S60789 B10040 OMM Rev. 1.0.pdf

Prepared by:

ProAct Services Corporation 1140 Conrad Industrial Dr.

Ludington, MI 49431

CONFIDENTIALITY NOTICE: The information in this document is legally privileged and contains confidential information intended only for the use of the individual or entity named above. Any dissemination, distribution, or copy of this document is strictly prohibited.

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Luckey, OH FUSRAP Site Wastewater Treatment System

B10040 Operations and Maintenance Manual

January 2018 phone 888.993.1179 proact-usa.com Rev.1.0 © 2018 ProAct Services Corp.

Table of Contents

1.0 Introduction

2.0 Cautions, Warnings and Hazards

2.1 Safety Definitions

2.2 Potential Hazards

3.0 System Description

3.1 Theory of Operations

3.2 System Layout

4.0 System Control

4.1 Control Panel

4.2 Allen Bradley CompactLogix & Red Lion Touchscreen

a. Main Menu Screen

b. Influent Screen

c. Bag Filters and RO Screen

d. Mode Select and Hand Setpoints Screen

e. Runtime, Start, and Flow Totals Screen

f. ALARM Screen

g. System Setup Screens

h. Maintenance Options (Setup Screen 2)

i. Maintenance Options

j. Chart Pages

k. Touch Calibration

4.3 Transfer Pump

4.4 Anti-scalent Drum

5.0 Procedures

5.1 Emergency Shut-Down Procedure

5.2 Placement

5.3 Electrical Connections

5.4 Startup Sequence

5.5 Cold Weather Operation

5.6 Normal Shut-down

6.0 System Faults and Troubleshooting

6.1 Touchscreen Warning and Alarm Messages

6.2 Troubleshooting

Appendices Appendix A - Drawings ...............................................................................................A-1 Appendix B - Preventive Maintenance .......................................................................B-1 Appendix C - System Components ............................................................................C-1 Appendix D - Safety Data Sheet ................................................................................D-1

1.0 Introduction

Thank you for choosing ProAct Services for your environmental treatment system. We know there are a lot of choices on the market today…and want to congratulate you for making the right choice! We at ProAct Services Corporation are confident in our products since they are designed and built to exceed customer expectations. We strive to be a “proactive” company that delivers the highest quality products and customer service.

This Operations and Maintenance Manual (OMM) was prepared to acquaint you with the operation and maintenance of your ProAct Water Treatment System (WTS), and to provide you with important safety information. Please study the entire OMM. It will answer most of your questions about the WTS. If you require more information or assistance, please contact ProAct Services Corporation.

PROACT SERVICES CORPORATION

Phone 888.993.1179 www.proact-usa.com

Note:

All information, illustrations, and specifications in this OMM are based upon the latest product information available at the time of printing. We reserve the right to make changes at any time without notice.

Keep this OMM with the system at all times

2.0 Cautions, Warnings and Hazards

This section summarizes the hazards associated with using this WTS.

IT IS VERY IMPORTANT TO READ THIS

SECTION FIRST!

IT IS VERY IMPORTANT TO READ THE

APPLICABLE ORIGINAL EQUIPMENT

MANUFACTURER’S (OEM) MANUAL

BEFORE SERVICING OR ADJUSTING ANY

COMPONENT!

IT IS VERY IMPORTANT TO CONSULT THE

SAFETY DATA SHEET FOR ANY CHEMICAL

USED OR TREATED WITH THIS SYSTEM!

2.1 Safety Definitions

Statements in this OMM presented in boxes like those below are especially significant:

WARNING

WARNING means a potentially hazardous situation which if not avoided, could result in death or serious injury.

CAUTION

CAUTION means a potential situation which if not avoided, could result in equipment or property damage.

2.2 Potential Hazards

Install, service, run and demobilize this system carefully. Stop work immediately if an unsafe condition is observed, and do not proceed until the hazard has been resolved.

This section summarizes some hazards, but other hazards may exist that are not described.

Wear personal protective equipment (PPE) suited to the current activity and conditions.

Minimum includes sleeved shirt, long heavy trousers, safety-toed work boots high-visibility vest shirt or jacket and safety glasses.

Be alert and careful and ask knowledgeable personnel about what is or is not a hazard.

Contamination The fluids being treated by this system may contain contaminants that may enter the body through inhalation, ingestion or skin contact. Some contaminants may cause short-term or long-term injury or illness. Be careful when sampling and servicing the system.

Take extreme care when sampling and servicing the system. Wear appropriate personal protective equipment (PPE), such as chemical-impervious gloves, safety glasses, face shields, or aprons to avoid exposure to contaminants.

Electricity This treatment system contains high and low voltage components. Electricity may cause injury, including burns, electrical shock or death by electrocution.

Do not disassemble any electrical parts without properly securing the power. When in doubt, consult a professional electrician.

The electrical system for this unit is configured for a specific power supply. Failure to connect the correct power will result in system damage.

High Pressure This system runs under water pressure up to 250 psi or more, and the air compressor operates at pressures of 125 psi or more. High pressure leaks or breaks are possible.

Objects, liquids or gases propelled by these pressures may cause injury or even death.

Do not adjust any valves or fittings without taking proper precautions.

Hot Surfaces Motors may be hot during and immediately after operation. Contact with hot surfaces may cause injury. Extreme heat may ignite combustible material.

Do not service a motor while it is running. Avoid contact with hot surfaces. Keep combustible material away from motors.

Lifting Back strain and other injuries can occur when lifting heavy objects such as spent bag filter socks, bags of sand, etc. Use proper lifting techniques. Heavy objects may require two people or mechanical assistance.

Use proper lifting techniques or assistance to avoid back strain or other injury.

Moving Parts Motors, pumps and other components may have moving parts. If fingers, clothing, hair or jewelry are caught in moving parts, injury or death may result.

Do not service motor while running. Do not run equipment unless all protective shields are securely installed. When servicing equipment, avoid loose clothing, hair or jewelry.

Noise This system is loud when running. Exposure to loud noises may cause hearing loss.

Use a smart phone app or other instrument to measure noise. If over 85 dB, wear hearing protection. If over 95 dB, wear double hearing protection. Take breaks in a quieter place away from noisy equipment.

Other Hazards Depending on the nature of the job, media used, site characteristics and additional equipment used, there may be hazards not described here.

Please be careful and ask knowledgeable personnel if there are any doubts about what is or is not a hazard.

Slipping, Tripping, and Falling Walking surfaces may be slick or uneven. Use proper footwear and caution to help prevent injury. Maintain neat and orderly work areas. Properly store and secure all unused tools and supplies.

Use caution, proper footwear, good housekeeping, and cones around hazards to avoid injury from slips, trips and falls.

Temperature

This system cannot process fluid hotter than 140°F. Hotter fluid will damage components.

Anti-scalent Chemical This system uses an anti-scalent chemical, which may be hazardous if misused.

Wear proper PPE, including gloves, goggles and respiratory protection if needed. Avoid breathing or eating chemical. Avoid contact with eyes, skin or clothing.

Read the SDS in Appendix D carefully for important health and safety information and precautions needed.

Unexpected starts Components with automatic control, such as pumps, may restart unexpectedly. Turn off and de-power components before servicing them.

Lock out and tag out components before servicing them.

3.0 System Description

This section explains how water moves through the system. This system is a collection of components working together. If one component fails, it may shut down other components or the entire system. Understanding the overall system helps troubleshoot.

3.1 Theory of Operations

The drawings in Appendix A show tag identifiers.

a. System components upstream of the ProAct system are (in order of primary treatment water flow):

i. An influent weir tank; and

ii. Two influent frac tanks.

b. The ProAct system water-bearing components are (in order of primary treatment water flow):

i. A transfer pump (TP1), draws water from the influent frac tanks;

ii. A 2-18 sand filter (Pods 1 and 2), which removes particulates;

iii. Two 2-stage bag filters in series, which remove smaller particulates;

iv. An anti-scalant injection system; and

v. A reverse osmosis system, from which treated water (permeate effluent) flows; and

vi. A discharge line with flow meter, pressure transmitter, and sample port which marks the end of the ProAct system.

c. Secondary flows include:

i. A sand filter bypass line;

ii. A sand filter backwash line; and

iii. A concentrate effluent line, leaving the RO system.

iv. The sand filter backwash line and concentrate effluent line run into the influent weir tank.

In addition, many valves, gauges, and transmitters control flow and allow the operator to monitor system operations. Water leaving the ProAct system flows into the three effluent frac tanks (by others).

d. ProAct non-water-bearing components are:

i. A control panel with a programmable logic controller (PLC);

ii. An air compressor for operating the sand filter backwash valves and for blowing down the bag filters; and

iii. Trailer accessories, such as heater, fan and lights.

3.2 System Layout

The major components of the system are listed below.

Table 3.2.1 Major Components Component Process and Instrumentation Diagram (P&ID) Number Control Panel:

• CPU

• I/O Modules

• HMI

• Power Supply

Transfer Pump TP1 Sand Filter Bag Filter Air Compressor Reverse Osmosis System R.O. Chemical Drum Flow Transmitters FT1, FT2, FT3 Pressure Transmitters PT1 – PT8 Pressure Indicators PI1 – PI17 Automated Valves AV1, AV2, AV3 Process Valves PV1 – PV16 Process Isolation Valves PIV1 – PIV8 Bypass Loop Valve BLV TP1 Blow Down Valve BDV1, BDV2, BDV3, BDV4 Air Bleed Valves ABV1, ABV2 Sample Ports SP1 – SP7 Drain Valves D Level Switch High High LSHH1 Level Switch Low LSL2

4.0 System Control

This section describes the controls for certain major system components.

4.1 Control Panel

The control panel for this system has an HMI touch screen, zip port, lights, and switches as shown in the figure below. The HMI screens are described in the next section. The lights and switches are described below.

Figure 4.1.1 Control Panel

Figure 4.1.2 Control Panel Layout View

Table 4.1.1 Control Panel Layout Type Color Label Purpose Light Green POWER The control panel has power

Switch Black C-FAN Turn the control room fan to either Hand, OFF, or Auto (controlled by thermostat)

Switch Black P-FAN Turn the process room fan to either Hand, OFF, or Auto (controlled by thermostat)

Light Yellow E-STOP READY The ESD switches have been pulled out and E-STOP RESET button pushed.

Light Red SYSTEM ALARM There is a fault condition, check the HMI alarm screen for details

Button Black E-STOP RESET Reset control panel after ESD knob has been set to run position (pulled out)

Light Yellow SYSTEM WARNING Active system alarm

Switch Red/Yellow EMERGENCY STOP Immediately shuts system down in case of emergency

Light Green SYSTEM ALARM CLEAR No active alarms

4.2 Allen Bradley CompactLogix & Red Lion Touchscreen

The PLC actively monitors and controls the treatment system. The PLC controls system operations in proper response to system conditions. The PLC gets inputs from transmitters and switches, then signals the pump to start or stop and valves to open or close.

The PLC also safeguards the system. Automatic shutdowns programmed into the PLC protect operation. During fault conditions, the PLC trips an alarm and shuts down malfunctioning component(s) or, if needed, the entire treatment system.

The operator communicates with the PLC through human-machine interface (HMI) screens, which are described in the following pages.

All screens have a MENU button in the lower left corner. Press this button to return to the Main Menu screen. An alarm banner at the bottom of each screen cycles through active warnings and alarms. Blue arrows on many screens let the user go to the upstream or downstream screen.

a. Main Menu Screen The figure below shows the system Main Menu screen. Press the green buttons to display conditions for different parts of the system. Press the other buttons to go to the corresponding screen.

Figure 4.2.1 Main Menu Screen

Table 4.2.1 Main Menu HMI Touchscreen Pages/Buttons

INFLUENT

SAND FILTERS

BAG FILTERS

RO

VIEW TRENDS TOTALS MODE SELECT ALARMS System Setup

Logout

Menu Button Press to return to the Main Menu screen

Alarm Banner Cycles through active warnings and alarms

b. Influent Screen This screen shows the level switch for the trailer Floor Sump. It also shows the status of TP1, AV1 and AV2 and the measured values for PT1, PT2, PT8, (Sand Filter) DP, and FT3.

Figure 4.2.2 Influent Screen

Table 4.2.2 Influent Screen Displayed Data (Real-time) Description FOOR SUMP (LSHH1) Floor Sump float status TP1 Pump status on/off PT1 (psi) Pressure downstream of TP1 PT2 (psi) Pressure at sand filter influent PT8 (psi) Pressure at air compressor DP (psi) Differential pressure across Sand Filter Pods AV1 (position) Sand Filter automated valve position AV2 (position) Sand Filter automated valve position FT3 (gpm) Backwash Effluent Flow rate from Sand Filter Pods

c. Bag Filters and RO Screen This screen shows the system pressure at the bag filters, RO Concentrate, and RO Permeate. This screen also shows the status of AV3 and the flow at FT1 and

FT2.

Figure 4.2.3 Bag Filters and RO Screen

Table 4.2.3 Bag Filters and RO Screen Displayed Data (Real-time) Description Chemical Feed Tank (LSL) Chemical Feed Tank float status RO System (Start, Lockout, Alarm) RO System status DP (psi) Differential Pressure across Bag Filters PT3 (psi) Pressure upstream of Bag Filters 1 and 2 PT4 (psi) Pressure upstream of Bag Filters 3 and 4 PT5 (psi) Pressure downstream of Bag Filters 3 and 4 PT6 (psi) Pressure of RO Permeate effluent PT7 (psi) Pressure of RO Concentrate effluent AV3 (position) Automated Valve upstream of RO System FT1 (gpm) Flow rate of RO Permeate Effluent FT2 (gpm) Flow rate of RO Concentrate Effluent

d. Mode Select and Hand Setpoints Screen This screen gives the user the ability to see the status and change modes on TP1, AV1, AV2, and AV3 as well as adjust the setpoint for AV3 so that the system controls its position.

Figure 4.2.4 Mode Select and Hand Setpoint Screen

Table 4.2.4 Mode Select and Hand Setpoint Screen Component Column Label Interaction Options TP1 Change Mode To: Select HAND/OFF AUTO AV1 Change Mode To: Select OPEN/CLOSE/AUTO AV2 Change Mode To: Select OPEN/CLOSE/AUTO AV3 Change Mode To: Select MANUAL/CLOSE/AUTO

e. Runtime, Start, and Flow Totals Screen This screen shows current and historic totals for system components.

Totalization periods provided are day, week, month, year, and cumulative.

Historic periods are previous day, previous week, previous month, previous year and trip total. The trip total can be reset by pushing the reset button. Transfer pump (TP1) run time is shown in Hrs, liquid flow meters (FT1, FT2, and FT3) values are in gal. or k-gal.

Figure 4.2.5 Runtime, Start, and Flow Totals Screen

Table 4.2.5 Runtime, Start, and Flow Totals Screen Component Description TP1 Pump TP1 run hours (day/week/month/year/accumulated) FT1 Flow total for RO Permeate Effluent (day/week/month/year/accumulated) FT2 Flow total for RO Concentrate Effluent (day/week/month/year/accumulated) FT3 Flow total for Backwash Effluent (day/week/month/year/accumulated)

f. ALARM Screen Alarms are displayed on this page. See Section 6.0 Troubleshooting for a table of faults and alarms. The PREV and NEXT buttons allow the user to move from screen to screen to see a history of alarms. Press the red ALARM RESET button to reset the alarms after the fault condition is resolved.

Figure 4.2.6 ALARM Screen

Table 4.2.6 ALARM Screen Buttons

PREV NEXT Toggle up and down through individual alarms on this screen.

Mute Mute will quiet an active alarm Accept Used for navigation of the screen

ALARM RESET Reset alarms, only if the fault condition is resolved.

MENU Go to the MAIN screen.

g. System Setup Screens These screens are password protected and should only be changed by knowledgeable personnel. These pages hold the settings for system warnings, alarms, and delays. A brief description of each is given below.

Figure 4.2.7 System Setup Screen 1 (Adjust Level Transmitter Setpoints)

Table 4.2.7 Typical SETUP Screen Buttons SETTING Enter value in these spaces to change the associated setting.

Go to the previous SETUP screen.

Go to the next SETUP screen.

Figure 4.2.8 System Setup Screen 5 (Adjust Alarm Setpoints)

Figure 4.2.9 System Setup Screen 6 (Adjust Alarm Setpoints)

Figure 4.2.10 System Setup Screen 7 (Adjust Alarm Setpoints)

Table 4.2.8 System Setup Pages

Setup Configuration Field Type Description

Screen 1 - ADJUST LEVEL TRANSMITTER SETPOINTS

Sand Filter Backwash Setpoint Operational Setpoint

Sand Filter runs Backwash when differential pressure reaches this set value (Dpsi)

Sand Filter Call Backwash TP1 Cycle Time Setpoint Operational Setpoint Sand Filter runs Backwash when TP1 runs for set value (minutes)

Sand Filter Backwash Time Setpoint Operational Setpoint Sand Filter runs backwash for set value (seconds)

Automated Valve 3 Auto Pressure Setpoint Operational Setpoint Automated Valve 3 closes at set value (psi)

Automated Valve 3 Manual Position Setpoint Operational Setpoint Automated Valve 3 is manually positioned to set value (%)

Screen 5 - ADJUST ALARM SETPOINTS

Transfer Pump 1 Effluent Pressure Alarm Delay Setpoint Alarm Delay Setpoint Alarm delay time (sec.) for TP1 effluent pressure

Transfer Pump 1 Effluent Pressure Hi-Hi Alarm Setpoint Alarm Setpoint High high alarm limit for effluent pressure (psi)

Transfer Pump 1 Effluent Pressure High Alarm Setpoint Alarm Setpoint High alarm limit for effluent pressure (psi)

Transfer Pump 1 Effluent Pressure Low Alarm Setpoint Alarm Setpoint Low alarm limit for effluent pressure (psi)

Transfer Pump 1 Effluent Pressure Lo-Lo Alarm Setpoint Alarm Setpoint Low low alarm limit for effluent pressure (psi)

Sand Filter Influent Pressure Alarm Delay Setpoint Alarm Delay Setpoint Alarm delay time (sec.) for Sand Filter influent pressure

Sand Filter Influent Pressure Hi-Hi Alarm Setpoint Alarm Setpoint High high alarm limit for influent pressure (psi)

Sand Filter Influent Pressure High Alarm Setpoint Alarm Setpoint High alarm limit for influent pressure (psi)

Sand Filter Effluent/Bag Filter Lead Influent Pressure Alarm Delay Setpoint

Alarm Delay Setpoint Alarm delay time (sec.) for Sand Filter effluent/ Bag Filter influent pressure

Sand Filter Effluent/Bag Filter Lead Influent Pressure Hi- Hi Alarm Setpoint

Alarm Setpoint High high alarm limit for Sand Filter effluent/ Bag Filter influent pressure (psi)

Sand Filter Effluent/Bag Filter Lead Influent Pressure High Alarm Setpoint

Alarm Setpoint High alarm limit for Sand Filter effluent/ Bag Filter influent pressure (psi)

Screen 6 – ADJUST ALARM SETPOINTS

Bag Filter Lead Effluent/Bag Filter Lag Influent Pressure Alarm Delay Setpoint

Alarm Delay Setpoint

Alarm delay time (sec.) for Bag Filter Lead effluent/Bag Filter Lag Influent pressure

Bag Filter Lead Effluent/Bag Filter Lag Influent Pressure Hi-Hi Alarm Setpoint

Alarm Setpoint High high alarm limit for Bag Filter Lead effluent/Bag Filter Lag Influent pressure (psi)

Bag Filter Lead Effluent/Bag Filter Lag Influent Pressure High Alarm Setpoint

Alarm Setpoint High alarm limit for Bag Filter Lead effluent/Bag Filter Lag Influent pressure (psi)

Bag Filter Lag Effluent/RO Influent Pressure Alarm Delay Setpoint

Alarm Delay Setpoint Alarm delay time (sec.) for Bag Filter Lag effluent/RO influent pressure

Bag Filter Lag Effluent/RO Influent Pressure Hi-Hi Alarm Setpoint

Alarm Setpoint High high alarm limit for Bag Filter Lag effluent/RO influent pressure (psi)

Bag Filter Lag Effluent/RO Influent Pressure High Alarm Setpoint

Alarm Setpoint High alarm limit for Bag Filter Lag effluent/RO influent pressure (psi)

RO Permeate Discharge Pressure Alarm Delay Setpoint Alarm Delay Setpoint Alarm delay time (sec.) for RO Permeate discharge pressure

RO Permeate Discharge Pressure Hi-Hi Alarm Setpoint Alarm Setpoint High high alarm limit for RO Permeate discharge pressure (psi)

RO Permeate Discharge Pressure High Alarm Setpoint Alarm Setpoint High alarm limit for RO Permeate discharge pressure (psi)

RO Concentrate Discharge Pressure Alarm Delay Setpoint

Alarm Delay Setpoint Alarm delay time (sec.) for RO Concentrate discharge pressure

RO Concentrate Discharge Pressure Hi-Hi Alarm Setpoint Alarm Setpoint High high alarm limit for RO Concentrate discharge pressure (psi)

RO Concentrate Discharge Pressure High Alarm Setpoint Alarm Setpoint High alarm limit for RO Concentrate discharge pressure (psi)

Screen 7 - ADJUST ALARM SETPOINTS

Air Compressor Pressure Alarm Delay Setpoint Alarm Delay Setpoint Alarm delay time (sec.) for Air compressor pressure

Air Compressor Pressure High Alarm Setpoint Alarm Setpoint High alarm limit for Air Compressor (psi)

Air Compressor Pressure Low Alarm Setpoint Alarm Setpoint Low alarm limit for Air Compressor (psi)

Sand Filter Delta Pressure Alarm Delay Setpoint Alarm Delay Setpoint Alarm delay time (sec.) for Sand Filter delta pressure

Sand Filter Delta Pressure Hi-Hi Alarm Setpoint Alarm Setpoint Alarm delay time (sec.) for Sand Filter delta pressure

Sand Filter Delta Pressure High Alarm Setpoint Alarm Setpoint High alarm limit for Sand Filter delta pressure (psi)

Lead Bag Filter Delta Pressure Alarm Delay Setpoint Alarm Delay Setpoint Alarm delay time (sec.) for Lead Bag Filter delta pressure

Lead Bag Filter Delta Pressure Hi-Hi Alarm Setpoint Alarm Setpoint High high alarm limit for Lead Bag Filter delta pressure (psi)

Lead Bag Filter Delta Pressure High Alarm Setpoint Alarm Setpoint High alarm limit for Lead Bag Filter delta pressure (psi)

Lag Bag Filter Delta Pressure Alarm Delay Setpoint Alarm Delay Setpoint Alarm delay time (sec.) for Lag Bag Filter delta pressure

Lag Bag Filter Delta Pressure Hi-Hi Alarm Setpoint Alarm Setpoint High high alarm limit for Lead Bag Filter delta pressure (psi)

Lag Bag Filter Delta Pressure High Alarm Setpoint Alarm Setpoint High alarm limit for Lead Bag Filter delta pressure (psi)

h. Maintenance Options (Setup Screen 2) This screen allows the user to manually adjust the time/date and screen contrast as well as calibrate the touch screen.

Figure 4.2.11 System Setup Screen 2 (Maintenance Options)

Table 4.2.9 Maintenance Options

12:00:00 AM 01-01-97 Enter time and date in this space.

CALIBRATE TOUCHSCREEN Press this button, and then follow the directions on the screen to set the touchscreen accuracy.

UP DOWN Press these buttons to change the screen contrast setting up or down.

Go to the previous SETUP screen.

Time and Date Setting

Screen Calibration Button

Screen Adjustment Button

Arrow Buttons Alarm Banner

MENU Button

i. Maintenance Options This screen has the controller security features. Use this screen to change or add users and set the password.

Figure 4.2.12 Maintenance Options

Table 4.2.10 Maintenance Options Screen Buttons

USER MANAGER Shows who is using screen.

SET PASSWORD Press this button, and then follow the directions on the screen to change the HMI password.

PREV NEXT Toggle up and down through individual options on this screen.

Go to the previous SETUP screen.

Screen

Set Password Button

Navigation Buttons

Arrow Button

j. Chart Pages The next three screens show trend graphs for various WTS parameters.

Figure 4.2.13 Typical CHART Screen

Table 4.2.11 Typical CHART Screen Buttons

<< Press this button to move to the first page of the chart.

>> Press this button to move to the last page of the chart.

< Press this button to move the previous chart page.

> Press this button to move the next chart page.

Live Press this button to see the current parameter readings.

In Out Press these buttons to zoom view in or out.

Go to the previous SETUP screen.

Table 4.2.12 Sensors and Transmitters Associated with Each CHART Screen Screen Associated Sensors and Transmitters

PT CHART PT1 – PT8

DPT CHART Sand Filter / Bag Filter Differential Pressures

FM CHART FT1 – FT3

Screen

Navigation Buttons

Arrow Buttons

k. Touch Calibration Use this screen to calibrate touch accuracy. Follow the instructions on the screen.

Figure 4.2.14 Touch calibration Screen

4.3 Transfer Pump

TP1 moves water into and through the system. The PLC monitors system conditions and controls the pump accordingly. The pump has 3 modes (HAND – OFF – AUTO) chosen using the touchscreen. The table below describes the 3 operational modes for TP1.

Table 4.3.1 TP1 Operational Modes

Mode Run Stops when HAND Continuous After 10 minutes OFF Never AUTO TP1 effluent pressure (PT1) is low or high.

Auxiliary component triggers a shutdown.

ESD button is pushed “IN” Downstream PT2-PT8 trips Hi-Hi alarm.

Differential pressure trips Hi-Hi alarm.

RO System alarm.

Floor Sump Level Hi-Hi.

4.4 Anti-scalent Drum

This drum fill level is visual only and will need to be checked periodically. The chemical used is Vitec® 3000 which is a proprietary liquid antiscalant/dispersant designed to inhibit scale and disperse colloidal particles in cellulose acetate and polyamide membrane separation systems.

5.0 Procedures

This section describes common procedures required to operate this system. The first procedure described is emergency shut-down. The remaining procedures are in roughly the sequence used.

5.1 Emergency Shut-Down Procedure

There are two RED Emergency Shutdown (ESD) buttons labeled EMERGENCY STOP inside this system trailer, one is located on the control panel door and the other is located near the pump TP1 and to the right of the process room door. Push IN the ESD button to shut down the entire treatment system and any components interconnected to it.

Figure 5.1.1 Emergency Stop Button(s) (below)

Another way to shut off the system is to pull DOWN the main power disconnect switch on the breaker box located outside and on the front of the WTS trailer. Know where the stop devices are before operating the system.

System ESD Buttons, Push IN to stop system.

Figure 5.1.2 Power Disconnect Switch

Box 5.1.1 Emergency Shut-down Procedure

If user CAN access the control panel or process room, then…

1. Push IN the ESD button on the control panel. OR

2. Push IN the ESD button located next to the process room door, near the pump TP1.

3. Contact the appropriate emergency response personnel.

If user CANNOT access the control panel or process room, then…

1. Pull DOWN the main power disconnect switch on the outside of the trailer.

2. Contact the appropriate emergency response personnel.

If user CANNOT approach the unit, then…

1. Get away from the unit.

2. Contact the appropriate emergency response personnel.

Pull DOWN to stop system.

Black part of the handle will be most visible when the switch is off.

5.2 Placement

a. Pull the trailer onto a level area with firm ground.

b. Use cribbing and other devices to ensure the ground under the trailer will hold the trailer even in wet weather and when it is full of water.

c. Place the trailer and external components (pump skid, etc.) according to the

Work Plan and/or drawings.

d. Connect components with hoses, pipes and other plumbing components.

e. Ground all components as needed.

f. Interconnect all components as needed.

5.3 Electrical Connections

This system needs an external power source; it has no generator. The electrical system is currently configured for a specific configuration. The box below gives details on the system’s current electrical configuration.

The electrical system for this unit is configured for a specific power supply. Failure to connect the correct power to the remediation system will result in substantial damage.

ProAct Services recommends using a professional electrical contractor or a certified ProAct technician to connect the main power supply to this remediation system.

Never power up the system unless absolutely certain the correct power supply is connected.

Severe damage to the electrical components is likely if the wrong power supply is connected and the system is powered up.

The correct power supply for this system is as follows:

Power Supply 480-3-60, 3-wire Service: 200 A Maximum Fuse: 125 A

FLA: 92 A

Follow these steps to connect the system to a power source:

a. Turn OFF the unit main power disconnect switch.

b. Shut OFF all circuit breakers in the control panel and in the single-phase breaker box to the left of the control panel.

c. Connect the correct electrical power to the trailer main disconnect.

d. Have a qualified person use a multimeter and verify the voltage is correct. It can often be useful to record these voltages.

e. Turn ON the main power disconnect switch.

f. Turn ON the Main Control Panel breaker that supplies power to the transformer.

g. Bump test TP1 (3 phase) to ensure proper motor rotation.

i. Have a qualified person open the Main Control Panel. Exercise caution -the panel is live.

The panel is live. Touching components or wires could result in electrical shock, burns or electrocution.

ii. Briefly switch TP1 to HAND using the control panel mode select screen.

iii. Have an assistant verify that the motor rotates in the proper direction shown by the arrow on the pump housing.

iv. If rotation is correct, go to Step l, otherwise go to Step h.

h. Turn OFF the Main Control Panel breaker that supplies power to the transformer.

i. Turn OFF the main power disconnect switch.

j. Have an electrician swap and 2 of the 3 main power (hot) lines.

k. Go to Step e.

l. The system is properly connected to the main power supply.

5.4 Startup Sequence

Follow these steps to turn on the WTS electrical components. If an alarm is triggered, a component fails to operate, a leak is detected, or any other malfunction is observed, stop the WTS, troubleshoot the problem and resolve before continuing.

1. Set the Reverse Osmosis unit (RO) controller to desired operation BEFORE starting the entire system. (Please see OEM Operation and Maintenance Manual for specific startup criteria of the RO unit).

2. Ensure all filters have elements/socks.

3. Set valves to recirculation configuration to prevent discharge until WTS is checked.

4. Follow Steps a–g for each of the system units. Start at the beginning of the treatment train and move downstream.

a. If the unit has a power switch, turn it to “ON”

b. If there is a 3-way or 2-way switch, turn the component to “ON” or

“HAND.”

c. If the associated component starts running, go to step d, otherwise, troubleshoot.

d. Prime pump, if needed.

e. Check all plumbing connections and resolve/repair any leaks.

f. Turn switch to “OFF.”

g. Repeat leak test for all components in the treatment train.

5. After verifying that all components work, and there are no leaks, turn all 3-way switches to “A” or “H,” and turn all 2-way switches to “OFF” or “ON.”

6. Continue to recirculate, or set valves to discharge into the effluent tanks, as desired.

7. Record all gauge readings.

5.5 Cold Weather Operation

Water can accumulate in the filters/membranes, filter media, pumps and plumbing. If the water in these components freezes, system damage is likely. Do not allow the machine to freeze unless it has been totally drained for at least 8 hours. The system must also thaw a minimum of 24 hours before starting.

This system has components that are sensitive to antifreeze, winterization of the system will require draining all equipment and plumbing completely without the use of antifreeze for storage.

When operating the system in outside air temperatures less than 32°F, protect the system from freezing. Failure to do so will cause equipment damage.

5.6 Normal Shut-down

The system may require shut down (deactivation) for repairs, maintenance, or general servicing. ProAct Services recommends these steps:

1. Before deactivating the system, record all flow rates, pressures, and other system or site conditions if needed.

2. On the control panel mode screen turn all components OFF.

3. Turn OFF all disconnects and breakers in the Control Panel and in Breaker Panel.

4. If treatment is done and the system being removed, go to step 6. Otherwise, go to step 5.

5. Close all valves in the system.

6. Open all valves, and drain all equipment and plumbing.

6.0 System Faults and Troubleshooting

6.1 Touchscreen Warning and Alarm Messages

The system control panel has fault condition lights to warn the user of certain fault conditions; they also help troubleshoot. The table below describes faults that activate the lights and the associated system response.

Table 6.1.1 Alarms and Warnings

Alarm Text on Touch Screen Description Text Background Warning Alarm

WARNING - PLC Battery is Low, replace battery Allen Bradley PLC battery is low Yellow X

WARNING - Analog Input Signal is out of range An analog Input signal is out of range (3.8mA>AS>20mA) Yellow X

WARNING - Analog Output Signal is out of range An analog output signal is out of range (3.8mA>AS>20mA) Yellow X

ALARM - System Power Failure Control system main line power was interrupted Red X

ALARM - PLC Communication Failure Allen Bradley PLC communication link is down Red X

ALARM - Auxiliary Input Auxiliary contacts input opened Red X

ALARM - System Emergency Stop Emergency stop was triggered Red X ALARM – System Lockout – Contact ProAct Services System access is blocked Red X

ALARM - A Device has been in Hand Mode for 10 minutes Any component in hand mode for 10 minutes Red X

ALARM - Reverse Osmosis System Alarm The Reverse Osmosis System has triggered an alarm Red X

ALARM - Floor Sump High Level The floor sump drain is signaling high level Red X

Alarm Text on Touch Screen Description Text Background Warning Alarm

WARN –“Any transmitter” Overrange Analog signal over range (>20mA) Yellow X

WARN – “Any transmitter” Underrange Analog signal under range (<4mA) Yellow X

ALARM - Transfer Pump 1 Effluent Hi-Hi Pressure TP1 effluent pressure is high high (PT1) Red X

WARN - Transfer Pump 1 Effluent High Pressure TP1 effluent pressure is high (PT1) Yellow X

WARN - Transfer Pump 1 Effluent Low Pressure TP1 effluent pressure is low (PT1) Yellow X

ALARM - Transfer Pump 1 Effluent Lo-Lo Pressure TP1 effluent pressure is low low (PT1) Red X

ALARM - Sand Filter Influent Hi-Hi Pressure Sand Filter influent pressure is high high (PT2) Red X

WARN - Sand Filter Influent High Pressure Sand Filter influent pressure is high (PT2) Yellow X

ALARM - Sand Filter Effluent/Bag Filter Lead Influent Hi-Hi Pressure

Sand Filter effluent/bag filter lead influent pressure is high high (PT3) Red X

WARN - Sand Filter Effluent/Bag Filter Lead Influent High Pressure

Sand Filter effluent/bag filter lead influent pressure is high (PT3) Yellow X

ALARM - Bag Filter Lead Effluent/Bag Filter Lag Influent Hi-Hi Pressure

Bag Filter lead effluent/bag filter lag influent pressure is high high (PT4) Red X

WARN - Bag Filter Lead Effluent/Bag Filter Lag Influent High Pressure

Bag Filter lead effluent/bag filter lag influent pressure is high (PT4) Yellow X

ALARM - Bag Filter Lag Effluent/RO Influent Hi-Hi Pressure

Bag Filter Lag Effluent/RO Influent pressure is high high (PT5) Red X

WARN - Bag Filter Lag Effluent/RO Influent High Pressure Bag Filter Lag Effluent/RO Influent pressure is high (PT5) Yellow X

ALARM - RO Permeate Discharge Hi-Hi Pressure RO Permeate Discharge pressure is high high (PT6) Red X

WARN - RO Permeate Discharge High Pressure RO Permeate Discharge pressure is high (PT6) Yellow X

ALARM - RO Concentrate Discharge Hi- Hi Pressure RO Concentrate Discharge pressure is high high (PT7) Red X

WARN - RO Concentrate Discharge High Pressure RO Concentrate Discharge pressure is high (PT7) Yellow X

WARN - Air Compressor High Pressure Compressed Air pressure is high Yellow X

WARN - Air Compressor Low Pressure Compressed Air pressure is low Yellow X

ALARM - Sand Filter Differential Hi-Hi Pressure Sand Filter differential pressure is high high Red X

WARN - Sand Filter Differential High Pressure Sand Filter differential pressure is high Yellow X

ALARM - Lead Bag Filter Differential Hi- Hi Pressure Lead Bag Filter differential pressure is high high Red X

WARN - Lead Bag Filter Differential High Pressure Lead Bag Filter differential pressure is high Yellow X

ALARM - Lag Bag Filter Differential Hi-Hi Pressure Lag Bag Filter differential pressure is high high Red X

WARN - Lag Bag Filter Differential High Pressure Lag Bag Filter differential pressure is high Yellow X

WARN - AV3 Position Out-of-Range (<10%) AV3 is positioned out of range of the PLC setting Yellow X

WARN - AV3 Analog Output Error There is an error in the analog output of AV3 Yellow X

ALARM - Transfer Pump 1 Fail to Run TP1 is not running due to error Red X ALARM - Transfer Pump 1 In HAND Mode TP1 is running in hand mode Red X

ALARM - Transfer Pump 1 Overload Tripped The overload for TP1 has been tripped Red X

ALARM - RO System Alarm The Reverse Osmosis System has triggered an alarm Red X

6.2 Troubleshooting

Use these tables to troubleshoot system malfunctions. The troubleshooting guides in the component OEM Manuals are bookmarked in Appendix C. Direct all other technical or unknown problems to a ProAct technician. Please call (231) 843-2711.

Table 6.2.1 Troubleshooting Alarms

Alarm Text On Touch Screen Possible Causes

WARNING - PLC Battery is Low, replace battery PLC battery is low or disconnected, replace battery

WARNING - Analog Input Signal is out of range mA value is out of spec A wiring short or break could cause this

WARNING - Analog Output Signal is out of range mA value is out of spec A wiring short or break could cause this

ALARM - System Power Failure Power failure has exhausted other power backups Disconnect on front of main control panel was left off

ALARM - PLC Communication Failure The Ethernet communications link is down Router does not have power Allen Bradley PLC does not have power

ALARM - Auxiliary Input Wrong fault or wire nut has come loose Auxiliary input is tripped

ALARM - System Emergency Stop An emergency stop was activated by pushing in an ESD switch Sometimes triggered by turning off the main control panel door disconnect

ALARM – System Lockout – Contact ProAct Services Access to the system was blocked Lockout mode needs to be disabled

ALARM - A Device has been in Hand Mode for 10 minutes

Operator has left a critical component in hand operation for too long.

Increase hand alarm delay setting or change component mode

ALARM - Reverse Osmosis System Alarm The control system RO System itself has encountered an error and needs to be checked

ALARM - Floor Sump High Level Water has accumulated in the floor sump

Alarm Text On Touch Screen Possible Causes

WARN –“Any transmitter” Overrange The analog signal from a device is over range (>20mA)

WARN – “Any transmitter” Underrange The analog signal from a device is under range (<4mA)

ALARM - Transfer Pump 1 Effluent Hi-Hi Pressure A downstream obstruction in plumbing Pressure Transducer 1 is faulty

WARN - Transfer Pump 1 Effluent High Pressure A downstream obstruction in plumbing Pressure Transducer 1 is faulty

WARN - Transfer Pump 1 Effluent Low Pressure An upstream obstruction in plumbing Pressure Transducer 1 is faulty

ALARM - Transfer Pump 1 Effluent Lo-Lo Pressure An upstream obstruction in plumbing Pressure Transducer 1 is faulty

ALARM - Sand Filter Influent Hi-Hi Pressure A downstream obstruction in plumbing Sand Filter is blocking flow Pressure Transducer 2 is faulty

WARN - Sand Filter Influent High Pressure A downstream obstruction in plumbing Sand Filter is blocking flow Pressure Transducer 2 is faulty

ALARM - Sand Filter Effluent/Bag Filter Lead Influent Hi-Hi Pressure

A downstream obstruction in plumbing Lead Bag Filter is blocking flow Pressure Transducer 3 is faulty

WARN - Sand Filter Effluent/Bag Filter Lead Influent High Pressure

A downstream obstruction in plumbing Lead Bag Filter is blocking flow Pressure Transducer 3 is faulty

ALARM - Bag Filter Lead Effluent/Bag Filter Lag Influent Hi-Hi Pressure

A downstream obstruction in plumbing Lag Bag Filter is blocking flow Pressure Transducer 4 is faulty

WARN - Bag Filter Lead Effluent/Bag Filter Lag Influent High Pressure

A downstream obstruction in plumbing Lag Bag Filter is blocking flow Pressure Transducer 4 is faulty

ALARM - Bag Filter Lag Effluent/RO Influent Hi-Hi Pressure

A downstream obstruction in plumbing AV3 is closed RO System not functioning correctly Pressure Transducer 5 is faulty

WARN - Bag Filter Lag Effluent/RO Influent High Pressure

A downstream obstruction in plumbing AV3 is closed RO System not functioning correctly Pressure Transducer 5 is faulty

ALARM - RO Permeate Discharge Hi-Hi Pressure An upstream obstruction in plumbing Pressure Transducer 6 is faulty

WARN - RO Permeate Discharge High Pressure An upstream obstruction in plumbing Pressure Transducer 6 is faulty

ALARM - RO Concentrate Discharge Hi-Hi Pressure An upstream obstruction in plumbing Pressure Transducer 7 is faulty

WARN - RO Concentrate Discharge High Pressure An upstream obstruction in plumbing Pressure Transducer 7 is faulty

WARN - Air Compressor High Pressure Air compressor malfunction Air compressor pressure setting adjusted too high

WARN - Air Compressor Low Pressure Air compressor is not working/has no power Air leaking Clogged or dirty air filters

ALARM - Sand Filter Differential Hi-Hi Pressure Sand filter requires backwash Obstruction in plumbing Pressure Transducer 2 and/or 3 faulty

WARN - Sand Filter Differential High Pressure Sand filter requires backwash Obstruction in plumbing Pressure Transducer 2 and/or 3 faulty

ALARM - Lead Bag Filter Differential Hi-Hi Pressure Bag filter requires changeout Obstruction in plumbing Pressure Transducer 3 and/or 4 faulty

WARN - Lead Bag Filter Differential High Pressure Bag filter requires changeout Obstruction in plumbing Pressure Transducer 3 and/or 4 faulty

ALARM - Lag Bag Filter Differential Hi-Hi Pressure Bag filter requires changeout Obstruction in plumbing Pressure Transducer 4 and/or 5 faulty

WARN - Lag Bag Filter Differential High Pressure Bag filter requires changeout Obstruction in plumbing Pressure Transducer 4 and/or 5 faulty

WARN - AV3 Position Out-of-Range (<10%) AV3 is in HAND mode and is out of spec Pressure Transducer 3 setup options need recalibration

WARN - AV3 Analog Output Error An analog output signal is out of range (3.8mA>AS>20mA)

ALARM - Transfer Pump 1 Fail to Run TP1 motor will not operate

ALARM - Transfer Pump 1 In HAND Mode TP1 was left in hand mode for 10 minutes

ALARM - Transfer Pump 1 Overload Tripped TP1 overload contact was tripped

ALARM - RO System Alarm The control system RO System itself has encountered an error and needs to be checked

Table 6.2.2 Troubleshooting Controller Indicator Color/Status Description

RUN

Off No task(s) running; PLC in program mode Green One or more tasks are running; PLC is in the run mode

FORCE

Off No forces enabled

Amber Forces enabled

Amber Flashing One or more input or output addresses have been forced to an on or off state, but the forces are not enabled

BAT

Off Battery supports memory Red Battery may not support memory, replace battery

OK

Off No power Green Controller OK Red flashing Recoverable controller fault

Red Non-recoverable controller fault:

Cycle power; the OK LED should flash red; if LED stays solid red, replace the controller

I/O

Off(1) No activity No I/O or communications configured

Green Communicating to all modules Green flashing One or more modules not responding Red flashing Not communicating to any modules

DCH0

Off User-configured communications active Green Default communication configuration active

Channel 0 Off No activity Green Network activity (DH485) Green flickering Data is being received or transmitted (DF1)

Channel 1 Off No activity Green Network activity (DH485) Green flickering Data is being received or transmitted (DF1)

Table 6.2.3 Troubleshooting Pump Motor Problem Possible Cause Troubleshooting

Pump does not run

Faulty connection of power supply circuit Check power supply circuit

Wrong wiring of control circuit Correct control circuit

Bound shaft Remove cause of obstruction

Mechanical seal faces stuck together Release seal by turning shaft

Faulty motor Repair or replace motor

Damage to bearing Repair or replace any damaged bearing.

Pump does not pump water/ Inadequate quantity

Considerable voltage drop Correct rotation direction

Rotation direction reversed Re-prime the pump

Lack of priming Re-examine the plan

High discharge head Re-examine the plan

Large piping loss Clear foot valve suction

Clogged foot valve Check and repair suction piping

Leakage from suction piping Re-install as per our instructions

Too high suction lift Foot valve in ample immersion

Low water level

Overcurrent

Considerable fluctuation of power supply voltage Throttle flow rate at outlet

Considerable voltage drop Replace any damaged bearing

Low head and overflow rate

Damaged bearing

Problem Possible Cause Troubleshooting

Pump vibrates, excessive operating noise

Beyond rated capacity Reduce flow rate

Cavitation Consult distributor

Improper piping Secure piping again

Damaged bearing. Replace any damaged bearings

Foreign matter clogging cooling fan Remove foreign matter

Pressurizing application Pump starts and soon stops

Too limited pressure switch setting Replace pressure switch to wider range

Check and repair leaks

Pump does not stop Leakage in system Reduce max pressure setting to the lower in pressure switch

Too high pressure setting

Table 6.2.4 Troubleshooting Reverse Osmosis System Problem Possible Cause Corrective Action

Low operating pressure

Insufficient feed water pressure or flow Open the feed pressure, open the feed water valve, check for restrictions.

Clogged pre-filter cartridge Replace the pre-filter cartridge.

High flow rates Close the concentrate valve, check the permeate and concentrate flow rates and adjust if necessary. Excessive permeate flow may indicate a damaged O-ring.

Dirty or fouled membrane elements Flush and clean the membrane elements.

Solenoid valve not opening Clean or replace the solenoid valve.

Pump rotating backwards (three-phase power only) Switch any two of the three-phase leads to the motor starter.

Insufficient electrical power Check the fuses or circuit breaker, measure the voltage.

Pump not operating correctly See the pump instructions.

Low permeate flow rate

Low operating pressure See the possible causes for low pressure.

Dirty or fouled membrane elements Flush and clean the membrane elements.

Operating on cold water less than 55ºF (13ºC)

Install a hot/cold feed water tempering valve if more permeate flow is needed. Operate with a feed water temperature of 72º - 77ºF (22º - 25ºC).

Membrane elements installed backwards or damaged concentrate seal

Install membrane elements in the direction of fluid flow. Flush and clean the machine immediately. Membrane elements with damaged concentrate seals should be cleaned and may be returned for repair.

Flow meter inaccurate Check the flow rate manually with a stopwatch and calibrated container.

Low concentrate flow rate, normal or higher than normal pressure

Concentrate valve plugged Remove the concentrate valve stem and/or disassemble the plumbing.

Clean the valve.

Concentrate outlet line restricted Examine the concentrate line for obstructions or kinks, repair or replace the tubing.

Flow meter inaccurate Check the flow rate manually with a calibrated container.

Pressure does not drop when concentrate valve opened

Dirty concentrate valve Disassemble and clean the plumbing to the valve.

High operating pressure

Recycle or concentrate valve plugged

Disassemble the plumbing to the recycle valve and remove foreign particles. Check the concentrate valve stem.

Inaccurate pressure gauge Replace or calibrate the gauge as required.

Restricted or reduced permeate flow rate See possible causes for low permeate rate.

Excessive pressure drop [over 50 psig (3.4 barg)] (high primary pressure -low final pressure)

Restricted flow after pump outlet Check for blockage of the concentrate flow at the inlets and outlets of membrane element housings.

Telescoped membrane element covering membrane element housing outlet port

Ensure that the anti-telescoping (ATD) is located properly on the membrane element.

Severely fouled or dirty membrane elements Flush the machine, then clean it with detergent.

Water flowing when machine is turned OFF

Inlet solenoid valve not closing or seating properly

Clean or replace the valve. Clean the membrane elements with detergent immediately. Water must not pass through the inlet when the machine is

OFF.

Declining rejection (high permeate conductivity)

Dirty or fouled membrane elements Flush and clean the membrane elements.

O-ring seal broken or damaged Replace the O-ring, check the sealing surfaces on the O-ring groove, interconnectors, and end caps. Replace damaged parts.

Change in incoming water quality Open the concentrate valve and flush. Test the water for pH, hardness, TDS, and iron content. A water analysis should be sent to GE Osmonics.

Inaccurate conductivity monitor or fouled probe

Calibrate the monitor with a solution of known conductivity or check the readings with another conductivity meter. Replace or clean the probe.

Check the connections between the probe and monitor.

Switch ON, unit not operating

Pressurized storage switch or float switch has cut power to machine Check the permeate back pressure or position of float in the storage tank.

Thermal overload in motor has tripped

Allow the machine to cool; check the feed water supply and/or AMP draw to the motor.

No power to machine Check the fuses or circuit breakers, measure the voltage.

Motor and/or pump not operating properly

See pump…