PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

PureBallast Ballast Water Treatment System

Pre-commissioning test form

Document name Pre-commissioning test
form 200001186

Valid for version: PureBallast 3.1-3.2 Ex Vessel name:

in deckhouse
Revision date: 2020-01-29 Hull no:

Serial number: IMO no:

(Beginning with
“PB-0”)
Deckhouse serial
number:
PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

Summary and open issues

Any damages and deviations must be documented and taken care of before the commissioning test can be performed.
Claims are handled in the normal Alfa Laval claim support system.

Summary

Open issues Done

Version log
Issued Changes since last version
2019-10-15 First release: PB 3.1 and PB 3.1 Ex Pre-commissioning test form was adapted for the deckhouse solution.
Added function and installation tests for the booster pump and the VFD.
2019-12-02 Updated with information valid for PB 3.2:
Information associated with the 1500 UV reactor added.
Salinity check for flow transmitter added.
Updated tests for deckhouse air heater and ventilation.
2020-01-29 Check regarding cable in FVD added.

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 PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

Table of content
1 INTRODUCTION 5

1.1 PREREQUISITES 5
1.2 EXECUTION AND TEST PERSONNEL 5
1.2.1 CONSIDERATIONS 5
1.3 PREPARATIONS AND CONDITIONS 5
1.4 CHECK LIST FOR PUREBALLAST SERVICE ENGINEERS 6
1.4.1 DOCUMENTS 6
1.4.2 SOFTWARE 7
1.4.3 TOOLS 7

2 PART 1 - INSTALLATION INSPECTION 8

2.1 PIPE 201 (BALLAST WATER TO/FROM PUREBALLAST) 8

2.2 PIPE 403 AND 404 (COOLING WATER TO/FROM UV REACTOR) 8
2.3 PIPE 401 AND 402 (TECHNICAL WATER / POTABLE WATER TO/FROM LDC) 8
2.4 PIPE 309 (BACKFLUSH WATER, OVERBOARD) 9
2.5 PIPE 310.1 (TECHNICAL WATER / POTABLE WATER WATER TO CIP) 9
2.6 PIPE 460.1 (DRAIN REACTOR S.W, F.W FROM CIP) AND PIPE 460.2 (DRAIN CIP FLUID FROM CIP) 9
2.7 DECKHOUSE AND ANCILLARY EQUIPMENT 10
2.8 PIPE 501 (INSTRUMENT AIR) 10
2.9 ELECTRIC INSTALLATION 10
2.10 CABINETS 13
2.11 FILTER 13
2.12 UV REACTOR 14
2.13 FLOW METER (FIT201-1) 14
2.14 VALVES 15
2.15 BALLAST WATER BOOSTER PUMP P201-1 (IF APPLICABLE) 15
2.16 VFD (IF APPLICABLE) 16
2.17 MISCELLANEOUS 18
2.18 FOLLOW-UP 19
2.19 SIGNATURE 19

3 PART 2 - FUNCTION TEST 20

3.1 LIGHT TEST IN DECKHOUSE 20

3.2 AIR HEATER TEST IN DECKHOUSE 21
3.3 DAMPER TEST IN DECKHOUSE 21
3.4 VENTILATION TEST IN DECKHOUSE 22
3.5 THERMOSTAT HIGH / LOW TEST IN DECKHOUSE 23
3.6 FIRE ALARM COMPONENTS TEST IN DECKHOUSE 23
3.7 CONTROL SYSTEM SETTINGS 23
3.7.1 CONTROL CABINET AND MAIN CONTROL PANEL 23
3.7.2 LAMP DRIVE CABINET AND UV REACTOR - FIRST POWER ON OF LDC AND LPS 25
3.7.3 REMOTE-CONTROL PANEL (IF APPLICABLE) 27

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PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

3.7.4 REMOTE INTERFACE (IF APPLICABLE) 28

3.7.5 ALARM CHECK 28
3.8 FUNCTION TEST OF COMPONENTS 29
3.8.1 PREPARATION – ALARMS AND WARNINGS 29
3.8.2 PNEUMATICS 29
3.8.3 VALVE V201-3, V201-9, V201-32, V403-35 29
3.8.4 BYPASS VALVE V212-31 30
3.8.5 CONTROL VALVE V201-8 30
3.8.6 FLOW TRANSMITTER FIT201-1 31
3.8.7 PRESSURE MONITORING DEVICE (INCL PT201-16, PI201-18, RV201 AND V201-15) 31
3.8.8 PRESSURE MONITORING DEVICE (INCL. PT201-1, PI201-1, RV201-1 AND V201-1) 32
3.8.9 UV REACTOR 32
3.8.10 LAMP DRIVE CABINET (LDC) 33
3.8.11 VALVE OPERATION UVR 33
3.8.12 BOOSTER PUMP CONTROL (IF APPLICABLE) 34
3.8.13 OVERBOARD VALVE CONTROL (IF APPLICABLE) 35
3.8.14 BALLAST PUMP CONTROL (IF APPLICABLE) 35
3.8.15 EXTERNAL SHUTDOWN SIGNAL (IF APPLICABLE) 36
3.8.16 ADDITIONAL BY-PASS SIGNAL (IF APPLICABLE) 36
3.8.17 GPS SIGNAL (IF APPLICABLE) 36
3.8.18 TEST OF COOLING WATER, UV LAMPS AND LPS 37
3.8.19 CIP MODULE 38
3.8.20 UVR DRAIN TEST 38
3.8.21 FILTER 39
3.8.22 POWER MANAGEMENT (IF APPLICABLE) 40
3.8.23 TEST OPERATION AND PI ADJUSTMENT OF V201-8 41
3.9 STORE THE TEST RESULT 42
3.10 SIGNATURE 42

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1 Introduction
Pre-commissioning is performed to secure that PureBallast is correctly installed and that components functions correctly
before performing the final Commissioning.

The document is a test form to be filled out during the test. This document is locked to function as a form. Password is
2007.

1.1 Prerequisites
Area to be checked OK

The deckhouse supplier shall perform a pre-delivery installation test. Is that pre-delivery installation
test successfully performed and is the test form signed?

Notes:

1.2 Execution and test personnel

The pre-commissioning test is performed in two main steps:
 Part 1 - Installation inspection of the installation. This test form only covers connections to the deckhouse and
components outside it. Performed by the ship yard, owner’s representative, installation company or Alfa Laval.

 Part 2 - Function test of mechanical components including software installation and control system settings.
Performed by Alfa Laval or a company authorized by Alfa Laval.

1.2.1 Considerations
During the test, the following matters must be considered:

 All tests must be performed in the order they are presented in this document.
 All damages related to the installation and all deviations during the test must be documented in the pre-
commissioning test form (this document).
 In this document the word “correctly” is used. This means that the installation has been performed according to
the requirements in the Design and installation guide, including drawings found in the PureBallast system
manual, chapter 6.

1.3 Preparations and conditions

Before the test, the matters in the list below must be fulfilled:
 System must not be powered before Alfa Laval set power to the system under item Lamp drive cabinet and UV
reactor – First power on of LDC and LPS. When powered on first time, this routine must be followed.
 Only relevant for Ex installations.
The customer is responsible for initial inspection according to (EN) IEC 60079 and to confirm this by presenting
a signed hazardous area initial report before a pre-commissioning is started.
 The system must be completely installed according to the Design and installation guide.
 A calculation must have been performed according to Design and installation guide, section Calculate pressure
and flow for backflush. The result must be available during the test.
 Piping must be completed, and the installation must be pressure-tested. The items listed in the connection list
and flowchart must have been installed accordingly.
 All cables, including cables not included in the scope of supply, must be correctly connected and routed

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PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

according to the cable lists and interconnection wiring diagrams supplied by AlfaLaval.
 Electric power must be available during the test. (See System manual, chapter 6.)
 Service air must be available and connected according to the drawing Air distribution and Quality specification /
Instrument air.
 Media (cooling waters and ballast water) must be available as described in System manual, section Connection
list. All pipes must have been flushed.
 If remote interface is used: Programming to monitor and control PureBallast from the customer’s own control
system (ISCS) must be ready to be tested by Alfa Laval. A list with implemented signals should be available for
the remote interface signal test. A list is available in the Remote interface implementation guide.

During the test, the matters in the list below must be fulfilled:
 Never leave PureBallast unattended with power on during the test, if not indicated for a specific test.

 Before switching on power to the LDC, always make sure that there is water in the reactor.

 Before opening valves for cooling water (V401-51, CV402) to LDC cabinets, secure correct installation
according section 2.4 to in this document.

1.4 Check list for PureBallast service engineers

To be able to plan the visit you need the PB number (the systems unique ID). Use this to identify the system in
PureBallast Registry to find information about type of system, installed options etc.

1.4.1 Documents
 Pre-delivery test form from the deckhouse supplier

 Pre-commissioning test form (deckhouse specific)

 Commissioning test form (deckhouse specific)

 Design and installation guides (both the common Ex guide and the deckhouse specific guide)

 Remote interface implementation guide (if applicable)

Also, ask yard/owner if they have a list of implemented signals

 Log box installation guide (if applicable)

 System manual and the deckhouse system manual addendum

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1.4.2 Software
The PureBallast software package:
 Software release note

 Installation routine

 PLC software on USB

 HMI software (USB for Compact and Compact flex. Flash card for Standard and Ex.)

 Control panel firmware on USB

Visualog: To be delivered to customer on USB. This is needed for the customer to be able to read the event log and
deliver it to authorities.

1.4.3 Tools
Apart from below, no special tools are needed to work with PureBallast.
 O ring tool needed to remove O rings if quartz sleeves is changed.
 Ex approved multimeter must be used to test barriers on Ex installations. Can normally be borrowed on board.

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PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

2 Part 1 - Installation inspection

This step covers installation inspection to secure that all system components has been installed correctly.

Prerequisites

 During this step no power must be connected to the PureBallast system.

 Performed by the ship yard, owner’s representative, installation company or Alfa Laval.

2.1 Pipe 201 (Ballast water to/from PureBallast)

Area/function to be checked OK

Is the piping done correctly to / from media connection point?

Does media flow and pressure fulfill requirements in the Connection list. If in doubt, ask shipyard / ship
crew.

Notes:

2.2 Pipe 403 and 404 (Cooling water to/from UV reactor)

Area/function to be checked OK

Is the piping done correctly to / from media connection point?

Does media flow, pressure and temperature fulfill requirements in the Connection list. If in doubt, ask
shipyard / ship crew.

Notes:

2.3 Pipe 401 and 402 (technical water / potable water to/from LDC)
Area/function to be checked OK

Is incoming cooling water pipe connected to V401-51 (blue) and outgoing to CV402 (red)?

Does media flow, pressure and temperature fulfill requirements in the Connection list. If in doubt, ask
shipyard / ship crew.

Notes:

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 PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

2.4 Pipe 309 (Backflush water, overboard)

Area/function to be checked OK

Is the piping done correctly to / from media connection point?

Ask the shipyard / crew for pressure calculation for pipe 309. Information about back pressure in pipe
309 is necessary to set parameter p304 Pressure setpoint during backflush. If possible, attach to this
test form.

Note pipe dimension, approx. length and number of bends. This is used to verify yard calculations.

Pipe dimension:

Pipe length:

No bends:

Notes:

2.5 Pipe 310.1 (Technical water / potable water water to CIP)

Area/function to be checked OK

Is the piping done correctly to / from media connection point?

Does media flow, pressure and temperature fulfill requirements in the Connection list. If in doubt, ask
shipyard / ship crew.

Notes:

2.6 Pipe 460.1 (Drain reactor S.W, F.W from CIP) and pipe 460.2
(Drain CIP fluid from CIP)
Area/function to be checked OK

Is the piping done correctly to / from media connection point?

Notes:

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PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

2.7 Deckhouse and ancillary equipment

Area/function to be checked OK

Do the deckhouse and the components installed outside the deckhouse have required access area
according to dimension drawings? See dimension drawings in the System manual.

Notes:

Are all ancillary equipment installed on top of the deckhouse according to the dimension drawing?

 Ladder

 Railing

 Filter lifting device

 Ventilation inlet/outlet

 Air inlet/outlet for vacuum breakers and CIP de-aeration.

Notes:

Are the de-aeration and ventilation pipes on the roof installed in the right direction according to the
dimension drawing?

Do they end in Safe zone?

Notes:

2.8 Pipe 501 (Instrument air)

Area/function to be checked OK

Is the piping done correctly to / from media connection point?

Does the air fulfill requirements in the Connection list? If in doubt, ask shipyard / ship crew.

Notes:

Is the pneumatic line correctly supported according to regulations?

Notes:

2.9 Electric installation

Area/function to be checked OK

Is the electric installation for the PureBallast system done correctly? See the Electrical system layout
in the System manual.

Notes:

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 PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

Area/function to be checked OK

Is the electric installation for the deckhouse components done correctly? See the Electrical system
layout in the deckhouse addendum to the System manual.

Is the deckhouse voltage compliant with the vessel’s voltage?

Notes:

If the ballast water pump P201-1 is installed: Is the electrical installation, done correctly? See the
Electrical system layout for the ballast water pump in the deckhouse addendum to the System
manual.

Notes:

Are all installed electrical cables properly suspended and supported according to relevant standard?
Notes:

Are signal cables from control cabinet to LDC connected?

Notes:

Are correct cable glands used for all Ex components regarding cable dimension and Ex class?

Notes:

Are the cables to the deckhouse routed through the correct Roxtec entries according to electrical
system layout in the addendum to the system manual?

Are the penetrations mounted and tightened correctly?

Notes:

Is the main switch board or a separate main power supply cabinet for PureBallast been installed in
safe zone?
Notes:

Is the electrical installation (400 or 440 VAC, 50/60 Hz.) done without creating ground-fault? This is
typically checked using the vessel’s installed Ohm meter or the vessel’s residual-current
device (RCD), normally installed at the main switch board.
Notes:

Is the lamp power cable between UV reactor and LDC delivered by Alfa Laval? It should be marked
with one of the following:

 Betatrans 4 GKW-Axplus C-flex

 RADOX 4 GKW – AX

 LAPP KABEL SPECIAL CABLE BWTS 105 C – Size – 1,8/3kV

This is crucial! If not, you are not allowed to power the system.

Notes:

If applicable: Is the bypass valve V212-31 correctly connected with signal cables to the ISCS and
the control cabinet?

Notes:

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PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

Area/function to be checked OK

Note: Only performed if the option remote control panel is installed:

Is the cable length correct depending on cable type for communication cable (W501) between
control cabinet and the remote-control panel?
 If the cable is shorter than 100 meters a Cat5e (or better) cable or fiber can be used.
(Max length for Cat cable is 100 meters.)
 If the cable is longer, a multi-mode fibre cable with LC connector must be used.
Notes:

Note: Only performed if the option remote interface is installed:

Is the Modbus cable W602 between the control cabinet terminal X15 and the integrated ship’s
control system (ISCS) installed and connected correctly?
Notes:

Note: Only performed if the option power management (hardwired) is installed:

Is the interface set-up correctly by the contracted company for the vessel’s power management
system? Automation in the vessel’s power management system needs to be functioning according
to the Design and installation guide.
Notes:

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2.10 Cabinets
Are the components correctly installed according to the basic size drawing? They must not be
subject to amplify vibrations from the vessel’s structure?

 LDC should be fixed at the bottom and top using delivered vibration dampers.

 Control cabinet should be fixed at the bottom and top.

 Deckhouse control cabinet should be fixed at the bottom and top.

Notes:

Do the components have required access area according to dimension drawings? See dimension
drawings in the System manual.

Notes:

Is the components connected to earth?

Notes:

Note: Only relevant for Ex installations:

Are the following cabinets placed in safe zone?

 Deckhouse control cabinet

 Control cabinet

 LDC

 Log box (if applicable)

 Remote control panel (if applicable)

 VFD (Only applicable if ballast water booster pump P201-1 is installed)

 VFD junction box (Only applicable if ballast water booster pump P201-1 is installed)

Notes:

2.11 Filter
Area/function to be checked OK

Enter the filter serial number. See plate on the side of the filter.

Serial number:

Can the filter motor rotate the filter nozzle inside the filter without any problem?

1. Start the motor in manual mode.

2. Listen and make sure that the nozzle is rotating inside the filter without any scratching
noises.

Notes:

Are the pipe connection flanges (inlet, outlet and backflush) well aligned and free from stress? If not,
the backflush nozzle cannot rotate inside the filter.

Notes:

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PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

2.12 UV reactor
Area/function to be checked OK

Are the pressure relief valve RV201-23n undamaged?

Are the seals intact?

Notes:

2.13 Flow meter (FIT201-1)

Area/function to be checked OK

Note: Only relevant for PB 3.1 Ex installations.

Are the jumpers on the flow transmitter I/O board correctly installed (2 below)?

Is the parameter current output set correctly in the flow meter?

For instructions see the internal service bulletin no. 32492.

The flow transmitter I/O board with the 2 different jumper settings.

1. Not correct.

2. Correct.

Notes:

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2.14 Valves
Area/function to be checked OK

Note: Only relevant for Ex installations and only relevant if cooling water in line 403 comes
from safe zone.

Is the check valve CV403 (Optional, not AL supply) for line 403 installed?

Notes:

2.15 Ballast water booster pump P201-1 (if applicable)

Note: Only relevant for Ex installations.

For more information about P201-1, see Addendum: Ballast water booster pump P201-1 or Addendum: Deckhouse

Area/function to be checked OK

Is the ballast water booster pump P201-1 installed correctly?

 Is the pump installed in a horizontal pipe?

 Is a 500 mm spool piece installed before the pump? See Filter / Dimension drawing in
System manual.

 Are the pipe connection flanges well aligned and free from stress?

 Is the pump correctly secured to a firm level surface?

 Is a lifting device installed in the ceiling above the pump?

Notes:

Is the component connected to earth?

Notes:

Is the correct power cable to motor selected for the motor size? See cable list in Electrical system
layout for P201-1, in Addendum: Ballast water booster pump P201-1.

 Is the motor delta connection correctly installed?

 Are the correct cable glands used for the motor cable and the thermistor cable?

 Is the length of the power cable between the P201-1 and VFD less than 150 m?

Notes:

Is PT201-1 inlet pressure transmitter installed correctly:

 Fitted on the suction side of the booster pump P201-1?

 Installed vertically?

 With a drain solution been attached to safety relief valve, so that the water can always be
drained to a scupper?

Notes:

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PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

Area/function to be checked OK

Verify that the signal cable connection of leakage sensor LS662-1 is fitted on the booster pump
P201-1.

Notes:

2.16 VFD (if applicable)

Note: Only relevant if ballast water booster pump P201-1 is installed.

Note: Only relevant for Ex installations.

For more information about the VFD, see Addendum: Ballast water booster pump P201-1 or Addendum: Deckhouse.

Area/function to be checked OK

Is the VFD installed in safe zone?

Notes:

Is the VFD installed with supplied vibration dampers?

Notes:

Is the component connected to earth?

Is the cross-section of the protective earth cable according to VFD dimension drawing?

Notes:

Is the FPTC cable removed inside the VFD, and is cable W510 installed instead?

Notes:

Unmount the VFD cover, and check the following:

 Is the PT201-1 jumper fitted on VFD AI-terminals according to circuit diagram?

 Is the Modbus cable connected?

 Is LS662-1 connected to terminal DI6 on the VFD?

 Is the busbar protective cover mounted in the VFD?

Remount the VFD cover, and fasten it with the two screws.

Notes:

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 PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

Area/function to be checked OK

Verify VFD parameters:

1. Read and write down the information on the booster pump P201-1 motor name
plates.

CONVERTER SUPPLY name plate, to be verified in parameter menu 99 in the VFD.

Motor type: ___________________________

Motor No: ____________________________

FC Type: ____________________________

Switch freq.: __________________________

F.W.P: ______________________________

V: ____________________________ (P99.7 in VFD)

Hz: _____________________________ (P99.8 in VFD)

kW: _____________________________ (P99.10 in VFD)

r/min: _____________________________ (P99.9 in VFD)

A: _____________________________ (P99.6 in VFD)

Nm: _____________________________ (P99.12 in VFD)

Duty: _____________________________

MOTOR name plate Motor type: ___________________________

Ex spec: ____________________________

AMB Spec: ____________________________

Man year: __________________________

Ins class: ______________________________

IP class: __________________________________

V: _____________________________

Hz: _____________________________

kW: _____________________________

r/min: _____________________________

A: _____________________________

Cos phi: _____________________________ (P99.11 in VFD)

Duty: _____________________________

2. Check that parameters 99.3-99.12 set in the VFD match the values from the
CONVERTER SUPPLY name plate. If not, proceed to step 3.

3. Change the parameters in the VFD so they are according to the document VFD
parameter setting. See Addendum: Ballast water booster pump P201-1.

Note: All parameters need to be verified.

Notes:

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2.17 Miscellaneous
Area/function to be checked OK

Is there a signed initial inspection report, confirming that an inspection has been performed
according to (EN) IEC 60079?
Note: A signed initial inspection report is required before pre-commissioning part 2 is started.

Notes:

Are the optional sampling devices Q201.1 and Q201.2 mounted correctly?
For Alfa Laval device: The pin should be pointing in the flow direction See Sampling device /
dimension drawing in System manual for details.

Notes:

Is the System manual available on board?

Notes:

Check the calibration certificates in the System manual binder, and note the individual number for:

Flow meter (serial number):

UV sensor (serial number- A below):

Notes:

Note: Only relevant for Ex installations.

Have used cables been calculated according to the document Exi maximum multicore cable length
calculation included in the Design and installation guide?

Notes:

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2.18 Follow-up
All damages and deviations found during the inspection must be documented. All open issues that prevents or endanger
function test must be taken care of before the next step can be performed.

Any damages or deviations are to be reported to the Alfa Laval claim support system.

2.19 Signature
Responsible inspector should sign when Part 1 – Installation inspection is completed, and all open issues are resolved.

Responsible inspector

_______________________ _______________________ _______________________

Signature Company Date

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PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

3 Part 2 - Function test

This step will secure that all components work correctly, and that the system is ready for the final commissioning test. It
covers installation of software and control system settings.

If applicable, the test includes optional remote-control panel and remote interface.

Note: The PureBallast system cannot start without the deckhouse ventilation on. The ventilation must be on for all
operations

Prerequisites

 Part 1 – Inspection test must be completed with no critical open issues.

3.1 Light test in Deckhouse

Area/function to be checked OK

1. Check that jumpers is installed in the deckhouse light junction box, according to circuit
diagram.

2. Apply 230VAC by switching on fuse F2 in the deckhouse control cabinet.

3. Activate the light switch, do all the lights work?

4. Deactivate the light switch, do all light turn off?

5. Wait for approx. 5 -10 minutes to charge the emergency Lumiere light battery and then
deactivate incoming 230VAC to the deckhouse light junction box, by switching off F2 in the
deckhouse control cabinet.

With no power, is the emergency light activated?

Notes:

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3.2 Air Heater test in Deckhouse

Area/function to be checked OK

1. Apply 440VAC to the heater element by switching on fuse F1 and Q2 in the deckhouse
control cabinet.

Does the fan start?

2. Check that the air flow direction goes from the bottom to the top of the heater. If air flow is
reversed, swap external conductors L2 and L3.

Does the lamp “heater on” light up on the deckhouse cabinet?

3. Adjust the heater thermostat to a temperature higher than the ambient temperature.

Does the heater start?

4. Adjust heater thermostat to a temperature lower than the ambient temperature.

Is the heater switched off? Note that the heater fan will still function.

5. Set the thermostat to 15°C.

Note step 6 and 7: Only relevant for Elmess heater installations.

6. In the deckhouse control cabinet, press the test button on thermistor relay B1.

Does the lamp “heater tripped” light up?

7. Press the reset button on B1. Does the “heater tripped” lamp go out?

Notes:

3.3 Damper test in Deckhouse

Area/function to be checked OK

1. Check that open/close signal are connected from the vessels fire alarm system to the
dampers.

Under normal conditions the dampers are open.

Does the vessel get damper open signal?

Does the lamp on K4 in the deckhouse control cabinet light up?

2. On the vessels fire alarm system, deactivate the +24 VDC output.

Do the dampers close?

Does the vessel get damper closed signal?

Does the lamp on K4 in the deckhouse control cabinet switch off?

3. Reactivate the +24 VDC output to the dampers.

Notes:

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3.4 Ventilation test in Deckhouse

Area/function to be checked OK

Note: Only relevant for Rosati ventilation installations.

1. Apply 440VAC to the ventilation by switching on fuse Q3 in the deckhouse control cabinet.

2. Check that the dampers are open and relay K4 in the deckhouse cabinet is active.

3. Press button “start fan” on the deckhouse control cabinet.

Does the lamp “fan on” light up?

Does the ventilation fan start in the deckhouse.

4. Check that the air flow direction is correct.

5. Press the “fan stop” button on the deckhouse control cabinet.

Does the “fan on” lamp switch off?

Does the fan stop?

Does a system stop alarm appear on the PureBallast control cabinet HMI?

6. Switch off Q3 in the deckhouse control cabinet.

Does the lamp “fan tripped” light up?

7. Switch on Q3.

Notes:

Note: Only relevant for Stiavelli ventilation installations.

1. Apply 440VAC to the ventilation by switching on fuse Q3 and Q5 in the deckhouse

control cabinet.

2. Check that the dampers are open and relay K4 in the deckhouse cabinet is active.

3. Press button “start fan low” on the deckhouse control cabinet.

Does the lamp “start fan low” light up?

Does the ventilation fan start in the deckhouse.

4. Check that the air flow direction is correct.

5. Press the “fan stop” button on the deckhouse control cabinet.

Does the “start fan low” lamp switch off?

Does the fan stop?

Does a system stop alarm appear on the PureBallast control cabinet HMI?

6. Do the same test for “start fan high”

7. Switch off Q3 or Q5 in the deckhouse control cabinet.

Does the lamp “fan tripped” light up?

8. Switch on Q3 and Q5.

Notes:

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 PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

3.5 Thermostat high / low test in Deckhouse

Area/function to be checked OK

1. Check that the connections are according to electric documents

2. Check that the signal is high from both low and high temperature thermostat.

If the temperature goes outside of the allowed range, either of the thermostats will go low and send
an alarm to the vessel.

Notes:

3.6 Fire alarm components test in Deckhouse

Area/function to be checked OK

Check that applicable fire alarm components are installed in the deckhouse and connected to the
deckhouse alarm junction box.

Depending on the vessels classification it can require:

 Smoke detector

 Gas detector

 Manual call point

 Beacon sounder

These components are not in Alfa Laval’s scope of supply.

Notes:

3.7 Control system settings

3.7.1 Control cabinet and main control panel

Area/function to be checked OK

Are node numbers set in control cabinet for communication with LDC (lamp drive cabinet)? The
setting is done on the X20 IF1082-2 module (A1) to secure correct control of individual UVRs from the
control system. Setting shall be: X16=0, X1=0.

Notes:

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PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

Area/function to be checked OK

1. Switch on the power to the cabinet using the main breaker at the left side of the cabinet
(Q1).
2. Measure incoming power to the cabinet on upper side of Q1.
It shall be: 400 or 440 VAC, 50/60 Hz. Note down result.
VAC: ___
Hz: ___

3. Make sure that the fuse settings are according to the electrical diagram for F42-F45.
4. Go to page 4.1 System info and look in field Control cabinet configuration.
If 1: Turn on fuses in this order: F1 and F2.
If 2: Turn on fuses in this order: Q2, Q3 and Q4.

5. Make sure that F42-F45 are switched on (green light). If not, push the reset button
(R/S) on the fuse (using a pointed tool).

Notes:

Make sure that the fuse setting (I nominal) for F2-F5 are set according to the motor marking plate for
measured power frequency.

1. On the filter motor and backflush pump motor (optional): Find area on the mark plate where
information is displayed for the frequency used for the system (50 or 60 Hz).

- Look at voltage (V), stated as an interval.

- Look at interval for I nominal amp setting (A), also stated as an interval.

2. Make an estimation for I nominal amp setting, so that it “match” the voltage in the range from
min to max.

3. Enter the estimate in the table below.

Fuse Motor Amp setting for I nominal.

F2 (filter motor M709-43)
F3 (pump P401-1)
F4 (pump P309-1)
F5 (pump P403-1)
4. Go to page 4.1 System info and look in field Control cabinet configuration.
If 1: Make the amp setting in control cabinet on fuse F2, and in pump cabinet for F3-F5.
If 2: Make the amp setting in control cabinet on fuses used for installed components.
For instruction on fuse setting, see instruction in System manual chapter 4.

Notes:

Is the latest version of the softwares installed in the control cabinet? Software versions are displayed
in page 4.1 System info? If not: Upload software according to the release note for the latest version of
the PureBallast softwares.

Note down version number for all 3 software.

T15BR firmware
HMI software
PLC software
Notes:

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 PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

Area/function to be checked OK

Set parameters to correspond with the installation on board? All parameters indicated by green arrow
symbol in chapter 4 must be set. Also see deckhouse addendum.

Notes:

Is correct IP address (192.168.0.10) set for main control panel in page 4.1 System info. See System
manual chapter 3, section Set control panel IP address.

If no remote-control panel is used, delete the default panel (192.168.0.11). See System manual
chapter 3, section Set remote control panel communication.

Notes:

Is date and time correct in the control panel?

If GPS is connected, time is retrieved from the vessel’s GPS system.

If not, set time in page 4.1 System info? After time is set, press the Synchronize button to
synchronize the PLC time to the same date and time as the control panel.

Notes:

3.7.2 Lamp drive cabinet and UV reactor - First power on of LDC and LPS

Area/function to be checked OK

Are node numbers set for communication with LDC (lamp drive cabinet)? The setting is done on the
X20 BC0083 module (A1) to secure correct control of individual UVRs from the control system.
Setting shall be: UVR1: X16=0.

Notes:

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PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

Area/function to be checked OK

The first time you power on the LDC and LPS

Warning! The UV lamps in the UV reactor are extremely hot when lit. Generally, there must be
a flow of cooling water through the UV reactor when the lamps are lit. If not, they will be
overheated in less than a minute. During this test, the intention is to make sure that no UV
lamp is lit when the LPS is turned on. Therefore, a filled UV reactor is sufficient.

Available water pressure must be 2 – 6 bar for leak test.

Follow the steps below:

1. Make sure that the motor circuit breakers for all LPS units are switched off in the LDC cabinet
and in the secondary LDC cabinet (for systems with a 1500 reactor).

300 reactor: Q101-Q103

600 reactor: Q101-Q105
1000 reactor: Q101-Q108
1500 reactor:
- LDC: Q101-Q108, F1
- Secondary LDC: Q101-Q105, F2

2. Switch on the power to the LDC using the main breaker on the LDC door.
3. Switch on fuse Q100 inside the cabinet.
4. Make sure that F41-F42 are switched on (green light). If not, push the reset button (R/S) on the
fuse (using a pointed tool or such).
5. Switch on fuse F2 inside the cabinet.
6. Fill up the UV reactor with water via the CIP unit:

- Enable manual mode. Open V310-8 (CIP manual) and V310-6 (CIP) for technical water /
potable water water.
- Open V321-2 (UVR) and V321-4 (CIP).
- Open V320-4 (UVR).
- When water reach the level switch LS201-29 (wet condition), close V321-2.
- Close V321-2, let other valves remain open for the leak test.
7. Switch on the motor circuit breakers one at a time and check corresponding LPS: The LED
indication shall indicate LPS on, no lit UV lamp and no error.
Note: If a UV lamp is lit, immediately turn of the motor circuit breaker for the LPS.
8. Check the cabinet visually and make sure that the equipment inside the cabinets is behaving
OK. If necessary, recheck and switch on any electric fuse that is switched off.
9. Turn off the power to the LDC using the main breaker.
10. Repeat this procedure for all installed LDCs.

Is the installation OK (no UV lamps lit)?

Notes:

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 PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

3.7.3 Remote-control panel (if applicable)

Note: Only performed if the remote control panel (optional) is installed.

Area/function to be checked OK

Before the power is switched on to the remote-control panel: Measure the incoming power to the
panel.

The power to the panel shall be 24 ±3 V. If more, do not connect power to the panel.

Notes:

Is the latest version of the control system software installed? Version is checked in page 4.1 System
info.
1. Check that the version of T15BR/TA150 firmware and HMI software is the same as installed in
the main control panel. If not, upload software according to the release note.
2. Make the same check for all remote-control panels.
Notes:

Is the correct IP address set for all remote-control panels in page 4.1 System info?
Panel 1: 192.168.0.11
Panel 2: 192.168.0.12

Notes:

Are all remote-control panels added in the main control panel? See System manual chapter 3, section
Set remote control panel communication.

Notes:

Is a device giving a visual and audible signal installed for all remote-control panels?

Notes:

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PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

3.7.4 Remote interface (if applicable)

If the remote interface (optional) is implemented, this test must be performed. It is recommended to be performed
together with the company responsible for the supply of the ISCS (integrated ship control system).
Preparations and conditions
 For detailed information, Read the Remote interface implementation guide, which includes all information
needed, including how to perform signal test.
 Ask shipyard for documentation to know which signals that are implemented in the ISCS. Only implemented
signals should be tested.

Area/function to be checked OK

Set the control system to local operation (Local function button) and activate test mode in page 4.5
Remote interface 1.

On page 4.5 Remote interface 1. Test all implemented signals from PureBallast to ISCS. Touch the
value square and put in new value. Check that the signals are received in the ISCS and affect correct
object or function.

Notes:

On page 4.5 Remote interface 1. Test all implemented signals from ISCS to PureBallast. Check that
the signals are received and affect correct object or function.

Notes:

Note: Only performed if alarm/warning signals are implemented (optional).

Open page 4.6 Remote interface 2. Test five random implemented alarm/warning signals from
PureBallast to ISCS.

Are the alarms/warnings displayed? Depending on implementation, alarms can be displayed as a

common alarm or actual alarm number.

Notes:

Is a device giving a visual and audible signal installed at all stations from where PureBallast can be
controlled?

Notes:

3.7.5 Alarm check

Make sure that no alarms or warnings are present in page 2.1 Alarm list. (Only alarm W140 “CIP
schedule timer elapsed” is allowed.)

Solve all alarms and warnings in the list one by one. After a problem has been solved, press Ack all
in page 2.1 Alarm list to make sure that the alarm/warning disappears.

Is the alarm list clear from alarms and warnings?

Notes:

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 PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

3.8 Function test of components

3.8.1 Preparation – Alarms and warnings

Area/function to be checked OK

Alarm and warning check. Open the alarm list to confirm that there is at least one alarm and one
warning present. If not, trigger one of each.

Check the following:

1. Alarms and warnings are present in the CAMS or ISCS (via hardwire or remote interface).

If no signals are active, check that the signals are active from PureBallast control cabinet
(according to below) to verify that the fault is on the ship’s side.

2. Go to page 4.1 System info and look in field Control cabinet configuration.
If “1” go to step 3. Note: Only relevant for PB 3.1.
If “2” go to step 4.

3. Common warnings are indicated on X20 module A12 in the control cabinet. Light 4 shall not
be lit.
Warnings are indicated on X20 module A12 in the control cabinet. Light 5 shall not be lit.
4. Common warnings are indicated on X20 module A11 in the control cabinet. Light 4 shall not
be lit.
Alarms are indicated on X20 module A11 in the control cabinet. Light 5 shall not be lit.

Notes:

3.8.2 Pneumatics

Area/function to be checked OK

Open the instrument air connected to the system. Is the air installation free from leakages?

Notes:

Is the air pressure for the CIP unit set to 6 bar (min 5 bar) on PRV501-2? If not, lift the knob and turn it
to adjust the setting.

Notes:

3.8.3 Valve V201-3, V201-9, V201-32, V403-35

Area/function to be checked OK

Enable manual mode in the control system. Open and close the valves.

Are the valves operating correctly and do they open counterclockwise and close clockwise?
Is feedback indicated in page 1.1 Overview? Flashing green = traveling. Green area = open. No color
= closed.

Notes:

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PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

Do the valves open and close in a smooth manner in the correct travelling speed?

If not, adjust the travelling speed using the throttle valves.

Notes:

3.8.4 Bypass valve V212-31

Perform the below test even if the bypass valve is other than Alfa Laval’s.

Area/function to be checked OK

Open and close the valve from the vessel’s valve operating system.

Is the valve is operating correctly and open counterclockwise and close clockwise?

Is feedback indicated in page 1.1 Overview?

Notes:

V212-31 is fitted with two sensors: One to PureBallast and one to the ISCS.

Is the feedback indicated correctly in:

 PureBallast control system page 1.1 Overview?

 Vessel’s ISCS?
Notes:

3.8.5 Control valve V201-8

Area/function to be checked OK

System in standby mode. Open the valve from the control system.

Is feedback indicated in page 1.1 Overview? Flashing green = traveling. Green area = open. No color
= closed.

Make sure that the valve position displayed in the following way:

0% = 0º open (shut).
50% = 45º open.
100% = 90º open.

If the valve feedback does not function correctly, follow the instruction Calibrate positioner on V201-8
system manual chapter 7.

Notes:

Verify that instrument air pressure to positioner of V201-8 is measured at 6 bar.

See requirements for instrument air in the Connection list.

Notes:

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 PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

3.8.6 Flow transmitter FIT201-1

The parameters in the flow transmitter are pre-set at delivery.

Area/function to be checked OK

Check that the signal from the flow transmitter is displayed in page 1.1 Overview.

The connection is correct if zero is indicated (same as displayed on the flow transmitter), or if the
indication fluctuates slightly.

Notes:

Note: Only relevant for PB 3.2 installations.

Check the salinity (PSU) value for QIT201-1 on page 1.1 Overview.

The connection is correct if the salinity (PSU) is around zero, when the sensor is in air or technical
water / potable water.
Note: The conductivity sensor measures conductivity (µS/cm). Salinity (PSU) is a calculated value
using conductivity (µS/cm) and temperature.

Notes:

3.8.7 Pressure monitoring device (Incl PT201-16, PI201-18, RV201 and V201-15)

Area/function to be checked OK

Check that the marking on the relief valve RV201 is correct according to system pressure:

 6 bar system marking is 8 bar

Notes:

Check that the signal from the pressure transmitter is displayed in page 1.1 Overview.

The connection is correct if zero is indicated (same as displayed in the pressure gauge PI201-18), or if
the indication fluctuates slightly.

Notes:

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PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

3.8.8 Pressure monitoring device (Incl. PT201-1, PI201-1, RV201-1 and V201-1)
Note: Only relevant if ballast water booster pump P201-1 is installed.

Area/function to be checked OK

Check that the marking on the relief valve RV201-1 is correct according to system pressure:

 6 bar system marking is 8 bar

Notes:

Check that the signal from the pressure transmitter is displayed in page 1.1 Overview.

The connection is correct if zero is indicated (same as displayed in the pressure gauge PI201-1), or if
the indication fluctuates slightly.

Notes:

3.8.9 UV reactor

Area/function to be checked OK

Is level sensor LS201-29 working correctly?

1. In the UVR popup and check that the feedback for the component is displayed correctly.

2. Remove the cable from sensor. Check after 10 sec. that KS1 relay (in LDC cabinet) breaks
the 24V power to LPS units (all LEDs lit on LPS).

Check all installed UVRs.

Notes:

Is temperature transmitter TT201-33 giving a correct signal? Open the UVR popup and check that the
temperature is likely and stable. Check all installed UVRs.

Notes:

Is temperature switch TS201-60 giving a correct signal?

1. In the UVR popup and check that the feedback from the switch showing green (temp. is OK).

2. Remove the cable from the switch. Check that the blue reset button S1 is lit and there is an
alarm present in the alarm list.

3. Connect the cable and press reset button S1.

Check for all installed UVRs.

Notes:

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 PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

3.8.10 Lamp drive cabinet (LDC)

Area/function to be checked OK

Is temperature transmitter TT401 and TT402 giving a correct signal? Open the UVR popup and
check that the temperatures are likely and stable.

Check all installed LDCs.

Notes:

Does the fan start correctly at warm condition?

1. Open page 5.3 UVR parameters. Set parameter p231 “Cabinet temperature low threshold”
to minimum 21 °C.
2. Check that the heat exchanger fan motor (M1) starts and that the fan rotates. Check all
installed LDCs.

3. Re-set parameter p231 to 40 °C.

Notes:

Are heat exchanger and pipe connections leakage tight?

Open valves for LT slightly keeping all LDC doors open. Check for any leakage from the heat
exchanger and pipe connections mounted at the bottom of the LDC. Check that W129 LDC cabinet
water alarm is not activated.

Notes:

3.8.11 Valve operation UVR

Area/function to be checked OK

Enable manual mode in the control system. Open and close the valves following valves: V201-19,
V201-20, V404-36, V320-4 and V321-2.

Are the valves operating correctly and do they open counterclockwise and close clockwise?

Is feedback indicated in the UVR popup

Check for all installed UVRs.

Notes:

Do the valves open and close in a smooth manner in the correct travelling speed?

If not, adjust the travelling speed using the throttle valves.

Notes:

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PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

3.8.12 Booster pump control (if applicable)

Note: Only performed if the option is installed.

Area/function to be checked OK

Booster pump P403-1 for cooling water:

1. Start the pump in manual mode from page 1.1 Overview.

2. Check that the pump is running with correct rotation as marked.

Was the test successful?

Notes:

Booster pump P401-1 for LDC cooling: Perform the same test as for P403-1. Start the pump from
the UVR popup.
Was the test successful?

Notes:

Booster pump P309-1: Perform the same test as for P403-1. Start the pump from page 1.1
Overview.
Was the test successful?

Notes:

Note: Only relevant for Ex installations.

Ballast water booster pump P201-1:

1. Set the VFD to local mode by using Loc/Rem button on VFD control panel.
Verify that VFD display indicates: Local.

2. Start the pump drive by pressing the start button on VFD control panel.

3. To verify correct pump rotation, look at the shaft in the gap between the pipe and the
booster pump motor stand. Is the shaft rotation clockwise?

4. Stop the pump drive by pressing the stop button on VFD control panel.

5. Set the VFD to remote mode by using Loc/Rem button on VFD control
panel. Verify that VFD display indicates: Remote.

Notes:

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 PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

3.8.13 Overboard valve control (if applicable)

Note: Only performed if the option is installed.

Area/function to be checked OK

Ask responsible person from the shipyard to open the overboard valve from the ISCS.

Does the valve open and is feedback indicated in page 1.1 Overview?

Notes:

3.8.14 Ballast pump control (if applicable)

Note: Only performed if the option is installed.

Area/function to be checked OK

Ask responsible person from the shipyard to start the ballast pump from the ISCS.

Does the pump start and is feedback indicated in page 1.1 Overview?

Notes:

Does the ballast pump have capability to control flow into pipe 201 via:
• External feed (VFD control)

• Hydraulic control

• Steam turbine control

• Throttle valve control (fitted on the discharge of ballast pump).

Notes:

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PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

3.8.15 External shutdown signal (if applicable)

Note: Only performed if the option is installed.

Area/function to be checked OK

Press the external shutdown button or ask responsible person from the shipyard to activate the signal
from the ISCS.

Is external shutdown alarm A50 present in the alarm list?

Notes:

3.8.16 Additional by-pass signal (if applicable)

Note: Only performed if the option is installed.

Area/function to be checked OK

Open all additional by-pass valves from the ISCS.

Is relevant alarm (W66 – W68) is present in the alarm list?

Notes:

3.8.17 GPS signal (if applicable)

Note: Only performed if the option is installed.

Area/function to be checked OK

Are correct GPS coordinates displayed in page 4.1 System info?

Notes:

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 PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

3.8.18 Test of cooling water, UV lamps and LPS

The test verifies if the cooling water installation is according to specifications regarding flow and temperature. The test
also covers UV lamps and lamp power supply.

Area/function to be checked OK

Warning! The UV lamps in the UV reactor are extremely hot when lit. There must be a flow of
cooling water through the UV reactor when the lamps are lit. If not, they will be overheated in
less than a minute.
Preparations:
 Secure that there is available electrical power to perform this test. Power consumption per
UVR is: 32 kW for a 300 m3/h reactor, 62 kW for a 600 m3/h reactor, 100 kW for a 1000 m3/h
reactor and 155 kW for a 1500 m3/h. Note that this must be checked manually, not using the
automatic power request in the control system.
 Make sure that the overboard valve is open for the cooling water line.
Procedure:
1. Enable manual mode.
2. Open all cooling water valves to all UVRs (V403-35, V404-36 and V201-19). If installed, also
start the booster pump (pump P403-1).
3. Check that level switches (LS201-29) indicates wet condition on all UVRs.
4. Note down (below) the initial water temperature detected by temperature transmitter TT201-
33 on all UVR.
5. From the UVR popup, open the LPS control popup and start all UV lamps for all UVRs.
Make sure that the UV lamps are lit within 10 seconds:
- In UVR popup: Lamp icons shall be correct: Grey=closed. Yellow =starting. Green=started.
- On LPSs: LPS on LED is lit.
6. In the UVR popup, check temperature indicated by TT201-33 for all UVR. Note! If the
temperature at any time during this test is higher than 60 °C, the UV lamps should be
switched off immediately.
7. Wait until the temperature, indicated by TT201-33, stabilizes (about 5 min.) Note down the
temperature for all installed UVRs below.
8. Stop all UV lamps.
9. If applicable, switch off the booster pump P403-1.
10. Close the following valves for all UVRs V403-35, V404-36 and V201-19.
11. Let the water remain in all UV reactors. It will be needed for the drain test later.

UVR 1 UVR 2 UVR 3

Initial UVR temperature:

Stabilized UVR temperature:

Temperature increase:
(Stabilized temp – Initial temp)

The test is approved if:

 The temperature does not increase more than 25 ºC per individual UVR.
 All lamps were lit, indicated in UVR popup and LED indication on all LPSs.
Notes:

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PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

3.8.19 CIP module

Area/function to be checked OK

Preparations: Close valve V310-8 (manually) and V460-3 (manually).

1. Open and close the following valves from the control system: V321-4, V460-2, V320-2,
V310-1, V310-6, V571-1 and V321-1.

2. Check that the valves are operating correctly and that the valves are indicated as open
(yellow indicator visible on the valve).

3. Check manually that the valve V320-11 under the CIP tank is open.

4. Re-open valve V310-8 (manually).

Notes:

CIP test.

1. Open valve V320-2, V321-1. Make sure that V320-11 (manually) is open.
2. Lower air valve 501-3 and 501-4 to a minimum to avoid damages due to high speed running
at start. Done by loosening the locking nut and turning the valve clockwise.

3. Start P320-1 from the control system. Check that the pump operates correctly. Increase the
speed by turning V501-3 so that the pump runs at approximately 2 Hz (2 strokes per
second). Fasten the locking nut.

4. Stop P320-1.
5. Start P321-5 from the control system. Check that the pump operates correctly. Increase the
speed by turning V501-4 so that the pump runs at approximately 2 Hz (2 strokes per
second). Fasten the locking nut.

6. Stop P321-5.

7. Close valve V320-2 and V321-1.

Notes:

CIP tank filling. To prepare for the finishing the test (Commissioning test with Customer), fill the CIP
tank with technical water / potable water. It shall be filled almost to the max indication on the CIP tank,
but leave room for 15 liters of CIP liquid, which is added as the last step of the CIP test in the
Commissioning test.

Notes:

3.8.20 UVR drain test

Area/function to be checked OK

Preparations:

 Make sure there is technical water / potable water supply available to the CIP.

 De-aerate the backflow preventer V310-3: Open the 3 manual test valves on the component
at the bottom of the CIP unit.

Notes:

38
 PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

This test is performed on one UVR, even if more are installed.

Make sure that there is water in the reactor. If not follow the steps below. If OK, go to next row.
1. Enable manual mode.
2. Fill up one UV reactor with technical water / potable water: Open V571-1, V321-2 and V320-
4.
3. Open V310-6 and fill up water until LS201-29 and LS201-30 indicates wet condition,
then close V310-6 directly.

Notes:

1. Open V571-1, V321-2 and V320-4.

2. Ensure that the valve(s) on pipe 460.1 are open, for example vessel’s over board valve or
bilge valve. If not opened in step 1: Open V571-1, V321-2 and V320-4.
3. Open valve V460-2 and start pump P321-5. Start timing.
4. Open the drain plug at the bottom of the UVR once a minute to check when the UV reactor is
drained. Drained UVR is also indicated by more intense noise from the pump.
5. Stop timing when the UVR is completely drained.
6. Note down the drain time below. If necessary, adjust parameter p200 Timeout UVR draining
to match the actual draining time.
7. Leave manual mode to deactivate all manually affected components (P321-5, V571-1, V321-
2, V320-4 and V460-2.)
8. Fill the UV reactor with water, see row above.

Drain time: This time (with a margin) is entered in parameter p200.

Notes:

3.8.21 Filter

Area/function to be checked OK

Check that the signals from the filter pressure transmitters are displayed in the filter popup.

The connection is correct if zero is indicated for all transmitters (same as displayed for PT201-16), or if
the indications fluctuates slightly.

Notes:

Open and close the backflush valve V309-1 from the control system. Check that the valve is operating
correctly.

Notes:

Check that the motor is functioning correctly.

Start the motor from the filter popup in the control system. Check that the motor is rotating in any
direction.

Notes:

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PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

3.8.22 Power management (if applicable)

Read the page description for page 1.4 Power request in manual chapter 3. Operating instructions and control system
description.

Choose the alternative for the installation:

 Hard wire fixed (only one power step representing all UV reactors).
 Hard wire ranged (binary combination of 5 signal represent how much power, UVR, needed).
 Remote interface controlled

Area/function to be checked OK

If hard wired: Follow the steps below to test the power management integration.
1. Activate manual operation in the control system.
2. Open the page 1.4 Power request.
3. Send request
If ranged: Send request for 1 UVR.
If fixed: Send request for “Common power”.
4. Check that the request signal is sent. Signal should be received in the ISCS.
5. Wait for indication of a granted signal. Signal should be sent from the ISCS. Indicated
with green lamp and “Yes” in PureBallast control panel.
6. Send “Running” signal for the same UVR. Wait for signal indication: green lamp and
“Running” in PureBallast control panel. Signal should be received in the ISCS.
7. If ranged: Repeat steps 3–6 for all UVRs.

Was the test successful?

Notes:

If remote interface controlled: Follow the steps below to test the power management integration
individually for each power step. Detailed information about remote interface addresses is found in
the Remote interface implementation guide.
1. Activate manual operation in the control system.
2. Open the page 1.4 Power request.
3. Send request for 1 UVR.
4. Open page 4.5 Remote interface 1 and check in address +075 if the signal is sent.
Signal should be received in the ISCS.
5. Check that a granted signal is received. Signal should be sent from the ISCS. Indicated
with green lamp and “Yes” in PureBallast control panel. Also check if address +005 is
active on page 4.5 Remote interface 1.
6. Send “Running” signal. Wait for signal indication: Green lamp and “Running” in
PureBallast control panel. Signal should be received in the ISCS.
7. Open page 4.5 Remote interface 1 and check in address +076 if the signal is sent.
Signal should be received in the ISCS.
8. Repeat steps 3–7 for all installed UVRs.

Was the test successful?

Notes:

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 PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

3.8.23 Test operation and PI adjustment of V201-8

It is recommended to test run the system and adjust control valve V201-8 before commissioning.

Note that PID adjustment only can be performed during an ongoing ballast operation. If this is not possible, PID
adjustment should be done in connection to the commissioning. See conditions for operation in the Commissioning test
form.

Area/function to be checked OK

Flow control during ballast/deballast

1. Start a ballast process.

2. Control that V201-8 regulates the flow smooth and without any remaining cyclic variations.

3. If needed, adjust parameters p120 (P value) and p121 (I value) on page 5.1 Main parameters
1.

Does the process function OK?

Notes:

Pressure control during backflush

Instruction, including example, on how to calibrate V201-8 is given in system manual chapter 3,
section Fine tune flow and pressure control.

1. Start a ballast process.

2. Initiate a backflush from the Filter popup.

3. Control that V201-8 travels to a steady position to create required pressure as fast as
possible.
4. If needed, adjust parameter p166 (P value) and p167 (I value) on page 5.2 Main parameters
2.

Does the regulation function OK?

Notes:

Additional parameters to be considered for higher flow systems:

 p111: Undershoot certified flow

 p113: Min opening of V201-8

 p304: Pressure setpoint during backflush

 p310: Backflush initial delay

Notes:

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PUREBALLAST BALLAST WATER TREATMENT SYSTEM ─ PRE-COMMISSIONING TEST FORM

3.9 Store the test result

After completed test, update the Global ships master data base.

Make sure that the following information is entered in the GSM:

 IMO number
 Hull number
 Vessel name
 PB serial number
 Option installed: Remote interface, remote control panels and power management.
 Attach this document in the job report in SMS. (If not used, attach it in GSM.)

3.10 Signature
Responsible engineer should sign when Part 2 – Function test is completed, and all open issues are resolved.

Responsible

_______________________ _______________________
Signature Date

Printed name

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