Addendum 003 - O and M Manual - Prelim Oper and Maint Manual - Template 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: NYCS000008146 Rev: 00

Description of Item: HDPE 8-inch Transverse O&M Template

Specification Section: N/A

Deviations: N/A

INDEX:

Page 1: Cover Page Information

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Date: 12/19/2019

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MMAA IINNTTEENNAANNCCEE MMAANNUUAALL

((CCUUSSTTOOMMEERR ))

Pall SAP Number: 01.000XXX

Pall DIR Number:

Pall SO Number:

Document Revision Level: 00

Document Issue Date: Month Year

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IMPORTANT – READ THIS FIRST

Before attempting to operate or install this equipment or modules, Pall Corporation requires all operators to read and understand this Operation and Maintenance manual.

Attempting to operate any Pall Corporation equipment without first reading the Operation and Maintenance manual may result in personal injury and/or product damage and may void any and/or all warranties.

Direct all questions and/or inquiries to Pall Technology Services, or your project representative:

Telephone: 1-866-475-0115* or 1-607-753-6041

Fax: 1-607-758-4526

Email: pall_technology_csc@pall.com

* 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.

Throughout this manual: The word “customer” refers to Customer.

PALL MICROFILTRATION SYSTEM

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T A B L E O F C ON T E N T S

REVISIONS 10

TABLE A – PALL CORPORATION REVISION HISTORY 10

TABLE B – SYSTEM OPERATOR REVISION HISTORY 11

1 SAFETY INFORMATION 13

1.1 DOCUMENT INDICATORS 13

1.2 USER RESPONSIBILITY – STATEMENT OF PROPER USE 14

1.2.1 INSTALLATION AND OPERATION SAFETY 16

1.2.2 SAFETY INSPECTIONS 18

1.2.3 ELECTRICAL SAFETY 19

2 INTRODUCTION 23

2.1 ABOUT PALL CORPORATION 23

2.2 DOCUMENT ACRONYMS, ABBREVIATIONS, AND TEXT CONVENTIONS 23

TABLE 2.1 – PROCESS ACRONYM IDENTIFICATION 23

TABLE 2.2 – COMMON TEXT ABBREVIATIONS AND TERMS 24

TABLE 2.3 – VISUAL TEXT CONVENTIONS 25

2.3 MICRO-FILTRATION SYSTEM OVERVIEW 25

2.4 SHIPMENT, INSPECTION, AND STORAGE 26

2.5 STORAGE AND PRESERVATION OF THE MICRO-FILTRATION MODULES 27

2.6 RETURN SHIPMENT OF PARTS AND EQUIPMENT – RETURN GOODS AUTHORIZATION 28

2.7 WARRANTY INFORMATION 29

3 SYSTEM COMPONENTS 31

3.1 INTRODUCTION 31

3.2 CONNECTING UTILITIES 32

3.3 MICROZA® MODULE INSTALLATION 32

3.4 PALL SYSTEM COMPONENTS 32

3.4.1 THE MICROZA MICRO-FILTRATION MODULES 33

FIGURE 3.1 – THE MICROZA® MICRO-FILTRATION MODULE 33

3.4.2 THE FILTER RACKS 34

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4 MICRO-FILTRATION SYSTEM OPERATION 37

4.1 INTRODUCTION 37

4.2 PERIODIC MANUAL REVIEWS AND UPDATES 38

4.3 THE MICRO-FILTRATION (MF) SYSTEM PROCESSES 38

4.4 PROGRAMMABLE LOGIC CONTROLLER (PLC) MODES 39

4.4.1 DEFINITION 39

4.4.2 GROUPING 39

4.4.3 MODES 39

4.4.3.1 AUTO 39

4.4.3.2 MANUAL 39

4.4.4 MODE SELECTION 41

4.5 AUTOMATIC MODE OPERATION 41

4.5.1 FILL SEQUENCE 41

4.5.1.1 INITIAL START-UP 42

4.5.1.2 FILL CYCLE 42

4.5.2 FORWARD-FLOW 43

4.5.3 FLUX MAINTENANCE (FM) 43

4.5.3.1 AIR SCRUB (AS) 44

4.5.4 FLUSH (FL) CYCLE 45

4.5.4.1 REVERSE FILTRATION (RF) CYCLE 45

4.5.5 INTEGRITY TEST (IT) 46

4.5.6 ARBITRATION 48

4.5.7 INDIVIDUAL FILTER RACK SHUTDOWN 49

4.6 EFM AND CIP PROCESSES 50

4.6.1 ENHANCED FLUX MAINTENANCE (EFM) 51

4.6.1.1 CLEAN-IN-PLACE 52

4.6.1.2 EFM AND CIP RECIPE STEPS 52

4.6.1.2.1 RECIPE STEP – PUMPED DRAIN TO NEUTRALIZATION 53

4.6.1.2.2 RECIPE STEP – ACID WASH 53

4.6.1.3 RECIPE STEP - CAUSTIC WASH 54

4.6.1.4 RECIPE STEP – RACK RINSE 54

4.6.1.5 RECIPE STEP – ACID RECOVERY 55

4.6.1.6 RECIPE STEP – CAUSTIC RECOVERY 55

Pall Microfiltration System

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4.6.1.7 RECIPE STEP – TIMED SOAK 56

4.6.1.8 RECIPE STEP – CONFIRMED PAUSE 56

4.6.1.9 RECIPE STEP – TRIGGER ACID REFRESH 56

4.6.1.10 RECIPE STEP – TRIGGER CAUSTIC REFRESH 56

4.6.1.11 RECIPE STEP – SKIP STEP 57

4.7 CIP SYSTEM NON-RECIPE OPERATION 57

4.7.1 ACID MAKE CYCLE 57

4.7.2 CAUSTIC MAKE CYCLE 58

4.7.3 ACID TANK FLUSH 59

4.7.4 CAUSTIC TANK FLUSH 59

4.7.5 SOLUTION VALIDITY FUNCTIONALITY AND FORCE VALIDITY 60

4.7.6 SEMI-AUTOMATIC TRANSFERS 61

4.8 NEUTRALIZATION SYSTEM 61

4.8.1 AUTOMATIC NEUTRALIZATION 61

4.8.1.1 SODIUM BISULFITE INJECTION 61

4.8.1.2 ACID INJECTION 62

4.8.1.3 CAUSTIC INJECTION 62

4.8.1.4 NEUTRALIZATION TANK DRAIN 62

4.9 SUPPORTING EQUIPMENT IN AUTOMATIC MODE 63

4.9.1 PLANT CONTROL OVERVIEW 63

4.9.1.1 PLANT FLOW REFERENCE 63

4.9.1.1.1 CLEARWELL LEVEL 63

4.9.1.1.2 HMI FLOW SET-POINT 64

4.9.1.2 PLANT FLOW REFERENCE DISTRIBUTION 64

4.9.1.2.1 RACK FLOW REFERENCE 64

4.9.1.2.2 FEED PUMP FLOW REFERENCE 65

4.9.2 FEED PUMP CONTROL 65

4.9.2.1 FLOW CONTROL MODE 65

4.9.2.2 PRESSURE CONTROL MODE 65

4.9.2.2.1 AUTO PRESSURE ADJUST FOR TMP 65

4.9.3 RF FLOW CONTROL 66

4.9.3.1 RF TANK FILL 66

4.9.4 AUTOMATIC FEED STRAINERS 67

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4.9.5 AIR COMPRESSORS AND RELATED EQUIPMENT 69

4.9.5.1 PLC/COMPRESSOR SIGNALS 69

4.9.5.2 CONTROL 70

4.10 INTEGRATION WITH EXISTING EQUIPMENT 71

4.11 MANUAL MODE OPERATION 71

4.12 DESCRIPTION OF INCLUDED COMPONENTS 72

4.13 THE CONTROL SYSTEM 72

4.13.1 HMI SCREEN EXAMPLES AND FUNCTIONS 73

4.13.1.1 SET-POINT SCREENS 73

4.13.1.2 HMI SCREENS’ BUTTON ROW 74

FIGURE 4.1 – HMI SCREEN BUTTON ROW AND ALARM ACKNOWLEDGE BUTTON 74

4.13.1.3 HMI COLORS AND CONVENTIONS 74

FIGURE 4.2 – THE SYSTEM COLOR LEGEND POP-UP 75

4.13.1.4 POP-UP CONTROL SCREENS 75

FIGURE 4.3 –DEVICE CONTROL POP-UP (LEFT) AND SYSTEM/SUB-SYSTEM CONTROL POP-UP

(RIGHT) 76

4.13.1.5 USER/LOG-IN SCREEN 77

FIGURE 4.4 – THE USER/LOG-IN SCREEN 77

4.13.1.6 MAIN PROCESS SCREEN 78

FIGURE 4.5 – THE MAIN PROCESS SCREEN 78

4.13.1.7 THE RACK SCREENS 79

FIGURE 4.6 – THE RACK 1 SCREEN 79

4.13.1.8 UTILITY SCREEN 80

FIGURE 4.7 – THE UTILITY SCREEN 80

4.13.1.9 CIP/EFM SYSTEM SCREEN 81

FIGURE 4.8 – THE CIP MAIN SCREEN 81

4.13.1.10 DOSING/XFER SYSTEMS SCREEN 82

FIGURE 4.9 – THE DOSING/XFER SYSTEMS SCREEN 82

4.13.1.10.1 CIP/EFM RECIPE SCREEN 83

FIGURE 4.10 – THE CIP/EFM RECIPE SCREEN 83

4.13.1.11 THE DATA SCREENS 84

FIGURE 4.11 – A DATA SCREEN 84

4.13.1.12 DEVICE RUNTIMES DATA 85

4.13.1.13 THE SETUP MENU SCREEN 86

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FIGURE 4.12 – THE SETUP MENU SCREEN 86

4.13.1.13.1 THE ALARM SET-POINTS SCREENS 87

FIGURE 4.13 – AN ALARMS SCREEN 87

4.13.1.13.2 PROCESS SET-POINTS SCREENS 88

FIGURE 4.14 – THE PROCESS SET-POINTS SCREEN 88

4.13.1.13.3 FEED AREA SET-POINTS 89

4.13.1.13.4 SCALING SCREENS 90

FIGURE 4.15 – AN EXAMPLE SCALING SCREEN 90

4.13.1.13.5 THE PID LOOP TUNING SCREENS 91

FIGURE 4.16 – A PID LOOP TUNING SCREEN 91

4.13.1.13.6 THE SYSTEM MODES SCREEN 92

FIGURE 4.17 – THE SYSTEM MODES SCREEN 92

4.13.1.14 THE ALARM SUMMARY SCREEN 93

FIGURE 4.18 – THE ALARMS SCREEN 93

5 SYSTEM SHUTDOWN AND RE-START PROCEDURES 95

5.1 AUTOMATIC SYSTEM SHUTDOWN 95

5.2 EMERGENCY SHUTDOWN 95

5.3 SHORT, MID & LONG TERM SHUTDOWN AND SYSTEM LAY-UP 96

5.3.1 INITIAL CONDITIONS 96

5.4 OPERATOR INSTRUCTIONS 96

5.4.1 SHORT TERM SHUTDOWN (<16 HOURS) 96

5.4.2 MID-TERM SHUTDOWN (16-72 HOURS) 97

5.4.3 LONG TERM SHUTDOWN (>72 HOURS) 97

5.5 MICROZA® MODULE PRESERVATION 99

5.6 START-UP AFTER INTENTIONAL OR EMERGENCY SHUTDOWN 99

5.6.1 INITIAL CONDITIONS 100

5.6.2 OPERATOR INSTRUCTIONS 100

6 MAINTENANCE 101

6.1 INTRODUCTION 101

6.2 INTEGRITY TEST FAILURE FOLLOW-UP 101

6.2.1 OPERATOR INSTRUCTIONS 102

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FIGURE 6.1 – TRANSPARENT PISTON-SEAL ADAPTER 103

6.2.1.1 IF NO BUBBLES ARE OBSERVED 103

6.2.1.2 IF BUBBLES ARE OBSERVED – FIBER REPAIR PROCEDURE 103

6.3 REPAIRING THE MICROZA® HOLLOW FIBER MODULES 104

6.4 REMOVAL OF A MICROZA® MODULE 106

6.5 COUPLING TORQUE TABLE 107

6.6 DAILY SUPPORT MAINTENANCE 108

6.6.1 DAILY INSPECTION 108

6.6.2 SAMPLING OF INFLUENT AND EFFLUENT WATER 108

6.6.3 MAINTAIN CHEMICAL STOCKS 108

6.6.4 MAINTAIN A REPLACEMENT PARTS INVENTORY 108

6.6.5 PERFORM SCHEDULED PREVENTIVE MAINTENANCE 109

TABLE 6.1 – GENERAL PREVENTIVE MAINTENANCE ACTIVITIES 110

6.6.5.1 PC PREVENTATIVE MAINTENANCE 110

6.6.6 UPDATE OPERATING RECORDS 112

6.7 SUPPLIES 112

6.7.1 CHEMICALS 112

6.7.2 LUBRICANTS 113

6.7.3 REPLACEMENT PARTS 113

6.7.4 TOOLS 113

6.8 RECORD KEEPING 114

6.8.1 DAILY OPERATIONAL RECORDS 114

6.8.2 LABORATORY DATA 115

6.8.3 MAINTENANCE RECORDS FORMS 115

TABLE 6.2 – DAILY INSPECTION FORM 116

TABLE 6.3 – CHEMICAL USAGE TABLES 117

TABLE 6.4 – REPLACEMENT PARTS INVENTORY RECORD 118

TABLE 6.5 MAINTENANCE SUMMARY FORM 119

TABLE 6.6 – EQUIPMENT SERVICE RECORD 120

7 PALL PRO SERVICES & SUPPORT 121

7.1 PALL PRO SERVICES & SUPPORT 121

7.2 PALL PRO SERVICES - HEALTH CHECK 122

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7.3 PALL PRO SERVICES – OPTIMIZATION 122

7.4 PALL PRO SERVICES – TECHNICAL SUPPORT 122

7.5 PALL PRO SERVICES – UPGRADES TO HARDWARE AND SOFTWARE 122

7.6 PALL PRO SERVICES – SPARE AND REPLACEMENT PARTS 122

7.7 PALL PRO SERVICES - SERVICE CONTRACTS 123

8 TROUBLESHOOTING 125

8.1 TROUBLESHOOTING 125

8.2 TABLE 8.1 – OPERATOR RESPONSE TO SYSTEM WARNINGS DURING FILTRATION 126

8.3 TABLE 8.2 – OPERATOR RESPONSE TO SYSTEM ALARMS DURING FILTRATION 126

8.4 TABLE 8.3 – OPERATOR RESPONSE TO SYSTEM WARNINGS DURING CIP 127

9 GLOSSARY 129

APPENDIX A FILTER VALVE AND DEVICE FUNCTION DESCRIPTIONS AND VALVE

TRUTH TABLES

APPENDIX B COMPONENT DOCUMENTATION

APPENDIX C RECOMMENDED SPARE PARTS LIST

APPENDIX D SAFETY DATA SHEETS (SDS)

APPENDIX E INSTALLATION GUIDELINES

APPENDIX F SYSTEM DRAWINGS

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REVISIONS

TABLE A – PALL CORPORATION REVISION HISTORY

Revision Date Originator Description

MONTH

YEAR

PALL WATER

PROCESSING

PRELIMINARY/INITIAL RELEASE.

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TABLE B – SYSTEM OPERATOR REVISION HISTORY

Revision Date Originator Description

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Blank Page

PALL MEMBRANE MICROFILTRATION SYSTEM

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1111 SSSSAFETY AFETY AFETY AFETY IIIINFORMATIONNFORMATIONNFORMATIONNFORMATION

1.1 DOCUMENT INDICATORS

The following highlighted boxes indicate important safety and process instructions or information.

IMPORTANT: These statements indicate special attention be given a particular procedure or information to prevent damage to equipment, false readings, or disruption to a process.

CAUTION: Caution indicators identify that potential personal hazards and hardware or product damage exist with the procedure and provide information for prevention.

CAUTION/WARNING:

This lightning symbol indicates that a dangerous voltage or other electrical hazard is present and may constitute a risk of electrical shock with the potential for BODILY HARM.

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WARNING::: THIS INDICATES THAT THERE IS AN IMMEDIATE DANGER

ASSOCIATED WITH A PARTICULAR PROCEDURE THAT COULD

CAUSE BODILY HARM. EXTREME CAUTION MUST BE

EXERCISED.

IMPORTANT: The above symbols and their combinations thereof, provide emphasis to important aspects of both safety and the operation of this system. Note however, that ALL information contained in this document is important for the safe and efficient operation of this system.

1.2 USER RESPONSIBILITY – STATEMENT OF PROPER USE

In keeping with its commitment to the safe operation of its equipment, Pall

Corporation provides the following information as good working practice safety guidelines and as a guide for safe operation of Pall equipment. Use of this information should be in conjunction with the safety procedures at the facility where the Pall system/equipment is located.

Personnel working with or around the equipment should read and understand ALL safety procedures before proceeding. Where there is conflict with existing safety procedures, the in-force local facility safety procedures take precedence. It is the buyer's responsibility to enforce the adherence to safe operating procedures.

DO NOT convert or alter the Pall Water Treatment System to any purpose other than its intended one without first contacting Pall Corporation. Pall Corporation is not responsible for any of its equipment altered by others without Pall Corporation’s prior approval.

CAUTION: All Pall Micro-filtration Membrane System operators must be properly trained by Pall Corporation or someone authorized by Pall Corporation. Any damage to any part of the Micro-filtration Membrane System caused by an untrained operator voids ALL warranties.

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WARNING::: THIS MANUAL SECTION CONTAINS SAFETY INFORMATION,

WARNINGS, AND CAUTIONS BOTH MECHANICAL AND

ELECTRICAL THAT, IF IGNORED, CAN RESULT IN BODILY HARM

AND/OR EQUIPMENT DAMAGE!

DO NOT OPERATE OR SERVICE THIS EQUIPMENT UNTIL YOU

HAVE READ THIS OPERATION AND MAINTENANCE MANUAL

AND THE SAFETY INFORMATION CONTAINED HEREIN. WHEN

INSTALLING, OPERATING, OR PERFORMING MAINTENANCE ON

THIS EQUIPMENT, ALWAYS OBSERVE CAUTION AND WARNING

NOTICES.

The design and manufacture of all Pall Corporation equipment is with due consideration and care for generally accepted safety standards. However, like any mechanical device, the proper and safe performance of this equipment depends upon using sound and prudent operating, maintenance, and servicing procedures by properly trained personnel.

For personal protection and the protection of others:

• Follow the safety guidelines outlined in this manual.

• Form safe working habits by incorporating and abiding by these guidelines in the daily work routine.

• Keep this manual available for review.

Always operate the system within the safety operating guidelines of this manual and the facility where the system is located.

DO NOT:

• Prevent the operation of any safety features.

• Remove the safety guards.

• Operate this equipment with any of the safety devices bypassed or the guards removed. Only qualified personnel should operate this machine.

• Perform service or maintenance procedures when the equipment/machine is running or toxic materials are present.

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This equipment includes an electrical system. To avoid shock or serious injury, only qualified personnel should perform maintenance on the electrical system. For maximum protection, the power source should be LOCKED OUT using a lock for which only the operator has the key. This prevents anyone from accidentally turning on the power while the operator is servicing the equipment/machine.

All electric power must be OFF before servicing the equipment/machine. If applicable, turn the main disconnect switch to the OFF (OPEN) position. If a main disconnect switch is not present, isolate (de-energize) the machine/equipment of all power sources before any service takes place. Refer to Section 1.2.3 “Electrical

Safety” on page 19 for more information.

CAUTION: If the main control panel is UPS protected, turning the disconnect switch to the off position does not fully de-energize the panel. Refer to the panel electrical drawings and schematics for means to disconnect the UPS output power.

1.2.1 INSTALLATION AND OPERATION SAFETY

Installation is to be performed by trained and authorized personnel only. Pall

Corporation requires licensed technicians or those authorized by the facility and/or the country of installation install power sources, including electrical, air (pneumatic), nitrogen, steam, and hydraulic. Pall Corporation is not responsible for these or other utilities installations performed by unqualified personnel.

• Only qualified or authorized personnel should be within the installation/operating zone when there is power applied to the equipment control circuits or when the equipment is in operation.

• Use a brightly painted guardrail and/or warning strips to define an operating zone.

Always operate the filter system within the safety guidelines of the facility and/or country where the system is located.

Installations must comply with all applicable codes and standards, including those established by OSHA or the codes and regulations of the country of installation.

Installations involving ASME pressure coded components must be in adherence to strict ASME specifications.

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CAUTION: Follow all site procedures regarding toxic, bio-hazardous, or corrosive process materials. Any solution drained from the system into a common drain must meet the requirements and/or standards set by the governing authority for waste disposal in the affected community/area.

DO NOT:

• Operate any equipment until thoroughly trained in all facets of its operation.

• Operate faulty or damaged equipment. Make sure that the performance of proper service and maintenance procedures on all equipment is up to date.

• Start any equipment until issuing warnings to all non-essential personnel in the area. After issuing warnings, verify that all non-essential personnel have moved outside the operating zone.

• Have loose clothing, neckties, necklaces, or unrestrained long hair near any operating equipment. These restricted items include rings, watches, bracelets, and other jewelry.

• Place fingers, hands, or any other part of your body on or into any equipment or near moving parts when the power is on.

• Touch surfaces that are in temperature ranges above 120°F (49°C) or below

0°F (-18°C).

• Operate any equipment if the removal or disconnection of a safety device or guard has occurred.

• Operate any equipment above or below specified speeds, pressures, or temperatures.

• Remove warning labels or signs that appear on any equipment. Replace torn, worn, and unreadable warning markers immediately.

• Sit, stand, kneel, or lay on anything that may cause you to fall against the equipment.

• Perform any unauthorized activity around or on any equipment at any time.

This is both dangerous and prohibited.

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• Attempt to clean any equipment while it is in operation.

Always check that the equipment to be cleaned is in a safe condition (not powered, at temperature extremes, etc) and that approved warning signs are posted and other personnel are aware that cleaning is in progress. Use lockout/tag-out procedures when applicable. Always use approved cleaning materials and dispose of properly.

ALWAYS:

• Remove any tools or other unauthorized objects from the operating zone before starting the equipment.

• Keep the operating zone free of obstacles that could cause a person to trip or fall against the equipment.

• Keep alert and observe indicator lights, warnings, and alarms that display on any equipment.

• Wear required safety equipment.

• Know the procedures for shutting down and starting up the Micro-filtration

System.

NOTE: Air, nitrogen, hydraulic, steam, and electrical power must be off when the equipment is not in use unless it is required for maintenance, testing, or troubleshooting purposes.

1.2.2 SAFETY INSPECTIONS

BEFORE START-UP OR RE-START:

• Before the start-up or re-start of the system, make sure that all:

• Guards and safety devices are installed and operative.

• Non-required personnel are clear of the equipment.

• Materials, tools, or other foreign objects that could cause bodily injury to personnel and/or damage the equipment are removed from the operating zone.

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• Equipment is in operating condition by checking that:

• All gas and fluid connections are tight and leak free.

• All moving components are properly lubricated.

• All process monitoring lights, horns, pressure gauges, and safety devices or indicators are in good working order.

AFTER SHUTDOWN:

• When the system is shut down, make sure that:

• All utilities such as air and electrical power are turned off and disconnected, unless required.

• All pressure is relieved from any tanks, vessels, or other pressurized equipment.

1.2.3 ELECTRICAL SAFETY

Pall Corporation requires that licensed electricians or those authorized by the facility and/or country of installation perform all required electrical work. This work includes but is not limited to:

• All electrical/electronic maintenance and service, including cleaning

• Maintenance on the electrical system to avoid bodily harm to other personnel

All electric power must be OFF before servicing the equipment unless required for maintenance, testing, or troubleshooting procedures.

• If power is required, EXTREME CAUTION must be observed by all personnel.

If applicable, turn the MAIN DISCONNECT switch to the OFF (OPEN) position.

• If a MAIN DISCONNECT switch is not present, isolate (de-energize) the equipment of all power sources before any service takes place unless required for maintenance, testing, or troubleshooting procedures.

Under circumstances where maintenance, testing, or troubleshooting requires the power to be ON, make sure:

• Your tools and body are clear of the chassis.

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• Proper grounding is in place.

• To take extra safety precautions in damp areas.

• To be alert and avoid outside distractions.

• To post proper ELECTRICAL HAZARD warning signs.

• To inform all personnel in the area that work is taking place with the electrical power turned on and applied to the equipment.

Always assume that the power is ON.

To remove the load from a circuit or equipment:

• OPEN the disconnect switch or the appropriate circuit breaker and lock it in the open position.

• Make sure that the circuit is OPEN by using the proper test equipment.

IMPORTANT: Check all test equipment at regular intervals for proper calibration and that it is functioning properly. Always check the calibration date tag on the instrument for last calibration date. If the test equipment does not have a tag listing the last calibration date, DO NOT USE IT and report it to management.

• For maximum safety, the power source should be LOCKED OUT using a lock for which only the operator has the key. This prevents anyone from accidentally turning on the power while the operator is servicing the equipment/machine.

• Whenever locking-out any power source, always use standard OSHA

LOCKOUT/TAG-OUT procedures (or the procedures required by the country of installation) when servicing the equipment, or the appropriate procedures of the governing body in the country where the equipment is located.

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WWWAAARRRNNNIIINNNGGG::: DANGER – USING A POWER SOURCE OTHER THAN THAT

SPECIFIED IN THIS MANUAL OR THE SYSTEM DRAWINGS CAN

CAUSE BODILY HARM AND/OR PRODUCT DAMAGE! MAKE

SURE THE POWER SUPPLY MEETS THE REQUIREMENTS AS

SPECIFIED. IMPROPER GROUNDING CAN CAUSE ELECTRICAL

SHOCK HAZARDS. MAKE SURE THAT PROPER GROUNDING,

BONDING, AND OVERLOAD PROTECTIONS ARE IN FORCE. DO

NOT DEFEAT THE GROUNDING OR POLARIZATION OF THE

EQUIPMENT/MACHINE.

Control panel doors should be open only when checking the electrical equipment wiring. When the panel door is closed, make sure that the disconnect handle mechanism (if applicable) is operating properly.

Protect all electrical connections by confining them inside a sealed junction box.

Close and secure all covers on electrical panels and junction boxes before leaving any job.

Replace fuses only with those of a similar rating and only when the electrical power is

OFF. If possible, the electrical power source should be LOCKED OUT.

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2222 IIIINTRODUCTIONNTRODUCTIONNTRODUCTIONNTRODUCTION

2.1 ABOUT PALL CORPORATION

Pall Corporation has been partnering with customers for over 60 years helping them to solve their most critical and difficult fluid management challenges. Pall has amassed the broadest filtration, separation and purification capabilities and experience in the world answering those challenges. Our commitment is to continuously enhance our ability to provide customers with the most effective Total Fluid ManagementSM solutions to help ensure their success. When our customers succeed, Pall succeeds and we will continue to follow the guiding principles that have brought us to where we are today. This means we will strive to do more for customers than others in our field and we will always do what’s right for them and for those who put their trust in us.

2.2 DOCUMENT ACRONYMS, ABBREVIATIONS, AND TEXT

CONVENTIONS

Tables 2.1, 2.2, and 2.3 identify common acronyms, abbreviations, and text conventions used throughout this manual for various MF Filtration System processes control programming.

TABLE 2.1 – PROCESS ACRONYM IDENTIFICATION

Process Process Acronym

Forward-Flow FF

Air Scrub AS

Reverse Filtration RF

Feed Flush FL

Integrity Test IT

Clean-In-Place CIP

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Process Process Acronym

Enhanced Flux Maintenance EFM

Strainer Backwash SBW

TABLE 2.2 – COMMON TEXT ABBREVIATIONS AND TERMS

Abbreviation or Term Description

Feed Flow The flow of water entering the MF system

Filtrate Flow The flow of water leaving the MF system

PC Personal Computer

SCADA Supervisory Control and Data Acquisition

PLC Programmable Logic Controller

Inch in or "

Foot ft or '

Millimeter mm

Meter m

Gallon gal

Liter ltr

Gallon Per Minute gpm

Liter Per Minute lpm

Liter Per Second lps

Pounds Per Square Inch psi

Other less used abbreviations may be defined within the text.

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TABLE 2.3 – VISUAL TEXT CONVENTIONS

Type Convention

Operator Adjustable Set-points Bold Italic Text

HMI Screens Bold Underlined Text

Control Types, Modes, and Processes

Bold Text

Selectable Screen Buttons Framed

Integrity Test IT

Clean-In-Place CIP

Enhanced Flux Maintenance EFM

Strainer Backwash SBW

For additional information on valves, devices, and equipment identified by tag number in the text of this document, refer to the supplied Pall Process and Instrument

Diagram (P&ID) drawing.

2.3 MICRO-FILTRATION SYSTEM OVERVIEW

For more than a century, conventional water treatment plants provided a first line of consumer protection for a community's drinking water supply. Now, older technologies such as rapid mix, coagulation and flocculation, sedimentation, or multi-media filtration are no longer able to provide adequate protection from illness-causing microscopic bacteria infiltrating that same water supply.

Micro-filtration is a means of trapping and removing such contaminants as Giardia cysts (8-30 µm), Cryptosporidium cells (3-8 µm), and other bacteria ranging from 0.2 to 50 µm by means of a porous barrier that is fixed in place. In micro-filtration, such impurities are simply too large to pass through. To put the size of these particles in perspective, the diameter of a human hair is in the range of 20 to 120 µm. Membrane treatment performance is relatively insensitive to rapid changes in the feed water composition unlike systems based on chemical addition and coagulation. Membrane technology is accepted throughout the world as an effective and economical water treatment method.

The degree of water purification required determines what level of membrane filtration is appropriate for a particular application. Micro-filtration (0.1 to 1.0 µm) is ideal for removing suspended particles, bacteria, and many viruses from water. Micro-

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filtration membranes normally operate at pressures of between 0 to 6.9 bar. The Pall

Microza® modules normally operate within a pressure range of 0 to 3.5 bar.

Ultrafiltration, Nano-filtration, and Reverse Osmosis can be used to purify water even further, but the pressure required for the feed water to these systems increases significantly.

In the process of providing filtered water for storage and later consumption, the Pall

Microza® Micro-filtration System operates in several different modes. These modes are described more fully in the Section 4 “Micro-filtration System Operation” beginning on page 37.

2.4 SHIPMENT, INSPECTION, AND STORAGE

All system components are inspected for any damage upon packing for shipment from the Pall Corporation manufacturing facility.

Upon arrival at the place of customer installation or storage, it is the customer’s responsibility to open and inspect all containers and their contents for any damage that may have occurred during shipping.

After inspection, if no damage is detected, repackage all components with the original packaging, where possible, place any storage containers in a dry, secure location until ready for installation. Take appropriate protective measures to prevent damage to equipment from any adverse environmental conditions. The site selected for storage must be inside and protected from extreme heating conditions (no direct sunlight), any adverse environmental conditions, and temperatures below the freezing point of water

(0°C). Properly seal all nozzles and tap openings. Retain the original factory-supplied shipping materials for protection and security of the equipment during storage.

CAUTION: Failure to comply with Pall Corporation storage requirements and conditions may cause damage to equipment and voids all warranties.

After inspection, if damage is observed or suspected contact the freight carrier and

Pall Water Processing Contract Administration (1-607-753-6041) immediately. Pall

Corporation recommends that customers record the damage as soon as possible in writing and, if possible, with photographs, obtaining the delivery person's signature and date. Obtaining the delivery person's signed agreement facilitates future damage claims. All shipping claims must be owner-processed with the carrier. Unless otherwise agreed upon by Pall Corporation and the customer, Pall Corporation is not responsible for and cannot handle shipping claims against the carrier. It is Pall

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Corporation’s standard policy to assist its customers in any way possible. Refer to the

Pall Corporation/customer sales and/or warranty contract for information on shipment responsibilities.

In all damage cases, either visible or suspected, please contact your local Pall

Corporation representative or Pall Technology Services before attempting to install the subject equipment.

2.5 STORAGE AND PRESERVATION OF THE MICRO-

FILTRATION MODULES

CAUTION: The Microza® micro-filtration module membranes can dry out if left un-wetted causing damage to the micro-filtration hollow fiber membranes. To avoid this, 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 from extreme heat (no temperatures over 104°F (40°C) with no exposure to direct sunlight) and cold (no temperatures below freezing 32°F

(0°C)). DO NOT STORE THE MODULES OUTSIDE.

IMPORTANT – Do not install the Microza® modules in the rack or attempt to start a filtration cycle until the Pall Micro-filtration Water Treatment System has been properly flushed using the included dummy module.

Using the Pall Micro-filtration system before flushing may cause damage to the modules and other system components from debris that has inadvertently entered the system through fabrication, shipping, storage, and/or installation.

― (Continued on Next Page) ―

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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.

After system installation, if the system is to be shut down for a short time (less than 48 hours), the Microza® modules membranes must be kept wet with clear water (see Section

5.4.1 “Short-Term Shutdown” on page 96). If the system is to be shut down for more than forty-eight (48) hours refer to

Section 5.4.3 “Long-Term Shutdown and System Lay-Up” on page 97 for more storage procedures.

DO NOT move or in any way transport the Pall Micro-filtration Water Treatment System with the modules mounted on the skid. Any vibration or shock may damage the module membrane. Always dismount the modules and install dummy modules for system transportation.

Failure to adhere to this caution results in the voiding of all module warranties!

2.6 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.

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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.

2.7 WARRANTY INFORMATION

Pall Corporation’s warranties are usually project specific and vary with customer process conditions and equipment sold. Please consult the specific warranty contained in the customer/Pall Corporation contract.

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3333 SSSSYSTEM YSTEM YSTEM YSTEM CCCCOMPONENOMPONENOMPONENOMPONENTSTSTSTS

3.1 INTRODUCTION

For system installation procedures and instructions, see the separate Pall Corporation

Micro-filtration Installation manual. Before operating this Micro-filtration System, the customer should thoroughly review this manual and the supplied Micro-filtration

System drawings.

Although not mandatory, Pall Corporation recommends that, if possible, system installation occur with Pall Technology Services technicians present. If questions or problems arise during installation and a Pall representative is not on-site, contact Pall

Technology Services.

If the customer elects to install the Pall MF System without Pall representatives, it is the customer’s responsibility to insure all Pall Corporation system installation procedures and guidelines are followed.

CAUTIONCAUTIONCAUTIONCAUTION:::: The disks on elastomer-seated butterfly valves must be at least partially open when tightening flange bolts. Failure to do so causes premature failure, and voids all warranties on the valve.

WARNINGWARNINGWARNINGWARNING:::: WHEN MOVING OR PLACING THE UNIT(S) IN A FINAL LOCATION, ALWAYS USE APPROPRIATE SAFETY PROCEDURES, PROPER

LIFTING EQUIPMENT, AND QUALIFIED INSTALLATION

TECHNICIANS. DO NOT ATTEMPT TO MOVE THE MODULE

RACKS WITH THE MF MODULES INSTALLED.

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3.2 CONNECTING UTILITIES

CAUTIONCAUTIONCAUTIONCAUTION:::: To ensure the safe and efficient operation of the equipment and adherence to existing laws and regulations, only qualified personnel should make utility connections. Pall Corporation requires that certified electricians complete all wiring connections and that qualified personnel, working with Pall

Technology Services representatives if possible, complete all plumbing work. Pall Corporation is not responsible for and equipment warranties may be voided from any damage or personal injury caused by unqualified personnel performing utility connections and/or installations!

3.3 MICROZA® MODULE INSTALLATION

CAUTIONCAUTIONCAUTIONCAUTION:::: Refer to the separate Pall Micro-filtration System Installation manual for detailed instructions on installing the micro-filtration modules. DO NOT install the micro-filtration modules on the rack until the entire micro-filtration system has had an initial flushing and been thoroughly checked.

Refer to the separate Pall Micro-filtration System Installation manual for details. Contact Pall Technology Services with any questions.

For module repair procedures refer to Section 6.2 “Repairing the Microza® Hollow

Fiber Modules” on page 101.

3.4 PALL SYSTEM COMPONENTS

Pall Corporation is supplying a system comprised of three filter racks containing 64 micro-filtration modules on each rack (192 total) with space for a total of 234 is necessary for future growth, 2 feed pumps, 2 feed strainers, 2 reverse filtration pumps, CIP equipment, compressed air equipment, valves, instruments, and control equipment required for system operation.

For MF system components not listed in this section, refer to the system drawings and the specific manufactures’ component documentation.

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3.4.1 THE MICROZA MICRO-FILTRATION MODULES

The Microza® Micro-filtration modules are rated at 0.1 micron. A “micron” is 1 micrometer or 1 x 10-6 meter (3.2808399 x 10-6 feet), abbreviated as 1 µm. Each module contains over 6200 hollow fibers made of polyvinylidene fluoride (PVDF).

The fibers have an outside diameter of 1.4 mm (0.06 in), and an inside diameter of

0.7 mm (0.03 in), that equals a combined total exterior surface area of approximately

50 m2 (538.2 ft2). Each fiber contains thousands of pores that have a nominal diameter of 0.1µ. The pores prevent virtually all particulate matter from passing through the membrane surface. The membranes provide a barrier against all bacteria and have been shown to be effective against viruses as well. The proprietary method used to fabricate the fibers provides a tough skin on both the inner and outer surfaces. This double skin is unique to the Microza® membrane, and also allows equal flow in either direction, as required.

The fiber ends are potted in epoxy and arranged so that the feed flow enters the bottom of the module (sealed fiber ends) and flows on the outside of the fibers in the body of the module. Filtration occurs through an “outside-to-inside” flow path and the filtrate leaves from the top of the module (open fiber ends, sealed from interaction with the water in the module body).

The Microza® micro-filtration modules are highly resistant to most oxidants and a variety of other chemicals, including most acids and bases. This characteristic allows the module to be used in chlorinated systems, and allows for aggressive chemical cleaning when necessary.

The outer shell is nominally 165 mm (6 in) diameter and 2364 mm (93 in) long including the end caps. Empty weight (moistened interior) is approximately 32 kg

(70 lbs), of which 14 kg (30 lbs) is the membrane preservative solution.

Excess Recirculation Outlet (Retentate)

PVC or ABS Housing

Filtrate Outlet

Bundle of Hollow Fiber MembranesBonded Area

Feed Inlet

FIGURE 3.1 – THE MICROZA® MICRO-FILTRATION MODULE

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COMPONENT SUMMARY:

Component Identification Code: Not applicable

Process Fluids Handled: All (process water, AS water, AS air, acid and caustic CIP solutions, CIP rinse water).

Component Function / Purpose: Filtration treatment of raw surface water to create reverse osmosis feed water for potable water storage.

Primary Materials of Construction: Polyvinylidene fluoride (PVDF) hollow fibers, PVC or ABS shell.

3.4.2 THE FILTER RACKS

All modules in each filter rack operate in parallel. Refer to the Pall Corporation drawings for a detailed diagram of the filter racks configured for this project.

Each individual micro-filtration module produces filtered water while the system is operating in Forward-Flow mode. There are also various cleaning processes, described later in this manual, which the modules go through to maintain peak operability and performance. Pall Corporation has designed the filter racks to facilitate (unassembled) transportation, on-site assembly, reliable operation, and long-term durability.

A filter rack system consists of two main parts:

• The “valve rack” arrives on-site as a pre-assembled unit and contains all of the control valves, instruments, and electronic controls for that filter rack.

• The “module racks” (one or more modular sections) consist of long manifolds which structurally support the modules, supply feed water, collect treated filtrate water, and also carry chemical cleaning solutions to and from the modules. The module racks for one filter rack connect to each other in series and, in addition, connect to a valve rack by a set of pipe spools.

COMPONENT SUMMARY:

Component Identification Code: Nine racks identified as Rack 1, 2, 3, 4, 5,6,7,8, and 9.

Process Fluids Handled: All (Process water, AS water, AS air, acid and caustic CIP solutions, and CIP rinse water).

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Component Function / Purpose: Provide structural support to MF modules, piping, and other appurtenances necessary to operate the modules in a variety of modes.

Primary Materials of Construction: Carbon steel with epoxy coating supports with

HDPE piping.

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4444 MMMMICROICROICROICRO----FILTRATIONFILTRATIONFILTRATIONFILTRATION SSSSYSTEM YSTEM YSTEM YSTEM OOOOPERATIONPERATIONPERATIONPERATION

4.1 INTRODUCTION

This Pall Corporation Micro-filtration System is designed to filter up to 4 million gallons of water per day (MGD) on average. Additional modules can be purchased and installed for increased capacity. The process begins as raw water is pumped through the membrane filtration system by the feed pumps. Variable frequency drives

(VFD’s) on the pumps control the feed manifold pressure or flow by varying pump speed. The feed water passes through automatic backwashing strainers, then through the micro-filtration system filter racks. Each rack has a number of automatic sequences that are described below. During operation, regeneration of the membranes is accomplished by five methods: Air Scrub (AS), Reverse Filtration

(RF), Feed Flush (FL), Enhanced Flux Maintenance (EFM), and Clean-in-Place

(CIP) chemical cleaning. Filtrate from the module racks flows to the finished water clearwell (T-4007).

CAUTIONCAUTIONCAUTIONCAUTION:::: All Pall Corporation Micro-filtration System operators must be trained by Pall Corporation or someone authorized by Pall

Corporation. Any damage to the Pall Corporation MF

System, its components, or the customer’s process and equipment through operation by an untrained operator is not the responsibility of Pall Corporation and voids all warranties.

Additionally, any damage to any part of the Pall Corporation

Micro-filtration System caused by modifying or loading computer software onto the Pall Corporation Micro-filtration

System computers unauthorized by Pall Corporation voids all warranties.

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4.2 PERIODIC MANUAL REVIEWS AND UPDATES

Over the service life of this micro-filtration system, experience gained through long-term operation may lead to the discovery of improved methods of operation. In addition, system equipment may undergo modification, replacement, and removal.

Pall Corporation recommends that the customer review this Operation, and

Maintenance (O&M) periodically to determine if an update is required. This manual should reflect the current system equipment and operating practices. As updates take place, the customer should record a summary of the changes on the revision sheets provided at the beginning of this manual. Note that there are two revision sheets: one sheet for changes issued by Pall Corporation and a second sheet for changes generated by the micro-filtration system operators.

CAUTION:CAUTION:CAUTION:CAUTION: Before making any changes to the Pall Micro-filtration

System, contact Pall Technology Services. Any changes instituted by the operator not authorized by Pall Corporation are not the responsibility of Pall Corporation and may void all warranties.

4.3 THE MICRO-FILTRATION (MF) SYSTEM PROCESSES

Automatic or Auto mode operation is the normal system operating mode. In Auto mode, the system PLC controls set-points and functions for each rack. Auto mode includes the following processes:

• Fill

• Auto Filter or Forward-Flow (FF) (production filtrate)

• Air Scrub (AS)

• Reverse Filtration (RF)

• Feed Flush (FL)

• Drain

• Enhanced Flux Maintenance (EFM)

• Integrity Test (IT)

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• Clean-In-Place (CIP)

CIP process is a special sequence used to chemically clean the modules. The use of this sequence is infrequent; typically the design CIP interval is approximately 30 days.

Descriptions of these processes are included in Section 4.5 “Automatic Mode

Operation” beginning on page 41.

4.4 PROGRAMMABLE LOGIC CONTROLLER (PLC) MODES

4.4.1 DEFINITION

Throughout the process, mode control is used to enable/disable pieces or groups of equipment in order to provide operational flexibility. Mode control occurs at the lowest defined unit level.

NOTE: Mode control is strictly a software function and cannot bypass or replace hardwired controls and interlocks.

4.4.2 GROUPING

If the smallest defined unit is the whole unit, the whole unit has one common mode control. If the smallest defined unit is a sub-unit, each sub-unit has its own mode control.

4.4.3 MODES

4.4.3.1 AUTO

In Auto Mode, all equipment in the unit/sub-unit is controlled according to the state of the logic sequencing software. In most cases, changing the mode to Auto enables the equipment to start through a process sequence that usually requires the operator to select a process start push-button. In some cases, however, the equipment may start immediately on entering Auto Mode if the logic so requires.

4.4.3.2 MANUAL

In Manual mode, the operator may cycle valves as desired from the SCADA PC

HMI.

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NOTE: All actuated rack valves (including block and bleed valves) are furnished with proximity-type limit switches to indicate confirm open/closed position. The off-rack valves do not have limit switches. The filter racks or racks each have distributed I/O modules, which communicates with, and is controlled by, the master PLC located in the main enclosure.

CAUTION:CAUTION:CAUTION:CAUTION: Manual mode is not recommended as it overrides all automatic equipment functions and can adversely affect the micro-filtration equipment, process, and results. The system operator is solely responsible for the outcome of system functioning while in Manual mode.

Any damage to the MF system, its components, or the customer’s process and equipment through manual operation is not the responsibility of Pall Corporation and may void all warranties. Only operators trained by Pall

Corporation or someone authorized by Pall Corporation may operate the MF system in Manual mode.

Selecting this mode results in all valves being closed and disabled. No further manipulation of the rack equipment can be made from the SCADA HMI – automated processes are not available and individual valves cannot be operated manually.

NOTE: Disable mode is not a replacement for equipment lock-out procedures.

Always de-energize and lock out equipment to be serviced.

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4.4.4 MODE SELECTION

Mode

Select

Operator Selection

Auto Manual Disable

Enable Process

Selection and Cycle

Start

Allow Individual

Device Control Via

HMI

Set All Devices To

OFF

4.5 AUTOMATIC MODE OPERATION

During normal operation, all racks are on line, i.e. in Auto mode and processing water in Forward-Flow (FF). However, the operator may take one or more of the filter racks off line in order to perform a Clean-In-Place (CIP) or other maintenance function. All enabled racks in Auto mode normally operate with identical parameters, including set-points, timer and volume presets, etc. However, a test mode is available to allow racks to operate with certain parameters independent, for performance testing purposes.

To place a rack in Auto mode, a rack graphic is selected on one of the Rack

Graphics Screens, which, in turn, displays the Rack Control Pop-up.