THE EXCELLENCE OF SIMPLICITY

Training BWTS Booklet

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ATTENTION NOTE:
This booklet is only for training purpose.

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Contents

1 Introduction.....................................................................................................................5

1.1 Problems and Solution................................................................................................5

2 General............................................................................................................................8

2.1 Water ballast treatment during ballasting.................................................................8

2.2 Water ballast treatment during de-ballasting...........................................................8

3 Operational Modes.......................................................................................................10

4 BWTS Control Panel......................................................................................................11

5 Ballast Operation..........................................................................................................13

6 De-Ballast operation.....................................................................................................17

7 Fresh Water Operation Description With SWP...........................................................18

8 Filter................................................................................................................................20

8.1 Filtersafe – Filtration Phase.......................................................................................20

8.2 Flushing Cycle............................................................................................................21

8.3 Filtrex..........................................................................................................................22

8.3.1 Filtration Phase.......................................................................................................22

8.3.2 Cleaning Phase.......................................................................................................22

8.4 Filter Safety and Preservation...................................................................................23

9 Electrolyzer ....................................................................................................................24

9.1 maintenance..............................................................................................................25

9.1.1 Once per year or after 300 hours of ballasting operation..................................25

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9.1.2 Upon Failure or lifetime.........................................................................................25

9.1.3 Safety Measures......................................................................................................25

10 Transformer / Rectifier (T/R) Unit...............................................................................27

10.1 Preventive maintenance..........................................................................................27

10.1.1 The following maintenance must be done yearly:.............................................27

10.1.2 The following maintenance must be done monthly:.........................................27

10.2 Troubleshooting.......................................................................................................27

11 TRO Sensor..................................................................................................................29

11.1 Purpose of Total Residual Oxidants.......................................................................30

11.1.1 Points of Attention................................................................................................31

11.2 Electrical Connections.............................................................................................31

12 TRO Gravity Drain Tank..............................................................................................32

13 Flow meter (FM)..........................................................................................................33

14 Sensors - Safety Measurements.................................................................................34

14.1 Flow Switch (FS).......................................................................................................34

14.2 Temperature Sensor (T)...........................................................................................34

14.3 Pressure Indicator (PI)..............................................................................................34

14.4 Salinity.......................................................................................................................35

15 Neutralizing Agent Tank (NAT) and Dosing Pump..................................................36

15.1 NAT...........................................................................................................................36
1
15.2 Dosing Pump...........................................................................................................38

16 The G2 sampling port................................................................................................39

16.1 The Initial Inspection...............................................................................................39

16.2 More Detailed Inspection.......................................................................................40

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1 Introduction
1.1 Problems and Solution

The ballast water, which is taken onboard by ships, it can contain thousands of
aquatic - marine microbes, plants or animals which are carried across the global.
Then, the ballast water is released at the ship’s destination so probably it may intro-
duce some new invasive marine species at the discharge aquatic environment.
Because the 80% of the world trade is carried by ship meaning that 10 billion of
ballast water is carried around the world per year, 7000 species are carried every
hour of every day, therefore we can imagine what the impact of the untreated bal-
last water can be.
The introduction of the first alien species was in 1903. After that, a lot of researches
and studies had done. So, around 1970s, the scientific community began reviewing
that problem in detail.
Then in 1980s, the IMO’s Marine Environment Protection Committee (MEPC) and
the Ballast Water Management Convention (BWMC) was adopted by Canada and
Australia and in 2004 they tried to prevent the spread of harmful aquatic organisms
from one region to other.
Last, on 8th Sept 2017, the BWMC was entered into force by a minimum of 30
states (35% of the world shipping merchant tonnage) and requires all ships to im-
plement:

• A Ballast Water Management Plan

Each ship shall have on board and implement a ballast water management plan.
Such plan shall be approved by the Administration considering guideless devel-
oped by the Organization. The BWMP shall be specific to each ship and shall at
least:
1. Detail safety procedures for the ship and the crew associates with ballast
water management.
2. Provide a detailed description of the actions to be taken to implement the
ballast water management requirements and supplemental ballast water manage-
ment practices.
3. Include the procedures for coordinating shipboard ballast water manage-
ment that involves discharge to the sea with the authorities of the state into whose
waters such discharging will take place.
4. Designate the officer on board in charge of ensuring that the plan is properly
implemented.
5. Contain the reporting requirements for ships provide for under this Conven-
tion.
6. Be written in the working language of the ship. If the language used is not
English, French or Spanish, a translation into one of these languages shall be in-
cluded.
7. Ship’s compliance strategy.
8. Apart from the operation description, it shall contain some contingency
measures, back-up plans when the BWTS is inoperable or when it is working out its
limitation.

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• A Ballast water record book

Each ship shall have on board a ballast water record book that may be an elec-
tronic records system, or that may be integrated into another record book or sys-
tem. Ballast water record book entries shall be maintained on board for a period
of two years and thereafter in the company’s control for a period of three years.
The BW record book will be kept readily available for inspection at all reasonable
times.

Figure 1: Ballast Water Reporting Form (based on MEPC 52/2, ANNEX 2)

• Ballast Water Management Procedures

1.1.1 Regulation D-1
Ballast water exchange standards. it is valued until the next IOPP Certificate Renew-
al. After 2024, it will be used only as contingency measure. 1
Exchanging ballast water in open sea away from coastal areas, with an efficiency of
95% volumetric exchange of ballast water or exchanging ballast water by pump-
ing-through method, pumping through three times the volume of each ballast water
tank.

1.1.2 Regulation D-2

Ballast water performance standards.
Indicator microbes, as a human health standards and USCG, shall include:
1. Toxicogenic Vibrio Cholerae (01-0139) with less than 1 colony-forming unit
(cfu) per 100 milliliters or less than 1 cfu per 1-gram zooplankton samples.

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2. Escherichia coli less than 250 cfu per 100 milliliters.

3. Intestinal Enterococci less than 100 cfu per 100 milliliters.

IMO Class IMO Standards

Plankton ≥ 50μm < 10 viable organisms/m3
Plankton ≥ 50μm < 10 viable organisms/ml
Escherichia coli < 250 cfu/100 ml
Enterococci < 100 cfu/100 ml
Toxicogenic Vibrio Cholerae < 1 cfu/100 ml or 1 cfu/gr wet weight

< 1 cfu/100 ml or 1 cfu/gr wet weight

Existing ships with renewal survey until 2019 must comply with the D-2 standards.

Existing ships with renewal survey after 8th Sept 2019 must meet the D-2 Standards
by this renewal. Finally, all ships must meet the D-2 standards by 8th Sept 2024.

New building ship must comply with D-2 standards from the first day.

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2 General
2.1 Water ballast treatment during ballasting

The Ballast Water Treatment refers to the technologies and methods to make sure
that the number of living organisms that are discharged during the de-ballasting is
below the IMO and USCG limits.

The IMO refers to viable organisms, alive but not able to reproduce while the
USCG refers to dead organisms via treatment process, which is critical for UV sys-
tems. The goal is not to discharge living organisms to a different aquatic environ-
ment. So, in order not to discharge them alive, they must be eliminated.

Therefore, all the BWTS have a disinfection stage.

There are various disinfection methods and means, like chlorine and other oxidants,
UV, cavitation, etc.

ERMA FIRST uses Electrochemical cell capable to produce sodium hypochlorite

from seawater and DC current to a concentration of up to 6 ppm directly into the
water.

Filtered water is fed into the electrochemical cell which produces chlorine from sea-
water and DC current. The water is disinfected.
During disinfection, energy is consumed. The more and bigger the living organisms
in the ballast stream exists, the more energy is consumed. Below there is an exam-
ple for Erma First Fit 1000.

With Filter No Filter

Filter: 40 μm N/A
Disinfection: 6 mg/lt of Chlorine Disinfection: 40 mg/lt of Chlorine
That means 8 times higher power Consumption
Erma First Fit 1000 installed power, KW Erma First Fit 1000 installed power, KW
(0.9 PSU) system congf. = 115.5 KW (0.9 PSU) system congf. = 924 KW
Table 2: Consumptions

1 so
Consequently, we must reduce the size and the number of the living organisms
as to reduce the power consumption. This is achieved by using filters.

Various types of filters and filtration degrees can be implemented.

ERMA FIRST has basket filters automatically backwashing and specifically designed
for ballast water capacity down to 40 μm mesh. ERMA FIRST offers two options for
the mechanical filtration of the intake water. The first option is the Filtersafe and
the second one is the Filtrex. Both brands, filter the ballast water which is taken on
board and remove any particle larger than 40μm, in order to reduce the ecological
load of the water and at the same time to guarantee minimum impact on the ballast
system capacity.

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The basket filters consist of one single screen or several depending on the hydrau-
lic capacity of the filters. Their capacity varies from 100 up to 4000 m3 / h, while the
number of baskets varies from 1 to 6. The maximum pressure drop across the filter
baskets is 0.4 bar.

2.2 Water ballast treatment during de-ballasting

During De-Ballasting, the organisms are already dead. We don’t need to pass them
through the filter and the cell. Only, monitoring and neutralizing equipment is in-
stalled on the discharge lines prior to overboard, to ensure that chlorine less than
0.1 mg/Lt is discharged in the sea. NOT TREATMENT, ONLY NEUTRALIZATION.

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3 Operational Modes
OFF: Monitoring and making sure that no untreated water enters into the tanks
bypass without event data logged and alarm activated.

BALLAST: 1. Treatment, 2. max flow restriction due to filter and cell capacity, 3.
Power consumption due to disinfection.

DE-BALLAST: 1. Only sampling and neutralization of the remaining chlorine, 2. No

flow restriction, 3. No power consumption. We may use the Pumps or Eductor or
Gravity.

EMERGENCY: Emergency.

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4 BWTS Control Panel

We activate the Modes from BWTS control panel. The ERMA FIRST local control
panel and repeater panel are used to monitor and control the operation of all
system components. BWTS parameters are constantly recorded in data logger and
stored for 24 months.

Table 2: Consumptions

MAIN SWITCH

ON: The system is powered on. Operation of BWTS will start depending on the
selection of position of the rest control panel switches. Always: ON position.

OFF: The system is powered off. No BWTS operation is possible and monitoring
and recording of BWTS parameters is stopped.

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MODE SWITCH
Ballast: BWTS in ballast mode.

De-ballast: BWTS in de-ballast mode.

Off: BWTS switched off and remain idle. This switch is also used to reset the criti-
cal alarms events triggered during ballasting or de-ballasting mode and be able to
restart the BWTS ballasting or de-ballasting operation.

CONDITION SWITCH
NORMAL: BWTS is operating according to main switch position.

EMERGENCY: Vessels emergency. In case of vessels emergency during ballasting

operation BWTS is powered off and its ballasting components are by-passed. If
emergency switch is activated during de-ballasting, samples are taken from TRO
measuring and the dosing of neutralizing agent continues to operate.

FRESH WATER OPERATION SWITCH

High Salinity water, which is stored in APT, feeds the BWTS inlet and increases the
salinity if it is needed. In order to increase the salinity, a Sea Water Feeding Pump
is activated when the Vessel operates under low salinity areas like rivers.

DEBALLAST SWITCH GRAVITY

De-ballasting is conducted via gravity.

PUMPS
De-ballasting is conducted through ballast pumps.

EDUCTOR
De-ballasting is conducted through the eductor.
Proceed in the proper valve arrangement from ballast tanks to overboard with
eductor.
Steps for the operator:
• Set BWTS to De-Ballast mode.
• Select means of de-ballasting: EDUCTOR.
• Make sure that the eductor is operating.
The only parameters monitored during de-ballasting are: 1. Chlorine (TRO) concen-
tration and 2. Dosing pump. 1
In case TRO concentration is more than 0.1 mg/L, an attention alarm is activated
and if the concentration continues, after 4 minutes, a critical alarm is activated
along with the Alarm indication on screen. The system remains in operation.

For the first 10 minutes of BWTS de-ballasting operation, a small variation of TRO
and neutralizing agent injection quantity might occur due to algorithm adjustment.
These variations, during BWTS initialization time, do not affect the efficiency of
BWTS.

Attention: When it’s time to stop the de-ballast operation, first stop the ballast
pump(s), then close the discharge valve and then, set BWTS to OFF mode.

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5 Ballast Operation
In order to proceed to ballast mode, it is important to follow the steps described
below:

1. Proceed in the proper valve arrangement from sea-chests to BWTS and then to
ballast tanks.

Figure 3: Ballasting mode (normal condition) with ballast pump and FW mode OFF

2. Set BWTS to Ballast mode.

3. Select the operating pump(s).
4. Start ballast pump(s).
5. Await the discharge pressure of pump(s) to reach maximum level to protect the
filter and the rest components from overpressure.
6. Open slowly the discharge valve of the ballast pump to fill in the BTWS slowly.
7. When it is time to stop the ballast operation, set BWTS to OFF mode, then stop
the ballast pumps.

Figure 4: Ballast process on BWTS

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Salinity measure device (SMD): Monitoring salinity, not critical.

PI1: System overpressure protection, critical.

Filter: Filtration at 40 μm, dirty water discharge via a suction pump to the same
environment.

Cell: Chlorine production.

Flow Switch (FS), Temperature sensor (T), Pressure Switch (PI): Sensors for the
safety of the cell, critical.

Total Residual Oxidants (TRO): Monitoring the chlorine, critical.

PI2: System outlet pressure, not critical.

Flow Meter (FM): Monitoring the flow.

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6 De-Ballast operation
Proceed in the proper valve arrangement from ballast tanks to overboard (Port &
Starboard Side), or sea chest.

Figure 5: De- ballast process on BWTS

Operator must arrange the ballast piping valves in such way that the flow is di-
rected from ballast tanks. De-ballast can be by Pumps, Eductor or Gravity to over-
board.

Steps for the operator when de-ballasting with pumps:

• Set BWTS to De-Ballast mode

• Select means of de-ballasting: PUMPS
• Start ballast pump(s)

During de-ballasting the BWTS major components are by-passed, and only chlorine
neutralizing and sampling stages are operating. Sample is taken by TRO1 to check
if the remaining TRO concentration exceeds MADC: 0.1 mg/lt, in this case the
neutralizing agent is injected. A second sample is taken by TRO2 to confirm that
TRO levels are less than MADC, otherwise the quantity of the neutralizing agent is
increased with maximum capacity and eliminate the risk of chlorine discharged.

Figure 6: Ballasting mode (normal condition) with ballast pump and FW mode OFF

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7 Fresh Water Operation Description With SWP

Figure 7: Fresh Water Operation

When the vessel operates at low salinity areas, the APT should be filled with salty water
to increase the salinity up to 1 PSU.

Fresh water operation is manually activated. If the system detects low salinity (<0.9 PSU),
it will give an ATTENTION ALARM after 30 seconds. During this operation the dedicat-
ed Sea Water Pump (SWP) is automatically activated to seed sea water from APT to the
ballast pump intake.
The amount of the sea water, which is needed, should be 2.5% of ballasting capacity. Ex-
ample, to ballast 10.000 m3 of 0.2 PSU salinity, 250 m3 of 35 PSU are needed in the APT.
Steps for the operator:
1. Set the Fresh water mode switch to ON
2. Turn the Sea-Water pump starter panel ON and set to AUTO

Note: Make sure that you need to make the correct valve arrangement. It can vary from
ship to ship.
1
When Fresh Water mode sets to ON the pumps start and after 10 seconds the Flow
Control Valve (FCV) opens at 75%. According to the SMD readings, the system automati-
cally adjusts the opening of FCV to achieve 0.9 PSU.
In case where the salinity does not increase despite the operation of the Fresh Water
module and the FCV being fully open, then:
• returns to a CRITICAL ALARM
• stops the SWP
• closes the FCV
which is low TRO production.

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Figure 8: Conversion of specific conductivity in millisiemens to centimeter, to salinity in

practical salinity units.

Diagram 1: Temperature - Salinity

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8 Filter

Figure 9: Filter

8.1 Filtersafe – Filtration Phase

This is an automatic backwashing filter with nominal filtration capacity down to

40μm. The filter is designed to capture all the organisms and impurities larger than
40 μm. All the smaller organisms that have passed through the filters, will be disin-
fected in the next stage by active chlorine.

Figure 10: Filtersafe, Description of the components of the filter

The water enters from an inlet flange and flows through the basket(s). The filtered water
flows to the next BWTS stage, disinfection. Whatever is larger than 40 μm remains on
the filter screen and creates a film of dirty on the screen. This causes a pressure across
the screen. When the differential pressure reaches the value of 0.4 bar, a flushing circle is
activated.

The multiscreen filters increase the filtration areas to treat flow up to 1500 m3/h.

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8.2 Flushing Cycle

The flushing cycle can be initiated through the PD switch. The cycle starts with the
following events:

1. the flushing valve opens

2. the suction pump turns on
3. the scanner motor starts

The open flush valve creates a differential pressure between the housing of the
filter and the pressure that exists at the outlet of the filter flushing line, which is
connected to an overboard line.

This differential pressure induces a suction action at the proximity nozzles of the
scanner.

The suction force is increased by using a suction pump. Water flows reverse from
the basket external to the basket internal, removes the dirty. It is passed through
the proximity nozzles as well as the scanner and it is finally discharged overboard.
The scanner is moved with a helical way, covers all the surface of basket and re-
moves the dirty.

Chart recorder 1

Cleaning process duration is approximately 40-120 seconds, depends on the filter

size.
• Activated when DP>0,4 bar and Stops when DP< 0,05bar
• Activated by one-hour time interval.

All filters are designed on the fact that ballast water solid content is: IMO 50 mg/lt
and USCG 35 mg/lt. When filter operates at very dirty load and a continuous flush-
ing happens, the filter is blocked. The flow of the ballast water must be reduced.

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8.3 Filtrex

This is an automatic backwashing filter with nominal filtration capacity down to 40μm.

Figure 11: Left, Filtration Phase – Right, Cleaning Phase

8.3.1 Filtration Phase

The filter works with on-condition back-washing using its own filtered fluid. The water
enters from the inlet flange (A) and flows through all the sectors of the filter (1).

The filtered water is collected in the chamber (D) and exits from the outlet flange (B).
During this phase, the filter operates as a static filter, and no cleaning processes of the
filtering element are taking place; the motor (2) does not operate, the nozzle (3) does
not rotate, and the backwash valve (6) is closed.

As more and more impurities build up on the cartridge surface, the differential pressure
DP is increased. This is detected by the differential pressure switch and is shown by the
gauge (4). Then the filter starts the cleaning phase. 1

8.3.2 Cleaning Phase

When the differential pressure has been shown on the gauge (4), the motor (2) starts
and drives the nozzle (3), moreover, the backwash valve (6) opens.

While all the sectors of the filtering element (1) assure the filtration of the fluid, the
sector in front of the nozzle (3) is cleaned by a high-efficacy backwash flow. This flow is
spilled from the filtered fluid present in the chamber (D) and exits from the nozzle (J)
through the backwash valve (6).

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As a result, the impurities on the filtering element surface are removed by the same
backwash fluid (filtered water) into the duct (5) and evacuated from the nozzle (J).

At the end of the backwash, the motor (2) stops, and the backwash valve (6) closes.
8.4 Filter Safety and Preservation
1. Open the BP discharge valve slowly and fill in the filter slowly too.
2. Flush 5 minutes at the end of ballast.
3. Repeat flushing once per week.
4. Keep filter always full of water (preferable option Fresh water, second option sea
water).

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9 Electrolyzer

Their type and their number of units depend on ship specific according to ballast water
pump capacity.

Figure 12: Electrochemical Cell / Electrolyzer

An electrochemical cell produces Chlorine from seawater and DC current. The capacity
is maximum 6 ppm for the specific flow (m³/h) rating of the system.

It is a bipolar electrochemical cell which consists of cathodes and anodes which are
made of titanium. The cell house is made of Glass fiber Reinforced Plastic (GRP).

Figure 13: Electrolyzer Section View

1.Housing 2.Inlet flange connection 3.Cabling (connection) boxes

4.Electrode assembly 5.Outlet flange connection

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Three factors are affecting TRO Production: 1. Flow, 2. Salinity and 3. Temperature. The
cell can operate at 0.9 PSU salinity and -2°C. The maximum flow depends on the cell
size.

Table 3: BWTS Power Consumption at Various Salinity

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A detailed example for ERMA FIRST FIT 1000: The installed power of the system is 77
KW. The 95% of the power is consumed for the disinfection when the BWTS works at
0.9 PSU. The 20% of the installed power is consumed when it works at 30 PSU. The
60% of the installed power is consumed when it works at 3 PSU and around 30% of the
installed power is consumed when it works at 7 and 10 PSU.

9.1 maintenance
9.1.1 Once per year or after 300 hours of ballasting operation

The electrodes shall be cleaned with weak hydrochloric acid (10%). The cell will be filled
and recirculated for 1-2h following the instructions of SOP REACTOR DEPOSITS RE-
MOVAL MANUAL which is included in Equipment Operations & Technical Manual Vol.
III – Suppliers’ manuals

9.1.2 Upon Failure or lifetime

Replace the existing electrolytic cell with a new when the electrodes coating is con-
sumed. Rough estimation for this to happen after 5.000 hours of ballasting operation at
low salinity. Consult ERMA FIRST on cell performance monitoring. If it is operated at 30
PSU, his lifetime is 30.000 hours.
The power control strongly depends on the proper operation of the TRO sensor. A
schedule maintenance is needed to keep both components. Following the instructions
of Class and maker’s manuals.

9.1.3 Safety Measures

The Electrolytic Cell will be powered on only if all the below conditions are met:
1. Positive flow indication on both flow switches
2. At least 20% of the nominal flow measured at the flow meter downstream the elec-
trolytic cell
3. Both cell inlet/outlet valves are open
4. Water temperature is less than 40°C
5. TR in auto mode

1
In case all the above fail, additional protection is ensured by a mechanical tempera-
ture switch and a mechanical pressure switch, which are installed in the inlet and the
outlet of the E/C. In case they detect high temperature or pressure, they will trigger
the Transformer Rectifier (T/R).

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10 Transformer / Rectifier (T/R) Unit

It is the direct current power supply of the electrolyzes. The unit consists of modular
power module 50V/2000A, and together with a control module forms a complete unit.
The rectifier consists of one control module and one to ten identical power modules.
The Transformer/ Rectifier is water cooled. The water is taken by the low temperature
cooling water network. It needs 0,15 m3/h per module. In case there is no water circula-
tion, the system is shut down within 1-2 min.
Points must be obeyed:
• The T/R shall not be direct exposed to gases, liquids and chemicals.
• Protected from mechanical damage.
• Specified quality and pressure as well as the flow within specification of the compo-
nent.
• Must be secured at the bottom and the top and fulfil the vibration specification.
• The cable length should be less than 40 m from TR to Cell.

10.1 Preventive maintenance

The maintenance intervals depend on the amount of fouling, moisture, etc. the rectifier
is exposed to.

10.1.1 The following maintenance must be done yearly:

• Check and tight the electrical connections.
• Check that water couplings do not leak and that they are undamaged.

10.1.2 The following maintenance must be done monthly:

• Electrolytic cell’s power supply cables – both on cell connections and on the T/R
• Main power cables of T/R
• Main power cables of Control panel
• Earth connection
• Check the cooling water network for leakages or closed valves.

10.2 Troubleshooting
If a fault has occurred in the rectifier, it can often be traced based on the fault symptoms
to the main unit, sub-unit or component, which can then be replaced or repaired.
Check which alarm is set:
1. control module
2. power module

The POWER GOOD LED on the power module with an alarm/warning is:
• Blinking, if the alarm/warning is active
• Turned off, if the power module has had an alarm/warning
• It is not turned on again until the rectifier is restarted and the reason for alarm/warn-
ing has disappeared.

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Check if the POWER GOOD LED on the power module is lit after restart.

Tips:

• If the mains lose a phase, the rectifier works on low load, with increasing load, the
rectifier sends a warning and blink all LEDs on the power modules missing a phase.
• If the warning is high temperature either in power modules or in control modules
the power modules LEDs will blink, and a message will appear on the display. This can
be an indication that the cooling water to the rectifier is not enough or the T/R is not
turned on at all.
• If the fault cannot be traced to a component, the quickest way is usually to divide the
rectifier into main parts and start by checking the main part closest to the supply net-
work, then work through the rectifier, finishing with the main part closest to the load.
• Consult Erma First.

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11 TRO Sensor

Figure 14: TRO Sensor, Ballast drawing

Figure 15: TRO Sensor, De-ballast drawing

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11.1 Purpose of Total Residual Oxidants

Figure 16: Front View of TRO Sensor, Photograph

The purpose of the Total Residual Oxidants or TRO sensors (TRO1 – TRO2) is to con-
stantly measure the chlorine in the ballast water both during treatment and discharge.

TRO1 measures TRO during ballasting, TRO1 and TRO2 during de-ballasting and TRO2
measures TRO after the neutralization stage.

During ballasting the readings regulate the applied current on the electrodes.

At the de- ballasting the readings direct the dosing rate of the neutralizing agent to
maintain it below the MADC of 0.1 mg/L. 1

Those installed at non-hazardous areas are called XT-Monitors. Those installed at haz-
ardous areas are called EX-Monitors.

To get the chlorine readings, a small amount of two chemicals (reagents), must be add-
ed to the water sample. The two chemicals (reagents) that are diluted in the water are:
1. The Indicator, which produce a pink color when chlorine is presented in the sample.
The pink color depth is measured by spectrophotometry. Its lifetime is 3 months and it
is ensured by a cooling chamber.
2. The Buffer Solution, which controls the PH of the sampler has a lifetime span of one
year.

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Every 60 sec, a new reading will be shown up in the monitor and it drains every 60 sec.

1. The sample enters and passes for the T-strainer to the sampling chamber.
2. A second sample enters and passes for the T-strainer to the sampling chamber.
3. A green-light blinks so Zero Calibration is taken.
4. The two reagents are added into the sample, so the color of the sample is turned
into pink.
5. A red-light blinks and measures the depth of the pink color.
6. The Zero calibration and the measurement of the depth of the pink color are com-
pared.
7. The quantity of the Chlorine, inside the sample, appears on the digital screen.

11.1.1 Points of Attention

• Once the reagents are finished or expired; the system cannot operate.
• Place a data sheet next to each sensor and monitor reagent replacement.
• Once per week check the level of the reagents and their lifetime. Clean the T-strainer
and check the connection.
• Replace the indicator reagent every 3 months and the buffer solution every 12
months.

Once mixed the indicator has an expected life of up to 90 days if kept in the pow-
ered cooling chamber. Write the mixing date on the reagent bottle labels in the
area provided. Dispose of expired reagents correctly.

11.2 Electrical Connections

The connections are labeled and identifiable. Plugs are inserted into the cable bulk-
heads when shipped, to ensure a watertight seal.

Figure 17: TRO Optics

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12 TRO Gravity Drain Tank

TRO gravity drain tank (TGDT) is filled with TRO gravity drain water, when the BWTS
is operating. TGDT is equipped with high- and low-level sensors. When the high-level
sensor is activated, a diaphragm pump starts to operate, emptying the water back in
the ballast line. This operation stops when the low-level sensor is activated. Its quantity
is 200 – 400 ml/min.

Figure 18: TRO Gravity Drain Tank

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13 Flow meter (FM)

The flow meter (FM) is the device which measures the flow rate of liquid at the outlet of
the BWTS. The flow meter (FM) used at BWTS is electromagnetic type.

Figure 19: Flow meter overview

It is used for process monitoring, data, logging and for safety. More specifically, it is
used to power on the cells, control excess flow and for other safety and operation is-
sues.
1. FM throttles the valve downstream in such way to keep the flow rate of the BWMT
below TRC.

2. FM is an additional safety measure to power on the electrolytic cell unless it is below

20% of TRC.

3. If the FM detects zero flow for 5 mins, a critical alarm will be activated and the BWTS
be shut down and by-passed.

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14 Sensors - Safety Measurements

14.1 Flow Switch (FS)

The FW is installed upstream or downstream of each Electrolyzer as a safety measure
of its operation. This switch sends a signal to the BWTS Control Panel in order to pow-
er on the Electrolytic Cells when their flow is greater than 20% of the BWTS Treatment
Rated Capacity. Every cell has two switches. Both FS need to provide a signal of flow
greater than 20% of TRC.

14.2 Temperature Sensor (T)

It is installed downstream of the Electrolyzer. If the water temperature in the areas of the
Electrolyzer is greater than 40 °C, the system is shut down and by-passed.

14.3 Pressure Indicator (PI)

It is installed in the inlet and outlet of the system as a safety measure. It monitors the
pressure during ballasting and the fine tune of the filter operation in the heavy dirt
load seas. When the pressure is greater than 5 bar at the BWTS inlet, the system is shut
down and by-passed.
1

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14.4 Salinity
The salinity meter is installed in the inlet of the system. It monitors salt content within
the ballast water.

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15 Neutralizing Agent Tank (NAT) and Dosing Pump

Figure 20: NAT, De-ballast drawing

15.1 NAT

Figure 21: NAT

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The disinfected water is pumped into the ballast tanks. As the days pass, there is less
quantity of chlorine due to the phenomenon of evaporation and the carbon content in
tanks which is lower in cold water. It is important that the existing chorine, from the dis-
infection during de-ballast be neutralized. That is achieved by injecting chemical which
is stored in the Neutralizing Agent Tank (NAT).

Table 4: Chlorine Decay Rate

There are two options of chemicals. The first opinion is the Aqueous solution 38% so-
dium Bisulfite which is stored in a plastic drum with liquid form. The second one is the
Sodium Metabisulfite.

The NAT produces on site the mixture of Sodium Metabisulfite with fresh water. The
chemical can be prepared by mixing sodium metabisulfite with fresh water (4 x 25 kg
packs of Sodium Metabisulfite in 200Lt water).

For a container of 200 lt:

• Add the required amount of fresh water in the tank of NAT (minimum 50 lt).
• Start the mixing motor.
• Add the required amount of powder Sodium Metabisulfite (25 Kg).
• Add more fresh water as per mixing ratio. Add the rest of the powder.
• Close the cap of the tank firmly and choose manual operation of the mixer (on MSP)
for approximately thirty (30) minutes.

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15.2 Dosing Pump

The diaphragm chemical dosing pump injects the chemical of NAT into the de-ballast
flow to overboard. The dosing pump is always installed at the top of the NAT. It is sized
in such way to be able to neutralize vessels maximum ballast water flow which is dis-
charged even directly after ballasting at (<5 mg/Lt TRO).

Figure 22: Dosing Pump

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16 The G2 sampling port

The G2 sampling port is placed on the discharge line enabling authorities to sample
treated ballast water prior to discharge and verify BWTS operation and efficiency.

Figure 23: The G2 sampling port

16.1 The Initial Inspection

The PSC Officer will:

• Inspect documentation (Certifications, BW Management Plan & Record Book).

• Check that an officer has been appointed for the BWTS on board.
• Check officer’s & responsible crew familiarity with BWTS.
• Visual inspection of ship’s condition, equipment and arrangements detailed in the
certificate BWMP and BWRB.

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16.2 More Detailed Inspection

The PSC Officer will:

• Clarify whether detailed BWMP operational procedures are followed (safety, sedi-
ments, record keeping cross check).
• Check if BWM is according to BWMP.
• Check BWTS operational record, including self-monitoring devices.
• Follow up on bypass and emergency records.
• Indicative sampling.
• Detailed analysis in laboratory.

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