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Operation and Maintenance Manual

540K GPD x2 SEAWATER REVERSE

OSMOSIS SYSTEM.

23 November 2012

Severn Trent Services Water Purification 970 W.190th Street Suite 302 Torrance, CA 90502 T: +1 310 324 1990

F: +1 310 324 4580

www.severntrentservices.com

http://www.severntrentservices.com/

O&M MANUAL

Table of Contents

1.0 INTRODUCTION ................................................................................................................................... 1

2.0 FUNCTIONAL AND PROCESS DISCRIPTION .......................................................................................... 2

2.1 Main Control Panel ........................................................................................................................................2 2.2 Underground Water Storage Tank (Supplied By Customer) .........................................................................2 2.3 Filter Feed and Backwash Pumps ..................................................................................................................2 2.4 Multimedia Filter ...........................................................................................................................................2 2.5 RO Cartridge Filter .........................................................................................................................................3 2.6 RO High Pressure Pump .................................................................................................................................3 2.7 Membranes ...................................................................................................................................................3 2.8 Underground Permeate Water Storage Tank ...............................................................................................3 2.9 CIP and Fresh Flush System ...........................................................................................................................4 2.10 Dosing Pumps ................................................................................................................................................4 2.11 RO System......................................................................................................................................................5

3.0 SYSTEM DESIGN AND PARAMETERS ................................................................................................... 6

3.1 Projection ......................................................................................................................................................6 RO Design Parameters ...........................................................................................................................................7 3.2 RO Equipment Specifications ........................................................................................................................8

3.2.1 Micron Element(s) for Skid -1 & 2 ........................................................................................................................ 8 3.2.2 RO High Pressure Pump (P-501-1 & 501-2) for Skid -1 & 2 .................................................................................. 8 3.2.3 Energy Recovery for Skid -1 & 2 ....................................................................................................................... 8 3.2.4 RO Pressure Vessel(s) and Membrane(s) for Skid -1 & 2 ..................................................................................... 8 3.2.5 pH & ORP Sensor(s) for Skid -1 & 2 ...................................................................................................................... 8 3.2.6 Conductivity Sensor(s) for Skid -1 & 2 .................................................................................................................. 9 3.2.7 Pump(s) for Skid -1 & 2 ........................................................................................................................................ 9 3.2.8 Pressure Gauge(s) for Skid -1 & 2 ........................................................................................................................ 9 3.2.9 Pressure Transmitter(s) for Skid -1 & 2 ................................................................................................................ 9 3.2.10 Temperature Transmitter/ Sensor(s) for Skid -1 & 2 .................................................................................... 10 3.2.11 Level Transmitter(s) ...................................................................................................................................... 10 3.2.12 Flow Meter(s) for Skid -1 & 2 ........................................................................................................................ 10 3.2.13 Chlorine Analyzer(s) ...................................................................................................................................... 10 3.2.14 Pressure Switch(s) for Skid -1 & 2 ................................................................................................................. 10 3.2.15 Level Switch(s) ............................................................................................................................................... 11

4.0 SYSTEM INSTALLATION ..................................................................................................................... 12

4.1 Unpacking ................................................................................................................................................... 12 4.2 Location ...................................................................................................................................................... 12 4.3 Plumbing Connections ................................................................................................................................ 13 4.4 Electrical Requirements .............................................................................................................................. 13

5.0 START-UP AND OPERATION .............................................................................................................. 14

5.1 First Time Start up after Installation .......................................................................................................... 14 5.2 Regular Start-up ......................................................................................................................................... 15 5.3 Control Process Description ....................................................................................................................... 16

5.3.1 Floats and Switches ............................................................................................................................................ 16

O&M MANUAL

5.3.2 Valves and Pumps .............................................................................................................................................. 16 5.3.3 Normal Operation .............................................................................................................................................. 16 5.3.4 Monitors ............................................................................................................................................................ 17 5.3.5 CIP ...................................................................................................................................................................... 17 5.3.6 Screen Settings ................................................................................................................................................... 17 5.3.7 Alarms List for RO System .................................................................................................................................. 17

5.4 HMI Screens ................................................................................................................................................ 22

6.0 MAINTENANCE AND SERVICE ........................................................................................................... 30

6.1 Preventive Maintenance ............................................................................................................................ 30 6.2 Instrument Calibration ............................................................................................................................... 31

7.0 RO MEMBRANE CHEMISTRY AND CLEANING ................................................................................... 32

7.1 Types of Fouling .......................................................................................................................................... 32 7.1.1 Inorganic Foulant ............................................................................................................................................... 32 7.1.2 Organic Foulants ................................................................................................................................................ 33

7.2 RO Membrane Cleaning ............................................................................................................................. 34 7.2.1 Procedure for Organic Cleaning ......................................................................................................................... 34 7.2.2 Cleaning RO PV-601-1/2 thru PV-622-1/2.......................................................................................................... 34 7.2.3 Drain the Cleaning Solution ............................................................................................................................... 34 7.2.4 Procedure for Cleaning Chemical 403 ................................................................................................................ 35

8.0 TROUBLESHOOTING .......................................................................................................................... 36

8.1 Reverse Osmosis ......................................................................................................................................... 36 8.2 Pumps ......................................................................................................................................................... 38

9.0 WARRANTY........................................................................................................................................ 41

10.0 DRAWINGS ........................................................................................................................................ 44

10.1 P&ID ............................................................................................................................................................ 44 10.2 Mechanical ................................................................................................................................................. 58 10.3 Electrical ..................................................................................................................................................... 99

11.0 O&M LITERATURE .......................................................................................................................... 185

11.1 Pumps ....................................................................................................................................................... 186 11.2 Pressure Vessels ....................................................................................................................................... 318 11.3 Membranes .............................................................................................................................................. 360 11.4 Instruments .............................................................................................................................................. 539 11.5 Electrical Components .............................................................................................................................. 611 11.6 Miscellaneous ........................................................................................................................................... 814

12.0 LOG SHEET ....................................................................................................................................... 831

O&M MANUAL PAGE 1

1.0 INTRODUCTION

This User’s Manual outlines installation, operating, maintenance and troubleshooting details vital to the performance of your system. The Water Treatment System described herein consists of Sea water Reverse Osmosis, Chemical Dosing pump system. The system design is based on sea water analysis from the customers’ facility.

The Reverse Osmosis system operating at 45% recovery concentrates nearly all impurities. When the feed water contains slightly soluble minerals such as calcium sulfate, silica, fluoride or colloidal clay, an anti-scalant should be considered. Precipitation of sparingly soluble salts or colloids on the RO membrane surface can lead to reduced water production and premature failure of the membranes. Material must not be allowed to precipitate in permeates.

The system is designed to provide an uninterrupted supply of Reverse Osmosis treated water when operated according to the specifications described in this manual. RO system is controlled through a PLC located in Main Control Panel (MCP). The projected results which are included with this User’s Manual (see section 3) indicate your systems permeate (product) performance. The RO system is designed to operate at a pressure of 958 PSI and at a feed flow of 833 GPM at (77°F) 25°C. The permeate recovery for your system is set at 45%.

If your system is altered at the site of operation or if the feed water conditions are changed then please contact STWP to determine the proper recovery settings for your application.

Section

1

O&M MANUAL PAGE 2

2.0 FUNCTIONAL AND PROCESS DISCRIPTION

This section describes the unit operations of the Reverse Osmosis explaining the functions, features and contribution to the overall process. There is one RO system and this manual describes the operation of this system.

2.1 Main Control Panel

The Water System is controlled by the Main Control Panel (MCP). The MCP is equipped with a PLC and HMI to perform the necessary functions to operate the system. Interface to the PLC is accessed through the HMI. All alarming, process control, and monitoring is performed in this manner.

2.2 Underground Water Storage Tank (Supplied By Customer)

The Underground Water Storage Tanks (TK-101) supplies water to the Filter Feed Water Pumps (P-301-1 and P-301-2). Filter Feed Water Pumps direct water to the Multimedia Filter Service Inlet.

The Underground Water Storage Tank (TK-101) is equipped with Level Transmitter (LT-161) to indicate tank level. If Tank level (LT-161) downs below 20% inlet Valve (MBF-131) open to fill tank and it close at 80% level, it will initiate tank level low alarm on HMI if level falls below 10%. However, when the Low Level Alarm is initiated, the RO system will perform a Normal Shutdown and go to an idle state until TK-101 level refills to sufficient level to re-start the systems.

2.3 Filter Feed and Backwash Pumps

The system is provided with (2) Filter Feed Pumps (P-301-1 and P-301-2). Pumps are enabled when the RO unit Start pushbutton is pressed by operator from the HMI, thereby enabling the RO. And, low level (LAL-161) is not indicated at the Raw Water Storage Tank, high level alarm (LAH-761) is not indicated at the Permeate water Storage Tank, and the RO System is not in a shutdown condition, or the MMF backwash active signal is present.

If the duty pump trip signal (DI-301-1 OR DI-301-2) is present, duty will be assigned to standby pump and faulty pump goes into standby. If trip signals for both pumps (DI-301-1 and DI-301-2) are present, the system goes in shutdown mode.

The system is provided with (1) Filter Backwash Pump (P-302). Pumps are Enabled when the MMF unit in Backwash Process.

2.4 Multimedia Filter

Three (3) MMF unit (MMF-301A/B/C) provides removal of suspended particles down to approx. 8-10 microns in the feed water which protects the RO membranes from sediment

Section

2

O&M MANUAL PAGE 3

fouling. The media filter allows a flow as high as 3-4 times that of a regular media with superior filtration. As filter accumulates particulates removed from the water, the pressure difference across the unit’s increases. The filter requires a periodic up flow backwash to flush particulate matter that the filters may have trapped. The filter is manually backwashed and removed from service if there is a High Differential pressure across the MMF inlet and outlet.

2.5 RO Cartridge Filter

There is One (1) Inline Filter after the Multimedia Filters and before the High Pressure Pump. The filter provides removal of suspended particles in the feed water that are too large for the HP Pumps and RO membranes. The filter ensures that no particles are directed to the pump that may damage the pump or plug the membranes.

2.6 RO High Pressure Pump

RO High Pressure Pump (P-501-1 and P-501-2) supplies filtered water to the RO

Membranes at a flow rate and pressure to produce permeate necessary to meet system

requirements.

The pump will starts, after a delay, when the RO unit Start pushbutton is pressed by operator from the HMI, thereby enabling the RO. And, water is supplied from the cartridge filter at sufficient pressure to the high pressure pumps (PSL-571-1/PSL-571-2).

The pump will stop when the RO unit Stop pushbutton is pressed by operator from the HMI, thereby disabling the RO.

If the fault signal for RO High Pressure Pump (DI-501) is present, it will initiate the RO High Pressure Pump (ML-501) fault alarm and any sequences dependant on the pump at the time will cease.

2.7 Membranes

Filtered water is directed to the membrane array by the High Pressure Pump at sufficient flow and pressure to remove dissolved solids from the process water to produce the desired quantity of Permeate to the Water Storage Tank.

2.8 Underground Permeate Water Storage Tank

The Permeate Water Storage Tank (TK-701) supplies water for the Customer use.

Permeate water Storage Tank (TK-701) is equipped with a Level Transmitter (LT-761) to indicate the tank level on the HMI.

When tank level reaches more than 80%, it will initiate a High Level Alarm (LAH-761). The RO system stops operating and all pumps and all valves close. RO System goes into idle condition.

O&M MANUAL PAGE 4

2.9 CIP and Fresh Flush System

The Fresh Flush system provides RO Permeate in sufficient quantity to the RO to rinse Filtrate from the membranes to prevent scaling or fouling. This sequence is performed when the RO ceases operation whether through a normal or alarm initiated shutdown.

The CIP to provide cleaning solution to the RO membranes to remove scaling or fouling. This process is performed manually by the operator as required by system conditions.

There are two (2) Fresh Flush Tanks (TK-901A/B), which stores permeate for the RO for use during the Fresh Flush step. Permeate water is supplied to tank from the RO permeate.

There is one (1) Fresh Flush Pump (P-901), which delivers solution from the Fresh Flush Tank to the RO membranes during the Fresh Flush process.

The pump will start in Fresh Flush during sequence steps requiring the flow as controlled by the operator. And, low level (LSL-961) and high level (LSH-961) is indicated in the Fresh Flush Tank.

The pump will be stopped automatically when low level alarm (LAL-961) is indicated in the Fresh Flush Tank.

If the fault signal for Fresh Flush Pump (DI-901) is present, it will initiate the Fresh Flush Pump (MA-901) fault alarm.

There is one (1) Cleaning (TK-801), which stores permeate for the RO for use during the CIP process. Permeate water is supplied to tank from the RO permeate.

There is one (1) Cleaning (P-801), which delivers solution from the Cleaning Tank to the RO membranes during the CIP process.

The pump will start in CIP steps requiring the flow as controlled by the operator. And, low level (LSL-861) is indicated in the Cleaning Tank.

The pump will be stopped automatically when low level alarm (LAL-861) is indicated in the CIP Tank.

If the fault signal for Cleaning (DI-801) is present, it will initiate the Cleaning Pump (MA-801) fault alarm.

2.10 Dosing Pumps

There are Three (3) dosing systems, one each for Antiscalant Chemical Feed (CFS-203), SMBS Chemical Feed System (CFS-205), and Pre Chlorination Chemical Feed (CFS-201). These pumps will start during the operation of the system and run continually as the system runs. If level of chemical in the tank goes below low level, then an alarm will be generated in the tank and the respective chemical pump will stop.

O&M MANUAL PAGE 5

2.11 RO System

The following equipment comprises the RO System:

One (1) Inline Static Mixer (MX-101).

One (1) Underground Water Storage Tank (Supplied By Customer) (TK-101) to provide

water to the Multimedia Filter Service Inlet.

One (1) Underground Filtered Water Storage Tank (Supplied By Customer) (TK-302) to

provide water to the Multimedia Filter Backwash Inlet.

Two (2) Filter Feed Pumps (P-301-1) and (P-301-2) to direct water to the Multimedia

Filter Service Inlet.

One (1) Filter Backwash Pump (P-302) to direct water to the Multimedia Filter Service

Inlet.

Three (3) MMF units (MMF-301A/B/C) to provide removal of suspended particles from

the feed water which protects the RO membranes from sediment fouling.

Two (1) Cartridge Filter (CF-401-1) to remove large particulates from the Filtrate for RO

units.

Two (1) RO High Pressure Pump (P-501-1) to direct water to the membrane array at

sufficient quantity and pressure to remove dissolved solids from the Filtrate.

One (1) RO membrane array to remove dissolved solids from the raw water and

produce the desired quantity of permeate.

One (1) Underground Permeate Storage Water Tank(TK-701) (Supplied By Customer).

One (1) CIP System.

One (1) CFS-201 - Pre-Chlorination Chemical Feed System.

One (1) CFS-203 - Antiscalant Chemical Feed System.

One (1) CFS-205 - SMBS Chemical Feed System.

Two (2) Fresh Flush Tanks (TK-901A and TK-901B)

One (1) Fresh Flush Pump (P-901).

(Note: For RO2 instrument/device nomenclature are used as XXX-2 )

O&M MANUAL PAGE 6

3.0 SYSTEM DESIGN AND PARAMETERS

3.1 Projection

Section

3

O&M MANUAL PAGE 7

RO Design Parameters

This section of the manual describes the technical specifications pertaining to this System. The system was designed based on the following raw water analysis: (without chemical dosing).

Note: The above specifications are achieved subject to the following:

1. The specifications given above are at Feed Water Temperature of 25°C.

2. Any oil content in the inlet water to the system is harmful and as such water to our plant inlet battery limit should be absolutely free from oil. Otherwise the warranty of the system performance would be void.

3. The feed quality is same as considered for design. In case of any change in quality of raw water, it may have implications on operating parameters or on end result of the system.

4. The operation of water treatment plant is strictly followed as per “STWP" operation manual and instructions.

5. Pure chemicals, original spares and consumables specified by supplier are to be used in water treatment plant and sufficient inventory of essential spares shall be maintained.

DESIGN SPECIFICATION

RO System

Feed Water TDS 38000.0 mg/l

Permeate Water TDS 212.58 mg/l

Feed Water Pressure 958.70psig

Feed Water Flow Rate 833.35gpm

Permeate Water Flow Rate 357.00 gpm

Concentrate (reject) Flow rate 458.35 gpm

Recovery 45 %

Based on Temperature of 25°C

O&M MANUAL PAGE 8

3.2 RO Equipment Specifications

This section describes the technical specifications of some of the major equipment, components and instrumentation for RO unit.

3.2.1 Micron Element(s) for Skid -1 & 2

Description Qty Type Part #

RO Replacement Filter Elements 2 5 Micron U126377

CIP Replacement Filter Elements 1 5 Micron U124232

3.2.2 RO High Pressure Pump (P-501-1 & 501-2) for Skid -1 & 2

Quantity 2

Flow rate 833 GPM

Operating pressure 619 PSI

Part # of Pump U126931

Fluid end Duplex stainless steel

Motor 350 HP

3.2.3 Energy Recovery for Skid -1 & 2

Quantity 2

Part # U126359

3.2.4 RO Pressure Vessel(s) and Membrane(s) for Skid -1 & 2

PRESSURE VESSELS

Make Protec-arisawa

Quantity 22 for Skid-1 and 22 for Skid-2

Part # U126549(34) and U126550(10)

R.O. MEMBRANES Dow Filmtec (SW30HRLE-400)

Quantity 112 for Skid-1 and 112 for Skid-2

Size of Membrane Elements 7.9”Dia X 40” long

Type of membrane TFC Spiral wound

Material of construction TFC (Thin Film Composite)

Part # U110867

3.2.5 pH & ORP Sensor(s) for Skid -1 & 2

# Location Part #

1 RO Feed pH Sensor Electronics / Electrode U120519, U111128

2 RO Feed ORP Sensor Electronics / Electrode U120519, U125675

3 RO Permeate pH Sensor Electronics / Electrode Customer scope

4 Cleaning water pH Transmitter / Electrode U190430,U111128

O&M MANUAL PAGE 9

3.2.6 Conductivity Sensor(s) for Skid -1 & 2

# Location Part #

1 RO Feed Conductivity U123938

2 RO Permeate Conductivity Sensor , Electrode

U125776,U190729

3.2.7 Pump(s) for Skid -1 & 2

# Location Part # Qty.

1 Filter Feed Pump U126357 2

2 Backwash Pump U126358 1

3 Fresh Flush Pump U126902 1

4 Cleaning Pump U126891 1

5 Dosing Pump U126758 6

3.2.8 Pressure Gauge(s) for Skid -1 & 2

# Location Qty Range Part #

1 Filter Feed Pump (P-301-1 & P-301-2) Suction Pressure Gauge

2 -30 - +30 PSI

U126081

2 Filter Feed Pump (P-301-1 & P-301-2) Discharge Pressure Gauge

2 0-100 PSI U124060

3 Backwash Pump (P-302) Suction Pressure Gauge

1 -30 - +30 PSI

U126081

4 Backwash Pump (P-302) Discharge Pressure Gauge

1 0-100 PSI U124060

5 RO CF Inlet & Outlet Pressure Gauge 4 0-100 PSI U124060

6 RO High Pressure Pump discharge Pressure Gauge

2 0-1000 PSI U124323

7 RO pre Membrane Pressure Gauge 2 0-1000 PSI U124323

8 RO post membrane Pressure Gauge 4 0-1000 PSI U124323 9 Permeate water outlet Pressure Gauge 2 0-100 PSI U124060

10 Concentrate water outlet Pressure Gauge 2 0-30 PSI U126081

11 Fresh Flush pump Discharge Pressure Gauge

1 0-100 PSI U124060

12 Cleaning Service Pre-Filter Pressure Gauge

1 0-100 PSI U124060

13 Cleaning Service Post-Filter Pressure Gauge

1 0-100 PSI U124060

3.2.9 Pressure Transmitter(s) for Skid -1 & 2

# Location Part #

1 Filter Feed Pump (P-301-1 & P-301-2) Suction Pressure Transmitter

U126497

2 Filter Feed Pump (P-301-1 & P-301-2) Discharge Pressure Transmitter

U123573

O&M MANUAL PAGE 10

3 Backwash Pump (P-302) Suction Pressure Transmitter U126497

4 Backwash Pump (P-302) Discharge Pressure Transmitter U123573

5 MMF Filtrate Inlet Pressure Transmitter U123473 6 MMF Filtrate Outlet Pressure Transmitter U123473 7 RO CF Inlet & Outlet Pressure Transmitter U123573 8 RO pre Membrane Pressure Transmitter U122135

9 RO post membrane Pressure Transmitter U122135

10 Permeate water outlet Pressure Transmitter U123573

11 Concentrate water Pressure Transmitter U123573

3.2.10 Temperature Transmitter/ Sensor(s) for Skid -1 & 2

# Location Part #

1 RO Feed Temperature Transmitter/Sensor U111132

3.2.11 Level Transmitter(s)

# Location Part #

1 Raw water storage tank (TK-101) Level Transmitter Customer scope

2 Filtered water storage tank (TK-302) Level Transmitter Customer scope

3 Product water storage tank (TK-701) Level Transmitter Customer scope

3.2.12 Flow Meter(s) for Skid -1 & 2

# Location Part # Tag #

1 RO Permeate water outlet Flow U124383 FT-652-1/2

2 RO Concentrate water outlet Flow U124383 FT-651-1/2

3 Cleaning water outlet Flow transmitter U106171, U126444

FT-851

3.2.13 Chlorine Analyzer(s)

# Location Part #

1 Raw water Chlorine Analyzer Customer scope

2 RO Permeate Chlorine Analyzer Customer scope

3.2.14 Pressure Switch(s) for Skid -1 & 2

# Location Qty Part #

1 High Pressure Pump Inlet Low Pressure Switch 2 U107040

2 Pre Membrane High Pressure Switch 2 U109412

O&M MANUAL PAGE 11

3.2.15 Level Switch(s)

# Location Qty Part #

1 Fresh Flush Tank Low Level Switch 1 Customer scope

2 Fresh Flush Tank High Level Switch 1 Customer scope

3 Cleaning Tank Low Level Switch 1 U110548

4 Pre-Chlorination chemical tank Low Level Switch 1 U108316

5 Antiscalant chemical tank Low Level Switch 1 U108316

6 SMBS chemical tank Low Level Switch 1 U108316

O&M MANUAL PAGE 12

4.0 SYSTEM INSTALLATION

4.1 Unpacking

The Reverse Osmosis System has been specially packaged for the maximum protection during the transportation. Please carefully unpack the system. Once the system is unpacked, please check carefully that nothing is broken or damaged during the transportation.

Please perform an immediate check of the following items:

All of the PVC plumbing and fittings

All of the front panel, instrumentation and electrical items

Pump and Motor

If applicable, check any separate items that were sent with the equipment

NOTE:

1. Should there be any visible surface rust or corrosion being developed, this could be a result of the deposition of saline mist from ocean freight transportation or even due to leaks in the RO system during transportation.

2. If anything is found broken or missing, immediately advise and file a complaint with the transportation company. Please inform us also at the earliest. It is the responsibility of the client to advise and claim any damage or losing of the goods, with the local delivery carrier or company within 24 hours after the receipt of the goods. No responsibility for the physical damage of goods can be taken once the system leaves our works.

3. Last but not least, tighten or adjust any fitting that look broken or need to be tightened before you start up the system.

4.2 Location

Depending on which model you have purchased, the installation procedure will vary.

The R.O. system should never be exposed to freezing temperatures. The system has been tested at the factory, and is shipped with a preservative solution in it to keep the membranes from deteriorating. If exposed to freezing temperatures, this solution will freeze and will cause damage.

Section

4

O&M MANUAL PAGE 13

4.3 Plumbing Connections

1. Please review the drawings carefully before plumbing the piping and fittings together.

Never use smaller piping than required

If in doubts about using the correct piping for plumbing, consult the factory immediately and do not proceed without a confirmed answer.

2. Make sure that the piping going from RO outlet to storage tank is absolutely unobstructed. No valves or other mechanical equipment should be connected in this line that might restrict or obstruct the flow of water. Any kind of restriction in this line, may result in a back pressure on the membrane, and may result in damaging the membranes permanently.

3. If any of the system components is damaged as a result of restrictions in piping Then the warranty would be void.

4.4 Electrical Requirements

The dedicated breaker for the system should always be of a greater capacity than the actual amperage used. For example, if the system's amperage draw is 14 amps at 110 volts, the dedicated breaker should be 30 amps. Never connect the R.O. unit to a line which services another device. The R.O. unit should have its own dedicated breaker. The feed water pump should be connected to a main breaker separate from the system.

WHEN IN DOUBT, PLEASE ALWAYS CALL THE FACTORY.

O&M MANUAL PAGE 14

5.0 START-UP AND OPERATION

Before starting up the system make sure that the raw feed pump, or any other pre-treatment devices supplied by the manufacturer or separately by the buyer are properly connected to the system. All motors and pumps should be tested for proper rotation (3 phase only!). Before proceeding with the start-up procedures, make sure that there is a sufficient water supply to the RO system.

To start up the operation of a plant, following procedures must be followed at all times.

5.1 First Time Start up after Installation

Check the rotation of High Pressure motors. See the rotation arrow imprinted on the top of the pump body, for correct direction. Prime the pump before startup.

NOTE: R.O. is equipped with a low-pressure switch. In case the feed water pressure is insufficient the high pressure pump will not start, or if it is already ON, it will shut down automatically.

Warning: If the motor is rotating incorrectly, switch any 2 of the three high voltage wires that you connected to the main electric power line (3 phase only).

1. All feed-water inlet valves, including valves outside RO skid, must be in the Normal operating position. All RO product valves must be open. If closed, then Membranes might get damaged.

2. Normally you turn on the main disconnect switch located on front panel, to the "ON" position.

3. When the system is started, the inlet feed water actuator valve will open. At this Point, observe the pre-filter gauge. It should read minimum 30 PSI.

4. Make sure the pump is primed before it starts by loosening the prime nut on the Pump. We suggest you stop the RO after 10 seconds, then closing it when you see a continuous flow from the nut. Close the nut, and then restart the RO.

5. Normally the system will start the flush cycle, and a brief delay happens before the high pressure pump will turns on.

6. Check product, reject and recycle flow meters for compliance with the design specifications.

Section

5

O&M MANUAL PAGE 15

5.2 Regular Start-up

The following steps should be followed in any start-up:

1. All RO product and concentrate valves MUST be open.

2. The system is equipped with a low pressure switch. The RO will not start unless there is sufficient water pressure is detected (about 30PSI).

Check RO unit membrane computer projection array in the enclosed manual. For correct pressure readings, flow readings, and product water quality.

WARNING:

During the warranty period, should the findings of the manufacturing engineers determine that the cause of a malfunctioning system was the lack of required maintenance or a change in water quality; the cost of a factory authorized engineer will be billed to the client at the quoted daily rate and expenses.

Equipment Pumps

Operation

Inspect all pipe connections to confirm the proper liquid flow direction. The system should be completely filled with water before starting. Be sure that the motor is properly wired in accordance with the motor manufacturer’s requirements and in conformity with safe procedure CAUTION: THE PUMP WILL BE DAMAGED IF IT IS OPERATED WITHOUT WATER.

Starting Immediately after starting the pump, verify the following:

-Pump discharge pressure is normal.

-Motor amperage is normal.

-No pipe leaks and no unusual noises or vibration.

If any of the above conditions are not normal then shut down the system and take corrective actions described in the “Trouble Shooting” Section.

O&M MANUAL PAGE 16

5.3 Control Process Description

5.3.1 Floats and Switches

The Low Feed pressure switch (PSL-571-1/2) and the High Pre-Membrane pressure switch (PSH-572-1/2) protect the RO High Pressure pump and the RO membranes and prevent the system from operating during undesirable pressure levels. When the Cleaning Tank Low Level (DI-861) is present, the CIP processes will automatically stop. When the Fresh Flush Tank Low Level (DI-961) is present, the Fresh Flush

processes will automatically stop.

5.3.2 Valves and Pumps

The Underground Storage tank Fill valve (MBF-131) opens when the Underground Storage Tank Level Low and closes when the Underground Storage Tank Level High. The Feed Valve (MBV-421-1/2) opens when the system is started and closes 10 seconds after the system is stopped. The Fresh Flush Feed Valve (MBV-921-1/2) opens for predefined time duration when the RO system is stopped and closes when low level alarm at Fresh Flush tank (LAL-961) is present or RO system is running. Permeate Actuator Valve (MBF-621-1/2) opens when the HP Pump is running. Flushing Tank Fill Valve (MBV-922-1/2) opens when high level alarm at Flushing tank (LAH-961) is not present. The Filter Feed pump (P-301-1 and P-301-2 operates in duty/standby sequence) turns on when RO system starts. The Filter Backwash pump (P-302) turns on when system backwash starts. The High Pressure Pump (P-501-1/2) is turned on after 15 seconds of the feed valve (MBV-421-1/2) opens and it is stopped if any of the shutdown conditions occurs. One Cleaning (P-801) is provided to direct cleaning solution to the RO units. It operates during CIP (Manual operation). One Fresh Flush Pump (P-901) is provided to direct solution to the RO units. It operates during Fresh Flush Process.

5.3.3 Normal Operation

From the main screen, press the Start Button to start the system. When the RO unit is enabled, the Feed valve (MBF-421) will open first. After 15 seconds, the High Pressure Pump (P-501) will turn on.

O&M MANUAL PAGE 17

From the main screen, press the Stop Button to stop the system. When the system is stopped; the High Pressure Pump (P-501) turns off immediately. After 15 seconds Feed Valve (MBV-421) will close.

5.3.4 Monitors

All sensors (e.g.TDS) can be reached from the HMI by pressing the “Monitors” button and then selecting the desired sensor. Set points can be entered from each individual monitor screen. If the RO is running and the actual value of the sensor is above or below the high or low set point for 30 seconds, then a warning screen will appear. If any sensor value remains high or low for 5 minutes, the shutdown will occur and the alarm/buzzer will sound.

5.3.5 CIP

The CIP (Cleaning in Place) is utilized to clean the RO membranes at periodic intervals or specifically when the membranes become fouled. The Cleaning Tank is filled with water and chemical as directed by the membrane manufacturer to achieve the desired cleaning for the current situation, whether normal routine maintenance or to respond to specific membrane fouling. The Cleaning Pump directs the cleaning solution through the RO membranes and then back to the Cleaning Tank.

5.3.6 Screen Settings

The following timers and set points can be adjusted through the screen:

High pressure pump ON & OFF delay Timers

Fresh Flush Duration Set point

High TDS set point – Specify the maximum TDS allowable before a delayed shutdown alarm occurs.

NOTE: Refer to the P&ID and the Analog inputs page of the electrical schematics to determine which sensors are being used on the RO system.

5.3.7 Alarms List for RO System

Tag

Alarm Messages

{ALARMS\AT_146_HIGH_ALARM} AT-146 CHLORINE ANALYZER HIGH

ALARM

{ALARMS\LIT_161_HIGH_ALARM} LIT-161 TK-101 WATER STORAGE

TANK LEVEL HIGH ALARM

{ALARMS\PT_373_1_HIGH_ALARM} PT-373-1 MMF FEED PUMP P-301-1

INLET PRESSURE HIGH ALARM


INLET PRESSURE HIGH ALARM


O&M MANUAL PAGE 18

OUTLET PRESSURE HIGH ALARM



{ALARMS\LIT_361_HIGH_ALARM} LIT-361 TK-302 FILTER WATER TANK

LEVEL HIGH ALARM

{ALARMS\PT_377_HIGH_ALARM} PT-377 BACWASH PUMP INLET

PRESSURE HIGH ALARM

{ALARMS\AT_344A_HIGH_ALARM} AT-344A TURBIDITY ANALYZER

HIGH ALARM

{ALARMS\AT_344B_HIGH_ALARM} AT-344B TURBIDITY ANALYZER

HIGH ALARM

{ALARMS\PT_375_HIGH_ALARM} PT-375 BACWASH PUMP OUTLET

PRESSURE HIGH ALARM

{ALARMS\PT_378_HIGH_ALARM} PT-378 MMF INLET PRESSURE HIGH

ALARM

{ALARMS\PT_379_HIGH_ALARM} PT-379 MMF OUTLET PRESSURE

HIGH ALARM

{ALARMS\TT_481_1_HIGH_ALARM} TT-481-1 RO1 FEED TEMPERATURE

ANALYZER HIGH ALARM

{ALARMS\AT_441_1_HIGH_ALARM} AT-441-1 RO1 FEED pH ANALYZER

HIGH ALARM

{ALARMS\CT_443_1_HIGH_ALARM} CT-443-1 RO1 FEED CONDUCTIVITY

ANALYZER HIGH ALARM

{ALARMS\PT_472_1_HIGH_ALARM} PT-472-1 RO1 CARTRIDGE FILTER

FEED PRESSURE HIGH ALARM



{ALARMS\AT_442_1_HIGH_ALARM} AT-442-1 RO1 FEED ORP ANALYZER

HIGH ALARM

{ALARMS\SI_501_1_HIGH_ALARM} SI-501-1 SPEED FEEDBACK FROM

VFD 501-1 HIGH ALARM

{ALARMS\PT_671A_1_HIGH_ALARM} PT-671A-1 RO1 PRE MEMBRANE

PRESSURE HIGH ALARM

{ALARMS\PT_672B_1_HIGH_ALARM} PT-672B-1 RO1 POST MEMBRANE

PRESSURE HIGH ALARM

{ALARMS\FT_651_1_HIGH_ALARM} FT-651-1 RO1 REJECT FLOW HIGH

ALARM

{ALARMS\PT_677_1_HIGH_ALARM} PT-677-1 RO1 REJECT PRESSURE

HIGH ALARM

{ALARMS\PT_672A_1_HIGH_ALARM} PT-672A-1 RO1 POST MEMBRANE

PRESSURE HIGH ALARM

{ALARMS\PT_678_1_HIGH_ALARM} PT-678-1 RO1 PERMEATE OUTLET

PRESSURE HIGH ALARM

{ALARMS\CT_643_1_HIGH_ALARM} CT-643-1 RO1 PERMEATE

CONDUCTIVITY ANALYZER HIGH

ALARM

O&M MANUAL PAGE 19

{ALARMS\FT_652_1_HIGH_ALARM} FT-652-1 RO1 PERMEATE OUTLET

FLOW HIGH ALARM

{ALARMS\AT_641_HIGH_ALARM} AT-641 RO1 PERMEATE pH

ANALYZER HIGH ALARM

{ALARMS\AT_646_1_HIGH_ALARM} AT-646-1 RO1 CHLORINE ANALYZER

HIGH ALARM

{ALARMS\LIT_761_HIGH_ALARM} LIT-761 TK-701 PRODUCT WATER

TANK LEVEL HIGH ALARM

{ALARMS\TT_481_2_HIGH_ALARM} TT-481-2 RO2 FEED TEMPERATURE

ANALYZER HIGH ALARM

{ALARMS\AT_441_2_HIGH_ALARM} AT-441-2 RO2 FEED pH ANALYZER

HIGH ALARM

{ALARMS\CT_443_2_HIGH_ALARM} CT-443-2 RO2 FEED CONDUCTIVITY

ANALYZER HIGH ALARM


FEED PRESSURE HIGH ALARM



{ALARMS\AT_442_2_HIGH_ALARM} AT-442-2 RO2 FEED ORP ANALYZER

HIGH ALARM

{ALARMS\SI_501_2_HIGH_ALARM} SI 501-2 SPEED FEEDBACK FROM

VFD 501-2 HIGH ALARM

{ALARMS\PT_671A_2_HIGH_ALARM} PT-671A-2 RO2 PRE MEMBRANE

PRESSURE HIGH ALARM

{ALARMS\PT_672B_2_HIGH_ALARM} PT-672B-2 RO2 POST MEMBRANE

PRESSURE HIGH ALARM

{ALARMS\FT_651_2_HIGH_ALARM} FT-651-2 RO2 REJECT FLOW HIGH

ALARM

{ALARMS\PT_677_2_HIGH_ALARM} PT-677-2 RO2 REJECT PRESSURE

HIGH ALARM

{ALARMS\PT_672A_2_HIGH_ALARM} PT-672A-2 RO2 POST MEMBRANE

PRESSURE HIGH ALARM

{ALARMS\PT_678_2_HIGH_ALARM} PT-678-2 RO2 PERMEATE OUTLET

PRESSURE HIGH ALARM

{ALARMS\CT_643_2_HIGH_ALARM} CT-643-2 RO2 PERMEATE

CONDUCTIVITY ANALYZER HIGH

ALARM

{ALARMS\FT_652_2_HIGH_ALARM} FT-652-2 RO2 PERMEATE OUTLET

FLOW HIGH ALARM

{ALARMS\AT_146_LOW_ALARM} AT-146 CHLORINE ANALYZER LOW

ALARM

{ALARMS\LIT_161_LOW_ALARM} LIT-161 TK-101 WATER STORAGE

TANK LEVEL LOW ALARM

{ALARMS\PT_373_1_LOW_ALARM} PT-373-1 MMF FEED PUMP P-301-1

INLET PRESSURE LOW ALARM


O&M MANUAL PAGE 20

INLET PRESSURE LOW ALARM


OUTLET PRESSURE LOW ALARM



{ALARMS\LIT_361_LOW_ALARM} LIT-361 TK-302 FILTER WATER TANK

LEVEL LOW ALARM

{ALARMS\PT_377_LOW_ALARM} PT-377 BACWASH PUMP INLET

PRESSURE LOW ALARM

{ALARMS\AT_344A_LOW_ALARM} AT-344A TURBIDITY ANALYZER

LOW ALARM

{ALARMS\AT_344B_LOW_ALARM} AT-344B TURBIDITY ANALYZER

LOW ALARM

{ALARMS\PT_375_LOW_ALARM} PT-375 BACWASH PUMP OUTLET

PRESSURE LOW ALARM

{ALARMS\PT_378_LOW_ALARM} PT-378 MMF INLET PRESSURE LOW

ALARM

{ALARMS\PT_379_LOW_ALARM} PT-379 MMF OUTLET PRESSURE LOW

ALARM

{ALARMS\TT_481_1_LOW_ALARM} TT-481-1 RO1 FEED TEMPERATURE

ANALYZER LOW ALARM

{ALARMS\AT_441_1_LOW_ALARM} AT-441-1 RO1 FEED pH ANALYZER

LOW ALARM

{ALARMS\CT_443_1_LOW_ALARM} CT-443-1 RO1 FEED CONDUCTIVITY

ANALYZER LOW ALARM

{ALARMS\PT_472_1_LOW_ALARM} PT-472-1 RO1 CARTRIDGE FILTER

FEED PRESSURE LOW ALARM



{ALARMS\AT_442_1_LOW_ALARM} AT-442-1 RO1 FEED ORP ANALYZER

LOW ALARM

{ALARMS\SI_501_1_LOW_ALARM} SI-501-1 SPEED FEEDBACK FROM

VFD 501-1 LOW ALARM

{ALARMS\PT_671A_1_LOW_ALARM} PT-671A-1 RO1 PRE MEMBRANE

PRESSURE LOW ALARM

{ALARMS\PT_672B_1_LOW_ALARM} PT-672B-1 RO1 POST MEMBRANE

PRESSURE LOW ALARM

{ALARMS\FT_651_1_LOW_ALARM} FT-651-1 RO1 REJECT FLOW LOW

ALARM

{ALARMS\PT_677_1_LOW_ALARM} PT-677-1 RO1 REJECT PRESSURE LOW

ALARM

{ALARMS\PT_672A_1_LOW_ALARM} PT-672A-1 RO1 POST MEMBRANE

PRESSURE LOW ALARM

{ALARMS\PT_678_1_LOW_ALARM} PT-678-1 RO1 PERMEATE OUTLET

PRESSURE LOW ALARM

O&M MANUAL PAGE 21

{ALARMS\CT_643_1_LOW_ALARM} CT-643-1 RO1 PERMEATE

CONDUCTIVITY ANALYZER LOW

ALARM

{ALARMS\FT_652_1_LOW_ALARM} FT-652-1 RO1 PERMEATE OUTLET

FLOW LOW ALARM

{ALARMS\AT_641_LOW_ALARM} AT-641 RO1 PERMEATE pH

ANALYZER LOW ALARM

{ALARMS\AT_646_1_LOW_ALARM} AT-646-1 RO1 CHLORINE ANALYZER

LOW ALARM

{ALARMS\LIT_761_LOW_ALARM} LIT-761 TK-701 PRODUCT WATER

TANK LEVEL LOW ALARM

{ALARMS\TT_481_2_LOW_ALARM} TT-481-2 RO2 FEED TEMPERATURE

ANALYZER LOW ALARM

{ALARMS\AT_441_2_LOW_ALARM} AT-441-2 RO2 FEED pH ANALYZER

LOW ALARM

{ALARMS\CT_443_2_LOW_ALARM} CT-443-2 RO2 FEED CONDUCTIVITY

ANALYZER LOW ALARM


FEED PRESSURE LOW ALARM



{ALARMS\AT_442_2_LOW_ALARM} AT-442-2 RO2 FEED ORP ANALYZER

LOW ALARM

{ALARMS\SI_501_2_LOW_ALARM} SI 501-2 SPEED FEEDBACK FROM

VFD 501-2 LOW ALARM

{ALARMS\PT_671A_2_LOW_ALARM} PT-671A-2 RO2 PRE MEMBRANE

PRESSURE LOW ALARM

{ALARMS\PT_672B_2_LOW_ALARM} PT-672B-2 RO2 POST MEMBRANE

PRESSURE LOW ALARM

{ALARMS\FT_651_2_LOW_ALARM} FT-651-2 RO2 REJECT FLOW LOW

ALARM

{ALARMS\PT_677_2_LOW_ALARM} PT-677-2 RO2 REJECT PRESSURE LOW

ALARM

{ALARMS\PT_672A_2_LOW_ALARM} PT-672A-2 RO2 POST MEMBRANE

PRESSURE LOW ALARM

{ALARMS\PT_678_2_LOW_ALARM} PT-678-2 RO2 PERMEATE OUTLET

PRESSURE LOW ALARM

{ALARMS\CT_643_2_LOW_ALARM} CT-643-2 RO2 PERMEATE

CONDUCTIVITY ANALYZER LOW

ALARM

{ALARMS\FT_652_2_LOW_ALARM} FT-652-2 RO2 PERMEATE OUTLET

FLOW LOW ALARM

{ALARMS\P_301_1_FILTER_FEED_PUMP

_ALARM}

P-301-1 RO1 FEED PUMP FAULT

ALARM

{ALARMS\P_302_BACKWASH_PUMP P-302 BACKWASH PUMP FAULT

O&M MANUAL PAGE 22

_ALARM} ALARM

{ALARMS\P_901_FRESH_FLUSH_PUMP

_ALARM}

P-901 FRESH FLUSH PUMP FAULT

ALARM

{ALARMS\P_501_1_HIGH_PRESSUE

_PUMP_ALARM}

P-501-1 RO1 HIGH PRESSURE PUMP

FAULT ALARM

{ALARMS\P_501_2_HIGH_PRESSUE_

PUMP_ALARM}

P-501-2 RO2 HIGH PRESSURE PUMP

FAULT ALARM

{ALARMS\VOLTAGE_VARIANCE

_ALARM}

VOLTAGE VARIENCE ALARM

{ALARMS\PSH_572_1_ALARM} PSH-572-1 RO1 PRE MEMBRANE HIGH

PRESSURE ALARM

{ALARMS\PSH_572_2_ALARM} PSH-572-2 RO2 PRE MEMBRANE HIGH

PRESSURE ALARM

{ALARMS\PSL_571_1_ALARM} PSL-571-1 RO1 FEED LOW PRESSURE

ALARM

{ALARMS\PSL_571_2_ALARM} PSL-571-2 RO2 FEED LOW PRESSURE

ALARM

{ALARMS\P_301_2_FILTER_FEED_PUMP

_ALARM}

P-301-2 RO2 FEED PUMP FAULT

ALARM

{ALARMS\ANTISCALANT_TANK_LOW

_ALARM}

LSL - 263 ANTISCALANT TANK LOW

ALARM

{ALARMS\PRECHLORINATION_TANK

_LOW_ALARM}

LSL - 261 PRE CHLORINATION TANK

LOW ALARM

{ALARMS\SODIUM_METABISULPHITE

_TANK_LOW_ALARM}

LSL - 265 SODIUM META BISULFITE

TANK LOW ALARM

5.4 HMI Screens

1. ALARM HISTORY

This Screen displays a list of all alarms that have occurred.

Press "ACK ALARM" to acknowledge the alarm.

O&M MANUAL PAGE 23

Press "ACK ALL ALARMS" to acknowledge the all alarms.

Use the and keys to scroll through Alarm History.

Press "Close" to close the Alarm History window.

2. HOUR COUNTER

This Screen displays Current Run counter and Total Run counter of the system.

Press "MAIN" button to navigate to "MAIN" screen.

Press "MENU" button to navigate to "MAIN MENU" screen.

Press "RETURN" button to navigate to previous screen.

Press "ACK" to acknowledge the current alarm.

3. MAIN

This screen displays Current Time of system to stop.

This screen displays Status of System in Local Message Display.

Press "SETTING" button to navigate to "RO SETTING" screen.


O&M MANUAL PAGE 24

Press "RESET" to reset the alarms.

Press "START" to start the system.


4. AI CONFIGURATION

This Screen shows Analog Input Configuration for selected Analog Input Sensor.

This screen shows set points (Engineering Maximum and Engineering Minimum) for selected

Analog Input.

For changing the Set points, Select the Set point Field which will pop-up keypad and then you

can enter the Set point value.

This Screen displays status of channel weather it is “Healthy” or “Out of Range” for selected

Analog Input.

This screen provides “Analog Enabled” and “Analog Disabled” selection for selected analog input.

Press "NEXT" button to navigate to next analog input configuration screen.

Press "SENSOR" button to navigate to analog monitor screen.


Press "BACK" button to navigate to previous screen.


5. RO BACKWASH

O&M MANUAL PAGE 25

This screen provides Backwash Valves Status.

Press "NEXT" button to navigate to next screen.



6. RO OUTPUT

This screen provides RO output Status.

Press "NEXT" button to navigate to next screen.



7. MENU

O&M MANUAL PAGE 26

Use the and keys to scroll through “Menu”.

Press the (enter) key to enter the selected screen.

Press "LOGIN / LOGOUT" to provide authentication / security to the system.



8. AI SETTING

This screen displays Real time value of selected Analog Input Sensor.

This screen shows set points (Set High and Set Low) for selected Analog Input Sensor.



This screen displays status for Analog Input Sensors.

Press "BACK" button to navigate to previous screen.

Press "MORE" button to navigate to next setting screen.




O&M MANUAL PAGE 27

9. AI MONITOR

This screen displays Value and status of selected Analog Input Sensors.

Press "MORE" button to navigate to next analog sensor monitor screen.

Press "SET" button to navigate to AI setting screen.




10. AI ENABLE/DISABLE

This screen provides ON/OFF selection for particular Analog Input Sensor.

Press "MENU" button to navigate to next Enable Sensor screen.




11. BACKWASH SETTINGS

O&M MANUAL PAGE 28

This screen shows set points for Backwash settings.



Press "MORE" button to navigate to next backwash setting screen.



Press "BW" button to navigate to Backwash Status screen.


12. CHEMICAL DOSING

This screen displays status of Chemical Pumps.

This screen provides ENABLE/DISABLE Selection of Chemical Pump Status


Press "MORE" button to navigate to next chemical dosing screen.


O&M MANUAL PAGE 29


13. STS INFORMATION


Press "Panel View Configuration" button to SHUT DOWN.


O&M MANUAL PAGE 30

6.0 MAINTENANCE AND SERVICE

This section consists of summary of system maintenance tasks which include scheduled maintenance and regular repairs. This section is to be read in conjunction with the detailed maintenance/troubleshooting/repair instructions in the respective manuals supplied by various manufacturers. All maintenance should be documented in a Maintenance log, as to maintain a chronological history of all maintenance tasks performed, while attempt has been made to make this section as exhaustive as possible. Site specific problems are not included here. Need to evolve and establish detailed maintenance schedule specific to site may exist and instruction for handling such situations may be added to this section, in conjunction with the manufacturer, where necessary.

6.1 Preventive Maintenance

Regular preventive maintenance tasks are recommended on a periodic basis. The Critical aspects are summarized below

Components Description of Service Remarks

Complete RO System (Daily)

General Inspection of the entire system to check for any leaks or malfunctioning. Clean any Visible surface corrosion. Clean and paint any surface skid frame corrosion as required. Take water samples at different stages and locations in the Reverse Osmosis plant and especially before and after the RO skid. Check for TDS, Chlorine, Organics.

Fill out daily log

Write in the log of all relevant instrumentation readings such as total hrs, all pressure readings taken periodically, flow meter readings, pH and temperature as well as TDS readings.

Fax these filled out details to the manufacturer on weekly basis.

RO Skid Cleaning

Organic as well as inorganic membrane cleaning.

Follow steps in the membrane cleaning section. We recommend keeping stock of the cleaning chemicals.

Section

6

O&M MANUAL PAGE 31

Cartridge Filters

Replace Cartridge Filter as required We recommend keeping a stock of cartridge filters as they get consumed very fast. Under no circumstances should the unit be allowed to run without cartridge filters.

6.2 Instrument Calibration

Recommend intervals for calibration tasks as recommended on a periodic basis. The critical aspects are summarized below to serve as a guide.

Instruments Frequency of Calibration Recommended

Conductivity instruments 60 days

Flow indicator 90 days

Pressure indicators 100 days

Pressure switch 60 days

Level Switch 60 days

pH and ORP instrument 60 days

O&M MANUAL PAGE 32

7.0 RO MEMBRANE CHEMISTRY AND CLEANING

What is RO Membrane Fouling?

The deposition of insoluble or sparingly soluble compounds is termed as fouling when this occurs in the RO system, an additional resistance to water flow is created which lowers the flow of water through the membrane itself; and /or increase the pressure drop across the elements. Either of these occurrences result in inefficiencies in the system which require more energy (due to increased applied pressure) to do the same work. To reverse this effect it is necessary to remove the scale and/or Foulant from the system. This is accomplished by cleaning the system. The effectiveness of cleaning will depend upon the technique and chemicals used as well as the severity of the conditions.

7.1 Types of Fouling

In a spiral wound membrane RO system, fouling can occur in two places, in the brine Channel and /or the membrane surface. All fouling situations will be one of these types of combination of the two. Each water source in general has its own fouling materials furthermore; each will tend to have its own fouling rate foulants falls into two broad categories, Inorganic and organic.

7.1.1 Inorganic Foulant

They occur as a result of inadequate or poorly operated pre-treatment or by exceeding the solubility limits of a sparingly salt.

7.1.1.1 Heavy Metal Hydrates

Hydrated metal oxides are a group of chemical compound that include iron, manganese, aluminum and chromium. In water, these compounds form hydrates with the water and are characterized by a fluffy appearance when allowed to agglomerate. Hydrated iron oxide is frequently encountered as a membrane foulant and easily identified by its reddish brown appearance.

7.1.1.2 Calcium Carbonate (CaCO3)

Calcium carbonate precipitation or scaling can be generally expected when Calcium and bicarbonate alkalinity are present in the water at pH above 7. As permeate is removed from the feed-stream with the consequent concentration of salts and as the bicarbonate- carbonate equilibrium shifts due to the transfer of carbon dioxide through the membrane, the following reaction occurs.

Ca++ + 2HCO3 = CO2 + CaCO3 + H2O

Calcium carbonate precipitation on the membrane surface can cause a significant loss of water flux. It is easily removed by flushing with acidified water.

Section

7

O&M MANUAL PAGE 33

7.1.1.3 Calcium and other insoluble Sulfates

Calcium sulfate is probably the most common sparingly soluble salt that limits the recovery of R.O. Systems. Others are barium and strontium salts. Any or all of these three salts. As foulants can cause failure at the Reverse Osmosis system generally due to excessive pressure drops and ultimate physical damage to the elements; once precipitated, these are difficult to remove as they go into solution very slowly.

7.1.2 Organic Foulants

Organic foulants includes oil and grease, algae and trace organic compounds causing biological growth. Biological foulants are most commonly encountered.

7.1.2.1 Algae

Algae if grows in the feed water supply system can seriously jeopardize a systems performance. Typically, the pre-treatment equipment would be overloaded due to this additional load of suspended solids leading to break through from channel causing increase in pressure drop. If allowed to proceed without corrective action can cause irreversible physical damage to the elements.

7.1.2.2 Bacteria

Bacteria have a unique ability to adapt to their environment, develop resistant strains and suddenly multiply and go out of control. If left unchecked the foulant layer can totally occupy the available space in the feed flow resulting into substantial loss of water flux and increase in pressure drop ultimately leading to physical damage. The effects of fouling are however apparent much earlier and hence data collection and interpretation are important factors in successful operation of R.O. Plants.

7.1.2.3 Lubricants, Grease and Oil

Normally grease and oils are not present in naturally occurring waters. These foul the membranes by forming an impervious layer on the surface. Small amounts of these foulants cause substantial reduction in the flux and permanent damage. Under no circumstances membranes must be exposed to any of the above.

In summary, RO Membranes need to be protected specially from the following:

Residual Chlorine, Bromine, Iodine

Suspended particles

Oil and grease

Hot water more than 40°C

Iron, Aluminum and heavy Metals

Dry condition (Storage)

O&M MANUAL PAGE 34

7.2 RO Membrane Cleaning

7.2.1 Procedure for Organic Cleaning

1. Make sure the Cleaning Tank is filled with fresh de-chlorinated water.

Note: The cleaning tank should only be filled with de-chlorinated fresh water. Make sure valves BF-814, BF-815 are closed.

2. Open cleaning valve BF-816.

3. Start the Cleaning Pump from MCP (Main Control Panel).

4. Pour the chemical cleaner 411 into the tank as the cleaning pump is re-

circulating the water. A ratio of 1 lb chemical to 5 gallons of water is used. Re-circulate for 10 minutes or until the powder is completely dissolved.

Warning:

The cleaning powder must be completely dissolved or else it will clog up the membrane pores and cause irreversible damage to the membranes. This kind of damage will not be covered under our warranty.

5. Shut off the cleaning pump.

7.2.2 Cleaning RO PV-601-1/2 thru PV-622-1/2

1. Make sure BF-814, BF-815 are closed. 2. Open Valve BF-816. 3. Start the cleaning pump again. The cleaning cycle has now begun. 4. Let the cleaning cycle run for 1 hour 5. Shut off the cleaning pump.

7.2.3 Drain the Cleaning Solution

1. Open drain valve.

2. Allow cleaning tank to drain completely

3. Close drain valve.

4. Fill the Clean fresh de-chlorinated water.

O&M MANUAL PAGE 35

5. Start the Cleaning pump

6. Run for 10 to 15 minutes the same level as the de-chlorinated fresh water. (Repeat step 1 thru 6 as necessary to the neutral pH)

7.2.4 Procedure for Cleaning Chemical 403

Follow exactly the same procedures above for all sets using chemical cleaner 403.

O&M MANUAL PAGE 36

8.0 TROUBLESHOOTING

This section is designed to guide the operator of a Severn Trent Services system in locating the probable cause of the most frequent encountered problems. Any problem not covered in this section may be resolved by contacting Severn Trent Services or an authorized service center in your area.

8.1 Reverse Osmosis

Sr.No.

Symptom Probable Cause Action

1. Low pressure at Pump Suction

a) Feed water Supply inadequate

b) Cartridge Filter plugged

a) Correct inadequate condition.

b) Remove blockage or change cartridge as required.

2. High Motor Current operation

a) Defective motor or low voltage at motor terminals.

b) High pressure pump or system defective.

c) RO recovery too low or flows too high.

a) I) Correct low voltage condition

ii) Check Motor

b) Check all the components for any failures leading to over load. Repair/Replace if required.

c) Adjust to specified values.

3. High pressure at pump discharge

a) Pressure Control valve malfunction

a) Check and rectify.

4. High permeate TDS

a) Unequal flows or pressure in RO section.

b) ‘O’ Ring leakage (inter-connector)

c) Membrane Fouling

d) Change in raw water TDS.

a) Check and adjust to specified level.

b) I) Test sample from each pressure tube.

ii) When tube with problem is located, probe the tube to identify the problem.

iii) Replace the ‘O’ ring at the location identified.

c) i) Clean & flush membrane element.

ii) Replace membrane element, if it cannot be cleaned in feed.

d) Consult Manufacturer.

Section

8

O&M MANUAL PAGE 37

Sr.No.

Symptom Probable Cause Action

5. Low Brine flow a) Flows & pressure imbalanced.

a) Check recovery & valve flows and adjust to specified levels.

6. High permeate flow

a) Change in feed pressure.

b) Feed water temperature.

c) Inter connector ‘O’ ring leakage.

d) Membrane element breakdown.

a) Check recovery & valve flows and adjust to specified levels.

b) Reduce feed pressure and adjust recovery.

c) Refer to 4(b) above.

d) i) Check individual membrane element performance.

ii) Replace faulty elements.

7. Low permeate flow

a) Change in feed pressure.

b) Feed water temperature low.

c) Membrane fouling.

a) Check recovery and adjust to specified level.

b) Increase feed pressure & readjust recovery.

c) Refer to 4 (c) above.

O&M MANUAL PAGE 38

8.2 Pumps

Problem: Suction pressure low

Danger Operating the pump with low suction pressure can damage the pump and result in low efficiency and low discharge pressure.

Danger Verify that pre-treatment filters are not plugged or excessively dirty.

Problem: Discharge pressure low

Danger If the flow is too high this will cause the discharge pressure to be low. This condition can overload the motor and may cause other damage to the pump and other components in the system.

Danger Verify that motor RPM is as expected. Verify that the flow rate is at the expected level Verify that the motor rotation is in the proper direction

Problem: Water Mist appears around the pump sheave

Comment If mist appears around the hub then a part of the bearing flow is escaping along

the shaft and into the pump hub. The rotating hub throws the water out as a fine mist. This is not steam. The pump can continue to operate. However, the mist is nuisance and should be corrected at the first opportunity. A large increase in the bearing leakage rate compared with the rate when the pump was new indicates that the pump needs to be overhauled.

O&M MANUAL PAGE 39

Here are general system operation guidelines. This should provide you as a quick check DO and DO NOT list to keep the system under control.

TO DO NOT TO DO

To follow the guide lines provided in the Operation Manual for proper starting and shut down of the plant.

Not to operate the plant when the SDI of the feed water is more than the limiting factor specified.

The plant to be operated by the trained and experienced personnel in Reverse Osmosis.

Not to operate the plant when the pressure difference across 5 micron filter is more than 20 percent.

To check the SDI of the feed water every day before the HP Pump.

Not to operate the plant when the feed water conductivity is more than the limiting factor specified.

To change the CF cartridges if the pressure difference exceeds more than 1.0 kg. /cm² OR 15-20 PSI OR once in three months whichever earlier.

Not to run the High Pressure Pump with insufficient suction pressure.

Before starting HPP, keep the system full of water and free of air.

Not exceed the product recovery rate more than the specified.

To check for any abnormality of HPP. Not to open and dismantle the HPP during the Warranty Period without prior information to the manufacturer.

To monitor the system pressure at different level of the process as per the recommendation provided in the Operation Manual.

Not to open the RO module incase of any deviations of the plant parameters without prior information to the manufacturer during the Warranty period.

To correctly balance the RO Product and reject flow rate as per the plant design and specifications.

Not to operate the plant without checking the presence of any oxidizing agents such as ozone, chlorine before the RO feed.

To ensure system interlocks are in line as a protection to the plant equipments.

Not to use duplicate spare parts / regular consumables, this may impair the long life of system and equipment.

To closely observe the pressure difference across the RO Module, quality of product water produced.

O&M MANUAL PAGE 40

To calibrate at regular intervals as per our recommendation all the instruments for accuracy and reliability of data for ensuring overall integrity and efficiency of the plant.

To keep proper record keeping such as daily operational log sheets, review the plant status, recording of daily events, activities carried out and to maintain the equipment history record to carry out necessary service in time.

Always maintain minimum inventory of original spares and regular consumables to reduce down time of the plant equipments.

O&M MANUAL PAGE 41

9.0 WARRANTY

ALL IMPLIED WARRANTIES INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED TO THE TERMS AND PERIODS OF WARRANTY SET FORTH BELOW, AND TO THE EXTENT PERMITTED BY LAW ANY AND ALL IMPLIED WARRANTIES ARE EXCLUDED.

THIS LIMITED WARRANTY IS EXTENDED IN LIEU OF ALL OTHER WARRANTIES, AGREEMENTS OR OBLIGATIONS, EXPRESSED OR IMPIED, COVERING SEVERN TRENT WATER PURIFICATION – UNIVERSAL AQUA (STWP/UAT) COMPONENTS. THE LAWS OF THE STATE OF CALIFORNIA SHALL GOVERN THIS WARRANTY.

THIS WARRANTY DOES NOT COVER DAMAGES, INCIDENTAL AND/OR CONSEQUENTIAL DUE TO THE FAILURE OF STWP/UAT’S EQUIPMENT.

1. FACTORY SERVICE / REPLACEMENT-EXCHANGE. STWP/UAT WILL REPAIR, OR

REPLACE, AT ITS OPTION, COMPONENTS FOUND TO BE DEFECTIVE DUE TO FAULTY MATERIALS OR WORKMANSHIP, WHEN SUCH COMPONENTS, EXAMINED BY AN AUTHORIZED SERVICE DEALER OR A FACTORY AUTHORIZED TECHNICIAN, ARE FOUND TO HAVE A DEFECT FOR WHICH THE COMPANY IS RESPONSIBLE. STWP/UAT WARRANTS ALL PARTS REPLACED DURING FACTORY SERVICE PERFORMED AT ITS PLANT OF MANUFACTURE FOR A PERIOD OF TWELVE (12) MONTHS FROM DATE OF DELIVERY OR (18) MONTHS FROM DATE OF SHIPMENT (WHICHEVER OCCURS FIRST), AGAINST DEFECTS IN MATERIALS AND WORKMANSHIP WHEN USED IN COMPLIANCE WITH STWP/UAT'S OPERATING MANUALS OR INSTALLED IN ACCORDANCE WITH STWP/UAT ASSEMBLY INSTALLATION INSTRUCTIONS AND GUARANTEES TO REPAIR OR REPLACE, WITHIN THAT PERIOD, AT ITS OPTION, ANY PRODUCT WHICH PROVES, UPON EXAMINATION TO THE SATISFACTION OF STWP/UAT, AT STWP/UAT'S PLANT OF MANUFACTURE, TRANSPORTATION CHARGES PREPAID BY BUYER, TO BE DEFECTIVE, OR, AT ITS OPTION, THE NET SALES PRICE OF SAID PRODUCT WILL BE REFUNDED, PROVIDED THE DEFECT OCCURRED IN MANUFACTURE AND NOT FROM ANY OTHER CAUSE WHATSOEVER. NO LABOR IS INCLUDED. LABOR COSTS ARE NOT COVERED UNDER THIS WARRANTY. THE STWP/UAT WARRANTY WILL ONLY COVER THE ORIGINAL PARTS ACTUALLY MANUFACTURED BY STWP/UAT. STWP/UAT WILL PASS ONTO THE BUYER THE ACTUAL WARRANTY OF THE THIRD PARTY WHO ACTUALLY SUPPLIED OR BUILT THE COMPONENT/EQUIPMENT IN QUESTION.

2. RECOMMENDATIONS AND ADVICE AS TO PROPERTIES AND USAGES OF MATERIALS,

DESIGN, INSTALLATION AND USE OF PRODUCTS, ENGINEERING AND OTHER MATTERS ARE PROVIDED AS AN ACCOMMODATION AND ARE INTENDED ONLY AS SUGGESTIONS. STWP/UAT ASSUMES NO OBLIGATION OR LIABILITY FOR ANY RESULTS OBTAINED IN THEIR USE OR APPLICATION, AND THEY ARE NOT TO BE CONSTRUED AS ESTABLISHING ANY WARRANTY, EXPRESS OR IMPLIED.

3. IF THE COMPONENT HAS TO BE EXAMINED AT THE FACTORY, THEN THE CUSTOMER

IS RESPONSIBLE TO SHIP THE COMPONENT IN QUESTION BACK TO THE FACTORY, FREIGHT PREPAID. IF THE CUSTOMER, PRIOR TO EXAMINATION OF THE COMPONENT, REQUESTS A REPLACEMENT OF THE COMPONENT IN QUESTION, THEN

Section

9

O&M MANUAL PAGE 42

THE CUSTOMER WILL BE CHARGED FOR THE REPLACEMENT COMPONENT. ONCE THE COMPONENT IN QUESTION IS RECEIVED AND EXAMINED, THE CUSTOMER WILL BE INFORMED IF THE ITEM FALL UNDER THE WARRANTY CRITERIA. IF THE COMPONENT IS TO BE REPLACED UNDER WARRANTY, AND THE CUSTOMER HAS ALREADY PAID FOR A REPLACEMENT, THEN A CREDIT WILL BE ISSUED BACK TO THE CUSTOMER. IF THE COMPONENT DOES NOT FALL UNDER THE STWP/UAT WARRANTY CRITERIA, THEN THE CUSTOMER WILL BE RESPONSIBLE FOR THE COST OF THE REPLACEMENT.

4. WARRANTY ON MEMBRANES:

STWP/UAT WARRANTS THAT MINIMUM PERMEATE FLOW, WHEN OPERATED UNDER

STANDARD CONDITIONS SHALL BE AT LEAST 15% PLUS OR MINUS THE SPECIFIED

INITIAL AVERAGE FLOW SHOWN IN THE STWP/UAT OFFER. THE MEMBRANES WILL

HAVE A 12-MONTH PRO-RATED WARRANTY. STWP/UAT WILL ON CONFIRMATION OF

LOSS OF PERFORMANCE DURING THIS WARRANTY PERIOD, CREDIT 1/12 OF THE

REPLACEMENT PRICE OF THE ELEMENT FOR EACH UNUSED MONTH OF THE

WARRANTY PERIOD TOWARD THE PURCHASE OF A REPLACEMENT MEMBRANE

ELEMENT AT THE CURRENT PREVAILING RETAIL PRICE.

THE WARRANTY DESCRIBED ABOVE FOR THE MEMBRANE SYSTEMS SHALL BE NULL AND VOID IF ANY OF THE FOLLOWING CONDITIONS ARE NOT MET:

I. THE FEEDWATER TEMPERATURE SHALL NOT EXCEED 40 DEGREES C. II. CHANGES IN FEED WATER QUALITY BASED ON THE ORIGINAL FEED WATER

QUALITY THE SYSTEM WAS SOLD AND DESIGNED FOR. III. DURING SHUTDOWNS, THE EQUIPMENT HAS TO BE PRESERVED AGAINST

MICROBIOLOGICAL CONTAMINATION. IV. THE MEMBRANES HAVE TO BE CLEANED PERIODICALLY FOLLOWING THE

EXACT INSTRUCTIONS GIVEN IN THE OPERATION MANUAL. V. FEEDWATER TO THE EQUIPMENT SHALL CONTAIN NO CHLORINE, OZONE,

PERMANGANATE OR OTHER STRONG OXIDIZING AGENTS. VI. MEMBRANES ARE ALLOWED TO FREEZE.

VII. THE SYSTEM DAILY LOG SHEETS MUST BE FILLED OUT AND SAVED BY THE BUYER. ONCE A WEEK A SUMMARY COPY MUST BE FAXED TO STWP/UAT TORRANCE CA USA (310)618-1204 ATTN: STWP-UAT SERVICE MANAGER.

5. THIS WARRANTY SHALL NOT APPLY TO:

A) FAILURES DUE TO NORMAL WEAR, ACCIDENT, MISUSE, NEGLIGENCE, OR IMPROPER INSTALLATION OR LACK OF REASONABLE AND NECESSARY MAINTENANCE.

B) PRODUCTS, WHICH ARE MODIFIED, REPAIRED OR ALTERED IN A MANNER NOT AUTHORIZED IN WRITING BY STWP/UAT.

C) INADEQUATE INSTALLATION PROCEDURES. D) SERVICE PERFORMED BY AN UNAUTHORIZED SERVICE DEALER WITHOUT PRIOR

WRITTEN AUTHORIZATION FROM STWP/UAT. E) ANY LABOR AND TRAVEL EXPENSES. F) TELEPHONE, TELEFAX, OR OTHER COMMUNICATION EXPENSES.

O&M MANUAL PAGE 43

6. STWP/UAT WILL NOT PAY FOR ANY CUSTOM DUTIES FOR REPAIR OR REPLACEMENT OF COMPONENTS

7. FREIGHT CHARGES FOR COMPONENTS RETURNED TO STWP/UAT MUST BE SHIPPED

BACK TO STWP/UAT FREIGHT PREPAID. PARTS RETURNED WITH COLLECT FREIGHT CHARGES WILL NOT BE ACCEPTED AND WILL BE RETURNED TO SHIPPER.

8. A RETURN GOODS AUTHORIZATION NUMBER “RGA” HAS TO BE ISSUED TO THE BUYER BY STWP/UAT FOR THE DEFECTIVE PART (S) TO BE RETURNED

9. DEFECTIVE PARTS ARE TO BE RETURNED FREIGHT PREPAID BY BUYER TO

STWP/UAT WITHIN THIRTY (30) DAYS OF RECEIPT OF REPLACEMENT PART BY BUYER, IF SO REQUESTED BY STWP/UAT

10. NO PERSON, DEALER OR COMPANY IS AUTHORIZED TO EXTEND ANY OTHER

WARRANTIES OR TO ASSUME OTHER LIABILITIES ON BEHALF OF STWP/UAT

11. THE FOLLOWING IS A SAMPLE LIST OF NORMAL RE-OCCURRING SRVICE/MAINTENANCE PARTS WHICH ARE NOT COVERED BY THIS LIMITED WARRANTY, OTHER ITEMS MAY BE INCLUDED THAT ARE NOT LISTED HERE:

a) ALL CARTRIDGE FILTER ELEMENTS b) PUMP SEALS c) PUMP PACKING d) PUMP VALVE ASSEMBLIES e) BELT DRIVES f) GAUGE INSTRUMENT CALIBRATION g) CHEMICAL INJECTION POINTS h) AUXILIARY TUBING i) FUSES AND RELAYS j) ALL INSTRUMENT TRANSMITTERS AND PROBES k) INDICATION LAMPS l) ALL O-RINGS AND SEALS m) MEMBRANE CLEANING CHEMICALS n) FEEDWATER PRETREATMENT CHEMICALS o) ALL BEARINGS p) MOTORS q) PNEUMATIC COMPONENTS, VALVES, AND PISTONS (MOVING PARTS)

12. THE FOREGOING STATES THE ENTIRE WARRANTY AND REPRESENTS THE BUYER'S

EXCLUSIVE REMEDY HEREUNDER. NO OTHER WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IS EXPRESSED OR IMPLIED. STWP IS NOT LIABLE FOR CONSEQUENTIAL DAMAGES OR CLAIMS FOR ANY DAMAGES WHATSOEVER (WHETHER DIRECT, IMMEDIATE, FORESEEABLE, CONSEQUENTIAL OR SPECIAL) SUFFERED BY BUYER OR ANYONE ELSE ARISING OUT OF ANY BREACH BY STWP.

CAUTION: USE OF NON – SEVERN TRENT WATER PURIFICATION – UAT PARTS AND PARTS NOT SUPPLIED DIRECTLY BY STWP/UAT, INCLUDING, BUT NOT LIMITED TO MAINTENANCE PARTS, CHEMICALS, LUBRICANTS, SPARE PARTS, REPLACEMENT PARTS, SYSTEM COMPONENTS AND OR SYSTEM ACCESSORIES, SHALL IMMEDIATELY NULL AND VOID ALL WARRANTIES.

O&M MANUAL PAGE 44

10.0 DRAWINGS

10.1 P&ID

10.2 Mechanical

10.3 Electrical

Section

10

O&M MANUAL PAGE 45

11.0 O&M LITERATURE

11.1 Pumps

11.2 Pressure Vessels

11.3 Membranes

11.4 Instruments

11.5 Electrical Components

11.6 Miscellaneous

Section

11

O&M MANUAL PAGE 46

12.0 LOG SHEET

Section

12

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