Addendum 003 - Equipment - Membrane Train R0.pdf

COVER PAGE OF SELLER’S SUBMITTAL

City Name: Hanford, WA - MSA

Pall Project No.: 01.000287

Job Number: Project L-897, Subcontract 70816

Task Register 6 (Task 1 – VI Submittal Package)

To: (Contractor)

Mission Support Alliance, LLC (MSA)

PO Box 650

Richland, WA 99352

From: (Subcontractor)

Pall Water

A Division of Pall Corporation

839 State Route 13

Cortland, NY 13045

Patty Willis

Phone: 607-758-1699

Name of Project: Hanford, WA, Central Plateau WTF

Pall Document Number: NYCS000015436 Rev: 00

Description of Item: Membrane Train

Specification Section: N/A

Deviations: N/A

INDEX:

Page 1: Cover Page Information

Page 2: Revision History and Approvals

Page 3-50: Tab 1 - NYCS000007271 HDPE 8-inch Transverse Rack Install Guide

Pages 51-60: Tab 2 - NYCS000010431 Compressed Air Piping Flushing Guidelines

Date: 12/19/2019

PALL ADVANCED SEPARATIONS SYSTEMS

DIVISION OF PALL CORPORATION, CORTLAND, NY

Rev Name Date Created By

Approved By

Created By

Approved By

Created By

Approved By

Created By

Approved By

Revision Description

Title

Document # Revision griffinju Text Box These commodities, technology, or software may only be exported from the United States in accordance with the Export Administration Regulations. Diversion contrary to U.S. law is prohibited.

PALL MICROZA® 8” TRANSVERSE-STYLE VALVE AND MODULE

RACK INSTALLATION GUIDELINES

(HDPE MANIFOLDS AND SPOOLS)

Pall DIR Number: NYCS000007271

Revision Level: 04

TABLE OF CONTENTS

Pall Corporation Document Revision History 5

1. INTRODUCTION 6

Table 1 – Definition of Terms and Symbols 6

2. OVERVIEW 6

2.1 Crew and Time Requirements 6

2.2 Equipment and Tools 7

2.3 Coupling Torque Table 9

2.4 Module Rack Assembly Weight 10

2.5 Valve Rack Assembly Weight 10

3. SITE PREPARATION 10

4. RECEIPT AND STORAGE OF MATERIALS 11

4.1 Return Shipment of Parts and Equipment – Return Goods Authorization 14

5. RACK LAYOUT 14

6. VALVE RACK INSTALLATION (STEP #1) 15

6.1 Materials Required 15

6.2 Valve Rack Installation 16

7. MODULE RACK INSTALLATION 17

7.1.1 Feed Header Placement (Step #2) 17

7.2 Rack Frame Assembly: Bottom Deck and Vertical Supports (Step #3A, 3B) 18

7.3 Rack Frame Assembly: Top Deck Section (Step #3C, 3D, & 3E) 20

7.4 Installing Multiple Decks (Step #4A – 6E if required) 21

7.4.1 Rack Frame Assembly: Bottom Deck and Vertical Supports (Step #4A, 4B, 4C, AND 4D) 21

7.4.2 Step # 7 – Installing Rack Frame End Kit 23

7.5 Empty Module Positions 23

7.6 HDPE Manifold Installation 24

7.6.1 Install Feed HDPE Manifold (Step # 8) 25

7.6.2 Install Filtrate HDPE Manifold (Step # 9) 27

7.6.3 Install XR HDPE Manifold (Step # 10) 27

7.6.4 Install Air Scrub HDPE Manifold and Air Scrub Connections (Step # 11 & 12) 28

7.7 Preparation for Commissioning Procedures 30

7.7.1 Installing Flushing Connections: (Step # 13) 31

7.8 Module Installation (Step # 14) 33

7.8.1 Coupling Torque Table 33

7.8.2 Installing the Longitudinal Cross braces - Final Step 42

8. PALL PRO SERVICES & SUPPORT 43

8.1 Pall PRO Services & Support 43

8.2 Pall PRO Services - Health Check 44

8.3 Pall PRO Services – Optimization 44

8.4 Pall PRO Services – Technical Support 45

8.5 Pall PRO Services – Upgrades to Hardware and Software 45

8.6 Pall PRO Services – Spare and Replacement Parts 45

8.7 Pall PRO Services - Service Contracts 45

Appendix A - Calcium Chloride SDS

Pall Corporation Document Revision History

Revision Date Originator Description

00 2015 P a l l C o r p o r a t i o n

Initial Document Release.

01 2015 P a l l C o r p o r a t i o n

Revised pictures & overall updates.

02 2015 P a l l C o r p o r a t i o n

Revised pictures to remove lifting lugs.

January

P a l l C o r p o r a t i o n

Updated to add module and rack assembly weights. Added module space tolerance specification.

January

P a l l C o r p o r a t i o n

Corrected torque table to read Min 5

ft. lbs, max. 7 ft. lbs for Pass HZ

Clamp.

1. Introduction

The intent of this document is to give customers, engineers, and contractors an indication of the requirements for installing the valve racks, module racks, and modules that make up the heart of a Pall Microza® Micro-filtration system. These instructions apply specifically to an HDPE Transverse rack.

Table 1 – Definition of Terms and Symbols

Term Symbol or Definition

Inch "

Foot ' lb pound

Millimeter mm

Meter m kg kilogram

2. Overview

Installing the valve and module rack is divided into three phases: site preparation and pad fabrication, valve rack and module rack erection and the installation of the Microza® modules after preliminary start-up and testing. Each valve rack has one module rack attached to it. Refer to project-specific drawings for additional information.

2.1 Crew and Time Requirements

The time required for the installation can vary substantially, depending on site conditions, available equipment, and crew experience. Typically, 15 - 30 man-hours is required to install a valve rack, and an additional ½ - 1 man-hour is required per module for the module racks. After preliminary wet testing is completed, an additional ½ - ¾ man-hour is required to install and leak check each module. These time requirements do not include site preparation, housekeeping pad construction, or wiring to the rack. Wiring and tubing internal to the valve rack are completed at the factory.

Suggested crew size is three people plus an equipment operator for rack erection, and at least three people for module installation. Large projects require multiple crews of this size. Modules weigh about 85 lbs (38 kg) and are 91⅞" (2384 mm) long, including end caps. Installation of the modules is simple, but physically strenuous and tedious. Crew members need to be careful and pay attention to detail, in order to prevent installation errors or damage to the modules.

2.2 Equipment and Tools

To some extent, equipment recommendations depend on the size of the project. A single rack system can be erected with very limited tools, if necessary. Large systems with sufficient working area will benefit from cranes, man-lifts, and other mechanized equipment.

Valve racks are about 163" (4140 mm) tall and weigh 2000 – 2500 lbs (900 – 1200 kg) dry, depending on model. Module rack lower frame and upper frame “decks” vary by project and method (how installation is intended to be completed), but may weigh approximately 1300 – 2000 lbs (590 – 900 kg) dry, or more each. Appropriately rated lifting equipment is required to set them in place. The module rack manifolds weigh 100 – 450 lbs (45 – 205

kg) each, and will need to be mechanically lifted into place by the use of small mobile cranes or other lifting equipment. Spreader bars (provided by others) are required for lifting module rack decks to ensure only vertical loads are present on the lift lugs. During module installation, one person spends a lot of time at the upper end of the rack, 8 – 12' (2.5 – 4 m) off the ground, and going up and down to retrieve parts. Rolling stairs, similar to those used in warehouses, are very convenient, and make this work easier and safer.

CAUTION:.Pall Corporation highly recommends the use of appropriately rated lifting devices for installing the heavier components of the micro-filtration system and requires the use of spreader bars for module rack deck lifting.

DANGER – To prevent personal injury and/or equipment damage, installers must make sure that loose components are properly supported during installation. Installers must follow all safety regulations and procedures mandated by the governing institution where the system is being installed

Suggested hand and power tools are as follows:

Stepladder, 8 – 12' (3 – 4 m)

Rolling stairs with small platform and locking wheels

Small cranes or other appropriate lifting equipment

Compressed air supply for wrenches and/or opening pneumatic valves

CAUTION: No air tools to be used on tightening grooved couplings.

They are to be hand-tightened. Please view the couplings torque chart on page 33.

Electric or pneumatic impact wrench

Rotary hammer drill with ⅞" and 1⅛" bits

(2) ½" wrenches

(2) ⅝" wrenches

9⁄16" wrench

¾" wrench

11⁄16" wrench

1⅛" Wrench

1⅝" Wrench

(2) ⅜" or ½" drive socket (deep socket) wrench set (through ⅝")

(2) Pall Corporation supplied module wrenches

Pall Corporation supplied slip coupling wrench

½" Drive torque wrench, 0 – 100 ft-lb. scale

4' (1 m) level

String level

Measuring tape

Chalk box

NSF-listed pipe lubricant (provided by Pall Corporation)

Lubricant statement

Please note that all lubricants used on this system shall be water soluble and compatible with the materials of construction.

Nickel-based anti-seize compound

2.3 Coupling Torque Table

Coupling Brand Size Ft/lbs

PASS Hangzhou Pass Fluid Equipment Co., LTD ¾-4” Min 5 ft. lbs, max. 7 ft. lbs.

Piedmont ¾ - 2” 5 Ft/lbs

Piedmont 2 ½ - 3” 7.5 Ft/lbs

Piedmont 4 & 6” 10 Ft/lbs

Gruvlok® Figure 7000 (Galvanized) 1 -2 ½” 45 Ft/lbs

Gruvlok® Figure 7000 (Galvanized) 3-4 ¼” 100 Ft/lbs

Gruvlok® Figure 7000 (Galvanized) 5 – 6 ½” 130 Ft/lbs

Gruvlok® Figure 7000 (Galvanized) 8” 180 Ft/lbs

2.4 Module Rack Assembly Weight

NOTE: The following weights do not include feed, filtrate, XR, and/or AS headers on the module rack (dependent upon the number of rows).

Do not forget to include the significant weight of water headers.

Assembly Without Modules With Modules

6 Row Assembly 1800 lbs. dry

2000lbs. wet (estimated)

4400 lbs. dry

7300 lbs. wet (estimated)

5 Row Assembly 1700 lbs. dry

1900lbs. wet (estimated)

3850 lbs. dry

6300 lbs. wet (estimated)

2.5 Valve Rack Assembly Weight

Assembly Weight

8T Assembly 3500 lbs. dry

4200 lbs. wet (estimated)

3. Site Preparation

Before assembling the racks, housekeeping pads need to be designed, laid out, and poured.

The pad height depends on the rest of the installation – the height may need to be adjusted to accommodate the plant piping going to and from the racks. Pads must be poured 1.5 to 2 inches below the finished elevation to allow space for grout.

The racks depend on the anchor bolts to keep them upright. Housekeeping pads must be anchored into the floor. Design of the pads is usually by the Engineer.

4. Receipt and Storage of Materials

The valve rack is pre-assembled and shipped on a wooden skid or in a crate approximately 15’ x 6’ x 5’ (4600 x 1800 x 1500mm), for valve racks with 8” or less feed connection.

The module rack sections are broken down for shipment, and are shipped in multiple crates. The crates containing the required parts will need to be identified using the Crated Material List (CML) and the packing lists. The following items are required for each assembled Transverse filter rack:

Valve Rack

Module Rack Feed-side Frames (lower) with Collector Transverse Manifolds

Module Rack Filtrate-side Frames (upper) with Collector Transverse Manifolds

Module Rack Vertical Support Columns

Cross-bracing and straight straps

HDPE Feed Manifold

HDPE Filtrate Manifold

HDPE XR Manifold

HDPE Air Scrub Manifold

Module Install Kits

To protect the membrane modules from harm, they are usually delivered after the rest of the filter racks and supporting systems have been assembled. The modules ship in tri-wall cartons that are 90” x 47” x 43” (2300 x 1200 x 1100), each containing sixteen (16) modules.

CAUTION:. The Microza® micro-filtration module membranes can dry out if left unattended. This adversely affects their performance. As a result, the modules are shipped containing a storage solution to preserve the membranes. This solution must be maintained in the modules until put into service.

For that reason, after receiving the modules and before they are stored, the shipping containers must be opened and the modules inspected for leaks or damage of any kind. If any module leakage or damage is noticeable or suspected, contact Pall Technology Services immediately.

After inspection, reseal the modules in their containers and place them in an environmentally controlled, enclosed storage area that provides adequate protection. The modules must not be stored in direct sunlight, and must be protected from temperatures less than -20° F (-30° C) or over 110° F (44° C).

Storage in conditions outside these limits may void the module warranty. Do not stack module crates more than two high. DO NOT STORE THE MODULES

OUTSIDE.

DO NOT drop or expose either the modules or their shipping containers to shock or impact. There may be damage to the membrane even if no visible damage to the module case is evident.

FAILURE TO ADHERE TO THIS CAUTION MAY RESULT IN THE VOIDING OF ALL

MODULE WARRANTIES!

In addition to the module storage cartons, there are also a number of crates that contain miscellaneous module parts and fittings, and at least one crate (the Module Install kit) with fittings that are used for assembly and start-up.

There will be other crates or pallets of equipment, the number of which vary depending on Pall Corporation’s scope of supply. On a large project, the number of crates may exceed one hundred (100), shipped in multiple truckloads.

Pall Corporation’s standard method of shipment in North America is by dedicated truck (enclosed van or flatbed truck). It is recommended that a loading dock be available, and that a fork truck with extended forks and at least a 5,000-pound capacity be available for unloading. If use of a loading dock is not possible, the crates may have to be dragged by chain to the tail of the van.

Disposal of the crates and packing is the responsibility of the contractor or customer.

The equipment includes various instruments, PLCs, and other electronic equipment.

Equipment crates may be left outdoors for short periods, but should be protected from rain, and, in extreme climates, direct exposure to the sun. The Microza® modules must be protected as noted above. Valve racks must not be stacked.

CAUTION:. DO NOT install the Microza® modules or attempt to operate the Pall Micro-filtration System until after the installation of all utilities, instruments, and interconnecting piping and the micro-filtration system has had an initial flushing.

DO NOT install the Microza® modules or attempt to operate the Pall Micro-filtration System until after the installation of all utilities, instruments, and interconnecting piping and the micro-filtration system has had an initial flushing.

The Pall Micro-filtration System requires flushing after these installations/connections are complete and before module installation. Refer to the section “Initial Start-up and Flush” in the Operation and Maintenance manual for further information.

If a Pall Technology Services representative is not on-site, contact Pall Technology Services with any questions.

IMPORTANT NOTE ON PROTECTING THE HDPE COMPONENTS:

When moving or working with HDPE components (including manifolds) installers must protect all sealing surfaces from any damage including impacting these components with any other objects or surfaces. The slightest scratch, gouge, indentation, or any other imperfection in these surfaces causes leaks between gasket sealed couplings or other HDPE sealing devices.

Failure by the customer or the customer’s contracted installers to properly protect any sealing surface voids the warranty

IMPORTANT NOTE ON BUTTERFLY VALVE INSTALLATIONS:

It is the installers’ responsibility to make sure the disks on elastomer-seated butterfly valves are at least partially open when tightening flange bolts. Failure to adhere to this procedure causes premature failure and voids all warranties on the valve. If unsure of the valve’s nomenclature, contact Pall Technology Services before installation.

4.1 Return Shipment of Parts and Equipment – Return

Goods Authorization

To ensure proper handling when returning material or equipment for repair or credit, please adhere to the following procedures:

1. Contact your Pall Project Manager to discuss potential returns. A Return Goods Authorization Form is mailed to the contact name and location indicated by the customer.

2. While completing this form be sure to explain if this particular piece of equipment was used or not. Was there contact with liquids? If so, please provide a SDS (Safety Data Sheet) for any and all liquids in contact with this equipment.

3. Attach the Return Goods Authorization Number received from Pall Corporation to the outside of the shipping container. If returning more than one container, clearly mark each additional container with the assigned authorization number.

4. Return subject equipment or material to the address listed on the Return Goods Authorization Form unless otherwise directed. Prepay all freight associated with returning the subject equipment or material to Pall Corporation.

When returning any equipment, it is the customer’s responsibility to make sure those responsible follow proper packing and shipping procedures. For packaging assistance, contact your Pall Project Logistics / Buyer.

IMPORTANT: Return Goods Authorization does not constitute in itself a guarantee of the issuing of credit by Pall Corporation. Final disposition of credit allowance rests with Pall after receipt and inspection of subject material or equipment.

Pall Corporation cannot and will not accept returned material or equipment without proper authorization. Pall Corporation will return any such shipments at the customer's expense.

5. Rack Layout The method of rack layout depends on how the rest of the plant is assembled. If some or all of the plant piping is prefabricated, the large feed and filtrate piping should be installed before the racks are anchored. If the plant layout precludes rigging the racks into place after the piping, the valve racks can be set in place ahead of time. They should not be anchored until after the prefabricated piping is set. However, provisions should be made to ensure the unanchored racks are stable.

Once the piping is in place, stand up the valve rack using the lifting eyes installed on the top of the frame. The valve rack should be positioned to match the piping. Care should be taken to keep the back of the rack perpendicular to the line of the housekeeping pads, so the module racks line up with the valve rack correctly. Assemble the module rack frames per Section 7, and place them on their respective pads. Verify the alignment between the valve rack and module rack.

Set the module rack frames to maintain the spacing shown on the project-specific assembly drawing. If desired, the module feed manifolds can be fit up to double check the spacing and alignment.

6. Valve Rack Installation (Step #1)

6.1 Materials Required

Valve rack materials are specific to each project. The following list may be used as a guideline. (NOTE: Numbers in parenthesis are referenced on the Right Before Sight ((RB4S)) Detail BOM Spreadsheet, located in the notebook in crate 1B).

Valve Rack (11), Pressure Transmitter Assembly (12), Pressure Transmitter Assembly (13), and Pressure Indicator Assembly (14), and Turbidimeter instruments (15).

Fastening hardware for piping connection flanges. Verify scope of supply for these fasteners. They are typically outside Pall’s scope of supply.

Expansion joints (scope is by others) per design (typically 4, for Feed, Filtrate, RF Supply, and RF/AS drain connections).

Note: Connections where an expansion joint ties directly to an elastomer-seated valve require an intermediate plate ‘washer’ or flanged pipe spool between the fittings to provide a sealing surface. Expansion joint supply is project specific – Pall Corporation typically does not supply these joints.

(4) ¾" anchors with epoxy capsules, nuts and washers. (Typically supplied by others)

6.2 Valve Rack Installation

As noted previously, connect all Pall scope to itself first, then attach to customer piping.

NOTE: All item number references in details refer to site-specific Installation Spreadsheet.

1. Mark the locations, and drill and clean the anchor bolt holes for each rack, being very careful that the holes are plumb. The valve rack uses ¾” anchors. Be sure to use the correct epoxy capsules for the anchors, and to follow the manufacturer’s directions for installation. The required anchor embedment length is project specific and is usually designed by the Owner’s Consultant Engineer. If Pall supplied seismic calculations, refer to the supplied calculations for the required embedment length, otherwise, see drawings for suggested anchor bolt installation.

2. After the anchor bolt epoxy has set, use leveling nuts on the anchor bolts or the ½”-20 UNF tapped leveling holes on the rack base plates to make sure the rack is plumb and square.

CAUTION IMPORTANT NOTE ON BUTTERFLY VALVE INSTALLATION:

Elastomer-lined butterfly valves must not be fully closed when tightening their flange bolts. Use a compressed air hose to open the valve during final tightening.

3. Install block and bleed valves on connections where required.

4. Install expansion joints on connections where required. An intermediate plate ‘washer’ or flanged pipe spool must be installed between connections where an expansion joint ties directly to an elastomer-seated valve. Failure to do this results in a bad seal. Where piping is not rigidly supported adjacent to the joint, joint restraints must be installed, or the joints will tear.

5. Install the rest of the piping connections.

7. Module Rack Installation

CAUTION IMPORTANT NOTE ON PROTECTING THE HDPE COMPONENTS:

When moving or working with HDPE components (including manifolds) installers must protect all sealing surfaces from any damage including impacting these components with any other objects or surfaces. The slightest scratch, gouge, indentation, or any other imperfection in these surfaces causes leaks between gasket sealed couplings or other HDPE sealing devices.

Failure by the customer or the customer’s contracted installers to properly protect any sealing surface voids the warranty

Refer to the project-specific assembly drawing for anchor bolt locations for the valve rack and module rack frames. Great care must be taken to properly orient the module rack to the valve rack. Be sure to read ALL of the installation steps prior to beginning installation.

7.1.1 Feed Header Placement (Step #2)

Place the Feed Header (51) on the floor in the direction that it will be installed. The installation will occur at a later time in the process.

7.2 Rack Frame Assembly: Bottom Deck and Vertical Supports

(Step #3A, 3B)

Refer to the project-specific assembly drawing and establish the location of the vertical supports (Section 1A legs ((21)) on the module rack frame. Cross-reference the measured length of the lower frame between fastening points to confirm the proper distance.

Confirm that the leg (21) orientation is square with respect to the back of the valve rack and with its adjacent support. Confirm that the support is plumb when locating the connecting points to the rack frame and that the elevation of the connecting points are located so the rack frame will be level.

1. Anchor the first two module rack frame legs. The module rack supports use 1/2" anchors. Be sure to use the correct epoxy capsules for the anchors, and to follow the manufacturer’s directions for installation. Anchor embedment is project specific. See project-specific drawings for suggested anchor bolt installation.

When the anchor has been driven to the desired depth, install a nut and washer on the bolt. The upper surface of the washer should be 1½" – 2" above the top of the pad.

2. When the anchored supports are ready for use, line up the bottom deck (22,24 or

26) with the valve rack (11) , careful to make note of which end mates to valve rack (the 3” feed nozzles on the Collector manifolds must be on the same side as the feed flow meter on the valve rack and facing down).

3. Lift the valve rack end of the bottom deck section into its place on the valve rack and install the bolts concurrently, lift the far end of the bottom deck section carefully into its place on two vertical supports. Install the bolts but do not torque to spec. Use anti-seize compound on all stainless fasteners throughout the assembly, using care to wipe off any excess.

7.3 Rack Frame Assembly: Top Deck Section (Step #3C, 3D, &

3E)

1. Lift the top deck (23, 25 or 27) carefully into its place at the valve rack and vertical support connection points. Install the bolts, but do not yet torque to spec.

2. Install threaded support rod (37) at the front of the section.

3. Install the transverse (steel) braces (42) & nut/bolt fasteners.

7.4 Installing Multiple Decks (Step #4A – 6E if required)

7.4.1 Rack Frame Assembly: Bottom Deck and Vertical Supports

(Step #4A, 4B, 4C, AND 4D)

Confirm that the leg (21) orientation is square with respect to the back of the valve rack and with its adjacent support. Confirm that the support is plumb when locating the connecting points to the rack frame and that the elevation of the connecting points are located so the rack frame will be level. Install the bottom deck (22, 24 or 26), install the top deck (23, 25, or

27), install the threaded rod (37), and the cross braces (42).

Section 2 of the transverse rack is now completed. Continue the above steps for sections 3 and 4 if applicable and until the rack is installed.

7.4.2 Step # 7 – Installing Rack Frame End Kit

Install one (1) threaded rod (37), and two (2) C-Beams (44).

7.5 Empty Module Positions

On some projects, some module positions closest to the valve rack are left vacant. For entire vacant rows, the transverse Collector manifolds should be removed and the HDPE manifolds (installed later) require 3” Grooved style cap fittings on their branch nozzles to the vacant (removed) rows. Also, a 1” Grooved style cap fitting must be installed on the corresponding nozzle from the Air Scrub HDPE manifold. Pall will provide the molded Collector manifolds for any vacant rows the customer for later use if required.

If a row is partially filled with modules, then Grooved style cap fittings are required on the Collector branch nozzles to the vacant module connections. For a partially-filled row, the module spaces closest to the HDPE feed manifold connection should be left capped and vacant. Maximum is one empty spot per row. Refer to project-specific drawings. Use a light coat of specified lubricant on all gaskets and elastomeric joints on grooved joints, O-rings, etc.

Lubricant statement

Please note that all lubricants used on this system shall be water soluble and compatible with the materials of construction.

7.6 HDPE Manifold Installation

This assembly step requires the following pieces:

(Qty 1) 8" Feed HDPE manifold (51) with 3” Grooved style branch nozzles, one Grooved style end and one 8” blind flange end (56). (See the CML and packing lists for the correct part number as the part number will vary per the project requirements).

(Qty 1) 8" Filtrate HDPE manifold (52) with 3” Grooved style branch nozzles, one sealed end and one Grooved style end.

(Qty 1) 8" XR manifold (53) with 3” Grooved style branch nozzles, one sealed end and one Grooved style end.

(Qty 1) 3" Air Scrub manifold (54) with 1” Grooved style branch nozzles, one sealed end and one Grooved style end.

(Qty 1) 3" Air Scrub pipe clamp (69) per vertical support on the Air Scrub manifold side.

Air Scrub pipe assemblies (73), one per module row (project-specific)

(Qty 3) 8" Grooved style clamps (62)

(Qty 3) 3" Grooved style clamps per module row (69) and (Qty 1) for Air Scrub Manifold connection to Valve Rack

(Qty 2) 1" Grooved style clamp (per row) (64)

7.6.1 Install Feed HDPE Manifold (Step # 8)

1. Remove the seals from 3” Grooved style clamps (63) and place them on the Feed HDPE manifold (51) nozzles.

2. Refer to the project-specific assembly drawing and carefully lift the entire Feed HDPE manifold (51) into its place underneath the lower frame.

3. Attach the manifold via 8” Grooved style clamp (62) to the feed flowmeter adapter spool.

4. Shift the feed flowmeter location slightly as needed to align the nozzles on the HDPE manifold with the matching nozzles on the Collector manifolds attached to the frame.

Once aligned, secure the flowmeter mounts to the valve rack frame.

5. Assemble the Grooved style clamps that connect the feed HDPE manifold nozzles to the Collector manifolds. Make minor adjustments to individual Collector manifold locations (bolted) as needed to align nozzles. Make sure these are aligned with the upper deck.

The Feed HDPE Manifold, unlike the others, has a blind flange observation / cleanout connection on the far end. After inspecting for, and removing any visible debris (or dropped items) that may be present in the Feed HDPE Manifold, install the 8” PVC blind flange (56) and gasket (57).

7.6.2 Install Filtrate HDPE Manifold (Step # 9)

1. Remove the seals from 3” Grooved style clamps (63) and place them on the filtrate HDPE manifold nozzles.

2. Refer to the project-specific assembly drawing and carefully lift the entire filtrate HDPE manifold (52) into its place above the upper frame.

3. Attach the manifold via 8” Grooved style clamp (62) to the valve rack Filtrate spool.

4. Shift the valve rack Filtrate spool location slightly as needed to align the nozzles on the HDPE manifold with the matching nozzles on the Collector manifolds attached to the frame. Once aligned, tighten the Filtrate spool pipe clamps to the valve rack frame.

5. Assemble the Grooved style clamps that connect the filtrate HDPE manifold nozzles to the Collector manifolds. Make minor adjustments to individual Collector manifold locations (bolted) as needed to align nozzles.

7.6.3 Install XR HDPE Manifold (Step # 10)

1. Remove the seals from 3” Grooved style clamps and place them on the XR HDPE manifold (53) nozzles.

2. Refer to the project-specific assembly drawing and carefully lift the entire XR HDPE manifold into its place above the upper frame.

3. Attach the manifold via 8” Grooved style clamp to the valve rack XR spool.

4. Shift the valve rack XR spool location slightly as needed to align the nozzles on the HDPE manifold with the matching nozzles on the Collector manifolds attached to the frame. Once aligned, tighten the XR spool pipe clamps to the valve rack frame.

5. Assemble the Grooved style clamps that connect the XR HDPE manifold nozzles to the Collector manifolds. Make minor adjustments to individual Collector manifold locations (bolted) as needed to align nozzles.

7.6.4 Install Air Scrub HDPE Manifold and Air Scrub Connections

(Step # 11 & 12)

1. Refer to the project-specific assembly drawing and carefully slide the entire Air Scrub manifold (54) into its place inside the module rack frame, alongside the vertical supports on the Air Scrub manifold side.

2. Loosely install the 3” Air Scrub manifold pipe clamps (63) around the manifold and into the vertical supports.

3. Attach the manifold via 3” Grooved style clamp loosely to the valve rack Air Scrub spool.

4. Insert an Air Scrub Pipe Assembly (73) into the 1” side nozzle of each transverse Feed Collector manifold. Confirm that the holes in the pipe are oriented down and secure the assembly into the Feed Collector manifold using a 1” Grooved style clamp.

5. Align the branch nozzles on the Air Scrub manifold pipe to best accept the hoses from the Air Scrub Pipe Assemblies.

6. Attach each hose to the manifold using a 1” Grooved style clamp (67).

7. Complete the connection between the valve rack Air Scrub spool and the Air Scrub manifold by securing the 3” Grooved style clamp. Complete the connection between the Air Scrub manifold and the module rack frame by securing the 3” pipe clamps on the vertical supports.

Confirm plumb, square, and level frame members. Confirm the specified distance between feed nozzles on lower frame and filtrate nozzles on upper frame throughout.

Tighten all frame joint bolts to the specified torque.

Lubricant statement

Please note that all lubricants used on this system shall be water soluble and compatible with the materials of construction.

7.7 Preparation for Commissioning Procedures

At this point, the filter rack should be in the following state:

The valve rack (pre-assembled) is in place and anchored.

The module rack frame is in place and anchored.

The Feed, Filtrate, and XR HDPE manifolds are connected securely to the valve rack piping and to the Collector transverse manifolds except where a 3” Grooved style cap and clamp blocks a manifold nozzle to a vacant row

The Air Scrub HDPE manifold is connected securely to the inside of the module rack frame and there is a 1” hose (from an Air Scrub pipe assembly) held by 1” groove-joint clamps from each feed Collector transverse manifold to an Air Scrub HDPE manifold nozzle. Where there is a vacant row, the corresponding Air Scrub HDPE manifold nozzle has a 1” Grooved style cap and clamp.

Each module feed and filtrate connection on the Collector transverse manifolds is covered by a factory-installed 2” Grooved style cap and clamp.

Each module XR connection on the Collector transverse manifolds is covered by a factory-installed 1” Grooved style cap and clamp.

The rack will now be prepared for a series of dry testing procedures, followed by flushing and wet testing procedures. Only after all of these testing procedures have been completed successfully is it then allowable, after approval from Pall commissioning engineers, to proceed with the module installation process described in the next section.

From a mechanical standpoint, testing preparation requires the installation of flushing connections between the feed manifolds and the filtrate manifolds. Debris from construction that may have become trapped in the piping during installation must be removed to prevent it from becoming lodged in the membrane after the modules are installed. The actual flushing process is addressed in the commissioning procedures.

7.7.1 Installing Flushing Connections: (Step # 13)

1. Remove the 2” Grooved style cap from the transverse feed Collector manifold nozzle farthest from the connection to the Feed HDPE manifold.

2. Remove the 2” Grooved style coupling from the corresponding transverse filtrate Collector manifold nozzle. Take a piston-seal adapter, lubricate the o-ring, and insert it into the filtrate nozzle. Place the Grooved style coupling gasket on the bottom grooved end of the piston-seal adapter.

3. Remove the 1” Grooved style cap from the corresponding transverse XR Collector manifold nozzle.

4. Position a flushing module (81) on the feed nozzle and slide the Grooved style coupling gasket up until it is centered between the grooves on the nozzle and flushing module. Place the 2” Grooved style coupling over the gasket, and start the bolts. Do not tighten.

5. Position the flushing module so the XR fitting is aligned with the mating XR manifold nozzle.

6. On the piston-seal adapter, slide the Grooved style coupling gasket down until it is centered between the grooves on the adapter and the flushing module. Place the 2” Grooved style coupling over the gasket, and start the bolts. Do not tighten.

7. Place a lubricated 1" Grooved style coupling gasket over the end of the XR manifold nozzle.

8. Remove the XR nut and gasket from the flushing module. Slide the XR nut over the blue XR hose from the grooved end. Insert the XR gasket into the fitting on the flushing module. Position the XR piping assembly so that the grooved end mates up with the XR manifold adapter fitting and the union end mates up with the XR connection on the flushing module. Screw the nut on the XR hose onto the XR connection and hand-tighten.

9. Slide the 1" Grooved style coupling gasket onto the XR hose so that half of the gasket is on the XR hose PVC grooved adapter while the other half is on the XR manifold adapter.

10. Place a 1" Grooved style coupling over the gasket and tighten all fittings.

CAUTION: Prior to initial flush, verify that ALL clamps are tightend.

7.8 Module Installation (Step # 14)

Only after flushing and testing is completed can the final module installation take place.

The following items are required to assemble and install the modules:

UNA-620 modules (91)

XR hose assemblies (98)

Piston-seal adapters (96)

XR fitting gaskets

2" Grooved style clamps

7.8.1 Coupling Torque Table

Coupling Brand Size Ft/lbs

PASS Hangzhou Pass Fluid Equipment Co., LTD

¾-4” 25 Ft/lbs

Piedmont ¾ - 2” 5 Ft/lbs

Piedmont 2 ½ - 3” 7.5 Ft/lbs

Piedmont 4 & 6” 10 Ft/lbs

Gruvlok® Figure 7000 (Galvanized) 1 -2 ½” 45 Ft/lbs

Gruvlok® Figure 7000 (Galvanized) 3-4 ¼” 100 Ft/lbs

Gruvlok® Figure 7000 (Galvanized) 5 – 6 ½” 130 Ft/lbs

Gruvlok® Figure 7000 (Galvanized) 8” 180 Ft/lbs

If you brand clamp is not mentioned on this chart, please contact Pall Corporation.

Please note that these clamps are to be hand tightened.

Module O-Rings (two per module)

Module Nuts (two per module)

Module End Caps (two per module)

Module Nut Wrench

Torque wrench, 30-150 ft.lb

Strap Wrench

Water Based NSF Rated Lubricant

Lubricant statement

Please note that all lubricants used on this system shall be water soluble and compatible with the materials of construction.

IMPORTANT: Do not open any module plastic bags until ready to install the module, and do not allow the module to sit open for more than twenty (20) minutes. Once the module packaging is open, install adapter fittings on the module and install the module on the rack without delay. Do not remove temporary fittings or flushing modules from a module position on the rack until ready to install the module in that position. Module installation should take place one rack at a time. After each rack is loaded with modules, it is important to fill the rack with water to prevent any drying of the modules.

1. Drain the rack. Remove the blind flange from the end of the Feed manifold.

Using a flashlight, verify that the manifold is clean and free of debris. Replace the blind flange and refill the feed manifolds with water up to the bottom of the Feed adapter nozzles.

2. Remove a module from the shipping container and determine which end is the top (filtrate end with the smaller holes in the epoxy potting). The feed end (with the larger holes in the epoxy potting) orients to the bottom. The upper end is labeled “Concentrate” on the side. Also, the module label is legible when the module is in the correct orientation.

3. Place the module on a flat surface tilted about 20 with the feed side down;

remove the tape and protective end cover from the ends of the module (Figure 7.1). The module contains a few ounces of shipping and storage solution (30% Calcium Chloride) to preserve the membranes.

CAUTION: This solution is corrosive and is an irritant, see the MSDS in Appendix A for appropriate handling and personal protective equipment.

Because of the corrosive nature of the solution; clean up any spills and wash down any exposed surfaces with water.

Figure 7.1

4. With a container placed to catch any solution that may drain out, carefully remove the tape and protective end cover from the filtrate end of the module (Figure 7.2 with collection container not shown).

Figure 7.2

5. Carefully lift the feed end of the module allowing any storage solution to drain out of the filtrate end into the container.

6. After draining the module, remove the tape and protective end cover from the feed end of the module. Be aware that there may be a small amount of storage solution remaining in the module that drains out when the cover is removed.

7. Follow the next steps (a - e) to install an end cap onto the feed end of the module:

a. Lubricate an o-ring with water-based, NSF rated lubricant and set in the groove inside the end cap (Figure 7.3).

Lubricant statement

Please note that all lubricants used on this system shall be water soluble and compatible with the materials of construction.

Figure 7.3

b. Lubricate the module threads with water-based, NSF rated lubricant (Figure 7.4).

Lubricant statement

Please note that all lubricants used on this system shall be water soluble and compatible with the materials of construction.

c. Lubricate the flat area located on the top outside edge of the end cap with water-based, NSF rated lubricant (Figure 7.4).

Lubricant statement

Please note that all lubricants used on this system shall be water soluble and compatible with the materials of construction.

Figure 7.4

d. With the end cap nut placed over the arm, position the end cap onto the module and hold in place (Figure 7.5).

Figure 7.5

e. Carefully slide the module nut over the end cap and thread hand-tight onto the module (Figure 7.6).

Figure 7.6

8. Repeat Step 7 for the filtrate side end cap.

9. With one person holding a strap wrench around the module body, torque both end caps to 66 lb-ft (89.5 Nm) utilizing the supplied module wrench with a torque wrench attached in the place provided (Figure 7.7).

Figure 7.7

10. Remove the clamps and pipe caps from the rack module positions on the feed and filtrate manifolds.

11. Connect the XR flexible hose to the XR manifold and hand-tighten fasteners (Figure 7.8). Do not lubricate the XR fitting gaskets.

Figure 7.8

12. Apply a thin film of lubricant to the Grooved style coupling gasket and the o-ring of the piston-seal adapter. Tighten the clamp on the cap and adapter.

(Figure 7.9).

Lubricant statement

Please note that all lubricants used on this system shall be water soluble and compatible with the materials of construction.

Figure 7.9

13. When the module is ready to be lifted into place, the piston-seal adapter will slip inside the filtrate nozzle on the rack first (Figure 7.10). Then the bottom of the module will be aligned with the feed nozzle and set down carefully.

IMPORTANT: Allignment tolerance at each module space is +0.25/-0.0 inches.

Figure 7.10

14. Slide a Grooved style coupling gasket over the exposed feed connection on the feed manifold. Push the gasket down to expose the end of the manifold nozzle.

15. Carefully lift the module (filtrate end up) and slide the piston-seal adapter inside the filtrate nozzle on the rack. Then place the module’s feed nozzle carefully on top of the feed manifold nozzle. The nozzle and end cap have mating chamfered surfaces to assist in locating the module correctly (Figure 7.11).

Figure 7.11

16. Put the Grooved style coupling in place on the feed nozzle and start the bolts.

Loosely hand-tighten.

17. On the filtrate manifold, the filtrate connection is already complete (Figure 7.12).

Figure 7.12

18. Make sure an o-ring (do not lubricate) is in place where the XR hose connects to the module, then carefully thread the XR hose fitting onto the module and hand-tighten (Figure 7.13).

Figure 7.13

19. Tighten all fittings. Be careful not to over tighten.

20. After adding all of the modules, pressurize the system to 45 psig (3 barg) in several steps, starting at 15 psig (1 barg). Check all joints for leaks at each pressure, and adjust where necessary. Usually, a leak in a module joint indicates a misaligned O-ring or gasket, or a nut that has not been torqued sufficiently.

Cycling pressure may reveal leaks in joints that were tight on the previous cycle, but once the joints hold at 45 psig (3 barg) over two or three cycles, they will remain tight. The module joints must be absolutely leak-tight to perform Integrity Tests.

21. Leave the rack full of water until start-up. If start-up is to be delayed for more than a few days, the water in the rack should have a free chlorine residual of 0.5

– 1.0 mg/L.

CAUTION: Before bringing the system online, an Integrity Test must be performed (refer to the separate Operation and Maintenance manual for this procedure).

7.8.2 Installing the Longitudinal Cross braces - Final Step

When all of the previous steps have been completed and are accurate, install the

Longitudinal Cross braces.

Refer to the Maintenance Section of the main Operational and Maintenance manual for information on repairing and replacing the Microza® modules.

If additional assistance is required, contact Pall Technology Services.

8. Pall PRO Services & Support

8.1 Pall PRO Services & Support

Pall PRO Services is your partner for aftermarket service, spare parts and technical support throughout the life of your system. The Pall Pro Health Check service can be employed throughout the life of your system to provide you with an up to date status of your system hardware, software, components and operator skill levels. Our Process Optimization offerings give you full access to the experience of our Process Engineering group and help you maximize return on your filtration investment. The latest best practices and operator skills are found in our hands on training programs. And to support your trouble shooting and problem solving needs our Technical Support persons are available around the clock. All of the above services as well as access to factory recommended spare parts are available throughout the life of your system. These are graphically summarized below.

8.2 Pall PRO Services - Health Check

Leading a variety of value added service offerings is the Pall PRO Health Check. This unique diagnostic tool performed by specially trained and skilled field service persons provides you with a clearly defined system status you can use to plan for future expansions, needed upgrades and changing requirements.

8.3 Pall PRO Services – Optimization

Get the most out of your system at the lowest cost by engaging any of our Process

Optimization studies. Improve module maintenance and cleaning effectiveness, focus on the right pre-treatment, obtain a data based estimate of remaining module life, reduce chemical and energy costs and maximize recovery by engaging the services of the Pall Process

Engineering Group.

8.4 Pall PRO Services – Technical Support

Get over the phone and online trouble shooting guidance and real time problem solving capabilities by engaging our Technical Support group around the clock.

8.5 Pall PRO Services – Upgrades to Hardware and

Software

Keep up to date with the “best fit” hardware and component replacements and make sure you are using the most compatible software packages for maintaining the reliability of your control system. Don’t get caught with unsupported componentry or packages or live with unnecessary risk of unscheduled downtime. Speak with our Technical Support team about upgrades.

8.6 Pall PRO Services – Spare and Replacement Parts

Refer to the recommended spare parts lists to identify the micro-filtration system information, part numbers, material numbers, and the quantity required for each replacement part required.

8.7 Pall PRO Services - Service Contracts

In order to more effectively manage your system, we recommend you implement a service contract in which you can regularly access Pall Process Engineering and Service expertise to optimize its performance, effectively monitor module status and minimize operational risk.

Pall Technology Services is dedicated to providing customers with practical, effective and value added service and support throughout the life of the system. Contact a Pall representative or Pall Technology Services to review the service and system purchase options that can best serve your needs.

Before contacting Pall Technology Services: Contact Details

Refer to the component manuals in Appendix

B for help in understanding any instructions

Address: Pall Technology Services or technical support for system components. P.O. Box 5630

839 State Route 13

Cortland, New York, U.S.A. 13045

When contacting Pall Technology Services you will need to provide the following system information:

Telephone: 1-866-475-0115*

(or 1-607-753-6041)

System SAP number: 01.000XXX Fax: 1-607-758-1811

Time in Service: (yrs, months) Email: pall_technology_csc@pall.com

Operating Conditions:

*The above telephone number (1-866-475-0115) is toll free from 9 A.M. – 4 P.M. U.S. Eastern Time. After 4

P.M., there is a service charge unless the customer has an existing Pall service contract. The charge is waived during the MF System warranty period.

For obtaining basic support and general information contact the local Pall representative.

Pall Water Processing

PO Box 5630 Cortland, New York 13045

USA

Telephone: 1-607-753-6041 Fax: 1-607-753-8525

Pall Corporation

2200 Northern Boulevard East Hills, NY 11548

USA

Phone: 1-516-484-5400 Alternate Phone: 1-800-645-6532 Fax: 1-516-484-5228 http://www.pall.com

Copyright and Trademark Notice

All data, specifications, and information contained in this publication are based on information we believe reliable and represent values in effect at the time of printing. Pall Corporation reserves the right to make changes without prior notice. Because of developments in technology, these data or procedures may be subject to change. Consequently, we advise users to review their continuing validity. The transmission of information in this document in any form to anyone other than the intended user(s) without prior written consent of Pall Corporation is a violation of applicable laws.

The Pall Corporation name and logo and all related product and service names, design marks and slogans are the trademarks, service marks or registered trademarks of Pall Corporation. Other manufacturers' products contained in this document are trademarks of their respective companies.

In this document a trademark, service mark, or other copyright indicator that appears on devices, brand, or product names are trademarks or registered trademarks of their respective companies and/or organizations and are copyrights of those companies and/or organizations and used with their permission. A copyright indicator displayed with a device, brand, or product name once, is equivalent to that indicator being displayed on every instance of that device, brand, or product name in this document whether it is displayed or not. The names of actual companies and products mentioned herein may be the trademarks of their respective owners. Documents, information, specifications, and/or other material, written or graphic, contained or attached to this document is the property of its owners and may not be altered, copied, or distributed without their consent.

© Copyright 2015, Pall Corporation. All Rights reserved.

Filtration. Separation. Solution.SM

PALL MICROZA® COMPRESSED AIR PIPING FLUSHING

GUIDELINES

IMPORTANT – READ THIS FIRST

Before attempting to operate or install this equipment, Pall Corporation requires all operators to read and understand this manual for the system. Attempting to operate any Pall Corporation equipment without first reading this document may result in personal injury and/or product damage and may void any and/or all warranties.

Direct all questions…