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Essential protection
Marine ecosystems are important, not only to the environment, but also to our own health and livelihood. This is why protecting the balance of species through ballast water treatment is a key aspect of Alfa Lavals Pure Thinking. Our approach to ballast water treatment is determined not only by the legislation surrounding it, but also by the important demands of shipyards, ship owners and ship operators. Now in its second generation, our PureBallast system incorporates the full spectrum of installation and operational needs, as well as lessons learned in years of full-scale, real-life operation at sea. This means that PureBallast maintains not only the balance of species, but also the balance between onboard and global considerations.
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Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Overview
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Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 EX version . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 34 Shipyards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 CD . . . . . . . . . . . . . . . . . . inside back cover
Onboard performance
The global regulations that govern ballast water treatment are designed to stop a devastating wave of marine biological invasions. However, they affect far more than the organisms in ballast water. They also affect you. While the problem of invasive species is universal, the means of solving it has to be carried on individual vessels. You as a shipyard, ship owner or ship operator face tough demands when it comes to ensuring compliance, but you also have your own demands on size, economy, ease of use and compatibility with onboard operations. To meet these demands, you need a mature treatment system that handles the rigors of business at sea. Specifically, you need one that is as well adapted to life on board as it is to the requirements of international law, and one that has proven its merits under real-life operating conditions. Fortunately, PureBallast is just such a system.
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INTRODUCTION
Worldwide experience
By choosing PureBallast from Alfa Laval, you choose both the right solution for your onboard needs and a proven solution with global backing. In addition, you choose the worlds most experienced supplier in ballast water treatment. Having worked with ballast water treatment for years, we understand not only the theoretical issues, but also the practical realities. PureBallast 2.0, Alfa Lavals second generation of the PureBallast system, builds on thousands of hours spent working with actual installations on site at shipyards, as well as in full operation at sea. Backing up that experience is Alfa Lavals network of harbour support, which can be found in ports all over the globe. Our far-reaching resources give you access to parts, service and advice worldwide, in ballast water treatment and beyond. Wherever you sail, Alfa Laval is there to bring you true peace of mind.
INTRODUCTION
Sailing on ahead
PureBallast is a clear and comfortable choice, having quickly established itself as the commercial leader in ballast water treatment since its launch in 2006. The system has been chosen for more vessels than any other ballast water treatment system, as well as for the greatest range of vessel types. These include everything from container vessels and tankers to offshore supply ships and naval vessels. Moreover, PureBallast has been installed at major shipyards all over the world. Behind the success of PureBallast is its unique combination of advantages. In addition to type-approved ballast water treatment, PureBallast offers: Easy installation in a compact space Automated, reliable and chemical-free operation Full integration with existing ballast water systems Low maintenance requirements and lifecycle cost
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OVERVIEW
OVERVIEW
All control and distribution functions are now integrated in a single cabinet.
PureBallast 2.0 offers a large number of improvements that simplify both installation and operation.
The flow meter and control valve are integrated for automatic flow control. A smaller and more effective filter is used.
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OVERVIEW
The most significant change in PureBallast 2.0 is the reduction of the systems power consumption by a full 40% compared to its predecessor.
PureBallast 2.0 EX features reinforced AOT units. Temperature sensors, level sensors and a non-return valve prevent ignition conditions from arising within the units.
OVERVIEW
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R E G U L AT I O N S
ns
R E G U L AT I O N S
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R E G U L AT I O N S
IMO limits for type approval are given in individuals per cubic metre or colony-forming units per 100 ml.
Treatment or exchange?
Once ratified, the IMO convention will introduce ballast water treatment requirements in phases (see right). Though not all vessels will have to perform ballast water treatment directly, all vessels without a type-approved treatment system will be required to perform ballast water exchange. This involves flushing out the ballast tanks at sea, which may reduce the chances of organisms surviving within them. The effectiveness of ballast water exchange is in dispute, as it may actually supply organisms with fresh oxygen and nutrients. Moreover, the procedure is a time-consuming process that can compromise stability and put a vessel at risk in heavy weather. As such, many ship owners and operators will want to avoid it by installing a treatment system before they are required to do so.
Implementation of requirements Newbuilds (constructed 2010 or later) Treatment required from 2010 for BWC >5000 m3 Treatment required aboard all vessels from 2012 Existing vessels (constructed prior to 2010) Treatment required from 2014 for BWC 1500-5000 m3 Treatment required aboard all vessels from 2016
Whentheconventionhasenteredintoforce,allvessels withoutaballastwatertreatmentsystemmustperform ballastwaterexchangeinopenwaters. Vesselsconstructedin2009withBWC<5000m3must installaballastwatertreatmentsystembytheirsecond annualsurveyandnolaterthan31December2011.
R E G U L AT I O N S
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TECHNOLOGY
TECHNOLOGY
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TECHNOLOGY
Uniquely effective
The PureBallast treatment process is based on a patented form of advanced oxidation technology (AOT), developed in cooperation with Wallenius Water. Related technologies can be found in many of todays smart products, such as the self-cleaning windows of skyscrapers and cars, which prevent the growth of organisms through an AOT reaction that occurs when sunlight strikes titanium dioxide. Within the PureBallast system, treatment occurs in a closed chamber known as a Wallenius AOT unit, in which radicals are generated. These radicals are potent yet exist for only a few milliseconds, which means they neutralize microorganisms but are incapable of leaving the treatment system.
Radical advantages
In addition to being safe for the ballast water tanks and the vessels crew, the use of radicals has advantages over other prominent treatment technologies. For example, the spread of radicals is not affected by the presence of particles, which means treatment is still effective when the water has high sediment content. Even more importantly, the radicals actually break down cellular membranes, which effectively destroys the microorganisms rather than rendering them unable to reproduce. As a result, the potential for them to do damage at the deballasting site is completely eliminated.
Before
After
PureBallast neutralizes the living threat in ballast water with the help of radicals, which disrupt the cell membranes of microorganisms. After passing through the PureBallast system, the dinoflagellate above has lost its chlorophyll.
TECHNOLOGY
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Keeping it compact
PureBallast is a perfect match for the cramped engine room. Built to fit where every bit of space is worth saving, it is as compact as it is effective. PureBallast is constructed from a series of block components, which gives the overall system exceptional flexibility. Each component is optimized for a minimum footprint, and with planning, components can actually be installed between existing pipes. Depending on the needs of the vessel, a single PureBallast system can handle flow rates of 250-3000 m3/h. If more capacity is required, even higher flow rates can be achieved by installing multiple systems in parallel.
Control system (5)
Filter (1)
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I N S TA L L AT I O N
Because PureBallast is flexibly constructed to suit the engine room, no single illustration can provide a complete overview. The sample layout here, in which the AOT units are arranged in a linear fashion, is designed for a flow rate of 1000 m3/h. 1. Filter A 40 m mesh filter is used during ballasting operations. This not only blocks the intake of larger organisms, but also reduces the amount of sediment in the ballast water tanks. This filter is bypassed during deballasting and is cleaned via automatic backflushing. 2. Wallenius AOT unit(s) One or more Wallenius AOT units comprise the active stage of PureBallast treatment, in which radicals are generated to neutralize microorganisms and other organic matter. The number of AOT units is determined by the systems flow rate, with individual units handling a flow of 250 m3/h. The AOT units can be placed in a number of configurations, including the linear configuration shown here. 3. CIP unit The performance of the AOT units is safeguarded by an automatic Cleaning-in-Place (CIP) system, which circulates a biodegradable solution to prevent seawater scaling within the AOT units. This solution is reusable and is replaced only once per year or when its pH level has become too high. The cleaning cycle, which takes 15 minutes per unit, is automatic and occurs after each ballasting or deballasting operation. 4. Flow meter A flow meter coupled with a control valve automatically ensures that the system does not exceed its certified flow rate. This meter also provides the main control system with valuable data regarding the amount of ballast that has been taken in or discharged. 5. Control system PureBallast can be operated either automatically or manually, as well as by optional remote control. The intuitive control panel provides a graphical overview of every aspect of the control system, including monitoring and log functions.
I N S TA L L AT I O N
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I N S TA L L AT I O N
Designed to capacity
The vertical reaction chambers in which treatment occurs, known as Wallenius AOT units, make up the bulk of a PureBallast system. Each of these units handles a flow rate of 250 m3/h, and with the introduction of PureBallast 2.0, they consume 40% less power than their predecessors. Up to twelve AOT units can be connected within a single system. If flow rates greater than 3000 m3/h are required, two or even three PureBallast systems can be installed, each with its own filter, Cleaning-in-Place (CIP) unit and control system. The AOT units are installed such that the flow and pressure of the water is equally distributed between them. Although the units are often arranged in a linear fashion, they can also be arranged in blocks or other configurations to suit the engine room layout.
Integrated benefits
With its flexible design and ability to fit between existing pipes, PureBallast adapts easily to existing engine room conditions. PureBallast 2.0 is even simpler to install than the previous generation of the system, thanks to a high level of integration that eliminates a remote interface cabinet, a control cabinet and one breaker cabinet per AOT unit. In addition, PureBallast is as integrated with ballast operations as it is with the space on board. PureBallast utilizes the ballast pumps that are already installed and requires no extra holding time in the ballast water tanks, so there are no additional procedures and no delays when ballasting or deballasting. This makes PureBallast as suitable for retrofits as it is for newbuilds.
PureBallasts modular components allow for truly flexible installation. With planning, components can even be installed between existing pipes.
I N S TA L L AT I O N
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O P E R AT I O N
O P E R AT I O N
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Ballasting operations
In preparation for ballasting, the lamps of the Wallenius AOT units undergo a brief startup sequence, during which they are cooled by a flow of seawater. During actual ballasting, fresh water is used to cool the systems electronic components. When ballasting begins, the incoming ballast water first passes through the filter, which removes organisms and particles larger than 40 m. The water then continues through the AOT units, which treat the water to IMOestablished limits before it enters the ballast water tanks. Once ballasting is complete, the AOT units are cleaned via an automated Cleaning-in-Place (CIP) cycle, which takes around 15 minutes per unit. This cycle can be automatically initiated directly after ballasting, or manually initiated from the control system within 30 hours. The AOT units are automatically rinsed with fresh water before the CIP cycle begins and filled with fresh water upon its completion. The filter is also rinsed with fresh water once ballasting is completed.
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O P E R AT I O N
Deballasting operations
The deballasting process is essentially the same as the ballasting process. However, the filter is bypassed during deballasting since the water has already been filtered. After leaving the ballast water tanks, the outgoing ballast water passes through the Wallenius AOT units to eliminate any regrowth of microorganisms that may have occurred in transit. Having thus been treated to the limits set by IMO, it is then discharged into the receiving water at the deballasting site. The same startup and shutdown sequence is employed during both ballasting and deballasting (see left).
O P E R AT I O N
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O P E R AT I O N
Simplicity at a glance
PureBallast can be operated either automatically or manually. The main control panel, which takes the form of a durable, full-colour graphical touchscreen in PureBallast 2.0, provides access to every aspect of the system, including its monitoring and log functions. Even PureBallast manuals are directly viewable from the control panel. In addition, PureBallast can be steered by optional remote control. Each PureBallast system can be complemented with a maximum of four remote control panels, which allow it to be started, stopped and monitored from any location on board. Modbus communication can also be used to integrate PureBallast with other automation systems, providing access to all PureBallast functions through the vessels standard interface.
Operational advances
In addition to the visual and intuitive control panel, PureBallast 2.0 offers a number of operational improvements over its predecessor. These include a connection between the flow meter and control vent for fully automatic flow control. The startup and shutdown sequences, which are faster in PureBallast 2.0, are bypassed in a new pause function, which allows operation to be suspended for short intervals. This can be done during heeling, for example, to facilitate the redistribution of ballast water without having to restart the ballast water treatment system. Finally, users now have the option of shutting down individual AOT units while the system is still running. This allows changes in flow rate as well as the exchange of AOT lamps without interrupting treatment.
PureBallast is fully automated and offers ample possibilities for remote control. Modbus communication ensures easy integration with the vessels general automation systems.
O P E R AT I O N
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Always on guard
Vessels like crude tankers and product tankers, which carry volatile cargo and thus have potentially explosive areas on board, are not exempted from ballast water treatment requirements. However, until now there has been a lack of treatment systems adapted to their needs. Today, as a part of PureBallast 2.0, Alfa Laval can supply an Ex version of the PureBallast system. Designed for Zone 1, group IIC and temperature class T4, PureBallast 2.0 EX is suitable for installation aboard most types of tankers that carry ignition-sensitive cargo. Since PureBallast 2.0 EX is a specialized version of our second-generation system, it naturally also features most of the improvements found elsewhere in PureBallast 2.0, including reduced power consumption and the ability to pause operation.
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EX VERSION
EX VERSION
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Thoroughly prepared
The creation of PureBallast 2.0 EX has been a comprehensive undertaking. Because of the extreme hazards that exist when working with oil and chemicals, it has been necessary to take every possible safety concern into account. For this reason, Alfa Laval has looked beyond mere regulations. Working closely with shipyards and shipping companies that deal with volatile cargo, we have designed PureBallast 2.0 EX to incorporate their suggestions and insights.
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EX VERSION
Internal and external modifications of the Wallenius AOT units eliminate explosion risk.
EX VERSION
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MAINTENANCE
Economical ease
PureBallasts limited maintenance can be handled without special tools and poses no difficulty for a mechanical engineer using the manual as a guide. This means the system can be serviced even by inexperienced crewmembers. For convenience and economy, the necessary maintenance items have been organized into kits, which contain all the instructions and tips for the relevant maintenance checkpoints. In fact, the maintenance costs for PureBallast amount to just a few dozen euro per thousand cubic metres of processed ballast water.
MAINTENANCE
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Strength to build on
Alfa Laval has been involved in ballast water treatment from the very beginning, having been among the very first to launch a ballast water treatment system. This means we were also among the first to meet with shipyards and discuss the practical realities of installing such a system. Today we are the commercial leader in ballast water treatment, having sold more ballast water treatment systems and equipped a greater range of vessel types than any other supplier. That experience yields clear benefits for shipyards, since it means we have worked extensively with them in a broad range of projects with varied installation demands. The improvements in our second-generation system, PureBallast 2.0, are based in no small part on the suggestions and wishes of our shipyard partners. These include a reduction in the number of units to install, as well as the reduction of power consumption by 40%, which makes it easier to use the designed power on board and to avoid installing an extra generator. From the drawing board to on board, PureBallast today is an optimized answer to shipyard needs.
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S H I P YA R D S
Drawing on experience
PureBallast has always been appreciated as a welldocumented system with comprehensive manuals. PureBallast 2.0 further gears that documentation toward the specific needs of shipyards. With the new documentations simplified drawings and more installation-oriented descriptions, it is easier not only to plan a PureBallast installation, but also to place it on board within the set timeframe for vessel construction.
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S H I P YA R D S
A world of support
PureBallast builds on a 100% chemical-free technology, which means there are no chemical additives to be kept in stock. Likewise, the system has no moving parts to wear or break, so there is little maintenance that has to be performed. In other words, PureBallast offers long-term self-sufficiency. Nonetheless, PureBallast comes with the backing of a truly global supplier. Alfa Laval has a full equipment portfolio and century of experience meeting the needs of maritime industry as well as a worldwide network of harbour support. Wherever your ship sails with PureBallast, you will find access to our dedicated team of peace-of-mind specialists. As a result, technical assistance, onboard service and genuine spare parts are never out of reach.
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SUPPORT
SUPPORT
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Greater depth
Lift the flap for a CD with multimedia content and additional information about PureBallast 2.0 and PureBallast 2.0 EX.
Overview animation
This brief animation serves as an introduction to the basic principles of PureBallast operation.
EMD00181EN 1008 PureBallast is a trademark owned by Alfa Laval Corporate AB. Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB. Alfa Laval reserves the right to change specifications without prior notification.
Alfa Laval in brief Alfa Laval is a leading global provider of specialized products and engineering solutions. Our equipment, systems and services are dedicated to helping customers to optimize the performance of their processes. Time and time again. We help our customers to heat, cool, separate and transport products such as oil, water, chemicals, beverages, foodstuffs, starch and pharmaceuticals. Our worldwide organization works closely with customers in almost 100 countries to help them stay ahead. How to contact Alfa Laval Contact details for all countries are continually updated on our web site. Please visit www.alfalaval.com to access the information.