HGS BWTS SL 20 0001

The Notice of Revised Maintenance Manual for an Electrolyzer
▪ Summary
We have continued experiments and tests related to electrolyzers to enhance equipment

stability and ensure efficiency.
[Pic 1] Experiments of Acid Cleaning
1% HCL 3% HCL 1% HCL 3% HCL
[Pic 2] Actual Test
In order to provide convenience to our customers, the maintenance manual of the electrolyzer
has been recently revised based on the results of repeated experiments and tests over the
years. The revised content is summarized and delivered to our valued customers, so please
refer to the following explanation.
1/3
Doc No : HGS-BWTS-SL-20-0001
▪ Major Revisions for Cleaning Electrolyzer

Acid cleaning is essential to efficiently maintain the electrolyzer.
For efficient maintenance and operation of the equipment, some of the Acid Cleaning Items
have been revised, so please note the table below.
[Table 1] Summary of The Updated Items

Item Present Revised
Concentration of Acid HCL 1% HCL 3% or SAF Acid 10%
≥ 2 hours (HCl 3%)

Cleaning Time ≥ 2 hours
≥ 4 hours (SAF Acid 10%)
Every 3month or every 60Hrs ballasting
Interval Every 3 month
operation time, whichever is earlier.
[Table 2] Acid Cleaning (Only for Reference)

3% HCL 10% SAF Acid
Before
Acid Cleaning
After
Acid Cleaning
* The scale of these pictures was intentionally generated.

* The amount of scale generated depends on sea water conditions and machinery working conditions.
2/3
▪ Revised Maintenance Schedule for Electrolyzer

According to the user survey conducted by HHI Group, many customers are requesting
detailed maintenance guides for stable operation. To meet the needs of our customers,
we provide the revised maintenance guide for electrolyzer. Please note the summary table
below and the attached maintenance manual.
[Table 3] Summary of The Updated Items regarding How to Maintain an Electrolyzer
Components Action Instruction Frequency
 Check power feeders and other parts

of electrolyzer for leaks.
Electrolyzer  Before Operation
If necessary, renew all defective
Visual Inspection  After Operation
O-rings or Insulation guides.
 Check cable connection.
Electrolyzer  See 3.2.3 of the attached maintained
 After Operation
Internal Inspection manual
Electrolysis  Every 3month or every
Unit 60Hrs ballasting
Electrolyzer  See 3.2.2 / 3.2.4 / 3.2.5
operation time,
Module Cleaning of the attached maintenance manual
Whichever is earlier.
 As required
Replace Insulation
guide and electrode
 Periodic replacement after inspection  Every year
end plate nut O-ring
(if any)
※ Since HiBallast will have been continuously improved, if you have any suggestions or other
useful information with operation and maintenance, please don’t hesitate to contact Green
Solution Team.
[End]
3/3
BALLAST WATER TREATMENT SYSTEM
MAINTENANCE MANUAL
OF HIBALLASTTM SYSTEM
Page
DOCUMENT NO. HiB-M01002
127
RESPONSIBLE PARTY Hyundai Heavy Industries Co., Ltd.
Rev. Date Reason for Issue Prepared Checked Approved

0 Feb. 28, 2016 First Issue J.S. SEO K.H. HAN J.H. LEE
1 Apr. 25, 2016 Reviison J.S. SEO K.H. HAN J.H. LEE
2 May 02, 2016 Revision J.S. SEO K.H. HAN J.H. LEE
... ... ... ... ... ...
... ... ... ... ... ...
10 Oct. 29, 2020 Revision J.S. SEO K.H. HAN J.H. LEE
HiBallast System Doc. No.
Maintenance Manual HiB-M01002
Revision Sheet
REV. NO. DATE CONTENT

0 Feb. 28, 2016 First Issue
1 Apr. 25, 2016 Revision
2 May 02, 2016 Revision
3 Mar. 22, 2017 Revision
4 Oct. 25, 2017 Revision
5 Dec. 14, 2017 Revision
6 Feb. 10, 2018 Revision
7 Mar. 07, 2018 Revision
8 Apr.11, 2018 3.2.2~5
9 Jun. 08, 2018 12.2,
10 Oct. 29, 2020 Reference manual list correction, 2. Maintenance schedule, 2.3 added,
3.2.2~5 EM cleaning procedure, Appendix A 2. Standard spare part list/4.
Spare parts for 5 years dry docking, Appendix B/C added
TABLE OF CONTENTS
1. General ...................................................................................................................................................................................................... 10
1.1. Information for Health & Safety .................................................................................................................................................. 10
1.2. Maintenance alarm ............................................................................................................................................................................. 10
1.3. Safety symbols ...................................................................................................................................................................................... 11
2. Maintenance schedule ............................................................................................................................................................................ 12
2.1. Instruments list and calibration schedule ................................................................................................................................ 21
2.2. Troubleshooting ................................................................................................................................................................................... 21
2.3. Functionality & Biological organism monitoring ................................................................................................................. 21
3. Electrolysis Unit ...................................................................................................................................................................................... 22
3.1. Electrolysis unit drain manual for maintenance.................................................................................................................... 22
3.2. Electrolyzer ............................................................................................................................................................................................. 23
3.2.1. Configuration .............................................................................................................................................................................. 23
3.2.2. EM (Electrolyzer module) cleaning procedure by using cleaning kit (optional) ...................................... 25
3.2.3. Check-up of scale ...................................................................................................................................................................... 38
3.2.4. EM (Electrolyzer module) cleaning procedure by manual for each plate ...................................................... 40
3.2.5. EM (Electrolyzer module) cleaning procedure by manual for internal module assembly ..................... 43
3.3. Cleaning inside gas separator ....................................................................................................................................................... 47
3.4. Gas separator vent system inspection....................................................................................................................................... 49
3.5. Blower ....................................................................................................................................................................................................... 51
4. Seawater Feed Unit ................................................................................................................................................................................. 53
4.1. Seawater feed pump ......................................................................................................................................................................... 53
4.2. Plate Heat exchanger ........................................................................................................................................................................ 56
4.3. Strainer ..................................................................................................................................................................................................... 60
5. Neutralization Unit ................................................................................................................................................................................. 62
Hyundai Heavy Industries Co., Ltd.

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5.1. Neutralization agent injection pump ......................................................................................................................................... 62
5.2. Handling of Neutralization agent solution ............................................................................................................................. 65
6. Control Cabinet ....................................................................................................................................................................................... 67
6.1. Safety instructions ............................................................................................................................................................................... 67
6.2. Description ............................................................................................................................................................................................. 68
6.3. Information of IP address of Control system ......................................................................................................................... 68
7. Motor Control Cabinet ........................................................................................................................................................................... 69
7.2. Description ............................................................................................................................................................................................. 70
8. Rectifier (RF) ........................................................................................................................................................................................... 71
8.2. Description ............................................................................................................................................................................................. 71
8.3. HiPower .................................................................................................................................................................................................... 72
8.3.1. Troubleshooting ......................................................................................................................................................................... 73
8.4. GiPower .................................................................................................................................................................................................... 75
8.4.1. Troubleshooting ......................................................................................................................................................................... 76
9. Filter Unit .................................................................................................................................................................................................. 77
9.1. Maintenance .......................................................................................................................................................................................... 77
9.2. High pressure cleaning for the filter elements ..................................................................................................................... 78
9.3. Acid cleaning: ....................................................................................................................................................................................... 79
9.4. Removing the filter elements ........................................................................................................................................................ 81
9.5. Troubleshooting ................................................................................................................................................................................... 84
9.6. Fresh water filling ................................................................................................................................................................................ 88
10. Flowmeter ................................................................................................................................................................................................. 89
10.1. Troubleshooting and Remedies .................................................................................................................................................... 89
10.1.1. Response of the measuring system to faults .............................................................................................................. 89

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10.1.2. Checking the electronics ....................................................................................................................................................... 89
10.1.3. Replacing the electronics module ..................................................................................................................................... 90
10.1.4. Procedure: ..................................................................................................................................................................................... 90
11. Gas detector .............................................................................................................................................................................................. 91
11.1. Sensor Exchange .................................................................................................................................................................................. 91
11.2. Caution ..................................................................................................................................................................................................... 91
11.3. Calibration............................................................................................................................................................................................... 92
11.3.1. Calibration procedure ............................................................................................................................................................. 92
12. TRO sensor ............................................................................................................................................................................................... 93
12.1. Overview (non-explosion proof type) ........................................................................................................................................ 93
12.2. Overview (explosion proof type) .................................................................................................................................................. 95
12.3. Routine Maintenance......................................................................................................................................................................... 98
12.3.1. Reagent tubing set ................................................................................................................................................................... 98
12.3.2. Replacing or Installing the Reagents ............................................................................................................................... 98
12.3.3. Maintenance Schedule ........................................................................................................................................................... 99
12.4. Troubleshooting .................................................................................................................................................................................104
13. Calibration ..............................................................................................................................................................................................105
14. Technical assistance..............................................................................................................................................................................105
Appendix A .......................................................................................................................................................................................................1
1. Equipment name plates .............................................................................................................................................................................2
2. Standard spare parts list ............................................................................................................................................................................7
3. Critical spare parts list ........................................................................................................................................................................... 11
4. Spare parts for 5 years dry docking .................................................................................................................................................... 12
Appendix B .......................................................................................................................................................................................................1
1. HiBallast functionality monitoring ........................................................................................................................................................2
2. HiBallast Monitoring Equipment Calibration .....................................................................................................................................4

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3. HiBallast Biological Organism Monitoring .........................................................................................................................................5
Appendix C .......................................................................................................................................................................................................1
Electrolyzer cleaning record book ...................................................................................................................................................................2

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LIST OF FIGURES
Figure. 1 Electrolyzer ............................................................................................................................................23

Figure 2 Control Cabinet .......................................................................................................................................68
Figure 3 Motor Control Cabinet ............................................................................................................................70
Figure 4 A view of the rectifier (15D) ...................................................................................................................72
Figure 5 Lamp display on the front panel of the rectifier ......................................................................................73
Figure 6 A view of the rectifier (100D) .................................................................................................................75
Figure 7 Cleaning the filter elements ....................................................................................................................78
Figure 8 Cleaning the filter elements using acid ................................................................................................80
Figure 9 Main flow transmitter ...........................................................................................................................90
Figure 10 TRO sensor front (left) and bottom (right) view ................................................................................93
Figure 11 TRO sensor overall mounting dimension ...........................................................................................94
Figure 12 Explosion proof type TRO sensor ......................................................................................................95
Figure 13 CLX-Ex with cover open ...................................................................................................................97
Figure 14 Reagent Tubing Set ............................................................................................................................98
Figure 15 TRO sensor T-strainer ......................................................................................................................103
LIST OF TABLES
Table 1 Maintenance schedule ...............................................................................................................................12

Table 2 Parts List of Electrolyzer ..........................................................................................................................24
Table 3 IP address of control system .....................................................................................................................68
Table 4 EOCR current set value ............................................................................................................................70
Table 5 Trouble shooting list for filter ...................................................................................................................84
Table 6 Flowmeter error indicator .........................................................................................................................89
Table 7 TRO sensor indicator lamp .......................................................................................................................95
Table 8 Troubleshooting for TRO sensor ............................................................................................................104

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REFERENCE MANUAL
100 . ACONIS software installation(recovery) guide

100-1. How to reset ACONIS MPM CARD
100-2. Log data backup manual
110. E-111_Electrolyzer maintenance manual
110-1. E-111_Electrolyzer power feeder replacement manual (P type)
111. E-111_Electrolyzer module_How to connect the power cable (P type)
112. CIT-1111_ Salinity sensor manual
112-1. CIT-1111_Salinity Sensor_calibration
113. LS-1111_ Level switch manual
114. FIT-1131_Injection flowmeter manual
115. FCV-1131_Positioner_manual
116. AIT-1121_Gas detector_instruction manual
116-1. AIT-1121_Gas detector_calibration manual
117. PT-1121_Pressure transmitter manual
118. B-117_Blower maintenance manual
120. F-121_Filter instruction manual
120-1. F-121_Filter maintenance procedure
121. FIT-1211_Main flow meter manual
121-1. FT-1211_Man flowmeter calibration manual
123. FCV-1211(BT-1211)_Main flow cControl valve maintenance manual
124. PT-1211_ Filter pressure transmitter manual
125. F-121_ Filter control panel manual
130. N A tank repair manual
130-1. Neutralization agent make-up and filling procedure
131. P-131_N.A injection pump instruction manual
132-1. LIT-1311 NA Level transmitter calibration manual
133. NA solenoid valve cleaning manual
140. RF-141_Rectifier operation manual
141. RF-141_Rectifier maintenance manual
142. RF-141_Rectifier cooler instruction manual
143. RF-141_Rectifier cooler alarm code
150. AIT-151_TRO sensor instruction manual

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151. AIT-151_TRO sensor instruction manual_Ex

151-1. Check valve replacement
151-2. AIT-151_TRO sensor sampling flow check manual
152. P-152_TRO sampling pump manual
170. PT-1721_Pressure transmitter manual
171. P-171_Sea water feed pump maintenance manual
173. HE-173_Plate heat exchanger manual
200. BWTS calibration schedule with letter
300. HiBallast MSDS list
400. HiBallast Troubleshooting Manual
500. HiBallast Preservation Manual
600. HiBallast code book

-7-
ABBREVIATION
Abbreviations Descriptions
AODD Air Operated Double Diaphragm
AL Alarm
AMS Alarm Monitoring System of a vessel
APT After Peak Tank
BS Existing Ballast System of the vessel
BWP Ballast water Pump
BWTS Ballast Water Treatment System
CC Control Cabinet
CCR Cargo Control Room
DP Deferential Pressure
ECR Engine Control Room
EM Electrolysis Module
EMC Electromagnetic Compatibility
ESD Emergency Shut-down
EU Electrolysis Unit
FIFRA The Federal Insecticide, Fungicide, and Rodenticide Act
FU Filter Unit
GPS Global Positioning System
GS Gas Separator
GSP General Service Pump
HAZOP Hazard and Operability study
HMI Human-Machine Interface
IAS Integrated Automation System
IMO International Maritime Organization
IP International Protection
J/B Junction Box
LOP Local Operating Panel
MCC Motor Control Cabinet

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Abbreviations Descriptions
MMO Mixed Metal Oxide
MTBF Mean Time Between Failure
NU Neutralizing Unit
PC Personal Computer
PLC Programmable Logic Controller
PMS Power Management System of a vessel
PSU Practical Salinity Unit
RF Rectifier
RH Relative Humidity
SD Shut-Down
SKID The place electrolyzer unit and gas separator installed
SCU System Control Unit
ST Strainer
SWFU Seawater Feeding Unit
TBD To be determined
TRO Total Residual Oxidant
TRC Total Rated Capacity(Total treatment Rated Capacity)
TSU TRO Sensor Unit
USCG United State Coast Guard
WBP, BWP Water Ballast Pump
BO Before Operation
AO After Operation
AR As Required

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1. General
To ensure the best performance of equipment, the following inspection and maintenance works are
recommended. The following table summarizes inspection schedule and maintenance period. The more details
about installation, inspection, maintenance and spare part can be found at each unit’s document.
1.1. Information for Health & Safety
⚫ The personnel for installation, commissioning, operation and maintenance of the HiBallast system and
its equipment must read and understand this manual including the health and safety section.
Depending on the qualification of the personnel, additional training might be necessary.
⚫ The installation of the HiBallast system has to be carried out in accordance with local regulations and
accepted code of good practice.
⚫ The installation, commissioning, operation and maintenance of the HiBallast system might only be
carried out by authorized and trained personnel.
⚫ Strictly comply with all relevant rules for accident prevention and local health and safety regulations.
⚫ Check all relevant safety procedures before you switch on the HiBallast system.
⚫ HHI accepts no responsibility for any damage arising from incorrect installation, incorrect use,
incorrect maintenance or own modifications of the HiBallast system.
⚫ Always disconnect the HiBallast system from the power supply before disassembling and
disconnecting.
⚫ All maintenance of the HiBallast system must be logged in the ship’s maintenance log.
1.2. Maintenance alarm
To carry out any maintenance or calibration work described in this manual and reference manual, BWTS
controller to be changed to maintenance or calibration mode in compliance with USCG 46 CFR § 162.060-20
(e) (2). Please refer to operation manual [7.6 Maintenance status indication function] for more information.

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1.3. Safety symbols
⚫ Hazard warning
⚫ Risk of damaging the System
⚫ Hazard warning
⚫ Risk of electrical shock
⚫ Risk of optical radiation
⚫ Wear safety visor
⚫ Wear safety goggles
⚫ Wear safety boots
⚫ Wear safety gloves
⚫ Wear safety mask

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2. Maintenance schedule
Follow maintenance schedule is to secure performance, safety and durability of the HiBallast system and its components.
Maintenance work can be classified as follows
⚫ Inspection
⚫ Periodic functional test
⚫ Maintenance: replacement or repair
Table 1 Maintenance schedule

D(daily), W(weekly), M(monthly), Y(yearly), BO(before operation), AO(after operation), AR(as required), PIC(person in charge)
FREQUENCY BY WHOM
COMPONENTS ACTION INSTRUCTION NOTES
D W M 6M Y BO AO AR (LEVEL)
Electrolysis Unit Check the level switch (LS-1111) Check the function See reference
at the outlet of electrolyzer ● manual
module L/B : 1hr
Check the level switch (LS-1141) Check the function See reference
at the drain tank of the gas ● manual
separator L/B : 1hr
Drainage of gas separator for Every 3months Every 20
flushing of sludge/scale ● PIC hours
operation

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FREQUENCY BY WHOM
L/B : 1hr
Visual inspection of gas detector Overhaul inspection L/B : 0.5hr

●
sensor
Check piping and all valves for Check any leakage during L/B : 1hr
●
leakage operation
Check performance of electrolysis Comparing TRO L/B : 2hr
unit concentration with the output
current/voltage of rectifiers ● PIC
during normal operation
condition
Check air blower Check any noise during L/B : 0.5hr
●
operation
Check the air pressure for Air pressure > 5 bar L/B : 1hr
●
pneumatic valves
Electrolyzer Visual Inspection 1) Check power feeders and L/B: 0.5 hr
other parts of electrolyzer for
leaks. ● ●
If necessary, renew all
defective O-rings or

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FREQUENCY BY WHOM
insulation guides for power
feeders.
2) Check cable connection
Electrolyzer Internal Inspection See 3.2.3 L/B : 4hr x
●
2M
Electrolyzer module cleaning See3.2.2, 3.2.4, 3.2.5 Every 60hrs
ballasting
operation
time or 3
● ● PIC month
whichever is
earlier
L/B : See
3.2.3 ~ 3.2.5
Replace insulation guide and Periodic replacement after L/B : 2hr
electrode end plate nut o-ring inspection ●
(if any)
Gas separator vent system See 3.4 L/B : 4hr x
● PIC
inspection 2M

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FREQUENCY BY WHOM
Check H2 vent pipe Check if vent pipe and head Refer to
is blocked or not troubleshooti
ng manual
●
3.1 (3)
L/B : 1hr
Check the corroded part or L/B : 0.5hr

●
area of vent pipe in visual
H2 gas detector calibration Periodic calibration See 11
●
L/B : 1hr
Salinity sensor performance check Periodic performance check ● L/B : 1hr
Salinity sensor cleaning Sensor cleaning ● L/B : 0.5hr
Seawater Feed Cleaning the filter inside of Remove particles on the L/B : 2hr
●
Unit strainer surface of filter
Check the seawater feed pump Check any noise during L/B : 0.5hr
●
operation
Check seal, bearing, sleeve, shaft, Check any leakage during L/B : 0.5hr
●
and impeller operation

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FREQUENCY BY WHOM
Check piping and all valves for Check any leakage during L/B : 0.5hr
●
leakage operation
Neutralization Fill up tank, if less than half L/B : 3hr x
Check the tank level ●
Unit of full 2M
See the output value of L/B : 0.5hr
Check the injection pump ●
pump(s)
Check the injection pump Check any leakage ● L/B : 0.5hr
Check the diaphragm Wearable part (4000 hrs) ● L/B : 0.5hr
Check the lubricant oil First 1year, then every 2years ● PIC L/B : 0.5hr
Check piping and all valves Check any leakage during L/B : 1hr
●
operation
Check injection nozzle Check and clean it if L/B : 1hr
● ●
necessary
Check back-pressure valves and Check and clean it if L/B : 1hr
check valves especially for necessary ●
blockage
Filter Unit Back-flushing filter element L/B : 8hr x
Check any visible damage(s) ● PIC
2M

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FREQUENCY BY WHOM
Check any noise during L/B : 0.5hr
Check any noise of gear unit 2W ●
operation
Check any leakage during L/B : 0.5hr
Check any leakage of gear unit ●
operation
Check the vent valve Cleaning vent valve outlet ● L/B : 1hr
L/B : 2hr x
Check fixing bolts for tightness Annually ●
2M
Seals Leakage, Visual check ● L/B : 0.5hr
Differential pressure sensor Leakage/normal operation 2W PIC L/B : 0.5hr
Check back-flushing L/B : 0.5hr

operation. Back-flushing to
Position switch ● PIC
be stop abt. 20~30s after
start.
See reference
manual
Filter element cleaning ● PIC
L/B : 12hr x
2M
Sea water drain and fresh water Fresh water filling is ● L/B : 2hr

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FREQUENCY BY WHOM
filling recommended if sailing
period is long to protect filter
element from corrosion
Electric Cabinet Check all cabinet doors are closed ● L/B : 1hr
Check cooling fans ● L/B : 1hr
Check any scratches and L/B : 1hr

●
corrosion
TRO Sensor Every
Replacement of the reagent of Replacement of the reagent
3M PIC 3months
TRO sensors kit
L/B : 2hr
1 year kit L/B : 2hr
(1 buffer bottle+ 4sets of ● PIC
indicator)
Check and clean the internal L/B : 0.5hr
Check the internal strainer ●
strainer if necessary
Check any excessive debris L/B : 0.5hr
Inspect the glass cuvette inside surface of the glass. ●
Replace with clean one, and

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FREQUENCY BY WHOM
clean the dirty one for future
use.
Replacement of pump tubes and L/B : 1hr
Replace if necessary ● PIC
check valves
See reference
Check any clogging and
Check any tubes and check valves ● PIC manual
leakage
L/B : 0.5hr
Check compressed air supply Only for
Compressed air & purge
and purge controller normal ● explosion
controller check
operation proof type
Flow Meter L/B : 6hr x
Check flow meter electrodes Check and clean if necessary ●
2M
Cables Check all cable connections L/B : 2hr
Check the cable connection status ●
in visual
Note
Above all maintenance works should be performed and managed by crew. Furthermore, it is recommended that some items marked by PIC are controlled by qualified
person such as chief officer or chief engineer. If any problem or defective part is found or replacement is required, please refer to HiBallast troubleshooting manual and
reference manual for more information. If further information or support is required, please contact manufacturer.

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AUTION! The warranty does not apply if the product (a) has been altered, except by the maker or its authorized representative, (b) has not been installed,
operated, repaired, or maintained in accordance with instructions supplied by the maker, (c) has been subjected to abnormal physical or
electrical stress, abnormal environmental conditions, misuse, negligence, or accident or (d) has provided for training purposes.
Especially, the following works must be conducted in accordance with the above PMS for stable operation, equipment protection and safety.
- Electrolyzer visual inspection and cleaning
- H2 gas detector calibration
- Replacement of the TRO reagent
- Normal operation status, leakage and connections shall be checked during operation after any maintenance work.

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2.1. Instruments list and calibration schedule
A periodic calibration should be carried out by user to secure performance, safety and durability of the
HiBallast system.
Please see reference manual 200. BWTS CALIBRATION SCHEDULE
2.2. Troubleshooting
Please see BWTS TROUBLE SHOOTING and REFERENCE MANUAL.
2.3. Functionality & Biological organism monitoring
To assess system functionality, specific parameters should be monitored periodically and biological indicator
compliance monitoring sampling of ballast water must be conducted. The required parameters to be monitored
and guidance for sampling are contained in Appendix B

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3. Electrolysis Unit
3.1. Electrolysis unit drain manual for maintenance
If the BWTS was stopped by emergency shutdown, the remaining water inside of
electrolysis unit is solution containing hypochlorite ions. So if drain is required for
maintenance after ESD, manual flushing should be performed by crew before drain.
Othewise this drain water should be neutralized properly.
Safety Strictly comply with all relevant rules for accident prevention and local health and
safety regulations. Wear your Personal Protective Equipment.
Do not expose your eyes and skin to the liquid inside EM. Protect your skin and wear
safety goggles.
Please make sure that the proper safety precautions are taken, when using the cleaning
agents according to the material safety data sheet. Also ensure that only trained and
instructed personnel is allowed to perform this cleaning-especially pay attention to the
mixing procedure and potential chemical reactions.
Purpose To drain water in electrolysis unit.
Frequency Maintenance for electrolyzer
Parts and Electrolysis unit

equipment required Sea water feed unit
Main ballast pipe line and tank
Procedure 1 Make flushing line-up from sea water feed unit to ballast tank by valves open
in manual.
2 Manual start sea water feed pump for 5 minutes.
3 Stop sea water feed pump
4 Close all valves.

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3.2. Electrolyzer
Electrolyzer is a core equipment of EU, which produces Sodium Hypochlorite through the electrolyzation
of seawater.
3.2.1. Configuration
For instance, the HiBallast system is composed of several electrolyzer modules connected in a row as
follows.
Figure. 1 Electrolyzer

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Table 2 Parts List of Electrolyzer

NO. PART MATERIAL REMARK
1 ELECTROLYZER PE COATED STEEL Bottom
2 ELECTROLYZER PE COATED STEEL Middle
3 ELECTROLYZER PE COATED STEEL Top
4 IN/OUT FLANGE PE COATED STEEL
6 BLIND FLANGE FE
7 ELECTROLYZER OPEN GASKET VITON
8 ELECTROLYZER CLOSE GASKET VITON
9 CLOSE PLATE PE COATED STEEL
10 OPEN PLATE PE COATED STEEL
11 BAFFLE PLATE PE COATED STEEL
12 CLOSE GASKET VITON
13 OPEN GASKET VITON
14 SUPPORT GUIDE FE

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3.2.2. EM (Electrolyzer module) cleaning procedure by using cleaning kit (optional)
Take care when handling Ti-electrode to prevent contamination by scales and

sediments stuck on electrode. Otherwise it will decrease efficiency of EU performance.
So cleaning shall be required with special caution and care because of using acid
solution for cleaning.
safety regulations. Wear your personal protective equipment.
safety goggles.
Purpose To remove scales and particles stuck on the surface of electrode.
Frequency See table1 maintenance schedule
Limitation This cleaning manual is only available when the electrolysis unit is equipped with
1. Cleaning kit connection nozzle
2. Electrolyzer isolation valve on the outlet of electolyzer train
3. Isolation valve between gas separator and electrolyzer

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Parts and Electrolyzer modules, circulation pump, hose, flange connector, neutralization power
equipment (Sodium Bicarbonate), Fresh water, Drum
required
(For reference only)

-26-
Required specification of each item of cleaning kits are as below
No Item Specification Remark
1 Circulation pump Head : < 10m Chemical pump

Flow : 10 ~ 20m3/h
2 Drum ≤ HiB-2000 : ≥400L Multiple tanks

≤ HiB-4000 : ≥500L could be used
to meet
≤ HiB-6000 : ≥800L
required
≤ HiB-10000 : ≥1,000L
volume
considering
access door and
hatch size
3 Acid (Chemical) 35%HCL (Hydrochloric acid) Abt. 3%

9L per 100L hydrochloric
acid
As an
alternative,
10% SAF
ACID can be
used.
4 Neutralization Sodium Bicarbonate (NaHCO3)

chemical 4kg per 100L acid solution

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5 PPE
6 Barrel pump or Suitable material to be used.

hand pump for Ex) PVC
acid chemical
supply
7 Table or stand for For handling chemical drum (if

acid chemical required)
8 pH indicator 1. for low range (≤ 5)

2. for high range (> 5)
9 Sampling bottle To check pH of chemical

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10 Barrel pump For acid

chemical
11 Scoop (500ml) For

neutralization
chemical

-29-
Solution How to make 3% HCL as the acid solution for cleaning.

make-up
HiBallast Acid solution total
35% HCL (L) Fresh water (L)
Model volume (L)
≤ HiB-2000 28 292 320
≤ HiB-4000 43 437 480
≤ HiB-6000 60 600 660
≤ HiB-8000 77 783 860
≤ HiB-10000 90 910 1000
How to make 10% SAF ACID as the acid solution for cleaning.
HiBallast Acid solution total

SAF ACID (kg) Fresh water (L)
Model volume (L)
≤ HiB-2000 32 288 320
≤ HiB-4000 48 432 480
≤ HiB-6000 66 594 660
≤ HiB-8000 86 774 860
≤ HiB-10000 100 900 1000

-30-
Required
neutralization
HiBallast Acid solution total volume Required neutralization
chemical
Model (L) chemical(kg)
≤ HiB-2000 320 13
≤ HiB-4000 480 20
≤ HiB-6000 660 27
≤ HiB-8000 860 35
≤ HiB-10000 1000 40

-31-
Procedure 1 Isolate EU unit and drain solution containing hypochlorite ions inside EU and other
parts.
⚫ Drain solution in EU
1) Open the drain valve (DV-1111)
2) After draining the solution, close the drain valve (DV-1111)
⚫ Isolate the electrolyzer modules(EM)

1) Close the manual valves(MV-1111 and MV-1181) to isolate EM

-32-
2 Install or prepare chemical tank and pump (Cleaning kit)
3 Connect the hose from the tank to the inlet/ outlet of the electrolyzer piping.
1) Remove the blind flange from the nozzles
2) Connect the valve with hoses
4 Fill up the acid tank with the fresh water only

-33-
5 Make line-up.
In case that the EU has multiple electrolyzer module trains such as HiB-4000 or
Hib-6000, circulation cleaning should be done one by one by closing and opening
electrolyzer outlet manual valve. Below figure shows an example of electrolyzer
circulation line-up.
Connect hose to
OPEN the acid tank

CLOSE
CLOSE CLOSE
CLOSE Connect hose to
the acid tank
6 Check any leakage by running circulation pump.

Pump rotating direction should be also checked
If any leakage is found, it should be fixed before making acid solution.
7 After leakage check and before use acid chemical, all flange and hose connection to
be covered with anti-splash tape.
8
Wear the full PPE (Personal Protection Equipment) before use of chemical!
Start the circulation pump and pour the acid solution into the tank using barrel
pump or hand pump. Do not pour all acid into the tank at once. 10L per 1 min. is

-34-
recommended when use 20m3/h of circulation pump.

Required acid solution for cleaning is as below
- ab. 3 %(vol.) hydrochloric acid (HCl)
Use of more than the recommended concentration may affect the life of
electrodes.
9 Keep running circulation pump for 2 hours.

(If SAF ACID is used as an alternate chemical, circulation time per electrolyzer
train to be changed to 4 hours)
10 Take a small amount of the sample chemical through tank drain valve and bottle.
11 Check pH of the chemical using low range pH paper

If the pH is 2 or above, add chemical 25% of initial filling more
If pH is below 2, circulate the chemical for 1 hour more.
12 Repeat step 9 to 11 for all electrolyzer trains one by one if required.

If additional chemical is required for circulation, please supplement the chemical.
Stop chemical pump before changing electrolyzer outlet manual valve.
13 Pour neutralization powders (NaHCO3) into the tank.

Required amount: 4kg(powder) per 100L acid solution
(FYI) Commercial product(powder) : 25kg/pack
Do not pour the neutralization powder at once. Otherwise, too much bubble
will be generated by chemical reaction. Add 500g at a time.
14 Circulate the neutralized chemical by running circulation pump for 30 minutes per
electrolyzer train.
This chemical circulation should be also carried out one by one for all trains
15 Take small amount of the sample chemical through the tank drain valve.
16 Check pH of the chemical using high range pH paper.

If the pH is less than 6, add more neutralization powder and repeat step 13 to 16.

-35-
17 After neutralization process is completed, open the isolation valves of EU.

MV-1111, MV-1181
And open EU drain valve (DV-1111)
18 Close the manual valve on the cleaning kit connection nozzle of EU.
19 Drain or return the neutralized chemical into tank
20 Drain the remaining neutralized water to bilge tank by opening tank drain valve.
21 Disconnect cleaning kit from EU and place the blind flange on the cleaning kit
connection nozzle of EU
22 Close EU drain valve (DV-1111)
23 Check the final position of all manual valves in EU for normal operation.
24 Write the date on the record book after completing cleaning work. Please see
appendix C for the record book

-36-
1) After cleaning work, all manual valves for electrolyzer module outlet should be set as marked position to
ensure even flow of the modules. The required manual valve position is set by maker before delivery and correct
position can be checked by marking on the indicator of each manual valves.
2) All manual valves should be re-installed, if it is disassembled, to its original position just as it was.

-37-
3.2.3. Check-up of scale
Generally scales are produced by sea water electrolysis as a by-product and these
scales could be accumulated in the each electrolyzer modules inside as time goes by. If
the scales are not removed properly and accumulated too much, internal electrode
module can be damaged by over voltage and heating. So, periodic inspection &
cleaning should be carried out by crews in accordance with the maintenance manual.
safety regulations.
Wear your Personal Protective Equipment.
The liquid remaining in the EM may splash. Wear safety gloves for handling.
The liquid may cause eye and skin irritation. Keep channel covers closed at all times.
The HG may remain. Wear clean safety gloves.
Purpose To check the build-up of scale or sediments stuck on electrode.
Frequency See table 1 maintenance schedule

-38-
Parts and Electrolyzer

equipment
required
<An example of the electrolyzer>
Open the square flange of the top side electrolyzer module

- : Water flow direction
- : Module inlet/outlet side square flange
Procedure 1 Isolate EU unit and drain solution inside EM.
2 Loosen bolts and nuts on the side flange to inspect inside of EM
3 Disconnect flange and gasket from the EM
4 Check inside of EM
If accumulated scale is founded, rake out it from inside of EM
5 Assemble the gasket and flange and tighten the bolts and nuts
6 Check leakage by pressurising electrolyzer using sea water feed pump
7 Check the change of rectifier voltage after the repair
8 Write the date on the record book after completing cleaning work. Please see
appendix C for the record book

-39-
3.2.4. EM (Electrolyzer module) cleaning procedure by manual for each plate
Take care when handling Ti-electrode to prevent contamination with scales and
sediments stuck on electrode. This can lower the efficiency of EU performance.
safety goggles.
Purpose To clean scales and particles stuck on the surface of electrode.
Parts and * Required acid solution for cleaning is 3 %(vol.) of hydrochloric acid (HCl) or 10% SAF
equipment ACID
required * A bath for one (1) electrolyzer module: 0.5 m (W) x 1.5m (L) x 0.6 m (H) acid cleaning
bath.
Initial filling level should not be over 50% of bath volume considering overflow of acid
solution during cleaning.
Electrode plate

-40-
Procedure 1 Disassemble the flange of electrolyzer module(s).
2 Disassemble the holding bracket from the electrolyzer module(s).
3 Pick out each electrode plate carefully from the electrolyzer module(s).
4 In order to clean the electrode plate(s), put them in a bath with the chosen
cleaning acid and leave them for 12hr (Max.) respectively until you see a
cleaning effect desired.
* Recommended immersion time: max. 12 hr
* Required acid solution for cleaning: ab. 3 % (vol.) hydrochloric acid (HCl)
or 10% SAF ACID (alternative)
Caution! Use of more than the recommended concentration may affect the
life of electrodes.

-41-
5 After cleaning, the elements are taken out from the bath, and you have to
ensure to clean off any remaining acid from the elements surface by suitable
method.
6 After cleaning, please assemble carefully the electrode plates in the correct
way. And then install flanges accordingly.
Caution! The +/- side of the plate should not be changed.
When the electrodes are reassembled in the electrolyzer after cleaning, the anode and cathode of the electrode
must be clearly identified and installed in their original position. If the anode and cathode are placed incorrectly,
the life of the electrode is seriously affected.

-42-
3.2.5. EM (Electrolyzer module) cleaning procedure by manual for internal module assembly
Take care when handling Ti-electrode to prevent contamination with scales and
sediments stuck on electrode. This can lower the efficiency of EU performance.
safety goggles.
Purpose To clean scales and particles stuck on the surface of electrode.
Parts and * Required acid solution for cleaning is ab. 3 % (vol.) hydrochloric acid (HCl) or 10% SAF
equipment ACID (alternative)
required * A bath for one (1) electrolyzer module: 0.5 m (W) x 1.5m (L) x 0.6 m (H) acid cleaning
bath.
Initial filling level should not be over 50% of bath volume considering overflow of acid
solution during cleaning.
Internal module

-43-
Procedure 1 Remove all power cables and power feeder ass’y.
→ →
→ →
Completely remove power feeder ass’y

-44-
2 Disassemble both end flanges of electrolyzer module(s).
3 Pull the internal module(s) ass’y out from electrolyzer.
Clamp by using a
jig at each end
It is recommended to install a jig at each end of the module to prevent disassembly

of the module.
Be careful not to damage the module when pulling it out.
To identify +/- (anode/cathode) side of the electrode module,

mark “ + ” and “ – “ on each side of the module.

-45-
4 In order to clean the electrode plate(s), put them in a bath with the chosen cleaning
acid and leave them for 12hr (Max.) respectively until you see a cleaning effect
desired.
* Recommended immersion time: max. 12 hr
* Required acid solution for cleaning: ab. 3 % (vol.) hydrochloric acid (HCl) or
10% SAF ACID (alternative)
Use of more than the recommended concentration may affect the life of
electrodes.
5 After cleaning, take it out from the bath and clean inside of the module(s) by
flushing with fresh water. Then check inside of the module before assembly.
6 When assembly, please put the internal module in the correct way.
And then install flanges, power feeder and cables accordingly.
Caution! The +/- side of the module should not be changed.
When the electrodes are reassembled in the electrolyzer after cleaning, the anode and cathode of the electrode
must be clearly identified and installed in their original position. If the anode and cathode are placed incorrectly,
the life of the electrode is seriously affected.

-46-
3.3. Cleaning inside gas separator
Take care when cleaning inside gas separator to prevent scales piling up inside GS.
This can cause downgrade of the efficiency of EU performance.
So cleaning shall be required with special caution and care because of acid liquid
remaining inside GS.
Do not expose your eyes and skin to the liquid inside GS. Protect your skin and wear
safety goggles. Ordinary glass or plastic is sufficient.
Purpose To clean scales and particles piling up inside GS.
Frequency Every 20 hours operation
Parts and Gas separator

equipment required

-47-
Procedure 1 Make sure that the electrolysis unit is stand-by (not in operation).
2 Open the drain valve of the gas separator.
3 Make sure that the gas separator is empty.
4 Fill the separator with sea water using sea water feed pump

-48-
3.4. Gas separator vent system inspection
Inspection of gas separator vent system is recommended when

- No H2 gas coming out is suspected
The performance of separator can be checked by blocking vent pipe end or vent
head. If H2 gas is detected by sensor it can be considered as a normal condition.
If not, clogging of vent valve would be suspected.
- AIT-1122, 1123 H2 gas detector alarm occurs
- Vent pipe over flow occurs
- Separator drain tank filling time is too short. (heavy drain)
Do not expose your eyes and skin to the liquid inside GS. Protect your skin and wear
safety goggles. Ordinary glass or plastic is sufficient.
Purpose To check leakage or performance of gas separator
Frequency If required
Parts and Gas separator

equipment required

-49-
Procedure 1 Drain gas separator
2 Disassemble cofferdam and vent pipe
3 Check below items

- Vent valve clogging
- Hose connection
- Any damage

-50-
3.5. Blower
Take care when checking the blower to able to cause the electric shock to the human.
Electric shock may happen by the malfunction of the motor.
Do not expose your eyes and skin to the mixed HG around blower. Protect your skin
and wear safety goggles. Ordinary glass or plastic is sufficient.
Purpose To maintain the blower to keep venting out HG safely.
Frequency Check if the blower needs checking when hearing abnormal noise.
Parts and Blower

equipment required
Procedure 1 Check surely blower shut off.

-51-
2 Separate carefully electric motor from body.
3 Inspect blower fan and case inside.
4 Inspect motor terminals and parts inside.
5 Assemble in reverse order.
6 Ensure the HiBallast System is in normal operation.
7 Note procedure in the operation logbook.

-52-
4. Seawater Feed Unit
4.1. Seawater feed pump
Take care when checking the seawater feed pump, electric shock may happen by
malfunction.
Do not expose your eyes and skin to the liquid in the pipe line.
Purpose To maintain the seawater feed pump to keep the functionality of EU continuously
and safely.
Frequency Check if the seawater feed pump needs maintenance when hearing abnormal noise.
Parts and Seawater feed pump

equipment required

-53-
Procedure 1 Isolate the seawater feed pump using the manual valves.
2 Drain the seawater in the pipe line around seawater feed pump.
3 Loosen bolts and nuts between the motor and adapter.
4 Remove the motor, coupling set and shaft.

-54-
5 Loosen studs and nuts between the casing and adapter.
6 Remove the adapter, casing cover, mechanical seal and impeller.
7 Check below list.

Weekly
- Check the vibration
- Check the leakage of mechanical seal
Yearly
- Check the wear parts such as impeller, sleeve, mechanical seal
- Check the bearing
- Check the lubricating oil (Maker : SHELL; TELLUS S2 V 46)
8 Assemble in reverse order of above 3-6 sequence with replacement parts.
9 Open the in/outlet valves of seawater feed pump.
10 Check the running condition of seawater feed pump
11 If any leakage or malfunction in the seawater feed pump occur, check it

following above procedure again.

-55-
4.2. Plate Heat exchanger
Take care when disassembling for cleaning the plate heat exchanger, the noise in
unlocking the bolts from the plates is no problem. Be careful hanging the plate
hanger to guide bar. (It can be solved by drive.)
Do not expose your eyes and skin to the liquid in plate heat exchanger.
Purpose To clean plate.
Frequency Check if the plate heat exchanger needs manual cleaning
Parts and Plate heat exchanger

equipment required
Procedure 1 Isolate plate heat exchanger using the manual valves in in/outlet of the plate
heat exchanger and on/off pneumatic valve in inlet of plate heat exchanger are
closed.
2 Unlock the moving frame nuts.

-56-
3 Unlock the middle part with spanner and then up and down
4 For example, if someone wants unlock the 8 bolted machine, he should unlock
upper 4 bolts firstly by 10mm individually, then unlock the 4 lower bolts by
10mm. Push the bolts to the fixed frame and pull out them from it. Move the
moving frame.
5 Disassemble them one by one at a time
6 Pull the plate by the hanger and pick out the plate with lowing upper port
7 When the plates are firmly jammed, take apart it using drive or something like
that
8 Be careful in using drive damage of gasket

Cleaning
9
Follow the next sequence to do cleaning after disassemble.
1) Clean the plate one by one.
2) Take care with a solid body that can be attached between gasket and the
plate that damage may occur and leak as well.
3) Clean the gasket using cloth.
4) Do not use steel brush that brings about corrosion by scratching the
surface. If it is necessary use stainless steel brush.
5) It must be inspection of the corrosion or scale on the surface. The more
check it in initial time and the end, better.
6) Removing ca deposition
➔ Submerge the plate in nitric acid (nitric acid of specific gravity 1.4,
1L + water 10L) for 5~10 minutes at normal temp and wash out
with water.
➔ After this acidation treatment, neutralize it with a soda solution and
wash it with water.
Chemical cleaning
- Beside regular disassemble cleaning; it can be cleaned in assembled
situation as Fig.2.

-57-
- In cleaning brine, the brine should be expelled completely and then run
the system with pure water at normal speed: till it is clean enough
(Fig.3).
- In cleaning brine with hot water, follow the sequence above and loose
the bolts for gasket’s expansion 100plates/5min.
The flow rate of cleaning water should higher than driving situation.
- In chemical cleaning, the temperature and density of soda are not that
critical but in nitric case they are important. Nitric acid should not be
touched with anything, except stainless steel.
- If the PH of fluid is below than 5, it needs it needs cleaning and should
be changed to over 7.
Piping for chemical cleaning
Piping for brine cleaning
10 Assemble ‘A’ plate first.

-58-
11 Insert opening plate in every other pass.
12 Tighten or loosen the bolts according to a diagonal line sequence.
13 In this case, never tighten or loosen exceed 10mm at a time.
14 Open the manual valves and on/off pneumatic valve.
15 If any leakage or malfunction in the plate heat exchanger occurs, check it

following above procedure again.

-59-
4.3. Strainer
Take care when replacing the filter basket in strainer to prevent particles piling up on
the mesh screen of the filter basket and increase pressure on that. This can cause to
prevent seawater as the electrolysis source from inflowing to the EU.
Do not expose your eyes and skin to the liquid in strainer.
Purpose To clean sediments and particles piling up on the mesh screen of the filter basket.
Frequency Check if the strainer needs manual cleaning
Parts and Strainer

equipment required
Procedure 1 Isolate strainer using the manual valves in in/outlet of strainer are closed.
2 Drain the seawater inside strainer opening the drain plug.
3 Loosen bolts and nuts on the cover flange.
4 Remove the top cover.

-60-
5 Take out the O-ring and filter basket carefully.
6 Eliminate the particles and sediments using the fresh water in vessels.
7 Assemble in reverse order of above procedure 2-5 with replacement parts.
8 If difference pressure is 0.3bar between in/outlet of the strainer, carry out

above cleaning work.
9 Open the manual valves in in/outlet of strainer.
10 If any leakage or malfunction in the strainer occurs, check it following above

procedure again.
11 Note procedure in the operation logbook

-61-
5. Neutralization Unit
5.1. Neutralization agent injection pump
Take care when checking the NP to able to cause the electric shock to the human.
Electric shock may happen by the malfunction of the motor.
Do not expose your eyes and skin to the liquid remaining in NT. Protect your skin
and wear safety goggles. Ordinary glass or plastic is sufficient.
Purpose To maintain the NP to keep the function of NU.
Frequency Check if the NP needs maintenance when hearing abnormal noise.
Parts and -Replacement of Ball Seat, Ball Guide, Check Ball-

equipment required
Procedure ■ Replacement of Ball Seat, Ball Guide, Check Ball

-62-
Disassembly
1 Isolate the injection pump using the manual valves closed.
2 Drain the acid liquid in the pipe line around injection pump.
3 Unfasten the pipes of the suction and discharge sides.
4 Unfasten the junction pipes of the suction and discharge sides.
5 Loosen the joint flange of the suction and discharge parts, and take out the
valve (ball seat, ball guide, check ball).
6 If there is any abnormal scar or wear-out in the check ball or ball seat,
exchange it.
Assembly
1 Assemble the valve while referring to “Part structure and name“ .
2 Assemble the joint flange of the suction and discharge parts, and tighten the
valve.
3 If the packing or O-ring part is damaged, leakage may continue even if

tightened.
4 Assemble the junction pipes of the suction and discharge sides.
5 Assemble the pipes of the suction and discharge sides.

Parts and -Replacement of Diaphragm-
equipment required
■ Replacement of Diaphragm

-63-
Disassembly
1 Isolate the injection pump using the manual valves closed.
2 Drain the acid liquid in the pipe line around injection pump.
3 Unfasten the pipes of the suction and discharge sides.
4 Unfasten the junction pipes of the suction and discharge sides.
5 Unfasten the pump head-fixing bolt with a wrench.
Operate the motor at a low speed. When the stroke length is 100%, grab the
outer diameter of the diaphragm and turn it counter-clockwise to remove the
6
diaphragm from the slider. Since it is a 2-head type, the other diaphragm can
be disassembled in the same way.
7 If the diaphragm is worn out or damaged, exchange it with a new one.
Assembly
1 Operate the motor at a low speed. When the stroke length is 100%, grab the
outer diameter of the diaphragm and turn it clockwise to assemble the
diaphragm to the slider. Turn it until it is tightly fixed.
2 Since it is a 2-head type, the other diaphragm can be assembled in the same
way.
3 Tighten the pump head-fixing bolt evenly (30kgf.cm), diagonally so that there
is no gap between the pump head and the gear box flange.

-64-
5.2. Handling of Neutralization agent solution
It requires checking and filling the NT with NA before the system run especially de-
ballasting. It is available to be filled additional supplement of NA during operation if
necessary.
(If an uncertified NA solution is used, it may cause performance degradation in the
system)
Do not inhale liquid. Protect your skin and wear safety gears. Ordinary glass or
plastic is sufficient. Keep away from incompatibles such as oxidizing agents, acid,
and alkalis. Keep container tightly closed. Keep container in a cool area.
*Refer the Material Safety Data Sheet (MSDS) for more information.
Purpose To fill the Neutralization Tank.
Frequency Based on the 12 hours de-ballasting operation in normal condition.
Parts and Neutralization agent solution and a hand pump (Spare part for NA).
equipment required One (1) drum: approx. 200 L (256kg)
Procedure 1 Check the NT level before every de-ballasting
2 If the low level alarm (50%) is occurred, NA supplement is required.
3 NA solution to be placed near by the NT.
4 Open the manual valve of NA inlet.
5 Open the NA drum and prepare the hand pump in right position adequately.
6 Transferring NA to the neutralization tank by potable pump.
7 Check the NT level and stop filling.
8 Clean up around the neutralization unit, and close the manual valve of NT.
Validity date of 1 The validity date of product is NOT specified, but it is recommended to check

-65-
product (NA) any external damages of the NA drum monthly.
Purchase of product If additional purchase is required, please contact to HHI Global Network or
1
(NA) bwts@hhi.co.kr before leaving the current port.

-66-
6. Control Cabinet
6.1. Safety instructions
1) Take care when handling stainless steel to prevent contamination with mild steel
materials, dust, shavings and the like as these small particles rust quickly and
discolour the surface of the stainless steel. This can destroy the protective oxide
film and render it liable to pitting corrosion.
2) Ensure that damaged devices must be cut off and disconnected from the power
source.
3) Before effecting any work or repairing on the device, there generally must be
executed a complete disconnection from power supply.
4) High operating voltage, firing impulse and high operating current!
5) Danger of life or severe personal injury through electric shock at improper
application!
6) Be sure the earth is ALWAYS connected. In accordance to the EN50178-
discharge current via the protective earth conductor-one of the measures must be
fulfilled related the EN50178.

-67-
6.2. Description
The Control Cabinet (CC) is an enclosure that contains LOP (Local Operation Panel) and all PLC modules such
as CPU & I/O module. The PLC system is to control all actuators and to communicate with the rectifier. The
following figure shows CC.
Figure 2 Control Cabinet
6.3. Information of IP address of Control system
Table 3 IP address of control system

ITEMS LOP HIMPM5_M HIMPM5_R HISCM3
10.8.1.206 10.8.1.109 10.8.1.110 10.8.1.153
IP address
11.8.1.206 11.8.1.109 11.8.1.110 11.8.1.153
Network Mask 255.255.255.0
Gateway 10.8.1.1 / 11.8.1.1

-68-
7. Motor Control Cabinet
source.
application!
6) Be sure the earth is ALWAYS connected. In accordance to the EN50178-
discharge current via the protective earth conductor-one of the measures must be
fulfilled related the EN50178.

-69-
7.2. Description
The Motor Control Cabinet (MCC) is an enclosure that contains power supply module, several circuit breakers
and magnet contactors for motor on/off control. This panel communicates with the CC (Control Cabinet). The
following figure shows MCC.
Figure 3 Motor Control Cabinet
Set value detecting over current for motor protection is listed in the table below
Table 4 EOCR current set value

SEAWATER FEED
BLOWER NA PUMP FILTER
PUMP
(B-117A/B) (P-132A/B) (F-121A/B)
(P-171A/B)
Rate(kW)
See the electric wiring diagram of “MCC-100”.
Set(kW)
Above set value can be adjusted by using setting dial of EOCR (Electrical Over-Current Relay) as figure below.

-70-
8. Rectifier (RF)
1) DO NOT TOUCH THE POWER SUPPLY CABLE AND ELECTROLYZER

BODY OF THE ELECTROLYZER DURING ENERGIZED.
source.
5) A simple switch-off over the control interface is NOT sufficient, as the control
gear operates the electrolyzer module over semiconductor.
application!
8) Be sure the earth is ALWAYS connected to the power supply. In accordance to
the EN50178-discharge current via the protective earth conductor-one of the
measures must be fulfilled related the EN50178.
8.2. Description

-71-
The rectifier (RF) is an enclosure that contains transform, power switching devices, control board and roof
type cooling unit, which is used to supply power to the electrolyzer module.
The rectifier allows several operation types, local, remote and remote/local mode. The HiBallast system uses
normally remote operation mode of the rectifier by using Ethernet communication.
The rectifier has a protection function such as high voltage, high current, short circuit of output power, high
temperature of device, internal high temperature and so on.
8.3. HiPower
Figure 4 A view of the rectifier (15D)

-72-
8.3.1. Troubleshooting
The warning lamp on the front panel of the rectifier blinks when an error occurs. The error has different
meaning according to lamp flickering interval.
Figure 5 Lamp display on the front panel of the rectifier
“0.5sec interval”: Indicates over current alarm when input/output power of the rectifier goes over higher than
rate power.
“1.0sec interval”: Indicates emergency input when emergency button is inputted.
“Blinking”: Indicates several alarms including over voltage, internal high temperature alarm, SCR high
temperature alarm and unbalancing alarm of output current.
NO BLINKING INTERVAL DESCRIPTION SOLUTION

1 Over current alarm when input/output Check the reason and replace
0.5 sec. power of the rectifier goes over higher fuses.
than rate power.
2 Indicates emergency input when Release emergency button after
1.0 sec.
emergency button is inputted. check the reason.
3 Indicates several alarms including over First check the specific error by
voltage, internal high temperature alarm, communication
Continuously blinking
SCR high temperature alarm and
unbalancing alarm of output current
Over voltage error of output power First check the primary power
voltage. If no problem, be doubt

-73-
NO BLINKING INTERVAL DESCRIPTION SOLUTION

whether the scale on the
electrode of electrolyzer
becomes thick.
Internal high temperature error Check the performance of
- Upper part, > 65℃ cooling unit.
- Low part, >100℃ Check the connection part for
transformer.
SCR high temperature error, >85℃ Check the performance of
cooling unit.
Unbalancing output current - Check the electrolyzer module.
> ±20% + actual current/4 - Check scale on the electrode
- Check the power supply cable
- Check shunts at the output
terminal of rectifier

-74-
8.4. GiPower
Figure 6 A view of the rectifier (100D)

-75-
8.4.1. Troubleshooting
The display on the front panel of the rectifier will shows error codes when an error occurs as below.
Error codes for module No. 1

1 Primary overcurrent error
2 Secondary overcurrent error
3 IGBT radiator temperature error
E1 4 Temperature point error
5 Left fan error
6 Right fan error
7 Fuse short-circuit error

5 Left fan error
6 Right fan error

5 Left fan error
6 Right fan error
Please see rectifier manual for more information

-76-
9. Filter Unit
For more detail information related on maintenance of the filter unit, refer to the chapter 8 in the attached
document, “Operating Instruction”, copyright by HYDAC Process Technology GmbH. Hereafter.
9.1. Maintenance
PARTS MEASURES OR ACTION FREQUENCY
Check gear unit noise for
Geared motor During operation
changes
Check fixing bolts are securely
Geared motor Annually
tightened
At the regular inspection of the
Filter inspection
installation
Back-flushing filter At the regular inspection of the
Visual inspection
Filter elements installation
Cleaning with high-pressure
Possibly after visual inspection
cleaner(water)
Function check
Shut-off valves installation
Replace As required
Function check
Position switch installation
Replace As required
Visual inspection of the internal
Back-flushing filter with At the regular inspection of the
corrosion protection
corrosion protection installation
layer
If corrosion protection layer is
Repair corrosion protection layer As required, as soon as possible
damaged
If corrosion protection layer is
Contact HYDAC Process
irreparably As required, as soon as possible
Technology GmbH
damaged

-77-
9.2. High pressure cleaning for the filter elements
Dismount the filter elements (see section 10.4 “Removing the filter elements”)
Secure the filter elements from outside to inside (see Figure 5)
Warning!
Clean the filter elements from outside to inside (see Figure 5)
Figure 7 Cleaning the filter elements
✓ Start the cleaning of the elements at a distance of the water jet of approximately 1m.
✓ Then slowly reduce the distance to app. 50 cm.
✓ The minimum distance between element and water jet pistol may not be less than 50 cm.
✓ The maximum water temperature should not exceed 60°C.
✓ No cleaning agents that could damage the filter material may be used.
✓ The minimum pressure of the water jet should be 20 bar
✓ The maximum pressure may not exceed 100 bar.

-78-
9.3. Acid cleaning:
In case that high pressure cleaning or ultrasonic cleaning cannot be performed or

show not the required cleaning effect, the filter elements can be cleaned by use
of cleaning agents on the base of acid / leaches with a pH value between 3 to 9 in
order not to damage the SuperFlush coating (if applicable). Sealings have to be
disassembled from the filter elements.
Typical cleaning agents are e.g. citric acid or hydrochloric acid. The kind of cleaning
agent to be used can be defined by the kind of deposit. A sour cleaning is better
suitable for mineral deposits (scaling). Alcaline cleaning agents are more suitable for
organic impurities.
Please make sure that the proper safety precautions are taken, when using
the cleaning agents according to the material safety data sheet. Also ensure that
only trained and instructed personnel is allowed to perform this cleaning -
especially pay attention to the mixing procedure and potential chemical
reactions.
In order to clean the elements, put them in a bath of the chosen cleaning acid and leave
them in for a maximum time of 1h respectively until you see a desired cleaning effect.
After the elements are taken out from the bath, you have to ensure to clean off any
remaining acid from the elements surface by suitable methods. A second high pressure
cleaning could be finally necessary to remove the dispensed dirt from the mesh
material.
Disposal of the cleaning acid is not covered by this manual, but has to be done in
accordance with safety regulations onboard and according to the applicable
regulations.

-79-
Figure 8 Cleaning the filter elements using acid
Always use appropriate protective equipment! Please refer always to

manufacturer’s safety data sheet and application / handle specifications.
Possible cleaning example for alkaline cleaning: (please refer to manufacturers

safety data sheet and application data sheet)
- Manufacturer/Product Type: Kluthe GmbH / Hakupur 445-1
- concentration: depending on contamination level 0,5-5%(ph-value: 8,1-9,1)
Summary: after application of above mentioned alkaline cleaning incl. a dwell time in
the bath of 15min. please thoroughly pressure wash the elements before use.

-80-
9.4. Removing the filter elements

Remove the filter element per the below sequence.
1) Open drain valve to drain inside water

Purpose To remove or exchange the filter element.
Procedure 1 Open drain valve to drain inside water
2 Turn off main switch
3 Untie earth wire on cover plate
4 Remove motor & sensor cable
5 Please hang the chain block and sling belt on the upper plate

-81-
6 Loosen bolts on cover plate.
7 Arrange bolts for prevention of loss
8 Please lift the upper plate using a chain block(up 700mm)
9 Loosen teflon washer(Use 19mm box wrench)
10 Take out the upper element mounting plate

-82-
11 Pull out elements and check rubber sealing
12 Place element on clean space

-83-
Troubleshooting for filter are as following Table.
Table 5 Trouble shooting list for filter
FAULT FAULT SOURCE CAUSE ACTION
Tighten cutting rings.

Pressure gauge
Cutting rings If necessary, replace hoses and
Leakage at the hoses
cutting rings
filter
Leakage at the Seal missing, or damage Replace seal
cover plate or bowl Bolts Tighten bolts
Check whether fuse is fault such as
ON light does a short circuit:
fuses or lamp Defective fuses or lamp
not light up If yes: Replace fuse
If not: Replace lamp
Connect the filter to the power
Filter is not connected to the
- Power supply supply. Follow the circuit diagram
power supply
of the filter.
- Main switch Main switch not on Turn on main switch
Power consumption of geared
No back-
motor too high due to
flushing Check geared motor
-Over heating
although the
-short circuit
differential
-Stop the back-flushing filter
pressure gauge
- Motor protection Flushing arm is blocked by a completely
has exceeded
switch responded foreign body -Open filter
the pre-set limit
-Remove foreign body
Compare setting of the motor
Incorrect setting of motor
protection switch with the data on
protection switch
the type code label of the geared
motor.

-84-
Check all electrical connections:

-geared motor
Connector has worked loose
Loose connector -position switch of cyclic control
or has been disconnected
-position switch for zero position
-drive of back-flushing valve
Geared motor Fault in geared motor See section 9.1
Differential pressure trigger
Excessive has been exceeded.
contamination of The contamination of the Reduce contamination
fluid to be filtered. fluid to be filtered is too high
for the filter type
Differential Check the setting of the differential
Setting of differential
pressure pressure trigger
pressure trigger is too low
trigger If necessary, increase this pressure
Pressure differential between
Pressure differential filtrate outlet and back- -Increase pressure at inlet
filtrate back- flushing line too low, filter -Reduce pressure of back-flushing
flushing line elements are not sufficiently line
cleaned.
Continuous -Stop the back-flushing filter
back-flushing -Remove filter elements
-Clean filter elements with high-
Filter elements are
Filter elements pressure cleaner. If the filter
permanently contaminated
elements cannot be cleaned or are
damaged, replace with new one
-Insert filter elements
Check the setting of the timer and
Timer switched on without
Timer increase it if required, see Section
setting a time
5.1
Only EPT:
-Set up compressed air supply
Shut-off valve does Compressed air supply of the
-Compressed air supply min. 4 bar
not open pneumatic actuator is not
max. 6 bar
connected

-85-
Check whether the solenoid valve

in the flush
position is supplied with power –
LED K1 in the
Only EPT: control box lights up
Solenoid valve is not If yes:
connected to the control unit Check function of the solenoid
valve and replace if necessary
If not:
Check connector and power cable
and replace if necessary
Check whether the shut-off valve in

the flush position is supplied with
power – LED K1 in control box
lights up.
Only EU:
If yes:
Shut-off valve is not
Check function of shut-off valve
connected to the control unit
and replace if necessary
If not:
Check or replace connector and
power cable
Excessive torque of shut-off

valve. -Stop the back-flushing filter
Valve is blocked -Disconnect shut-off valve
Remove foreign housing
Actuator defective Replace actuator
Compare the rotation direction of

Wrong rotation
the geared motor with the direction
direction of geared Incorrect polarity
arrow marked on the motor.
motor
If the direction is wrong, then the

-86-
polarity of the power supply must

be reversed
Leakage at the Leakage at the
Tighten the spindle seal.
shut-off valve spindle seal

-87-
9.6. Fresh water filling
It requires drain sea water and filling fresh water. By filling fresh water, the filter
elements can be protected from sea water corrosion. It’s to be carried out after
ballasting.
(If an uncertified NA solution is used, it may cause performance degradation in the
system)
Do not inhale liquid. Protect your skin and wear safety gears. Ordinary glass or
plastic is sufficient. Keep away from incompatibles such as oxidizing agents, acid,
and alkalis. Keep container tightly closed. Keep container in a cool area.
Purpose To protect the filter elements from sea water corrosion.
Frequency After use.
Parts and Fresh water.

equipment required Required volume : Please see filter drawing.
If fresh water supply line is not installed permanently, fresh water supply line to be
prepared.
Procedure 1 Drain sea water inside of filter by manual drain valve open.
2 Open manual fresh water supply valve.
3 Close fresh water supply valve when the pressure transmitter indicates abt.
1bar.
4 If the pressure of filter is released in few seconds, repeat 2-3.

-88-
10. Flowmeter
10.1. Troubleshooting and Remedies
10.1.1. Response of the measuring system to faults
● Error messages which occur during measurement are always indicated via the current and, depending
on the preset relay function, also via the relay output.
● In addition, a system or process error is always indicated when the red LED flashes.
Table 6 Flowmeter error indicator

RELAY CURRENT
TYPE OF ERROR RED LED
(when set in "limit+error" position) OUTPUT
System Amplifier error
de-energised flashing 2 mA
errors: EEPROM error
Process
Overflow de-energised flashing 2 mA
errors:
10.1.2. Checking the electronics

- The Magphant can be set to a test mode using miniature switch No. 1:
1) Set test mode switch to "test".

2) Turn the full-scale potentiometer anticlockwise until it comes to the mechanical stop, the current output must
now be exactly 20 mA.
3) If this is not the case, then the electronics module must be replaced.

-89-
10.1.3. Replacing the electronics module
Switch off the power supply before unscrewing the cover to the electronics compartment.
Figure 9 Main flow transmitter
10.1.4. Procedure:
1) Switch off the power supply.

2) Unscrew the housing cover.
3) Remove all wires from the terminal block.
4) Undo the Phillips screws of the circuit board plate.
5) Undo the mounting screw of the ground wire (cable socket).
6) Carefully remove the board support plate from the housing.
7) Remove the excitation current cable plug from the power supply board.
8) Remove the electrode signal cable plug from the amplifier board.
9) Remove the old electronics module.
10) Replace with a new electronics module and reassemble in reverse order.

-90-
11. Gas detector
11.1. Sensor Exchange
Catalytic sensor of DA-500 is built as one-body molded structure of sensor cap and sensor filter for the
protection of the sensor. Therefore, the sensor exchanging work should be done by the method of exchanging
sensor, filter and the one-body structure of sensor cap. Sensor exchange should be done according to following
procedure by referring to AMP BOARD.
● Cut the power off the detector.

● Open the cover of detector by turning counter-clockwise.
● Three line Connector connecting the sensor and Sensor Board should be separated.
● Turn counter-clockwise the headless bolt connecting sensor housing and sensor cap, then separate the
sensor cap.
● Remove sensor by losing screw blot and disconnecting cable
● Install new sensor by connecting cable and tighten screw bolt
● Assemble sensor cap and headless bolt.
● Supply the electric power.
● Set-up the sensor though the sensor calibration work.
● After the sensor setting finishes, detecting mode is automatically done.
11.2. Caution
● For sensor exchanging work or separating board, power should be cut firstly.
● After checking the possibility of remaining combustible gas or flammable materials near, and cutting power,
then you can do sensor exchanging.
● If the direction of sensor cable and Sensor Board connector socket is different, they cannot be inserted.
● Sensor cap and detector cover should be tightened in order to maintain the pressure-resistant explosion-
proof structure.
Other H2 gas detectors such as DA-100 and GTD-2000Ex can be installed or

supplied as an alternative. Furthermore, required calibration interval is different
depending on sensor maker. So please see calibration schedule and relevant
manuals included in reference manual for more information

-91-
11.3. Calibration
Gas sensor’s feature is able to be changed little by little in accordance with the environment such as temperature,
humidity and wind, or the lapse of used time by sensing response degree. This feature is common to all sensors,
and the optimum condition of sensor should be maintained though a periodic calibration.
For the optimum condition of gas detector, regular inspections which includes calibration test are needed
according to the recommended schedule. The recommended calibration schedules are as follows:
Gas detector model Recommended calibration Reference

schedule
DA-100 (Primary) every 6 months Ref. manual 116. AIT-1121_DA-100
GTD-2000 EX (Alternate) every 3 months Ref. manual 116. AIT-1121_GTD-2000EX
Standard gas with density range from 10 %LEL to 100 %LEL must be used for span cali
bration. With the high density gas beyond the sensing range, sensor calibration is impossib
le, and with the excessiveness, some damages may happen to the sensor or life span of the senso
r may be extremely shortened.(basic setting = gas density: 50%LEL, measuring range 0 ~ 100%L
EL)
After exchange of a sensor at the site, the SPAN Calibration should be carried out after 1
0 minutes of power approval.
11.3.1. Calibration procedure
Please see CALIBRATION SCHEDULE and manual in reference manual.

-92-
12. TRO sensor
Take care when checking the TRO sensor to be able to cause the electric shock to the
human. Electric shock may happen by the malfunction of the device.
12.1. Overview (non-explosion proof type)
Figure 10 TRO sensor front (left) and bottom (right) view

-93-
Figure 11 TRO sensor overall mounting dimension

-94-
12.2. Overview (explosion proof type)
Lamp
Key cover
By-pass key
Figure 12 Explosion proof type TRO sensor
Table 7 TRO sensor indicator lamp

LAMP COLOR MEANING POWER TO REST OF CLX-EX
All lamps GREEN Safe Operation Power ON
TIMER Lamp RED Instrument Purging Power OFF
PRESSURE lamp RED Unsafe Operation Power OFF
Pressure Low
BYPASS lamp RED Bypass Key Operating Power ON
NO lamps No power out applied No power applied : everything OFF

-95-
Warning: Do not apply power to the Purge Control X-Purge controller unless the area has been
properly tested and is known not to contain explosive materials.
By-Pass Key
Warning: Use of the by-pass key disables the safety features and safe operation of this instruction.
It is imperative that this operation be performed only after the area has been tested and known to
be safe.
Warning: If the by-pass key can be used to test parts of instrument while the door open. Use
caution as power is live inside the enclosure.
Upon turning the key, the indicator will display a FLASHING RED lamp. This is an indication of the
maintenance mode. Power is retained to the instrument. The key cannot be removed in this mode of operation.
After maintenance has been performed the door should be closed and latched. Air pressure will once again
pressurize the enclosure. The maintenance key can now be turned and removed and the key cover replaced. The
purge controller will display a SOLID GREEN lamp indicating a safe operation and power is kept applied to the
instrument.

-96-
Figure 13 CLX-Ex with cover open

-97-
12.3. Routine Maintenance
12.3.1. Reagent tubing set
Check Valve
Cap Assembly "A"
Flow
Tube"B"
Figure 14 Reagent Tubing Set
12.3.2. Replacing or Installing the Reagents
Each indicator reagent will last a maximum of 3 months based on reagent aging when kept in the
operating cooling chamber.
1) Indicator Reagent Preparation
Remove the cap and add the contents of the DPD powder bottle (small brown bottle).
Cap and shake to fully dissolve the powder.
30 seconds

-98-
2) To replace the reagents, press the SERVICE button;
this will empty the cuvette and stop any flow of water.
3) Remove the cap on both bottles replace with the blue cap supplied with the CLX-XT.
Be sure to replace the reagents in the correct location as labeled on the inside of the CLX-XT. The
buffer is installed on the left and the indicator is installed on the right side. The suction tube for both
reagents will reach the bottom of the bottles.
4) press the PRIME button and then the  button.
This will draw enough of each reagent to completely prime
the tubes and replace any old solution.
The system will automatically return to normal operation after it has primed.
Use caution when changing the reagents as they are caustic. These reagents will stain
clothing and anything they contact. After changing the reagents,
operators should wash their hands.
12.3.3. Maintenance Schedule
Flushing the System

It is recommended that the tubings replacements be timed with reagent replacement. Press the
SERVICE button to stop the water flow. Remove old reagents and discard. Place the inlet tubings in a
small container of clean water. Press SERVICE to return to operation mode, press PRIME and then  to
flush the system with water. Remove the inlet tubings from the water Press PRIME and then  to
remove most of the water.
Tubing Replacement
1) Press SERVICE to stop the flow of sample water and drain the cuvette.
2) Remove and retain the thumb screw on top of the pump; pull the pump hammer and spring up and
out of the way.

-99-
3) Replace the pump (black) tubing between optics inlet

and the check valve OUTLET. Discard the old pump tubing.
4) Ensure the check valve is placed into its seat.
5) Replace the hammer and spring back into place and secure with the
thumb screw.
6) Return to operation as described.
Annual Tubing Replacement
Check the condition of cuvette and change if it appears badly soiled or discolored. Follow the steps
below:
1. Replace the two Cap Assemblies.
2. Turn the knurled top on the optics system counterclockwise

(as viewed for the top) until the cuvette just “pops” out,
but do not remove the top.
3. When the cuvette “pops” out, move the retaining o-ring

& remove the cuvette. You may need a stiff wire such as
a bent paper clip to grasp the cuvette.
Retain this cuvette for future use if it can be cleaned.

-100-
4. Install the new cuvette by pushing it firmly in place and turning the knurled top clockwise until the
cuvette is held securely.
5. Check the drawing on the following page to ensure correct installation.
6. Return to operation as described.
Return to Normal Operation

Press the SERVICE button to return sample flow to the system. Check for leaks. If a leak occurs press
SERVICE again, repair leak and try again. Once the system is operating correctly, return or replace
reagents and press PRIME and then  one time to restart reagent flow. The system will automatically
return to normal operation.
Setting Flow Rate
The flow rate on the CLX-XT was factory adjusted and should not need adjustment. Installation
variances may affect the flow. The optimal flow rate through the CLX-XT may be adjusted if needed.
The flow is adjusted by removing regulator vinyl cap and turning the adjustment screw on the pressure
regulator. To assist in this adjustment follow the procedure shown below:
1. Press the SERVICE button.
2. Wait for the display to read HOLd, then press Mode/ Exit.

-101-
3. Display will show FLOW with the number 0.

Press either the  or  button.
4. CLX-XT will drain, and then pulse in water while a count is displayed on the screen.
5. The display will show one of three messages

HI, LO or Good. (6~12 setting)
The flow test determines if the flow rate is suitable for proper operation. Loosen the locking nut then
adjust the pressure regulator using a coin or a large flat blade screwdriver. Press either the  or 
button while in the FLOW routine to display a new flow rate. Please note that only ¼ turn incremental
adjustments should be made to the regulator on each attempt.
If the message is LO, turn the regulator control clockwise. If the message is HI, turn the regulator
counterclockwise. If the message is Good, no adjustment is required. Tighten the locking nut after
adjustment and replace the regulator vinyl cap. To return to normal operation, press the  button.

-102-
T-Strainer Cleaning
A T- strainer is integral to the instrument and must be checked occasionally. When necessary it must be
removed and cleaned.
Steps:
1. Press SERVICE to stop the flow of sample water and drain the cuvette.
2. Ensure the source water is turned off.
3. The T-strainer is clamped to the intake regulator. The removal requires the use of a flat blade
screwdriver as shown in the photo. Once the clamp is opened the T-strainer can be removed.
4. Disconnect the T-strainer and regulator from the tubing and clear of the case.
5. Clean the T-strainer screen and replace.
6. Be certain the clamp is tightened fully and the pumping connections are complete.
7. Turn source water back on.
8. Return to normal operation.
Figure 15 TRO sensor T-strainer

-103-
The purpose if calibration is to ensure that a measuring device is accurate, reliable and consistent. If any
fault occurs, the message is displayed in the bottom row of the LCD as following message.
Table 8 Troubleshooting for TRO sensor

NO MESSAGE DESCRIPTION SOLUTION
1 MA 4-20mA enabled & loop open Check 4-20mA wiring
2 CAL Calibration invalid-not accepted Recalibrate if needed
3 WATR No water flowing Check water flow
4 FAST Intake water flow too fast Set flow rate
5 SLOW Sample cuvette filling too slowly Check water flow
6 PURG Sample cuvette has slow purge Check drain lines
7 NPRG Sample cuvette not purging Check drain lines
8 H2O CLX cannot determine water level Check water flow
9 ISOL Problem with intake solenoid Check wiring, check for clogged solenoid
10 PSOL Problem with purge solenoid Check wiring, check for clogged solenoid
11 RGNT Problem with reagent Check reagent and lines
12 GLAS Dirty cuvette Replace or clean cuvette
13 WCAL Water level calibration invalid Clear fault
14 REPL Reagents expired Replace reagents and press PRIME

-104-
13. Calibration
The purpose of calibration is to ensure that a measuring device is accurate, reliable and consistent. So
Calibration shall be performed by user regularly in order to maintain performance and normal operation
condition of HiBallast system. Instruments intended for calibration are figured out in BWTS CALIBRATION
SCHEUDLE.
Please refer to the documents, 200. BWTS CALIBRATION SCHEDULE, are provided individually.
14. Technical assistance
BWTS technical support can be provided by maker (HHI). Please contact us via below e-mail address.
bwts@hhi.co.kr
sales@hyundai-gs.com
service@hyundai-gs.com
bwts-tech@hyundaiwelding.com
bwts-cs@hyundaiwelcing.com
【 END 】

-105-
Appendix A

-1-
1. Equipment name plates
NO. CLASSIFICATIONS TAG NO.

Electrolyzer
1 Electrolyzer Module E-111
2 Electrolyzer gasket set
Equipment List
Electrolysis unit
1 Blower B-117A
2 Blower B-117B
3 Expension-Joint
4 Venting pipe
5 Drain Assy
6 Drain Tank
7 Drain pump (Magnetic Pump) P-115
8 2way Solenoid Valve(drain pump) XV-1141
9 Filter & Regulator
10 NON-Return Valve
11 Union
12 Male connector
13 Male connector
14 Elbow connector
15 Elbow connector
16 Male connector
17 Elbow connector
18 Male connector
19 Socket
20 Hex Nipple
21 Connector
22 Ball valve MV-1141
23 Cable Gland
24 Bolt Assy (HIB-2000)
25 Gasket Assy (HIB-2000)

-2-
26 Name Plate Assy (HIB-2000)

Seawater feed unit
27 Sea Water Feed Pump P-171A
28 Sea Water Feed Pump P-171B
29 Plate Heat Exchanger HE-173
30 Strainer S-172A
31 Strainer S-172B
Neutralizing Agent unit
32 Neutralizing Agent Tank V-131
33 Neutralizing Agent Injection Pump P-132
34 Neutralizing Agent Injection Pump P-232
35 Y-Strainer S-1321
36 Expension-Joint
37 Expension-Joint
38 Expension-Joint
39 Reduce Union
40 Hex Nipple
41 Male Connector
42 Male Connector
43 Tube
Miscellaneous parts
44 Male Connector
45 Globe valve
46 Y-strainer
47 Back Pressure Valve
Spare parts
48 Sea Water Feed Pump seal set
49 Neutralizing Agent Injection Pump seal set
50 Strainer O-Ring
51 Neutralization Agent Solution
52 Hand Pump
PPE
Valve List

-3-
Electrolysis unit
1 Manual Butterfly valve MV-1181
2 Manual Ball valve DV-1121
4 Control valve (Intermediate butterfly) FCV-1131
8 Swing Check NRV-1111
9 Auto vent Valve AV-1121
10 Auto vent Valve AV-1121
11 On-off valve XV-1171A
12 On-off valve XV-1171B
SPACER
Seawater feed unit
13 Manual Butterfly valve MV-1711A
14 Manual Butterfly valve MV-1711B
22 On-off valve XV-1732
23 On-off valve XV-1731
Neutralizing Agent unit
26 Manual Ball valve MV-1313

-4-

39 Solenoid Valve XV-1321
40 Solenoid Valve XV-2321
46 Back Pressure Valve BPV-3321
System valve
4 On-off Valve BT-3211
Sensor List
Electrolysis Unit
1 Conductivity Transmitter CIT-1111
2 Conductivity Sensor Indicator CIT-1111
3 Level Switch LS-1111
4 Level Switch LS-1141
5 Pressure Indication Transmitter PIT-1121
6 Flow meter FIT-1131
8 Hydrogen gas detector AIT-1121

-5-

13 PT+PG Assy
14 Level Transmitter & Indicator LIT-1311
15 DP sensor DPS-1321
16 DP sensor DPS-2321
Electric part List

TRO sensor
1 TRO Sensor (S) AIT-151
2 TRO Sensor (P) AIT-251
3 TRO Sensor (APT) AIT-351
4 Sampling Box (S) V-153
5 Sampling Box (P) V-253
6 Sampling Box (APT) V-353
Electrical Part
7 MCC PANEL MCC-100

-6-
2. Standard spare parts list
NO Items Code Q’ty Figure(Photo)

1 Gasket for electrolyzer 900-100-001-001 1
2 Electrolyzer power bolt ass’y 900-100-001-002 Lot

or
100-101-002-007
1set per electrolyzer train
3 Seal set complete for filter 900-100-001-003 1
4 Mechanical seal set for SWF 900-100-001-004 1

pump
5 Diaphragm for N.A. pump 900-100-001-005 1
6 Check ball for N.A. pump 900-100-001-006 1
7 Cover seal for strainer 900-100-001-007 1

-7-
8 Reagent kit for TRO sensor 900-100-001-008 1

(1set of TRO Reagent kit / Sensor
will be supplied with TRO sensor
and this will be placed in sensor
box. Buffer and one mixed
indicator will be ready for Indicator: 4EA, DPD Powder: 4EA,
commissioning and delivery) Buffer : 1EA
(1 set of TRO Reagent kit will
be placed in spare box)
9 Tubing/cuvette kit for TRO 900-100-001-009 1
sensor
(1 set/sensor)
10 TRO sensor check valve 900-100-001-010 1

flushing kit
11 Fuse for MCC Panel 900-100-001-011 10
12 Lamp for MCC Panel (Green) 900-100-001-012 3
13 Lamp for MCC Panel (Red) 900-100-001-013 3

-8-
14 Fuse for RECTIFIER (Rapid 900-100-001-014 3

fuse)
15 Fuse for RECTIFIER (Diazed 900-100-001-015 3
fuse)
16 Fuse for RECTIFIER (Glass 900-100-001-016 3
fuse)
17 Lamp for RECTIFIER (Green) 900-100-001-017 4
18 Lamp for RECTIFIER (Red) 900-100-001-018 2
19 Lamp for RECTIFIER (White) 900-100-001-019 2
20 Fuse for Control Cabinet (5A) 900-100-001-020 10
21 Fuse for Control Cabinet (20A) 900-100-001-021 2
22 Lamp(DC) for Control Cabinet 900-100-001-022 5

(Red)
23 Lamp(DC) for Control Cabinet 900-100-001-023 3
(White)
24 Lamp(AC) for Control Cabinet 900-100-001-024 3
(White)
25 H2 CAN gas(50%LEL) 900-100-001-025 1
26 Neutralization Agent 900-100-001-026 Lot
Equivalent quantity to 90% of NA tank

-9-
27 Spare box 900-100-001-027 1

-10-
3. Critical spare parts list
No. Item Serial No. Tag No. Part Name

1 TRO sensor 1 XV-X51X Sol. Valves
2 MV-X51X Manual valve
3 - Check valve set
4 Tubing & cuvette set
5 - TRO reagent
2 Pneumatic valve - Sol. Valves & regulator
3 Rectifier 1 RF-142A/B/C PCB
2 Fan
3 Rapid fuse
4 Fuse
5 Diazed fuse
4 MCC(Motor Control Cabinet) 1 Relay
2 Fuse
5 Gas detector 1 AIT-1121 H2 gas Sensor
2 AIT-1122 H2 gas Sensor
3 AIT-1123 H2 gas Sensor
4 Calibration kit
6 Level switch - LS-1111 Level switch
7 Sea water pump - P-171A/B Mechanical seal & O-ring
8 Filter Backflushing sol. valve
- PT-1211/1212/2211/2212 Pressure transmitter
9 N.A. pump 1 P-132/232 Diaphgram & Ball Ass'y
2 P-132/232 Fuse
10 N.A. Injection sol. Valve 3 XV-X32X Solenoid valve
11 DPS 4 DPS-X32X Differential pressure switch
12 Pressue transmitter - PT-1121 Blower pressure transmitter
13 Control cabinet 1 CC-100 Fuse
2 DI card
3 DO card
4 AI card
5 AO card
6 SCM card
The above list could be different according to vessel’s type and application of HiBallast.

-11-
4. Spare parts for 5 years dry docking (Recommended)
COMPONENT PARTS Q'TY REMARK
Neutralization
Neutralization Agent (N.A.) - As required
Unit
1) Seal set 1/unit
Neutralization
2) Check ball set 1/unit
Injection Pump
3) Diaphragm 1/unit
TRO Sensor
Reagent kit, Tubing kit 1/unit
Unit
1) Gasket set 1/unit
Electrolyzer
2) Power feeder O-ring set 8/unit
Unit
3) Power feeder ass’y set 8/unit
Seawater Feeding 1) Mechanical seal set 1/unit
Pump 2) Bearing set 1/unit
Only for damaged or
Elements -
Filter Unit corroded part
Seal set 1/unit
Pneumatic valves Sol. valve & regulator 1/unit
Pneumatic diaphragm
Diaphragm 1/unit
pumps

-12-
Appendix B

-1-
1. HiBallast functionality monitoring
- Reference : 2013VGP 2.2.3.5.1.2, 2.2.3.5.1.5

- Following specific parameter are required to assess functionality of HiBallast at least once per month.
Filter
TRO for Salinity of Temperature Main ballast TRO for
Rectifier current Rectifier voltage differential
ballasting feed water of feed water water flow deballasting
pressure (DP)
Date
5.5 ~ 10 ppm ≥15 PSU 1) ≥10 ℃ 2) < Max. current < Max. voltage < TRC (m3/h, < 0.5 bar 3) < 0.1 ppm
(DD.MM.YYYY)
(A/B/C/D) (A/B/C/D) Treatment Rated
(㎍/l) (㎍/l)
Capacity, Project
specific)
(Sample) 05.04.2019 Avg. 8 20 15 250/250 120/120 4000 Avg. 0.2 Avg. 0.03

-2-
Filter
TRO for Salinity of Temperature Main ballast TRO for
Rectifier current Rectifier voltage differential
ballasting feed water of feed water water flow deballasting
pressure (DP)
Date
5.5 ~ 10 ppm ≥15 PSU 1) ≥10 ℃ 2) < Max. current < Max. voltage < TRC (m3/h, < 0.5 bar 3) < 0.1 ppm
(DD.MM.YYYY)
(A/B/C/D) (A/B/C/D) Treatment Rated
(㎍/l) (㎍/l)
Capacity, Project
specific)
1) Dedicated sea water tank or salt tank should be used in low salinity area for ballasting.
2) Min. 4℃ with reduced treatment capacity.
3) Filter will start back-flushing when DP is above 0.5 bar

-3-
2. HiBallast Monitoring Equipment Calibration
- Reference : 2013 VGP 2.2.3.5.1.3

- Calibration for gas detector should be conducted every six month.
- See reference manual [116-1 Gas detector calibration manual] for calibration procedure
H2 gas detector for vent pipe H2 gas detector for room H2 gas detector for cofferdam
Date
Remark
(DD.MM.YYYY)
AIT-1121 AIT-1122 AIT-1123
(Sample) 05.04.2019 Done Done Done

-4-
3. HiBallast Biological Organism Monitoring
- Reference : 2013 VGP 2.2.3.5.1.4

- Biological indicator compliance sampling of ballast water must be conducted 2times during first year the system is installed or used for vessel.
- If sample result are below permit limits for two consecutive event, the vessel may reduce monitoring to one time per year after the first year.
- If the vessel exceed a permit limit on any sampling event, must return to monitoring two times per year until two additional results are below permit limits.
Date Contents Result

Remark
(DD.MM.YYYY) (1st or 2nd sampling) (A/N)1)
(Sample) 05.04.2019 1st sampling A
(Sample) 05.10.2019 2nd sampling A
1) A : Accepted, N : Not accepted

-5-
Note
Ballast water discharge from the vessel will be subject to limitations in following table.
Microorganism category Performance standards
Organism, size ≥50 μm <10 living organisms/m3
Organism, 10≤ size <50 μm <10 living organisms/mL
Toxicogenic Vibrio cholera <1 cfu/100 mL
Escherichia coli <250 cfu/100 mL
Intestinal Enterococci <100 cfu/100 mL
To ascertain compliance with above limitations, EPA is establishing the following biological indicator compliance monitoring.
Instrument or Standard
Measurement EPA Method ASTM ISO Other
Analysis Method
Total heterotrophic EPA Method 1103.1 and

Plate counts SM 9215 ASTM D5465 ISO 6222:1999
bacteria 1603
E. coli Selective substrate SM 9223B ASTM D5392 – 93 ISO 9308-1:2000 Colilert®
EPA Method 1106.1 and ASTM D5259 –

Enterococci Selective substrate SM 9230C ISO 7899-2:2000 Enterolert®
1600 92(2006)
For more information, please see 2013 VGP 2.2.3.5

-6-
Appendix C

-1-
Electrolyzer cleaning record book
Cumulative Train No. 1 Train No.2 Train No.3 Train No.4 Train No.5
Date operation Visual Visual Visual Visual Visual
Cleaning Cleaning Cleaning Cleaning Cleaning
time (hrs) inspection inspection inspection inspection inspection
(Sample) 05.04.2019 70hrs Done Done Done Done NA NA NA NA NA NA

-2-

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The Notice of Revised Maintenance Manual for an Electrolyzer

We have continued experiments and tests related to electrolyzers to enhance equipment

[Pic 1] Experiments of Acid Cleaning

1% HCL 3% HCL 1% HCL 3% HCL

[Pic 2] Actual Test

▪ Major Revisions for Cleaning Electrolyzer

[Table 1] Summary of The Updated Items

Concentration of Acid HCL 1% HCL 3% or SAF Acid 10%

≥ 2 hours (HCl 3%)

[Table 2] Acid Cleaning (Only for Reference)

* The scale of these pictures was intentionally generated.

▪ Revised Maintenance Schedule for Electrolyzer

[Table 3] Summary of The Updated Items regarding How to Maintain an Electrolyzer

Components Action Instruction Frequency

 Check power feeders and other parts

Rev. Date Reason for Issue Prepared Checked Approved

REV. NO. DATE CONTENT

1.1. Information for Health & Safety .................................................................................................................................................. 10

1.2. Maintenance alarm ............................................................................................................................................................................. 10

1.3. Safety symbols ...................................................................................................................................................................................... 11

2. Maintenance schedule ............................................................................................................................................................................ 12

2.1. Instruments list and calibration schedule ................................................................................................................................ 21

2.2. Troubleshooting ................................................................................................................................................................................... 21

2.3. Functionality & Biological organism monitoring ................................................................................................................. 21

3. Electrolysis Unit ...................................................................................................................................................................................... 22

3.1. Electrolysis unit drain manual for maintenance.................................................................................................................... 22

3.2. Electrolyzer ............................................................................................................................................................................................. 23

3.2.1. Configuration .............................................................................................................................................................................. 23

3.2.3. Check-up of scale ...................................................................................................................................................................... 38

3.3. Cleaning inside gas separator ....................................................................................................................................................... 47

3.4. Gas separator vent system inspection....................................................................................................................................... 49

3.5. Blower ....................................................................................................................................................................................................... 51

4. Seawater Feed Unit ................................................................................................................................................................................. 53

4.1. Seawater feed pump ......................................................................................................................................................................... 53

4.2. Plate Heat exchanger ........................................................................................................................................................................ 56

4.3. Strainer ..................................................................................................................................................................................................... 60

5. Neutralization Unit ................................................................................................................................................................................. 62

Hyundai Heavy Industries Co., Ltd.

5.1. Neutralization agent injection pump ......................................................................................................................................... 62

5.2. Handling of Neutralization agent solution ............................................................................................................................. 65

6. Control Cabinet ....................................................................................................................................................................................... 67

6.1. Safety instructions ............................................................................................................................................................................... 67

6.2. Description ............................................................................................................................................................................................. 68

6.3. Information of IP address of Control system ......................................................................................................................... 68

7. Motor Control Cabinet ........................................................................................................................................................................... 69

7.1. Safety instructions ............................................................................................................................................................................... 69

7.2. Description ............................................................................................................................................................................................. 70

8. Rectifier (RF) ........................................................................................................................................................................................... 71

8.1. Safety instructions ............................................................................................................................................................................... 71

8.2. Description ............................................................................................................................................................................................. 71

8.3. HiPower .................................................................................................................................................................................................... 72

8.3.1. Troubleshooting ......................................................................................................................................................................... 73

8.4. GiPower .................................................................................................................................................................................................... 75

8.4.1. Troubleshooting ......................................................................................................................................................................... 76

9. Filter Unit .................................................................................................................................................................................................. 77

9.1. Maintenance .......................................................................................................................................................................................... 77

9.2. High pressure cleaning for the filter elements ..................................................................................................................... 78

9.3. Acid cleaning: ....................................................................................................................................................................................... 79

9.4. Removing the filter elements ........................................................................................................................................................ 81

9.5. Troubleshooting ................................................................................................................................................................................... 84

9.6. Fresh water filling ................................................................................................................................................................................ 88

10. Flowmeter ................................................................................................................................................................................................. 89

10.1. Troubleshooting and Remedies .................................................................................................................................................... 89