s
Table 43 - Flow monitoring parameters
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9.3.7 UV lamp health monitoring
The UV controller monitors the health of the UV lamps.
A current sensor is used to register if there is a current flow in the conductor. If no current is
measured, an alarm signal is transmitted from the UV controller to the BWMS controller and an
alarm is raised to the IAS by the BWMS controller.
To ensure that UV lamps ignite, a start relay is used to short circuit one lamp in a group during
ignition. This prevents both lamps from drawing current simultaneously, which would drop the
voltage below the necessary level for ignition. Once the first lamp is ignited, the relay switches off,
current flows through both lamps and the voltage remains high enough to ensure ignition of the
second lamp.
The start relay has an auxiliary contact (NC) monitored by the UV controller. If this contact is opened
for more than 4 s, an alarm signal is generated. The relay is active for 1 s and there is a 3 s delay, i.e.
4 s before the alarm is triggered.
The UV controller counts the operating hours for the UV lamps and generates a warning when a
predetermined number of running hours is reached. The BWMS controller raises a warning message
to the IAS.
Parameter
Core1…n
current
Value
0 A = lamp group
failure
Action
If lamp group failure
then
Error: UV1_18, Log
entry
If all lamps fail
then
Error: UV1_9, Log
entry
Start relay active
UV lamp hour
counter
Delay
Closed = 24 V: not
active
Open = 0 V: active
3000 hrs
If relay active > 1 s
then
Error: UV1_12, Log
entry
If counter > 3000 hrs
then
Warning: UV1_16,
Log entry
Comment
BWMS enters “Stop” mode.
Alarm text UV1_18: UVUnit1:
lamp group 1..n failure
Alarm text UV1_9: UVUnit1: All
lamps failure
Similar alarms for UVUnit2
when installed.
BWMS does not enter “Filling”
or “Discharge” modes
Similar alarms for UVUnit2
when installed.
BWMS continues operation.
Similar alarms for UVUnit2
when installed.
Current signal: 25 s
Start relay: 3 s
Hour counter: 0 s
Table 44 - UV lamp health monitoring parameters
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9.3.8 UV light sensor monitoring
The UV control system monitors the status and the output of the UV light sensor. The sensor is
mounted centrally in the UV chamber and the output from the sensor is a 4-20mA signal.
If the UV sensor signal is outside the expected range or missing, an alarm is transmitted from the UV
controller to the BWMS controller and an alarm is raised to the IAS by the BWMS controller.
Parameter Value
LT1 signal <3.8 mA = sensor failure
4 mA = 0 w/m2 UV
intensity
20 mA = xxxxx w/m2 UV
intensity
Delay
0s
Action
If sensor failure
then
Error: UV1_1, Log
entry
Comment
BWMS enters “Stop” mode.
Similar alarms for UVUnit2 when
installed.
Ref. Part III, A.1 for values
Table 45 - UV light sensor monitoring parameters
9.3.9 UV lamp wiper motor health monitoring
The UV chamber is configured with either a manual or an electrical operated wiper system to help
clear fouling and debris off the UV lamp quartz sleeves.
The UV controller monitors the position of the wiper when an electrical wiper system is installed.
The system monitors an encoder signal, which is used to determine the position of the wiper relative
to the stops at either end of the UV chamber.
To avoid melting the wiper rings, the wiper can only be safely parked at either end of the UV
chamber. The UV controller will attempt to return the motor to the end it was coming from when it
stopped, and generate the alarm.
If either of the following events occur, an error is transmitted from the UV controller to the BWMS
controller and an error is raised to the IAS by the BWMS controller. The alarm, UV1_15, is the same
in both cases:
•
•
Encoder signal is missing
The wiper stops in an unexpected position (i.e. not at an end stop).
The UV controller counts the wiper cycles and transmits a warning to the BWMS controller when a
predetermined number of cycles have been completed. The BWMS controller raises a warning.
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Parameter
Encoder
signal
Encoder
signal
Cycle
counter
Delay
Value
Detected: running
Missing: not running
Action
If not running
then
Error: UV1_15,
Log entry
Count/position = end stop:
wiper ok
Count/position = not at end
stop: wiper blocked
If wiper blocked
then
Error: UV1_15,
Log entry
8000 cycles
If counter > 8000
then
Warning: UV1_6,
Log entry
Wiper running: 0 s
Wiper blocked: 0 s
Cycle counter: 0 s
Table 46 - UV lamp wiper monitoring parameters
104
Comment
BWMS enters “Stop”
mode.
Similar alarms for UVUnit2
when installed.
BWMS enters “Stop”
mode.
Similar alarms for UVUnit2
when installed.
BWMS continues
operation.
Similar alarms for UVUnit2
when installed.
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9.3.10 Temperature monitoring in UV cabinets
The UV controller monitors temperatures in the UV control and power cabinets by means of two
thermostat switches installed in the cabinet.
The thermostats are of NC type and are set to two different temperatures:
•
•
A lower threshold temperature triggering a warning
A higher limit temperature triggering an alarm
The thermostat circuits will failsafe to open in the event of a sensor failure and the corresponding
warning or alarm will be generated. The thermostats must be manually inspected to distinguish a
high temperature alarm from a sensor failure.
If either of the thermostat switches are triggered, an error (or warning) is transmitted from the UV
controller to the BWMS controller and an error (or warning) is raised to the IAS by the BWMS
controller.
Parameter
UV cabinet
temperature
UV cabinet
temperature
Delay
Value
< 50°C: Closed = 24 V > 50°C:
Open = 0 V
< 60°C: Closed = 24 V > 60°C:
Open = 0 V
Action
If open
then
Warning: UV1_5
Log entry.
If open
then
Error:
UV1_11, Log
entry.
0s
Table 47 - UV cabinet monitoring parameters
105
Comment
BWMS continues operation.
Similar alarms for UVUnit2
when installed.
BWMS enters “Stop” mode.
Similar alarms for UVUnit2
when installed.
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9.3.11 Temperature monitoring in the UV chamber
The UV controller monitors the water temperature in the UV chamber by means of a PT100 element
installed in the UV chamber.
The PT100 signal is routed through a temperature controller / signal conditioning unit in the UV
control cabinet.
The temperature controller converts the PT100 voltage signal to a 4-20 mA signal which is read by
the UV controller.
Based on pre-set temperature limits, the UV controller triggers a warning when the water
temperature exceeds the warning limit and an error when the temperature exceeds the error limit.
In case of a temperature sensor malfunction or cable break, the temperature controller will failsafe
to a current ≤ 3,5 mA which will be interpreted by the UV controller as a sensor error and trigger a
stop mode.
Parameter
PT100 scaling
Value
0° C = 4 mA
100° C = 20 mA
Action
UV chamber
temperature
warning limit
50°C = 12 mA
UV chamber
temperature,
error limit
60°C = 13,6 mA
PT100 error
detection
I ≤ 3,8 mA
If I > 12mA
then
Warning: UV1_4
Log entry.
If I > 13,6 mA
then
Error:
UV1_10, Log entry.
If I ≤ 3,8 mA
then
Error: UV1_26, Log
entry
Delay
Comment
Analog input to UV controller.
Voltage signal from PT100 converted
to mA by temperature controller
BWMS continues operation.
Similar alarms for UVUnit2 when
installed.
BWMS enters “Stop” mode.
Similar alarms for UVUnit2 when
installed.
BWMS enters “Stop” mode.
Similar alarms for UVUnit2 when
installed.
0s
Table 48 - UV chamber monitoring parameters
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9.4 Troubleshooting for filling operations
In case of trouble during a "Filling" operation, you must perform the following troubleshooting and
fault detection activities:
1. If the BWMS does not enter InitFilling or remains in InitFilling significantly longer than 5
minutes (the UV warm up time), the operator should check:
•
•
•
•
Is the ballast water pump running?
Is the BWMS bypass valve closed?
Is the flow stable and above the minimum limit?
Are there any alarms pertaining to the UV lamps which prevent the UV from warming up
and running normally? If a lamp is broken, the UV will not start.
2. If the BWMS valves V1, V2, V3, V4, V5 and V10 are not in their expected position (see Table
26) or if a feedback signal is missing, the BWMS will either not enter, or will remain in the
InitFilling state depending on when the valve fault is registered. You must then:
•
•
•
•
•
Check that there is air and power supply to the valves
Visually inspect the valves and record their status / position
Compare the status shown on the touch screen to the actual status
Check against the expected position
Deviations indicate either a malfunctioning valve or malfunctioning feedback sensor
on the valve. The valve must be serviced or replaced. See section 8.6.6 for
information on feedback sensor adjustment
3. If the filter backflushes continuously or at very short intervals, the filter insert is in danger of
becoming completely clogged.
•
The filter should be inspected and cleaned at the earliest opportunity. See Part III,
Appendix D.1 section 8.5
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9.5 Troubleshooting for discharge mode
In case of trouble during a "Discharge" operation, you must perform the following troubleshooting
and fault detection activities:
1. If the BWMS does not enter InitDischarge or remains in InitDischarge significantly longer
than 5 minutes (the UV warm up time), the operator should check:
•
•
•
•
Is the ballast water pump running?
Is the BWMS bypass valve closed?
Is the flow stable and above the minimum limit?
Are there any alarms pertaining to the UV lamps which prevent the UV from warming up
and running normally? If a lamp is broken or not igniting, the UV will not start.
2. If the BWMS valves V1, V2, V3, V4, V5 and V10 are not in their expected position
(see Table 26) or if a feedback signal is missing, the BWMS will either not enter, or will
remain in the InitDischarge state depending on when the valve fault is registered. You must
then:
•
•
•
•
•
Check that there is air and power supply to the valves
Visually inspect the valves and record their status / position
Compare the status shown on the touch screen to the actual status
Check against the expected position
Deviations indicate either a malfunctioning valve or malfunctioning feedback sensor
on the valve. The valve must be serviced or replaced. See section 8.6.6 for
information on feedback sensor adjustment
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9.6 Troubleshooting for stripping mode
In case of trouble during a stripping operation, you must perform the troubleshooting and fault
detection activities for the “Discharge” mode, with the following modifications:
1. If the BWMS does not enter InitStripping or remains in InitStripping significantly longer than
5 minutes (the UV warm up time), the operator should check:
• Is the ejector pump running?
• Is the BWMS bypass valve closed?
• Is the flow stable and above the minimum limit for UV operation?
• Are there any alarms pertaining to the UV lamps which prevent the UV from warming up
and running normally? If a lamp is broken or not igniting, the UV will not start.
2. If the BWMS valves V1, V2, V3, V4, V5 and V10 are not in their expected position (see Table
26) or if a feedback signal is missing, the BWMS will either not enter, or will remain in the
InitStripping state depending on when the valve fault is registered. You must then:
• Check that there is air and power supply to the valves
• Visually inspect the valves and record their status / position
• Compare the status shown on the touch screen to the actual status
• Check against the expected position
• Deviations indicate either a malfunctioning valve or malfunctioning feedback sensor
on the valve. The valve must be serviced or replaced. See section 8.6.6 for
information on feedback sensor adjustment
3. If the flow is not above the minimum flow limit for UV operation, as listed in the technical
specification, Part III, Appendix A.1, the UV-units will shut down to protect the UV lamps
from overheating. The operator must then:
• Check if the tank being stripped is empty
• Switch to suction from a different tank, if relevant
• Adjust ejector pump such that sufficient local water is taken in and circulated
through the BWMS
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9.7 Troubleshooting for stop mode
There are no mechanical faults which will prevent a stop order from being executed.
Should valves malfunction, the UV lamps will power off as usual. Valves may remain in wrong
positions, but this does not prevent stopping of the UV system.
The BWMS will enter a state called "Stopping" while waiting for the flow to cease. If the flow does
not drop below the lower flow limit (5-126 m3/h – see section 7.6) the BWMS will remain in the
"Stopping" state until flow reduces below the limit.
Should the UV unit or UV controller malfunction, the failsafe condition is shut down of the UV lamps.
9.8 Troubleshooting for flushing mode
If the flushing cycle fails to complete, you should check the following:
1.
2.
3.
4.
Check that there is air and power supply to the valves
Is there a freshwater supply?
Active alarms related to PT3 and/or backflush pump?
Are valves opening and closing correctly? Ref. section 7.7
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10 Data logging
The control system continually logs operational data and various events. The logged data are stored
for at least 24 months in a database on the internal hard drive of the control system onboard
computer.
As the log database fills up, the oldest entries are discarded to make room for newer entries.
10.1 Back-up of log data
The application contains a scheduled back-up function which takes a snapshot of the log database
and the application itself every 24 hrs. The snapshots can be stored to a USB memory stick or HDD
connected to the BWMS controller.
The USB memory stick or HDD can be removed for off-site back-up of the data. The back-ups will
continue when the USB stick is re-inserted into the BWMS controller.
This allows all data to be recovered in the event of damage to the BWMS controller hard drive.
10.2 Accessing the logs
The logs are accessed through the “Logs” page on the main control screen interface as explained in
section 5.1.4.
10.3 Contents of logs
Every logged entry contains a date and time stamp indicating when the entry was logged.
•
•
Dates are logged using the format: YYYY-MM-DD
Time is logged using the format: HH:MM:SS
The log contains the following categories:
1.
2.
3.
4.
5.
6.
7.
8.
System
Event
Mode
Alarm
Filling
Discharge
Flow
Intensity
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10.3.1 System log
The system log is a summary of running times and operational status for the different components.
This page is designed to provide “at-a-glance” information about the general status and
performance of the system.
All information on the system log tab can also be accessed and printed through the other log pages.
Figure 35 - System log tab
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10.3.2 Event log
The event log contains entries for events occurring in the system. Examples of this are:
•
•
•
•
An operation was started or stopped.
A UV unit was started or stopped
Control mode was changed
Filter was backflushed
Figure 36 - Event log tab
The complete list of possible entries is:
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Event
category
Control mode
Event text
Description or reference
Section 6.1
Operation
Service mode was
selected
Remote control was
selected
Local control was
selected
Remote control was
requested
System flush was started
System flush was stopped
or finished
Preparing for sampling
Sampling preparation
was stopped or finished
Filling was started
Operation
Filling is active
Operation
Discharge was started
Operation
Discharging is active
Operation
Filling was canceled
Operation
Discharge was canceled
Operation
Filling was stopped
Operation
Discharging was stopped
Operation
Stripping is active
Operation
Stripping was started
Operation
Stripping was cancelled
Operation
Stripping was stopped
Operation
Operation
Backflush pump started
Backflush pump is
running
Backflush pump was
stopped
Boll filter motor started
Control mode
Control mode
Control mode
Maintenance
Maintenance
Maintenance
Maintenance
Operation
Operation
Section 6.1 and 7.2
Section 6.1 and 7.2
Section 6.1 and 7.2
Section 7.7
Section 7.7
Section 7.9
Section 7.9
“Start filling” order was given. System is in
“InitFilling” state. Section 7.3
Filling is in progress. System is in “Filling” state.
Section 7.3
“Start discharge” order was given. System is in
“InitDischarge” state.
Section 7.4
Discharge is in progress. System is in “Discharge”
state.
Section 7.4
Filling operation was stopped while system was still
in “InitFilling” state. Section 7.3
Discharge operation was stopped while system was
still in “InitDischarge” state. Section 7.4
Filling operation was stopped while system was in
“Filling” state. Section 7.3
Discharge operation was stopped while system was
in “Discharge” state. Section 7.4
Stripping operation is in progress. System is in
“Stripping” state. Section 7.5
“Start stripping” order was given. System is in
“InitStripping” state. Section 7.5
Stripping operation was stopped while system was
still in “InitStripping” state. Section 7.5
Stripping operation was stopped while system was in
“Stripping” state. Section 7.5
Start order given to backflush pump motor.
Running signal from backflush pump motor relay
received. Section 9.3.2
Stop order given to backflush pump motor and
running signal lost/ceased.
Start order given to particle filter motor.
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Event
category
Operation
Operation
Operation
Operation
Operation
Operation
Operation
Operation
Operation
System
Treatment
Treatment
Treatment
Treatment
Treatment
Treatment
Treatment
Treatment
Treatment
Treatment
Treatment
Treatment
Treatment
Treatment
Event text
Description or reference
Boll filter motor is
running
Boll filter motor stopped
Running signal from backflush pump motor relay
received. Section9.3.3.
Stop order given to particle filter motor and running
signal lost/ceased.
Backflush operation completed.
“Other operation” mode was requested. Section 7.10
Backflushed
Other operation
activated
Other operation ended
“Other operation” mode was completed. Section
7.10
UV Unit 1 is warming up
UV lamps are warming up prior to filling or discharge.
Normal warm-up duration is 5 min. Section 7.3, 7.4
and 7.5
UV Unit 1 is running
UV units are operating normally
UV Unit 1 is Cooling down UV unit was shut down due to a “Stop” order. UV
units need a 10 min. cooling time before a re-start is
possible.
Possible service mode
Valve positions indicate risk of discharge during
discharging detected
service mode.
System boot detected
The BWMS control system was rebooted due to user
action or power failure.
Bypass valve closed
The main bypass valve was closed (from IAS or
manually). Section 4.3.3
Bypass valve opened
The main bypass valve was opened (from IAS or
manually). Section 4.3.3
Flow reduction active
Flow has been reduced. Section 6.3.5
No Flow Reduction active System operating at nominal flow. Section 6.3.5
UV Intensity nearing
UV intensity is below warning limit. Section 6.3.5
minimum for UV unit 1
UV Intensity below
UV intensity is below lower / error limit for current
minimum for UV unit 1
flow. Section 6.3.5
No or reduced treatment UV intensity under limit and acknowledged by
allowed by operator
operator within 60 seconds. Section 6.3.5
Treatment restored
UV-Intensity restored above minimum limit.
Flow above system rating Maximum TRC reached or exceeded, Section 6.3.2
detected
Flow rating restored
Flow restored below allowable level. Treatment is in
compliance.
System is bypassed
Main bypass valve is open and system is being
bypassed.
System bypass ended
Main bypass valve is closed and system is no longer
bypassed.
System bypassed during
Main bypass valve is open and system is being
other operation
bypassed while in “Other operations” mode.
System bypassed during
Main bypass valve is closed and system is no longer
other operation ended
bypassed while in “Other operations” mode.
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Event
category
Treatment
Event text
Description or reference
Filling stopped due to
high difference pressure
Possible clogged filter detected and filling stopped to
protect filter. Section 9.3.5
Table 49 - Summary of possible event entries in event log
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10.3.3 Mode log
The mode log contains entries for all changes between operating modes. The log shows the change
from one mode to another, and the time spent in the mode that you changed from.
Figure 37 - Mode log tab
The mode log contains entries for changes between control modes only. The possible entries are:
Mode text
LocalControl
RemoteControl
ServiceMode
Description
BWMS is controlled from the LOCAL touch screen on the BWMS main
control cabinet. Automatic operating modes as described in section 7 are
available
BWMS is controlled from an IAS screen / operating station with the BWMS
REMOTE interface enabled. Automatic operating modes as described in
section 7 are available.
BWMS is in service mode for maintenance and is controlled manually from
the LOCAL touch screen on the BWMS control cabinet. Automatic
operation modes are not available. All components can be operated
manually and independently.
Table 50 - Summary of possible control mode entries in Mode log
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10.3.4 Alarm log
Alarms are logged in the alarms log. The log contains information on alarm timestamp, alarm status
as defined in section 9.1, the level (error or warning) and a descriptive text.
Figure 38 - Alarm log tab
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10.3.5 Filling and discharge
The filling and discharge logs contain process information. Examples of the filling and discharge logs
are shown below. The backflush log has a similar structure.
The logs contain information on start and stop time of each operation, the operating mode, elapsed
time and total filled (or discharged) volume. In addition, flow, UV intensity are logged. Backflushing
count and interval data are also logged for the filling operations.
Figure 39 - Filling log tab
Figure 40 - Discharge log tab
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10.3.6 Flow and intensity logs
The flow and intensity logs display actual, as-measured values of flow and intensity, logged over 30
second intervals during operation. The log entry contains the recorded min and max peaks and the
calculated average value.
These logs are useful for monitoring and spotting trends in the treatment process.
Figure 41 - Flow log tab
Figure 42 - Intensity log tab
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10.3.7 Reading, printing and archive logs
The logs can be read on screen or exported to pdf as explained in section 5.1.4.
The generated pdf file can be saved to a USB memory stick or external hard drive for backup and
export, and/or for printing.
Be aware that you do not have access to the local file system on the BWMS controller
PC from the GUI.
You must save the pdf file to an external device, such as a USB memory stick or
external hard drive and access it on a regular PC or laptop.
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BWMS capacity range 30-3100
11 Appendices
To be considered as part of User documentation Part II:
A.
Technical Specifications
A.1
A.2
A.3
A.4
BWMS Technical specification
IAS interface specification
Alarm List
Software revision log
B.
BWMS system documentation
B.1
B.2
B.3
B.4
B.5
P&ID
Dimensional sketches – BWMS and main components
Bill of Materials
BWMS wiring diagram
Electrical diagram – BWMS main control cabinet
C.
UV units
C.1
C.2
C.3
C.4
UV unit user manual
Dimensional sketches – UV unit main components
Electrical drawings – UV units
Handling of broken UV lamps
D.
Particle filter and backflush pump
D.1
D.2
Filter user manual
Backflush pump user manual
E.
Instrumental measure units
E.1
E.1.1
E.2
E.2.1
E.3
E.3.1
E.4
Flow sensor user manual
Flow sensor calibration certificate
Pressure sensor datasheet
Pressure sensor calibration certificate
Inductive conductivity transmitter datasheet
Inductive conductivity transmitter calibration certificate
UV-I Sensor calibration certificate
F. Valves
F.1
F.2
Valves datasheet
Dimensional sketches
G.
Installation instructions
G.1
Tightening of bolted connections and installation of seals in flanged connections
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BWMS capacity range 30-3100
H.
Test procedures
H.1
H.2
H.3
Installation check-list
Functional test procedure
Sampling tube installation and sample taking procedure
I.
Approvals
I.1
IMO Type Approval certificate
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