Manual on Reverse Osmosis

(RO) and Pre-treatment

Manual on Reverse Operation
Chapter 1 ........................................................................................................................ 1
Introduction To Membrane filtration .................................................................................................. 1
Chapter 2 ........................................................................................................................ 2
Fundamentals of Reverse Osmosis unit ................................................................................................ 2
Chapter 3 ........................................................................................................................ 8
Components of Reverse osmosis unit ................................................................................................... 8
Chapter 4 ...................................................................................................................... 12
Factors affecting RO Membranes ....................................................................................................... 12
Chapter 5 ...................................................................................................................... 14
Pretreatment........................................................................................................................................ 14
Chapter6 ....................................................................................................................... 18
Operation of pressure filters (PSF, ACF & IRF) ................................................................................ 16
Chapter 7 ...................................................................................................................... 21
RO Plant Operation ............................................................................................................................ 18
Chapter 8 ...................................................................................................................... 21
Chemical Cleaning ............................................................................................................................. 21
Chapter 9 ...................................................................................................................... 23
Troubleshooting RO Plant .................................................................................................................. 23
Chapter10 ..................................................................................................................... 26
Operation of pumps ........................................................................................................................... 26
Chapter 11 .................................................................................................................... 30
Cartridge Filter ................................................................................................................................... 30
Chapter 12 .................................................................................................................... 31
Filter maintenance .............................................................................................................................. 31
Chapter 13 .................................................................... Error! Bookmark not defined.
Electrical Motor Troubleshooting....................................................... Error! Bookmark not defined.
Chapter 14 .................................................................................................................... 33
Membrane Loading ............................................................................................................................ 33
Chapter 15 .................................................................................................................... 33
Data sheet of Equipment..................................................................................................................... 33
Chapter 1
Introduction to Membrane filtration

1.0 Introduction
De-mineralizing is a process of removing dissolved inorganic solids also called
Total Dissolved solids (TDS) from water, There are various processes by which this
can be achieved. They are
Freezing
Distillation
Reverse Osmosis
Electrodialysis
Ion Exchange
Freezing and distillation are phase change method primarily used for sea water
distillation.
Reverse Osmosis (RO), Electrodialysis (ED) and Ion Exchange (IX) are systems are
the most commonly employed systems in Industry.
The selection of the process depends on the following factors
1. TDS of water
2. Product water quality desired.
3. Brine disposal facilities
4. Pretreatment required
5. Need to remove other material like bacteria & viruses.
6. Availability of energy and chemicals required for the process
7. Cost.
The basic process for all the three demineralizing system is same and is

Feed water supply - Source of water and quality

Pretreatment Removal of impurities which may foul demineralizing

Process

Pump Pumping water to the demineralizing process

Process IX, RO, ED

Post Treatment pH adjustment, further demineralizing

Degasification and disinfection

The End use determines the quality of water to be produced. For example
semiconductor industries require ultrapure water, whereas potable water may be of
higher TDS value. Remember that better the quality, higher will be the cost.
Ion exchange process was the most widely used process for demineralizing. This
process is economical at low salinity. Today RO and ED are gaining advantage over
Ion exchange because of deteriorating water quality, water recycling etc
RO and ED are more economical at higher TDS.

1
Chapter 2
Fundamentals of Reverse Osmosis unit
Reverse osmosis is a membrane separation unit. It is the forced passage of water
through a membrane against the natural osmotic pressure to accomplish separation of
water and ions.

2.1 Osmosis
Osmosis is a process which can be defined as a passage of liquid from weak solution
to a more concentrated solution across a semipermeable membrane.
The semipermeable membrane allows the passage of liquid (solvent) but does not
allow solids (solutes) to pass through.

2.2 Explanation.
Let us consider pure water It is in contact with both side of semipermeable membrane.
Pressure and temperature are equal on both sides. It is in equilibrium because there is
no net flow across the membrane. This means that the chemical potential is equal on
both sides. If the soluble salt is added on one side, the equilibrium is disturbed and
there will be an osmotic flow till the chemical potential is disturbed.
When does the equilibrium occur?
Equilibrium occurs when the hydrostatic pressure differential resulting from the
volume changes on both sides is equal to osmotic pressure. This is a solution property
independent of membrane.

2.3 Reverse Osmosis (RO)

Application of external pressure to the salt solution side equal to osmotic pressure will
also cause equilibrium. Additional pressure will raise the chemical potential of water
in the salt solution and cause a solvent flow to pure water side, now at a lower
chemical potential. This phenomenon is called Reverse Osmosis

Applied pressure
Dilute Concentrated
Solution solution

Osmosis Reverse Osmosis

2
2.4 Membrane Characteristics
The basic behavior of Reverse osmosis and Nanofiltration membrane can be
described by the following characteristics
1. Water flux
2. Salt flux
3. Salt rejection rate
4. Recovery rate
2.4.1 Flux
Flux is the amount of water or salt that passes through, a permeate through a unit area
of membrane.
2.4.2 Water flux
The flow of water (product) through a membrane can be expressed by equation
Fw = A(∆p-∆π) equation 1
Where
Fw = water flux (gm/sqcm –sec)
A = water transport coefficient
∆p = differential pressure applied across the membrane (atm)
∆π = Osmotic differential pressure across the membrane.(atm)
2.4.3 Salt flux
The flow of salt through the membrane can be expressed by the equation

Fs = B (C1-C2) equation 2
Where,
Fs =salt (mineral) flux
B =Mineral permeability constant
C1-C2 =Concentration gradient across the membrane.
Refer equation 1 & 2
Water permeability constant A and salt permeability constant B are a characteristic of
a particular membrane that is used and processing it has received.
Water flux is dependent on the applied pressure.
Salt flux is dependent on concentration gradient but is independent of applied
pressure.
2.4.4 Mineral Rejection
The purpose of demineralization is to separate minerals from water. The ability of
membrane to reject mineral is called mineral rejection. Mineral rejection is defined by
the equation

Rejection % = (1- Pc/Fc) *100% equation 3

Where
Pc = product concentration
Fc = Feed concentration
2.4.5 Recovery
Recovery is defined as the percentage of feed flow which is recovered as product
water.
Recovery % = (Pf/Ff) * 100 % equation 4
Where
Pf = product flow
Ff = feed flow.

3
2.5 Parameters affecting feed water performance
Apart from feed water concentration, the membrane performance is affected by the
following performance

1. Applied feedwater pressure

2. Feedwater temperature
3. Permeate recovery ratio
4. Membrane life
5. pH
6. Oxidants

2.5.1 Effect of pressure

Refer to equation 1 from which it is clear that water flux is directly proportional to
applied pressure.
The equation says that if pressure increases then both quality and quantity should
increase. This does happen because there is more water for dilution for the same
amount of mineral.
From equation 2 we can see that if feedwater concentration increases, ∆π also
increases. This will reduce water flux.
If presser is increased there will be force against the membrane at a higher velocity,
forcing greater amount of foulants in the stream to interact at membrane surface. This
can increase the scaling potential of membranes.

2.5.2 Effect of Temperature

Temperature has a significant effect on membrane performance. It is taken into
consideration when designing and therefore should considered during operation.
Essentially the value of water transport coefficient is constant for the given
temperature. As the temperature increases the flux increases. Membrane
manufacturers generally provide Temperature correction factor (TCF)
The TCF is proportional to change in pressure needed to maintain the 25*C flux rate
and is equal to 1 at 25*C.

2.5.3 Effect of pH
The pH of feed water can affect the membrane structure and scaling potential of brine
stream. Cellulose Acetate membranes (CA membrane) are very sensitive to pH
change. It operates in a narrow pH range of 4-6. In fact some CA membranes are so
sensitive that operate in range of 5.5 to 6. Thin film composite membrane made of
polyamide material can withstand higher pressure.
Membrane can hydrolyze at both lower and higher pH. Hydrolysis results in lessening
of mineral rejection capability.
At higher pH (above 7.7) and higher temperature solubility of silica increases
At lower pH (<8) and lower temperature calcium carbonate is soluble. Thus if brine is
saturated with both silica and calcium carbonate, changes in temperature and pH will
cause one or the other to precipitate. Therefore care must be taken to find the best
condition for scale prevention.

4
2.5.4 Effect of Recovery

The recovery rate is affected by two conditions

1. Desired product water quality is influenced by the difference in concentration
between the brine and product. There is a possibility of exceeding product quality
criteria with excessive recovery.
2. Brine should not be concentrated to a degree that would precipitate minerals on
membrane. This effect is known as Concentration polarization.

2.5.5 Tolerance to Oxidants.

Oxidants like chlorine and ozone are added to water to control microbiological growth
and to improve taste and odor. These oxidants can affect membrane.
CA membranes are more chlorine tolerant. TFC membranes do not tolerate Chlorine
and if TFC membrane is used, dechlorination should be included in pretreatment.

2.6 Types of Membrane

Increased use of Reverse Osmosis process and other membrane process has led to
development of variety of membranes. Membranes most widely used in water
treatment are:
1) Cellulose Acetate or CA membrane
2) Polyamide membrane or PA membrane
3) Thin film composite membrane or TFC membrane.

2.6.1 Cellulose Acetate Membrane (CA)

CA membranes are constructed of cellulose acetate or cellulose triacetate or blend.
Though these membranes achieved acceptable results with brackish water but not
with sea water due to compressibility of Membrane at high pressure.
Its use is also limited for the following reason:-
1) Works under a narrow pH range.
2) Is temperature sensitive
3) Performance limitation

2.6.2 Polyamide Membrane (PA)

Polyamide membranes are made of aromatic polyamides, PA membranes works in a
broader pH range and hence it is more resistant to hydrolysis has better salt rejection
and organic rejection and they are non biodegradable. The feed water to PA
membrane should be free from chlorine as they are subject to attack by Chlorine.

2.6.3 Thin film Composite Membrane

The above two membranes are of asymmetric structure are dense, thin layer (salt
rejecting layer) supported by a thick, porous layer. They are both composed of the
same polymer.
TFC membrane consists of three layers are based on polyamide membrane and
consists of poly sulfone membrane as a support for very thin polyamide layer.
Advantages of TFC membrane are:-
1) High flux rate
2) Wider pH range
3) More resistant to chlorine than PA
4) High silica rejection.

5
2.7 Configuration of membrane
Major configurations of membranes are:-
1) Spiral wound
2) Hollow fiber
3) Tubular frame
2.7.1 Spiral Wound
In spiral wound configuration are assembled from flat sheet polymer Membrane and
spacers are wound around the permeate collection tube to produce flow channels for
permeate and feed water. These are the most commonly used in Industrial
application. The advantages of this configuration are:-
1) Simpler plumbing system
2) Easier maintenance
3) Greater design freedom
4) Less prone to fouling
5) Can withstand higher level of pre-treatment upsets.

2.7.2 Hollow Fiber

Hollow fiber contains a bundle of extremely small diameter Membrane tubes which
creates a tremendous membrane area in a small volume. Feed water is fed to the
center of vessel through a porous pipe. The ions get rejected through these hollow
fibers when water permeates the wall and is discharged as product water.
Concentrated reject is collected at the opposite end of the vessel.
One major advantage of CA membranes is that they are more resistant to chlorine and
foulants and is still considered as a first choice for many applications.

2.7.2 Tubular Membrane

Tubular membranes are inserted into or coated onto the inside surface of a porous
tube and are designed to withstand the operating pressure. Feed water enters the end
of the tube permeates through the membrane and is collected and discharged through
a concentrator concentrated reject water leaves through the end of porous tube.

6
 Permeate

Reject brine

Permeate flow
In collectors
Saline water

Fig 2 Schematic of spiral wound module

Saline Permeate
water

Reject Brine
Permeate tube

7
Chapter 3
Components of Reverse osmosis unit
Reverse osmosis unit comprises of following components. The schematic is shown
below. (See fig 3). The unit includes the following components.
1. Pressurization pump
2. Piping
3. Concentrate control valve
4. Sample valve
5. Flush connection
6. Cleaning connection
7. Permeate rinse valve
8. Permeate draw back tank
9. Energy recovery device
10. Membrane
Cleaning
connection
Separate
Flush water
inlet
Membrane
From Array
Pretreatment
PERMEATE

Pump
Discharge
Control Drain
valve
CONCENTRATE
Pressurization
Pump

Concentrate
Control valve

Flush
Cleaning outlet
connection

Fig 3 Schematic of Reverse Osmosis unit

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3.1 Pressurization pump
The pressure required for RO unit can range from 100 psi ( ) to about 1200 psi ( ).
The feed pump used for pressurizing feed water is called the pressurizing pump and is
either a centrifugal pump or a positive displacement pump. Centrifugal pumps are
used for lower pressure. Positive displacement pumps are preferred for higher
pressure. For sea water desalination it is the preferred pump.
The output of centrifugal pump may be throttled by use of throttling valve. This is
often done for new system or after membrane cleaning.
The output of positive displacement pump is not throttled. The pump discharge line
should contain a pressure relief mechanism.

3.2 Piping
Choice of piping material is generally based on the salinity of water. For sea water
desalination high grade stainless steel is used for high pressure lines .
Brackish water use SS304 and low pressure plant (House old RO) use PVC piping.

3.3 Pressure vessel housing

Spiral wound membranes are housed in pressure tube generally called as pressure
vessel housing. The elements are connected in series and held in
Pressure vessel. Generally six elements are housed in one vessel. With later design of
spiral wound membrane seven 40 inch long elements have been placed in single unit.
Seventh element housing is useful if it is necessary to increase the system recovery
marginally.

3.4 RO Array
The array structure is determined during the design process by the hydraulics of the
system. The most common arrangement has six membranes in each pressure vessel.
This arrangement recovers as permeate 50% of the water fed to it. For a 75%
recovery, two stages are required. When using two stages, 50% of the feed is
recovered in the first stage. The remaining 25% is recovered by the second stage, as it
yields a 50% recovery on the concentrate from the first stage. The largest number of
stages normally used is a three-stage unit. If pressure vessels with fewer than six
elements are used the recovery per stage is decreased

3.5 Valves
Various valves are used in RO. The major valves are
1. Pump inlet
2. 1st stage inlet
3. Product outlet
4. Reject outlet
5. System flush inlet & outlet
6. Stage isolators
7. Cleaning connection
8. Permeate rinse
9. Sample valves

9
 3.5.1 Concentrate control valve
A regulating valve located in the concentrate line (reject) provides a means of
applying backpressure to membranes. Positioning this valve in conjunction with
pump discharge valve will set the permeate and concentrate flow rate.

3.5.2 Sample Valve

Sample valve is located on feed, permeate and concentrate line. It is so located that
sampling is possible during all mode of operation like servicing, flushing or
cleaning.

3.6 Cleaning connection

All units should have cleaning connections for each bank of permeators or pressure
vessels connected in parallel , isolation valves for each bank would allow for one
bank to soak while the upstream or downstream bank is cleaned.
Permeate Rinse
Provision for sending the permeate from one bank or unit proves useful when
troubleshooting. Some process require that permeate achieve quality by rinsing after
shutdown period.

3.7 Membranes
RO membranes are commercially available in the following configuration
1. Spiral wound
2. Hollow fiber
3. Tubular
4. Plate & frame
Tubular & plate & frame are used more in food and dairy industries.
Spiral wound and hollow fiber are the most widely used Membranes in water
treatment.

3.7.1 Spiral Wound

The spiral wound module as shown is constructed of large membrane sheets

covering both sides of a porous backing material that collects the permeate
and is sealed with glue on three of the four edges of the laminate. The laminate is
also sealed to a central tube which has been drilled to allow the demineralized water
to enter. A spacer material separating membrane surface is added which acts as a
brine spacer. Several of these membrane envelopes with brine spacer are rolled up to
form a spiral wound module. The modules are then loaded into pressure vessel.
Saline water enters the end of the module through voids between membrane
envelopes provided by mesh spacer. Under high pressure , water is forced from the
brine in the spacer voids through the membranes and conveyed by the enclosed
porous permeate collectors to the perforated tube in the center of module. Reject
brine discharge from the spacer voids at the outlet end of tube.

3.7.2 Hollow fine Fiber

The hollow fine fiber membranes are made of aromatic polyamide. The fiber is
about the size of human hair. The outside diameter of the fiber is approximately 85
to 100 µm and inside diameter of 42 µm . This membrane bundle is contained in a
cylindrical housing called permeator. Saline water enters the module through a
central perforated feed tube and flows readily through the fiber bundle toward the

10
 outer shell of the cylinder. Under high pressure, water from the surrounding brine
enters the hollow fibers and exits from their open ends at the outlet end of module.
Reject brine arriving at the outer shell of the pressure vessel is collected by flow
screen and conveyed by the module.

3.8 Membrane element construction.

The membrane element is constructed of parts mentioned below

3.8.1 The Center Tube (CT)

The center tube is also called permeate collection tube. The membrane leaves,
permeate carrier and spacer material is wound around this. The CT provides structural
strength to the element.

3.8.2 Anti telescopic device (ATD)

Anti telescopic device are attached to the end of element. This can be either bonded or
loosely attached top the CT to form an integral part of interconnector. ATDs fill
space between elements in a pressure vessel. It also facilitates in flow of feedwater
from one element to next which helps in preventing pressure build up.

3.8.2 The Interconnector (IC)

The IC connects the center tubes of neighboring elements and directs the flow to one
or both ends of pressure vessel. The IC is connected to CT by O rings.

3.8.2 Product end adapter(EA)

The product end adapter is (EA) is used at both ends if the permeate volume is high.
Otherwise it is provided at only one end. It is more common to find membrane
element with one end plug. The other is sealed with dead end plug (DEP).

3.8.3 Permeate carrier

This is a sheet of material inserted between the backsides of the membranes , forming
a membrane envelope to promote the flow of permeate toward the center tube for
discharge at the ends of the vessel.

3.8.4 Feed spacer

This is the material inserted between neighboring membrane surfaces to create the
best possible flow conditions over the membrane.

11
Chapter 4
Factors affecting RO Membranes
4.1 Scale
Membranes can clog through the formation of scale.
The scale could be due to
1) Calcium carbonate
2) Calcium sulfate
Calcium carbonate scale is normally prevented by proper pH control. pH is normally
kept between 5.5 - 6.0.
Polyphosphate such as SHMP is normally used for preventing sulfate scaling. A
common concentration of polyphosphate is around 4-6 (4 –6 mg/L). The use of poly
phosphate is made to control Fe and Mn is in very low concentration. Poly
phosphate oxidizes the iron and manganese. If concentration of Fe is greater than 1
mg/L then some iron removal method is employed. Poly phosphate also prevents
fluoride crystals.

4.2 Suspended matters, micro organism

Membranes can be affected because of the suspended matter, colloids, coagulants &
flocculent. Filtration and micro filtration, depending upon the suspended matter and
colloidal matter is used as pretreatment of RO feed water. It is also possible for
membrane to get fouled due microorganism. Thus to prevent this, some kind of
disinfectant is used for pretreatment. Chlorination followed by activated carbon is
one of the most common disinfectants used.

4.3 Membrane age

Irrespective of operating conditions, all membranes deteriorate with age.
Manufacture normally suggests membrane replacement after every three years. Good
maintenance may increase the membrane age.

4.4 Membrane deterioration

The reasons for the premature membrane deterioration are

4.4.1 Chlorine
Membranes are very sensitive to Chlorine. CA membranes can resist. Some amount
of chlorine generally less than 1 ppm. PA and TFC membrane are very sensitive to
even trace amount of chlorine. The feed water containing free chlorine should be
dechlorinated either by activated carbon or sodium bi sulfite.

4.4.2 pH
pH assumes a very important role in RO operation. CA Membranes are highly pH
sensitive. CA membranes are normally operated in 4-6 pH range and Optimum pH is
5.5. Above 8.5 CA membrane deteriorates. PA/TFC membranes have wider pH
compatibility but pH is normally kept around 6 to avoid scaling.

12
4.4.3 Hydrolysis
CA membrane can get hydrolyzed at low or high pH. CA membrane hydrolyses with
time but can be accelerated due to high temperature. PA membranes do not hydrolyze
but deteriorate due to physical failure.

4.4.4 High pressure

Membrane compacts when high pressure is applied. The amount of product water
falls (reduces) of to a point where membrane has to be replaced.

4.4.5 Bacteria
CA Membranes are prone to bacterial attack. PA membranes are not attacked by
bacteria but substance formulating at surface can act as a nutrient.

4.5 Foulants affecting RO membrane

Monitoring of R.O plant is very critical since it helps in recognizing a problem and
taking a timely remedial action. R.O Membranes even during normal operation over a
period of time is subject to fouling by suspended or sparingly soluble material which
may be present in the feed water. Monitoring of plants helps in identifying the foulant
and also cleaning procedure to be adopted.
Typical foulant encountered in R.O are the following:-
1) Calcium carbonate or calcium sulfate
2) Iron oxides
3) Silica
4) Suspended or colloidal impurities
5) Organic
6) Biocide, fungi or slime.

13
Chapter 5

Pretreatment
Water to be demineralized always contains impurities which should be removed by
pretreatment to protect the membrane and to ensure maximum efficiency in the RO
process. Membrane can get clogged or fouled by undissolved impurities or by
impurities that precipitates during the process.
The pretreatment used with RO system are the following
1. Media filters for removing suspended solids.
2. Acid addition
3. Addition of oxidizing agent
4. Activated carbon filter
5. Greensand filter
6. Anti scale & dispersant.

5.1 Media filtration

Media filtration is used for removal of suspended impurities. Media filters contain
sand and anthracite. Filtration is the process of passing liquid containing suspended
matter through a suitable porous material (filtering medium) to effectively remove the
suspended impurities in the liquid.

5.2 Cartridge filters

This is provided to almost all RO system irrespective of size to prevent particles in feed water,
chemical feed equipment or pretreatment media from entering the RO membrane. This is the last stage
of pretreatment step. Generally used pore size is 5 micron. But when better filtration is required 5
micron is followed by 1 micron. Remember that cartridge filters are not replacement for media filters
but only last stage protection to RO membranes.

5.3 Scale control

Feed water which comes as product water is pure water but the waste water which is
called brine or reject becomes more saline. As the salinity (TDS) increases some salts
precipitate and scale the membrane.
The following compounds are generally responsible for scaling
Calcium carbonate & Calcium sulfate
Silica complex
Calcium fluoride
Some compounds like hydroxides of iron and aluminum also form scale but generally
they precipitate before they contact membrane and do not crystallize on it.
The scale is controlled by one of the following methods
1. Removal of calcium & magnesium ions by softening
2. Addition of acid to remove bicarbonate alkalinity.
3. Use of scale control agents.
Note: - Softening has some drawback like a) more salt is required in comparison to
acid (b) Brine disposal problem (c) membrane rejects divalent compound better.

14
5.4 Iron Removal filter
Water which contains iron is not suitable for membrane and can easily get fouled.
Water having iron greater than 0.3 ppm is removed by Iron Removal Media.
Greensand is catalyzed manganese oxide which oxidizes iron & manganese and filters
them out.
5.5 Activated carbon filter
Activated carbon filters are used for two purposes
1. Removal of organic impurities
2. De-chlorination
Most RO membranes are destroyed by oxidizing agents especially chlorine. Though
CA membranes are more tolerant to chlorine than polyamide membrane, it also gets
damaged to some extent. Therefore chlorine should be removed from feed water
before it enters the RO membrane. This is done by passing the feedwater through
activated carbon bed.
5.6 Chemical feed
Oxidizing agents like chlorine and ozone are added to remove microorganism from
feed water which can foul the membrane surface. The residual oxidants have to be
removed before feedwater enters the membrane. Sodium bisulfate is for de-
chlorination. Ozonized water is passed through UV rays before feed water enters
membrane unit.

Figure Basic flow diagram of pretreatment

MMF - Multimedia filters

IRF - Iron removal filter
ACF - Activated Carbon filter
AD - Acid Dosing
SI - Scale inhibitor
CF - Cartridge filter
HP - High pressure Pump

15
Chapter 6
Operation of PSF, IRF & ACF

6.1 Pressure Filter

Filtration is the final step in the solid removal process which includes coagulation,
flocculation and sedimentation. The purpose of filter as mentioned earlier is to
remove the particulate impurities and floc from the water being treated. Where water
turbidity is not very high filtration follows coagulation.
Pressure Filters are closed cylindrical vessel either vertical or horizontal (mostly
vertical) containing the filter media over a collector system. Water flows from top
downwards percolating through the media and is drawn off through the collector
system at the bottom. Cycle of operation are service, back wash, short rinse to waste
and return to service. Increase in pressure drop indicates that filter media is fouled
and requires backwashing.
The following materials are normally used as filter media - Quartz sand, silica sand,
anthracite, coal, garnet etc.
Filter which uses only sand is called sand filter. Back wash water for filters should
always be filtrate water.

6.2 Operation of pressure filter

1) Start the raw water pump
2) Open inlet valve V1 (see drawing and valve Nomenclature)
3) Open Backwash outlet valve V4 and then slowly open backwash inlet
Valve V3.
4) Carry this operation for 10 minutes.
5) If the unit has been idle for long time or is being backwashed for first
Time then duration of backwash should be longer.
6) Close V3 and V4
7) Open Rinse inlet (drain) valve V5 and rise for 5 minutes or till clear
Effluent starts flowing.
8) Close V5 and open outlet valve V2.
9) The unit is ready for service

16
V1 INLET
V2 OUTLET
V3 BACKWASH INLET
V4 BACKWASH OUTLET
V5 RINSE OUTLET (drain)

Raw water

V1 V4

V3 V2

V5

OPERATING STEPS FOR FILTER

S.No STEP VALVES OPEN VALVES CLOSED

1 Vessel filling V1 V2, V3, V4 &V5

2 Backwash V3 & V4 V1, V2 & V5
3 Rinse V1 & V5 V2, V3, &V4
4 Service V1 & V2 V3, V4, & V5

STOPPING
1) Stop the Raw water pump
2) Close all valves

Note
1. Activated carbon filter (ACF) and iron removal filter (IRF) are operated
Similarly. IRF media is regenerated with KMnO4 (for intermittent type) or
KMnO4 is continuously dosed (for continuous type).
Continuously dosed.

17
Chapter 7
RO Plant Operation
After the water has been properly pretreated and desired quality of water is obtained it
is fed to the membrane through high pressure pump. Typical RO pump layout is
shown below.

MF
PG PG
PC

HP
Manual
valve
MF – Micron filter PG – pressure gage
HP – High pressure pump
PC – Pressure controller

High pressure
Continued switch
from “A”

RO Module

Product flow meter

Total flow
RO Module

18
7.1 RO Operation
Feedwater to the RO system is first pumped through a micrometer filter. This is a
replaceable cartridge element filter nominally rated at 10 µm . The purpose of this
filter is to remove any turbidity and particulate matter from feed water before it enters
the RO system.
The filtered raw water than flows to high pressure pump, which feeds the water at a
pressure of 400 psi through the RO membrane unit. Valves and pressure guages
between the cartridge filter, the high pressure pump and membrane modules control
the flow.
The RO system consists of two stages. The raw water is pumped through the
membrane modules. The stage 55% of purified water fed to the system and rejects the
remaining 45% which contains all the impurities.
The RO system removes 90 to 95% of dissolved solids in the raw water. The exact
percent of product purity, product recovery and reject water depends on the amount of
TDS in feedwater, temperature and on maintenance.

7.2 Checklist for RO Operation.

1. Before starting the RO pump check the cartridge filter. If not properly installed in
can damage the High pressure pump or foul the membrane element. It should be
replaced whenever the headloss exceeds the recommended specification of delta
pressure 2.5 – 3 psi or if the effluent turbidity exceeds 1NTU.
2. Start and check the scale inhibitor (Antiscalant Dosing Pump) feeder equipment
and adjust feed rate to desired dose (2 to 5mg/L)
3. Remember that if scale inhibitor is not added membrane can get scaled because of
calcium salts and other inorganics. Inhibitor commonly employed is Sodium hexa
Meta phosphate (SHMP).
4. Depending on the type of membrane and the recommendation adjust the pH to
desired level and bypass the feedwater till pH is adjusted. The acid dosing pump
should stop when the high pressure pump stops. In most RO plants acid dosing
start and stop is directly linked to High pressure pump.
5. Check the suction pressure. The high pressure should not start till the desired
pressure is reached. Low pressure tripping is included in RO plant.
6. RO pump should trip if the discharge pressure is higher than recommended. High
pressure switch is provided for tripping for protecting the membranes.
7. Adjust permeate and concentrate flow to establish the desired recovery rate.
8. Check the following after the desired flow rate have been achieved.
Check the differential pressure (∆p) = Feed pressure – concentrate pressure. This
should be noted. Bigger plants have recorder which records this continuously.
Increase in ∆p indicates that the system requires cleaning. ∆p should not increase
more than 414 kpa or 4.1 kg / sq cm
9. With the system online monitor all flows, pressure, level and the quality of water
being produced.
10. It is very necessary and also proves very useful if pretreatment is monitored and
record maintained. More problems in RO membranes are caused by faulty
pretreatment.

19
7.3 Chemical Cleaning
RO plant is provided with cleaning skid called CIP (Cleaning in Place).
The skid contains a cleaning tank, pump, cartridge filter, and sample valves.

Reverse osmosis units should be cleaned when they show evidence of fouling, or just
before a long shut down or as a matter of schedule maintenance. RO cleaning
frequency may vary site to site but roughly once every three to twelve months is
acceptable.

In this chapter we are not describing why cleaning should be done or other aspects of
cleaning. Here we are considering cleaning as a part of operation which the operator
has to do; the procedure mentioned below is just a guideline for the operator.
1. Connect the cleaning skid to the appropriate stage of selected RO unit with
flexible hoses.
2. Carry out low pressure flush with feed water or permeate water to remove
foulants. Do this for 15 minutes at 50 psig and at 75 % of the maximum flow for
that size (diameter) of the element.
3. The cleaning is done stage by stage.
4. Prepare the cleaning solution as per manufacturer’s instruction. Chemical
Solution procedure
5. Cleaning solution should be properly mixed and pH and temperature adjusted
according to recommendation.
6. Introduce the cleaning solution at high flow rate and drain. When you observe the
solution in the drain, stop the pump and close all valves. Allow the unit to get
soaked for 15 minutes.
7. Repeat procedure 6, three or four times and observe the colour change of spent
chemical. If colour pick up is significant continue the process, other wise stop.
8. Re-circulate the brine to cleaning tank for 45 minutes after the above process is
over.
9. Empty the cleaning tank.
10. Flush the unit with RO product water for 15 minutes at moderate flow rate (at
50%) and at 50 psig. Flush water temperature should be above 20*C.
11. Continue flushing but now at higher flow (75%) with product water or feed water
for 30 minutes.
12. Check the following
a) Brine pH is within 1 unit of feed pH
b) Brine conductivity is within 100 micromhos /Cm of feed
conductivity.
c) Brine is not foamy
13. Cleaning is completed if all the above three condition is met.
14. Repeat the procedure for the next unit with fresh chemicals

20
Chapter 8
Chemical Cleaning
RO membranes get fouled with suspended solids contained in the feedwater or with
sparingly soluble salts, as minerals are concentrated. Pretreatment is done to reduce
the fouling potential of feedwater but inspite of that fouling occurs over a period of
time.
The various pretreatment methods for preventing fouling as mentioned earlier are
1. Acid addition
2. Ion exchange softening
3. Antiscalants.
Ion exchange is generally considered to be slightly costlier than other two methods.
Inspite of efficient pretreatment system, all pressure driven membrane system foul
over time. Symptom of fouling is indicated by
1. Decrease in permeate flow.
2. Increase in salt passage.
3. Increase in differential pressure
4. Deterioration in permeate quality
5. Increase in the differential pressure across the RO stage
Indications that the system requires cleaning are
1. A 10 to 15 % decline in normalized permeates flow.
2. A 10 % increase in salt passage.
3. !5 % increase in differential pressure.

8.1 Foulants
For RO plants operating on natural waters, the most common foulants are
Metals like iron, manganese and aluminum (From coagulation)
Scale forming compounds like calcium carbonates, calcium sulphate , some silica
salts and calcium fluoride.
Colloidal and silt are the most common foulants.
Humic and fulvic acid
Biofoulants
Chemical foulants due to chemical treatment.
These have been already described in chapter 4 (Factors affecting RO membrane)
There is various method of removing deposits from fouled membrane but the most
widely used method is chemical cleaning. Other methods are cleaning with high
velocity water, spongeball or brush cleaning and ultrasonic cleaning. Our discussion
is limited to chemical cleaning.
Chemical cleaning agents reacts with foulants that affect flux rate and product water
quality. The chemical agents can be classified into four categories
1. Acid
2. Alkalis
3. Chelants
4. Formulated products
Acids are used for removing calcium carbonate scale and metal foulants. They are not
very effective in removing silica scales or organic foulants.
Alkalis are used for removing biofoulants, humic and fulvic acid and difficult deposits
such as silica scales.

21
EDTA a chelant is sometimes used for removing alkaline earth metal sulfates.
There are number of proprietary chemicals for removing deposits and they are
superior to more traditional cleaners like citric acid.

Basic design of cleaning system

From Membrane
CIP Tank MCF Array

PERMEATE

Pump
Discharge
Control CIP
valve Tank CONCENTRATE
CIP Tank
CIP
Pump

Concentrate
Control valve

Fig 3 Schematic of CIP unit

22
Chapter 9
Troubleshooting RO Plant
Troubleshooting of any plant is carried when it performance does not meet the
Specification or when there has been abrupt change in its performance. Similarly RO
plants also require troubleshooting if there is unacceptable change in quality and
quantity of water produced.
The following indicates that RO plants need troubleshooting.
1. Normalized production changes by 15 %
2. Normalized salt passage changes by 50%
3. Differential pressure changes by 15 %

Troubleshooting steps for RO plant are

9.1 Checking and verifying instrument operation.

Conductivity, pressure and pH plays very important role in RO operation. It is
therefore very necessary that instrument measuring this should be accurate and
functioning properly. Recalibrate all instruments.
The recommended calibration schedule is
pH sensors, indicators and recorder 30 days
Conductivity sensors, indicators and recorders 90 days
Flow sensor indicators and recorders 90 days
All other instrument 180 days
Though this is recommended by most companies, I suggest that pressure monitoring
instrument should be recalibrated more often because it is an important measurement
in RO operation.
Once it is checked that all instrument are working properly go the next step

9.2 Reviewing operating Data

Check the operating log sheet. These will you in diagnosing whether there is a system
upset or fouling. RO may be working properly but changes in critical operating
parameters like TDS, Temperature, recovery or flux can mislead you.
The following points will help in identifying the problem.
1. Increase in feed water TDS increases feed pressure requirement.
2. Decrease in feed water temperature increases feed pressure requirement.
3. Increase in feed water TDS also increases peremeate conductivity.
(Remember RO rejects a fixed percentage of salts)
4. Increase in percent recovery of the system increases the reject TDS
(This boosts permeate conductivity)
5. We had mentioned earlier that passage of salt is independent of passage of water
through the membrane. Therefore if recovery is constant, a reduction in permeate
flow results in a lower water flux, which will increase conductivity.
RO operation can be done by examining operating logs and by normalizing the logged
operating data. Normalizing helps in predicting system performance and also helps in
scheduling the cleaning frequency.
Normalization is the mathematical procedure for correcting actual production and salt
rejection value to standard condition. Most membrane suppliers today have developed
computer software for projecting “Normalization”. The program graphically chart

23
normalized permeate flow, percent salt rejection and feed to reject pressure drop
called corrected ∆p.

9.3 Checking for component failure

The system upset can also be due to mechanical problem
The mechanical failures can be
1. Damaged O rings
2. Damaged brine seals
3. Failure of high pressure pump
4. Failure of dosing pumps
5. Valve leakage
6. Piping failure
7. Cartridge filter

Checking for chemical upset

The chemical upset can be
1. Improper pretreatment
2. Improper acid addition: More acid can lead to membrane damage and sulfate
scaling if H2SO4 is used. Lower dosage can lead to meta-oxide formation or
carbonate scaling.
3. Improper scale inhibitor dosing: High dosing leads to fouling and low leads to
scaling.
4. Higher than recommended dosing of coagulants and polymer can lead to
membrane fouling.
Once all the above problems – Mechanical, chemical upset and water chemistry have
been ruled out as the likely cause, the next step is to identify the foulants. This is done
by studying the water analysis of feed, brine and product stream over a period of time
which will help in verifying if any extraordinary changes have taken place. This will
help in identifying the problem and the likely foulant which caused the problem.
Shutdown
Before shutting down RO plant, make sure that reject water from the service operation
from the system is flushed out.
If the unit is going to be shut down for long, carry out the recommended procedure of
storing.

24
9.4 Troubleshooting
Troubleshooting of RO Plant is done whenever the plant deviates from its normal
operation. In the next page we have provided troubleshooting chart which will help in
fault diagnosis
A troubleshooting chart is always helpful in fault diagnosis
CHECK VERIFY
Pressure drop between feed and Has not increased by more than
reject. 15%.
Pressure drop between feed and Has not increased by more than
permeate 15%.
Permeate conductivity Has not increased by more than
15%.
Acid dosing Is within recommended value.
Instruments Reading Verify by calibration and
carryout of lab check of the
parameters the instrument is
monitoring.
pH meter calibration & control Acid dosing pumps are
generally controlled by pH
controller. pH controller Should
be calibrated periodically and
tripping of dosing pump to the
set point should be checked.
O ring Probing with ¼ ‘plastic tube
and by measuring how far it has
been inserted.
Brine valve Should not be closed fully.
EFFECT
More than 15% indicates
fouling of feed path and
membrane surface. Requires
cleaning
More indicates fouling of
membrane surface. Requires
cleaning.
More indicates fouling of
membrane surface. Requires
cleaning.
More can cause membrane
damage or sulfate scaling. Less
can cause carbonate scaling or
metal oxide fouling.
Wrong operation
False sense of security that
everything is OK.
More or less acid dosing than
required. Effect of this as
already been mentioned earlier.
Failure can lead to increase salt
passage, increase permeate
flow. Decrease pressure drop.
If fully closed,100% recovery
will result and cause membrane
damage due to precipitation of
inorganic salt.
25
Chapter10
Operation of pumps
Pumps are one of the most widely used equipment in water treatment. It is used for
various applications. Pumps in water treatment therefore get classified in different
ways.
By mode of operation ---Centrifugal, propeller, reciprocating etc
By condition of pumping ---high lift, low lift, high capacity and high pressure
By application ---Raw water pump, filtered water pump, Dosing pump

In reverse osmosis systems, pumps are used for various purposes. In fact, the high
pressure pump apart from membrane is the most important component of RO system.
The other widely used pumps are metering pumps for dosing chemicals and generally
referred as dosing pumps.

10.1 Centrifugal pump

A centrifugal pump is a simple device as shown. It consists of an impeller arranged to
rotate within a casing. The impeller is supported on a shaft which in turn is supported
by bearings. Liquid coming in at the center (*eye of an impeller) is picked up by
vanes and by the rotation of the impeller and is thrown out centrifugal force into
discharge.
Discharge

Volute
Nozzle

Impeller
Pumps are costly and hence require proper maintenance. Preventive maintenance and
trouble shooting methods are described in the next section (see Section C –
Troubleshooting equipment). Starting and stopping of pumps also play a crucial role
in pump operation.

26
10.2 Starting a new pump
1. lubricate the pump as per suppliers instruction
2. Check alignment of pumps. The shaft should rotate freely when rotated by hands.
3. Check the motor characteristics and wiring
4. Set the thermal overload relay.
5. Start the motor for just enough time to observe the rotation. The rotation should be
in the same direction as that of pump. The direction of pump rotation is marked on
the pump.
6. Check that all lines are open
7. A new pump should never be started without priming.
8. After starting the pump check the following
a) recheck the direction of rotation
b) Check stuffing box (packing glands) for slight leakage.
c) Check that bearing do not get overheated because of over or under lubrication
d) Check for noise. The reasons for noises are misalignment improper adjustment
or clearance and low voltage.
e) Compare the pump performance with pump performance curve or with
specification provide.
The above is generally applicable to new pump or pump which is being reinstalled
after repair.

10.3 Starting and stopping pump running pumps

6.3.1 Starting the pump
1. Check the MCC (Motor control center) panel for lock and tag. Generally a danger
tag is provided for motor or pump which is not in operation.
2. Inspect the equipment
3. Check lubrication
4. Check all valves.
5. Check pipe routing to see that valves are in their proper position and the flow of
pump will discharge where intended.
6. Return to MCC and switch the supply on.
7. Open suction valve fully.
8. Start the pump through local pushbutton provided. In automatic plant this step
may not be necessary.
9. In most cases you can start a pump with discharge valve open provided check
valve is provided.

10.3.2 Stopping the pump

1. Record all reading
2. Stop the pump
3. Close all valves
4. Remember to close the discharge valve of pump which is not provided with check
valve before stopping.

27
10.4 Some points to observe in operation of centrifugal pumps
1. Do not operate the pump when safety guards are not installed over or around
moving parts
2. Never operate a pump which is tagged or locked. Some body can get injured.
3. Never run a centrifugal pump when impeller is dry. Always prime the pump
before starting. (In water treatment most pumps have positive head or low suction
lift and hence this point may not be very significant )
4. Do not operate a pump whose impeller or shaft is spinning backward.
5. Never operate a pump which vibrates excessively. Check for blockage in suction
line or impeller

10.5 Improving Pump efficiency

Opportunities for savings in pump operation are often overlooked because
Pump inefficiency is not readily apparent.
The following measures can improve pump efficiency:
1. Shut down unnecessary pumps.
2. Restore internal clearances if performance has changed significantly.
3. Trim or change impellers if head is larger than necessary.
4. Control by throttle instead of running wide open or bypassing the flow.
5. Replace oversized pumps
6. Use multiple pumps instead of one large pump
7. Use a small booster pump
8. Change the speed of the pump for the most efficient match of horsepower
requirements with output

10.6 Metering pumps

Metering pumps are required in RO operation for dosing various chemicals. These
pumps are generally positive displacement diaphragm pumps but there are times when
piston type pumps have been used. This type of pump deliver predetermined amount
of chemicals. Pumps of this kind are available from 0 to 100 liters/hour with
maximum injection pressure of around 20 kg/cm2 and powered by AC voltage of 120
or 240 volts or 12 or 24 volt DC. They are fitted with head made of different chemical
resistant material. Ball valve with o-ring seats in the suction inlet and discharge outlet
of the head provide tight seals when closed for positive displacement without
backflow. The four function valve with a return line to chemical container is primarily
for safety. An internal check valve prevents backflow into head of the pump.

28
10.7 Pump Operation
These types are started and stroke length adjusted to deliver a required quantity of
chemicals. Priming is required for pump which has high suction lift.

10.7.1. Priming
Priming is done only against atmospheric pressure when using a suction lift
installation. Flooded suction installations allow the unit to prime itself even under
pressure.
1. Temporarily remove tube from injection check valve and hold the end of tubing so
that it is above pump level.
2. Set pump at 100 % stroke and start pump.
3. As soon as chemical is visible through translucent discharge tubing just past the
discharge tube, stop the pump.
4. Pump is now primed.
5. Reconnect tubing to injection check valve.
6. Pump is normally self priming if suction lift is below 1.5 Meter. Follow step 1 to
3.
7. If the pump does not self prime, remove discharge housing and ball and pour
water or chemical slowly into discharge port until it is filled. Follow step 2 to 5
thereafter.
Note: - In all cases priming will be assisted by releasing or reducing pressure on the
pump. This can be done by the pressure relief valve provided.

10.7.2 Output adjustment

In metering pump the most important operation is output adjustment. Adjustment of
output is necessary because more or less chemical can prove harmful to membrane.
This is done by adjusting the stroke length. Most pump catalogue give the method of
adjusting the stroke length.

29
Chapter 11
Cartridge Filter
In RO systems cartridge filters are used as a last stage of pretreatment to remove any
suspended or particulate matter before the water enters the membrane unit.
The filter elements are of standard diameter and are available in various lengths. For
industrial application the standard lengths are 30 or 40 inch. The flow rate of the
service water determines the length and number of filter elements necessary. Filter
elements are held between two plates inside a pressure vessel.

11.1 Operation
1. Open the inlet water valve
2. Open the outlet water valve
The water will enter the vessel, flow through the cartridge element and then enter the
RO membrane unit.

11.2 Removal of choked cartridge filter element

Over a period of time the cartridge filter element will get clogged with impurities.
This is indicated by the pressure drop across the cartridge.
1. Stop the cartridge filter system.
2. Close the inlet and outlet valve
3. Open the vessel in which the cartridge element is housed.
4. Take out the dirty filter element
5. Replace them with new elements.
6. Close the vessel.
7. Open the inlet valve but keep the outlet valve closed.
8. Open the drain valve provided
9. Rinse to remove dirt
10. Put the unit back into service by closing drain valve and opening outlet valve.

30
Chapter 12
Filter maintenance

12.1 Routine maintenance

The routine maintenance of pressure filter include the following
12.1.1 Valves
At periodic intervals (say one month) open the valves and check for
Seating, change gland packing or diaphragm depending on the type of valve.
Carry out lubrication of spindle.
12.1.2 Extended backwash
Once in a week the backwash should be given for more time say at least for 45
Minutes. This will help to keep the bed clean.
12.1.3 Air scouring & cleaning of Media
The manhole should be opened once in 6 months and the condition of media
Should be checked. Any lumps formed on the top of bed should be thrown away.
On units where no regular air scouring is provided; air scouring can be done in
As follows:-
a) If compressed air supply is available, take a temporary tapping (say 1” hose).
Attach the hose to a M.S. pipe about 1 meter long. The water level inside the
vessel should be about 3” above the bed. The pipe is inserted into the bed till it is
half way through the bed. The media will get violently agitated. Move the pipe
all over the bed. Carry out the air scour for a period of 10 minutes.
b) After the air scour carry out an extended backwash. This extended backwash also
called open manhole backwash is given very care fully.
c) Drain the bed till the surface of the bed and scrape of all the dust.
d) Close the manhole.

12.2 Vessel condition

Once a year vessel internal condition should be checked for paints and internals
Repaint the vessel after removing the media. Filter media replacement can also be
done if required. Filter media is replaced normally once a year.
The routine maintenance guidelines are given both for mild steel filters as well as FRP
filters. FRP filters normally require less attention once installed. Operational care is a
must for FRP Filter. The pressure should not be more than the recommended pressure
or it is likely to damage the filter. FRP filters are of molded design and hence repair is
not possible and has to be replaced.

12.3 Trouble shooting of Pressure filter

Trouble shooting of Pressure filter: - Pressure filters are basically very simple in
operation and normally do not give much problem. The final effluent from filter if is
not f required quality then the reason could be more because of preceding steps and if
there is only filter then it is because of filter not being backwashed regularly. A chart
for trouble shooting is shown below.

31
TROUBLE SHOOTING OF FILTERS

PROBLEM CAUSE REMEDY

Turbidity Breakthrough Change in Raw water 1) Analyze Raw water

2) Backwash

Loss of media Broken internals Change the laterals or

Rectify internals

High backwash flow control backwash flow

High pressure drop Media dirty 1) Give backwash

Across the bed 2) If backwash does not
Solve problem give
Extended backwash.
3) Change filter media if
step 1 &2 does not work

Mud ball formation change in raw water quality 1) Air scour and give
Extended backwash
2) Check pretreatment
steps if any. Adjust if
Necessary.
3) Decrease Velocity
4)Change media if
required

12.5 Trouble shooting of Activated carbon filter

The activated carbon filter maintenance is similar to dual media filter and once the
Life of media is over it is discarded and replaced with new media. In water treatment
the media is replaced once a year if used only for de-chlorination purpose .and faster if used
for organic removal.

32
Chapter 13

Electrical Motor Troubleshooting

Symptoms Cause Result Remedy

1 Motor does not A. Incorrectly connected Burnout Connect correctly per diagram
Start.
(switch is on and B. Incorrect power supply Burnout Use only with correctly rated
not defective) power supply
C. Fuse out ,loose or open Burnout Correct open circuit condition
connection

D. Rotating parts of motors Burnout Check & correct

May jammed 1. Bent shaft
Mechanically 2. Broken housing
3. Damaged bearing
4. Foreign material in motor

E. Driven Machine may be Burnout Correct jammed condition

jammed

F. No power supply None Check for voltage at Motor and

work
G. Internal circuit open Burnout Back at power supply
Correct

2..Motor starts but A. Same as 1,2,3 above Burnout Same as 1,2,3 above
does not come up
to speed. B. Overload. Burnout Reduce load to bring current to
Rated limit. Use proper fuses &
Over Load protection.

C. One or more phases Burnout Look for open circuit

Out on 3 phase
Motor.

3. Motor noisy A. Same as 1,2,3 above Burnout Same as 1,2,3 above (Col. 1)
Electrically

33
Motor runs hot A. Same as 1,2,3 above Burnout Same as 1,2,3 above (Col. 1)
(Exceeds Rating)
B. Overload Burnout Reduce Load

C. Impaired Ventilation Burnout Remove obstruction

D. Frequent start &stop Burnout 1. Reduce number of starts or

Reversals
2. Secure proper motor for this
duty
E. Misalignment between Burnout
Rotor & stator Realign
Lamination

Noise (mechanical)A. Misalignment of Bearing failure Correct misalignment

coupling Or sprocket Broken shaft,
Stator burnt due
Motor drag

B. Mechanical unbalance Same as Find unbalanced part, then

of rotating parts Above Balance.

C. Lack of or improper Bearing failure Use correct lubricant, replace

Lubricant Parts as necessary

D. Foreign material in Bearing failure Clean out and replace bearing

Lubricant.

E. Overload Bearing failure Remove overload condition.

Replace Damaged Parts.

F. Shock loading Bearing failure Correct causes and replace

Damaged parts
G. rotor dragging due to
Worn bearings, shaft
Or brackets Burnout Replace Bearing , shaft ,or
Bracket as needed

Bearing failure A. Same as 5A,B,C,D&E Burnout, Replace bearing and follow

Damage shaft, And follow remedial action
Damaged 5. A,B, C, D,E
Housing
Entry of water or foreign Same as above Replace bearing & protect
Material in bearing housing motors

34
 Symptoms Caused by Appearance
Shorted motor winding Moisture , chemicals, foreign Black or burned with
Material in motor, damaged remainder of winding good
winding
All windings completely a. Overload a. Burnt equally all around
burned b. Stalled winding .
c. impaired ventilation b. Burnt equally all around
d. frequent winding .
e. reversal or stop c. Burnt equally all around
f. incorrect power winding .
d. Burnt equally all around
winding .
e. Burnt equally all around
winding .

Single phase condition a. Open circuit in one line a. If 1800 rpm motor –four
The most common causes are Equally burned groups at
loose connection, one fuse 90o intervals.
Out, loose contact in switch.b. If 1200 rpm motor – six
Equally burned groups at
60o intervals.
c. If 3600 rpm motor – two
Equally burned groups at
180o intervals.

NOTE
If Y connected each Burned
group consists of two adjacent
phase groups. If delta connected
each burned group will consist
of one phase
group.

Other a. Improper connection Irregularly burned groups or

b. ground spot burns

35
Troubleshooting / remedy chart for induction motors

A Motor will not start.

Overload control tripped, Wait for overload to cool then try to start again. If motor still does not
start, Check for the causes outlined below
1. Open fuses; test fuses
2. Low voltage: check nameplate values against power Supply characteristics. Also check voltage
at motor Terminals when starting under load to check for
Allowable voltage drop
3. Wrong control connections: check connection with Control wiring diagram.
4. Loose terminal – lead connection : turn power off and Tighten connection
5. Drive machine locked: disconnect motor from load. If Motor starts satisfactorily, check driven
machine
6. Open circuit in stator or rotor winding; check
7. Short circuit in stator winding; check
8. Winding grounded ; test for grounded wiring
9. Bearing stiff; free bearing or replace
10. Overload; Reduce load

B. Motor noisy
1 Three phase motor running on single phase; stop Motor, then try to start. It will not start on
single Phase. Check for open circuit in one of the line
2. Electrical load unbalanced; check current balance.
3. Shaft bumping (sleeve bearing motor ) check alignment
4. Vibration; Driven machine may be unbalanced, remove Motor from load, if motor is still noisy,
rebalance.
5. Air gap not uniform : Center the rotor and if necessary Replace bearing
6. Noisy ball bearing: check lubrication, replace bearing if noise excessive and persistent
7. Rotor rubbing on stator: Center the rotor and if necessary
Replace bearing.
8. Motor loose on foundation: tighten bolts, realignment may be required.
9. Coupling loose : insert feelers at four places and check alignment

C. Motor at higher than normal temperature or smoking

1. Over load; Measure motor loading with ammeter. Reduce load
2. Electrical load unbalance: check for voltage unbalance.
3. Restricted ventilation: Clean air passage and windings.
4. Incorrect voltage & frequency: Check for nameplate values for power supplies and also check
voltage at motor terminals.
5. Motor stalled by driven tight bearings; remove power from motor. Check machine for stalling.
6. Stator winding shorted or grounded; test windings by standard method
7. Rotor winding with loose connection, if possible or replace with another rotor.
8. Belt too tight; Remove excessive pressure on bearing
9. Motor used for rapid reversing service ; replace with motor designed for the particular service
D. Bearing Hot
1. End shields loose or not replaced properly ; Make sure end shield fit squarely and are properly
tightened
2 Bent Shaft: straighten shaft and realign.
E. Sleeve bearing
1. Insufficient oil: add oil –If supply is very low drain, flush and refill.

36
2. Foreign material in oil or poor grade oil : drain oil , flush and re-lubricate using industrial
Lubricant as recommended by manufacturer of motor.
3. Oil ring rotating slowly or not rotating at all; oil too heavy; drain and replace worn out
Oil ring.
4. Rings bent or otherwise damaged in reassembling; replace rings.
5. Rings out of slot. (Oil ring retaining clip out of place).Adjust or replace retaining clip.
6. Defective bearing: replace.

F. Ball bearings
1. Too much grease: remove relief plug and let motor run. If excess grease does not come, flush
and re-lubricate.
2. Wrong grade of grease: flush bearing and re-lubricate with proper amount of grease.
3. Insufficient grease: remove relief plug and grease bearing.
4. Foreign material in grease: flush bearing and re-lubricate. Make sure grease supply is clean.

37
Chapter 14

Membrane Loading Guidelines

This bulletin provides general information and guidelines for installing RO membrane elements in
order to provide optimally reliable performance.

Storage of elements (Membrane) prior to loading

If the elements cannot be loaded upon delivery, be sure to store elements out of direct sunlight.
Do not expose elements to temperatures below freezing, 32 °F (0 °C), or above 113 °F (45 °C).).

Flushing

If the system is new, it is strongly recommended to flush the system (pipes, pumps, pressure
vessels, etc.) with clean, fresh water prior to element loading. This allows any debris,
preservatives, and solvents to be flushed out so that they do not come in contact with the
membranes.

Material, tools and equipment requirements

• Glycerin
• Pure silicone lubricant (Molykote 111 or Parker Super O-Lube)
• Permeate or fresh water
• PVC pipe or rope – length depends on the length of pressure vessels
• Sponge ball (to be fixed at one end of PVC pipe or rope)
• Towel or cotton rag
• 6” PVC Cap (when loading 8” pressure vessels)
• Shims (sizes of 1, 2, 2.5 and 5 mm thickness recommended)
• Brush or dauber for lubrication of brine seals
• Tools as per pressure vessel manufacturer recommendations for removing and
installing of end cap assembly
• Spare parts for end caps (e.g. o-rings, lock rings, Victaulic clamps, nuts, bolts)
• Personal protection equipment (gloves, glasses, shoes, hard hat)

Note: When loading elements into a system, do NOT use oil, grease, or petroleum based
compounds to lubricate o-rings and brine seals as these may cause damage to membrane or
other components of the element. Use only silicone based gel or a mixture of 50% glycerin in
water to lubricate o-rings and brine seals.

38
Pressure Vessel Preparation

1. Remove pressure vessel end caps from both sides of the vessel (Note: Refer to pressure
vessel manufacturer’s manual for removal and re-installation of end caps assembly).

2. Disassemble and wash all end cap parts (i.e. o-rings, end adapters, etc.) in fresh water and
keep them clean for re-installation. Perform an inspection and count all parts prior to
reassembling to ensure integrity and inventory.

3. Clean the inside of the vessels to remove any dust and debris that could mechanically
damage the membrane surface. Hosing down the insides of the pressure vessels with
water usually will not be sufficient to clean the vessels.

4. Use a sponge ball wrapped in a towel or cotton rag and soaked in a 50-75% solution of
glycerin and water. The sponge ball can be pushed/pulled through the vessel with a piece
of rope or long PVC pipe. Alternatively, the sponge ball can be pushed through the length
of the vessel with a piece of PVC pipe with a PVC flange attached to the end. The
Glycerin solution will lubricate the inside surface of the pressure vessel to ease the
loading of elements. Another method is to use a 6” PVC cap covered in rags (should fit
snuggly into the pressure vessel) attached to a rope slightly longer than the length of the
vessel. Pull the 6” PVC cap covered in rags and soaked in glycerin through the vessel
with the rope.

5. After cleaning the pressure vessel, re-install the brine side end cap assembly without
covering side port openings with the thrust cone/sleeve. Before installation, lubricate end
plate permeate adaptor O-rings and head seal with thin layer of pure silicone lubricant
(Molykote 111 or Parker Super O-Lube).

Note: A 65/30/5% Glycerin/Water/SBS (sodium metabisulfite) solution can be used to

help disinfect the vessels. Also, a 15:1 mixture of water and SBS (add about 1 cup of
SBS powder to 1 gallon water) can be made to swab the vessels before the glycerin for
disinfection, if necessary.

Caution: Be sure to avoid scraping the pipe along the vessel surface. Also, take care to
push the end cap in squarely to avoid rolling the head seal.

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Loading of elements (RO membrane)

1. Prior to loading, ensure all brine side end cap assemblies (including thrust cone/sleeve,
head seal, end adapters, O-rings, etc.) are installed in the pressure vessels.

2. Maintain a loading record of each element serial number, vessel location, and position.

3. Open the element bag partially and expose the upper one-third of the element. This
allows for the operator to have minimum exposure to the Fiberglass Reinforced Plastic
(FRP) shell, while installing each element.

4. Gently slide the first element into feed side of the pressure vessel three-quarters of the
way and remove the plastic bag.

Note: Always load elements in feed flow direction with brine seal properly seated in seal
groove of anti-telescoping device (ATD) and facing the flow direction. If the element
uses a V-cup brine seal, ensure that the V-cup seal opens in the flow direction – Figure 1.

Figure 1 - Element Loading Direction

Note: The flow direction may not be the same for all vessels in a system.

Caution: Never put V-cup brine seals on both ends of an element.

Caution: RO elements are preserved with a solution containing 1% sodium bisulfite. Avoid
direct contact with this solution.

5. Gently lubricate interconnector O-rings with thin layer of pure silicone lubricant
(Molykote 111 or Parker Super O-Lube) and insert interconnector in permeate tube of
first element.

6. Lubricate element brine seal with glycerin solution using brush or dauber.

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7. Connect next element to interconnector and push both elements into pressure vessel up to
three-quarters of the length of the element and again remove the plastic bag. Caution:
Ensure the weight of the outboard element is not supported by the interconnector by
supporting the element if necessary – Figure 2.

Figure 2 - Interconnector Configuration between Two RO Elements

8. Repeat above steps with all other elements.

9. When installing last element, place hand on the face of the seal carrier and push the
element stack completely inside the pressure vessel towards the brine end until the last
element fully connects with end plate permeate adaptor on brine side of the pressure
vessel.

Caution: Watch fingers and hands for pinch points.

10. After loading all elements determine if shimming the vessel is necessary prior to
installing the upstream end cap.

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Personal Safety Note:
Element loading and unloading can require extended and repetitive physical motion. Simple
stretching exercises before, during, and after loading/unloading multiple elements may help
to reduce tightening and fatigue of joints and muscle groups used repeatedly during this type
of work. So, if you begin to experience muscle tightness and/or joint fatigue, take a break and
S-T-R-E-T-C-H. Use the following visual illustrations and instructions for proper stretching
technique:

HANDS
Stretch Exercises
Hand Stretch
Extend your right arm
out in front of you
Turn your palm so your
fingers point upward.
With your left hand,
gently pull fingers toward
your body while locking
your right elbow.
Hold it for 5 seconds
Repeat on the left hand.

LEGS
Stretch Exercises
Thigh & Quad
Stretch
Start in a standing position.
Raise your left leg behind you
and grab your left foot.
Keep your thighs parallel
when performing this
exercise.
Don’t arch your back.
Hold for 5 seconds, then
switch sides. (repeat 2
times).

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 SHOULDER/BACK/NECK
Stretch Exercises
Shoulder/Back/Neck
Stretch
With your right hand, pull
your left shoulder across
your chest as far as
comfortable.
Hold it for 10 seconds
Switch arms and repeat.

SIDES/ARMS
Stretch Exercises
Side Stretch
Reach up with both hands,
elbows straight.
Hold your right wrist with
your left hand and pull
upward.
Lean to the left and push
your hips to the right.
Hold for 5 breaths.
Reverse arms and stretch
to the right.

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LEGS/BACK
Stretch Exercises
Hamstring Stretch
Stand with feet spread
apart and knees slightly
bent.
Slowly bend from the waist
and reach for the floor.
Stay in this position for 5
breaths.
Switch sides and repeat.

SHOULDERS
Stretch Exercises
Shrugs & Circles
Shrugs: Pull your
shoulders toward your
ears.
Hold for count of 5,
Repeat 3 times.
Circles: roll your
shoulders forwards then
backwards
Repeat 3 times.

44
Pressure Vessel Shimming
All pressure vessels are built with some tolerance in length to account for small differences in the
length of the elements. Furthermore, the length of the pressure vessel also changes slightly due to
expansion during operation. Therefore it is recommended to shim elements to take up free space
in the vessel. This helps to prevent elements from moving when the system is shutting down and
starting up. The appearance of leaks between elements is also minimized when the elements are
shimmed and movement minimized. Insufficient shimming can lead to premature wear of
interconnector and end plate adaptor O-rings or even to disconnections of elements from end
plate adaptors. This will result in feed to permeate leaks and poor permeate quality.

Note: Always shim vessels from feed end side. Shimming from brine end side can lead to telescoping of the elements.

The following procedure is recommended to shim the pressure vessel:

1. Remove O-rings from permeate adapter (element side) and head seal from feed end cap
assembly.

2. Remove adapter from head assembly and gently lubricate adapter seal with silicone
lubricant (Molykote 111 or Parker Super O-Lube).

3. Insert adapter into element permeate tube.

4. Gently slide end cap on adapter until bearing plate is in line with retaining ring
groove on pressure vessel.

5. Gently remove end cap assembly from pressure vessel and measure the gap between
adapters and permeate port (Figure 3).

6. Insert required quantity of shims over adaptor to completely fill the gap.

7. Insert adapter into end cap permeate port.

8. Install O-rings and lubricate them gently with pure silicone lubricant (Molykote 111
or Parker Super O-Lube).

9. Install head seal and lubricate it with glycerin.

10. Install end cap assembly.

11. Repeat above procedure on all pressure vessels.

12. Finally install end cap retaining device (segmented ring or spiral lock ring).

13. Re-install all connecting pipes

45
Note: A gap of 2 mm between the end plate and the shims will not cause problems in performance.

Figure 3 - Shimming

14. Slowly fill the system with water at low pressure to prevent hydraulic shock (water hammer) at start-
up. When all air is purged from the system, slowly bring the system up to design pressure and flow. RO
membrane recommends that the RO system be pressurized at no more than 10 psi (0.69 bar) per second
to ensure no damage is done to the membrane element.

1
Chapter 15

Data Sheet of all Equipments.

15.01 RO Feed Pump

15.02 High Pressure Pump
15.03 Filter Feed Pump
15.04 Lorry Filling Pump
15.05 FRP Vessel
15.06 Dosing Pump
15.07 pH correction System
15.08 PLC Panel
15.09 Process and Instrumentation Diagram
15.10 RO Projection
15.11 RO Chemicals Data Street.
15.12 Membrane Arrangement

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3