1

Washington State Dept. of Fish and Wildlife

Application Package

Ballast Water Treatment System

Severn Trent DeNora

1110 Industrial Blvd.

Sugar Land, Texas 77478

281-240-6770

www.severntrentdenora.com

sales@severntrentdenora.com

CONTACT: 

Rudy Matousek

Technology Manager

281-274-8493

rmatousek@severntrentservices.com

NAME:

BalPureTM– Chemical classification as sodium hypochlorite

MODEL:

BP-1000

AVAILABLE DATE:

Nov 1, 2005

SUBMITTED:

August 8, 2005
2

Table of Contents

SECTION I: Vendor Letter of Intent

SECTION II: Vessel Owner Letter of Intent

SECTION III: Resume of Principal Investigator

SECTION IV: Shore Based System (not applicable)

SECTION V: System Description

+ General Background

+ Chemistry

+ Operating Environments and Conditions

+ Operating and Maintenance Manual

+ Installation

+ Equipment and Operation

+ Maintenance and Consumables

+ Costs

SECTION VI: Discharge Validation

SECTION VII: Land Based Experiments

SECTION VIII: Performance Capabilities

SECTION IX: Shipboard Test Plan

SECTION X: Ancillary Documentation

+ Operating Manual

+ Nautilus Toxicity Report

+ September U of W Report

+ October U of W Report

+ December U of W Report

+ EJR Technology – Literature Review

+ ISO 2001 Certificate
3

SECTION I Vendor Letter of Intent

See next page
4

Memorandum

Date: August 8, 2005

To: Scott Smith

From: Rudy Matousek

Subject: Application for Approval to Conduct 

 Shipboard Testing of the BalPure BWT 

 System in Washington State Waters

STSDN 

1110 Industrial Blvd.

Sugar Land, TX 77478

Tel 281 240 6770

Fax 281 240 6762

Dear Mr. Smith,

Severn Trent DeNora wishes to conduct shipboard testing of its BalPureTM

Ballast Water Treatment System on a Marine Transport Corporation vessel. The 

chosen vessel ballasts and de-ballasts in Washington State waters. This letter 

serves as a request for approval to conduct such ballast water tests. Also 

enclosed is the accompanying documentation required by the State of 

Washington as part of the review and approval process. The document list is 

identified in the table of contents of this submittal titled “Washington State Dept. 

of Fish and Wildlife Application Package Ballast Water Treatment System”.

Severn Trent DeNora understands and agrees to the terms and conditions set 

forth by Washington Department of Fish and Wildlife for this approval process.
5

SECTION II Vessel Owner Letter of Intent

See next page.
6
7

SECTION III Principal Investigator

See next five pages.
8

RESUME

NAME: Russell P. Herwig

TITLE: Research Associate Professor and Marine Ballast Water Specialist

DEPARTMENT: School of Aquatic and Fishery Sciences and Washington Sea Grant 

Program

INSTITUTION: University of Washington

DAY TELEPHONE: 206 685-2163 FAX: 206 685-7471

E-MAIL: herwig@u.washington.edu

EDUCATION

Ph.D. University of Washington, Seattle, Washington (Fisheries, concentration in 

Marine Microbiology). Chairperson: Dr. John Liston. Dissertation: Ecology and 

Properties of Marine Bdellovibrios. 1989.

M.A. College of William & Mary, Williamsburg, Virginia (Marine Sciences). 

Chairperson: Dr. Howard I. Kator. Thesis: Bacterial Response to Crude Oil Spillage 

in a Salt Marsh. 1978.

B.S. Muhlenberg College, Allentown, Pennsylvania (Honors in Biology). 1974.

HONORS AND AWARDS

College of Ocean and Fishery Sciences, University of Washington – Award for 

Outstanding Undergraduate Teaching, 1999

Navy-ASEE Summer Faculty Research Program, Summer Faculty Research 

Associateship, 1994

J.V. Shankweiler Award, for outstanding graduating Biology student, Muhlenberg 

College, 1974

East Coast Athletic Conference Merit (Scholar-Athlete) Award, Muhlenberg College, 

1974

Graduated with Honors in Biology, cum laude, Muhlenberg College, 1974

POSITIONS HELD (1991 to present)

Marine Water Ballast Specialist, Marine Advisory Service, Washington Sea Grant. 2002 

- present

Research Associate Professor, School of Aquatic and Fishery Sciences, University of 

Washington. 1998- present

Adjunct Research Associate Professor, Department of Microbiology, University of 

Washington. 1998-present.

Adjunct Research Assistant Professor, Department of Microbiology, University of 

Washington. 1996-1998.

Research Assistant Professor, School of Fisheries, University of Washington. 1995-1998.

Research Assistant Professor, Department of Microbiology, University of Washington. 

1991-1995

PROFESSIONAL MEMBERSHIPS

American Society for Microbiology, International Society for Microbial Ecology, American Association 

for the Advancement of Science

PROFESSIONAL AND OUTSIDE SERVICES

Editorial Board, Journal of Food Protection, 1/1998 - present
9

Graduate Fellowship Review Panel: EPA Terrestrial Ecology and Ecosystems, 2000, 2001; EPA 

Microbiology, 2005

Grant Proposal Review Panel: EPA Exploratory Research in Environmental Biology, 

1998

Ad Hoc Journal Reviewer: Aquaculture, Applied and Environmental Microbiology, 

Organic Geochemistry, Water Environment Research, International Journal of 

Systematic and Evolutionary Microbiology

Ad Hoc Grant Proposal Reviewer: University of Washington Royalty Research Fund, 

Washington Sea Grant, Maryland Sea Grant, Michigan Sea Grant, Oregon Sea Grant, 

Illinois/Indiana Sea Grant Program, National Science Foundation, Cooperative 

Institute for Coastal and Estuarine Environmental Technology

SELECTED PUBLICATIONS

Estes, R.M., C.S. Friedman, R.A. Elston, and R.P. Herwig. 2004. Pathogenicity testing 

of shellfish hatchery bacterial isolates on Pacific oyster Crassostrea gigas larvae. 

Dis. Aquat. Organisms 58:223-230.

Lee, S.B., S.E. Strand, H.D. Stensel, and R.P. Herwig. 2004. Pseudonocardia 

chloroethenivorans sp. nov., a chloroethene-degrading actinomycete. Int. J. Syst. 

Evol. Microbiol. 54:131-139.

Dong, F.M. A.R. Cook, and R.P. Herwig. 2003. High hydrostatic pressure treatment of 

finfish to inactivate Anisakis sp. J. Food Prot. 66: 1924-1926.

Herwig, R.P. 2002. Role of bacteria in the nutrition of bivalve molluscs: intriguing 

results and research possibilities, p. 31-60. In C.-S. Lee and P. O'Bryen (ed.), 

Microbial Approaches to Aquatic Nutrition within Environmentally Sound 

Aquaculture Production Systems. The World Aquaculture Soc.: Baton Rouge, 

Louisiana.

Sun, T, G.M. Pigott, and R.P. Herwig. 2002. Lipase-assisted concentration of n-3 

polyunsaturated fatty acids from the viscera of farmed Atlantic salmon (Salmo salar

L.) viscera. J. Food Sci. 67: 130-136.

Herwig, R.P. 2000. Pathogens transmitted by seafoods, p. 109-182. Y.H. Hui, D. Kitts, 

and P.S. Standfield (ed.), Foodborne Disease Handbook: volume 4, Seafood and 

Environmental Toxins. Marcel Dekker: New York.

Shaw, T.R., R.P. Herwig, and J. Wakeman. 1999. Microbial degradation of intertidal creosoteWyckoff/Eagle Harbor Superfund Site, p. 315-319. Bioremediation technologies for polycyclic 

aromatic hydrocarbon compounds: proceedings from the Fifth International In Situ and On-Site 

Bioremediation Symposium, San Diego, April 19-22, 1999.

Rockne, K.J., H.D. Stensel, R.P. Herwig, and S.E. Strand. 1998. Cometabolic 

enhancement of PAH degradation by marine methanotrophic enrichment cultures. 

Bioremediation J. 1: 209-222.

Herwig, R.P., and J.P. Gray. 1997. Microbial response to antibacterial treatment in 

marine microcosms. Aquaculture 152: 139-154.

Herwig, R.P., J.P. Gray, and D.P. Weston. 1997. Antibacterial resistant bacteria in 

surficial sediments near salmon net-cage farms in Puget Sound, Washington. 

Aquaculture 149: 263-283.

Ederer, M.M., R.L. Crawford, R.P. Herwig, and C.S. Orser. 1997. PCP degradation is 

mediated by closely related species of the genus Sphingomonas. Molecular Ecology 

6: 39-49.
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Gray, J.P., and R.P. Herwig. 1996. Phylogenetic analysis of the bacterial communities in 

marine sediments. Appl. Environ. Microbiol. 62:4049-4059.

Geiselbrecht, A.D., R.P. Herwig, J.W. Deming, and J.T. Staley. 1996. Enumeration and 

phylogenetic analysis of polycyclic aromatic hydrocarbon-degrading marine bacteria 

from Puget Sound sediments. Appl. Environ. Microbiol. 62: 3344-3349.

Dyksterhouse, S.E., J.P. Gray, R.P. Herwig, J.C. Lara, and J.T. Staley. 1995. 

Cycloclasticus pugetii, gen. nov., sp. nov., an aromatic hydrocarbon-degrading 

bacterium from marine sediments. Int. J. System. Bacteriol. 45: 116-123.

RECENT MEETING PRESENTATIONS

Lawrence, D., and R.P. Herwig. March 2005. Enumerating phytoplankton abundance in 

ballast water treatment experiments. 2005 Puget Sound Georgia Basin Research 

Conference. (Seattle, WA).

Perrins, J., and R.P. Herwig. March 2005. Analysis of ozone and chlorine disinfectant 

by-products concerning ballast water treatment. 2005 Puget Sound Georgia Basin 

Research Conference. (Seattle, WA).

Nielsen, B., and R.P. Herwig. March 2005. Efficacy of an on-site filtration and 

chlorination ballast water treatment system. 2005 Puget Sound Georgia Basin 

Research Conference. (Seattle, WA).

Herwig, R.P., and J.R. Cordell. March 2005. Defending Our Shores: Ballast Water 

Treatment Technologies. 2005 Puget Sound Georgia Basin Research Conference. 

(Seattle, WA).

Herwig , R.P., J.C. Perrins, J.R. Cordell, N.C. Ferm, P.A. Dinnel, G.M. Ruiz, R.W. 

Gensemer, W. J. Cooper. November 2004. Shipboard testing of a prototype ballast 

water treatment system: experiments on the West Coast with ozone. Fourth SETAC 

World Congress. Society for Environmental Toxicology and Chemistry (SETAC). 

(Portland, OR).

Herwig , R.P., J.R. Cordell, J.C. Perrins, N.C. Ferm, J.L. Grocock, E.R. Blatchley III. 

November 2004. Mesocosm experiments for evaluating potential ballast water 

treatment systems. Fourth SETAC World Congress. Society for Environmental 

Toxicology and Chemistry (SETAC). (Portland, OR).

Cordell , J.R., N.C. Ferm, J.L. Grocock, J.C. Perrins, R.P. Herwig. November 2004. 

Examination of mesozooplankton present in ballast water of ships entering Puget 

Sound, Washington. Fourth SETAC World Congress. Society for Environmental 

Toxicology and Chemistry (SETAC). (Portland, OR).

Perrins , J.C., R.P. Herwig. November 2004. Flow cytometry versus other methods for 

enumerating microorganisms present in ballast water. Fourth SETAC World 

Congress. Society for Environmental Toxicology and Chemistry (SETAC). 

(Portland, OR).
11

RESUME

NAME: Jeffery R. Cordell

TITLE: Principal Research Scientist

DEPARTMENT: School of Aquatic and Fishery Sciences

INSTITUTION: University of Washington

DAY TELEPHONE: 206 543-7532 FAX: 206 685-7471

E-MAIL: jcordell@u.washington.edu

EDUCATION

M.S. University of Washington, Seattle, Washington (Fisheries). Chairperson: Dr. 

David Armstrong. Thesis: Structure and Dynamics of an Epibenthic Harpacticoid 

Assemblage and the Role of Predation by Juvenile Salmon. 1986.

B.S. Huxley College of Environmental Studies, Bellingham, WA. 1976.

POSITIONS HELD

Fisheries Biologist, School of Fisheries, University of Washington, 1977-2002

Principal Research Scientist, School of Aquatic and Fishery Sciences, University of 

Washington, 2002 - present

PROFESSIONAL MEMBERSHIPS

Crustacean Society, Estuarine Research Federation, International Association of Meiobenthologists, Pacific 

Estuarine Research Society, Western Society of Naturalists, World Society of Copepodologists.

SELECTED PUBLICATIONS

Dean, A.F., S.M. Bollens, C.A. Simenstad, and J.R. Cordell. 2005. Marshes as sources 

or sinks of an estuarine mysid: demographic patterns and tidal flux of Neomysis 

kadiakensis at China Camp marsh, San Francisco estuary. Est. Coast. Shelf Sci. 63: 

1-11.

Levings, C.D., J.R. Cordell, S. Ong, and G.E. Piercey. 2004. The origin of invertebrate 

organisms being transported to Canada’s Pacific coast by ballast water. Can. J. Fish. 

61(1): 1-11.

Toft, J.D., C.A. Simenstad, J.R. Cordell, and L.F. Grimaldo. 2003. The effects of 

introduced water hyacinth on habitat structure, invertebrate assemblages, and fish 

diets. Estuaries 26(3): 746-758.

Tanner, C.D., J.R. Cordell, J. Rubey and L.M. Tear. 2002. Restoration of freshwater 

intertidal habitat functions at Spencer Island, Everett, Washington. Rest. Ecol. 10(3): 

564-576

Bollens, S.M., J.R. Cordell, S. Avent, and R. Hooff. 2002. Occurrences, causes and 

consequences of zooplankton invasions: a brief review, plus two case studies from the 

northeast Pacific Ocean. Hydrobiologia 480: 87-110.

Toft, J.D, J.R. Cordell, and W.C. Fields. 2002. New records of crustaceans (Amphipoda, 

Isopoda) in the Sacramento/San Joaquin Delta, California, and application of criteria 

for introduced species. J. Crust. Biol. 22(1): 190-200.

Simenstad, C.A. and J.R. Cordell. 2000. Ecological assessment criteria for restoring 

anadromous salmonid habitat in Pacific Northwest estuaries. Ecol. Eng, 15:283-302.

Giles, S.L. and J.R. Cordell. 1999. Zooplankton composition and abundance in Budd 

Inlet, Washington. Pages 634-642. In: Puget Sound Research '98: From Basic 
12

Science to Resource Management, Puget Sound Water Quality Action Team, 

Olympia, Washington.

Prahl, F.G., L.F. Small, B.A. Sullivan, J.R. Cordell, C.A. Simenstad, B.C. Crump, and 

J.A. Baross. 1998. Biogeochemical gradients in the lower Columbia River. 

Hydrobiologica. 361: 37-52.

Cohen, A, C. Mills, H. Berry, M. Wonham, B. Bingham, B. Bookheim, J. Carlton, J. 

Chapman, J. Cordell, L. Harris, T. Klinger, A. Kohn, C. Lambert, G. Lambert, K. Li, 

D. Secord, and J. Toft. 1998. Puget Sound expedition, a rapid assessment survey of 

non-indigenous species in the shallow waters of Puget Sound. Nearshore Habitat 

Program, Aquatic Resources Division, Wash. State Department of Natural Resources, 

Olympia, WA. 37 pp.

Morgan, C. A., J. R. Cordell, and C. A. Simenstad. 1997. Sink or Swim? Copepod 

population maintenance in the Columbia River estuarine turbidity maxima region. 

Mar. Ecol. Progr. Ser. 129: 309-317.

Cordell, J.R. and S.M. Morrison. 1996 The invasive Asian copepod Pseudodiaptomus 

inopinus in Oregon, Washington, and British Columbia estuaries. Estuaries 16 (3): 

629-638.

Bollens, S.M., B.W. Frost and J.R. Cordell. 1994. Chemical, mechanical, and visual 

cues in the vertical migration behavior of the marine planktonic copepod Acartia 

hudsonica. J. Plankton Res. 16 (5): 555-564.

Cordell, J.R., C.A. Morgan, and C.A. Simenstad. 1992. Occurrence of the Asian 

calanoid copepod Pseudodiaptomus inopinus in the zooplankton of the Columbia 

River estuary. J. Crust. Biol. 12(2): 260-269.
13

SECTION V System Description

General Background

The BalPureTM System that will be used by MTC for this test is a scaled up version of the 

system that has been tested by the University of Washington at the Marrowstone Island 

USGS facility. The BalPureTM process is a patent pending system to generate, control, 

and optimize hypochlorite use for the treatment of ballast water. It is proven high 

capacity, compact, and modular technology, which can handle in excess of 3,000 cubic 

meters of ballast per hour. The system also neutralizes all the chlorine before deballasting. Several system variables including key ones, residual chlorine to the ballast 

tank and sulfite in the deballast, are recorded in a data logger to document proper system 

operation. 

The BalPureTM system as proposed for the MTC shipboard test program is designed to 

treat a ballast flow of 5000 gpm. Based upon the STDN experience with the treatment of 

seawater in cooling water applications, the typical dosage is 1-2 ppm. Port water used for 

ballast has a higher chlorine demand, so greater chlorine dosage is required. The field 

tests carried out on behalf of STDN and work done at the University of Washington show 

that 5 ppm chlorine is a maximum dosage required for the kill necessary to meet the 

Washington State and recent IMO proposed regulations. A more typical dosage ranges 

from 3.0-3.5 ppm of hypochlorite for typical seawater with < 5 ppm TOC. The installed 

BalPureTM system will have the capability to reach 5 ppm hypochlorite or 320 pounds per 

day. Adjusting the current applied to the BalPureTM generator will increase or reduce the 

amount of oxidant generated within the design conditions of the system. Therefore 

hypochlorite production can be tailored to meet both organic and aquatic life content of 

the ballast water. This adjustment can be done both automatically or manually through 

the PLC.

The main BalPureTM system will be delivered fully contained on an epoxy painted (meets 

marine requirements) steel skid with dimensions of 144 inches long by 72 inches wide by 

96 inches high. Lifting lugs are provided to facilitate movement and installation (shown 

in Dwg. D006711-P-01). All equipment is provided in NEMA 4 enclosures or rated for 
14

full wash down service. Total weight of the skid is projected to be 7800 pounds. In cases 

where space is a constraint the various components can be installed separately to 

bulkheads or as space permits and field connected to operate as a fully skid mounted 

integrated system. This will be done with this project as shown in Dwg. D006711-P-50. 

Major components on the skid, hung on the room walls, and method of operation are 

listed in the following sections.

The BalPureTM system is sold and built by Severn Trent DeNora (STDN) a leader in 

water treatment and marine sanitation devices. Severn Trent DeNora has been 

manufacturing like equipment for the offshore industry since 1974. It has an installed 

base of these systems producing over 1 million pounds of hypochlorite per day. STDN 

accounts for 65% of the worldwide operating on-site hypochlorite capacity with over 400 

systems operating in 59 countries. For Offshore applications STDN offers 21 different 

size systems capable of producing from 3 to 2400 pounds per day of hypochlorite. Our 

manufacturing facility is ISO-9001-2000 certified and we manufacture NSF 61 certified 

products. We also have received the ABS certificate of Product Design Assessment for 

our SC-96, which is the precursor to our BalPureTM BP-500 model. All these 

certifications are provided in the Ancillary Documentation Section.

Chemistry

Chlorination is now established as an integral part of water and wastewater treatment 

practice in the United States. Several hundred technical articles have been written on the 

subject. It is the consensus that the primary use of chlorine is for disinfection. 

Disinfection practices are governed by the chlorine residual-contact time envelope. The 

major factors affecting the germicidal efficiency of the free residual process are: chlorine 

residual concentration, contact time, pH, and water temperature. Increasing the chlorine 

residual, the contact time, or the water temperature increases the germicidal efficiency. 

Since seawater has a relatively constant pH and volumes are large, this is assumed to be a 

constant. Contact time for ballast water treatment is the length of the voyage, but the 

BalPureTM system is based on contact times of less than 4 hours. This therefore sets the 

chlorine to be added based on the chlorine (oxidant) demand of the seawater.
15

Seawater (normally between 15 and 35 grams/liter NaCl) or other water containing NaCl 

may be used to generate a disinfecting solution containing chlorine by passing a direct 

electrical current through the solution. On-site generation of hypochlorite from seawater 

has been used for over 25 years. These systems can be purchased as completely skid 

mounted systems that generate sodium hypochlorite from seawater. These systems are 

used in refining, petrochemical power plants, offshore drilling production, and marine 

applications around the world. Systems can be scaled to the appropriate size depending 

on the quantity of hypochlorite required. 

The type of electrolytic cell commonly used in these marine and offshore applications is a 

“tube within a tube.” Due to the high chlorine demands for ballast water applications the 

cells offered in this design are the dense pack monopolar / bipolar electrolyzers. This 

allows high chlorine production in a relatively small space. The anode surface is coated 

with proprietary precious metal oxides, primarily ruthenium and iridium. Seawater enters 

one end of the electrolyzer and passes between the cathodes and the anodes. The 

hypochlorite solution, depleted seawater, and hydrogen exit out of the opposite end of 

each electrolyzer. Up to three horizontal electrolyzers can be stacked vertically on top of 

one another and flow serpentines through all three to increase pounds per hour production 

rate linearly by the number of electrolyzers. Electrolyzer size may vary and can produce 

up to 220 pounds/hour per electrolyzer.

In some applications, such as ballast water treatment, a dechlorination step can be added 

to the process. This requires adding a reducing agent such as sodium sulfite to the end of 

the system to neutralize any residual chlorine at the point of discharge. The end result is 

a non-toxic stream with no free chlorine.

The process is based on the partial electrolysis of NaCl present in seawater as it flows 

through an unseparated electrolytic cell. The resulting solution exiting the cell is a 

mixture of seawater, sodium hypochlorite (hypo), hydrogen gas and hypochlorous acid. 

Electrolysis of sodium chloride solution (seawater in this application) is the passage of 

direct current between an anode (positive pole) and a cathode (negative pole) to separate 

salt and water into their basic elements. Chlorine generated at the anode immediately 
16

goes through chemical reactions to form sodium hypochlorite and hypochlorous acid. 

Reactions are shown below:

Eq. 1 Cl-  Cl2 (aq) + 2eEo = 1.396 V

Which is hydrolyzed in solution to form hypochlorous acid:

Eq. 2 Cl2 + 2H2O  2HOCl + 2H+

Hypochlorous acid dissociates to hypochlorite at alkaline pH levels:

Eq. 3 HOCl  OCl- + H+pKa = 7.5

In seawater bromide ions are present, together with a range of inorganic cations as well as 

possibly ammonia and a variety of organic compounds. The reaction of molecular 

chlorine or hypochlorite ions with ammonia or amino compounds leads to the 

disinfectants and react to destroy bacteria and microorganisms in the water just as do 

chlorine, hypochlorous acid and hypochlorite ions. The rapid oxidation of bromide ions 

will also occur and (as with chlorine) in the aqueous environment form hypobromous 

acid (HOBr) and hypobromite ions (OBr-). These reactions will also be equilibrium 

processes, dependent upon temperature and pH. Note also that brominated species will 

react with ammonia and/or amino compounds if present in the water, just like the 

chlorine analogues. 

Hydrogen and hydroxides are formed at the cathode, the hydrogen forms a gas and is 

vented and the hydroxide aids in the formation of sodium hypobromite and increases the 

exit stream pH to approximately 8.5. This reaction is shown below:

Eq. 4 2H2O + 2e-  H2 (g) + 2OHEo = -0.828 V
17

Because the electrolytic cell used for this application is unseparated the reactants at both 

anode and cathode can further react to form the respective end products shown in the 

overall electrochemical and chemical reaction below:

Eq. 5 NaCl + H+ + Br- + 2e  NaOBr + H2 + ClSalt + Water + Energy  Sodium Hypochlorite + Hydrogen

In some applications, such as ballast water treatment, a dechlorination step can be added 

to the process. This requires adding a reducing agent such as sodium sulfite to the end of 

the system to neutralize any residual chlorine at the point of discharge. The end result is 

a non-toxic stream with no free chlorine. The neutralization of the free halogen 

(hypochlorite and hypobromite) between the discharge point and the ballast tanks. 

Sodium sulfite is used and the simplified reaction is shown below to form sodium sulfate. 

As shown in the equation, neutralization occurs at one to one molar ratio but two to one 

(sulfite to halogen) as a weight ratio.

Eq. 6 Na2SO3 + Cl2 + H2O –> Na2 SO4 + 2HCl

Sodium Sulfite + Chlorine + Water –> Sodium Sulfate + Hydrochloric Acid

Typically there are 4 g/L sulfate in seawater and based on the concentrations of halogen 

required only 10 mg of sulfate will be added to the discharge ballast water. Also the 

amount of HCl generated is negligible and will not change the pH of the discharge ballast 

water.

Operating Environments and Conditions

Ballast water turbidity: At this time STDN does not limit the turbidity of the incoming 

ballast water.

Ballast water pressure: A nominal 10 PSIG is required to pass through the inlet strainers, 

otherwise there are no requirements on minimum pressure because the provided system 
18

has booster pumps to increase pressure through the BWT system. Due to the 

construction of the cells STDN does limit the line pressure from the shipboard ballast 

pump to 50 psig. 

Ballast water temperature: The inlet temperature to the electrolytic cells must be above 

38 degrees F. The split in ballast flow and portion to the generator is 220 to 1 so a small 

heat exchanger can be added in applications where ambient ballast water temperature will 

be below 38 degrees F. Maximum ambient temperature up to 120 degree F is acceptable.

Ballast Water Flow: The system that is being provided in this proposal can treat 5000 

gpm flow at an organic loading of 5 ppm. STDN has provided offshore systems to treat 

40,000 gpm at 5 ppm. Therefore we do not restrict flow rate but require matching the 

hypochlorite production unit to standard ship rate of ballast.

Electrical Requirement: The proposed BalPureTM unit will require 54 kVA at 480 volts, 

3 phase, 60 HZ.

Air: There are no process air requirements.

Weight: Approximately 7800 pounds

Dimensions: 144 inches long X 72 inches wide X 96 inches high

Environment: All equipment is provided in NEMA 4 boxes or with full wash down 

capabilities. Equipment can be provided to meet class 1 div. 1 hazardous zones. 

Therefore selective environment is not required.

Treatment Limitations: STDN does not know of any at this time. The amount of 

disinfection by-products will be proportional to the amount of TOC in the ballast water.
19

Operating and Maintenance Manual

See Ancillary Document One.

Installation

Installation instructions are listed in the O&M Manual. STDN is committed to a 

successful installation and operation of any equipment we provide to MTC. STDN will 

provide on-site service during the installation and commissioning phase of this project by 

at least one field service engineer. Those available for field service are listed below:

Harold Childers – 281-274-8459

Rudy Matousek – 281-274-8493

Lucette Falcon - 281-274-8460

STDN will also make available for phone consultation the following individuals:

Vince Wedlich – 281-274-8488 Electrical Engineering Supervisor

Sean McMillan – 281-274-8492 Instrument and Electrical Engineer

Larry Knight – 281-274-8402 PE Mechanical Engineer

James Moore – 281-274-8452 Mechanical Engineer

Hydraulic and Mechanical Connections:

Please refer to drawings D006711-F-01, D006711-F-02, D006711-P-01 and the 

O & M manual sections 11 and 12.

Electrical Connections:

Please refer to drawing D006711-EP-01, D006711-E-21, D006711-E-01. 

Operation and Equipment

Operation:

1.1 The BalPure System is a safe and simple electrolytic process for on-site 

generation of sodium hypochlorite solutions via the electrolysis of 

seawater. Seawater will be supplied by the customer at a minimum 

pressure and will be fed to the system inlet via a booster pump. Seawater 

passes through the electrolyzer where it is subjected to a DC current. The 
20

current passing through the seawater solution causes the disassociation of 

NaCl (salt) and H2O (water), which then allows for the formation of 

sodium hypochlorite. The proposed system is designed to produce 320 

lb/day (13.75 pounds/hour) maximum capacity. Lower outputs can be 

achieved by reducing the current to the electrolyzer.

1.2 Optimum performance of the BalPure System is obtained by maintaining a 

 constant seawater flow through the electrolyzer. Varying the DC 

 amperage applied to the cell then controls the production of hypochlorite.

1.3 The BalPure System, as proposed, will control and pass the seawater 

 through the electrolyzer at a constant value using an orifice-type flow 

 controller. An inlet flow transmitter protects the system. This transmitter 

 will shut down the electrical current to the electrolyzer should seawater 

 flow through the electrolyzer stop. The inlet seawater temperature should 

 be at least 5 C and have a chloride concentration of at least 19,000 ppm for 

 optimum performance. The BalPure system will be tied into the ballast 

 water pump. The system will not operate in automatic mode if the ballast 

 water pump is not operating. The BalPure system must also be set to the 

 “Ballast” mode of operation. With the unit in the ballast mode the 

 automatic valve on the inlet side will open as well as the valve on the 

 discharge side permitting the flow of seawater.

1.4 An inline booster pump will feed a slip stream from the main ballast water 

 line at a feed rate of 32 gpm. A duplex strainer will filter the water 

 with a DP alarm (based on actual field experience with sea water) to 

 remove any particles larger than 800 microns.

1.5 The BalPure System, as proposed, is designed to operate automatically. 

 After the unit is energized, the system will sense that adequate seawater 

 flow is available. After the unit is purged, the transformer/rectifier will 

 supply DC current to the electrolyzer to produce hypochlorite. Again, for 

 the ballast water treatment mode of operation, the system will be designed 

 to operate when the ballast pumps are activated. The sodium hypochlorite 

 will be injected into the discharge stream of the ballast pumps. The system 

 may also be activated during voyage if required in manual mode. 

1.6 The system is arranged and designed to provide flexibility of the operation 

 in terms of solution and dosing strength.

1.7 In the Ballast Water mode, there is a continuous chlorine analyzer that will 

 measure the oxidant concentration of the treated ballast water after the 

 injection of the hypochlorite into the main ballast water stream. This 

 analyzer will feed the results to the system PLC and data logger to 

 automatically adjust the DC current to the generator in order to maintain the 

 oxidant level at the desired set point in the ballast water feeding the ballast 

 water tanks
21

1.8 In the deballast mode of operation, liquid sodium sulfite will be metered 

 into the inlet of the deballast water pump. With the mixing effect of the 

 deballast water pump and the 39’ of pipe to overboard, the sulfite will 

 easily react with any free oxidants. A sensor in the deballast line will 

 monitor the level of sulfite and feed back a signal to the sulfite metering 

 pump to insure the proper dosage of sodium sulfite. We will plan to supply 

 a drum manifold line (suction side of metering pump), metering pump, 

 sulfite analyzer, and of course PLC control and data logger.

1.9 All measured hypochlorite levels during system operation will be recorded 

 with date and time in the date logger. All measured sulfite levels during 

 deballasiting will be recorded with date and time in the data logger. 

1.10 The BalPure System needs seawater to operate. If the vessel is going to 

 be ballasting in water that has less than 10,000 ppm of chlorides in it, the 

 normal operation of the BalPureTM system will have to change and an 

 automatic briner system using bulk salt will be activated. The briner system 

 is automatic except for adding salt. The hold tank also serves as the briner 

 and holds 4,900 pounds of salt. Based on ballast tank data there are 12 

 tanks each requiring 180,000 gallons. This will require approximately 

 2,000 pounds of salt if the ballast is fresh water. The metering pump 

 attached to the tank will be electrically tied to the conductivity of the brine 

 through cell voltage. When the voltage rises above a pre-set value the 

 metering pump will turn on and have a variable frequency drive to allow for 

 fine adjustments of the flow to maintain proper salinity for the electrolytic 

 cell. The brine tank and pump will be mounted within the shop building 

 and the discharge line from the pump will inject into the BalPure system 

 just before the booster pumps. The salt will be added manually and should 

be purchased in 2,000 pound “super-sacs”. The sack is designed to release 

 full contents from a nozzle at its bottom. A small jib crane will be required 

to lift the bag over the tank to empty the contents. This is a semi manual 

job required of the operator and can be done anytime prior to the ballasting 

operation.

1.11 Hydrogen gas is generated at the cathode of the BalPure unit. Immediately 

upon exiting the electrolytic cell the gas liquid mixture will be separated in 

the Hydrogen Degas Separator. Hydrogen is removed and immediately 

diluted with ambient air from a blower to less than 1%. The (LEL) lower 

 explosive limit of a hydrogen / air mixture is 4% hydrogen. 

1.12 The ballast water tanks use an Ameron coating. According to Ameron, 

 there will be no problems with the coating as long as the oxidants are less 

 than 10 ppm. (see Ancillary Documents – Coating Letter)

Equipment:
22

The major items of equipment are listed as follows:

2.1 Seawater Booster Pump: Vertical multistage, inline pump, all stainless, with 

stainless steel impeller, diffusers, shaft, chamber and head, with 2” x 2” 

grooved end connections. The pump is equipped with a cartridge type 

mechanical seal, with silicon carbide faces and EPDM elastomers. Pumps are 

rigid coupled to a 7.5 HP, 3450 RPM, TEFC enclosure, standard efficient, 

230/460V, 3ph, 60Hz, 1.15SF vertical 56C motor. Pump is 36.5” tall.

2.2 Transformer/Rectifier: The transformer/rectifier is NEMA 3R rated, and 

constructed of painted carbon steel. The transformer/rectifier is shipped loose 

and connected to the generator panel by the interconnecting cable. The control 

panel converts 480 VAC to 800 ADC @ 47VDC. The internal electrical items 

consist of a current adjust switch, a set of diodes, fuses and required relays. 

The panel has the following local 

indications and controls: 

-Ammeter – DC - meter 

-Voltmeter – DC - meter 

-Current adjust DC pot 

Power On / flow is OK – lamp

The control panel/transformer/rectifier dimensions are 20” Deep x 84” high x 

72” wide.

The control panel contains the Operator Interface Panel, which is used to 

control the overall operations of the BalPure system. The OIT provides a 

visual display of the status of the various system components, and alarm 

messages are used to indicate malfunctions in critical areas. The following 

control devices are necessary to protect the BalPure System. The PLC uses 

the output from the flow transmitter to monitor the flow of the seawater at the 

inlet to the electrolyzer, and will shut the system down if the flow rate drops 

to 30 gpm. Temperature switches in the transformer will cut the power to the 

rectifier if the internal temperature is above 350 F. DC over-current will 

cause the circuit breaker to trip. Displayed on the control panel:

- Electrolyzer voltage and current meters: Actual DC Current 

(Amps) to the electrolyzers is displayed on the cell current 

meter. These meters are provided to ensure that the power 

supplied to the cells is at the proper amperage. An increase in 

voltage indicates a possible decrease in salinity (due to fresh 

water) or a dirty electrolyzer.

- Current Adjust Knob: In the manual mode, this knob allows 

the operator to manually adjust the current to the required 

value. In the feedback mode the current is adjusted 

automatically.

- Power on/Flow OK Light: This is a light to indicate that the 

unit is running, the transformer temperature is acceptable, and 

there is sufficient seawater flow, sensed from the flow meter. 
23

In the event of an electrical trip or low-flow actuation, the unit 

will turn off and the light will turn off. If the unit turns off due 

excess transformer temperature or insufficient seawater flow, 

there will be a time delay until the unit and the light turn off 

and an external alarm could be indicated. When the light is off 

and an alarm actuated, the unit will require operator 

investigation and correction of system valves, flow, or electric 

power

- Power On/Off Knob: Allows the operator to start or stop the 

unit. There is a time delay from switching the Knob to “On” and 

the Power On/Flow OK light turning on, indicating that the 

rectifier is energized.

2.3 Generator Panel: The generator panel converts seawater to sodium 

Hypochlorite. The generator panel assembly consists of an inlet automatic 

electric valve, a flow meter (with visual indication and a switch), one 

electrolyzer, and an outlet automatic valve used for isolation and flow control. 

2.4 BalPure Electrolyzer: The Balpure electrolyzer consists of 8 bipolar cells 

with an electrode area of 0.8 square meters. One end of the electrolyzer is an 

anode (+) and the other end a cathode (-). The bipolar plates are inserted in each 

of the electrolyzer’s terminal electrodes. The seawater flow is channeled between 

the electrode plates.

The main body of the electrolyzer is about 8.5 feet long with an overall length of 

10.5 feet long when the electrical connections are included. The electrolyzer is 

about 2 feet in diameter. There is a 3 inch seawater inlet and a 3 inch outlet even 

though we are using 2” pipe to and from. The electrolytic cell is stable under all 

normal operating conditions and has a guaranteed life of 5 years. 

2.5 Continuous On-Line Analyzers: The chlorine analytical instrument can 

measure free oxidants on a continuous basis. The sulfite analyzer measures the 

sulfite level in the deballast water stream. The oxidant results are fed to the PLC 

where when in ballast mode, the current from the transformer/rectifier will be 

adjusted to maintain the generated oxidants at the proper set point. In the 

deballast mode, the sulfite analyzer will feed a signal back to the PLC to adjust 

the metering pump to dose the correct amount of 42% liquid sodium sulfite into 

the inlet of the deballast pump to remove any free oxidants in the deballast water.

2.6 Sulfite Addition System: The sulfite addition system is comprised of two 

metering pumps, one on-line and the other an in-line spare. They will be 

mounted on an exterior wall inside the present shop building. The suction line 

 will run from the sulfite storage tank to the metering pumps. The pump is 

 supplied to meter the sodium sulfite into the inlet of the deballast pump. The 

 pump will be PLC controlled based upon the BalPure system in the deballast 

 mode, and a signal from the analyzer (2.5) that there is sulfite in the deballast 

water. The sodium sulfite will be pumped from 55 gallon drums.
24

 The operator will have to check tank volume before each deballasiting operation 

 to insure sufficient material. 

2.7 PLC and Data Logger: A PLC is supplied to control the BalPure system. A 

data logger is supplied to collect and store the data for future down loading and 

record of ballast water treatment and dechlorination. Data such as run time, 

amperage, voltage, oxidant levels, sulfite levels, etc. will be recorded and logged.

The Solid State Data Recorder is a Paperless Recording instrument. Data is stored 

on either an internal floppy disk, a removable PCMCIA memory card or a Zip 

Drive. All data is stored in MSDOS format and may be archived or analyzed on 

any IBM compatible PC running Microsoft Windows 3.1 or Windows 95/98 using 

the available Companion Software. The instrument retains all the features of a 

traditional Paper Chart Recorder by virtue of its large STN monochrome or TFT 

color Liquid Crystal Display (LCD), which presents the data in the traditional 

chart mode as well as in bar graph or digital numeric form. The unit has many 

features and functions, which are unique and cannot be performed on traditional 

paper recorders, such as data compression and historic data browsing. The 

recorder is programmed via a touch screen keypad on the display. The recorder 

will measure and process up to six direct inputs, calculated, conditional, or 

external points for logging, trending, or data manipulation. If direct inputs are not 

desired, the Data Recorder will accept up to fifteen points from a combination of 

calculated, conditional, or external point types.

2.8 Sample Station: There will not be a master sample station. STDN requires 

the MTC vessel operators to sample and analyze the available chlorine content of 

each ballast tank 24 to 48 hours prior to de-ballasting. The sampling and analysis 

procedures will be detailed in the operating and maintenance manual provided 

with the equipment. This task is estimated to take 15 minutes per ballast tank. 

2.9 Hydrogen Dilution: The electrolyzer output enters the Hydrogen Degas 

Separator where the hydrogen is separated from the Sodium Hypochlorite 

solution. In the Hydrogen Degas Separator, H2 that is being generated is 

removed from the two-phase (liquid/gas) solution and safely routed to the vent 

stack. The hydrogen in the vent stack is diluted to less than 1% by one (1) of the 

two (2) dilution air blowers. The lower explosive limit (LEL) of a hydrogen/air 

mixture is 4% hydrogen. Two 100% blowers are provided to ensure an automatic 

standby to the operator selected lead blower. Inlet filter screens prevent unwanted 

dust/debris from being admitted to the vent system. Each blower line is provided 

with an individual airflow switch to provide logic feedback for the standby blower 

startup. Dampers prevent backflow through the standby blower during operation. 
25

After the hydrogen is diluted to below the lower flammability limit, it is safely 

vented. The Sodium Hypochlorite solution flow from the degas separator is 

routed to the required injection points. 

2.10 Briner System: Seawater will enter the brine tank through a side feed 

chamber. Liquid lever control maintains water at 30% from the bottom to ensure 

full saturation. Flow requirements will be approximately 1.5gpm to achieve the 

required brine concentration to the electrolyzer. The brine tank is sized for a 

working volume of 4,900 pounds to facilitate additions via 2000 pound super 

sacks. The brine tank will be installed inside next to the generator. It will be 

made of HDPE with bulkhead fittings. Brine addition to the electrolyzer will be 

controlled by salinity of the incoming seawater.

2.11 Alarms: Various alarms will display through the control panel PLC for 

proper operation of hypochlorite generator, sulfite addition, hypo addition, and 

concentrated brine addition. There will also be a general purpose audible and 

visual alarm on deck outside of the room housing the generator.

Maintenance and Consumables

Refer to the O & M manual; section 14 regarding maintenance and appendix A for spare 

parts. 

Sodium bisulfite is the other consumable material used during de-ballasting for chlorine 

neutralization. The stoichiometric ratio of sulfite to chlorine is 1.6 to 1. To be safe 

assume 2:1 by weight and assume a 2 ppm residual chlorine that must be neutralized with 

a 2 ppm sulfite excess. Therefore the worst-case consumption rate for the MTC test 

protocol for a 5,000 gallon (18,925 liters) per minute would be:

18,925 kg X 2 ppm = .0378 kg (.083 lb.) of chlorine to neutralize

At 2:1 ratio .0378 kg X 2 = .0757 kg sodium bisulfite

At 2ppm excess 18,925 kg X 2 ppm = .0378 kg of bisulfite extra

Therefore total sulfite per 5,000 gallon discharge would be .15 kg (.33lb) of bisulfite per 

minute. The MTC total ballast is 2.6 million gallons or 173 pounds of sulfite per full deballast.
26

Costs 

The purchase price for the BP-1000 unit as delivered for this proposal will be less than 

$500,000. This price covers all hypochlorite generating equipment, gas separation, all 

instrumentation, all analyzers, brine supplement system, and data logger.

Operating costs are projected to be $0.03 per cubic meter of treated ballast water. The 

only consumables in operating the system (assuming proper salinity seawater is 

available) are electricity and sodium sulfite. Breakdown would be as follows:

At power costs of $0.15 per Kwh, electricity would be $0.02 per cubic meter of ballast 

treated. Sulfite costs are $0.004 per cubic meter of ballast treated. The other major 

replacement item is the electrodes in the electrolytic cell. Operating life is 3000 hours 

with a contributing cost of $0.003 per cubic meter of ballast treated. Other 

miscellaneous operating costs for reagents, pump seals, etc. would be another $0.003 per 

cubic meter of treated ballast water.
27

SECTION VI: Discharge Validation

We at Severn Trent DeNora believe that the de-ballasted water from any ship using our 

BalPureTM ballast water treatment system, when operated as designed, will meet all 

regulatory requirements. This belief is based on the following land based testing, clinical 

toxicity testing, and input from Federal agencies.

Toxicity 

Nautilus Environmental Northwest Laboratory conducted tests per the guidelines 

published by the Washington Department of Ecology titled “Toxicity Testing to Establish 

the Environmental Safety of Proposed Ballast Water Biocides”. The more aggressive 7-

day survival tests were conducted. Water environments were prepared following the full 

cycle of our electrolytic ballast water treatment system. Puget Sound water was treated 

with chlorine using the BalPureTM chlorinator. That seawater was then neutralized with 

varying amounts of sodium sulfite to establish a safety factor for commercial operation. 

Standard treatment will require a residual of 1-2 ppm sulfite during normal operation. 

Results indicate no adverse effect on Mysid (M. bahia and M. beryllina), bivalve larval, 

kelp germination, and herring embryo up to 16 ppm residual sulfite. The summary report 

is attached in the Ancillary Documents.

The University of Washington also did toxicity tests following a similar test protocol 

with systems of 75 gallons, which indicate no adverse effects on bacteria, phytoplankton, 

and mesozooplankton. This work is summarized in the December 2004 report, also 

attached in the Ancillary Documents.

Disinfection By-Products

Disinfecting agents such as chlorine, ozone, chlorine dioxide, and chloramines react with 

natural organic material present in water to produce disinfection byproducts (DBPs). 

Most of the research and interest in DBPs has been with drinking water. DBPs have been

known since 1974, when chloroform was identified as DBP resulting from the 

chlorination of tap water. Since then, hundreds of DBPs have been identified in drinking 
28

water. The benefit of disinfecting drinking water is obvious as thousands of people died 

from waterborne disease before municipalities began to disinfect drinking water, but it is 

also generally recognized that it is important to minimize the formation of DBPs in 

drinking water. Several DBPs have been linked to cancer in laboratory animals, and as a 

result, the U.S. EPA has regulated some DBPs.

While we anticipate that most people will not be drinking ballast water and other treated 

seawater, we have evaluated the formation of selected DBPs that may be formed 

following the generation of hypochlorite in seawater. Seawater is significantly different 

than freshwater, not just because of the relatively high concentration of Na+ and Cland 

oftentimes higher levels of natural organic material, but also because of the presence of 

Br-(bromide). The presence of this ion may lead to the formation of bromate (BrO3

-

), a 

compound that is considered a possible human carcinogen. In the U.S., bromate is 

regulated at 10 μg/L (10 parts per billion) in drinking water. Seawater contains a typical 

bromide concentration of 65 mg/L so the concentration in seawater is significant. 

Therefore, bromate was one of the DBPs measured in our research. In addition, the 

presence of haloacetic acids (HAAs) and trihalomethanes (THMs) are a concern and were 

measured as part of the overall study.

Results are provided in the December 2004 University of Washington Report. 

Indications were that when treating Puget Sound water spiked with 50% more 

zooplankton and phytoplankton than normal concentrations, result in de-ballasted water 

that meets drinking water standards for THM, HAA5, and Bromate.

Permitting and Certifications

Chemicals that are involved in the BalPureTM process are: 0.1 wt% hypochlorite solution 

or 50 times weaker than household bleach is not subject to the same regulations that 

govern strong hypochlorite greater than 1.0 wt%. In fact we do not know any regulations 

that pertain to this hypochlorite concentration. Sodium bisulfite, either 42 wt% liquid or 
29

dry powder made to 42 wt%. Both are only classified as irritants. The MSDS sheets are 

attached in the ancillary documents. 

STDN spoke with Dennis Edwards of the EPA in Washington D.C. pertaining to the 

BalPureTM system and how it would be classified as a pesticide generation device. We 

presently have our manufacturing site registered and all our pesticide devices built on this 

site are covered by Establishment Number 048482-TX-001. We submit documentation 

annually and will include our BalPureTM in the future. Mr. Edwards mentioned that this 

documentation was more than adequate to cover any regulations pertaining to a chemical 

Ballast Water Treatment System. No other FIFRA laws pertain to our situation at this 

time.

A literature review by Dr. E. Rudd (PHD in Electrochemistry) from ElectroTechnologies 

is included in the Ancillary Documentation. The review concludes that hypochlorite / 

chlorine concentrations as low as 0.1 ppm can be effective as a disinfectant to kill living 

marine organisms. The review also indicates sodium sulfite is a non-toxic and nonhazardous chemical. The report is included in the Ancillary Documentation.
30

SECTION VII: Land Based Experiments

Discharge Water Quality

Per the work of Russ Herwig at Marrowstone Island, the BalPureTM unit can treat 

seawater to meet the Washington State interim ballast water discharge standards:

Inactivation of ninety-five percent of Zooplankton organisms

Inactivation of ninety-nine percent of Phytoplankton

Inactivation of ninety-nine percent of Bacteria

Per the work of Russ Herwig at Marrowstone Island, the BalPureTM unit can treat 

seawater to meet IMO standards:

< 10 Viable Organisms per cubic meter at > 50 micron

< 10 Viable Organisms per milliliter at < 50 micron

Eliminate bacteria to < 250 colony forming units per 100 ml

Please refer to the three summary reports by Russ Herwig for the work done by the 

University of Washington at the Marrowstone Island USGS site. The work is contained 

in the Ancillary Documents - Marrowstone Sodium Hypochlorite Mesocosm September 

2004, Marrowstone Sodium Hypochlorite Mesocosm October 2004, Marrowstone 

Sodium Hypochlorite Mesocosm December 2004.
31

SECTION VIII: Performance Capabilities

As outlined above in the ballast flow section, STDN has provided offshore seawater 

treatment systems up to 40,000 gpm at 5 ppm available hypochlorite. STDN is proposing 

a system to handle 5000 gpm at 5 ppm available hypochlorite. All results should be 

scalable up or down in production capacity. Please see the table below for various 

available BalPureTM Systems. STDN is marketing six different size BWT systems based 

on ballast water flow rates in increments of 500 cubic meters per hour.

MODEL SEAWATER TO BE 

TREATED @ 5 ppm

SYSTEM 

OUTPUT 

REQUIREMENTS

AC POWER 

REQUIRED

DC POWER

M

3

/H GPM kg/H Lbs/Day AC KVA AMPS VOLTS

BP-500 400-825 2200 2.5 132 35 500 48

BP-1000 826-1250 4400 5.0 264 52 500 72

BP-1500 1251-

1800 6600 7.5 396 78 500 108

BP-2000 1801-

2200 8800 10.0 528 103 500 144

BP-2500 2201-

2600 11000 12.5 660 110 800 96

BP-3000 2601-

3600 13200 15.0 792 165 800 144
32

SECTION IX: Shipboard Test Plan

Objectives

Demonstrate operational efficacy and reliability of the BalPure system.

+ Hypochlorite Generation

+ Chlorine monitor and control

+ Sulfite monitor and control

+ Data logger operation

Characterize geochemical and biological composition of ballasted and de-ballasted 

treated and un-treated seawater.

Introduction

The BalPure system is divided into hypochlorite generation, chlorine monitoring and 

control, sulfite monitoring and control, sulfite dosing, and data logging. Only the 

monitoring systems will require some operator attention. The analyzers operate with prepackaged reagents with somewhat short shelf life and should be changed (once opened) 

every 14 days. The rest of the system is relatively free of maintenance and has a 20-year 

proven history in power plants and offshore applications.

The intent of the sampling and analysis program is to provide initial start-up, training, 

and commissioning assistance to the Crowley staff. Once the mechanical system 

operation is verified a second phase would be to execute a detailed sampling and analysis 

program with a team from University of Washington and STDN. This program would 

establish the efficacy of the BalPure unit with ballast water from various ports. This 

program would be conducted over the first three voyages. The sampling and analysis 

sequence would follow that listed in Table 1. To provide a control for this test, we will 

fill one ballast tank with un-treated seawater and the rest with treated seawater. This will 

aid in determining efficacy of the system with the same quality seawater and characterize 

both types of ballast water with time. Accommodations will be required for the sampling 

and test team of two people to do analyses at the prescribed intervals.
33

The demonstration portion of the test program follows the intense one month period 

described above. This portion of the overall program will cover the next two months. 

This period is required to demonstrate reliability of the equipment and provide logged 

data to demonstrate system control and meeting operating parameters. 

The final portion of the program is a six-month maintenance period to establish 

maintenance cycles and further demonstrate robustness of the system. If all critical 

validation points are met during the first six months it would be Marine Transport’s 

decision to continue the elevated monitoring program or pursue the STEP program.

Test Procedure – Every Ballasting Operation

Four hours prior to Ballasting, turn on power to chlorine analyzer to warm up, move 

sensor from holding tube to unit. Replace sample line filter and reagent bottle if required.

1. Once ballast pump(s) begin pumping and BalPure unit is making chlorine, collect 

sample ballast water after the mix point. Do chlorine analysis using Hach 

Colorimeter and adjust BalPure Chlorine analyzer (see manual) to match test kit 

value. (Should be infrequent and minimal adjustment).

2. Set BalPure unit to desired chlorine residual, to be determined (3.0 – 5.0 ppm 

range) based on initial efficacy tests during the first two weeks of operation. 

Allow BalPure unit to control residual chlorine concentration.

3. When system is fully commissioned, take samples per sampling Table 1 for 

 three ballasting operations during the next month.

4. Once per month (for the next two months) collect two ballast water samples from 

the none treated tank and two ballast water samples from a treated ballast tank 

right after tank is full. Send samples immediately to laboratory (to be determined) 

for analysis. Sampling could be scheduled through University of Washington or 

STDN to minimize time spent by Marine Transport personnel. 

5. Once per month (for the next two months) collect two ballast water samples from 

the none treated tank and two ballast water samples from a treated ballast tank 

right before de-ballasting.

Test Procedure – Every De-ballasting Operation

Two hours before de-ballasting, install sensor and then turn on power to 

the sulfite analyzer. Confirm there is at least 30 gallons of sulfite solution in the dosing 
34

drum. Turn on power to the chlorine analyzer to confirm there is residual chlorine in the 

ballast tanks just prior to de-ballasting.

 1. Once ballast pumps begin pumping, confirm de-chlorination unit is working. 

2. Sample overboard discharge and check for chlorine with Hach test kit to confirm 

no chlorine is present. Match hand held reading with analyzer.

3. Confirm sulfite analyzer is working and if required, adjust sulfite analyzer per 

manual. Maintain 1-2 ppm sulfite in the exit stream.

 4. Once de-ballasting operation is completed, shutoff power to sulfite analyzer. 

 Record sensor sensitivity, rinse, remove sensor and affix storage cap.

4. When system is fully commissioned, follow intense sampling sequence in Table 1 

for three de-ballasting operations that match like ballasting cycles.

5. Once per month (for the next two months) collect two samples after 

dechlorination system that match those taken in item 5 under ballasting. Send 

samples to laboratory (to be determined). Sampling could be scheduled through 

University of Washington or STDN to minimize time spent by Marine Transport 

personnel.

Sample Analysis

All returned samples will be analyzed to characterize the geochemical and 

biological composition of the seawater. The data will include the following:

1. Salinity

2. Dissolved Organic Carbon

 3. Live organisms greater than 50 micron and smaller than 50 micron

 4. Chlorophyll a

 5. Bacteria

 6. Disinfectant By-Products

 7. Sulfite and Sulfate Conc.

 8. Toxicity
35

Table 1. Data collected during ballast water treatment and voyage of Crowley vessel with STDN BalPure 

system installed. The number of intermediate samples collected will depend on the length of the voyage.

Data Collected Ballast Tank 

After Filling

Ballast Tank 

24 h 

Ballast Tank 

48 h

Ballast Tank Before 

Discharge

Discharge 

Chemistry Data

Salinity X

Temperature X X X X X

Organic carbon X

Total residual 

oxidant (TRO)

X X X X X

Disinfection 

byproducts

X X X X X

Sulfite X

Biology Data

Zooplankton X X X X

Chlorophyll a X X X X X

Culturable 

phytoplankton

X X X X X

Bacteria X X X X X
36

SECTION X: Ancillary Documentation