O and M Water Midde East-ABB-Senthil RO DSS-Ver1

7/30/2019 O and M Water Midde East-ABB-Senthil RO DSS-Ver1

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DSS for SWRO Plant O&MTechnical experience and lessonslearned from O&M of a membrane basedwater plant

Dr. Senthilmurugan, Technology Manager ABB Water Industry Segment Initiative, 17 April - 2012


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O&M of SWRO plant

ABB profile in water Market

Challenges in O&M of SWRO plant

Importance of DSS for O&M of SWRO plant

Asset management of SWRO plant

Membranes, Pumps, ERDs, Pretreatment filters etc.

Advance operation of SWRO plant

Energy optimization (operation of RO / NF/UF/MFmembranes, Pumps, ERDs, filters etc. )

Maintenance schedule optimization (membranes,pumps)

ABBs solution for O&M of SWRO plant

Optimax Membrane Performance

DSS for O&M of SWRO plant

Content of talk

Month DD, Year | Sl ide 2 ABB Group

ABB profile in waterMarket

Challenges

Importance of DSS

Asset Management

Advance operation

ABB solution

Summary

ERD - Energy recovery deviceSWRO- Sea Water Reverse Osmosis


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ABB in Water cycle

ABB profile in water

Market

Challenges

Importance of DSS Asset Management

Advance operation

ABB solution

Summary

Where do we operate in Water market and applications?


Overall Water

Cycle

Basics Pumping

Stations

Desalination

Water Treatment

Waste water

treatment

Water Network

Wastewater

Network

Irrigation Water Industry water

Sum up

Raw water

Pumping station

Desalination plants

IRRIGATION WATER

Pumping stationsIrrigation Network

INDUSTRY WATERIndustrial Pumping stationsIndustrial Water TreatmentIndustrial Wastewater Treatment

Waste Water

NetworkWater Network

Waste Water

Treatment Plants

WaterTreatment Plants

Water Discharge & Monitoring

Water Abstraction &

Monitoring


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A proper selection and operation of pretreatment process

will prevent or minimize bio fouling,scaling and membrane plugging in reverseosmosis units

Optimal operation and accurate control offlow and pressure to pretreatment system

leads to energy minimization inpretreatment and RO section

leads to life extension for RO andpretreatment filters

also leads to minimal performancedegradation of membrane due to fouling

Typical maintenance activities of

pretreatment units to sustain plant productionlevel such as

Flushing of membrane (order of days)

Chemical cleaning of membrane (order ofmonths)

Partial replacement / full replacement ofmembrane elements (order of years)


Challenges

Importance of DSS

Asset Management

Advance operation

ABB solution

Summary

SWRO desalination plant O&M activitiesChallenges in Operation of SWRO plant

Month DD, Year | S lide 4 ABB Group

Conventional pretreatment

Membrane based pretreatment

MF UF NF

Sea water Treated water

to desalting unit


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High pressure is applied at membrane feed

side

to overcome the osmotic pressure of thesolute

to cause transport of the solvent from feedside to permeate side (product water)

Particles accumulate near the membrane

surface (concentration polarization)

concentration increases over time

membrane performance decreases

Membrane fouling rate due to concentration

polarization is influenced by multiple factors,

e.g. changes in process conditions

(temperature, feed flow concentration,)

Root cause analysis for changing foulingrate is difficult

Actions to overcome fouling include cleaning

(backwashing, chemical cleaning),

membrane exchange, change of pump

setpoints to keep productivity level


Challenges

Importance of DSS

Asset Management

Advance operation

ABB solution

Summary

SWRO desalination plant O&M activitiesChallenges in in Operation of SWRO plant


Time

Membraneperformance

Differentialpressure

Permeateflux


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SWRO desalination plant O&M activities

Major process units of SWRO plant

RO, UF / MF membranes of pretreatment units, Pumps, ERD

Due to fouling the membrane under goes for regular maintenancesactives such as

Flushing of membrane (order of days)

Cleaning of membrane (order of months)

Partial replacement / full replacement of membrane elements(order of years)

Due to regular wear and tear of pumps, ERD, the efficiency of pumpsvaries ~ 5%, the maintenance activities are

Maintenance for mechanical components Challenge: how to schedule of maintenance activates of membrane

systems

To optimize water production cost

To minimize carbon footprint per m3 of water production


Challenges

Importance of DSS

Asset Management

Advance operation

ABB solution

Summary

Challenges in Maintenance of SWRO plant


MF - Micro FiltrationUF Ultra Filtration


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Decision support system (DSS) for SWRO plant

Membrane fouling monitoring and its impact on membranechemical cleaning schedules, and optimization of RO process(Gauder et al., 2010) is important

Lu et al., (2006) determined optimal membrane maintenanceschedules without considering the membrane life cycle intooptimization problem fromulation

ABBs DSS for SWRO calculates the optimal membranemaintenance schedules

By minimizing water production cost over membrane lifetime

Also helps in minimizing the specific energy consumption

(SEC) of the plant by optimally distributing the productionload among RO trains.

The proposed DSS consists of several functionalities, namely,scheduler, load distributor, membrane management systemand simulator.


Challenges

Importance of DSS

Asset Management

Advance operation

ABB solution

Summary

Importance of scheduling membrane maintenance activities



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Estimation of optimal membranemaintenance schedules

Reduces unplanned plant outages due tonon-optimal schedules.

Minimizes the overall water production costduring membrane life cycle and considersconstraints on

product quality - in order to maintainacceptable salt level in the product water,

product water demand - in order toachieve the plant production target, andalso

concentration polarization factor - toimprove membrane life time, duringoptimization.

The trend of water permeability parameter

with respect to membrane chemicalcleaning and replacement schedules (referFig)

The water permeability increases as andwhen the membrane gets cleaned orreplaced.

The optimal schedule is always better thanfixed schedule in terms of production cost


Challenges

Importance of DSS

Asset

Management

Advance operation

ABB solution

Summary

Decision support system (DSS) for SWROScheduler

Month DD, Year | S lide 8 ABB Group


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Provides the membrane operational and maintenancehistory for analysis like

Any violations (process or maintenance) happened inpast operation

Provides proof for membrane warranty from operationperspectives

It can extracts events like cleaning and chemical andwater usage back flushing and chemical cleaning

It also facil itates operator to represent process violationsby means of rules.

It will provide % hrs of plant is operated above thresholdvalue recommended by supplier and OEM

Compares the OEM and optimal schedules

Decision support system (DSS) for SWROMembrane Management System (MMS)



Challenges

Importance of DSS

Asset

Management

Advance operation

ABB solution

Summary

Operation

C Cleaning

R Replacement

OEM Schedules Optimal

Schedules

C 20/08/2010 10/08/2010

C&R 16/04/2011 25/05/2011

C 2/10/2011 30/9/2011

C&R 10/10/2015 1/12/2015


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In RO plant, several RO trains will berunning in parallel

Each train will have differentmembrane fouling status

Trains that are more fouled requiremore energy to produce samequantity of product water

Optimal production load distributionamong RO trains is required tominimize overall SEC of a ROsection


Challenges

Importance of DSS

Asset Management

Advance operation

ABB solution

Summary

Decision support system (DSS) for SWROLoad distributor



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The simulator helps the operator to validatedifferent scenarios which otherwise cannot betested in the real plant.

It helps the operator in analyzing the effect ofoperational and maintenance parameters(such as feed flow, feed pressure and numberof membrane cleanings) on the productioncost.

Simulator allows to compare differentmembrane maintenance schedules in terms ofcost ($/m3 of product water produced).


Challenges

Importance of DSS

Asset Management

Advance operation

ABB solution

Summary

Decision support system (DSS) for SWROSimulator



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ABBs solution for SWRO plant

Optimax Membrane Performance

Monitor membrane fouling and optimize membraneoperation including pumps and Membranes

Overcomes known drawbacks of other approaches(ASTM and thumb rule)

Provides advanced operation of membrane systems Consists of two modules:

Module 1: Online Membrane Performance Monitoring

Module 2: Online Membrane Process Optimization

Applicable for membrane systems based on ReverseOsmosis (RO) and Nano-Filtration (NF) treatmenttechnology

Model-based membrane monitoring solution for individualmembrane trains

For more details: http://www.abb.com/water


Challenges

Importance of DSS

Asset Management

Advance operation

ABB solution

Summary

Advance Operation and Maintenance



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Scheduler

Provides optimal schedule formembrane maintenance activities

When the membrane are to becleaned and replaced

How much % of membranes are tobe replaced

Load distributor

Provides optimal production load

distribution between RO trains

Optimal production load

distribution minimizes overall

specific energy consumption

Membrane Management System

Provides operational andmaintenance history

Displays process violations viaalarms

Conditions for processviolations can be provided bymeans of rules

Simulator

Facilitates to validate what - ifscenarios

How energy consumptionchanges with processvariables

How production cost changeswith membrane maintenanceactivities


Challenges

Importance of DSS

Asset Management

Advance operation

ABB solution

Summary

SummaryDSS for SWRO Plant O&M



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O and M Water Midde East-ABB-Senthil RO DSS-Ver1

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