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2020.07.24
CONFIDENTIAL
CONFIDENTIAL
This document may contain confidential information and is the property of Hyundai Welding Co., Ltd.
No disclosure is permitted without the express written approval by Hyundai Welding Co., Ltd. Only
for the use of Hyundai Welding Co., Ltd own production.
Onboard Test
Crew demonstration
1. Self-introduction
2. HiBallast Description and Introduction
3. HMI Usage and Operation Methods
4. Local Equipment Training
5. Equipment Maintenance
6. Q n A
1. 자기 소개 및 HiBallast 소개
1) Good morning, Nice to meet you all. My name is OOO, a BWTS engineer.
2) Today, we will conduct a safety functional test and operation test of BWTS.
3) Before the test, let me introduce HiBallast System.
4) Our HiBallast System is an indirect electrolysis type of BWTS.
5) Main equipment includes the Filter unit, Electrolysis unit, Neutralization unit,
Seawater feed unit, and TRO sensor unit.
6) During ballasting, marine organisms and sediment larger than 50μm are
filtered by the Auto Back-flushing filter, and the remaining organisms and
sediment are disinfected inside the ballast tank by injecting sodium
hypochlorite. To produce this disinfectant, only 1% of total ballast water
capacity has to be fed to electrolyzer.
7) During deballasting, ballast water by-pass the filter unit, and the ballast water
is neutralized by dosing neutralization agent in order to comply with IMO (0.2
ppm) and USCG (0.1 ppm) regulations.
8) I briefly explained the HiBallast system and will talk about the certification status of
HiBallast .
2. HiBallast 인증 현황
3-1. Test 방법 및 절차 소개
3-2. Test 방법 및 절차 소개
- Operation Test
1) Operation Test will be carried out for about 30 minutes each for Ballasting Operation and
Deballasting Operation.
2) After ballasting start, the time taken for stabilization of the TRO normal range is
approximately 10 minutes. The TRO normal range is from 5.5 ppm to 10 ppm.
3) After deballasting, the time for stabilization of the TRO is also required.
4) TRO stabilization time is also required. The effluent standard is 0.1 ppm for USCG and
0.2 ppm for IMO, which automatically controlled according to mode selection.
5) Stripping utilizes the same principle of deballasting and TRO control, the only different
thing is using an educator instead of ballast pump.
6) That is it for the Onboard Test. Thank you.
De-ballasting USCG/IMO
1. 자기 소개
1) Good Morning, Nice to meet you. I'm OOO, a BWTS engineer in charge
of crew training today.
2) Training takes approximately 4 hours, including 2 hours of HMI
introduction and 2 hours of system care & maintenance training.
3) I will let you know how to use HMI and how to operate it at CCR, and I will
proceed with the system description and maintenance training at Local.
4) The training includes HiBallast System Description, Introduction, Configuration,
HMI instruction, Operation Method, and Description and Maintenance at Local.
2. HiBallast System 및 장비 교육
(HMI P&ID를 보면서)
9) When the operator operates the ballast pump, the Filter in & outlet valve opens and
the ballast water starts to flow through the filter.
10) Filter calculates differential pressure through In & outlet pressure measurement,
and when differential pressure is greater than 0.5 bar, it automatically operates
backflushing. This can also be operated manually by the operator.
11) When hypochloric acid and ballast water are mixed with ballast water, and TRO
sensor measures TRO concentration to verify that sodium hypochlorite is being
properly injected. The method of controlling TRO concentration will be explained in
detail later.
12) Main flow control valve and flow meter are installed at ballast main pipe and are
controlled automatically through related parameters. But operator can adjust flow by
changing FCV position in manual mode, If needed.
13) The operator may adjust the flow rate by changing the FCV to Manual mode, but
auto mode operation is recommended.
14) Next, I will explain about deballasting.
15) In order to neutralize the residual sodium hypochloric acid in the discharge water
during deballasting, inject neutralizer into the main pipe by using N.U pump.
16) The ballast water bypass the filter and discharge outside the vessel. At the same
time, the TRO sensor measures and monitors the TRO concentration.
17) Next, I will tell you about the method of controlling the TRO and the reference
values according to Operation.
2. HiBallast System 및 장비 교육
1) During ballasting operation, Rectifier control the electric current tro maintain the Target
TRO value.
- The titration concentration of TRO is from 5.5 to 10.0 PPM. If this value is lower than the target
value, increases the electric current of the rectifier, and vice versa.
2) During De-ballasting Operation / Stripping Operation, control the amount of injection of
neutralizer to remove residual TRO.
- TRO concentration in discharging water for De-ballasting, it should be satisfied less
than 0.1ppm based on USCG, 0.2ppm on IMO. If the TRO concentration is lower
than the target value, the NU Pump Stroke decreases; if the TRO value is higher
than the Target value, the NU Pump Stroke increases to adjust the injection volume
of the neutralizer.
3) We strongly recommend to perform de-ballasting operation in IMO Mode to
reduce neutralizer consumption in areas other than USA.
4) The target TRO value of the discharging water for each mode is as shown in
the table below.
2. HiBallast System 및 장비 교육
2) Detailed training for each unit will be provided during the system training at Local.
3. HMI 사용 방법 및 Operation 방법
- ID : aconis
- PW : aconis
1) You can check PC information, current login ID, UTC and LOCAL time (click to modify) in
the top menu.
2) (From the left) ALARM, exception ALARM, analog signal trend, network status, tag
search, Logging Data and REPORT downloads, setting up the Low Salinity zone, and the
Operation page buttons are installed on the mimic
3) The 'Page Ack' button allows you to acknowledge all alarms by one click, the 'Sound'
button turns off the sound only, and the 'Ack' button checks the ALARM one by one.
4) The 'E-STOP' button is an emergency stop button, and the 'RESET' button is a button for
reset when PSD or ESD happens. It is recommended that you press the button before
starting Operation.
5) This system can display up to three alarm signs at the bottom of the system, and all
alarms can be checked on page.
1) If you want to extract Report, insert the USB into the main body after Operation and click
the button.
2) Click a date and copy it.
3) Logging also works the same way.
4) It is important to note that the downloaded reports should be checked on another PC and
when using USB, always check the Virus Free before using the USB.
3) Enter the GPS coordinates for the low salinity area you want to register.
- LATITUDE: Enter S location, LONGITUDE: Enter E location,
- RADIUS(Km): If you enter the radius and press the "ADD" and "UPDATE" buttons, the Area
is designated as Low Salinity Area and automatically generates an alarm when the vessel
enters the designated coordinates.
4) For low salinity area ballasting, at least 1% of the total ballast water must be prepared in
the dedicated S.W. Tank.
5) If the salt tank unit is installed as an option, the salt tank must be prepared with sufficient
salt.
(Ex) 4 tonnes of salt is required for HiB-2000.)
6) When operating in the low salinity area, the level of the Dedicated Tank is measured to
protect the BWTS.
7) The interlock alarm for the level is activated when the Tank level in use button in the
BWTS Operating overview is pressed.
5) Make sure that the Operation status light is grey as shown below.
6) If it is red, press the Reset button to make it stand by status.
7) If Status circle becomes grey color, the arrangement is completed.
7) If the Red light does not disappear when you press Reset button, click Red status to find
out why it does not reset and take action.
8) You can start Operation by clicking the Start button in Stand by Status.
10) Start the ballast pump when the below pop-up appears
12) in case of turbine ballast pump, click the P/P OFF button to turn it on when a pop-up
appears
13) After the pump starts, the rest of the sequence will be followed.
14) Check if Operation status has been converted to green color.
15) Press Stop button for Operation Stop.
16) When you want to use ballast pump continuously, Check Sea to Sea mode box on Stop
pop up.
17) Sea to sea mode allows you to stop the BWTS without stopping the ballast pump.
18) After clicking YES, You can view the Sequence page by clicking the flashing lamp.
19) If Ballast pump stop appears in the Warning popup, stop the Ballast pump.
20) If Turbine Ballast Pump, click P/P ON button to make it turn it off.
21) Verify that the status light has been converted to grey color.
30) After the pump starts, the rest of the sequence will be followed.
31) Check if Operation status has been converted to green color.
32) The deballasting stop is carried out in the same way as the ballasting stop.
2) In case of Filters, if Manual Back Flushing is required, it can be operated by clicking the
'Filter' button and then clicking Back-Flushing button.
3) Let me tell you how to operate FCV Manual.
- Click MANUAL > Enter SET VALUE > Enter key > Click CMD for OPEN/CLOSE.
4) Let me tell you how to operate the P-132/232 neutralization pump in Manual
- Click MANUAL > Enter SET VALUE > Enter key > Click CMD > Click RUN.
5) Let me tell you how to operate the RF-142A/B/C/D Rectifier in Manual.
- Click MANUAL > Enter CMD VALUE > Enter key > Click CMD > Click RUN button to
operate.
※ The rectifier can only be operated when the following conditions are met. When LS-1111
electrolyte level switch is ON and FIT-1131/2131 EU injection flow must be maintained at least
30%.
6) So far, we have explained how to operate BWTS on HMI, and if you have any questions,
please ask us.
7) Next, I will explain about system introduction and maintenance in local.
4. Local 장비 및 Maintenance 교육
1) The S.W.F.U. pulls up the seawater and injects it into electrolyzers. There are two intake
points, one in S.C., and the other in a dedicated S.W. Tank. Seawater is taken from S.C.
in the seawater region, and the seawater in dedicated S.W. Tank can be used when the
vessel is passing the low salinity area. There is a manual valve on each water intake line,
so you can put the valve line up according to the purpose.
2) Each component in the SWFU is Seawater Pump, Strainer, On/Off values, and Heat
Exchanger.
3) Seawater Pump supplies seawater to electrolyzers, removes foreign substances with a
strainer, and checks the In & Outlet pressure of the strainer with the Pressure Transmitter
to measure differential pressure.
4) The Heat Exchanger opens the inlet valve to maintain the temperature of the seawater
supplied to the electrolyzer above 10 °C if the seawater supplied to the electrolyzer is
below 10 °C.
5) The XV-1731 valve is normally open when the sea temperature is above 10 °C, and the
XV-1732 valve, as previously described, is open when the sea temperature is below
10 °C.
1) The Seawater Feed Pump consists of two, and only one pump is operated during
operation, and the another one exists as Redundancy. The pump can be selected
and used as required.
2) During ballasting, the alarm is triggered at DP 0.7 bar of the strainer, and the
strainer needs to be cleaned.
FU (Filter Unit)
1) The Filter Unit removes microorganisms and foreign substances that are greater than 50
㎛ in the ballast water.
2) The Filter Unit includes PT Sensors, Back-Flushing Motor & Valve, F.W Supply, and
Drain Valve.
3) The PT Sensors are installed in Inlet and Outlet.
4) Back-flushing is automatically performed when the differential pressure of the PT Inlet &
Outlet sensor is 0.5 bar or higher, and foreign substances are discharged into the
Overboard.
5) The F.W Supply / Drain valve is the valve used for Maintenance after Operation.
FU (Filter Unit)
1) Regarding Maintenance, the inside of the filter shall be drained and filled with fresh water
to prevent corrosion of the filter element after ballasting.
2) If back-flushing occurs frequently in normal conditions during ballasting operation, the
element condition shall be checked after completion of operation, the element cleaning
shall be performed, and the filter shall be opened and cleaned once every six months
according to the Maintenance Manual.
TRO sensor
1) The TRO sensor is an instrument that measures residual hypochlorite in ballast water.
2) TRO sensors have explosion proof type and non-explosion type.
(If explosion proof type is installed)
I will explain the instructions for explosion proof type TRO sensor. The purge controller is installed to
maintain the explosion-proof condition inside the TRO sensor and to maintain the inside the TRO sensor
housing at constant pressure. Therefore, the supplied air must be supplied with the driven control air. Also,
the TRO sensor is installed in the explosion proof area and interlocked with Ventilation Fan signal, so please
note that the power supply to the TRO sensor is cut off when the Ventilation Fan is turned off. (if it is installed
inside the Pump R/M, Pump R/M Fan, if it is installed inside the Filter R/M, Filter R/M Fan)
(If non-explosion proof type is installed)
I will explain the instructions for non-explosion proof type TRO sensor.
3) The TRO sensor consists of a PCB, an Optic sensor, a Filter regulator, a Reagent Pump,
Tubing lines and a cooling chamber.
4) The OPTIC SENSOR is used to measure the TRO PPM in the Sampling Water using
light emitted from the sensor.
5) The Regulator can adjust the flow rate of the Sampling Water required for TRO
measurement, and the Reagent Pump supplies a certain amount of reagents into the
cuvette, and the Cooling chamber maintains the DPD solution below 25 degrees.
6) Reagent consists of Buffer solution, DPD powder, and DPD indicator. Buffer solution
must be replaced every year, and DPD solution is a mixture of powder and indicator, and
this must be replaced every three months.
TRO sensor
1) Regarding the maintenance of TRO sensor, as I mentioned earlier, the buffer solution
has a replacement cycle of one year and the DPD solution is three months.
2) When replacing Reagent, the tubing line must be cleaned and primed after replacement.
Please note that the TRO value may be Hunting if there is air bubbles inside the tubing.
3) The regulator strainer and Cuvette must be cleaned every month and the tubing line and
check valve must be replaced every year.
4) Blockage may occur if the check valve and reagent tube line are not used for a long
period of time, so you need to prime and check the supply of reagent and buffer. If it is
not supplied, remove the solids inside check valve and tube line with distilled water by
using a syringe or clean them with warm water.
5) If you do not use BWTS for a long time, it is recommended that you refrigerate it
separately to prevent reagent deterioration.
6) For adjustment of the sampling flow rate , it is necessary to ensure that sufficient
sampling water is located inside Cuvette and that the drain is working well during BWTS
operation.
1) In order to remove residual TRO during deballasting, inject neutralizer into the main
ballast line.
2) The LIT sensor is a Level Indication & Transmitter. You can check the level of the tank
with this sensor.
3) Low level alarm occurs when N.U. Tank level is less than 50%, and PSD occurs when it
is more than 15%. It is recommended to fill the N.U. Tank at least 90% before operating
Deballasting.
4) N.U Pump adjusts the Stroke according to the TRO PPM in order to adjust the amount of
neutralizer injection.
EU (Electrolysis Unit)
1) The seawater supplied by SWFU is electrolyzed and produced hypochlorous acid, and
this acid injected into the main ballast line. The components in the electrolysis unit are
Electrolyzer, Gas separator, CIT Sensor, Blower, PT Sensor, FCV, FIT, and Dilution Air
Unit.
2) Sea water is supplied by the sea water feed pump.
3) The seawater entering the E.U goes through the CIT Sensor and Temperature Sensor to
measure salinity and temperature.
4) When seawater with proper salinity and temperature comes in, electrolysis occurs in the
electrolyzer.
5) Hypochlorous acid and hydrogen gas produced during electrolysis are separated from
the separator.
6) Discharge the separated hydrogen gas by using the Blower .
7) The Pressure Transmitter that located on the side of the Blower measures the pressure
and check the normal operation of the Blower.
8) In situations like Black out where it is not possible to use the blower, use the dilution air
to release hydrogen gas.
9) Hypochlorous acid produced by electrolysis regulates the amount of injection with FCV.
EU (Electrolysis Unit)
1) The Electrolysis unit is an equipment that generates hypochloric acid by using current
supplied from the Rectifier and must always be careful because there are high voltage
and current flow around the Electrolyzer during operation.
2) Scale builds up inside the electrolyzer during electrolysis, and according to the
Maintenance Manual, the scale must be checked every 1 month and Acid Cleaning must
be performed after every 3 months or 60 hours of operation.
3) There are 2 methods for using Acid Cleaning, one is by using Chemical Pump and the
another one is using Chemical with Cell Module. Please refer to Maintenance Book for
details.
5. 장비 유지 보수
1) Please be familiar with the following terms before seeing the Maintenance Chart Period
table.
2) D : Daily, W : Weekly, M : Monthly, Y : Yearly, BO : Before operation, AO : After
operation, AR : As required, PIC : Person in charge
3) It is divided into the period above and maintenance is required within that period.
※ Areas with severe pollution such as China (Shanghai, Zhoushan) are exceptional, and the
cycle may be pulled.
Electrolysis Unit
Electrolysis Unit
Neutralization Unit
Filter Unit