Addendum 003 - O and M Manual - System Functional Description (SFD) 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: NYCS000015571 Rev: 00

Description of Item: SFD

Specification Section: N/A

Deviations: None

INDEX:

Page 1: Cover Page Information

Pages 2-50: NYCS000015571,Rev00 -SFD

Date: 2/10/2020

Hanford 01_000287 SFD Rev00.docx Rev. 00

PALL WATER

MICRO-FILTRATION

SYSTEM

FUNCTIONAL DESCRIPTION

Pall SAP Number: 01.000287

Pall Document Number: NYCS000015571

Document Revision Level: 00

Document Issue Date: 02 05 2020

IMPORTANT – READ THIS FIRST

Before attempting to operate or install this equipment, Pall Water requires all operators to read and understand this Operation and Maintenance manual. Attempting to operate any Pall Water 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:

Telephone: 1-866-475-0115*

Fax: 1-607-758-4526

Email: pall_technology_csc@pall.com

The above telephone number (1-866-475-0115) is toll free and is answered 24 hours a day. Service charges apply unless the customer has an existing Pall service contract or the system is under warranty.

Throughout this manual:

- The word “customer” refers to HANFORD WA-CENTRAL PLATEAU.

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

REVISIONS 5

1 INTRODUCTION 6

1.1 OVERVIEW 6

1.2 THE MICRO-FILTRATION (MF) SYSTEM PROCESSES 7

1.3 PROGRAMMABLE LOGIC CONTROLLER (PLC) MODES 8

1.3.1 DEFINITION 8

1.3.2 GROUPING 8

1.3.3 MODES 8

1.3.4 MODE SELECTION 9

1.4 ALARM HANDLING 10

1.4.1 CONTROLLED STOP OF SYSTEM IN RESPONSE TO AN ALARM 10

1.4.2 RESTARTING FROM A CONTROLLED STOP OF SYSTEM FROM ALARM 11

1.5 QUICK STOP 11

1.5.1 RESTARTING FROM QUICK STOP 11

1.6 GLOBAL SYSTEM STOP 11

1.6.1 RESTARTING FROM SYSTEM STOP 12

1.7 POWER ON 12

2 MICRO-FILTRATION SYSTEM OPERATION 12

2.1 FILTER RACK UNIT 13

2.1.1 FILTER RACK AUTOMATIC MODE OPERATION 13

2.1.2 ENHANCED FLUX MAINTENANCE (EFM) AND CLEAN-IN-PLACE (CIP) 21

2.2 CIP SYSTEM NON-RECIPE OPERATION 29

2.2.1 ACID MAKE CYCLE 29

2.2.2 CAUSTIC MAKE CYCLE 30

2.2.3 ACID TANK FLUSH 31

2.2.4 CAUSTIC TANK FLUSH 32

2.2.5 SOLUTION VALIDITY FUNCTIONALITY AND FORCE VALIDITY 32

2.2.6 SEMI-AUTOMATIC TRANSFERS 33

2.3 NEUTRALIZATION SYSTEM 33

2.3.1 AUTOMATIC NEUTRALIZATION 33

2.4 SUPPORTING EQUIPMENT IN AUTOMATIC MODE 36

2.4.1 PLANT FLOW CONTROL OVERVIEW 36

2.4.2 RF FLOW CONTROL 37

2.4.3 AUTOMATIC FEED STRAINERS 37

2.4.4 AIR COMPRESSORS AND RELATED EQUIPMENT 39

2.5 MANUAL MODE OPERATION 39

3 GLOSSARY 41

APPENDIX A: FILTER RACK VALVE TRUTH TABLES 44

APPENDIX B: OPERATION PROTOCOL 45

REVISIONS

TABLE A – PALL WATER REVISION HISTORY

Revision Date Originator Description

00 02-05-2020 C. Montreuil Initial Release.

1 INTRODUCTION

1.1 OVERVIEW

(For additional information on valves, devices, and equipment identified by tag number in the text of this document, please refer to Pall P&ID Drawing NYCS000008172.)

This Pall Water Micro-Filtration (MF) System is designed to produce up to 3.5 million gallons of water daily. Additional modules can be purchased and installed for increased capacity.

Pall Water is supplying a system comprised of four (4) filter racks, zero (0) feed pumps, two (2) reverse filtration pumps, CIP equipment, compressed air equipment, valves, instruments, and control equipment required for system operation.

Raw water is delivered to the MF system by the customer feed system. The feed water passes through two (2) automatic backwashing strainers, then through the micro-filtration system filter racks. Each rack has several automatic sequences that are described below. During operation, regeneration of the membranes is accomplished by four methods: Air Scrubbing (AS), Feed Flush (FL) or Reverse Filtration (RF), Enhanced Flux Maintenance (EFM), and Clean-in-Place (CIP) chemical cleaning.

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

Throughout this document, Bold Italic Text indicates operator adjustable set-points. Modes and processes appear as Bold Text. Graphic buttons on HMI screens are Framed, while the screens appear in Bold, Underlined Text.

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.

NOTE

CAUTION

All Pall Water Micro-Filtration System operators must be properly trained by Pall Water or someone authorized by Pall Water. Any damage to any part of the Pall Water Micro-Filtration System caused by an untrained operator voids all warranties.

Additionally, any damage to any part of the Pall Water Micro-Filtration System caused by modifying or loading computer software onto the Pall Water Micro-Filtration System computers unauthorized by Pall Water voids all warranties.

1.2 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 of filtrate)

Air Scrub (AS)

Reverse Filtration (RF)

Feed Flush (FL)

Drain

Enhanced Flux Maintenance (EFM)

Integrity Test (IT)

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 between 14 and 30 days.

Descriptions of these processes are included in the functional description portion of this manual.

1.3 PROGRAMMABLE LOGIC CONTROLLER (PLC) MODES

1.3.1 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.

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

1.3.2 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.

1.3.3 MODES

1.3.3.1 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.

1.3.3.2 MANUAL

In Manual mode, the operator may cycle valves or turn on or off the equipment as desired from the control room HMI.

Note that all actuated rack valves (excluding block and bleed valves) are furnished with proximity-type limit switches to indicate confirm closed and/or open position. The off-rack valves, with a few exceptions, do not have limit switches. These would include Feed, CIP and Filtrate area valves. The filter racks each have I/O modules, which communicate with, and are controlled by, the system PLC.

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. Operators should NOT use Manual mode unless trained to operate the micro-filtration system in Manual mode by Pall Water or someone authorized by Pall Water.

1.3.3.3 DISABLE

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

1.3.4 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

1.4 ALARM HANDLING

In the program there are a number of alarms detailed. The logic related to the alarms where relevant is as follows:

Process Alarms: These alarms relate to a high or low deviation from a set point active in a particular step or sequence. These warning alarms allow the operator to adjust operating parameters to improve the control of the system and to avoid the possibility of the system shutting down in the future.

Instrument Warning: These are fixed values related to specific analogue instruments which raise a warning to advise the operator that in a certain operating condition the system is approaching a condition that is unacceptable either from a process or safety reason.

Critical Alarm: These are again fixed values similar to the Warning Alarms but in this case action is taken to shut down the operation to prevent incorrect operation continuing. The part of the system shut down cannot be restarted until the reason for the alarm is cleared. Instrument and equipment failures also generate critical alarms.

Watchdog Alarms: These alarms are associated with time limits assigned to operational sequences. If a particular process exceeds its watchdog timer setpoint, the sequence for that process will shut down.

Alarm Timers: A de-bounce time is associated with each of the alarms to avoid activation during transient conditions. The measured value must remain above the set point continuously for the duration of the alarm timer before the alarm or warning is activated.

Recording: All alarms are recorded by the control system as below:

Time/date of the alarm

Time/date of acknowledgement

Time/date of it being cleared

Reason for the alarm

1.4.1 CONTROLLED STOP OF SYSTEM IN RESPONSE TO AN ALARM

The Operator screen initially displays an alarm notification at the bottom of the screen, and depending on the alarm, additional graphical alarm information. If the alarm condition results in a controlled stop request then the subsystem (Rack, CIP, etc) or MF system stops.

1.4.2 RESTARTING FROM A CONTROLLED STOP OF SYSTEM FROM ALARM

Once the alarm condition has been cleared the system behaves as described in “Power On” section. The system requires manual intervention to restart after an alarm stop.

1.5 QUICK STOP

The system is equipped with a system QStop (Quick Stop) function, which is designed to allow an operator to minimize any potential safety hazards due to system malfunction. QStop buttons are located on the main PLC Panel and all other electrical panels throughout the MF system. The main PLC Panel Qstop automatically brings the entire MF system to a stopped and safe condition. The operator screen remains active throughout the Quick Stop state, and displays the QSTOP Alarm. Additional QStop buttons only stop the functional area they are associated with. For instance, pressing a QStop button on a particular rack will only stop that rack. The QStop should not be used to stop the operation of the installation unless an emergency is observed.

1.5.1 RESTARTING FROM QUICK STOP

To restart, the User retracts the QStop button, then resets all the alarms.

Pumps that were stopped remain in their stop state.

All valves remain in their fail-safe mode.

The system/subsystem can then be started via the HMI as for “Power On”.

1.6 GLOBAL SYSTEM STOP

Under certain conditions, the PLC program generates a Global System Stop to shut down active processes of the MF system. Conditions that cause this shutdown are loss of system air, loss of incoming power, or activation of the main panel Quick Stop. Additionally, other interlock conditions received from the plant may be included in the Global System Stop programing, as necessary.

The Operator screen remains active throughout and subsequent to the System Stop:

All pumps stop

All actuated valves in fail safe position

The instruments remain powered, sending their signals to the PLC

The PLC remains powered

1.6.1 RESTARTING FROM SYSTEM STOP

After the condition causing the System Stop has been cleared, the Operator needs to restart the system from the HMI.

1.7 POWER ON

When the system is Powered-On the system does not start.

All Pumps are to remain in their stop state.

All Valves are to remain in their fail-safe position.

The system can be started via the HMI by placing each of the unit/sub-units into auto mode and then by pressing the start buttons on each of the racks that the operator wishes to have in operation.

It should be possible to operate the racks in Auto-Filter assuming the valve rack, the air system, and the RF system are in auto. The rack(s) can then operate until cleaning is required. For cleaning to be performed, the CIP system needs to be in auto and available (no failure active).

2 MICRO-FILTRATION SYSTEM OPERATION

Throughout the System Operation description, references are made to typical setpoint values and durations. For specific plant design setpoints, see the attached Operation Protocol in Appendix B.

2.1 FILTER RACK UNIT

2.1.1 FILTER RACK AUTOMATIC MODE OPERATION

During normal operation, up to three racks are on-line, i.e. in Auto Mode and processing water in Forward-Flow (FF). An additional rack, in Auto, is in standby and available to return to service when one of the on-line racks goes into a Flux Maintenance. One on-line rack may go off-line for EFM or IT, or the operator may take a rack off-line to perform a CIP or a maintenance function.

When a rack is removed from service for maintenance, the system is running with one or two racks on-line, with one rack in standby.

All enabled racks in Auto mode operate with identical parameters, including process and alarm set-points, timer and volume presets, etc. However, a test mode is available to allow a rack to operate with certain parameters independently, for performance testing purposes.

To place a rack in Auto mode, the rack graphic is selected and the AUTO push-button is selected. To start the filtration process, the AUTO FILTER push-button is selected. Note that “Auto Filter” is only enabled if the system is capable of processing water, and the plant itself is enabled to run. The Auto Filter process first sequences through a Fill cycle, then enters Forward-Flow

(FF).

During FF, a volume totalizer keeps track of the filtrate flow through the rack and, after reaching a preset value, requests permission from the system PLC to perform a Flux Maintenance (FM). Upon receiving permission, the rack goes into the FM process, while at the same time the rack in Standby goes into service. After completing the FM processes, the rack in FM goes into Standby.

Occasionally, based on time of day or operator intervention, the rack also performs an Integrity Test, which assures that the membranes are still performing reliably. Details of each step follow.

2.1.1.1 FILL SEQUENCE

The Fill sub-cycle purges the piping and modules of air before the rack enters Forward-Flow. To effectively purge air from all of the enabled module racks, the racks are placed on-line, one at a time (manually selected by the operator), according to the sequence described below. The rack will perform a Fill sequence automatically before entering production under the following conditions:

The last cycle performed was a Drain or IT

The rack was taken out of Auto mode

Or

A CIP drain or chemical recovery step was performed without a follow up rinse.

An adjustable Fill Cycle Watchdog timer checks to make sure the Fill cycle sequence takes place in a reasonable amount of time (approximately two minutes or less). If the timer times out, the rack shuts down, and the operator is alerted to the problem by an alarm message on the HMI.

FILL CYCLE

1. At the start of the Fill cycle, all on-rack automated valves are closed.

The normal position for off-rack automated “block and bleed” valves is to allow Forward-Flow and provide air gaps in the CIP piping.

2. The CIP Return Bleed valve (V-1014) is open. This is changed only when the CIP piping is used during a CIP or EFM.

3. At the filter rack, Upper Drain valve (V-1010) is opened, venting the feed side of the modules to drain; Feed Flow Control valve (FCV- 1001) is opened to a present FCV Fill Position to introduce feed water to the module rack.

4. The flow through the Feed Flow Transmitter (FIT-1005) is totalized.

5. After the Feed Fill Volume is processed, the Filtrate valve (PCV- 1018) opens and after it proves open the Upper Drain valve (V-1010) closes. Filtrate Vent valve (V-1017) can be used instead of the Filtrate valve if plant configuration dictates.

6. After an additional Filtrate Fill Volume is processed, a short stabilization hold is performed for Min Time for Flow Stabilization.

7. At this time the rack transitions to Forward-Flow. The Fill Volume set-points allow site-specific customization. Once an effective Fill Volume is established during start-up (rack filled and minimized vent drainage), these parameters do not normally require adjustment.

2.1.1.2 FORWARD-FLOW

After each rack completes the Fill cycle, it is then operating in Forward- Flow. This is the filtration process, and is the primary operating cycle for the racks.

1. The Filtrate Outlet Valve (PCV-1018) opens to begin Forward-Flow (it may have been opened in a previous cycle, such as the Fill cycle).

2. At the start of Forward-Flow, the Feed Flow Control Valve (FCV-1001) PID loop is put in Manual and the valve is automatically opened to the same position it was in when last operating in Forward-Flow.

3. When flow through the rack has time to stabilize (15 seconds fixed), at a predetermined flow-rate for a fixed amount of time, the feed flow PID control is put in Auto mode. Feed Flow Control Valve (FCV-1001) controls the filtrate flow through each rack. During Forward-Flow operation, the Filtrate Valve (PCV-1018) is open, and Feed Flow Control Valve (FCV-1001) modulates as required by the PID loop to maintain the Rack Flow set-point.

2.1.1.3 FLUX MAINTENANCE

Each filter rack periodically executes Flux Maintenance (FM) procedures.

A Flux Maintenance cycle is an AS (Air Scrub with Filtrate) followed by a Reverse Filtration (RF). The Flux Maintenance frequency is based on the totalized filtrate flow volume through each rack compared to the Flux Maintenance Interval Volume set-point. The program for each individual rack will compute filtrate flow volume between cycles by measuring the filtrate flow through the rack, determined from the Feed Flow Transmitter (FIT-1005), and converting to volume at one-second intervals. Ideally, the volume of water processed between each regeneration cycle should remain the same. For example, if the running average flow-rate decreases, the interval between regeneration cycles will increase. At design conditions, the interval will range from 17 to 21 minutes. Operators will have the ability to set the Flux Maintenance Interval Time (in minutes), which will override the treated volume set-point described above if the time-out occurs before the volume set-point is reached. The minimum interval time limit will be set at 45 minutes.

The Flux Maintenance cycle sequencing follows:

AIR SCRUB (AS)

The Air Scrub process is used to physically remove particulate buildup on the feed side of the module fibers. The AS process is followed by a Reverse Filtration cycle.

When a particular rack requests an Air Scrub, the sequence progresses as follows:

1. The system checks the air pressure in the receiver to ensure that the AS Minimum Air Pressure is at or above the proper air pressure. This is accomplished by reading the PIT-6011 (PIT-6041) before the AS process can begin.

2. The PLC stores the position of Feed Flow Control Valve (FCV-1001) for use when going back to Forward-Flow.

3. The Feed Flow Control Valve (FCV-1001) and the Filtrate Valve (PCV-1018) close, isolating the rack from the system.

4. Upper Drain Valve (V-1010) opens.

5. Water will now be introduced, in addition to airflow, to enhance the cleaning of the module fibers, and to flush away dislodged particles.

The rate during the AS cycle is determined by the AS Water Flow Rate set-point.

6. The RF Supply valve V-1013 opens, FCV-1001 remains closed, and the RF pump P-4302A or P4302B starts. The system PLC uses a PID loop to adjust the pump speeds for pumps P-4302A & B to maintain the AS Water Flow Rate through FIT-4305.

7. Once a minimum flow is reached, the Air Supply Valve (V-1006) will open. A PID loop will modulate either FCV-6034A or FCV-6034B to control air flow-rate at AS Air Flow-Rate.

8. This step continues for AS Cycle Time (a typical duration of 60 seconds).

9. When the AS Cycle Timer finishes, the Air Supply valve (V-1006) closes, and the RF pumps stop and air flow control valves close.

When the RF pump speed equals 0, the RF Supply valve closes (V- 1013).

REVERSE FILTRATION (RF) CYCLE

A Reverse Filtration cycle follows each AS cycle. During the RF cycle, filtrate is forced through the membranes in the reverse direction. The objective during this cycle is to flow in the reverse direction. A typical duration is 20 to 30 seconds. RF Supply Flow Transmitter (FIT-4305) monitors the RF (reverse direction) flow-rate.

When a RF cycle for a particular filter rack is initiated, the filter rack is isolated from the feed manifold and the RF cycle proceeds according to the following sequence:

1. The flow-rate during the RF cycle is determined by the RF Flow-Rate set-point, as input by the operator. The PLC maintains the RF flow-rate by controlling the speed of RF Pumps P-4302 (A-B). A PID loop controls the pump speed to maintain the RF flow. The loop starts in Manual at the previous speed of the last RF sequence. If this is the first sequence the speed initializes to 10%. The loop remains in Manual for a fixed amount of time (approximately 5 seconds) to allow the flow to stabilize before being placed into Auto. The PLC must maintain the set-points individually for each rack, since the pressure requirements vary from rack to rack.

2. At the start of the RF cycle the Feed Flow Control Valve (FCV-1001) and the Filtrate Outlet Valve (PCV-1018) close.

3. After these valves prove closed, the Lower Drain Valve (V-1002), the Upper Drain Valve (V-1010), and the RF Supply Valve (V-1013) on the rack open, and the RF Pumps P-4302 (A-B) starts ramping up to the previous speed of the last RF sequence. The PLC alternates which pump starts for each RF cycle based on runtime hours (lowest runtime pump is used). The VFD controlling the pump is set to ramp up to speed in about 6 seconds (ramp speed is adjustable). After about 5 or 6 seconds the RF PID loop will be put in Auto to control the pump speed for the duration of the RF cycle.

4. Flow is totalized through RF Flow Transmitter (FIT-4305). Once the RF Cycle Volume is reached, the RF Pump (P-4302 A-B) ramps to a stop and the Lower Drain Valve (V-1002), the Upper Drain Valve (V- 1010), and the RF Supply Valve (V-1013) close.

5. The rack flow totalizer resets to zero volume.

6. When the rack valves prove closed, the rack returns to standby status.

2.1.1.4 INTEGRITY TEST (IT)

On a regular basis, the integrity of the filters must be tested to ensure that there are no leaks in the membrane fibers. This Integrity Test can be performed on a regular basis automatically, or at the operator’s discretion.

If performed automatically the test is performed on either Hours Between Integrity Tests or Days Between Integrity Tests basis. “Hours Between” is used if “Days Between” is zero; otherwise “Days Between” takes precedence. If “Days Between” is used, the rack will be marked as needing an IT after the number of days has elapsed, and the Integrity Test Auto Start Hours and Integrity Test Auto Start Minute has passed. If “Hours Between” is the active set-point, the rack will totalize the number of hours since the last IT, even if not running, and once the time elapsed has exceeded the set-point, the rack will be marked as needing an IT.

Racks will perform ITs automatically after the next naturally occurring FM cycle, if they are marked as needing one and all other permissive conditions are satisfied. ITs will be inhibited if a CIP or EFM is in process.

However they are enabled, each enabled rack will perform an IT, one at a time, until all racks have completed the process. During IT pressurization and stabilization, Flux Maintenance procedures are not allowed on the other racks. While a filter rack is in the later pressure hold step of its IT, the other racks can perform Flux Maintenance procedures. Eventually, all filter racks in the system receive their scheduled IT.

If performed at operator request, the operator may select any active rack.

The test is performed immediately, unless the rack selected is in a FL or AS cycle, in which case the test is performed immediately after the completion of the cycle. Only one rack may be placed in Manual IT at a time.

The IT is a pressure decay test. The extremely small pores in the module fibers do not allow free passage of undissolved air through the membrane.

Therefore, if one side of the module is pressurized with compressed air, and then isolated, the pressurized side should maintain nearly constant pressure if the membrane has no flaws. However, if one or more of the modules being tested has broken fibers, the air is allowed to pass through to the other side of the membrane, and the pressure on the high-pressure side decreases.

1. To start the test manually, the operator selects the rack graphic and selects Integrity Test from the rack control pop-up. The first step of the sequence is the closing of the Feed Flow Control and Filtrate Outlet

Valves (FCV-1001, PCV-1018) and V-1052, and then opening of the Upper Drain Valve (V-1010).

2. The IT Air Valve (V-1096) opens, admitting compressed air to the filtrate side of the modules.

3. As the air enters the modules, it displaces the water from the upper filtrate manifolds, as well as from the inside of the fibers through the module to the feed side, and then out the Upper Drain. When all the water is displaced, the pressure reading on Filtrate Pressure Transmitter (PIT-1021) increases above the Minimum IT Pressure (25 PSI), and then stabilizes.

4. The system waits for pressure at the Filtrate Pressure Transmitter (PIT- 1021) to stabilize, as determined as less than 0.04 PSI change within 60 seconds, although the stabilization set-points are adjustable.

5. IT Air Valve (V-1096) and Upper Drain (V-1010) close, and the CIP Return Valve (FCV-1015) and CIP Bleed Valve (V-1014) open to disconnect from the pressurized drain, and the rack goes through pressure stabilization. The system waits for pressure at Filtrate Pressure Transmitter (PIT-1021) to stabilize, determined as less than

0.04 PSI change within 60 seconds, though again the stabilization parameters are adjustable.

6. At this time, a timer starts and runs for the IT Pressure Decay Test Time. (typically 5 minutes). The pressure at Filtrate Pressure Transmitter (PIT-1021) is recorded. For the remaining test time, the current pressure is compared to this benchmark. If, during this time, the pressure at Filtrate Pressure Transmitter (PIT-1021) does not decrease by more than the IT Maximum Pressure Decay (about 0.20 -0.30 PSI), the rack passes. The actual decay value is recorded by the HMI.

7. The CIP Return Valve (FCV-1015) closes, and Filtrate Vent Valve (V- 1017) opens, venting the rack pressure. To prevent rapid (and noisy) release of air, the Filtrate Vent Valve (V-1017) cycles open and closed at no more than 1-second intervals, until the rack pressure is reduced below the IT Vent Maximum Pressure.

8. When Filtrate Pressure Transmitter (PIT-1021) reads less than the IT Vent Maximum Pressure, the rack performs a Fill cycle, and then goes back to Forward-Flow.

9. If, however, the pressure decreases by more than the target before the timer times out, and the operator has selected Shutdown on IT

Failure, an alarm message is displayed to this effect, and the rack is taken off line (after the pressure relief and Fill cycles) for further operator action. Typically, a second Integrity Test should be performed manually to confirm the results. If Shutdown on IT Failure is not selected, the system issues a Warning to the operator, and the rack goes back on-line as normal.

2.1.1.5 ARBITRATION

The PLC contains a “ticketing” system to coordinate the execution of the Flux Maintenance (AS & RF) and EFM and IT cycles.

The PLC rack program totals the flow through the rack between FM cycles.

It determines when an FM is due by comparing the total to the Flux Maintenance Interval Volume. When a rack is ready to perform an FM, an internal flag is set which triggers the FM Arbitration to assign the next available FM ticket. When a rack completes an FM, its ticket is released, and the arbitration routine decrements all remaining tickets, allowing the next rack to proceed. The rack requesting the cycle first will take precedence. It is possible that all racks might hold a ticket for Flux Maintenance, and the program must accommodate this circumstance.

The FM arbitration is “blocked” when another rack finishes up with an EFM or a CIP, and that rack is required to perform an immediate FM cycle. The rack presently in an FM sequence is allowed to finish, but the arbitration does not advance until the EFM/CIP rack has finished its required FM.

When the arbitration selects the next rack to perform an FM, the rack must wait for specific permissive to be met, depending on the sequence to be performed.

For an AS to be performed, any IT sequence running must be finished with its use of the air system.

2.1.1.6 INDIVIDUAL FILTER RACK SHUTDOWN

If, while the membrane system is in operation, a specific rack must be shut down for troubleshooting or maintenance, the operator has a variety of options available at the HMI:

Process Stop in Auto Mode – Keeping the rack in Auto Mode but selecting Stop simply closes the on-rack feed and filtrate, valves. No rack draining occurs. The operator keeps the option to perform other automated processes such as an AS, RF (Reverse Filtration), IT, etc.

assuming the permissive for those sequences are true. Pressing Stop will cause the rack to enter a Stop sequence, which will shut the rack down in a controlled manner, to prevent water hammer.

Disable – Selecting this Mode results in the closure of all valves, and no further manipulation of the rack equipment can be made from the HMI – other automated processes are not available and individual valves cannot be operated manually. The rack must be stopped (idle) for disable to be available.

Manual – Selecting this Mode results in the closure of all valves, but individual valves can be selected and operated. The automated processes are not available. The rack must be stopped (idle) for manual to be available.

CAUTION

A chlorine residual must be maintained in the water held in any disabled rack if it is shut down for one day or longer.

Failure to perform correct shutdown, lay-up, and re-start procedures voids the Pall Water MF System warranty.

2.1.2 ENHANCED FLUX MAINTENANCE (EFM) AND CLEAN-IN-PLACE (CIP)

The EFM and CIP processes both use the same equipment and are recipe driven. EFM is an automatically scheduled and unattended cleaning process, typically of shorter duration than a CIP, which is operator initiated and operator managed. The mode that the system is operating in (EFM or CIP) is contained within the loaded system recipe. If an EFM recipe is loaded, the system is set to operate in EFM mode, and vice versa. Additionally, the loaded recipe determines the chemical make-up parameters for acid and caustic solutions.

Both the EFM and CIP processes can use any recipe step described in the following sections. Multiple recipes can be defined for each type, and the recipe that is desired is loaded prior to starting EFM or CIP procedures. In the case of EFM, normal procedure is to load the desired EFM recipe and leave the system prepared for automatic EFM execution.

An EFM or CIP will not be able to start while an Integrity Test (IT) is in process.

2.1.2.1 ENHANCED FLUX MAINTENANCE (EFM)

In addition to membrane regeneration by periodic application of AS and RF cycles, another effective technique for maintaining low Trans-Membrane Pressure (TMP) and high flux is Enhanced Flux Maintenance (EFM). The EFM cycle is an automatic process, programmed to occur after an operator-defined volume of treated water has been processed. A typical EFM duration is 45 – 90 minutes per filter rack.

The EFM process is a recipe driven sequence defined by a set of operator-input parameters that are maintained in the recipe and downloaded to the PLC for use. The EFM sequence typically includes warm water and chlorine. However, since the EFM is recipe driven, different recipes can be created to perform caustic/chlorine only EFM, or acid only EFM, or even a 2-part EFM with caustic/chlorine followed by acid. All of the steps available for CIP operations can be used by an EFM recipe, keeping in mind that no operator prompts are issued in EFM mode. Some additional points regarding the EFM process:

The EFM process uses the same system equipment as the Clean-In- Place (CIP) process.

An EFM procedure on one rack requires an interruption of Forward- Flow of approximately 45 – 90 minutes. During that time, the remaining racks continue in Forward-Flow and perform other Flux Maintenance routines. Only one rack may perform an EFM at a time.

When working with any chemicals, always follow appropriate safety procedures.

When the system is in EFM mode, the EFM Interval Volume set-point determines when an EFM is triggered on a rack. When the volume through the rack, as totalized by FIT-1005, is greater than the EFM Interval Volume set-point, a flag will be set indicating the rack needs to schedule an EFM. After the next regularly scheduled FM, if this flag is set, the system will check that the CIP systems are ready to start an EFM. If the system is ready to perform an EFM, the rack will start an EFM following the next naturally occurring FM, and the EFM recipe will be initiated as described below.

EFM will not start unless the solution(s) used in the loaded recipe are valid, and not spent (too many washes), are within the defined temperature range, and there is enough volume in each to fill the rack.

All CIP areas must be in auto, along with the CIP circulation/drain pumps. EFM must also be enabled on the rack.

The steps listed below will be performed based on the sequences in the recipe.

When an EFM recipe is completed, the rack is put in the FM queue and will perform an AS/RF combination as soon as possible. At that time, it will return to FF (production filtering).

2.1.2.2 CLEAN-IN-PLACE (CIP)

The CIP cycle is a semi-automatic process initiated by an operator when desired. This operation may be performed on one rack, or sequentially on all the racks.

The CIP process is defined by operator-programmed sequences, or “recipes”, which are maintained in the HMI computer. Prior to initiating a CIP, the operator will select which recipe is to be used. All of the steps within the CIP process will be defined within the recipe; including event durations, flow-rates, etc. An operator will be able to create or modify recipes as required. Some miscellaneous points regarding the CIP process:

A CIP procedure on one rack requires approximately 3-4 hours in total.

Only one rack can execute a CIP or EFM at one time.

The steps listed below will be performed based on the sequences in the recipe.

When a CIP recipe is completed, the rack is put in the FM queue and will perform an AS/RF combination as soon as possible. At that time, it will return to an idle state.

2.1.2.3 EFM AND CIP RECIPE STEPS

The following steps are available to be used in both EFM and CIP type recipes. In EFM operation, no operator prompts are displayed except the deliberate operator confirmed prompt step. In all other places where prompts would appear, the prompt is skipped, and if it is a decision, the default choice is automatically made.

No pre-configured rack drain is done prior to recipe start. The rack must be drained of water, so the first step in any recipe should be a pumped drain to waste.

As soon as the recipe sequence begins, the rack block and bleed valves are switched to the CIP positions and confirmed, opening air gaps between lines filled with chemical and the headers. If not in EFM mode, the operator is notified via a prompt to confirm step process start. Following confirmation, the system processes the recipe steps in order. Any undefined step will end the recipe processing.

RECIPE STEP – PUMPED DRAIN TO WASTE

The rack CIP Supply (V-1003), CIP Return (FCV-1015 and V-1012) and CIP Return Block (V-1029) valves are opened. Also opened is CIP Supply Block (V1023), and CIP Vent valve (V-5216) for venting of the CIP Return piping. This arrangement allows drainage out the bottom of the rack and air relief on the top. After a delay, the Filtrate Vent valve (V- 1017) and CIP Return Bleed (V-1014) are also opened to provide additional air relief. The delay is to prevent the CIP return from draining out through the filtrate vent.

Off-rack valves V-5218, and V-5217 are opened to provide a drain-to-waste path to the Backwash Waste Tank.

The Circulation/Drain Pump P-5204A/B is run for the recipe-driven drain time, and may be stopped and re-started multiple times if this is required to drain the rack.

Once it is determined that the rack is drained, the pump is stopped, and all previously opened valves are closed. A completed pumped drain will reset the flag indicating that there is chemical in the rack.

RECIPE STEP – ACID WASH

The system reserves the Acid area for use, and checks that the solution temperature and volume are within set-point limits (acid set-points

MINIMUM TEMP FOR CIRCULATION, MAXIMUM TEMP FOR

CIRCULATION, and MINIMUM VOLUME FOR CIRCULATION). The CIP Supply (V-1003) and CIP Feed Return (FCV-1015), and depending on step chosen CIP Filtrate Return (V-1012) valves are opened on the rack and confirmed.

Acid Tank Outlet (V-5132), Acid Tank Return (V-5212), and Circulation Pump Feed valves (V-5282 A/B), and Circulation Pump Block valves (V- 5244 A/B) are opened to create a path to circulate acid solution.

Inappropriate off-rack valves are closed.

CIP Circulation Pump P-5204A/B is started and run for the recipe-driven wash duration (in minutes). If, during the wash, the temperature as measured by TT-5107 rises above the maximum temperature set-point, the pump is stopped and the process is paused until the temperature returns below the maximum.

At the end of the recipe wash time, the pump is stopped, the off-rack valves are closed, and the acid area reservation is released. The on-rack valves are left open, as that configuration is default for all recipe steps.

RECIPE STEP – CAUSTIC WASH

The system reserves the Caustic area for use, and checks that the solution temperature and volume are within set-point limits (caustic set-points

MINIMUM TEMP FOR CIRCULATION, MAXIMUM TEMP FOR

CIRCULATION, and MINIMUM VOLUME FOR CIRCULATION). The CIP Supply (V-1003) and CIP Return (FCV-1015), and depending on step chosen CIP Filtrate Return (V-1012) valves are opened on the rack and confirmed.

Caustic Tank Outlet (V-5025), Caustic Tank Return (V-5213), Circulation Pump Feed valves (V-5282 A/B), and Circulation Pump Block valves (V- 5244 A/B) are opened to create a path to circulate caustic solution.

Inappropriate off-rack valves are closed.

CIP Circulation Pump P-5204A/B is started and run for the recipe-driven wash duration (in minutes). If, during the wash, the temperature as measured by TT-5007 rises above the maximum temperature set-point, the pump is stopped and the process is paused until the temperature returns below the maximum.

At the end of the recipe wash time, the pump is stopped, the off-rack valves are closed, and the caustic area reservation is released. The on-rack valves are left open, as that configuration is default for all recipe steps.

RECIPE STEP – POTABLE RACK RINSE

The CIP Supply (V-1003) and CIP Return (FCV-1015), and depending on step chosen CIP Filtrate Return (V-1012) valves are opened on the rack and confirmed. Circulation Pump Feed valves (V-5282 A/B), Circulation Pump Block valves (V-5244 A/B), Potable Rinse (V-5227), and Return to Waste valve (V-5242) are opened to allow potable rinse water to flow through the non-operational circulation pump, through the rack, and into the Backwash Waste Tank.

The flow through the rack flow meter FIT-1005 is totalized until the recipe-driven rinse volume is counted.

A completed rinse will reset the flag indicating that there are chemicals in the rack. The off-rack valves are then shut.

RECIPE STEP – ACID RECOVERY

This step recovers the fluid in the rack to the Acid Tank.

The system reserves the Acid area for sequence use, ensuring other sequences cannot simultaneously use the equipment.

Rack valves remain in or are moved to CIP positions, with V-1003, FCV-

1015, and V-1012 open. (Note: It may also be necessary to open CIP Return valve V1029 and CIP Return Vent V5216 to allow recovery of chemical in the CIP Return line.)

Inappropriate off-rack valves are closed and Drain Pump to CIP Supply Header (V-5218), CIP Reclaim Block (V-5289), Acid Tank Outlet (V-5132), and Acid Tank Return (V-5212) valves are opened, allowing fluid pumped from the rack by the circ-drain pump to be returned to the tank via the outlet valve.

CIP Circ-Drain Pump P-5214A/B is run for the recipe-driven drain time.

The drain pump may stop and re-start multiple times to fully drain the rack.

When it is determined that the rack is properly drained, the drain pump is turned off, and the off-rack and rack valves are closed.

A completed recovery will reset the flag indicating that there are chemicals in the rack.

RECIPE STEP – CAUSTIC RECOVERY

This step recovers the fluid in the rack to the Caustic Tank.

The system reserves the Caustic area for sequence use, ensuring other sequences cannot simultaneously use the equipment.

Rack valves remain in or are moved to CIP positions, with V-1003, V-1015, and V-1012 open. (Note: It may also be necessary to open CIP Return valve V1029 and CIP Return Vent V5216 to allow recovery of chemical in the CIP Return line.)

Inappropriate off-rack valves are closed, and Drain Pump to CIP Supply Header (V-5218), CIP Reclaim Block (V-5289), Caustic Tank Outlet (V- 5025), and Caustic Tank Return (V-5213) valves are opened, allowing fluid pumped from the rack by the circ-drain pump to be returned to the tank via the outlet valve.

CIP Circ-Drain Pump P-5214A/B is run for the recipe-driven drain time.

The drain pump may stop and re-start multiple times to fully drain the rack.

When it is determined that the rack is properly drained, the drain pump is turned off, and the off-rack and rack valves are closed.

A completed recovery will re-start the flag indicating that there are chemicals in the rack.

RECIPE STEP – TIMED SOAK

The process holds for the recipe-driven pause time (in minutes).

RECIPE STEP – CONFIRMED PAUSE

In this step, the prompt system requests simply that the operator confirm continuation of the process.

RECIPE STEP – TRIGGER ACID REFRESH

This step starts the refresh process on the Acid Tank, and ensures that it starts, then moves on to the next step. It does not wait for the refresh to complete.

The Refresh process adds water up to the recipe-driven Acid Make Water Volume, and adds the recipe-driven Acid Refresh Acid Volume to the tank. If, however, the Acid solution has been used for more wash procedures than the recipe Acid Solution Washes Allowed set-point, the refresh will instead jump to a full make procedure, which includes a tank drain. (See 2.2.1 - Acid Make Cycle.) A full make procedure will reset the solution wash counter and thus allows the solution to return to validity.

RECIPE STEP – TRIGGER CAUSTIC REFRESH

This step starts the refresh process on the Caustic Tank, and ensures that it starts, then moves on to the next step. It does not wait for the refresh to complete.

The Refresh process adds water up to the recipe-driven Caus Make Water Volume, and adds the recipe-driven Caus Refresh Caus Volume and Caus Refresh NaOCI Volume to the tank. If, however, the Caustic Solution has been used for more wash procedures than the recipe Caus Solution Washes Allowed set-point, the refresh will instead jump to a full make procedure, which includes a drain. (See 2.2.2 – Caustic CIP Make Cycle.) A full make procedure will reset the solution wash counter and thus allows the solution to return to validity.

RECIPE STEP – SKIP STEP

This step does nothing but skip to the next step. It can be used to put gaps in the recipe without causing a shutdown (an undefined step will end the recipe).

2.2 CIP SYSTEM NON-RECIPE OPERATION

2.2.1 ACID MAKE CYCLE

The operator initiates the automatic preparation of CIP or EFM solutions at the HMI by selecting the tank graphic and selecting the ACID MAKE button.

After the first batch has been made by a manual initiation by the operator, the remake of the tank solutions can occur automatically if a recipe REFESH step is run. If a REFRESH is triggered and the solution is already spent (too many washes), a full MAKE process is triggered instead of the limited REFRESH.

If the level in the acid tank is above the Acid Make Seq Tank Empty Level SP when the acid make is selected, then the operator is prompted if a tank drain is required first.

The ACID MAKE sequence is as follows:

The Acid CIP Tank Water Supply Valve (V-5109) opens to fill the Acid CIP Tank with potable water. The PLC will close the valve when the tank level reaches the recipe Acid Make Water Volume, as measured by Acid CIP Tank Level Transmitter (LIT-5106). While the tank is filling, the Acid CIP Tank Heater (H-5104) will be disabled until the tank level is above the Heater Enable Level set-point. The heater will turn on when the tank temperature is below the Temperature set-point by more than the Temperature Deadband as measured by the Acid CIP Tank Temperature Transmitter (TT-5107). The heater will turn off when the tank temperature is above the Temperature set-point. If should be noted that the heater control is always active if the heater is in automatic mode – if the level is high enough, the heater will always be trying to maintain the requested temperature, if in auto.

While the Acid Tank is still filling but almost full of potable water, the PLC instructs the Acid Supply Pump P-5115 to deliver the recipe Acid Make

Acid Volume into the Acid tank, via the acid supply valve V5124. During the Make sequence, the solution is circulated with Acid Mixing Pump P5101.

The Make sequence completes when all the required water and acid have been added and mixed for the Acid Mix Time.

After the solution is made and at the appropriate temperature, and minimum volume; the chemical solution is ready for use by either the EFM or CIP recipes.

2.2.2 CAUSTIC MAKE CYCLE

This operator-started procedure makes up a batch of solution in the tank.

The chemical make-up parameters are obtained from the currently loaded recipe. The Make Cycle is not a recipe step and is first manually initiated by the operators’ selection of the Tank graphic and then selecting CAUSTIC MAKE from the tank selection pop-up.

After the first batch has been made by a manual initiation by the operator, the remake of the tank solutions can occur automatically if a recipe REFRESH step is run. If a REFRESH is triggered and the solution is already spent (too many washes), a full MAKE process is triggered instead of the limited REFRESH.

If the level in the caustic tank is above the Caus Make Seq Tank Empty Level SP when the caustic make is selected, then the operator is prompted if a tank drain is required first.

The CAUSTIC MAKE sequence is as follows:

The Caustic CIP/EFM Tank Water Supply Valve (V-5009) opens to fill the Caustic CIP/EFM Tank with softened water. The PLC will close the valve when the tank level reaches the recipe Caus Make Water Volume, as measured by Tank Level Transmitter (LIT-5006). While the tank is filling, the Tank Heater (H-5004) will be disabled until the tank level is above the Heater Enable Level set-point. The heater will turn on when the tank temperature is below the H-5004 Temperature set-point by more than the Temperature Deadband. The heater will turn off when the tank temperature is above the Temperature set-point. It should be noted that the heater control is always active if the heater is in automatic mode – if the level is high enough, the heater will always be trying to maintain the requested temperature, if in Auto.

While the Caustic CIP/EFM Tank (T-5001) is still filling but almost full of softened water, the PLC instructs the chlorine supply pump (P-5402) to deliver the recipe Caus Make Dis Volume into the Caustic CIP Tank.

Likewise, if the loaded recipe includes caustic solution, the recipe set-point

Caus Make Caus Volume is added via the caustic supply valve and the caustic supply pump (P-5015). During the Make sequence, the solution is circulated with Caus Mixing Pump P5001.

The Make sequence completes when all of the required water and caustic/chlorine have been added and mixed for the Caus Mix Time.

After the solution is made and at the appropriate temperature and minimum volume, the chemical solution is ready for use by either the EFM or CIP recipes.

2.2.3 ACID TANK FLUSH

The acid tank flush procedure is used to drain the tank and refill it with potable water. It is started by the operator pressing the FLUSH TANK button on the tank pop-up. The system reserves the Circulation and Caus (Neutralization) areas for use, ensuring that other processes cannot control equipment in those areas simultaneously.

Acid Tank Outlet (V-5132), Circulation Pump Feed (V-5282A/B) and Circ- Drain Pump to Neut Tank (V-5288) valves are opened to create a path from the Acid tank to the Caustic/Neutralization tank via the circulation-drain pump. Inappropriate valves are closed.

CIP Circ-Drain Pump P-5204A/B is run until…