ROUTINE CHECKS OF BASIC BWTS
COMPONENTS
ERMA FIRST ESK Engineering Solutions S.A.
Schisto Industrial Park (VIPAS), Block 13
Keratsiniou – Skaramagas Ave., 188 63
Perama, Greece
Tel: (+30) 210 40 93 000 / Fax: (+30) 210 46 17 423
service@ermafirst.com
Copyright Notice
All information contained in this document, are provided for use by ERMA FIRST ESK Engineering Solutions S.A.
personnel and owners.
You are respectfully reminded that none of the following may be directly or indirectly released, reproduced,
modified or used in anyway without the explicit permission of ERMA FIRST S.A., neither can it be used for the
reproduction of the BWT System or any of its components.
All specifications included in this document are nominal and may change as design improvements occur.
ERMA FIRST ESK Engineering Solutions S.A. shall not be responsible or liable for damages resulting from
misapplication or misuse of its products.
ERMA FIRST ESK Engineering Solutions S.A.
Schisto Industrial Park (VIPAS), Block 13
Keratsiniou - Skaramagas Ave., 188 63, Perama, Greece
Tel.: (+30) 210 40 93 000
service@ermafirst.com
Table of Contents
1 SCOPE ........................................................................................................................................................ 2
2 BWTS START-UP PROCEDURES ................................................................................................................... 3
2.1 BALLAST MODE ....................................................................................................................................... 3
2.1.1 Start Up Procedure .................................................................................................................... 3
2.2 DEBALLAST MODE ................................................................................................................................... 4
2.2.1 Start Up Procedure .................................................................................................................... 4
3 HF SCIENTIFIC TRO .................................................................................................................................... 5
3.1 T-STRAINER SCREEN CLEANING ................................................................................................................. 5
3.2 COOLING CHAMBER ............................................................................................................................... 6
3.3 PURGE LINE ............................................................................................................................................ 7
4 HALOGEN TRO ........................................................................................................................................... 8
5 VALVES ....................................................................................................................................................... 8
6 TRANSFORMER RECTIFIER (T/R) ................................................................................................................. 9
7 NEUTRALIZING AGENT TANK (NAT) ........................................................................................................ 10
8 MODBUS COMMUNICATION ................................................................................................................. 12
8.1 SCHNEIDER PLC ................................................................................................................................... 12
8.2 MITSUBISHI PLC .................................................................................................................................... 13
9 BWTS CHEMICALS.................................................................................................................................... 15
9.1 REAGENTS ............................................................................................................................................ 15
9.2 NEUTRALIZING AGENT (BISULFITE) ............................................................................................................. 15
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1 Scope
The purpose of this document is to provide guidelines for routine checks, which should be carried out on bi-
weekly basis, to maximize BWTS performance and availability periods.
This document does not substitute the maintenance actions and routine checks described in the system’s
manuals and the issued Service Bulletins.
• Revision History
Revision No Date Comments Author
00 10 July 2024 Initial release
Chapters 2 and 9 were added MSC Technical
01 26 July 2024
General improvements Support Team
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2 BWTS Start-up procedures
Prior to any operation that involves the BWTS, user will need to perform the following checks:
1) Check that the involved valves that are not controlled by the BWTS, are set in proper position to ensure
the water flow in piping.
2) Electrical power is supplied to all involved components. Circuit breakers are not tripped, and power
switches are in ON position.
3) Air connections are correct, and air supply is available for all equipment.
2.1 Ballast mode
Before proceeding with ballast operation, and further to the generic checks described above user must ensure
that:
• Electrolytic cells’ valves (or spectacle flanges) are in open position.
• Filter operation switch is set to “AUTO” (when applicable) position to engage the automatic flushing.
• Filter starter panel should be powered ON.
• Ballast pump’s discharge valve is closed or slightly open2.
• Ensure that the Condition Switch is set in “NORMAL” condition.
• Cooling Fresh water supply to Transformer Rectifiers is uninterrupted. If a dedicated pump is used,
make sure it is in operation and that the Fresh cooling water pump starter panel is powered on and set
to “AUTO”
2.1.1 Start Up Procedure
1. User must set the proper valve arrangement as indicated in the PID and 6.4 Valve arrangement. There is
a time limit of 10 minutes within which user must complete the valve arrangement.
2. Select the required Ballast operation on the Control Panel or the Repeater panel as described in 5.2
User Interface SCP.
3. Following the selection of the operation, if the valve arrangement is set correctly and there is no critical
alarm activated, the system will automatically set the inlet and outlet valves in start-up position and all
involved components in working status.
4. If a critical alarm is activated follow the instructions for reset and acknowledgement as indicated in
chapter 7 Alarms
5. Start up the ballast pump(s) as required for the selected operation.
6. Gradually open the discharge valve of the ballast pump(s)2 to ensure the water is introduced slowly into
the BWTS.
7. System is operating
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2.2 Deballast mode
Before proceeding with de-ballast operation, and further to the generic checks described
previously user must ensure that:
• There is sufficient quantity of neutralizing agent in NAT, adequate for at least one full deballast. If not,
proceed to refilling of NAT and preparation of neutralizing agent.
• Ballast pump’s discharge valve is closed or slightly open
• Ensure that the Condition Switch is set in “NORMAL” condition.
2.2.1 Start Up Procedure
1. User must set the proper valve arrangement as indicated in the PID and 6.4 Valve arrangement. There is
a time limit of 10 minutes within which user must complete the valve arrangement.
2. Select the required de-ballast operation on the Control Panel or the Repeater panel as described in
Section 5.2User Interface SCP.
3. Following the selection of the operation, if the valve arrangement is set correctly and there is no critical
alarm activated, the system will automatically set all involved components in working status.
4. If a critical alarm is activated follow the required actions for rectification and resetting.
5. Start up the ballast pump(s) or eductor required for the selected operation.
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3 HF Scientific TRO
3.1 T-Strainer screen cleaning
1. Press SERVICE to stop the flow of sample water and drain the cuvette
2. Ensure the source water is turned off.
3. Remove Screen Case and clean T-strainer screen.
4. Inspect Screen Case for signs of cracks.
5. After installing the clean screen, turn source water back on.
6. Return to normal operation and Check for any leaks.
Figure 1 - T-Strainer screen with heavy dirt
CAUTION: Do not use tools to tighten the cap. Make sure that it is only hand tighten and no excessive force
is applied.
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3.2 Cooling chamber
Remove the indicator bottle and check with an IR thermometer the temperature in the interior of the cooling
chamber (Chamber should be maintained between 20-25˚C).
Figure 2 - Cooling Chamber
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3.3 Purge line
Check for signs of dirt or cloggage in the purge line of the cuvette and, if necessary, remove and clean it.
Figure 3 - Purge line
ii. Electrical and electronic components
Visually check all electrical/ electronic cards for watermarks, presence of salt formation or any other
abnormal sign that requires attention.
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4 Halogen TRO
During ballast operation open the installed manual valve of the chamber and verify proper flow through the
sensor.
Figure 4 - Manual valve
5 Valves
i. Manual operate using their positioner (applicable in valves V1-02, V1-03 and V6-01) or the solenoid
valve (applicable in valves V1-01 and V5-01) the BWTS valves and verify smooth operation and identical
status indication in positioner’s display screen, actuator’s mechanical indicator and HMI panel.
Manual operation:
a. Positioner: Press the “HAND” button and then use the “+” and “-“buttons in order to operate the
valve.
Figure 5 - Positioner's buttons
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b. Actuators: Use a screwdriver and set the solenoid to position “1”.
Figure 6 – Solenoid
CAUTION: After completing the operation, set the solenoid to position “0”
ii. Ensure that the supplied air is oil/ water free and manually drain the BWTS air manifold prior to any
operation of the pneumatic components.
6 Transformer Rectifier (T/R)
Check the cooling water inlet temperature (<40 ◦C) and pressure (2-5 bar), during ballast mode.
Figure 7 - TR cooling system
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7 Neutralizing Agent Tank (NAT)
i. Check impeller’s integrity.
ii. Ensure that the tank is clean and there are no solid particles/foreign objects.
iii. Ensure that the neutralizing liquid has a yellowish clear color (replace the liquid every 6 months
after having thoroughly cleaned the tank).
Figure 8 – NAT
iv. Manually operate the mixing device for at least 10 minutes via the respective panel (verify that the
motor’s thermal relay is set to 0,6 A).
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Figure 9 - Mixer motor
v. Ensure that there are not alarm/ warning indications in the display screen of the Dosing Pump (DP)
and verify that the pump is in Standby state.
Figure 10 - Dosing Pump's States
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8 Modbus Communication
i. Ensure that communication of the BWTS components is established at all times.
Figure 11 - IO Scanner Status in the HMI panel
i. In case where the communication is lost, the below instructions should be followed
depending on the type of PLC installed in the control panel:
8.1 Schneider PLC
1. Perform PLC reset:
• Set the PLC to STOP
• Wait 1 minute
• Set the PLC to RUN
Figure 12 - SCHNEIDER PLC
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2. Perform “IO SCAN RESET”:
Figure 13 –IO SCAN RESET
8.2 Mitsubishi PLC
1. Perform PLC reset:
• Perform PLC reset as per bellow:
1.Turn the PLC to 'stop'
2.Turn the PLC to 'reset' and hold for 3 seconds
3.Turn the PLC to 'stop'
4. Turn the PLC back to 'run’
Figure 14 - MITSUBISHI PLC
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2. Perform 'IO SCANNER RESET':
• Press the “hand” symbol
• In the pop-up window that will show up press “IO SCAN RESET”
Figure 15 – Hand symbol
Figure 16 - IO SCAN RESET
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9 BWTS Chemicals
9.1 Reagents
Verify that there are enough non-expired reagents at all TRO units on weekly basis.
Lifespan after removing the cap:
a. 12 months for the Total Chlorine Buffer (large bottle)
b. 3 months for the Total Chlorine indicator (small bottle – set with DPD powder).
Ensure that there is always at least one spare annual kit available on board (consists of 1 Buffer and 4
Indicator-DPD sets).
Figure 17 - Reagents
9.2 Neutralizing agent (bisulfite)
Inspect any new supply of bisulfite and onboard stock, for confirmation of the following information that should
be available on each sack:
• Expiration date
• CAS number
For bisulfite in powder form (most common), CAS number is 7681-57-4
For bisulfite in liquid form (already mixed with water – cannisters), CAS number is 7631-90-5
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