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REVERSE OSMOSIS WATER TREATMENT PLANT

HOLDEN LTD - ELIZABETH

OPERATING AND MAINTENANCE MANUAL

TABLE OF CONTENTS

1. General 2. Plant Description 3. Process Description 4. Description of Controls and Touchscreen Manual 5. Performance Data 6. Plant Operation 7. Datalogging and Routine Maintenance 8. Preventative Maintenance 9. Troubleshooting 10. Membrane Projections 11. Spare Parts List 12. Electrical Control Description

Appendices: A. Mechanical & Electrical Drawings B. Calibration Certificates

C. Comissioning Check Sheets D. Material Safety Data Sheets

E. Pumps & Variable Speed Drives Grundfos CRN32-6 Grundfos CRN16-120 Stenner 45MHP2 Danfoss VLT-6016 11kW F. Valves & Flow Controllers

G. Pneumatics H. Flowmeters

IJ. Instruments K. RO Components L. Miscellaneous

REVERSE OSMOSIS WATER TREATMENT PLANT HOLDEN LTD - ELIZABETH


Holden Ltd Elizabeth RO Water Treatment Plant 2 of 30 Operating and Maintenance Manual Version 1.0

SECTION 1 - GENERAL THE REVERSE OSMOSIS PROCESS Reverse Osmosis (RO) is a membrane process that acts as a molecular filter to remove 95 - 99% of dissolved salts and organics, and more than 98% of biological and colloidal matter from water. Osmosis and reverse osmosis depend on the characteristics of a semi - permeable membrane, which allows water to pass readily but retards the flow of dissolved salts. Osmosis is a natural process in which pure water flows through a membrane from a dilute solution to more concentrated solution thereby diluting the latter. In reverse osmosis the osmotic pressure of the system is overcome by applying an external pressure. Thus the flow of water is reversed and pure water is removed from the feed solution, leaving a more concentrated salt solution. The process water flow in reverse osmosis desalination systems can be divided into 3 basic streams. 1) Feed the filtered raw water supplied to the machine. 2) Permeate the purified water produced by forcing the feed through the semi- permeable membranes. 3) Reject the discarded waste water containing the concentrated salts removed from the feed water. These bold terms will be used frequently throughout this manual. A flow schematic of the reverse osmosis process is as follows. Feed Permeate Water RO Membrane Water High Pressure Feed Pump Reject Water




The major factors affecting the operation of a reverse osmosis system include the following. Feed Water Salinity As the Total Dissolved Solids (TDS) level in the feed water rises the feed pressure requirement also rises. A higher feed pressure in turn usually results in higher rejection of the dissolved salts (ie the proportion of salts passing through the membrane into the permeate stream). Feedwater Temperature The reverse osmosis process is greatly affected by temperature. Designs are normally based on 25ºC. As feed water temperature falls below this, the permeate flowrate drops. For a true membrane performance analysis, the raw results from the RO system must be normalised to a standard temperature. Recovery Rate The recovery rate is the term used to describe the volume of permeate recovered as a proportion of the total feed water supplied to the machine and is expressed as a percentage. For example, if the feed flow to the machine was 60 litres per minute and the permeate flow was 27 litres per minute then the recovery rate would be (27/60 x 100%) or 45%. With multistage centrifugal main system pumps, the recovery rate can vary widely with the system pressure. It also can vary widely with the age of the membranes, the temperature and salinity of the feed water. Increasing the recovery rate reduces the amount of water wasted and also improves the power efficiency of the unit. It is important that the recovery rate is not increased above the recommended maximum set out in the Operating Specifications, or irreversible fouling of the RO system can occur.




SECTION 2 - PLANT DESCRIPTION The Reverse Osmosis Water Treatment Plant generally consists of the following main equipment. A more detailed information for equipment items can be found in Appendices E to L. 1. Multi Media Filter Quantity : 2 Maker : Gebel Model : PT10518 Diameter : 1050mm Vessel Material : FRP 2. UV Steriliser Quantity : 1 Maker : Australian UV Model : Uviflo 15,000-S-170 Housing Material : 316SS Sleeve Material : Quartz glass Service Flow (per UV) : 15 kL/hr 3. Cartridge Filter (5 micron) Quantity : 2 Maker : Amazon Model : 610540AN20G1EE

Type : 40” x 5 element housing Housing Material : 316SS Cartridge Filter : Wound Polypropylene, DPPPB-4 Service Flow (per filter) : 15 kL/hr Rating : 5 micron nominal 4. Cartridge Filter (1 micron) Quantity : 2 Maker : Amazon Model : 610540AN20G1EE Type : 40” x 5 element housing Housing Material : 316SS Cartridge Filter : Wound Polypropylene, DPPPY-4 Service Flow (per filter) : 15 kL/hr Rating : 1 micron nominal




5. High Pressure Feed Pump RO Pass # 1

Quantity : 2 (Duty & Standby) Type : Multistage centrifugal Maker : Grundfos Model No. : CRN 32-6 Material : 316 stainless steel wetted parts Duty Flow each : 21.0 kL/hr Duty Head : 9.0 bar Motor : 415VAC, 11KW, 50Hz Accessories : Variable speed drive

RO Pass # 2 Quantity : 2 (Duty & Standby) Type : Multistage centrifugal

Maker : Grundfos Model No. : CRN 16-120 Material : 316 stainless steel wetted parts Duty Flow each : 16.0 kL/hr Duty Head : 9 bar Motor : 415VAC, 11KW, 50Hz Accessories : Variable speed drive 6. Reverse Osmosis Block Pressure Vessel Manufacturer : Codeline Pressure Vessel Model No. : 80A30-5D-ports 4-8 Pressure Vessel Quantity : 6 RO Pass # 1 : 3 : 1 (number of vessels in each stage)

RO Pass # 2 : 1 : 1 (number of vessels in each stage) Membrane Details : Dow BW30LE-440 Membrane Quantity : 30 (5 per vessel) Feed Flow : 18.0 kL/hr Permeate Flow : 12.5 kL/hr Reject Flow : 4.5 kL/hr Recovery : 70% 7. Coagulant Dosing System Coagulant : TBA by Osmoflo Coagulant dosing rate# : TBA Coagulant dosing pump type : Peristaltic

Quantity : 2 Coagulant dosing pump details : Stenner Series 45 MHP5 Coagulant tank : Suppliers Drum (typically 200 Ltrs)




8. OsmoDechlor (SMBS) Dosing System Concentration : 37% w/w Dechlor dosing rate# : 3 mg/l added to feed, (typical) SMBS dosing pump type : Peristaltic

Quantity : 2 SMBS dosing pump make/model : Stenner 45 MHP5 SMBS storage tank : 200L drum 9. OsmoTreat (Antiscalant) Dosing System Antiscalant type : Osmotreat Antiscalant dosing rate# : 4.8mg/l added to feed, (typical) Antiscalant dosing pump type : Peristaltic

Quantity : 2 Antiscalant dosing pump make/model : Stenner 45 MHP5 Antiscalant tank : 200L drum

# Dosing rates are variable and are changed as required to maintain output specifications.




SECTION 3 - PROCESS DESCRIPTION The water treatment plant comprises of a 2 pass Reverse Osmosis (RO) water treatment plant (each pass containing 2 stages) with preceding multimedia filters, suppling a net capacity of 300 kL per day of RO Permeate. The mains water going to the Multimedia Filters is dosed with coagulant (if required). The feed to the RO is dosed with Sodium Metabisulphite (SMBS) and antiscalant chemicals during normal operation and during membrane flush. These chemicals are fed via dosing pumps. The pretreated mains water is then fed into a high pressure pump. This high pressure feed pump is controlled with a variable speed drive, to ensure precise flow of feed water to the RO membranes. The operation of the whole system is by high/low level set points in the treated water tank. With the RO process the overall level of salts dissolved in the feed water are reduced to a very low level. The system installed has been designed to be fully automatic, backed up by routine preventative maintenance. A description of the major components making up the system is given below. To increase the efficiency and life of a reverse osmosis system, effective pretreatment of the feedwater is required. The correct pretreatment maximises the efficiency and membrane life by minimising: Fouling Scaling Membrane Degradation The net result of the above will be the optimisation of: Product Flow Salt Rejection (ie what percentage of salt in the feedwater has been removed) Product Recovery (ie what percentage of feed flow is converted to product) Operating Costs The system has been designed to be fully automatic and will give many years of operation with a minimum of maintenance. A more detailed description of all the components making up the system is given below.




Multimedia Filters The 2 x 100% multimedia filters are for removal of suspended solids in the feed water. The units have a large contact volume and surface area for effective removal, and a fully automatic backwashing cycle. This backwash is programmed to occur once per day at a preset time, with a differential pressure override. Only one multimedia filter operates at a time, with the other in standby until the operating filter requires regeneration. The filter is equipped with pressure gauges to allow calculation of differential pressure and thereby the extent of fouling. Raw water is used for backwashing of the filter. Coagulant Dosing A provision for coagulant dosing has also been allowed. When dosed up stream of the multi media filters, coagulant increases the efficiency of the multimedia filters. The coagulant dosing system comprises a chemical storage tank and a duty / standby set of peristaltic dosing pumps. Ultraviolet Disinfection System To prevent a common problem of biological fouling of the membrane elements, an ultraviolet disinfection system has been included as part of the pre-treatment. This will extend the life of the membranes and result in a smoother operating system. Cartridge Filters The cartridge filters are a safety device to protect the membranes and high-pressure pump from suspended solids. Softened raw water will be pumped to the cartridge guard filters. The first is rated at 5 micron nominal, followed by a 1 micron nominal for removal of fine solids and residual colloids. The cartridge filter is made of corrosion resistant polypropylene. Cartridge filters are usually replaced monthly. Antiscale Dosing Scaling of a reverse osmosis membrane may occur when sparingly soluble salts are concentrated within the membranes beyond their solubility limit. For example, if a reverse osmosis plant is operated at 50% recovery, the concentration in the reject stream will be double the concentration in the feed stream. The higher the recovery of a plant is, the higher the risk of precipitation (scaling) occurring. In a reverse osmosis system the most common salts that are likely to precipitate are CaSO4, CaCO3 and silica. The solubility of CaCO3 in particular depends on a number of variables. When an antiscalant is added the CaCO3 is kept in solution to avoid precipitation on the membranes. In this case, the antiscale dosing system comprises a chemical storage tank and a duty / standby set of peristaltic dosing pumps.




Chlorine Control Chlorine in the feed water will damage the membranes by oxidisation. In order to remove these Sodium Metabisulphite (SMBS) is dosed to remove the free chlorine from the feed water. In this case, the SMBS dosing system comprises a chemical storage tank and a duty / standby set of peristaltic dosing pumps. High Pressure Pumps The multistage centrifugal duty / standby pumps are supplied for boosting the pressure at the inlet to each pass of the RO membranes. The design discharge pressure for each stage is approximately 1200 kPa. Safety features for the pump include a low pressure sensor on the suction side. The capacity of the high pressure feed pumps is controlled via a variable speed drive (for each pump) which ensures precise and reliable operation of the RO system. Reverse Osmosis Block The RO system consists of 6 vessels containing 5 membrane cartridges in each vessel. The plant is a 2 pass system, with each pass having 2 stages. The first pass has 3 vessels in parallel, with the reject going into a single vessel (ie the second stage of the first pass). The reject from this is disposed to drain. The permeate from the first pass then enters the second pass after the pressure is boosted through a duty / standby pump set. The reject from this then goes to a second vessel (ie the second stage of the second pass). The reject from the second stage is then returned to the start of the plant and mixed with the feed water. The permeate from the stages within the second pass is supplied to the termination point. The performance of the RO block is monitored by flowmeters on the feed and reject streams. These flowmeters are a magnetic type. The recovery of the system is continually monitored by the ratio of the permeate flow to the feed flow, and displayed. A conductivity monitor is included for the RO permeate stream in both stages 1 and 2. This feeds directly into the PLC controller to advise if the conductivity falls within preset quality limits. Another conductivity monitor is located in the feed stream to determine the rejection characteristics of the RO membranes. Automatic Control System A microprocessor-based control system has been selected which will provide fully automatic operation during normal procedure. The RO system will start and stop depending on the level in the storage tank, and also on a number of alarms. These alarms include low pump pressure (on HP pump) and high permeate conductivity. Included in the system is an automatic flush cycle for routine purging of the system lines. This is activated at a preset interval after shutdown, and is designed to reduce the chance of bacteria build-up.




The control system is designed for ease of use, with as many automatic features as possible. A key feature of this system is the touch-screen interface panel, whereby all necessary functions of the plant can be monitored easily. All alarms of the system are logged automatically and operational status of equipment is easily identified. An in-built modem allows full communications between the control system and the technical support based at OSMOFLO. With this modem the logged data and alarm history can be downloaded and presented in regular reports.




SECTION 4 - DESCRIPTION OF CONTROLS 4.1.1 Control Panel Description Main ON/OFF Switch - Latching switch on side of the control panel is for power isolation. This switch is not intended for routine switching on/off of the RO system. It should only be used for repair and maintenance of the electrical system. Emergency Stop - Red pushbutton that isolates the electrical system in case of emergency. This is the main method of isolating the system in case of serious faults, in order to determine what logged alarms were active at the time of failure. Reset Pushbutton - This red button will flash when a fault has occurred with the system. If the fault has corrected itself, the system will continue to operate as normal, however the red button will flash to indicate a fault occurred. Pressing the reset button will remove the fault, and it will no longer appear in the active alarm box. Touch-Screen - This is the interface to the PLC and control system, displaying all of the operating parameters and system status information. The PLC program of the system is backed by an EEPROM memory chip which automatically downloads to the RAM of the system whenever power is turned off and on again with the main power on/off switch. The result of this download is that all logged alarms and data are lost as the program is completely overwritten. Thus it is important that the main power on/off switch kept on at all times and is turned off as a last resort only. The emergency stop pushbutton can be safely used to electrically stop the machine without losing the logged data and alarms. Internally the Main Control panel contains all of the main control functions for the Water Treatment Plant, PLC, switchgear for the dosing pumps and HP pumps, modem, autodialler etc. For the full explanation of the control philosophy, see the Electrical Control Description Section of this manual.




SECTION 5 - SYSTEM PERFORMANCE DATA 5.1 Treated Water Capacity Requirement 300 kL/day (1 x 300 kL/day RO trains) 5.3 Temperature of Raw Water 10-30 °C Performance Data 5.4 RO System Capacities Feedwater : 432 kL/day ( 18.0 kL/hr) RO Reject : 132 kL/day ( 5.5 kL/hr) RO Permeate : 300 kL/day ( 12.5 kL/hr) 5.5 RO System Recovery 70% 5.6 Performance Guarantee

The system offered here is guaranteed to achieve the stated performance criteria when the system is operated in strict accordance with the guidelines that are presented with the operating manuals of the system. Note that this performance data is based on the provided feed water quality.




SECTION 6 - PLANT OPERATION 6.1 Pre-Start Checks 6.1.1 Valves Ensure the manual valves are set as follows during operation.

Valve No. Description Open Closed

V02 Inlet isolator X

V08 UV Inlet Isolation X

V09 Cartridge Filter Outlet Isolation X

V10A RO#1 HP Pump Inlet Isolation X

V10B RO#1 HP Pump Inlet Isolation X

V12A RO#1 HP Pump Outlet Isolation X

V12B RO#1 HP Pump Outlet Isolation X

V13 RO#1 Reject flush valve X

V14 Cleaning hose isolator X

V15 Line isolator for cleaning X

V21A RO#2 HP Pump Inlet Isolation X

V21B RO#2 HP Pump Inlet Isolation X

V23A RO#2 HP Pump Outlet Isolation X

V23B RO#2 HP Pump Outlet Isolation X

V26 Product Water to Tank Isolation X

V29 Cleaning tank drain valve X

V30 Cleaning tank to RO#1 HP Pump Inlet X

V20 RO#1 Permeate Back pressure Valve SET DURING

COMMISSIONING – DO NOT ADJUST

SV Sample Valves X




6.1.2 Cartridge Filters Ensure 5 micron and 1 micron cartridges have been inserted into appropriate housing, and that each housing is tightly sealed. 6.1.3 UV Steriliser Ensure the quartz sleeve and UV lamp have been installed correctly and the lamp is operating. 6.1.4 Low Feed Pressure

There must be sufficient pressure (greater than 100 kPa) on the suction side of the high pressure feed pump at start-up to avoid the system cutting out due to low pressure. There is an in-built 10 second delay to allow the feed pipework to pressurise above the low pressure set point.

6.1.5 Chemical Dosing

Ensure the coagulant dosing pump, antiscalant dosing pump, and SMBS dosing pumps are primed and have sufficient feed to draw from.

6.2 Starting Procedure for Automatic Operation 1. Ensure all manual valves are adjusted as above. In addition check that there

are no restrictions in the permeate line.

2. Push in the Emergency Stop button on the front panel. Turn the main power to ON.

3. Ensure all actuated valves and pumps have been set to Auto mode. Returning to the Main Menu will automatically reset these actuated valves and pumps to Auto mode.

4. Release the Emergency Stop Button and the Reset pushbutton. The system will automatically drop into “SERVICE” mode if the level transmitter in the storage tank is low.

5. The capacity of the High Pressure Feed Pump is adjusted via the variable speed drive on the touch screen (Maintenance Menu, Control Setpoints). The pump will automatically be set to the required speed to achieve the desired feed flowrate. The Reject let-down valves V19 and V27 will automatically adjust to increase back-pressure on the membranes which produces treated permeate water.

6. When installing new membrane elements into the system ensure the permeate is diverted to drain for at least 30 minutes to remove any traces of membrane preservative solution.




6.3 Post Start Checks 1. Check the pressures for both cartridge filters. These should indicate the

pressure specified in the Operating Specifications listed below.

2. Check the RO Feed Pressure and the RO Reject Pressure. In addition check the flowrates indicated for Permeate Flow and Reject Flow. All of these parameters should indicate that specified in the Operating Specifications listed below. Please note when new membranes are installed the performance may differ from the Operating Specifications, whereby a lower feed pressure is required to produce the permeate.

3. The system pressure and required flow rates are set to Operating Specification automatically. The output of the High Pressure feed pump is automatically adjusted to the control setpoint and no further adjustments are necessary.

4. Adjust the dosing rate of the antiscalant dosing pump to ensure the solution strength matches that set out below in Operating Specification.

6.4 Shut-Down Procedures 6.4.1 Shut-Down During Automatic Operation 1. DO NOT TURN OFF MAIN POWER SWITCH. The system is fully automatic

and does not need to be turned on and off after use. As described above the PLC program of the system is backed by an EEPROM memory chip which automatically downloads to the RAM of the system whenever power is turned off and on again with the main power on/off switch. The result of this download is that all logged alarms and data are lost as the program is completely overwritten. Thus it is important that the main power on/off switch kept on at all times and is turned off as a last resort only. The emergency stop pushbutton can be safely used to electrically stop the machine without losing the logged data and alarms.

2. Do not touch any other control switches on the control panel. The system has

a pre-programmed flushing cycle which is carried out at regular intervals during periods of non-operation to reduce bacterial build-up.




6.5 RO System Operating Specification (per RO Train) Multimedia filter inlet pressure : 400 kPa

5-Micron cartridge filter inlet pressure : 300 kPa typical

5-Micron cartridge filter outlet pressure : 250 kPa typical

1-Micron cartridge filter outlet pressure : 200 kPa typical

RO Feed pressure Pass 1 : 900 kPa typical

RO Feed pressure Pass 2 : 850 kPa typical

RO Reject pressure : 700 kPa typical

Reject flowrate : 5.5 kL/hour

Permeate flowrate : 12.5 kL/hour

RO System Recovery Rate : 70%

Feed water conductivity : <1200 µS/cm typical

Permeate conductivity : <15 µS/cm typical

Antiscalant dosing pump rate : 62.0ml/hr

Coagulant dosing pump rate : TBA

SMBS (37%) dosing pump rate : 37.5ml/hr

(Note: Dosing rates adjusted on site as required)




6.6 RO Cleaning Procedure 1. Whilst the system is in Service Mode, add 400L of permeate by opening valve

V30 to the cleaning tank, ensuring cleaning tank low level switch LS03 is in the “up” position and cleaning tank drain valve V29 is closed. Close RO permeate valve V30 after filling tank.

2. Soft Stop the plant, and close the Inlet Valve V09. Remove the vitaulic connections to the vessel to be cleaned, and connect up hoses to the respective inlets/and return lines from the trains and cleaning tank.

3. On the ‘Control Setpoints’ page of the touchscreen, set the desired cleaning flowrate, cleaning pressure, cleaning temperature and cleaning duration. Circulate to 10 kL/hr. Set the cleaning pressure to <300 kPa, cleaning temperature to 40deg C and duration for 60 minutes. NB: These cleaning flow and pressure setpoints are estimates, the rule of thumb is, if permeate is being forced through the membrane during a clean, then back off either or both the flowrate or pressure.

4. Press CLEANING on the menu; then ENABLE. A prompt will remind you to 3 check that all hoses and manual valves are set and correct. When ready, press cleaning start.

5. If discolouration of cleaning solution occurs then divert the reject hose to drain while keeping cleaning tank full of permeate with the other available train.

6. Depending on the nature of the foulant, it maybe necessary to start with a high pH clean (to remove the top layer of colloidal/bio fouling), then follow with a low pH clean (to remove scale precipitate) and then finish with a high pH clean to reset the membrane polymer and restore rejection abilities. (It is important always to finish with a high pH clean)

PLEASE NOTE: All safety precautions listed in the Material Safety Data Sheets for the above must be strictly followed. See Appendix D for further information.

7. The low pH chemical will consist of Osmoclean CD at 1-2% strength (4-8 litres dissolved in 400 litres of permeate. The high pH chemical will consist of Osmoclean DW at 1-2% strength (4-8 litres dissolved in 400 litres of permeate.

All circulation should be for a minimum of 30 minutes at the recommended temperatures, if the cleaning solution discolours dramatically, then divert the reject hose to drain, flush out with permeate and repeat with a new batch of chemicals. Extended application or soak times would improve the cleaning performance.

8. IMPORTANT: Ensure the membranes are well flushed before changing from low to high pH chemicals solutions (and vice versa) At the end of the chemical clean and in Service Mode, divert any permeate produced to drain for at least 30 minutes.




SECTION 7 - DATALOGGING & ROUTINE MAINTENANCE 7.1 Data Logging The in-built datalogger records all of the critical parameters for the successful operation of the system. Diligent analysis of trends in this data can result in detection of potential problems and action can be taken before a failure occurs. In addition a water sample should be taken for detailed analysis if the Conductivity of either the Mains Water or the Permeate Water increases by more that 25% and also on a yearly basis, and the results sent to OSMOFLO for review. As a minimum the sample analysis should detail: Typical Feedwater Analysis

Physical Characteristics Units pH pH Dissolved Salts Calculated mg/L Electrical Conductance µS/cm @ 25oC Turbidity NTU Solids - Suspended Cations Calcium Ca++ mg/L Magnesium Mg++ mg/L Sodium Na+ mg/L Potassium K+ mg/L Anions Chloride CI- mg/L Sulphate SO4

- - mg/L Bicarbonate HCO3

- - mg/L Fluoride F- mg/L Nitrate NO3

- mg/L




Others Strontium Sr++ mg/L Barium Ba++ mg/L Silica – Reactive SiO2 mg/L Metal Aluminium – Total AI mg/L Iron – Total Fe mg/L Iron –Dissolved Fe++ mg/L Manganese – Total Mn++ mg/L

7.2 General Routine Maintenance At regular intervals the following routine checks should be made on the system to maintain successful operation. 7.2.1 Inspect the system for water leaks and rectify as necessary. 7.2.2 Check High Pressure Feed Pump for water leaks or noisy operation. 7.2.3 For particular equipment maintenance please refer to the manufacturers’

literature in the various sections for individual items. 7.2.4 Replace the quartz sleeve every 2 years and UV lamp at intervals of 12

months. Follow UV manufacturers instructions closely when replacing these items.

7.2.5 Check condition of Cartridge Filters by removing the element from the housing

and note whether the cartridge is discoloured on the inside surface. Replace the cartridge if excessive contamination is evident. Check the pressure drop across each cartridge filter. When the differential pressure between the inlet gauge on the 5-micron and the outlet gauge on the 1-micron reaches 200 kPa, the cartridge requires replacement. Replacement of cartridge filters must be made at 2-3 monthly intervals regardless of pressure loss at that time, to avoid excessive build up of bacterial matter.

7.2.6 Check for residual chlorine from the sample valves on the HP Pump inlet

sample valve on a weekly basis. Report any detection immediately and adjust the SMBS dosing pump rate to remove traces of chlorine. Residual chlorine can be detected by the use of a chlorine analyser such as the SWAN Instruments ‘Chematest’. The levels recorded should be zero.




A less accurate method is to use chlorine detection strips such as Aquacheck 5” Water Quality Test Strips. However these strips can only indicate 0, 0.5,1.0, 2.0, 4.0, 10.0 ppm. Existence of chlorine results in a reduction of membrane service life and the effects are cumulative. A continuous reading of 1ppm chlorine will reduce the service life of a membrane to 1000 hours.

7.2.7 SDI checks before and after the Multimedia vessels should be carried out at least fortnightly to determine the effectiveness of the coagulant dosing. There may be a need to adjust the coagulant dosing rate and/or backwashing details. 7.3 Extended Shutdown of System If the system is left not operating for any longer than 2 weeks there is a high risk that bacteria will quickly propagate throughout the membranes and lead to a rapid fall off in performance. It is recommended to run the system for at least 30 minutes per day during times when the system would not normally be required. If the unit is to be shut down for extended periods (longer than 2 weeks) the membranes should be left to soak in a preservative solution (1% SMBS). The procedure is the same as above for cleaning, following steps 1 to 4 inclusive, finishing by leaving all isolation valves closed to ensure the preservative chemical is kept secure in contact with the RO membranes. 7.4 Replacement of Membrane Elements It is expected that under normal operating conditions the membranes will perform satisfactorily for some years. When chemical cleaning fails to revive the performance to a satisfactory level, the membranes should be replaced.




SECTION 8 - PREVENTATIVE MAINTENANCE The following preventative maintenance should be carried out to minimise downtime due to normal service wear and tear and to maximise service life of the major subsystem.

No Item Preventative Maintenance Action Interval

1. High Pressure Feed Pump

Replace seals using seal kit. Refer spares list.

Yearly or as required

2. Multimedia Vessels

Manually airscour media to break up any retained coagulated solids

Yearly

3. Cartridge Filter Housings

Clean/Flush out housing of filtered matter during element changeover

At cartridge element changeover

4. Membranes Chemical clean of membranes 6 Monthly or as required

5. Instruments Check calibration Yearly and calibrate any new replacement before installation

6. Dosing pumps Replace peristaltic tube Six-monthly




SECTION 9 - TROUBLESHOOTING Important Note: In the event of control operating difficulties, before referring to this section, switch the main power isolator off, and then restart the operation. Troubleshooting is simplified in this system due to the operator interface panel, which details the exact cause of fault in most cases. The range of alarms that are likely to be encountered are listed in Section 2 of the Electrical Control Description of this manual. The following alarms appear as a fault in the bottom box of the touch-screen. If there are any active alarms at least one of them will appear in the Main Menu.

No. Alarm Possible Cause Remedy 1 Emergency stop Emergency stop button

manually depressed by an operator

Investigate cause Press alarm reset button and release emergency stop button

2 High pressure feed pump drive fault

Emergency stop button has been pushed Variable speed drive tripped out Return signal from pump contactor not registered Pump prevented from operating Overload on VS drive not set correctly

Release Emergency Stop, wait 10 seconds and then push Alarm Reset button Check for errors on drive display (inside cabinet) Check wiring Clear any obstacles from flow path of HP pump Consult OSMOFLO for correct settings

3 Coagulant pump C/B trip

Pump prevented from operating

Clear any obstacles from flow path of pump

4 SMBS pump C/B trip



5 Anticscalant pump C/B trip



6 Cleaning heater C/B trip

Electrical fault Consult electrical tradesman and/or manufacturer




Alarm Possible Cause Remedy

7 UV Steriliser lamp fail

UV Lamp failure Faulty electrical connection

Replace as recommended in this manual Check by installing new lamp, if alarm still active replace electrical connections

8 Control Supply C/B trip

Electrical fault Consult electrical tradesman and/or manufacturer

9 Lights/GPO fault Electrical fault Consult electrical tradesman and/or manufacturer

10 Low Air Pressure, PS

Insufficient air pressure to operate the actuated valves

Rectify as soon as possible

12 Coagulant tank low level

Coagulant tank empty Replace coagulant tank with new (full) tank

13 SMBS tank low level

SMBS tank empty Replace SMBS tank with new (full) tank

14 Antiscalant tank low level

Antiscalant tank empty Replace antiscalant tank with new (full) tank

15 Membrane cleaning high pressure

Restrictions to cleaning flow

Check cleaning is i.a.w. cleaning procedure Check for obstructions in flow path Check for membrane mechanical damage

16 Low cartridge filter pressure

External supply issues Cartridge filters blocked Faulty pressure transmitter

Open all service valves and check Nufarm feed pump is OK Inspect cartridge filters and replace as required Replace transmitter

17 Low permeate flow after 5 minutes

Membranes possibly fouled or blockage in permeate lines

Review logged data and contact manufacturer for advice

18 Maximum recovery exceeded

Higher conversion of product to feed than designed, which will result in rapid membrane scaling

Adjust reject let-down valve to establish design conditions once again




Alarm Possible Cause Remedy 19 High feed water

temperature Inlet temperature exceeds maximum If the RO is shut down for an extended period, the heat from the UV’s may show on the temperature transmitter

Investigate source of high feed water temp Alter the alarm set point to be slightly higher than the actual feed water temp. and alert OSMOFLO System should not operate above 45°C Flush water through the system to refresh with cold feed water

20 High RO Feed Pressure

Inlet pressure to RO membranes has exceeded design maximum

Schedule chemical clean Review datalogged information to determine how quickly pressure increased Investigate pretreatment system to investigate why pressure increased

21 Permeate conductivity high

Treated water conductivity quality higher than set point during service

Check antiscalant dosing system to ensure correct amount of antiscalant chemical is entering feed Check individual pressure vessels to determine source of conductivity Check O-ring seals between membranes and at ends of pressure vessels Perform chemical clean to remove scale build up




SECTION 10 – MEMBRANE PROJECTIONS Reverse Osmosis System Analysis for FILMTEC(TM) Membranes ROSA v5.02

Project: Holdens Worst Water Case: 1 Bob Masters, Osmoflo Pty Ltd 17/04/2003

System Summary -- Pass 1

Feed Flow to Stage 1 20.83 m3/h Permeate Flow 15.62 m3/h Raw Water Flow to System 20.83 m3/h Pass Recovery 74.99 % Feed Pressure 8.76 bar Feed Temperature 25.00 C Fouling Factor 0.85 Feed TDS 728.43 mg/l Chem. Dose (100% H2SO4) 0.00 mg/l Number of Elements 20 Total Active Area 713.01 M2 Average System Flux 21.91 Lmh Conc. Flow from Pass 2 0.00 m3/h Conc. TDS Ratio 0.10 times feed System Recovery 59.99 % Water Classification RO Permeate SDI < 1

Stage Element #PV #Ele Feed Flow

(m3/h)

Feed Press (bar)

Recirc Flow

(m3/h)

Conc Flow

(m3/h)

Conc Press (bar)

Perm Flow

(m3/h)

Avg Flux

(Lmh)

Perm Press (bar)

Boost Press (bar)

Perm TDS

(mg/l) 1 BW30-365 3 5 20.83 8.42 0.00 10.15 7.64 10.67 20.99 0.00 0.00 9.13 2 BW30LE-440 1 5 10.15 7.30 0.00 5.21 6.23 4.94 24.19 0.00 0.00 29.36

(mg/l, except pH) Raw Water Adj Feed Permeate Concentrate NH4 0.00 0.00 0.00 0.00 K 8.20 8.20 0.40 31.58 Na 162.00 164.29 3.52 646.43 Mg 27.00 27.00 0.34 106.94 Ca 37.00 37.00 0.65 146.00 Sr 0.00 0.00 0.00 0.00 Ba 0.00 0.00 0.00 0.00 HCO3 115.00 115.00 3.57 449.17 CO3 0.10 0.10 0.00 0.40 NO3 2.84 2.84 0.21 10.71 Cl 284.00 284.00 5.20 1120.10 F 0.00 0.00 0.00 0.00 SO4 71.00 71.00 0.73 281.73 SiO2 19.00 19.00 0.90 73.27 CO2 4.36 4.36 4.36 4.36 TDS 726.14 728.43 15.54 2866.35 pH 7.60 7.60 6.07 8.21




Reverse Osmosis System Analysis for FILMTEC(TM) Membranes ROSA v5.02 Project: Holdens Worst Water Case: 1 Bob Masters, Osmoflo Pty Ltd 17/04/2003

System Summary -- Pass 2

Feed Flow to Stage 1 15.62 m3/h Permeate Flow 12.49 m3/h Raw Water Flow to System 15.62 m3/h Pass Recovery 79.99 % Feed Pressure 8.62 bar Feed Temperature 25.00 C Fouling Factor 0.85 Feed TDS 15.54 mg/l Chem. Dose (100% H2SO4) 0.00 mg/l Number of Elements 10 Total Active Area 408.76 M2 Average System Flux 30.57 Lmh System Recovery 59.99 % Water Classification RO Permeate SDI < 1

Stage Element #PV #Ele Feed Flow

(m3/h)

Feed Press (bar)

Recirc Flow

(m3/h)

Conc Flow

(m3/h)

Conc Press (bar)

Perm Flow

(m3/h)

Avg Flux

(Lmh)

Perm Press (bar)

Boost Press (bar)

Perm TDS

(mg/l) 1 BW30LE-440 1 5 15.62 8.62 0.00 8.74 6.56 6.88 33.66 0.00 0.00 0.27 2 BW30LE-440 1 5 8.74 6.56 0.00 3.12 5.81 5.61 27.47 0.00 0.00 0.67

(mg/l, except pH) Raw Water Adj Feed Permeate Concentrate NH4 0.00 0.00 0.00 0.00 K 0.40 0.40 0.02 1.92 Na 3.52 3.52 0.09 17.21 Mg 0.34 0.34 0.01 1.70 Ca 0.65 0.65 0.01 3.20 Sr 0.00 0.00 0.00 0.00 Ba 0.00 0.00 0.00 0.00 HCO3 3.57 3.57 0.13 17.33 CO3 0.00 0.00 0.00 0.02 NO3 0.21 0.21 0.02 1.00 Cl 5.20 5.20 0.11 25.55 F 0.00 0.00 0.00 0.00 SO4 0.73 0.73 0.01 3.61 SiO2 0.90 0.90 0.05 4.33 CO2 4.36 4.36 4.36 4.36 TDS 15.54 15.54 0.45 75.87 pH 6.07 6.07 4.63 6.62





Solubility Warnings

Langelier Saturation Index > 0 Stiff & Davis Stability Index > 0 Antiscalants may be required. Consult your antiscalant manufacturer for dosing and maximum allowable system recovery.

Scaling Calculations

Raw Water Adj Feed Concentrate pH 7.60 7.60 8.21 Langelier Saturation Index -0.36 -0.36 1.38 Stiff & Davis Stability Index 0.12 0.12 1.37 Ionic Strength (Molal) 0.01 0.01 0.06 TDS (mg/l) 726.14 726.14 2866.35 HCO3 115.00 115.00 449.17 CO2 4.36 4.36 4.36 CO3 0.10 0.10 0.40 CaSO4 (% Saturation) 0.61 0.61 5.28 BaSO4 0.00 0.00 0.00 SrSO4 0.00 0.00 0.00 CaF2 0.00 0.00 0.00 SiO2 15.20 15.20 47.32

To balance: 2.29 mg/l Na added to feed.





Array Details -- Pass 1

Stage 1 Element Recov. Perm Flow

(m3/h)

Perm TDS

(mg/l)

Feed Flow

(m3/h)

Feed TDS (mg/l)

Feed Press (bar)

1 0.11 0.76 6.52 6.94 728.43 8.42 2 0.12 0.73 7.56 6.18 817.24 8.20 3 0.13 0.71 8.85 5.45 926.46 8.02 4 0.15 0.69 10.52 4.74 1064.15 7.86 5 0.16 0.66 12.74 4.05 1243.12 7.74

Stage 2 Element Recov. Perm Flow (m3/h)

Perm TDS

(mg/l)

Feed Flow (m3/h)

Feed TDS (mg/l)

Feed Press (bar)

1 0.11 1.13 20.51 10.15 1484.64 7.30 2 0.12 1.06 24.22 9.02 1667.93 7.00 3 0.12 0.99 28.83 7.97 1885.88 6.75 4 0.13 0.92 34.70 6.98 2148.53 6.54 5 0.14 0.85 42.34 6.06 2469.36 6.37





Array Details -- Pass 2


(m3/h)

Perm TDS

(mg/l)

Feed Flow

(m3/h)

Feed TDS

(mg/l)

Feed Press (bar)

1 0.10 1.54 0.20 15.62 15.54 8.62 2 0.10 1.45 0.23 14.08 17.22 8.07 3 0.11 1.36 0.27 12.63 19.16 7.60 4 0.11 1.29 0.31 11.27 21.45 7.19 5 0.12 1.24 0.37 9.97 24.19 6.85


(m3/h)

Perm TDS

(mg/l)

Feed Flow

(m3/h)

Feed TDS

(mg/l)

Feed Press (bar)

1 0.14 1.19 0.43 8.74 27.56 6.56 2 0.15 1.15 0.52 7.55 31.82 6.33 3 0.17 1.12 0.63 6.40 37.44 6.14 4 0.21 1.09 0.78 5.29 45.20 5.99 5 0.26 1.07 1.01 4.20 56.75 5.88

DISCLAIMER: NO WARRANTY, EXPRESSED OR IMPLIED, AND NO WARRANTY OF MERCHANTABILITY OR FITNESS, IS GIVEN. Neither FilmTec Corporation nor The Dow Chemical Company assume liability for results obtained or damages incurred from the application of this information. Any final design should be reviewed by the appropriate engineering personnel.




SECTION 11 – SPARE PARTS KEPT IN HOLDEN STORE

Quantity Description

1 Keystone F79U 003 Valve Actuator

5 No. 1 Stenner Peristaltic Tubes for Dosing Pumps

2 Keystone F250 50mm Valve Service Kits

1 0 – 16 Bar Danfoss MBS3000 Pressure Transmitter

2 Membrane Interconnectors

1 Vessel End Quad Seal

2 Vessel End Plastic Spacer Rings

2 UV Lamps

2 UV Thimbles

10 5 Micron Cartridges

10 1 Micron Cartridges

1 Membrane Brine Seal

Documents

Holden Operating Manual - blackboxproductions.com.au Operating Manual.pdf · reverse osmosis water treatment plant holden ltd - elizabeth operating and maintenance manual table of