22 67 19.16 - CEP Reverse Osmosis Water Purification System - Complete OM.pdf

TELEPHONE: +1 941 480 9101

FACSIMILIE: +1 941 480 9201

WEBSITE: www.cranewater.com

CRANE WATER • 730 COMMERCE DRIVE • VENICE, FL • 34292 USA

BELCO WATER • CHICAGO HEATER • COCHRANE • ENVIRONMENTAL PRODUCTS • WESTINGHOUSE CONDENSERS

35 gpm Water Purification System Operating and Maintenance Manual

For

Customer: Crown Solutions Co. LLC Customer Purchase Order Number: PO 13004358 OL 05500

Crane Shop Order (SO) Number: 143823

End User: SLVHCS DBE-2720554-02/EWP-07-CMHP-Central P1

TELEPHONE: +1 941 480 9101

FACSIMILIE: +1 941 480 9201

WEBSITE: www.cranewater.com

CRANE WATER • 730 COMMERCE DRIVE • VENICE, FL • 34292 USA

BELCO WATER • CHICAGO HEATER • COCHRANE • ENVIRONMENTAL PRODUCTS • WESTINGHOUSE CONDENSERS

TABLE OF CONTENTS

Section 1 Introduction

Section 2 Safety

Section 3 Principals Of Operation

Section 4 Control Systems

Section 5 Operation

Section 6 Maintenance Procedures

Appendix 6-1 Pipe Flushing, Hydrotesting & Sanitization

Section 7 Troubleshooting

Appendix 7-1 Normalization Equations

Appendix 7-2 RO Water Chemistry

Section 8 Sampling & Testing

Section 9 General Installation Instructions

Component Cut Sheets & User Manuals

Major Component Cut Sheets & Manufacturer User

Manuals

1-1

SECTION 1 – INTRODUCTION

1.1 PURPOSE OF THIS MANUAL

This manual is intended to assist the installer and operator of the Crane Water Purification System to operate and maintain the system effectively. The focus of this manual is strictly on the Water Purification Equipment, and is not intended to address other customer-supplied equipment. Although this manual has been specially prepared for this unit, conditions may occur which are not specifically covered. If unusual conditions occur, it is recommended that you contact a Crane Water Field Service Representative prior to attempting any corrective measures that are not specifically outlined in this manual.

The information contained in this manual is intended for use by installers and/or operators of this equipment at their own discretion and risk. Since conditions of use are outside the control of the manufacturer, we cannot assume liability for results obtained or damages incurred through the application of the information presented. This information is not intended as a license to operate under or a recommendation to infringe upon any patent or copyright.

DESIGN OVERVIEW

This Water Purification System is a skid-mounted 9 x 840 Reverse Osmosis system mounted on a single frame. The 9 x 840 Reverse Osmosis Water Treatment System was designed in accordance with membrane projections based on the customer’s water requirements, specifications, and the feed water analysis. Final Permeate production is projected to be 35 gpm, with Conductivity of 1.79 mg/L TDS. Actual production rates will depend on the actual feed conditions at the installed location of the water purification system.

Basic components of the 9 x 840 Reverse Osmosis Skid include a sediment prefilter housing, a high-pressure pump, reverse osmosis pressure vessels, membranes, control valves. ORP, Conductivity, pH, Pressure, and Flow are monitored by sensors for display and logic decisions within the Microprocessor control system.

The Microprossor Enclosure is mounted on the 9 x 840 skid frame. The Control Enclosure houses the Variable Frequency Drive (VFD) for the RO high-pressure pump motor, contactors, switches, and a DC power supply and the microprossor controller with display. The enclosure is fan cooled. The display screen is located on the front panel of the Control Enclosure, with an Emergency Stop mushroom switch and the chemical dosing pumps HOA switches.

1-2

This Water Treatment System is designed to process raw feed water from the customer-supplied source at a rate of 46 gpm and a minimum pressure of 40 psig.

Feed water is dosed with both dechlorination and pH adjust solutions. The influent then enters the 5 µ (micron) filter housing before being pumped by the VFD-controlled RO high-pressure booster pump to the first array of the RO unit. The total recovery rate varies with water temperature and other site conditions.

The final Permeate flow of 35 gpm from the RO unit is fed to the customer’s Permeate Storage Tank. The entire system will continue to run, producing Permeate until the customer’s water tank level float switch reaches the “high” level.

Following is an outline of the components and conditions relating to this equipment order:

1. One (1) skid mounted 9 x 840 RO Unit with Mircroprossor Controls Enclosure

2. One (1) Prefilter Housing with seven (7) 5 micron filter cartridges, installed on the

RO skid

3. Fast Flush Feature (full flow of feed water bypassing the Concentrate Control valve) upon RO shut down.

4. One (1) Variable Frequency Drive (VFD) unit for control of the RO High Pressure

Pump

5. One (1) Antiscalant Chemical Dosing Unit, installed off-skid from the RO frame

6. One (1) pH adjustment Dosing Unit, installed off-skid from the RO frame

7. Permeate divert feature is provided to divert permeate to drain when water quality is below the desired set point.

1-3

Figure 1-1 Reverse Osmosis Unit P & ID

1-4

1.2 SYSTEMS DESCRIPTION

1.2.1 FEED WATER CHEMICAL DOSING

Dechlorination Dosing is used prior to this RO unit to remove chlorine from the feed water stream. Chlorine can permanently damage RO membranes. This dosing pump injects Sodium Bisulfite. The dosing pump is manually controlled. The Dechlorination dosing unit provides calculated injection of the chemical solution into the feed water flow stream at a constant rate, based on the chemical dosing projections. This dechlorination dosing unit is installed off-skid from the RO.

The dechlorination dosing unit consists of a dosing pump 101, and a dosing solution tank 101. A static mixer, SM-100, insures mixing of the sodium bisulfite for maximum dechlorination of the feed water flow (See PID, Section 4 – Control and Section 5 – Operation for details).

This RO unit also has a pH chemical dosing system for optimal membrane performance. A pH adjustment dosing unit is installed on the feed to the RO unit. The pH adjust dosing unit consists of chemical dosing pump 100, and solution tank 100. The acid dosing unit provides calculated injection of the chemical solution into the feed water flow stream at a constant rate, based on the chemical dosing projections. Consult the chemical dosing projections for the dosing unit (included at the end of this section) for details of the solution strengths and injection rates.

The dosing pump tank levels for both dosing units are monitored by the Control panel, and will fault and alarm when low, shutting down the dosing pumps (See Section 4 – Control and Section 5 – Operation for details).

1-5

Table 1-1 Major Dosing Unit Components

P & ID, Part Number Description Qty Remarks

Dosing Pumps -100 & 101/

DPO54P-1

Dosing Pump, 0.21 GPD 110V, 150 psi, PVDF 2

Pulsafeeder model LB02SA-

KTC1-

XXX

Dosing tanks – 100 & 101/

23G21832PN7C00

35 Gallon 18”zx33” Chemical Solution storage tank 2 Polyethylene

DTLSASSMY01 Dosing Tank Level Switch assembly 2 Assembled components

SM-100/

STM02 2” Static Mixer, 6 elements 1 PVC

1.2.2 9 x 840 REVERSE OSMOSIS UNIT

Feed Water enters the RO skid through the manual skid isolation valve HV-100, and passes through the prefilter 100, removing suspended solids 5 micron and larger. The feed water inlet isolation solenoiod valve SV-100 on the RO skid is opened by the micoprossor if low-solenoid pressure switch PSL100, prior to the high-pressure pump, sees the minimum pressure. If the minimum inlet pressure is not reached, the low-pressure switch will initiate a low-pressure alarm through the microprossor, and the RO unit shuts down. When the pressure requirement is met, the feed water flows to the RO high-pressure boost pump 1, which applies hydrostatic pressure greater than the osmotic pressure, creating Permeate flow from the membranes. Permeate, or product water, flows from the RO unit to the Raw Water Storage Tank. The RO unit will continue to operate until the tank level switch in the Raw Water Storage Tank reaches the high level.

Controls for the RO unit include automatic fast flush, low-pressure shutdown, permeate divert and shutdown on high Permeate Storage Tank level.

1-6

Table 1-2 Major RO Unit Components

P & ID Tag #, Part Number Description Qty Remarks

Pump-100/

CRN15-12

High-pressure pump, Grundfos, 25 hp, 230-460 v/60 hz/3 phase, 2” flange (300 # class)

1 316 SS

HV-100/

UBV12

2” PVC Feed water inlet isolation valve 1 ASAHI

5090A020

Filter housing -100/

SFH730

Prefilter housing, uses seven 30” cartridges, ½” drain ports & ¼” drain ports

1 316 SS

PFC25 30” L x 2.75’ Pleated 5 micron cartridge 7 WB-931-5

SV-100/

GCV200BM

Feedwater inlet 2” solenoid valve, 150 # class, 120 v/60 hz operator w/ override

1 316 SS

PV1 thru PV3/

ASI05-ASME

Pressure Vessel, 300 psi, 3 membrane length, ” sideport 3 Fiberglass

Membranes/

ETB85

Membrane element, 9,10500 gpd, brackish water, 8” x 40” 9 Filmtec BW30-

400/34i

XV-104/

MBV01SW

Concentrate fast flush,1” Motorized ball valve, 1000 # class, socket weld, 120v/60 hz operator

1 316 SS w/ Apollo actuator

PSL100/

E1H-H90

Low pressure switch, 3.5-90 psi, Buna-N diaphragm 1 Low pressure protection

PSH100/

E1H-H250

High Pressure switch, 11-250 psi, Buna-N diaphragm 1 High pressure protection

HV-111/

VGS20- Korea

Concentrate Control globe valve, 1” valve, 800 lb class 1 316 SS

DGO 58/

PI 102,104 & 105

0-300 psi liquid filled 4” dia pressure gage 3 316 SS

DGO57/

PI100, 101,103 & 106

0-100 psi liquid filled 4” dia pressure gage 4 316 SS

ARV 102/

PRV36

Pressure relief valve, ss, ¾” MNPT x 1

½”FNPT 1

ASME code valve 100 psi set pressure

SV102/

GCV150B-N/O

Permeate TDS divert to drain solenoid valve 1 300 psi

SV103/

GCV150B

Permeate to point of use water solenoid valve 1 300 psi

1-7

HV110/

TWBV150-SPEARSH

Permeate 3-way valve for cleaning return & POU 1

SP103,SP105,SP106,

SP107,SP109 &

SP112/

SPV01

Sample port valves ¼” ball valve 1 PVC

HV104/

JFL32-Italy

HP Pump throttle vavle, 2” SS Ball valve 3 pc SW 1

HV108/

JFL31-Italy

Arrray isolation valve, 1 ½” SS Ball valve 3 pc SW 1

HV112/

JFL49-Korea

Concentrate recycle vavle, ¾” ss globe valve sw, 800# 1

1-8

GLOSSARY OF TERMS

The following terms are commonly used when discussing RO units and related equipment.

ALKALINITY- the measurement of a solution’s acid neutralizing ability.

ANION – A negatively charged ion; in water treatment also a factor in conductivity or resistivity. As an example, Strong Base Anion Exchange Resin may be used for the removal of negative ions, or “anions” in a water treatment process.

ARRAY – An arrangement of process equipment in a parallel and/or series configuration.

BASICITY - the power/measurement of an acid to react with bases, dependent on the number of replaceable hydrogen atoms of the acid

BIRM – Birm, for the removal of dissolved ferrous iron, is a trademarked name owned by Clack Corporation. Birm is an acronym for “Backwashable Iron Removal Media” composed of a granular manganese-coated aluminum silicate. With Birm as a catalyst, iron particles are formed when oxygen and ferrous iron compounds dissolved in the water form chemical bonds and precipitate out as “rust” or solid iron particles. This precipitate is rinsed to drain during backwash / rinse cycles.

BRINE - (1) Reject - normally, the waste stream from reverse osmosis which contains most of the dissolved solids from the feed in a concentrated form.

(2)Water or solution containing high volume or concentration of salt

CATION – A positively charged ion; in water treatment also a factor of conductivity or resistivity of water. As an example, Strong Acid Cation Exchange Resin may be used for the removal of positive ions, or “cations” in a water treatment process.

CHLORINE - Symbol Cl; atomic weight 35.43; atomic number 17; valence 1, 31 5, or 7.

Chlorine is often used in water treatment as a disinfectant. Chlorine is also used in conjunction with Greensand Plus filter media as a pre-oxidizer. It may be used as a gas or as a hypochlorite (OCl-) compound. Chlorine in the air is toxic at concentrations over

0.1 ppm.

COMPACTION - Tightening of a membrane structure due to compressive stress of operating pressure. Compaction results in reduced productivity.

1-9

CONCENTRATE - The reject (waste) from a reverse osmosis element or an ultra-filtration filter.

CONCENTRATION - The amount of substance in weight, moles, or equivalents contained in a unit volume.

CONCENTRATION POLARIZATION - This phenomenon results when the water at the surface of a reverse osmosis membrane Permeates the membrane at a rate that is much greater than the diffusion rate of the dissolved minerals. As a result, the mineral concentration in the "film" of liquid at the membrane surface is much higher than the solution being treated. This inhibits permeation and can cause scaling, if solubility limits are reached. This phenomenon is more of a problem with the sheet-type membrane, because of their greater flux rates as compared with fiber-type membranes.

CONDUCTIVITY – Also called “specific conductance” The ability of a substance to conduct heat or electricity. Commonly, used as an expression of electrical conductivity in microhms/cm.

CONTAMINANT - Any foreign component present in another substance; e.g., anything in water that is not H20 is a contaminant.

% CONVERSION - (% Recovery) - The proportion of the feed water converted to product, i.e.:

Feed water - brine rate X 100 Feed rate

OR

Product rate X 100 Product rate + brine rate

DEIONIZED WATER-Water treated with a ion exchange resin specific for removing ions, especially cations, except for H3O+ and OH−.

EFFLUENT - The solution that emerges from a liquid treatment unit.

FEED - Any type of influent or process liquid that is to be treated in a filter, ion exchange vessel, etc.

FEED WATER - The influent water to the membrane unit.

FILTRATION - The process of separating solids from a liquid by means of a porous substance through which only the liquid passes.

FLOW RATE - The volume of solution which passes through the unit within a given time. Flow rate is usually expressed in terms of gallons per minute (GPM), or as liters per minute (LPM).

http://www.reference.com/browse/wiki/Hydronium http://www.reference.com/browse/wiki/Hydroxide

1-10

FLUX RATE - Flow or Permeate per square foot of membrane area.

FRP – Fiberglass Reinforced Plastic; commonly used in water treatment to describe the vessels used for media filter tanks.

Greensand Plus™- filter media composed of a silica sand core coated with manganese dioxide, where manganese dioxide serves as a catalyst for the oxidation reduction reaction of iron and manganese. This media is used for the removal of iron, manganese, hydrogen sulfide, arsenic and radium from untreated ground or well water, and can be intermittently regenerated or continuously generated.

HARDNESS - The scale forming and lather inhibiting qualities which water, high in calcium and magnesium ions, possesses hardness caused by the presence of magnesium ions, possesses. Temporary hardness, caused by the presence of magnesium of calcium bicarbonate, is so called because it may be removed by boiling the water to convert the bicarbonates to the insoluble carbonates. Calcium sulfate, magnesium sulfate, and the chlorides of these two metals cause permanent hardness.

HARDNESS as CALCIUM CARBONATE - The expression ascribed to the value obtained when the hardness forming salts are calculated in terms of equivalent quantities of calcium carbonate; a convenient method of reducing all salts to a common basis for comparison.

HEADER - A main or common piping line. The portion of the internal vessel distribution from which branch the individual laterals.

HMI Human Machine Interface-A controls enclosure or component which allows viewing, monitoring, altering, or updating programmed control elements.

INFLUENT - The solution which enters a water treatment unit.

MEMBRANE - A barrier, usually thin, that permits the passage only of particulates up to a certain size or of a special nature.

MEMBRANE ELEMENT - An individual membrane assembly, usually tubular, must be housed in some type of pressure vessel.

MODULE - A single pressure vessel or housing containing membrane elements.

MODULE ASSEMBLY - An array of membrane housings.

MOLECULE - The smallest unit quantity of matter which can exist by itself and retain all the properties of the original substance.

1-11

NANOFILTRATION (NF) - Forced flow of solvent (water) from a solution through a semi-permeable membrane with a larger pore size than typical RO membranes by means of hydrostatic pressure in excess of the osmotic pressure.

NEUTRALIZATION - The act of adding acid to an alkaline effluent or alkali to an acidic effluent to make the effluent pH neutral (7.0 pH).

Oxygen Reduction Potential (ORP) – In water treatment, the electrical potential required to transfer electrons from one compound or element (the oxidant) to another compound or element (the reductant); used as a qualitative measure of the state of oxidation.

OSMOSIS - The passage of water molecules through a permeable membrane separating two solutions of different concentrations (the water passes into the more concentrated solution).

OSMOTIC PRESSURE - Pressure required to prevent spontaneous flow of solvent (water) into a solution when separated by a semi-permeable membrane.

OXIDATION - Any process which increases the proportion of oxygen or acid forming element or radical in a compound.

PERMEATE - The filtered effluent from a NF, RO element or UF cartridge.

pH - An expression of the acidity of a solution; the negative logarithm of the hydrogen ion concentration (pH 1 very acidic; pH 14, very basic; pH 7, neutral).

PLC Programmed Logic Control-A control component or module that can accept and store commands for control sequences, and operate mechanical or electrical components according to readings or conditions with preset or preprogrammed limits.

PREFILTER - A filter placed before and in series with some other type of liquid treatment equipment.

PRE-TREATMENT- The process applied to feed water before being processed by a nanofiltration or reverse osmosis unit. This typically consists of filtration and chemical injection units designed to remove impurities that diminish the performance of RO or nanofiltration elements.

POST TREATMENT- The process applied to the Permeate water or effluent, making it suitable for the final intended purpose or point of use.

1-12

PRODUCTIVITY - The measurement of rated output, expressed in gallons/24 hour day under a given temperature, pressure and salinity (Product Flow)

PRODUCT WATER - Water that has been treated by some type of liquid treatment process.

PURITY - The percentage of desirable versus undesirable components on a weight basis per unit volume of sample.

RAW WATER (Feed) - Untreated water from wells, municipalities, or surface sources;

water prior to all treatment processes in a treatment system.

REGENERANT – A solution that restores the ion exchange capability of a substance.

RECOVERY - The quantity of a given component by weight in the product stream versus the amount of that specific component in the feed.

RESISTIVITY – Measured in megaohms-cm; opposition to electrical current flow, also the inverse of “Conductivity.” Resistivity is a more accurate measurement for High Purity or Ultra High Purity water.

REVERSE OSMOSIS (RO) - Forced flow of solvent (water) from a solution through a semi-permeable membrane by means of Hydrostatic pressure in excess of the Osmotic Pressure.

RINSE - The operation which follows backwash or regeneration; a flushing out of excess regenerant solution.

REDUCTION & OXIDATION REACTION (REDOX) – The combination of the processes involved in the flow of electrons from a traducing agent (reducer) to an oxidizing agent (reducer) to an oxidizing agent (oxidant). The total number of electrons lost by one substance is the same as the total number of electrons gained by another substance.

Oxidation & reduction always occur together simultaneously and are really opposite sides of the same reaction, often called the “redox reaction.”

SCFM – Standard Cubic Feet per Second, a term that can be used to describe the flow of compressed air or other volumetric flow of gas, “corrected to standardized conditions of temperature and pressure.”

SEMI PERMEABLE MEMBRANE-A membrane which allows transfer of some molecules, solvents or dissolved solids or particles, but not others; as dictated by pore size or electrical charge.

1-13

SHEAR - The frictional force created by a process liquid flowing across a membrane or other surface.

SDI (SILT DENSITY INDEX)- A measure of the amount of suspended solids (silt) present in the feed water to a reverse osmosis unit.

TDS (Total Dissolved Solids) – Total mass of dissolved solids suspended in a solution.

Particular to water purification, cations, anions, or molecules generally consisting of salts and minerals to be removed by pre-treatment filtration or Reverse Osmosis.

Approximate measurement of TDS determined by (electrical) conductivity, where higher TDS will have greater conductivity and lower TDS will have less conductivity.

TOC - Total organic carbon. A measure of the total organics load in a feed water.

TRANS-MEMBRANE PRESSURE - The pressure across the membrane - RO inlet pressure minus the product pressure.

TURBIDITY - A suspension of fine particles that obscure light rays but require many days for sedimentation because of small particle size.

ULTRA FILTRATION (UF) – A method of cross-flow filtration using lower pressures of 5-150 psig, (as compared to Reverse Osmosis Filtration) using a semi permeable membrane with pore sizes ranging from 0.005 – 0.1 micron, to separate small colloids and large molecules, as dictated by the pore size of the semi permeable membrane, from water and other liquids.

VFD Variable Frequency Drive (for water treatment) - a specific type of adjustable speed drive, used as a control device with large pump motors that allows smooth operation at all power settings, and more efficient speed control once the motor is running. A VFD helps to conserve energy and the life of the motor by preventing high amperage on start up by controlling the frequency of the electrical power applied to control the speed of rotation.

Project Information:

Case-specific:

System Details

Permeate Flux reported by ROSA is calculated based on ACTIVE membrane area. DISCLAIMER: NO WARRANTY, EXPRESSED OR IMPLIED, AND NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, IS GIVEN. Neither FilmTec Corporation nor The Dow Chemical Company assume any obligation or liability for results obtained or damages incurred from the application of this information. Because use conditions and applicable laws may differ from one location to another and may change with time, customer is responsible for determining whether products are appropriate for customer’s use. FilmTec Corporation and The Dow Chemical Company assume no liability, if, as a result of customer's use of the ROSA membrane design software, the customer should be sued for alleged infringement of any patent not owned or controlled by the FilmTec Corporation nor The Dow Chemical Company.

Reverse Osmosis System Analysis for FILMTEC™ Membranes ROSA 7.2.7 ConfigDB u392554_146

Project: 28813 VA Central Plant REV 1 Case: 1

Loren Rideout, Crane Environmental 12/1/2011

Feed Flow to Stage 1 56.68 gpm Pass 1 Permeate Flow 35.01 gpm Osmotic Pressure:

Raw Water Flow to System 46.68 gpm Pass 1 Recovery 75.00 % Feed 2.05 psig

Feed Pressure 284.88 psig Feed Temperature 10.0 C Concentrate 7.83 psig

Flow Factor 0.85 Feed TDS 294.76 mg/l Average 4.94 psig

Chem. Dose None Number of Elements 9 Average NDP 253.76 psig

Total Active Area 3600.00 ft² Average Pass 1 Flux 14.00 gfd Power 8.78 kW

Water Classification: Surface Supply SDI < 5 Specific Energy 4.18 kWh/kgal

Stage Element #PV #Ele Feed Flow

(gpm)

Feed Press

(psig)

Recirc Flow

(gpm)

Conc Flow

(gpm)

Conc Press

(psig)

Perm Flow

(gpm)

Avg Flux

(gfd)

Perm Press

(psig)

Boost Press

(psig)

Perm

TDS

(mg/l)

1 BW30-400/34i 1 3 56.68 279.88 10.00 44.27 266.66 12.41 14.89 30.00 0.00 1.21

2 BW30-400/34i 1 3 44.27 261.66 0.00 32.63 252.92 11.64 13.97 30.00 0.00 1.64

3 BW30-400/34i 1 3 32.63 247.92 0.00 21.67 242.75 10.96 13.15 30.00 0.00 2.51

Pass Streams

(mg/l as Ion)

Name Feed Adjusted Feed Concentrate Permeate

Initial After Recycles Stage 1 Stage 2 Stage 3 Stage 1 Stage 2 Stage 3 Total

NH4 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

K 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Na 23.45 33.86 51.67 66.11 89.61 134.74 0.16 0.23 0.39 0.25

Mg 6.56 6.56 10.03 12.84 17.41 26.21 0.01 0.02 0.03 0.02

Ca 40.08 40.08 61.25 78.40 106.33 160.03 0.06 0.10 0.16 0.11

Sr 0.20 0.20 0.31 0.39 0.53 0.80 0.00 0.00 0.00 0.00

Ba 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

CO3 2.98 2.98 5.20 6.98 9.98 16.00 0.00 0.00 0.00 0.00

HCO3 122.01 122.01 185.21 236.48 319.76 479.30 0.63 0.78 1.08 0.82

NO3 7.32 7.32 11.01 14.03 18.91 28.18 0.24 0.35 0.58 0.38

Cl 32.62 32.62 49.85 63.81 86.54 130.26 0.05 0.07 0.12 0.08

F 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

SO4 42.24 42.24 64.57 82.66 112.13 168.79 0.04 0.06 0.10 0.06

SiO2 6.80 6.80 10.38 13.28 18.00 27.07 0.03 0.04 0.07 0.05

Boron 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

CO2 0.43 0.43 0.61 0.77 1.03 1.56 0.41 0.60 0.93 0.63

TDS 284.35 294.76 449.56 575.05 779.28 1171.46 1.21 1.64 2.51 1.76

pH 8.70 8.70 8.72 8.71 8.70 8.67 6.53 6.45 6.40 6.45

Page 1 of 3ROSA Detailed Report

4/30/2012file:///C:/Users/lrideout/Desktop/28813%20VA%20Central%20Plant%20REV%20101Det...

Design Warnings

Solubility Warnings

Stage Details

Permeate Flux reported by ROSA is calculated based on ACTIVE membrane area. DISCLAIMER: NO WARRANTY, EXPRESSED OR IMPLIED, AND NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, IS GIVEN. Neither FilmTec Corporation nor The Dow Chemical Company assume any obligation or liability for results obtained or damages incurred from the application of this information. Because use conditions and applicable laws may differ from one location to another and may change with time, customer is responsible for determining whether products are appropriate for customer’s use. FilmTec Corporation and The Dow Chemical Company assume no liability, if, as a result of customer's use of the ROSA membrane design software, the customer should be sued for alleged infringement of any patent not owned or controlled by the FilmTec Corporation nor The Dow Chemical Company.

Reverse Osmosis System Analysis for FILMTEC™ Membranes ROSA 7.2.7 ConfigDB u392554_146

Project: 28813 VA Central Plant REV 1 Case: 1

Loren Rideout, Crane Environmental 12/1/2011

-None-

Langelier Saturation Index > 0

Stiff & Davis Stability Index > 0

Antiscalants may be required. Consult your antiscalant manufacturer for dosing and maximum allowable system recovery.

Stage 1 Element Recovery Perm Flow

(gpm) Perm TDS

(mg/l) Feed Flow

(gpm) Feed TDS

(mg/l) Feed Press

(psig)

1 0.07 4.21 1.12 56.68 449.56 279.88

2 0.08 4.13 1.21 52.47 485.46 274.92

3 0.08 4.07 1.32 48.34 526.81 270.53

Stage 2 Element Recovery Perm Flow

(gpm)

Perm TDS

(mg/l)

Feed Flow

(gpm)

Feed TDS

(mg/l)

Feed Press

(psig)

1 0.09 3.94 1.47 44.27 575.05 261.66

2 0.10 3.88 1.63 40.33 630.96 258.30

3 0.10 3.82 1.84 36.46 697.84 255.39

Stage 3 Element Recovery Perm Flow

(gpm) Perm TDS

(mg/l) Feed Flow

(gpm) Feed TDS

(mg/l) Feed Press

(psig)

1 0.11 3.70 2.13 32.63 779.28 247.92

2 0.13 3.65 2.47 28.93 878.49 245.84

3 0.14 3.61 2.95 25.28 1004.89 244.13

Page 2 of 3ROSA Detailed Report

Scaling Calculations

To balance: 10.41 mg/l Na added to feed.

Raw Water Adjusted Feed Concentrate pH 8.70 8.70 8.67

Langelier Saturation Index 0.50 0.50 1.60

Stiff & Davis Stability Index 1.37 1.37 1.97

Ionic Strength (Molal) 0.01 0.01 0.02

TDS (mg/l) 284.35 294.76 1171.46

HCO3 122.01 122.01 479.30

CO2 0.43 0.43 1.56

CO3 2.98 2.98 16.00

CaSO4 (% Saturation) 0.43 0.43 5.37

BaSO4 (% Saturation) 0.00 0.00 0.00

SrSO4 (% Saturation) 0.25 0.25 2.03

CaF2 (% Saturation) 0.00 0.00 0.00

SiO2 (% Saturation) 4.29 4.29 17.38

Mg(OH)2 (% Saturation) 0.06 0.06 0.20

Page 3 of 3ROSA Detailed Report

DRAWING TABLE OF CONTENTS

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WATERCRANE

CRANE WATER

SECTION 2 - SAFETY

2.0 SAFETY

This section contains general safety guide lines that all person nel must follow when installing, operating, and maintaining RO water treatment facilities and related systems.

Safety information in this section must be read, understood, and adhered to in order to prevent personal injury and equipment damage.

2.1 SAFETY SUMMARY

CHEMICALS – Range from mildly irritating to extremely corrosive, depending on the specific chemical exposure. Always refer to the MSDS (Mate rial Safety Data Sheets) supplied with the specific chemical.

OPERATIONS SAFETY – Hazards include:

High-voltage electricity can cause severe burns, cardiovascular failure, and death.

High liquid or pneumatic pressures can inflict a variety of physical injuries when accidentally released.

High temperatures of liquids or machine parts can cause severe burns.

Rotating components such as pumps and motors are potentially dangerous when hands, feet, long hair, or loose clothing come in contact. All guards and shields as provided by the manufacturer must be kept in place to prevent potential injury.

This equipment must be grounded. Never defeat the ground conductor or operate the equipment in the absence of a suitably installed ground conductor. Also, all exposed non-current carrying metal parts must be properly grounded. Ensure grounding is in compliance with all local codes and requirements.

2.2 GENERAL SAFETY GUIDELINES

OPERATOR TRAINING – A m ajor contribution to th e safe operation of proces s equipment is to ensure that operat ors and maintenance personnel are adequately trained. Only experienced oper ators who have been properly trained should be allowed to operate the equipment or manage the process.

PERSONAL PROTECTION EQUIPMENT – Personnel working around equipment or hazardous chemicals must wear the safety equipment, such a safety glasses, face shields, respirators, protective clothing, or other appropriate types of gear.

Warning: Refer to the MSDS sheets provided by the specific chemical manufacturer for recmmended safety wear and emergency response information.

EQUIPMENT ACCESS – Use extreme caution when working around s ystem components. Valve handles, sample pipes, and other protruding components can cause injury. Personnel should wear hard hats and saf ety glasses when working around water treatment equipment.

Caution: Equipment requiring service that is out of normal reach requires the use safe, approved ladders, scaffolding, or lifting devices.

ELECTRICITY – All personnel must use caution when working with motors, control panels, and other electrical equipment. Electrical components must be properly connected and grounded and should not be allowe d to come in contact with process fluids or water. Onl y qualified personnel should be allo wed to test, connect, or repair electrical components.

Warning: DANGER OF ELECTROCUTION – Always perform a “Lock-out/Tag-out procedure before attempting maintenance or repairs to electrical circuits or components.

AUTOMATIC SYSTEM TESTING – Any automatic system that handles liquids or chemicals must be test-run wit hout process liquids prior to initial operation of the equipment. Technicians must be sure t hat the entire system operates properly before chemicals or process fluids are introduced.

Warning: Improper flows of corrosive chemicals or other liquids during a system test run can cause injury or equipment damage. All hand valves must remain closed to prevent accidental entry of process liquids.

SERVICING COMPONENTS - Before performing maintenance on system components, and especially when disassembling individual units, it must be certain that the component is isolated from pressure, fluids, and electricity.

Spring-loaded devices, such as valves, must have the spring unloaded to avoid the sudden movement of individual parts. Always refer to the individual vendor component literature for specific guidelines as special tools and step-by-step procedures will be required to prevent injury to equipment and personnel.

Before working on automatically contro lled components, make sure that the automatic controller is disabled to the point that it cannot be used to operate remote components.

Warning: Accidental and unexpected operation of remote components can cause personal injury or death.

Lockout/Tagout related valves and electrical controls and inform operators and control room personnel that a service procedure is in progress.

2.3 SAFETY PRECAUTIONS - HAZARDOUS CHEMICALS

2.3.1 Acids and Caustics

Acids and caustics can cause severe burns to the skin and eyes. Flush immediately with wat er for a minimum of 15 minutes . Inhalation of aid vapors may cause coughing, chest pains, difficulty breathing, or unconscious ness.

Ingestion of acids or caustics may be fatal. If swallowed, do not induce vomiting.

Give water, milk, or milk of magnesia. Seek immediate medical attention.

Protective safety goggles face s hield, protective suit, and rubber gloves must be worn when working on the equipment or manually pumping ac id from bulk tanks to day tanks.

Any maintenance of the acid or c austic feed system must include precautionary steps as defined by established work prac tices around or near electrical and/or mechanical components.

A Lock-out/Tag-out procedure must be used to confirm the applic ation components are safely out of service.

2.3.2 Antiscalant

Antiscalant chemicals can cause severe burns or irritation to the skin and eyes.

Flush immediately with water for a mini mum of 15 minutes. Medical evaluation must be conducted if the chemical comes in contact with the eyes.

Protective safety goggles, face shield, protective suit, and rubber gloves must be worn when working on the equipment or manually pumping ac id from bulk tanks to day tanks.

Any maintenance of the acid feed system must include precautionary steps as defined by establis hed work practices around or near electrical and/or mechanical components.

A Lock-out/Tag-out procedure must be used to confirm the application components are safely out of service.

2.3.3 Dechlorination

Sodium metabisulfite powder, commonly mi xed with water to be used as a de-chlorinating agent, will cause irritation to eyes and mucous membranes. As a respiratory irritant, sore throat, coughi ng, and shortness of breath may occur.

Skin irritation or rash may develop from contact. Flush skin with water for 20 minutes and remove contaminated clothi ng. In the event of exposure, seek medical attention for acute reactions or contact with eyes. Personnel protectiv e such as goggles or safety glasses, gloves, long-sleeved clothing, and boots can be worn to minimize exposure. In confined spaces, a respirator or SCBA may be necessary. Available in liquid form as So dium Bisulfite, the same precautions should be observed.

Always use a Lock-out/Tag-out proc edure when working on the dosing equipment to prevent accidental activation.

2.4 SAFETY PRECAUTIONS - EQUIPMENT

2.4.1 Cartridge Filtration System

Operation and maintenance of the cartridge filter system does not have specific safety concerns. Always relieve all pre ssure before opening a filter housing .

Working with any portion of the RO tr ain should include the Lock-Out/Tag-Out procedure to isolate a portion of, or the entire train.

Note that cartridge filter s have contained water that has been treated using chemicals including sulfuric acid and antiscalants. Safety precautions relating to those chemicals as described above should be followed.

2.4.2 Reverse Osmosis System

The RO membranes may have contained wa ter that has been pH adjusted wit h sulfuric acid. The RO pressure pumps may have contained water that has been treated with antiscalant chem ical. Exposure to these c hemicals to skin or eyes may result in injury. Always wear t he appropriate protective equipment when performing maintenance or repairs.

During periods of system shutdown, sodi um metabisulfite solutions may be used to preserve the RO m embrane. Appropriate protection for skin and eyes may be required. Consult the MSDS for specific precautions.

Any maintenance of the RO system must include precautionary steps as defined by established work practices around or near electrical and/or mechanical components.

2.4.3 Instrumentation

Operation and maintenance of t he instrumentation and control s ystem does not have specific safety concerns.

Any maintenance of the RO system must include precautionary steps as defined by established work practices around or near electrical and/or mechanical components.

Working with any portion of the RO fa cility should include the Lock-Out/Tag-Out procedure to isolate a portion of, or the entire train.

NOTE: Operators and technicians should read and follow additional instructions and procedures given in the vendor component literature.

SECTION 3 - PRINCIPLES OF OPERATION

3.1 PRE-TREATMENT

The efficiency and life of any reverse osmosis s ystem depends on the characteristics of the feed water and effectiveness of the pre-treatment system.

Proper pre-treatment will als o maximize efficiency and increase membrane life.

The type of Pre-treatment proce ss applied depends upon both the feed water quality and the final quality of water desired.

3.1.1 Antiscalant Dosing

Chemical dosing is also an important component in t he pre-treatment process, together with cartridge filtration, prepares the feed water before entering the RO system.

Antiscalant is a scale inhibitor pr ovided to protect the RO membranes downstream from salt precipitation by delaying the precipitation process.

As water moves from one membrane to the next, the water becomes more concentrated (more dissolved solids). In a typical sy stem the concentration factor increases to 4 times that of the original feed.

High concentrations of dissolved so lids means higher potential for precipitation of salts s uch as calcium carbonate, calcium sulfate, barium, strontium sulfate, and silica. The precip itation process star ts by a crystal growth of the salt particles that eventually adhere to the membrane surfaces and begin to block the flow channels.

Scaling is caused by the following:

Salts such as calcium carbonate, calcium sulfate, barium, strontium sulfate

Metal hydroxides – more common in high iron water Microbiological (bacteria) – very common, especially in warm environments Silica

Scaling can be removed using different chemicals, except f or silica.

Severe silica scaling cannot be treated.

The antiscalant chemical (phosphate based polymers) inhibits the process of crystal growth – but only for a shor t time. Water remain ing in the last stages of the RO system will scale rapidly because of higher salt concentration. This explains why it is recommended that system flushing be done at startup and also at shutdown.

NOTE: Always use antiscalant chemicals that are manufacturer approved.

3.1.2 Dechlorination Dosing

On water purification systems using munici pal water or other chlorinated feed water sources, the feed water must be dechlorinated before contact with the membranes to prevent permanent oxid ation damage. Chem ical dosing with sodium metabisulfite effectively can reduce the chlorine to a safe level. An ORP (Oxygen Reduction Potential) sensor s hould be included in the dechlorination dosing system, installed inline f ollowing the dosing injection point. To ins ure mixing of the dechlorinati on solution in the feed wate r stream, a static mixer should be installed inline. A proportional dosing pump c an deliver the amount of solution necessary to dechlorinate t he feed water based on feedback from an ORP sensor with a dosing controller or a PLC (programmed Logic Controller).

3.1.4.1 Prefilter Housing

As water enters the cartridge filter housing, it is diffused from the outside to the inside of the cartridge by passing thr ough a spun or pleated me dia cartridge. As foreign particles accumulate in the cartri dge media, the pressure drop across the filter increases (as indicated by the pressure gauges on the cartridge housing feed water entry and exit). Cartridges need replacing when pressure drop reaches 1 bar (14.5 psig). There is no sc hedule that can be applied, as feed water characteristics are variable.

Alternately, bag filters can be used in a bag filter housing to accomplish the same goal. Depending on t he desired feed water quality, the ca rtridge filter media or bag filters may range in micron rating.

3.2 REVERSE OSMOSIS EXPLAINED

Osmosis is a process that will occur naturally when a semi-permeable membrane is placed between a body of pure water and a solution of inorganic salts. In this process, the pure water will n aturally pass through the membrane into the concentrated solution of salts because of its greater osmotic pressure.

The water in the salt s olution has a lower osmotic pressure than the pure water because it is diluted with salts. Since the membrane allows only H 2O molecules to pass through, the greater number of H 2O molecules in the pure water causes water to flow to the concentrated side of the membrane.

This process will continue until the H 2O molecules in the sa lt solution are sufficiently energized (as the result of increasing pressure) to equalize the pressure exerted by the pure water. This is called the point of os motic equilibrium. This process occurs naturally and is called Osmosis.

If a force greater than natural osmotic pr essure is exerted on the salt solution, water will reverse direction and will flow through the semi-permeable membrane from the concentrated solution to the body of pure water (see Figure 2-1). This is called Reverse Osmosis.

As the water molecules leave the salt solution, the concentration of salts increase with a corresponding decrease in the osmotic pressure of the solution. This means that the higher the percentage of pure water that is extracted from the salt solution, the greater the pressure that must be applied on that solution.

The force required to operate a reverse osmosis system is a total of:

The difference in osmotic pressure The force required to overcome frictional losses Backpressure at the outlet of the system

While most dissolved substances cannot penetrate the membrane, dissolved gasses such as carbon dioxide (CO2) and Oxygen (O2) are able to move through the membrane.

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3.5 RO MEMBRANE CONSTRUCTION

The most commonly used membranes are constructed of composite polyamide.

They are spiral wound membranes, o ffering a large membrane surface area within a c ompact unit and are resistant to high trans-membrane differential pressure. Polyamide membranes provide a very stable performance bec ause of their neutral surface, tolerance to chlorine , and controlled poros ity that will reject most dissolved minerals, particulate ma tter, and organics, wh ile allowing t he water to pass through the membrane (see Figure 3-2).

The semi-permeable membrane for reverse osmosis applications consis ts of a thin film of polymeric mate rial several thousand Angstroms thick cast on a fabric support. The stability of these properties over a period of time in field conditions will provide a usable life expectancy of 3 to 5 years with proper maintenance.

Figure 3-1 Natural & Reverse Osmosis

The RO t rain recovery rate has been set per the design projection. This separates the feed into permeate/product stream and concentrate/reject stream.

3.3 REVERSE OSMOSIS CONFIGURATION (Example)

To achieve final 95% recovery afte r the second s tage (95% of feed water converted to Permeate water), the RO is designed in two arrays operating in series. The first array consist s of four (4) vessels or RO housings, each containing six (6) elements or memb ranes arranged in parallel and inter-connected in series.

The reject (Concentrate) water from the first array becomes feed to the second array. The second array has two (2) RO housings arranged also in parallel, each containing six (6) membrane elements.

Permeate water from the first and se cond arrays is combined and discharged through a common header. The RO product wa ter (Permeate) i s transferred to the product water storage (Permeate) tank (see Figure 3-3).

Your Water Purification System may be configured differently; the system design is derived from the desired quality and quantity of product or Permeate water required for your process, whic h in turn determines the components of the system to achieve those results. Y our projections are contained in Section 1- Introduction, along with the Scope of Supply and a description.

3.4 RO PRESSURE VESSEL FLOW PATTERN

Pretreated water enters the RO system through the RO high-pressure boost pump, raising the pressure above what is required by the membranes. The feed water flow is controlled manually by adjusting the RO pump throttle valve.

Figure 3‐2 Spiral Wound Membrane Construction

Pressurized feed water enters the RO pressure vess els through the feed water header piping which directs the flow into each of the pr essure vessels. As water moves from one side of the membrane to the other, it travels through flow spacers and across the membrane surfac e allowing low T DS pure water to permeate through the membrane and high TD S concentrate water is rejected to the drain. Individual membrane elem ents are joined with inter-connectors (see Figure 3-4).

Permeate water travels through the permeate tubes connecting all membranes and leaves the pressure vessel housing where eventually it is collected and is directed through the permeate manifold.

3.5 CLEANING SYSTEM

The Crane cleaning s tation is designed to enable cl eaning of each mem brane array in the reverse osmosis unit. T he cleaning station may be a stand- alone component or included on the Reverse Osmosi s skid as “Clean In Place” or CIP.

Both the stand alone Cleaning Station an d the integrated CI P feature require manual initiation and flow control to meet the requirements for cleaning the membranes. The cleaning proc ess will reverse the fouling that occurs during filtration. Regular c leaning helps prevent both short and long-term membrane fouling. This assures avoiding long te rm fouling and allows membranes to function near peak efficiency over a longer period of time under most conditions.

During operation, impuritie s are slowly deposited on the membrane surface.

These impurities bloc k the flow of wa ter through the membrane, resulting in higher feed-to-Concentrate and feed-to-Pe rmeate pressure drops, resulting in lower permeate flow. When the RO Unit r eaches a high differential pressur e, or low Permeate flow set point, it is taken out of service and the membrane cleaning operation is performed. (Normally at the pressure differential is approximately 10- 15% above the design projection.)

When membrane cleaning is required, cl eaning chemical solution is pumped through the RO pres sure vessels during a backwash cycle, followed by a brief soak period. The chemical used for cleaning is bas ed on the type of foulan t deposited on the membrane surface and t he chemical formulation of the membranes. The chemical dissolves the m aterial deposit, returning the pres sure drop and permeate flow to normal.

A typical flow rate for cleaning each RO housing is 35 – 40 GPM maximum at a temperature not to exceed 95 OF (35OC). The cleaning feed pressure should range between 20 psi (1.4 bar) and 60 psi (4.1 bar). Please see Section 5- Operation for specific details of the cl eaning process for your equipm ent configuration, and Section 6-Maintenance for additional inf ormation on this process.

3.6 POST TREATMENT PROCESSES

The final product or Permeate water quality determines the type of post treatment processes included in a water purification system. Your Water Purification System may include some or all of the following components . Details of the operation of your system will be contained in Section 4-Controls and Section 5- Operation.

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SECTION 4 – SYSTEM CONTROL

This RO system is operated by a combination of manual and automatic controls, with a microprocessor-based control box. Certain instrumentation included on the unit provides input for the control box for automatic operation, while some instrumentation provides a visual reference for manual controls. The most important control components and operations are described herein.

4.1 RO CONTROL PANEL

This RO unit has a single Series 200 control panel to operate and control the main functions of the RO. The front of this control panel contains an LCD display area (4 line X 20 character, backlit) and a key pad for data selection and input.

The Series 200 Control panel is located to the right of the High Pressure Pump. This panel contains a step down transformer to reduce the incoming 460 VAC / 60 Hz / 3 phase power supply to 120 VAC / 60Hz control voltage. The Series 200 RO Controller Users Manual is

Figure 4-1 Series 200 Front Panel

LCD Display Area

Keypad

Dosing pump HOA switches

Emergency Stop switch

4-2 included at the end of this section. Please refer to the Series 200 RO Controller Users Manual for details regarding connection points, flush preferences, or other information regarding control connections inside this control enclosure.

4.2 FEED WATER INLET SOLENOID VALVE

Feed water entry to the RO unit is controlled by a solenoid valve (SV-100) on the feed water inlet line, located between the Prefilter cartridge housing and the high-pressure RO pump.

(See figure 4-10) When the RO unit is energized, this solenoid valve opens, allowing flow past the low pressure switch (PSL100) to the high pressure pump 100. The valve will close when the RO unit is de-energized, or if the RO pump fails to engage due to feed pressure lower than the preset range in the control enclosure (see Figure 4-2).

Figure 4-2 Feed Water Inlet Solenoid Valve

4-3

4.3 FLOW SENSORS & FLOW METERS

Paddlewheel flow sensors are used to measure the Permeate (FE/ FT100), Concentrate recycle (FE/FT102) and Concentrate (FE/ FT101) flows in the RO unit. Digital readout of these flows in gallons per minute can be found on the front of the control enclosure on the backlit LCD display.