WTP Manual

SUBJECT : PT.
MENAMAS
BELAWAN UF, RO Pass-1, RO Pass-2 AND MB
WATER TREATMENT PACKAGE.
NUMBER.
DATE : 21.07.2009
REV. A / 25.12.2010
OPERATION AND MAINTENANCE MANUAL

FOR
WATER TREATMENT PACKAGE
PROJECT
PT. MENAMAS
BELAWAN
SUPPLIED BY
ION EXCHANGE ASIA PACIFIC PTE. LTD.,
SINGAPORE.
SUBJECT : PT. MENAMAS

BELAWAN UF, RO1, RO2 AND MB
NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
INDEX
1. INTRODUCTION
2. DESCRIPTION
3. OPERATING PHILOSOPHY
4. OPERATING INSTRUCTION
5. CHEMICAL CONTROL
6. TROUBLE SHOOTING
7. MAINTENANCE
8. SAFETY

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
SECTION 1
INTRODUCTION

NUMBER.
DATE : 21.07.2009
REV. A / 25.12.2010
1.0 INTRODUCTION
1.10 GENERAL
This document is produced as a Training Manual of Water Treatment Package which is a part of
the MENAMAS, BELAWAN Power Station. This manual has to be considered as a basis for
operation in conjunction with the operating philosophy.
This manual is basically divided in various sections mainly as:
Introduction: This gives a general introduction and basic water treatment fundamentals.
Description: This gives the description of the total package and also the details of individual
equipment used write from the water intake upto production of De-mineralised water which will
be used in the power plant.
Operating Philosophy: The operating parameters, the sequential operation of the units and
interlocks.
Erection Instructions: this section describes about the general erection procedures.
Chemical Control: This section basically gives the laboratory analytical procedures for various
parameters involved in water treatment.
Trouble Shooting: This section gives the trouble shooting of the plant.
Maintenance: This gives the general maintenance of the water treatment plant.
Safety: This gives the safety procedures for the chemical handled in water treatment plant.

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
1.20 FUNDAMENTALS OF WATER TREATMENT:

1.20.1 WATER
Water, which is required for Industrial or process use, is available from two sources. Surface
supplies - such as from rivers, lakes and surface wells - and underground supplies such as tube
- wells.
Natural water contains dissolved salts. The water dissolves these salts in flowing over limestone,
gypsum, dolomite and other mineral deposits containing them. Natural water is likely to contain
different concentrations of:Alkaline salts such as Bicarbonates and (rarely) Carbonates of Calcium, Magnesium and
sodium.
Neutral Salts such as Sulphates, Chlorides and Nitrates of Calcium, Magnesium and Sodium.
Other dissolved impurities such as Silica, dissolved Carbon Dioxide and metals - Iron,
Manganese - and Organic Matter may also be present to a lesser extent. The range of minerals
contained in most natural waters is quite limited. The CATIONS present are normally Calcium,
Magnesium and Sodium while the ANIONS are mainly Chlorides, Sulphates and Bicarbonates
with lower concentrations of Nitrate and Silica.
Thus for most waters, analysis of the ions mentioned above will give the TOTAL DISSOLVED
SOLIDS.
The range of uses of water in Industry is very wide. Where water is to be heated within a
process such as in boilers, heating and cooling systems, laundries, bottle washing, scale
formation is the most immediate hazard but for high pressure boilers, for laboratory purposes,
electronic and metal finishing industries any dissolved impurities in the water may contaminate
the product and the complete removal of all dissolved ions - DEMINERALISING OR
DEIONISING becomes necessary.

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1.20.2 ULTRAFILTRATION PROCESS

Ultra filtration is a tangential flow, pressure driven filtration process that separates particles on the
basis of their molecular size. Pore diameters of Ultra filtration membranes are in the range of
1,000 to 1,000,000 Molecular Weight Cut Off (0.001 to 0.02 micron). Solvents and species having
a diameter smaller than the pore size of the membrane will pass through the membrane and
emerge as UF Product, known as Permeate. Rejected species are progressively concentrated in
the reject stream. Ultra filtration membranes are reusable and cleanable with standard chemicals.
Ultra filtration of process water provides:
Specific Removal of virtually all-particulate matter, suspended solids, bacteria, viruses, and
pyrogenic species purely based on their Molecular Weight Cut Off from pharmaceutical and
industrial process water.
Removal of colloidal material (non-reactive silica, iron, aluminium, Turbidity, Silt etc.)
Removal of high molecular weight organic.
The Ultra filtration membrane is a thin polymeric material, either polysulfone or polyacrylonitrile,
with an anisotropic pore structure. This means the membrane does not have the same pore
structure throughout its matrix.
The combination of the very smooth surface with small pores and the support structure with much
larger pores results in filtration of small particles with a low resistance to flow.
Ultra filtration is a cross flow or tangential flow process. The stream to be purified (the feed stream)
flows along the surface of the membrane. These results in a fluid shear condition at the wall on the
inside of the fiber, which will tend to keep the surface of the membrane free of fouling matter. The
suspended material of the feed stream will be concentrated and exit the process as the reject stream.
This tangential flow process technique serves to prevent particles from building up on the surface of the
membrane and enhances long term productivity of the filter between cleaning cycles.
The difference in pressure between the feed and reject streams will determine the flow of water
across the surface of the membrane. In addition, a portion of the feed stream will pass through the
membrane. This product stream is the Ultra filtrate, otherwise known as Permeate. The pressure
difference between the feed stream and the product side of the membrane is directly related to the
product flow. When pressure is applied to the feed stream, it flows tangential to the membrane
surface. Ultra filtration is a dimensional separation process. Generally Ultra filtration membranes
are rated on their Molecular Weight Cut-off, abbreviated MWCO. This is an indicator of the relative
size of the globular molecules, which a membrane will remove. Koch Membrane Systems has Ultra
filtration membranes with MWCO ranges between 1,000 and 1,000,000. The aqueous phase and
material smaller than the membranes nominal MWCO will pass through the membrane. Therefore,
the product stream will contain water, ionic species, and low molecular weight material, whereas
colloidal matter, particles, bacteria, viruses and pyrogenic species will be rejected by the
membrane.

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
1.20.3 REVERSE OSMOSIS PROCESS

This section describes the process of demineralisation by reverse osmosis (RO) and the main
equipment used.
Osmosis and Reverse Osmosis
Osmosis is a natural process involving fluid flow across a semi permeable membrane barrier. It is
selective in the sense that the solvent passes through the membrane at a faster rate than the
dissolved solids. The difference of passage rate results in solvent solids separation. The direction
of solvent flow is determined by its chemical potential, which is a function of pressure, temperature
and concentration of dissolved solids.
Pure water in contact with both sides of an ideal semi permeable membrane at equal pressure and
temperature has no net flow across the membrane because the chemical potential is equal on both
sides. If a soluble salt is added on one side, the chemical potential of this salt solution is reduced.
Osmotic flow from the pure water side across the membrane to the salt solution side will occur until
the equilibrium of chemical potential is restored. Equilibrium occurs when the hydrostatic pressure
differential resulting from the volume changes on both sides is equal to the osmotic pressure. This
is a solution property independent of the membrane.
Application of an external pressure to the salt solution equal to the osmotic pressure will also cause
equilibrium. Additional pressure will raise the chemical potential of the water in the salt solution and
cause a solvent flow to the pure water side, because it now has a lower chemical potential. This
phenomenon is called reverse osmosis.
In the reverse osmosis process, the water that passes through the membrane is commonly referred
to as permeate or product water, the water that remains behind the membrane along with dissolved
and suspended solids is referred to as the concentrate, brine or reject water. We have used these
terms interchangeably in this manual.
Pressurised feed water is introduced into one end of the pressure tube. Some of the water, driven
by the feed pressure through the RO pressure tube feed port permeates through the membrane,
passes into the product tube and exits the pressure tube from the pressure tube product port as
product water, less most of the dissolved solids and all of the suspended solids. The remainder of
the water passes along the surface of the membrane with the concentrated dissolved and
suspended solids and passes out of the pressure tube concentrate port as concentrate, brine or
reject.
The pressure tubes are generally arranged in stages when more product water is desired than one
module can produce. The staging of the modules is designed to optimise the water flow patterns
across the surface of the membrane. This uniform water flow promotes good flushing velocity
across the membrane surface to prevent the accumulation of suspended solids on the surface
which would foul the membrane and reduce the productivity. Multiple stages are referred to as
arrays.
Different ions also pass through the membrane to different extents depending on various factors
such as valency, ionic size, concentration, etc. Therefore, the product water does have some salts,
usually approximately 10% of the salts in feed water. Salt passage is defined as the ratio of total
dissolved solids (TDS) in permeate to TDS in feed water.

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A certain minimum reject water flow is always maintained to flush the membrane surface and also
keep certain sparingly soluble salts below their solubility limits. As a result, the ratio of the product
water or permeate flow to feed water flow, called the recovery, is always less than 1.0.
1.20.4 MIXED BED ION EXCHANGE PROCESS
The mixed bed demineralization process consists of SAC and SBA resins intimately mixed in the
same unit to bring about the demineralization of water. In effect it is multiple and random two bed
demineralising pairs resulting in very high quality of demineralised water.
The strong acid cation (SAC) resin exchanges all cations in water. The cations associated with
alkalinity or those combined as neutral salts are all removed by the SAC resin. Hence this resin is
used universally in a demineralization process.
Likewise the strong base anion (SBA) resin exchanges all anions in water. Alkalinity, anions of
neutral salts and weakly ionised species such as carbon dioxide and silica are all removed by the
SBA resin. Hence this is used also universally for complete removal of all anions present in water
The SAC resin is in the hydrogen form and the SBA resin is in the hydroxide form.
But the leakage of ions, caused by the regenerative effect of free mineral acidity (FMA) or of
sodium hydroxide (NaOH) formed in the exchange process, is absent in the mixed bed
demineralization process. This is so because FMA generated by the SAC resin is exchanged by
neighbouring SBA resin; likewise NaOH generated by the SBA resin is exchanged by the adjacent
SAC resin. In this manner the products of reaction of the resins are immediately removed driving
the reactions to completion and the equilibrium reactions do not exist. This results in good quality of
treated water and the multiple contacts provides a polishing action yielding extremely pure
demineralised water.
Conductivity is an importation indicator of water quality. The final treated water from the mixed bed
unit with conductivity less than 1 S/cm and mostly in the range 0.2 - 0.5 S/cm
Silica residual obtained from mixed bed demineralization are generally in the range 0.02 - 0.05 mg/l
commonly achieved in mixed bed demineralization.
When the treated water quality from the mixed bed is out of specification or the designed
throughput is attainted, the unit requires regeneration.
1.20.5 INLET WATER QUALITY
Because the Ultra Filtration Membrane must be kept clean to function efficiently, the inlet water or
RAW WATER must be cold, clean and colourless.
The water should be free of suspended matter, organic matter, oil, algae, slime and heavy metals
such as iron, aluminium. These impurities would collect on or within the resin particles and reduce
their capacity for removal of the ions. Hence some waters may require coagulation and filtration
prior to being fed into the UF system.

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
1.20.5.1ULTRA FILTRATION SYSTEM DESCRIPTION

The system consists of UF MODULES / MEMBRANES of 10 dia x 72 long hollow fiber module.
The treated water will have SDI less than 1 and Turbidity less than 1 NTU. The feed shall be Bore
Well.
The system consists of the following:a) Koch Membrane system 10 dia x 72 long cartridge / module of 1, 00,000 Molecular
Weight Cut-off.
b) Stainless Steel Centrifugal pumps which is used for Recirculation and Back flush
operation of the Ultra filtration System.
c) SS316 basket strainer (100 microns).
d) Feed / CIP Tank, Permeate water tank.
e) Pressure gauges.
i) Differential pressure across the feed and reject of membrane.
ii) Trans membrane pressure across the UF module.
f)
Set of pipes/fittings (SS316 / PVC)

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REV:1 DT 25.12.2010
1.20.5.2 REVERSE OSMOSIS PASS-1 SYSTEM DESCRIPTION

The entire system is mounted on a Skid (excluding tanks)
The following gives brief description regarding the major components
2.1 Pretreatment cartridge filter (CF)
The Cartridge Filter which is installed upstream of the high pressure pump removes particulate
matter up to 5 microns from the feed water and minimises the fouling of the RO membrane
elements.
2.2 High pressure pump
A high pressure pump of stainless steel construction is provided to boost the feed pressure for the
reverse osmosis membrane. A low pressure switch is provided at the pump suction to safeguard
the pump.
A stainless steel globe/ball/butterfly valve is provided on the pump discharge for regulating the
pressure and flow to the reverse osmosis membrane.
A pressure gauge is provided upstream of this valve to monitor the pump performance.
2.3 Reverse Osmosis system
Basically the system consists of Reverse Osmosis membranes, pressure vessels (called pressure
tubes) in which the membranes are mounted and piping for feed, reject and product with necessary
instruments.
A cut-away view of the Reverse Osmosis membranes shows the details of the spirally wound
configuration. The feed water is applied at one end of the membrane at high pressure. Because of
the high pressure, reverse osmosis process takes place and permeate flows through the
membrane and is collected through the core tube and normally flows out of the end opposite the
feed. The reject is also collected from the opposite side.
In order to maximize the recovery, a number of membranes are put end-to-end in a pressure tube
made of FRP. The pressure tube is designed to withstand the pressure at which the RO system has
been designed.
To further improve the recovery, a number of pressure tubes are arranged in different combinations
in such a way that the reject from the first "stage" becomes the feed for the next, and so on.
Permeate is normally collected in a parallel manner from all the pressure tubes. The exact
arrangement of staging would depend on the raw water characteristics and the desired treated
water quality.
High pressure piping with necessary fittings is provided for the above purpose.
1.20.5.3 REVERSE OSMOSIS PASS-2 SYSTEM DESCRIPTION
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3.1 Wet panel

A "Wet" panel is provided for mounting of pressure instruments.
A high pressure gauge & a low pressure gauge are provided on the wet panel with a 5-way & a 3way valve. By operating the valve, the operator can note the feed pressure to various stages and
the concentrate pressure. From these, stage wise pressure drop can be calculated.
Stainless steel sample valves are also provided to collect samples from the various stages and
final concentrate.
3.2 Electrical control panel
The electrical control panel has a sheet steel enclosure and houses the controls and instruments
for operation of the RO unit.
Relay/timer based controls are provided for starting and stopping of the RO unit and for the safety
of the high pressure pump.
Please see the Technical Data Sheet for details of instruments provided.
11

NUMBER.
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REV:1 DT 25.12.2010
1.20.5.4 MIXED BED UNIT:

In the Mixed Bed Polishing, the Cation and Anion exchange resins are mixed in certain proportion
to achieve the finest quality to meet the Boiler water requirements.
The unit essentially consists of carbon steel rubber lined pressure vessel. It is externally fitted with
rubber lined pipe work, necessary valves, pressure gauges and sampling valves at the inlet and
outlet.
Internally the unit is provided with an inlet distributor, caustic distributor, middle collector for acid /
caustic effluent during regeneration. A bottom collecting system is provided for collecting the
treated water and distributing the acid during regeneration and distributing air during air mix
operation. Bottom collector will also used for giving the water during the backwash operation.
The middle collector is of header lateral type. Polypropylene strainers are fitted to the laterals which
are connected to the header.
The vessel is provided with inspection windows, one at interface of cation and anion resins to
watch resin separation during backwash and mixing operation during air mix and other one at the
top of the unit to observe the inside water level during DRAIN DOWN operation and one below the
center to observe mixing of resin during the air mix operation.
Water from a strong base anion unit enters mixed bed unit for removing the traces of impurities
remaining in the demineralised water. The mixed bed exchanger contains a mixture of cation and
anion resins, thus presenting a large number of demineralising stages (cation and anion resin
combination) inside the unit. This results in production of extremely pure water.
When treated water quality goes beyond the conductivity of 0.5 S/cm or reactive silica content of
0.02 ppm as SiO2 or the pH (@25 deg. C) beyond the range of 6.5 to 7.5 or the unit has delivered
its specified output of 1000 m3 between two regenerations whichever appears first, the unit is said
to be exhausted at this stage the unit needs to be regenerated. y.
4.1 REGENERATION:
The regeneration of the mixed bed consists of the following basic steps
Backwash
Regenerant injection
Regenerant rinse
Air mix
Final rinse
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4.2 Backwash
The backwash is a very important and critical step in the regeneration of the mixed bed. It brings
about the separation of the SAC and SBA resins to enable their individual regeneration.
During backwash, water is admitted into the bottom of the unit and flows upwards to expand and
fluidise the resin bed. The wash water is led to drain.
The wash flow rate is so adjusted as to bring the lighter anion resin to the top and permit the
denser cation resin to settle down. In this manner the cation and anion resins are separated
distinctly into two layers with the anion layer on top of the cation layer.
The backwash also performs the other functions of decompacting the resin bed, cleaning it and
reclassifying the beads each so important for satisfactory resin functioning.
Care must be taken during backwash to prevent loss of costly ion exchange resins by carryover
through excessive flow rate.
Insufficient backwash flow rate will not separate the resins completely and lead to improper
regeneration affecting the quality of water and the throughput.
Backwash is done for a minimum specified time and until clean effluent is obtained.
4.3 Regenerant Injection
Once the resins are separated thoroughly, they can be regenerated properly to bring them into the
operating forms.
To regenerate the SBA resin, the solution of sodium hydroxide is introduced above the resin bed,
flows through the anion resin layer and is withdrawn at the interface of the anion and cation resins.
The SAC resin is regenerated by injecting the solution of hydrochloric acid or sulphuric acid at the
anion-cation interface down through the cation layer and out from the bottom of the unit.
A small upward (buffer) flow of water is maintained through the cation resin during the injection of
regenerant into the anion resin to minimise the diffusion of sodium hydroxide into the cation layer
and avoid its exhaustion.
Likewise during the injection of regenerant into the cation resin, a downward (buffer) flow of water
is maintained through the anion layer to reduce the diffusion of acid into the anion resin and
minimise its contamination.
The above buffer flows are necessary when the regenerants are injected successively.
The regenerants may be injected simultaneously in which case the sodium hydroxide flows as
before downwards through the anion resin but the acid flows upwards from the bottom of the unit
through the cation resin. The combined waste effluents are withdrawn from the anion - cation
interface.
13

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In this method of simultaneous regenerant injection there are the following advantages
saving of overall time of regeneration
saving of waste water as the buffer flows are not required during the injection and
subsequent rinse stages
Instantaneous neutralization of the acidic and alkaline waste effluents from the SAC and
SBA resins respectively.
The injection concentrations are indicated below

Sodium hydroxide 5 % w/v
Hydrochloric acid 5 % w/v
The regenerant must be injected within a particular range of flow rates to maintain adequate
contact time for the regeneration reactions to take place.
4.4 Regenerant Rinse
This rinse operation is done subsequent to regenerant injection and follows the same direction of
flow as the injection and at nearly the same flow rate.
The rinse enables a better utilization of the regenerant lately injected to contact the rest of the resin
bed. It also washes the excess regenerant off the resin to minimise the cross exhaustion of resins
in the subsequent stages.
A few bed volumes of water are required for this purpose.
4.5 Air Mix
The air mix is the next critical step after backwash in ensuring good treated water quality. The
better the mix of the two resins, the better is the quality of treated water.
In this step air is used to agitate, stir and mix the cation and anion resins thoroughly to provide the
infinite stages of two bed demineralization. When the mixing is not adequate, there are layers
rather than pairs of resin and the effect of multiple stages is not realised.
As the agitation with air is done with water present in the unit, some settlement does take place.
This is minimised through a partial drain down prior to air mix.
The air mix operation is done for a specified time with low pressure air at a particular flow rate.
2.3.10 Final Rinse
This is the last step of the regeneration stage and aims at settling the resin in the mixed state after
air mixing and washing away the trace regenerants from the resin bed.
The final rinse must follow the air mix quickly to prevent reclassification of resins under gravity
resulting in some centimeters of anion resin at the top and cation resin at the bottom of the bed.
The final rinse is normally at service flow rate or a specified minimum flow rate with influent water.
14

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The end of rinse is determined by water quality usually its conductivity or silica content. When
these parameters are normal, the rinse is stopped and the regeneration of the mixed bed is
complete. The mixed bed may be isolated or taken to service for production of demineralised water.
The mixed bed demineraliser is a down flow service unit. The SBA resin in it is always regenerated
co flow while the SAC resin is amenable to both co flow and counter flow regeneration.
The mixed bed is normally employed as a polisher downstream of a two bed demineraliser.
15

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TECHNICAL DATA SHEET

1.3.1
FEED WATER SPECIFICATIONS

Water Inlet
Temperature
PH
1.3.2
: Well Water
: < 45 C
: 6-8
UF MEMBRANE SPECIFICATIONS
Molecular weight cut off
Nominal operating pressure
Maximum Operating temperature
: 100,000 MWC
: 10-70 PSI
: 65 C.
A. QUANTITY
: 10 NUMBERS
Diameter/Length of cartridge
: 10 diameter x 72 long.
B. Fast flush Pump

Capacity (Maximum)
: 114 m3/hr @ 2.0 kg/cm2.
C. Back flush pump

Capacity(Maximum)
: 124 m3/hr @ 2.5 kg/cm2
D. Material of Construction
All wetted parts other than UF
Ultra filtration Membrane
Pre filter
Gasket material
E.
:
:
:
:
SS 316 / PVC
Polysulphone
Stainless Steel
Silicone/EPDM
Service utilities
Electrical
Feed water
:
:
16
380V/50Hz/3 Phase
50 m3/hr

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RO MEMBRANE SPECIFICATIONS
1.3.3.1 RO FEED PUMP
Quantity
2 Nos.
Model
Capacity
CR 45 - 2
3
m /h
45
Head meter
35
Make
Grundfos
MOC
SS316 / CI HOUSING
Motor rating kw
7.5
Motor speed RPM
2900
Make
Grundfos
1.3.3.2 Micron Cartridge Filter

Quantity
1 No.
Size
Jumbo 20 Long
MOC
PP
Filter Element /Type
5-micron
1.3.3.3 RO PASS-1 HIGH PRESSURE PUMP

Quantity
2 Nos.
Model
Capacity
CR 64-5-1
3
m /h
45
Head meter
120
Make
Grundfos
MOC
SS316 / CI HOUSING
Motor rating kw
30
Motor speed RPM
2900
Make
Grundfos
1.3.3.4 Reverse Osmosis Pass-1

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Model No.
RO PASS -1
Number of stages
Array
4X6:3X6
Pass
Number of pressure tubes
Pressure tube rating psi
250
Make of pressure tube
Advanced Composites
Size of pressure tubes
Elements/pressure tube
Element model
TM 720-370
Number of elements
42 nos.
Maximum feed flow
45 m3/h
Maximum permeate flow
35 m3/h
Maximum reject flow
5 m3/h
Reject recycle flow
5 m3/h
Recovery
70%
1.3.3.4 RO PASS-2 HIGH PRESSURE PUMP

Quantity
2 Nos.
Model
Capacity
CRN 45-4
m3/h
32
Head meter
80
Make
Grundfos
MOC
SS316
Motor rating kw
15
Motor speed RPM
2900
Make
Grundfos
1.3.3.5 Reverse Osmosis Pass-2

Model No.
PASS-2
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Number of stages
Array
3X6:2X6:1X6
Pass
Number of pressure tubes
Pressure tube rating psi
250
Make of pressure tube
Advanced Composites - Goa
Size of pressure tubes
Elements/pressure tube
Element model
TM 720-370
Number of elements
36 nos.
Maximum feed flow
32.4 m3/h
Maximum permeate flow
27.5 m3/h
Maximum reject flow
4.9 m3/h (TO RO-1 FEED)
Recovery
85%
1.3.3.6 DEGASSER TOWER, TANK WITH BLOWER:

Degasser tower Diameter
600mm
Degasser tower Height On Straight
3200mm
Blower Capacity
6m3/minute
Head meter
50mmWC
Make
IEI
MOC
CS
Motor rating kW
0.37
Motor speed RPM
2900
Degasser tank diameter
2000mm
Length On Straight
4000mm
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1.3.3.7 Cleaning system:

CIP tank capacity
2000Litres
Tank MOC
HDPE
CIP Pump
1 No.
Model
Capacity
CRN 32-2
3
m /h
27
Head meter
35
Make
Grundfos
MOC
SS316
Motor rating kW
Motor speed RPM
2900
Make
Grundfos
1.3.3.9 Mixed Bed Feed Pump:

Model
Capacity
GSHF 40-100
3
m /h
25
Head meter
35
Make
Goulds
MOC
SS316
Motor rating kW
5.5
Motor speed RPM
2900
20

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1.3.3.10 Mixed Bed Unit:

Diameter
1400mm
Height On Straight
2800mm
Material of Construction
Carbon Steel
Internal Protection
Rubber Lining
Cation Resin 225 H
800 Litres
Anion Resin FFIP
1250 Litres
Cation Bed Depth
500mm
Anion Bed Depth
800mm
Hydrochloric Acid (100%)
80 Kgs
Caustic Soda (100%)
125 Kgs
1.3.3.11 Mixed Bed Regeneration Pump:

Model
GSHF32-200
Type
Capacity
Horizontal Centrifugal
3
m /h
15
Head meter
35
Make
Goulds
MOC
SS316
Motor rating kW
Motor speed RPM
2900
1.3.3.12 MIXED BED BLOWER:

Blower Capacity
4.5m3/minute
Head meter
Make
IEI
MOC
CS
Motor rating kW
0.18
Motor speed RPM
2900
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1.3.3.13 Neutralization Pit Waste Transfer Pump:

Model
NH 405 PW N CV
Type
Capacity
Self Priming Magnetic Driven Seal less

3
m /h
20
Head meter
25
Make
Pan World Pumps (Japan)
MOC
FRPP
Motor rating kW
3.7
Motor speed RPM
2900
1.3.3.14 BULK CHEMICAL TANKS:

Diameter
1800mm
Height On Straight
2500mm
Capacity
5M3
FRP Vinyl Ester
Type
Horizontal Dished End
Pressure
Atmospheric Pressure
Temperature
Ambient 25 D Celsius
Application
Chemical Storage
Breather Pot
Provided
Level Transmitter
Top Mounted
1.3.3.15 CHEMICAL DOSING TANKS:

Diameter
1800mm
Height On Straight
2500mm
Capacity
5M3
FRP Vinyl Ester
Type
Horizontal Dished End
Pressure
Atmospheric Pressure
Temperature
Ambient 25 D Celsius
Application
Chemical Storage
Breather Pot
Provided
Level Transmitter
Top Mounted
22

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
2.DESCRIPTION
23

NUMBER.
DATE : 21.07.2009
REV. A / 25.12.2010
2.1 DESCRIPTION OF RAW WATER

The Raw water source is from the borewell in the backwater is a manual system
consisting of two pumps, each stream capable of pumping the full flow rate of 55 m3/hr.
Can be automatically Start and Stop. The pumps are designed to be operated at a
constant flow rate (Clients Scope).
2.1.1 DESCRIPTION OF ULTRA-FILTRATION PLANT
2.1.2
2.1.3
2.1.4
DESIGN BASIS OF ULTRA-FILTRATION

Operating Data
NUMBER OF STREAM
ONE
NORMAL FLOW
45 M3/HR.
Design raw water quality

Raw Water
UF Product
pH
7.3-7.5
7.3-7.5
TOTAL DISSOLVED SALTS
1796
1796
TOTAL SUSPENDED SOLIDS ppm
<1
CALCIUM HARDNESS,
ppm as Ca
TOTAL HARDNESS
ppm as CaCO3
20
20
SODIUM (CALCULATION)
ppm as Na
48
48
CHLORIDES
ppm as Cl
16
16
SULPHATES
ppm as SO4
nd
nd
NITRATE
ppm as NO3
11
11
TOTAL ALKALINITY
ppm as CaCO3
165
165
REACTIVE SILICA
ppm as SiO2
20
20
IRON
ppm as SiO2
0.2
nil

2.1.5
NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
DESCRIPTION OF ULTRA-FILTRATION
The Ultrafiltration Process

Ultrafiltration is a tangential flow, pressure driven filtration process that separates
particles on the basis of their molecular size. Pore diameters of Ultrafiltration
membranes are in the range of 1,000 to 1,000,000 Molecular Weight Cut Off (0.001 to
0.02 micron). Solvents and species having a diameter smaller than the pore size of the
membrane will pass through the membrane and emerge as Ultrafiltrate, known as
Permeate. Rejected species are progressively concentrated in the reject stream.
Ultrafiltration membranes are reusable and cleanable with standard chemicals.
Ultrafiltration of process water provides:
Removal of virtually all-particulate matter, suspended solids, bacteria, viruses, and

pyrogenic species from pharmaceutical and industrial process water.
Removal of colloidal material (non-reactive silica, iron, aluminum, etc.)
Removal of high molecular weight organic.
The Ultrafiltration membrane is a thin polymeric material, either polysulfone or

polyacrylonitrile, with an anisotropic pore structure. This means the membrane does not
have the same pore structure throughout its matrix.
The combination of the very smooth surface with small pores and the support structure
with much larger pores results in filtration of small particles with a low resistance to flow.
Ultrafiltration is a cross flow or tangential flow process. The stream to be purified (the feed
stream) flows along the surface of the membrane. This result in a fluid shear condition at the
wall on the inside of the fiber, which will tend to keep the surface of the membrane free of
fouling matter. The suspended material of the feed stream will be concentrated and exit the
process as the reject stream. This tangential flow process technique serves to prevent
particles from building up on the surface of the membrane and enhances long term
productivity of the filter between cleaning cycles.
The difference in pressure between the feed and reject streams will determine the flow
of water across the surface of the membrane. In addition, a portion of the feed stream
will pass through the membrane. This product stream is the Ultrafiltrate, otherwise
known as Permeate. The pressure difference between the feed stream and the product
side of the membrane is directly related to the product flow. When pressure is applied
to the feed stream, it flows tangential to the membrane surface. Ultrafiltration is a
dimensional separation process. Generally Ultrafiltration membranes are rated on their
Molecular Weight Cutoff, abbreviated MWCO. This is an indicator of the relative size of
25

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
the globular molecules, which a membrane will remove. Koch Membrane Systems has
Ultrafiltration membranes with MWCO ranges between 1,000 and 1,000,000. The
aqueous phase and material smaller than the membranes nominal MWCO will pass
through the membrane. Therefore, the product stream will contain water, ionic species,
and low molecular weight material, whereas colloidal matter, particles, bacteria, viruses
and pyrogenic species will be rejected by the membrane.
2.2 PRINCIPLE OF OPERATION
There are various modes of operation required for Production, Cleaning and Sanitization of
the UF system to produce Suspended solid and Turbidity free water suitable for further
purification by Reverse Osmosis Membrane.
2.2.1
PRODUCTION MODE
In the production mode, water from feed tank will pass through the Ultrafiltration
membrane from bottom inlet of the UF housing. Turbidity and Suspended solids
will be rejected by UF Membrane while the clear water stream will pass through
the membrane to the permeate tube. Permeate tube will carry the product water
and reject will exist from the top end of the membrane to the drain connections.
2.2.2
RECIRCULATION MODE
In the recirculation mode the water is circulated from a feed pump through the
prefilter and membrane. Both permeate and reject stream are returned to the
same feed tank. Here no permeate is produced, hence this mode is also called
as ZERO RECOVERY MODE.
2.2.3
FAST FLUSH MODE

In the fast flush mode reject valve is open to have maximum differential pressure
(20 psi) along the membrane to have high velocity along the membrane which
results in sweeping action for cleaning the GEL polarised layer on the
membrane. This method allows for high fluid shear at the surface of the
membrane.
2.2.4
FAST FLUSH WITH CHEMICAL CLEANING

The FAST FLUSH WITH CHEMICAL CLEANING MODE is same as fast flush
mode with introduction of chemicals to clean and regenerate the membrane flux.
This mode should be followed by DRAIN AND RINSE cycle to clear out chemical
residue.
26

2.2.5
NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
SYSTEM SANITIZATION MODE

In system sanitization mode sanitization chemicals like sodium hypochloride, or
hydrogen peroxide, Caustic Soda, Citric acid are introduced in recirculation mode
or fast flush mode type of operation. This should also be followed by DRAIN
AND RINSE cycle to rinse out residual chemicals from the system.
4.2.6
BACK FLUSH MODE
The Back Flush hinge serves to remove accumulated particles from the surface
of the Hollow Fiber Membranes and then pushes the particles out of the lumen to
the feed manifolds.
27

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
2.3 PREPARATION FOR OPERATION

2.3.1
INSTALLATION
a) Carefully remove all crating packing material from the unit.
b) Set the unit at a place convenient to a drain and source of water supply and
power. The entire unit is skid mounted.
2.3.2
FLUSHING AND MEMBRANE LOADING PROCEDURE

a) Thoroughly scrub the vessels and accessible interconnecting piping with an
appropriate detergent and rinse.
b) Sanitize with an appropriate chemical agent e.g. 2% Hydrogen peroxide or
200 ppm sodium hypochlorite solution.
c) Before loading the membrane, flush the system and determine baseline
parameters (bacteria level, resistivity, TOC, etc.) with samples taken from the
sampling point.
d) Load the membrane taking reasonable precaution (gloves, face mask not
letting cartridge or part lie on the floor in other surface etc.) to produce as
little contamination as possible.
e) Resanitize the vessel and interconnecting piping by recirculating 2%
caustic chlorite solution for 1-2 hours. Use a feed rate of 16 Cu.mtrs/hr
per vessel and a bleed rate of 400 Litres per hour. Monitor sodium
hypochloride level to 200 ppm.
f) Start flushing of UF membrane at a product rate of at least 5 m3/hr.
Flush until desired product water parameters are obtained.
g) During normal operation, run the system at design parameters.
28

2.3.3
NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
SYSTEM START-UP
MAKE SURE THAT THE MEMBRANE IS PROPERLY POSITIONED and ensure
that the electrical and water connections are complete.
Fill the feed tank with water. Operate the system manually for start up.
Open the manual valve as per attached valve schedule. The auto valve will get
open as per the PLC logic. Keep the valves closed as per the schedule.
Switch ON the feed pump
Slowly open discharge and bring the pressure upto the normal.
Check for any leaks.
When the system is running, adjust the UF reject and permeate. Adjust the
RECOVERY & TRANSMEMBRANE PRESSURE.
CHECK THE LEAKS AGAIN.
STOP the system and drain the system completely.
2.3.4 VALVE SCHEDULE
29

UF
V1
V2
V3
V4
V5
V6
V7
V8
V9
V10
V11
V12
V13
V14
V15
V16
V17
V18
V19
V20
V21
V22
V23
V24
V25
V26
V27
V28
NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
CIP RECIRCULATION TANK INLET

RECIRCULATION / CIP PUMP SUCTION
RECIRCULATION / CIP PUMP DELIVERY
RECIRCULATION / CIP BY-PASS
UF FEED INLET
FAST FLUSH CIP INLET
MICRON FILTER OUTLET
UF PERMEATE OUTLET
REJECT HEADER BACKFLUSH DRAIN
RECIRCULATION OUTLET
FEED HEADER BACKFLUSH DRAIN
REJECT OUTLET
BACKFLUSH INLET
PERMEATE RECIRCULATION
RECIRCULATION / CIP PUMP NON-RETURN
PERMEATE SAMPLE
CIP / RT DRAIN
UF PERMEATE OUTLET
REJECT OUTLET
PERMEATE DRAIN
BACKFLUSH PUMP SUCTION
BACKFLUSH PUMP DELIVERY
BACKFLUSH INLET MODULE
UF MODULE PERMEATE OUTLET
UFPWT DRAIN
BACKFLUSH PUMP DELIVERY (NON-RETURN)
BASKET FILTER WASH INLET
BASKET FILTER WASH OUTLET
2.3.5 START UP AND NORMAL RUNNING MODE
30

FEED PUMP
BACKFLUSH PUMP (P2)
FASTFLUSH PUMP (P1)
NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
ON
OFF
OFF
MANUAL VALVES TO BE KEPT IN OPEN CONDITION

V19
UF Reject outlet & adjust for the designed recovery
V24
UF Module permeate outlet
All other manual valves will be in closed condition

UF AUTO VALVE INTERLOCK SCHEDULE-NORMAL MODE
VALVE
V5
V6
V7
V8
V12 V10 V11/
NO.
V9
NORMAL
O
C
O
O
O
C
C
MODE
O
C
S
ST
OPEN
CLOSE
STOP
START
31
P1
P2

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
2.3.6 BACK FLUSH MODE

Feed pump
OFF
Fast Flush pump
(P1)
OFF
Back Flush pump
(P2)
ON
- The Feed pressure should not exceed more than 10mwc at the inlet of UF
modules.

V21
Back Flush pump suction
V22
Back Flush pump delivery
V13
Back Flush inlet
All other manual valves will be in closed condition.

UF AUTO VALVE INTERLOCK SCHEDULE-BACKFLUSH MODE
VALVE
V5
V6
V7
V8
V12 V10 V11/ P1
NO.
V9
BACK
C
C
C
C
C
C
O
S
FLUSH
MODE
O
C
S
ST
OPEN
CLOSE
STOP
START
32
P2
ST

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
2.3.7 FAST FLUSH MODE

Feed pump
OFF
Back Flush pump
(P2)
OFF
Fast Flush pump
(P1)
ON
To avoid Hydraulic hammer and vibration, it is very important to keep the Fast flush
pump, Bye-pass valve in open condition
MANUAL VALVE TO KEPT IN OPEN CONDITION
V2
Fast Flush pump suction
V3
Fastflush pump delivery
V4
By-pass
V14
Permeate recirculation
V24
Permeate outlet (UF module)
All other manual valves are in close position.

UF AUTO VALVE INTERLOCK SCHEDULE-FAST FLUSH MODE
VALVE
V5
V6
V7
V8
V12 V10 V11/ P1
NO.
V9
FAST
C
O
O
C
C
O
C
ST
FLUSH
MODE
O
C
S
ST
OPEN
CLOSE
STOP
START
33
P2
S

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
2.3.8 CHEMICAL DOSING SYSTEMS

The dosing systems comprise of a NaOCl (at 10.5 pH), Citric Acid and Sodium
Hydroxide dosing tanks, and dosing pumps. The tanks (FRP) are provided with level
Switch, overflow and drain pipe work and the agitators. The dosing done during the
cleaning process of Ultra Filtration.
34

2.4
2.4.1
NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
DESCRIPTION OF RO PASS-1 AND PASS 2
OPERATING DATA
RO PASS -1 & 2
2.4.2
NUMBER OF STREAM
ONE
NORMAL FLOW
34 & 25 M3/HR
DESIGN WATER QUALITY

PARAMETER
UF
pH
CALCIUM HARDNESS,
ppm as Ca
TOTAL HARDNESS
ppm as CaCO3
SODIUM (CALCULATION) ppm as Na
CHLORIDES
ppm as Cl
SULPHATES
ppm as SO4
NITRATE
ppm as NO3
TOTAL ALKALINITY
ppm as CaCO3
REACTIVE SILICA
ppm as SiO2
35
7.3-7.5
1796
<1
5
20
48
16
nd
11
165
20
RO PASS-2
6.4
<5
<1
NIL
NIL
<4
<0.5
nd
<0.2
<1
<0.2

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
Osmosis is a natural process involving fluid flow across a semi permeable membrane
barrier. It is selective in the sense that the solvent passes through the membrane at a
faster rate than the dissolved solids. The difference of passage rate results in solvent
solids separation. The direction of solvent flow is determined by its chemical potential,
which is a function of pressure, temperature and concentration of dissolved solids.
Pure water in contact with both sides of an ideal semi permeable membrane at equal
pressure and temperature has no net flow across the membrane because the chemical
potential is equal on both sides. If a soluble salt is added on one side, the chemical
potential of this salt solution is reduced. Osmotic flow from the pure water side across
the membrane to the salt solution side will occur until the equilibrium of chemical
potential is restored. Equilibrium occurs when the hydrostatic pressure differential
resulting from the volume changes on both sides is equal to the osmotic pressure. This
Application of an external pressure to the salt solution equal to the osmotic pressure will
also cause equilibrium. Additional pressure will raise the chemical potential of the water
in the salt solution and cause a solvent flow to the pure water side, because it now has
a lower chemical potential. This phenomenon is called reverse osmosis.
In the reverse osmosis process, the water that passes through the membrane is
commonly referred to as permeate or product water, the water that remains behind the
membrane along with dissolved and suspended solids is referred to as the concentrate,
brine or reject water. We have used these terms interchangeably in this manual.
Pressurised feed water is introduced into one end of the pressure tube. Some of the
water, driven by the feed pressure through the RO pressure tube feed port permeates
through the membrane, passes into the product tube and exits the pressure tube from
the pressure tube product port as product water, less most of the dissolved solids and all
of the suspended solids. The remainder of the water passes along the surface of the
membrane with the concentrated dissolved and suspended solids and passes out of the
pressure tube concentrate port as concentrate, brine or reject.
The pressure tubes are generally arranged in stages when more product water is
desired than one module can produce. The staging of the modules is designed to
optimise the water flow patterns across the surface of the membrane. This uniform
water flow promotes good flushing velocity across the membrane surface to prevent the
accumulation of suspended solids on the surface which would foul the membrane and
reduce the productivity. Multiple stages are referred to as arrays.
Different ions also pass through the membrane to different extents depending on
various factors such as valency, ionic size, concentration, etc. Therefore, the product
water does have some salts, usually approximately 10% of the salts in feed water. Salt
passage is defined as the ratio of total dissolved solids (TDS) in permeate to TDS in
feed water.
A certain minimum reject water flow is always maintained to flush the membrane surface
and also keep certain sparingly soluble salts below their solubility limits. As a result, the
ratio of the product water or permeate flow to feed water flow, called the recovery, is
always less than 1.0.
36

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
2.4.5 Equipment Description

Please see the enclosed flow diagram for further clarity regarding the various
components that make up the Reverse Osmosis Plant.
The following gives brief description regarding the major components:
2.4.6 Pretreatment cartridge filter (CF)
The Cartridge Filter which is installed upstream of the high pressure pump removes
particulate matter upto 5 microns from the feed water and minimises the fouling of the
RO membrane elements.
2.4.7 High pressure pump
A high pressure pump of stainless steel construction is provided to boost the feed
pressure for the reverse osmosis membrane. A low pressure switch is provided at the
pump suction to safeguard the pump.
A stainless steel globe/ball valve is provided on the pump discharge for regulating the
pressure and flow to the reverse osmosis membrane.
A pressure gauge is provided upstream of this valve to monitor the pump performance.
2.4.8 Reverse Osmosis system
Basically the system consists of Reverse Osmosis membranes, pressure vessels (called
pressure tubes) in which the membranes are mounted and piping for feed, reject and
product with necessary instruments.
A cut-away view of the Reverse Osmosis membranes shows the details of the spirally
wound configuration. The feed water is applied at one end of the membrane at high
pressure. Because of the high pressure, reverse osmosis process takes place and
permeate flows through the membrane and is collected through the core tube and
normally flows out of the end opposite the feed. The reject is also collected from the
opposite side.
In order to maximise the recovery, a number of membranes are put end-to-end in a
pressure tube made of FRP. The pressure tube is designed to withstand the pressure at
which the RO system has been designed.
To further improve the recovery, a number of pressure tubes are arranged in different
combinations in such a way that the reject from the first "stage" becomes the feed for
the next, and so on. Permeate is normally collected in a parallel manner from all the
pressure tubes. The exact arrangement of staging would depend on the raw water
characteristics and the desired treated water quality.
37

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
High pressure piping with necessary fittings is provided for the above purpose.
Overall recovery from the Reverse Osmosis unit is controlled by a stainless steel
concentrate throtting valve.
2.4.9 Wet panel
A "Wet" panel is provided for mounting of pressure instruments.
A high pressure gauge & a low pressure gauge are provided on the wet panel with a 5way & a 3-way valve. By operating the valve, the operator can note the feed pressure to
various stages and the concentrate pressure. From these, stagewise pressure drop can
be calculated.
Stainless steel sample valves are also provided to collect samples from the various
stages and final concentrate.
2.4.10 Electrical control panel

The electrical control panel has a sheet steel enclosure and houses the controls and
instruments for operation of the RO unit.
Relay/timer based controls are provided for starting and stopping of the RO unit and for
the safety of the high pressure pump.
Please see the Technical Data Sheet for details of instruments provided.
38

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
2.4.11 DEGASSER TOWER (DG)

This is a FRP vessel packed with pall rings. Internally it is fitted with a top distributor
which distributes water evenly over the packing and also provides an outlet for the
carbon-dioxide enriched air, a bottom tray is in the form of a grill which supports the
bed of pall rings and also acts as a distributor for low pressure air.
A vent for carbon dioxide and air is provided on the top of the degasser. The outlet
for degassed water is at the bottom of the degasser and is an acid resistant pipe
(which extends down in to the degassed water tank). An air seal FRP fitting is
provided at the outlet which acts as an air seal and prevents air that enters the
bottom of the degasser from escaping to atmosphere via degassed water tank.
The inlet water which contains free carbon dioxide or carbonic acid, flows down the
column against a counter current of low pressure air supplied by a motorized air
blower at the bottom of the degasser. The pall rings provide a large surface area for
contact of water with air. Due to scrubbing action by air, carbon dioxide is stripped
from water and carried out through the vent. The degassed water is collected in the
degassed water tank.
2.4.12 DEGASSER AIR BLOWER
These are motor driven blowers installed at the side of degassed tower to provide
low pressure air for degassing water rich in carbon dioxide. The blower is fitted with
a suction strainer and the delivery end is connected to the bottom of the degasser
by means of a mild steel duct line. The dampener valves are provided at the
discharge of each blower. One blower is normally in service, other will be a standby.
The changeover of the blower is a manual operation and will be carried out from the
CRT panel.
2.4.13 DEGASSED WATER TANK (DGWT)
This is a mild steel rubber lined horizontal tank. The tank is provided with an inlet for
degassed water, an outlet leading to degassed water pump, an overflow and a drain
connection and a gauge glass type level indicator.
39

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
DESCRIPTION OF MIXED BED POLISHER

2.5.1
2.5.2
OPERATING DATA
NUMBER OF STREAM
ONE
NORMAL FLOW
25 M3/HR
DESIGN WATER QUALITY

PARAMETER
pH
CALCIUM HARDNESS,
ppm as Ca
TOTAL HARDNESS
ppm as CaCO3
SODIUM (CALCULATION) ppm as Na
CHLORIDES
ppm as Cl
SULPHATES
ppm as SO4
NITRATE
ppm as NO3
TOTAL ALKALINITY
ppm as CaCO3
REACTIVE SILICA
ppm as SiO2
40
RO PASS-2
MB
6.4
5
NIL
NIL
NIL
<4
<0.5
nd
<0.2
<1
<0.2
6.8 7.2
<0.1
NIL
NIL
NIL
ND
ND
ND
ND
<1
<0.02

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
DE-MINERALISATION BY MIXED BED

2.5.3 MIXED BED FEED PUMP
These are horizontal centrifugal pumps used for pumping of water from degassed
water tank to MB. The pumps are provided with a pressure gauge and a non return
valve on discharge line individually.
2.5.4 MIXED BED UNITS
The unit essentially consists of carbon steel rubberlined pressure vessel. It is
externally fitted with rubberlined pipework, necessary auto valves, pressure gauges
and sampling valves at the inlet and outlet.
Internally the unit is provided with an inlet distributor, caustic distributor, middle
collector for with drawing the acid/ caustic effluent during regeneration. A bottom
collecting system is provided for collecting the treated water and distributing the acid
during regeneration and distributing air during air mix operation. Bottom collector will
also used for giving the water during the backwash operation.
The middle collector is of header lateral type. Polypropylene strainers are fitted to the
laterals which are connected to the header.
The vessel is provided with inspection windows, one at interface of cation and anion
resins to watch resin separation during backwash and mixing operation during air
mix and other one at the top of the unit to observe the inside water level during
DRAIN DOWN operation and one below the center to observe mixing of resin during
the air mix operation.
Water from a strong base anion unit enters mixed bed unit for removing the traces of
impurities remaining in the demineralised water. The mixed bed exchangers contains
a mixture of cation and anion resins, thus presenting a large number of
deminerlising stages (cation and anion resin combination) inside the unit. This
results in production of extremely pure water.
When treated water quality goes beyond the conductivity of 0.2 S/cm or reactive
silica content of 0.02 ppm as SiO2 or the pH (@25 deg. C) beyond the range of 6.5
to 7.5 or the unit has delivered its specified output of 1000 m3 between two
regenerations whichever appears first, the unit is said to be exhausted and will come
out of service operation automatically. At this stage the unit needs to be
regenerated. The following are the stages of regeneration which will be carried out
automatically either based on the specific time or the interlocks such as the low level
of regenerant tank during the injection. Operator will have to decide for the
regeneration and put the unit in regeneration mode manually through the CRT panel
in control room, rest of all the stages till completion of the regeneration will be
carried out automatically.
41

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
2.5.5 REGENERATION OF MIXED BED UNIT

Based on the above mentioned conditions the regeneration stages will follow as
given below:
I)
BACKWASH
Water is passed upwards through the resin column from bottom to top and then
discharged to the drain for 5 minutes at the flow rate of 13.8 m3/hr and the two
resins layers are separated. This operation loosens and cleans the resin bed and
prevents it from becoming tightly packed. The anion resin being lighter goes to the
top while the cation resin settles down when an upward flow of the water is passed.
The separation of the resin can be seen through the middle inspection window. This
operation may be required to continue till the clear separations of resin layers are
observed.
II)
MIDDLE COLLECTOR FLUSHING.

To flush the middle collector for removing any resin attached to the strainers. Water
is passed from the middle collector and is drained through backwash outlet valve.
This operation is carried out for 5 minutes at the rate of 13.8 m3/hr.
III) ACID PRE INJECTION / ALKALI PRE INJECTION

This stage is basically to adjust the power water flow rate for acid and caustic
injection. prior to the injection stage. Power water enters the unit through caustic and
acid inlet valves and discharges out to drain through the middle collector outlet
valve. At this stage the power water flow rate is maintained at 5.2 / 10.41 m3/hr for 2
minutes.
IV ) ACID INJECTION/ ALKALI INJECTION
Once the pre injection flows are set for acid and alkali injection, the Acid injection
valve to open and this stage will continue for 15 minutes or till the low level of acid
measuring tank and Caustic measuring tank is achieved. The effluent is taken out
through the middle collector outlet valves to drain.. Once the low level is achieved
then the sequence will further to next stage.
42

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
V) ACID RINSE/ ALKALI RINSE

After the injection is completed the respective tank outlet valves to be closed, rest of
all other devices will remain active same as of the injection stages of respective
ejectors are closed and power water is continued to pass through the unit for total
utilization of regenerant and to remove residual acid/caustic. This operation takes 31
minutes at the flow rate of 5.2 / 10.41 m3/hr from acid and caustic power water.
VI) DRAIN DOWN
During this stage power water supply to the unit will be stopped and vessel will be
drained up to about 400 mm above the top surface of resin bed (approx. half of top
inspection window). This procedure is done for 10 minutes. This stage is a
preparation stage for the air mix operation. After 10 minutes the sequence will move
on to the next stage of air mix.
VII) AIR MIX
This operation is carried out to mix both the resins which were separated during the
backwash stage. Air is passed from the bottom of the unit to mix the resins
thoroughly. The mixing and movement of the resin bed can be observed through
inspection windows. This procedure is carried out for 10 minutes at the rate of
3.0m3/min @ 0.5 kg/cm2 g.
VIII ) FORCED SETTLE
Immediately after air mixing water is fed through inlet and drained through bottom
collecting system keeping air release valve close. This is carried out to avoid
separation of resin due to different settling velocities. This operation is carried out for
the 5 minutes at the rate of 25 m3/hr.
IX) FINAL RINSE
Service water is taken from inlet and drained from the rinse outlet for 10 minutes at
the rate of 25 m3/hr or till the rinse water quality is within acceptable limits i.e. by
checking conductivity meter which should be less than 0.5 S / cm. The conductivity
of the MB outlet water has to be checked online to avoid the atmospheric
contamination.
43

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
2.5.6 ACID MEASURING TANK FOR MB (AMT)

This is a FR Plastic atmospheric tank. An adequate quantity of acid which is 80Kgs
as 100% is taken in this tank prior to the regeneration which is then injected into the
mixed bed unit. The acid is injected by the Venturi Ejector through a mixing tee. A
gauge glass type of level indicator is provided to measure the draw of acid in the
tank during regeneration a level Transmitter to measure for low and high level. A
fume absorber is provided as a accessory to absorb the fumes evolved by the 30%
HCl. A continuous flow of water is ensured to the fume absorber for the purpose.
2.5.7 CAUSTIC DILUTION TANK FOR MB (CDT)
This is a FR Plastic atmospheric tank. A required amount of caustic 125 Kgs as
100% is taken in this tank and the required strength of 24% solution is prepared by
diluting with water. The tank is provided with a agitator to prepare a homogenous
solution, a gauge glass type level indicator to measure the caustic draw, an overflow
line and a drain connection and a level Transmitter to measure for low and high
level.
2.5.8 BULK ACID TANK (BAT)
This is a FRP atmospheric tank provided for bulk storage of acid. It is provided with
an inlet for filling acid, an outlet leading to acid measuring tanks. The tank is also
provided with overflow and drains connections and gauge glass type level indicators.
A fume absorber is also provided for absorption of fumes evolved by 30% HCl. A
continuous flow of water is maintained through this for the absorption purpose.
2.5.9 BULK CAUSTIC TANK (BCT)
This is a FRP atmospheric tank provided for bulk storage of caustic. It is provided
with an inlet for filling caustic. The tanks are also provided with overflow and drain
connections and gauge glass type level indicators.
44

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
2.5.10 MIXED BED REGENERATION PUMP

These are horizontal centrifugal pumps used for pumping of water from demin water
tank to MB. The pumps are provided with a pressure gauge and a non return valve
on discharge line individually.
2.5.11 MIXED BED BLOWER
These are Twin Lobe blowers used for Resin Mixing in the Mixed Bed unit. The
Blowers are provided with a pressure gauge and a non return valve on discharge
line individually.
2.5.12 N-PIT PUMP
These are horizontal centrifugal Self Priming Seal less pumps used for pumping of
Neutralisation Pit water from N-PIT to Sewers after Neutralisation. The pumps are
provided with a pressure gauge and a non return valve on discharge line individually.
The pH instrument is provided at the outlet to monitor the pH for the safe disposal of
N-Pit waste water.
45

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
SECTION 3
OPERATING PHILOSOPHY
46

3.0
NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
OPERATING PHILOSOPHY
3.1.0
CONTROL AND OPERATING PHILOSOPHY ULTRA-FILTRATION
3.1.1
Salient Features of the Control Philosophy of Ultra-Filtration
Following are the salient features of the control philosophy for operation of Ultrafiltration.
A. Operation of the plant is through PROGRAMABLE LOGIC CONTROL SYSTEM,

which is used for the purpose of the Backwash, CIP and normal operation.
B. The Normal operation (Service) is manual and the frequency of Automatic

backwash is once in 60 minutes as a default setting. However it can be changed
to 15, 30 and 45 as per the water quality. Once the Backwash process is
activated the following process takes place sequentially Back Flush Direction-I
(40 Secs), Back flush Direction-II(40 Secs) and Fast Flush (60 Secs).
C. Once the Fast Flush is over the unit automatically starts generation the UF
product water (During Service / Normal Operation).
D. Voltage free outputs are envisaged to operate solenoid valves for starting /
stopping of pumps / blowers / mixers and analogue outputs shall be 4-20 mA DC
to have control action on the control valves
47

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
UF UNIT WILL BE CUT OFF FROM SERVICE AUTOMATICALLY BASED ON

FOLLOWING CONDITION WHICHEVER IS EARLIER.
1. The UF product tank is high level.
5. The Raw water tank is Low level.
6. UF feed Pressure is High.
PROCESS DESCRIPTION
Following commands are envisaged for the operation :
a) PRODUCTION MODE
b) RECIRCULATION MODE
c) FAST FLUSH MODE
d) FAST FLUSH WITH CHEMICAL CLEANING
e) SYSTEM SANITIZATION MODE
f) BACK FLUSH MODE
LIST OF ALARMS: Alarms to be displayed unit wise on display screen.
1.
RAW WATER TANK LOW
2.
UF FEED PRESSURE HIGH
3.
BACKFLUSH DISCHARGE PRESSURE HIGH
4.
UFPW TANK HIGH
5.
CIP TANK LOW
6.
CIP TANK HIGH
48

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
Following are the salient features of the control philosophy for operation of Ultrafiltration system.
A. Operation of the plant is through PROGRAMABLE LOGIC CONTROL SYSTEM,

which is used for the purpose of the normal operation and During sequence of
Backflush operation. Signals for various alarm conditions, e.g. high level in
UFPWT, Low level in RWT, High pressure during normal process and high
pressure during Backflush etc. are displayed on the local panel display lamps.
E. The starting of the Backflush and service operation is Automatic. After

initialization subsequent stages will proceed automatically.
D. The Ultrafiltration Membrane banks are provided with pneumatically actuated

Butterfly Valves. These valves are operated automatically by Pneumatic
Solenoid valves to Open/Close with respect to the process requirements by PLC.
49

3.1.2
NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
INITIAL FLUSHING AND SANITIZATION OF THE SYSTEM
As the UF cartridge is shipped moist, an initial flux is required each time a new cartridge
is used.
On a periodic basis, all membrane filtration systems require cleaning to remove fouling
material from the membrane. Membrane systems should be cleaned when productivity
reaches a maximum of 70% of the original flux of the system. (i.e. when the permeate flow
goes below 70% of the rated flow rate.)
Cleaning a membrane system is a combination of hydrodynamic removal and chemical

degradation of the foulants. The cycles typically involve recycling water with chemicals such
as chlorine, sodium hydroxide and acids. The duration of a cycle is usually about 1.0 hour,
and the frequency of the cycle ranges from weekly to monthly, depending on the fouling level
of the feed water. The frequency recommended is once in a month for the UF System.
Ultrafiltration membranes are compatible with high levels of cleaning chemicals. Chemical
concentrations used for cleaning are:
Chlorine 250 ppm

Acid (nitric, phosphoric, citric, or oxalic) pH 2-3
NaOH pH 11-12
Peroxide 1,000 ppm (used in place of chlorine)
Cleaning cycles involve flushing the membranes with water, recycling the chemicals through
the cartridges and then flushing the system with clean water.
Before the system is put into operation we have to make sure the fabricated parts of the
machinery like the piping, tanks etc. are free of particulate materials. These particles
especially the metallic particles can damage the membranes very badly and even can
rupture the same. The flushing of all the piping, pumps, instruments before put into
operation is recommended with clean filtered water or Demineralised water. Clean
filtered water or Demineralised water should be taken to flush the system, as the water
entering the membranes should be free of any particulate material.
50

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
The new membranes are generally filled with glycerine for the preservation and the
glycerine should be flushed out in order to put the system in service mode. The fresh
water is taken in to the CIP tank and the inlet to the suction of P1 pump is opened and
the permeate and reject lines are opened to the drain. The Byepass line is opened
partially to the CIP tank as the flow of the pump is going to be very high. The flushing of
the membranes is done at a feed pressure of 1.5 to 2 kg/cm2 and reject pressure of 1
kg/cm2 pressure at a high recirculation flow.
Fill the tank with fresh water to 80% level and start the recirculation pump. Adjust the inlet
pressure at the feed of membrane to 2 kg/cm2. Adjust valve to achieve 1 kg./cm2 reject
pressure at the membrane reject side. Adjust the flow in the flow meter to
124m3/hr(Maximum). Continue the flushing for ten minutes.
51

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
3.1.3 INITIAL FLUSHING

a) Keep manual & auto valves in open mode as per the schedule given
below. Close manual valve to divert the permeate into drain.
b) Keep the reject and permeate stream to drain.
c) Start the system and bring the normal pressure. Flush approx. 2000 litres
of water through the system.
d) Stop the pump and drain the tank.
FEED PUMP
BACKFLUSH PUMP (P2)
FASTFLUSH PUMP (P1)
OFF
OFF
ON

V19 UF Reject outlet & adjust for the designed recovery
V20 UF permeate drain
V24 UF Module permeate outlet
UF AUTO VALVE SCHEDULE INITIAL FLUSHING
VALVE
V5
V6
V7
V8
V12 V10
NO.
NORMAL
O
C
O
C
O
C
MODE
O
OPEN
C
CLOSE
S
STOP
ST
START
52
V11/
V9
C
P1
P2

3.1.4
NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
SYSTEM SANITIZATION
a) Fill up the tank with feed water by opening the feed tank inlet valve
b) Prepare a solution of concentration of Caustic & Hypochlorite for
sanitization.
c) Open the manual and auto valve as per schedule .
d) Keep the bypass valve of the fast flush pump fully open and close
gradually once the pump is started to the required flow rate.
e) Switch on the pump and slowly open valve from partial closed position
adjust the position of valve to get recirculation flow of 124 m3/hr.
f)
Adjust the valves to obtain pressure differential of 1 kg/cm2 between inlet

and outlet pressure.
g) Run in this mode for 20 minutes.

h) Stop the system
i)
Drain entire system and flush the system as the procedure given in (a)
initial flushing above.
In order to preserve the performance of the UF cartridge as well as to

maintain a good SDI reduction in permeate water, it is recommended to
sanitize the system on a regular basis which can be validated further.
53

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
Fill the tank with fresh water to 80% level and add caustic (NaOH) till the pH reaches 1112.
Start the recirculation pump. Mix the water using the bypass line in the tank. Only after the
required pH is achieved the water should be taken into the system. Adjust the inlet pressure
at the feed of membrane to 2 kg/cm2. Adjust fast flush recirculation valve to achieve 1
kg./cm2 reject pressure at the membrane reject side. Adjust the flow in the flow meter FI-2 to
124 m3/hr. Continue the flushing for 20 minutes. This will clean the system from the glycerine
traces that are left during the flushing.
The Cleaning mode is designed to restore flux. The Cleaning mode is performed:
1) After Production flows are reduced to 70% of the design flow due to fouling of the
membrane.
2) After new modules are loaded to remove the membrane preservative solution.
The Caustic/Chlorine Cleaning is used to remove preservative after new modules
are loaded and to sanitize the system. It is also used as part of the regular cleaning
to remove dirt and organic fouling material. Each Chemical Cleaning mode is
comprised of 2 cycles. These are 1. wash cycle and 2. rinse cycle.
Prior to starting a chemical wash, complete the following tasks.
- Drain System and CIP tank
- Check that the Strainer Filter is clean and in tact.
- Check that sufficient chemicals are available.
1. Select the desired wash, the options are:
Caustic Wash
Chlorine Wash
Caustic/Chlorine wash
I.
Fill CIP Tank till the tank level reaches to 80 % or more.
Operator checks pH is 11-12 using the pH meter/ paper. If more Caustic is needed, add
Caustic. When the pH is correct, the operator presses recirculation pump on. In cleaning
mode.
II.
Caustic + Chlorine Wash
Chlorine in form of NaOCl is added to the CIP tank to get the concentration of 200 ppm in
the CIP tank.
54

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
Important Chlorine is consumed during the wash. The operator must monitor the
chlorine concentration every 5 minutes.
Manually dose chlorine as needed to
maintain a 150-200 ppm concentration.
III.
Check System pH
The system is ready for production operation, once the pH reaches to normal (7). Please
check with pH paper at the permeate sampling point. If system pH is between 6 and 9, then
repeat System Drain and CIP Tank Drain cycle and Rinse cycle. The selected Cleaning Mode
is Complete.
The Operator is suggested to observe if air bubbles are oozing from the module fibers
into the upper end caps. If necessary, tag any leaking modules for repair (if any). Isolate
leaking modules using the permeate isolation valves. Once the modules pass the
integrity test, put the system in Production mode
THE SYSTEM IS NOW READY FOR PRODUCTION MODE
55

3.1.5
NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
PRODUCTION RUN
a) Connect permeate outlet to product water storage tank or product water loop.
b) Open the manual and auto valves as per schedule. Adjust the permeate
outlet and UF reject valve gradually for the required recovery and to get
specified pressure drop across membranes.
c) With the above valve position switch ON the pump. Adjust permeate outlet
valve to get the required flow. Throttle permeate outlet valve to obtain
recovery of 90% and Trans membrane pressure of 20 psi.
NORMAL RUNNING MODE

FEED PUMP
BACKFLUSH PUMP (P2) FASTFLUSH PUMP (P1) -
OFF
OFF
ON

V19 UF Reject outlet & adjust for the designed recovery
V24 UF Module permeate outlet
UF AUTO VALVE INTERLOCK SCHEDULE-NORMAL MODE
VALVE
V5
V6
V7
V8
V12 V10 V11/
NO.
V9
NORMAL
O
C
O
O
O
C
C
MODE
O
C
S
ST
OPEN
CLOSE
STOP
START
i.
% RECOVERY
P1
P2
PRODUCT
X 100
PRODUCT + DRAIN
Average recovery of the system should be = 90%. The recovery (and the
reject flow) depends on the water quality and can be lower or higher than
90% depending on feed quality water.
56

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
ii. TRANS MEMBRANE PRESSURE (TMP)

TMP = FEED PRESSURE + REJECT PRESSURE - PERMEATE
PRESSURE
2
Maximum limit of TMP for this KOCH Membrane system is 30 psi.
Continue to run the system to produce required quality of water in this
mode. Subject the reject stream to drain.
KOCH Hollow fiber membranes may be operated in either a once-through or recirculating
process mode. In a dead-end mode, the raw water feed enters the cartridge at a low cross
flow rate and the reject water exits the cartridge at the opposite ends of the cartridge at a
fraction of the original feed rate. Product water is produced on the permeate side of the
cartridge. The recovery rate of water is typically 90 95%, depending on the concentration
of retained particles species in the water. The choice to use recirculating or dead-end is a
function of water quality, fiber diameter, and system cost economics. The dead-end process
mode offers reduced expensive capital and operating costs compared to recirculating flow
systems, but may limit the recovery rate and flux performance of the system.
To prevent particle built-up in the fibers during this low flow velocity process mode, the
cartridges are periodically fast flushed. This technique creates an intermittent high
turbulence to remove particles from the membrane. The technique is described later in this
paper.
In a recirculation process mode, the feed water is continuously recycled across the surface
of the membrane. The high velocity of the recirculating water prevents particles from
accumulating on the surface of the membrane and enhances the flux rate.
The system is designed for continuous feed & bleed operation as well as recirculation mode
operation.
The pressure of the UF system is controlled by the high-pressure switch HPS1 on the reject
header. Feed pressure will typically be 2-3 kg/cm2. This pressure can be adjusted up to as
high as 3.5 kg/cm2 (limit pressure to be set on HPS1).
Once in the system the UF Feed is passed through the membrane fibers where the UF
Permeate water permeates through the membrane surface. The retentate flow rate will
typically be about 10% of the feed flow. Retentate is constantly removed to prevent over
concentration. Permeate flow will typically be about 45 m3/hr. Reject flow will be about 5
m3/hrs.(Please Check with IEI )
57

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
Operating Pressures
Flux is the flow per unit membrane area per unit time. It is regulated by trans-membrane
pressure. It is optimized by operating at the maximum pressure drop, since water is usually a
pressure dependent process. For most Koch Hollow Fiber Membrane Trans membrane
pressure is 10-25 psi, although as high as 40 psi may be used for lower temperature
applications. Permeate backpressure may be applied to the cartridges as a method of
productivity control.
System Recovery
The recovery of purified water from an ultrafiltration system will be in a proportion to the
incoming feed water and discharged reject water. Recovery may be defined as:
% Recovery = Permeate Rate x 100/Feed Rate
The percent recovery depends on the amount of suspended solids, colloidal material or
microorganism in the feed water. During the normal filtration process, recovery may drop as a
result of membrane fouling. As less water passes the membrane, more water is rejected to
drain. To maximize water recovery, regular membrane cleaning and/or back flushing or
reverse flushing may be required.
In most applications, the reject water is discharged to drain, since the volume of reject water
is small compared to the incoming feed and recovered water. In applications where water
usage constraints exist, the reject water may be reprocessed with an additional membrane
system. This second system is usually designed to handle a higher concentration of retained
materials.
58

3.1.6
NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
CLEANING PROTOCOLS
On a periodic basis, all membrane filtration systems require cleaning to remove
fouling material from the membrane. The requirement for cleaning will be
manifested as a reduction in water productivity from original start-up valves.
Cleaning a membrane system is a combination of hydrodynamic removal and
chemical degradation of the foulants.
Cleaning mode
Cycle Time Duration

(minutes)
Fast flush with chemical
45 Mins 60 Mins.
Static soak
30 Mins.
Fast flush
20 Mins.
Pre-Production rinse
As per requirement
Backflush
1 Min.
Cleaning frequency
The frequency of cleaning, process techniques and chemical requirements will
be dependent on the application and the degree of fouling.
Normally, membrane systems should be cleaned when productivity reaches a
maximum of 70% of the original output capacity of system.
FAST FLUSH MODE
This mode of operation uses high shear sweep along the UF Membrane
cartridge.
After filling the feed tank, stop the supply to tank.
Open the manual and auto valves as per schedule.
As per the set time fast flush mode operation will start and pump will start
automatically. (for a time duration of 1min) at a frequency of once per hour.
59

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
FAST FLUSH MODE

Feed pump
OFF
Back Flush pump
(P2)
OFF
Fast Flush pump
(P1)
ON
To avoid Hydraulic hammer and vibration, it is very important to keep the Fast flush
pump, Bye-pass valve in open condition
MANUAL VALVE TO KEPT IN OPEN CONDITION
V2
Fast Flush pump suction
V3
Fast Flush pump delivery
V4
By-pass
V14
Permeate recirculation
V24
Permeate outlet (UF module)
All other manual valves are in close position.

UF AUTO VALVE INTERLOCK SCHEDULE-FAST FLUSH MODE
VALVE
V5
V6
V7
V12 V8
V10 V11/ P1
NO.
V9
FAST
C
O
O
C
C
O
C
ST
FLUSH
MODE
O
C
S
ST
P2
S
OPEN
CLOSE
STOP
START
This mode will give the required fast flush flow rate as per the design. This fast
flush will sweep gel layer accumulated on membrane surface.
Stop the Pump.
Drain entire system
60

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
A fast flush process usually is followed by backflush. Feed water at a high flow velocity is
pumped through the cartridge, usually from a fastflush/cleaning tank. The fastflush serves to
remove highly concentrated material from the hollow fiber and usually is timed for
approximately 5-15 minutes. The permeate lines are closed of at this time, which allows for
an increase in flow velocity at the membrane surface. Fastflush water may be used several
times before discarding to drain.
FAST FLUSH WITH CHEMICAL CLEANING
If above mentioned FAST FLUX does not yield original flux then cleaning chemical can
be introduced in above mode of cleaning. Type of chemical will depend on fouling
nature. Recommended cleaning temperature is 30 - 45 C.
MEMBRANE FOULANT
CHEMICAL
CONCENTRATION
General fouling
(Organics & bacteria)
Iron fouling
NaOCl
(at 10.5 pH)
Citric acid and NaEDTA
200 ppm as NaOCl
Silica
NaOH
Heavy organic fouling
NaOH
Frequency of this mode is once per month.
61
0.5%
0.2%
0.5%
0.5%
by weight
by weight
by weight
by weight

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
BACKFLUSH MODE OF CLEANING
This mode of operation is done as mentioned in following steps:-.
Stop the normal operation of System.
Open manual valves and auto valves as per schedule. Back flush pump will start and
stop automatically. UF reject valve opens for first half flush and UF backflush drain
valve second half.
The Backflush process gets tripped after 60seconds.
BACK FLUSH MODE

Feed pump
OFF
Fast Flush pump
(P1)
OFF
Back Flush pump
(P2)
ON
- The Feed pressure should not exceed more than 10mwc at the inlet of UF
modules.
62

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
V21
Back Flush pump suction
V22
Back Flush pump delivery
V13
Back Flush inlet
All other manual valves will be in closed condition.
UF AUTO VALVE INTERLOCK SCHEDULE-BACKFLUSH MODE

VALVE V5
V6
V7
V8
V12 V10 V11/ P1 P2
NO.
V9
BACK
C
C
C
C
C
C
O
S
ST
FLUSH
MODE
O
C
S
ST
OPEN
CLOSE
STOP
START
IV.
BACKFLUSHING
After producing water for a period of time, typically about 1hour, the cartridge productivity is
restored with a backflush cycle using permeate water. The backflushing serves to remove
accumulated particles from the surface of the hollow fiber membrane and then pushes the
particles out of the lumen to the feed manifolds. The backflush period is usually about 60
seconds. A tank and backflush pump is the preferred method for this flux restoration
technique, where the tank is filled with clean permeate water.
The trans-membrane pressure must not exceed 1.0 bar (15 psi) during the backflush
process. Given this constraint, the backflush flow rate will start low and increase as the
membrane cleans.
NOTE: In order to keep the system free from contamination and flux reduction, it is
suggested that water be flowing in the system at all times. If the permeate is not being
used then it is recommended that the permeate be returned to the feed side of the
system. This mode of operation will help to prevent bacterial buildup in the system.
63

3.1.7
NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
LONG TERM MEMBRANE STORAGE
KOCH Hollow fiber cartridges are shipped from Koch in a solution of 70% glycerine (food
grade). This glycerin inhibits microorganism growth and prevents freezing of cartridges.
Glycerine should be washed from the cartridges with standard cleaning and flushing
procedures prior to use.
When cartridges are not used for a period of over two days the system should be filled
with one of the following solutions after a complete sanitization procedure is run.
1.
Glycerine
Use 70% glycerine
2.
Phosphoric acid
Adjust pH 2-3
3.
Benzoic acid or sodium benzonate
1000 ppm
4.
Sodium Bisulfite
50 - 150 ppm
5.
Quarternary ammonium compounds
Storage of Used Cartridges
50 - 100 ppm
After the shipping glycerin is removed from the cartridges, the membrane should be kept
moist at all times. If the membrane is allowed to dry out, a change in the flux and rejection
performance will occur. Modules removed from a system must be kept moist by capping the
cartridge ends or putting the cartridge in a plastic bag.
The cartridges do not have to be filled with water. A 100% moisture condition is sufficient to
prevent membrane performance loss. Prior to storing the cartridges must be washed
thoroughly to remove contaminants that may accelerate micro-organism growth. A
preservative may be used to prevent microorganism growth during the storage period. The
solutions include:
For long term storage, a preservative is recommended. For short term a (less than 2 to 4
weeks), clean water may be sufficient.
Procedure
Use soft, DI, WFI or RO water. Fill the tank with water. Fill the tank with water. Prepare the
solution using one of above chemicals at required pH or concentration. Fill the complete
system with this solution. Exchange the solution once in two weeks.
64

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
RO Pass I UNIT WILL BE CUT OFF FROM SERVICE AUTOMATICALLY BASED ON

1.
2.
3.
4.
5.
6.
High Chlorine.
High Feed Conductivity.
High Product Conductivity.
High Pressure
pH Fault
Low Inlet Pressure
PROCESS DESCRIPTION
Following commands are envisaged for the operation:
a) SERVICE MODE
b) IDLE MODE ( No water Demand)
LIST OF ALARMS: Alarms to be displayed unit wise on panel board.
1. HIGH CHLORINE.
2. HIGH FEED CONDUCTIVITY.
3. HIGH PRODUCT CONDUCTIVITY.
4. HIGH PRESSURE
5. PH FAULT
6. LOW INLET PRESSURE
65

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
3.2.Following are the salient features of the control philosophy for operation of
Reverse Osmosis Pass 1.
1. Operation of the plant is through PROGRAMABLE LOGIC CONTROL SYSTEM,
which is used for the purpose of the normal operation and stop during Alarm
Condition. Signals for various alarm conditions, e.g. High Chlorine, High Feed
Conductivity, High Product Conductivity, High Pressure, pH Fault, Low Inlet
Pressure etc. are displayed on the local panel display lamps.
2. The Reverse Osmosis Membrane banks are provided with pneumatically
actuated Butterfly Valves. These valves are operated automatically by Pneumatic
Solenoid valves to Open/Close with respect to the process requirements by PLC.
3.2.1 RO PASS II UNIT WILL BE CUT OFF FROM SERVICE AUTOMATICALLY
BASED ON FOLLOWING CONDITION WHICHEVER IS EARLIER.
1.
2.
3.
4.
High Pressure.
Low Inlet Pressure.
High Product Conductivity.
Degassed Water Tank Level High.
PROCESS DESCRIPTION
Following commands are envisaged for the operation:
c) SERVICE MODE
d) IDLE MODE ( No water Demand)
LIST OF ALARMS: Alarms to be displayed unit wise on panel board.
1. HIGH PRESSURE.
2. LOW INLET PRESSURE.
3. HIGH PRODUCT CONDUCTIVITY.
4. DEGASSED WATER TANK LEVEL HIGH.
66

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
Following are the salient features of the control philosophy for operation of Reverse
Osmosis Pass II.
Operation of the plant is through PROGRAMABLE LOGIC CONTROL SYSTEM, which
is used for the purpose of the normal operation and stop during Alarm Condition.
Signals for various alarm conditions, e.g. High Pressure, Low Inlet Pressure, High
Product Conductivity, Degassed Water Tank Level High etc. are displayed on the local
panel display lamps.
3.2.2 Precommissioning
After completing installation activities including electrical wiring and before initial start
up, a number of precommissioning activities need to be carried out.
1. Check and ensure upstream pumps and units are in proper operating condition.
2. Do not load the cartridge filter elements. Close the cartridge filter vessel cover.
Without starting the high pressure pump, flush the RO system with pretreated water.
3. Separately check the running of all dosing pumps, all instruments.
4. Dry check the operation sequence by electrically simulating various conditions.
5. Clean the RO pressure tubes and associated piping with a jet of water.
6. Check and ensure correct direction of rotation of the high pressure pump.
7. Check and confirm that feed water to RO will meet all limiting conditions.
8. Stop the pumps, close all valves, switch off the main electrical supply for membrane
loading.
67

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3.2.3 Membrane Loading

1. Remove the victaulic connections from both ends of the pressure tubes.
2. Remove the allen screws. Carefully tap the end cap with a rubber mallet to relieve
the tension from the retaining rings. Then remove the rings one by one.
3. Put distinguishing marks on the end caps and respective tube ends (for ease of
reassembly). By using an even pulling force and ensuring that no damage occurs to
any fittings, remove the end caps.
4. Remove the required number of membrane elements from the packing. Note down
the serial number of each membrane element and enter the same on the membrane
loading chart (see Table 5.10) as the membrane element is loaded.
5. Apply a liberal coat of silicone grease on the membrane `O ring and seals.
6. Insert the membrane elements into the pressure tube from the feed end (i.e. where
the piping from high pressure pump enters the RO unit). Membrane should enter so
that the seals are near the feed end of the pressure tube.
7. If the pressure tube has more than one element, make the next membrane element
ready. Fix the interconnector on the leading end and join the same with the element
which was already inside the pressure tube. Now push the new element so that the
element inserted earlier goes in fully.
8. On the product end of the pressure tube, fix the product adaptors using silicone
grease.
9. Reinstall the end caps carefully and refix the rings and allen screws.
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3.2.4 Initial start up

1. Open the cover of the cartridge filter vessel. Fix the filter elements and close the
cover lightly.
2. Check the quality of the feed water, particularly pH, temperature, chlorine, hardness,
conductivity and silt density index (SDI) to ensure that the parameters are not worse
than the design water analysis given in Technical Data sheet.
3. Open reject control valve fully.
4. Open the high pressure pump discharge valve fully.
5. Remove the drain on the product header and connect a hose pipe to drain. This will
ensure that the product water during initial start-up and initial flushing does not
contaminate the product water tank.
6. Open the manual feed water isolation valve to allow water flow into the RO system.
The cartridge filter will show a positive pressure and water will flow intothe drain near
the reject outlet.
7. Continue this operation for 15 minutes to expel all air pockets in the system.
Remove the air from the high pressure pump casing by opening the vent.
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3.2.5 Initial flushing

The purpose of initial flushing is to remove the preservatives from the membranes and
antifreeze chemicals applied on them at the time of shipping.
3.2.6 Continuing after initial start-up,
1. Remove the lock out tag from the electrical control panel main ON/OFF switch and
switch on the power supply.
2. Close the high pressure pump discharge valve fully and reopen it to be open.
3. When the high pressure pump starts, slowly open the pump discharge valve to
increase the pressure and obtain and note the product flow. Close the reject control
valve slowly and note the reject flow. As the reject control valve is closed, the
permeate flow will increase. Simultaneously and carefully control both these valves
to obtain product and reject flow rates as per the Technical Data sheet.
4. Start the dosing pumps (if present) and maintain the required dosage for the various
chemicals.
5. Continue for at least 2 hours, and keep observing the operating pressure and flow
rates. As the membrane gets conditioned, there will be some initial changes in these
parameters, but they will soon stabilise.
6. Start operation of the various instruments provided on the panel.
7. Refix the drain plug on the product header.
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3.2.7 Normal starting

In general, the operation of a reverse osmosis plant is fairly simple, the operator needs
to ensure that
The pretreatment plant is operating satisfactorily
Necessary chemicals are available
There are no leaks in the high pressure piping
Various important parameters are entered in the log sheet.
1. Ensure that the manual feed water isolation valve is fully open.
2. Turn the main switch to ON position.
3. Ensure that the high pressure pump discharge valve is open at least .
4. Ensure that the reject control valve is partly open.
(CAUTION: A COMPLETELY CLOSED REJECT CONTROL VALVE CAN CAUSE
SEVERE MEMBRANE DAMAGE.)
5. Ensure that all valves downstream of the product water header (e.g. inlet to product
water storage or inlet to degasser tower) are fully open.
6. Adjust the pump discharge valve and the reject control valves as described in point 3
& 4 of 5.4 so as to maintain the desired operating pressure, product and reject flow
rates. Note the treated water quality parameters.
7. Adjust the reject control valve and the high pressure pump discharge valve to
maintain the treated water quality within acceptable limits. The operating pressure
will rise slightly compared to the previous step.
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3.2.8 Normal Shutdown

When the reverse osmosis unit needs to be shutdown for brief periods( less than 7
days), follow the procedure below:
1. Switch off the high pressure pump.
2. Switch off upstream units and pumps including dosing systems.
3.2.9 Long Term Shutdown
When the reverse osmosis unit needs to be shutdown for periods exceeding 7 days,
use the following procedure:
1. Carry out a "Normal" shutdown as per the procedure given in 5.7 above.
2. Refer to 7.3 on disinfection and storage of Reverse osmosis membranes.
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Table 3.2.10
DAILY LOG SHEET
Client Name and Location
Time
Date
Pressure, kg/cm2
m3/h
1
Key
1
2
3
4
5
6
Pressure Reading Locations

Cartridge Filter Inlet
Cartridge Filter Outlet
RO Feed -1
RO Feed -2
RO Feed 3
RO reject
73
Flow, Reco- Conductivity Raw

very
microsiemen water
s/cm
temp.
o
C
B C %
Prod
Key
A
B
C
Flow Reading Locations

Feed
Product
Reject
Remarks

NUMBER.
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Note
1. Under the "Remarks" column record any routine activity like cleaning as well as any
malfunction of instruments, control panel etc.
2. Record any change in raw water source.
3. Measure and record the SDI value of feed water once a week.
4. A detailed raw water analysis should be done once in three months or whenever the
raw water conductivity changes by more than 10%.
5. Raw water analsysis should ensure the calcium, magnesium, sulphate, chlorides,
silica, cod, iron, pH, turbidity and TDS.
6. A change of more than 10% in the product flow or feed pressure or the product
conductivity should be reported immediately.
Feed water to the reverse osmosis unit should be within following parameters:
Turbidity
Oil and Grease
SDI
Organics
Temperature
Less than 1 NTU

Nil
Less than 4
Nil
Less than 400C
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Table 3.2.11
RO Membrane Loading Chart
Note:
Use the blocks above to enter membrane Serial numbers.
Mark the feed and the reject end for every tube.
Enter various tubes as PT1, PT2 etc. (PT stands for pressure tube)
Membrane Model :
Date of Installation
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3.3 MB UNIT WILL BE CUT OFF FROM SERVICE AUTOMATICALLY BASED ON

MB units: High conductivity more than 0.2 s/cm or high totalised flow of 1000 m3
whichever is earlier.
At the completion of regeneration sequence, the units will go in standby mode and
operator will take decision to put back the stream in service. This will not be
automatic.
Pneumatic Solenoid valves are provided for operation of individual pneumatically
Actuated Butterfly valves.
Pressure to open valve are given at rinse outlet, measuring tanks outlet valve, power
water valve and Acid/Caustic inlet valve to measuring tanks. for fail safe operation.
Caustic should be fail safe by providing positive dilution water flow signal before the
caustic dilution valve.
(a) Selection of exchanger unit/pumps/ blowers/ chemical tank required for particular
operation.
(b) Mode selection like regeneration/service/chemicals filling, etc.
(c) Hold, reset, advance (for regeneration operation of stages).
(d) Display of stages and related set and elapsed time.
Indication lamps/graphic display of exchangers / pumps / blowers / chemicals tanks
showing dynamic status.
(f) Alarm status.
(g) Display instrument readings.
Digital inputs are mainly from open/close limit switches of each of the pneumatically
operated valve, level switches & analogue inputs are from level transmitters, flow
transmitters, conductivity and pH transmitters, etc.
Voltage free outputs are envisaged to operate solenoid valves for starting / stopping
of pumps / blowers / mixers and analogue outputs shall be 4-20 mA DC to have
control action on the control valves.
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The operation will be menu based either through keyboard or touch screen. Related
page can be called on display unit and operation will be carried out accordingly.
Following commands are envisaged for the operation :
a)
b)
c)
D)
E)
f)
Service
Extend Service
Batch Off
Regeneration
Hold Sequence
Emergency Stop.
g) Regeneration Sequence Steps
h) Fill
LIST OF ALARMS: Alarms to be displayed on display screen / Indication lamps.
DGT, DGWT
a)
b)
c)
d)
Low Level DGWT

High Level DGWT
Blower-A/B tripping
Mixed Bed Feed Pump P3-A/B tripping
MIXED BED UNIT

a)
b)
c)
d)
e)
f)
g)
High Conductivity
High Totalised Flow
Low / High pH
DM Storage Tank High Level
Low level HCL Acid Dilution tank
Low level NaOH Caustic Dilution tank
MB Blower A/B tripping
NEUTRALISATION PIT
a) Low Level
c) pH Low
d) pH High
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SECTION 4
OPERATING INSTRUCTIONS
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4.1 UF OPERATING PROCEDURE

PROCEDURE FOR STARTING SERVICE OF THE ULTRA-FILTRATION SYSTEM:
1. Switch on the MCC feeders for UF panel and Switch on the Air compressor
2. Power ON by switching S1.
3. Select S2 in Auto mode and make sure there is sufficient level in the Raw Water Tank.
4. The Normal mode Red lamp will get on and the following process starts automatically,
5. Solenoid Valves SV1, SV3 and SV4 opens to open UF valves 12, 13, 14 & 15 with the
UF feed pump starts. The PLC outputs Q1, Q3, Q4 and Q9 is ON.
6. The service Cycle is by default as 60 Minutes, to ensure the Backflush followed by

Forward flush done at an interval of 60 minutes.
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4.2 PROCEDURE FOR STARTING SERVICE OF THE RO PASS 1:
1. Switch on the MCC feeders for RO - 1 panel and Switch on the Air compressor.
3. Check for NO chlorine in the UF product water.
4. Select S1 for Automatic mode
5. The RO Feed pump starts and after 30 seconds the High pressure pump starts
automatically.
6. Check for the Flow, Pressure and Conducitivity and record the same after 30 minutes
of operation after normalisation.
4.3 PROCEDURE FOR STARTING SERVICE OF THE RO PASS 2:
1. Switch on the MCC feeders for RO - 2 panel and Degasser Blower A / B.

3. Check for RO-1 is service and feeding the product the RO -2.
4. Select S1 for Automatic mode
5. The High Pressure Pump starts after 30 seconds automatically.
6. Check for the Flow, Pressure and Conducitivity and record the same after 30 minutes of
operation after normalisation.
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4.4 PROCEDURE FOR STARTING SERVICE OF THE MIXED BED UNIT:
1. Select the MB Feed pump A/B and switch ON the MCC feeders and Switch on the Air
compressor.
2. Start the Mixed Bed Feed pump A or B by pressing the start push button provided on the
local push button station near the pumps.
3. Ensure that pump A or B is ON.

4. Open the respective Solenoid valve to open the Service Inlet and Service Outlet Valves
of the Mixed Bed unit.
4.5 PROCEDURE FOR STARTING REGENERATION OF MIXED BED UNITS :
1. Check the caustic level in CDT and Acid Dilution tank if it is HIGH (go to point no 5). If not
HIGH, open the respective valves to fill the tank manually to the desired level as marked
in the respective tanks.
2. Switch ON the MCC feeders for the pumps Regeneration Pumps A/B.
3. Select pump A or B local push button near the pump location.
Now regeneration will be carried out in pre determined sequence for given time as follows.
1. BACKWASH - 5MINUTES
2. MIDDLE COLLECTOR FLUSH - MINUTES.
3. ALKALI / ACID PRE INJECTION - 2 MINUTES.
4. ALKALI/ ACID INJECTION.
5. ALKALI/ ACID RINSE - 24 MINUTES.
6. DRAIN DON - 5 MINUTES.
7. AIR MIX- 10 MINUTES
8. FORCED SETTLE - 2 MINUTES.
9. REFILL - 5 MINUTES.
10. FINAL RINSE 15 MINUTES.
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SECTION 5
CHEMICAL CONTROL
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5.0 CHEMICAL CONTROL

5.1 TURBIDITY & ITS MEASUREMENT :
Turbidity in water is caused by the presence of suspended matter such as clay,
silt, finely divided inorganic or organic matter. Plankton and other microscopic
organisms. It is measured by comparing the light scattered at 90 by the sample
with that of a standard solution and is dependent on the optical properties of the
suspended solids - their surface area, shape etc.
Suspended solids on the other hand refers to the weight of the suspended solids
present in a unit volume of the solution and is dependent only on properties like
the specific gravity of the particle and not on its optical properties. Suspended
solids are measured by filtering a known volume of the solution through a
weighed glass fibre disc, or membrane filter and evaporating it to dryness at
105 C and measuring the differences in weight. The increase in weight can be
expressed in mg/lit.
Nephelometric Turbidity Unit (NTU) is the most widely accepted unit for
measurement of turbidity. It is measured by comparing the light scattered by a
sample of water whose turbidity is to be measured (at 90 to incident light) with
that of a sample of a standard solution of formazine of a particular concentration
whose turbidity is taken as 40 units. The turbidity of the solution thus prepared
remains constant since the solution is stable. It is also sometimes referred to as
the Formazine Turbidity Unit (FTU).
Turbidity may also be expressed in Jackson Turbidity Unit (JTU). In this method,
the flame of a standard candle is observed vertically through a column of water
whose turbidity is to be measured) in a standard measuring cylinder and the
length of the column of water at which the flame of a candle just disappears is
measured. A standard solution of Fuller's earth ( a particular type of clay
containing sodium aluminium silicate) is used to calibrate the measuring cylinder
in terms of JTU. In this method the transmitted light is observed while in the
previous method, the scattered light at 90 to the incident light is measured.
It is not recommended to express turbidity in terms of ppm SiO2 scale. For a
particular water (under standard conditions of preparation of sample) we can
relate suspended solids and turbidity by means of a calibration graph. The
relationship will hold good only for the particular water.
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FORMULA FOR CALCULATING DRY LOAD FOR FILTERS :

Formula :
Dry Load
(lbs/sq.ft).
= Turbidity x Hrs of run x Sp. Velocity

5
10
Turbidity = PPM = MG/LIT = GMS/M3

= lbs/GALLON
CONVERSION :
450 grams = 1 lb
1000 lts
= 1M3 = 220 gallons
lb/gallon = 1/450 x 1/220 =

______
99,000
=
1
___
5
10
Dry Load :
lb
x hours x gallons
_______
_______
gallons
hr
___________________________________
Sq.Ft.
Dry Load = lbs/sq. ft.
84

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5.2 DEMINERALISATION BY REVERSE OSMOSIS

The following notes will explain the operation and the types of analytical tests to be
conducted for the control of the units and the possible variations in the quality and
capacity of the units that can be expected. The individual analytical test methods
referred\ to are found at the end of this section.
Osmosis is a natural process involving fluid flow across a semi permeable membrane
barrier. It is selective in the sense that the solvent passes through the membrane at a
faster rate than the dissolved solids. The difference of passage rate results in solvent
solids separation. The direction of solvent flow is determined by its chemical potential,
which is a function of pressure, temperature and concentration of dissolved solids.
Pure water in contact with both sides of an ideal semi permeable membrane at equal
pressure and temperature has no net flow across the membrane because the chemical
potential is equal on both sides. If a soluble salt is added on one side, the chemical
potential of this salt solution is reduced. Osmotic flow from the pure water side across
the membrane to the salt solution side will occur until the equilibrium of chemical
potential is restored. Equilibrium occurs when the hydrostatic pressure differential
resulting from the volume changes on both sides is equal to the osmotic pressure. This
Application of an external pressure to the salt solution equal to the osmotic pressure will
also cause equilibrium. Additional pressure will raise the chemical potential of the water
in the salt solution and cause a solvent flow to the pure water side, because it now has
a lower chemical potential. This phenomenon is called reverse osmosis.
In the reverse osmosis process, the water that passes through the membrane is
commonly referred to as permeate or product water, the water that remains behind the
membrane along with dissolved and suspended solids is referred to as the concentrate,
brine or reject water. We have used these terms interchangeably in this manual.
Pressurised feed water is introduced into one end of the pressure tube. Some of the
water, driven by the feed pressure through the RO pressure tube feed port permeates
through the membrane, passes into the product tube and exits the pressure tube from
the pressure tube product port as product water, less most of the dissolved solids and all
of the suspended solids. The remainder of the water passes along the surface of the
membrane with the concentrated dissolved and suspended solids and passes out of the
pressure tube concentrate port as concentrate, brine or reject.
The pressure tubes are generally arranged in stages when more product water is
desired than one module can produce. The staging of the modules is designed to
optimise the water flow patterns across the surface of the membrane. This uniform
water flow promotes good flushing velocity across the membrane surface to prevent the
accumulation of suspended solids on the surface which would foul the membrane and
reduce the productivity. Multiple stages are referred to as arrays.
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Different ions also pass through the membrane to different extents depending on
various factors such as valency, ionic size, concentration, etc. Therefore, the product
water does have some salts, usually approximately 10% of the salts in feed water. Salt
passage is defined as the ratio of total dissolved solids (TDS) in permeate to TDS in
feed water.
A certain minimum reject water flow is always maintained to flush the membrane surface
and also keep certain sparingly soluble salts below their solubility limits. As a result, the
ratio of the product water or permeate flow to feed water flow, called the recovery, is
always less than 1.0.
5.3 MIXED BED UNITS :
Capacity :
For the first six months of operation, the Mixed Bed unit must be run to the rated
capacity as stated in the TECHNICAL DATA SHEET and should then be regenerated.
Thereafter the capacity may be gradually stepped up until after a further three months
the run may be terminated either on silica breakthrough or on conductivity break
through depending on the quality of treated water required.
As two types of ion exchange resins are used in the Mixed Bed unit, two ionic loads
have to be considered for capacity. Any increase in either will result in a decreased
capacity.
TOTAL CATIONS (TC) = M.ALK + E.M.A.
TOTAL ANIONS (TA) = M.ALK + EMA + FREE CO2 + SILICA
All parameters expressed as ppm as CaCO3.
If either the TC or TA increases, the capacity will decrease. If the Cation exchange
resin exhausts first, the treated water conductivity will rise. At exhaustion of the Cation
resin the treated water pH will increase. If the Anion resin exhausts first, the treated
water pH will decrease.
Treated Water Quality :
The quality of treated water from a Mixed Bed unit is extremely pure. High purity water
is an excellent solvent and is therefore easily contaminated. If exposed to the air it will
absorb Free Carbon Dioxide and other gases from the atmosphere very rapidly.
Great care is therefore required when sampling and analysing the water. The
cleanliness of apparatus, purity of reagents, speed in analysis are critical items. The
best method for checking its purity is by measuring its specific conductance
(conductivity) using an in-line cell assembly and an accurate measuring instrument.
Errors can arise if a sample is taken and measured elsewhere.
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The pH should also be checked using an in-line electrode assembly although it has
been found that readings may tend to be erratic because the liquid being measured is
so very close to being absolutely neutral.
The presence of silica in the treated water does not appreciably effect its conductivity.
If silica free water is required, silica tests should be conducted as a regular routine just
before the end point of the treatment run and the unit should be regenerated when the
silica content of the treated water is no longer acceptable. The treated water
conductivity will generally be below 1.0 micro siemen/cm. The minimum will normally be
in the range of 0.2 -0.5 micro siemen/cm. It is important to check the temperature of
the water and make necessary corrections to the reading.
An empirical relationship between the total dissolved solids (TDS) and conductivity may
be considered. This is generally accepted as follows:
1 ppm TDS = 2 micro siemen/cm i.e. a ratio of 1 : 2.
A check on the Raw water and Treated Water should include tests for
CONDUCTIVITY
pH
CHLORIDES
SULPHATES
NITRATES
TOTAL HARDNESS
M ALKALINITY
IRON
OIL AND GREASE
FREE CHLORINE
FREE CARBON DI OXIDE
E.M.A.
SILICA (1-20 ppm)
SILICA (0-1 ppm)
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Oxygen Absorbed in 4 hours
88

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5.4 CHLORIDES (MERCURIC NITRATE METHOD)

Reagents and Apparatus :
Burette for Mercuric Nitrate
0.02N Mercuric Nitrate Hg (NO3)2 Solution
Concentrated Nitric Acid
Distilled water
0.02N Sodium Chloride Solution
0.1 % W/V Solution Diphenylcarbazone
Nickel Nitrate (Buffer solution)
100 ml. graduated cylinders
10 ml. graduated pipettes
250 ml. conical flasks.
Reagents
0.02N Mercuric Nitrate Hg (NO3)2
Dissolve 3.24 gms Hg (NO3)2 in approximately 500 ml. of deionised or distilled
water which contains 3 ml. of concentrated Nitric Acid. When totally dissolved make
up to 1 litre. Standardise as under `Procedure' against standard Sodium Chloride
solution.
Standard Sodium Cloride Solution (0.02N).
Dissolve 1.17 gms. of predried Analar Sodium Chloride in 1 lit of distilled or
deionised water (i.e. 1 ml. 0.02N NaCl = 1 mg Cl as CaCO 3).
0.1% w/v solution of Diphenylcarbazone in Iso-propanol or Methanol. This solution
is unstable and should be renewed monthly.
Nickel NItrate (buffer solution)
4 molar crystalline Nickel Nitrate solution containing 5 ml.
Acid per 100 ml. of solution.
Procedure :
89
of concentrated Nitric

NUMBER.
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Measure 100 ml. of sample into a 250 ml. flask. Add 2 ml. Diphenylcarbazone
solution and mix. Add 1 ml. of Nickel Nitrate buffer solution and mix again. The
resulting solution should be a pale green colour. If the solution has an orange tint,
add Nickel Nitrate dropwise until the green tint is achieved. Titrate the solution with
0.02N Mercuric Nitrate until a faint but persistent violet colour is observed. (i.e. the
end point).
Calculation :
Chloride, as ppm CaCO3 = ml. of titration x 1000
ml. of sample.
90

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5.7 TOTAL HARDNESS :

N/50 E.D.T.A. :
4 grams of disodium dihydrogen ethylene diamine tetra acetate are dissolved in 800
ml. of water and standardised
and adjusted against a standard hardness solution
until 1 ml = 1 mg CaCO3.
Ammonia Buffer:
Dissolve 16.9 g ammonium chloride. NH4Cl in 143 ml. conc. ammonium hydroxide
NH4OH; add 1.25 g of magnesium salt of EDTA (this salt is available commercially)
and dilute to 250 ml with distilled water.
A buffer containing the magnesium salt of EDTA may also be
made as follows:
Dissolve 16.9 g NH4Cl in 143 ml. conc NH4OH. Weight out 0.25 g MgCl2. 6H2O or
MgSO4. 7H2O, transfer quantitatively to a
100 ml volumetric flask, and make up
to volume with distilled water. Pipette 50.0 ml. of this solution into a porcelain dish,
add a few drops of the NH4Cl-NH4OH solution (sufficient to achieve a pH of 10.010.1); add 2-3 drops of indicator solution and titrate with EDTA with continuous
stirring until a steel-blue colour with no tinge of red is present. To the 50 ml. of
solution remaining in the volumetric flask add exactly the volume of EDTA required in
the above titration. Add this solution to the NH4Cl-NH4OH mixture and make up to
250 ml. with distilled water.
Keep the solution in a plastic or resistant glass container, tightly stoppered to
prevent loss of NH3 or pickup of CO2.
Indicator :
Mix 0.5 g of Erichrome black T with 4.5ghydroxylamine hydrochloride. Dissolve this
mixture in 100 ml. of 95 percent ethyl or isopropyl alcohol.
91

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Apparatus :
Burette for N/50 EDTA
250 ml. beaker
Stirring Rod
For soft water use 750 ml. evaporating dish and magnetic or electric stirrer.
50 ml. measuring cylinder.
Method :
For raw water :
A 50 ml. quantity of the water is measured out in a measuring cylinder. 40 ml. of this
are placed in a 250 ml. beaker; 1 ml. of buffer solution and 6-8 drops indicator are
added. The titration is then carried out by adding EDTA solution from the burette,
until the last tinge of red disappears. The last 10 ml. of water are then added and
the titration completed to the same end-point. The liquid in the beaker is stirred and
supported on a stand, through which the beaker is illuminated from underneath by a
blue light.
For soft water :
Rinse the cylinder and the evaporating dish thoroughly with
the water to be used.
Measure 500 ml. of the sample into the evaporating dish and add 3 ml. of buffer
solution followed by 10-12 drops of indicator solution.
Run 0.5 ml. of EDTA from burette and stir the liquid in the
dish thoroughly.
If a steel blue colour is obtained with no tinge of Red, the

ppm as CaCO3.
hardness is less than 1
If a red colour is observed add EDTA drop by drop with continuous stirring until a
steel blue colour with no tinge of red is obtained -i.e. until the last tinge of red just
disappears.
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Calculation :
Total hardness, as ppm CaCO3 = ml. of titration x 1000
ml. of sample
Note :
As the strength of the red tinge diminishes, the EDTA should be added carefully one
drop at a time with stirring between each addition.
If the end point has not been reached after adding total of 10 ml. of EDTA the test
should be repeated using 250 ml. of sample with 2 ml. of buffer and 8-10 drops of
indicator.
The indicator solution should be kept in a cool place and out of the light as much as
possible. It must be replaced after two months.
93

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
5.8 ALKALINITY (METHYL ORANGE AND PHENOLPHTHALEIN) :

Burette for standard acid
Nitric Acid 0.02N (N/50) or 0.02 NHCl
100 ml. graduated measuring cylinder
Conical flask (150 ml.)
Phenolphthalein indicator solution
Screened Methyl Orange indicator solution
10 ml. Graduated pipettes
Sodium Thiosulphite 10 % W/V Solution
Method :
If the alkalinity of the water is low, 100 ml. of sample should be measured using the
graduated cylinder. Otherwise a 10 or 20 ml. portion of sample should be taken with
the pipettes.
Transfer the appropriate amount of sample to the conical flask and add 5 drops of
Phenolphthalein indicator.
Run in 0.02 N Nitric Acid or 0.02N HCl from the burette
until the pink coloration is just discharged.
Note the volume (ml) of acid used, multiply by the appropriate factor (see table) and
record as `P'.
mls. of sample taken
Factor
100
10
20
50
10
100
If water is chlorinated, add 2 drops of Sodium Thiosulphite solution. Add 2 drops of
Screened Methyl Orange indicator and continue the addition of acid until the solution
just turns to smokey grey.
Read the burette again, note the total amount of acid (ml) used in both titrations
and multiply by the appropriate factor (see the table above). Record result as `M'.
94

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
Interpretation of results :
The relative quantities of Bicarbonate and Carbonate and Hydroxide alkalinity can
then be obtained from the following table:
Bicarbonate
P = Nil
Carbonate
Nil
Nil
P < 1/2 M
M-2P
P = 1/2 M
Nil
2P
P > 1/2 M
Nil
2 (M-P)
P=M
Nil
Hydroxide
2P
Nil
Nil
Nil
2P-M
P
The above results are expressed in parts/million (ppm) as CaCO3.

Note :
Screened Methyl Orange Indicator solution.
Preparation of Indicator Solution :
Dissolve 0.2 g of Crystalline Methyl Orange in a mixture of 25 ml. Methylated Spirits
and 25 ml. Deionised Water. Dissolve 0.28 g. Xylene Cyanol FF in a mixture of 25
ml. Methylated Spirits and 25 ml. deionised water. Mix the two solutions together.
For most RAW WATER samples, as also LIME SOFTENED water a 100 ml. sample
can be used. For BOILER WATER samples use 10 ml. or 20 ml. sample.
Use Sodium Thiosulphite solution before addition of Methyl Orange only if water has
been chlorinated e.g. from Bottling Precipitators.
95

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
5.9 DISSOLVED AND TOTAL IRON

Spectrophotometer Method :
Principle :
Iron is brought into solution, reduced to the ferrous state by boiling with acid and
hydroxylamine hydrochloride and treated with 1- 10 phenanthroline at pH 3.2 to 3.3.
Three molecules of phenanthroline chelate each atom of ferrous iron to form an
orange - red complex. The coloured solution obeys Beer"s law; its intensity is
independent of pH from 3 to 9. A pH between 2.9 and 3.5 insures rapid colour
development in the presence of an excess of phenanthroline.
Apparatus :
Spectrophotometer, for use at 510 nm providing a lightpath
of 1 cm or longer.
Acid wash glassware. Wash all glassware with conc. hydrochloric acid and rinse with
distilled water or iron free DM water.
Reagents for Dissolved Iron :
10% W/v hydroxylamine hydrochloride in 100 ml distilled
water.
water or iron free DM
Ammonium Acetate buffer solution (NH4C2H3O2).

Dissolve 250 g Ammonium acetate in 150 ml distilled water or iron free DM water.
Add 70 ml conc. (glacial)Acetic acid. Because even a good grade of acetic acid
contains a significant amount of iron, prepare a new reference standard with each
buffer preparation.
1 - 10, Phenanthroline solution.
Dissolve 100 mg 1, 10. Phenanthroline monohydrate (C12H7N2H20) in 100 ml
distilled water or iron free DM water by stirring and heating to 80 Deg C. Discard the
solution if it darkens. Heating is unnecessary if 2 drops conc. HCl are added to the
distilled water.
Stock Iron solution :
Dissolve 1.404 g ferrous ammonium sulphate Fe (SO4)2 (NH4)2 in 250 ml distilled
water or iron free DM Water.
Add separately 20 ml Conc. H2SO4 in 50 ml distilled water or iron free DM water.
Add both the solution together in a 1000 ml volumetric flask and add 0.1 N
Potassium permaganate(KMnO4) drop wise until a faint pink colour persist. Dilute to
the mark with distilled water or iron free DM water.
96

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
Working Iron Solution :

Pipette 50 ml stock solution and dilute to 1000 ml.
1 ml = 10.0 ug Fe (Microgram Fe.)
Preparation of Calibration Curves :
Pipette out 1.0, 2.0, 3.0, 4.0, 5.0 ml of working iron solution in 50 ml volumetric flask,
corresponding to 0.20, 0.40, 0.60, 0.80, and 1.00 ppm.
Add 5 ml hydroxylamine hydrochloride followed by 10 ml Ammonium acetate buffer
and shake it thoroughly. Now add 2 ml 1-10 phenanthroline and make up to the
mark. Wait for 10 minutes and take the reading in spectrophotometer at 510 nm
against a reagent blank prepared by distilled water or iron free DM water and plot the
graph.
Procedure for Dissolved Iron :
Take 25 ml sample in a 50 ml volumetric flask.Add 5 ml hydroxylamine hydrochloride
followed by 10 ml Ammonium Acetate Buffer. Shake it thoroughly and add 2 ml 1-10.
Phenanthroline and dilute upto the mark with distilled water or iron free DM water.
Wait for 10 minutes and measure the reading at the 510 nm, and find out the
concentration from the standard graph (Use Reagent Blank).
Procedure for Total Iron :
Take 25 ml sample in a volumetric flask and add 2 ml HCl followedby 1 ml 10%
hydroxylamine hydrochloride. Add a few glass beads and heat to boiling. To ensure
dissolution of all the iron continue boiling until volume is reduced to 15 to 20 ml.
Cool to room temperature and transfer to 50 ml Volumetric Flask. (Next follow the
Dissolve Iron Procedure).
Calculation :
mg/l Iron = ppm iron (from graph) x Dilution factor.
Interference :
Among the interfering substances are strong oxidising agents, Cyanide, Nitrite, and
Phosphate. Cobalt and copper in excess of 5 mg/lt and Nickel in excess of 2 mg/lt.
Bismuth, Cadmium, Mercury, Molybdate and Silver precipitate phenanthroline.
97

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
5.11 FREE CHLORINE OR CHLORAMINE :

Reagent and Apparatus :
Lovibond Comparator
Disc for Free Chlorine 0-1.0 ppm
Two 10 ml. test tubes for Lovibond Comparator
0.1 ml. pipette
Ortho-Toluidine Indicator
Method :
Fill the two test tubes to the mark with the sample to be tested.
Fit the disc into the comparator and with the hinged lid facing D. Place one of the
tubes in
the left hand compartment.
To the other tube add 0.1 ml. of Ortho-Toluidine solution, mix well and place in the
right-hand compartment of the comparator. Allow to stand for 5 minutes when
estimating Chlorine, 20 mins. when estimating Chloramine.
Holding the comparator upto a good source of northern day light, rotate the disc until
a colour match is obtained.
Result :
The residual Chlorine or Chloramine content can then be read off from the window at
the bottom right hand corner of the case.
Note :
If the presence of Nitrites is suspected, add a small crystal of Sodium Thiosulphite to
the sample containing the Ortho-Toluidine. The yellow colour due to the presence of
Chlorine or Chloramine will be discharged, but if there are any nitrites present, the
solution will remain yellow.
98

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
5.12 FREE CARBON DIOXIDE :

Burette for Sodium Carbonate solution
Sodium Carbonate solution 0.04N (N/25)
Phenolphthalein indicator (solution or tablets)
100 ml. Nessler cylinder
Glass stirring rod
Procedure :
Fill the Nessler cylinder to the 100 ml. mark with the water to be tested avoiding
splashing and add 2 tablets or 20 drops of Phenolphthalein indicator.
Run in 0.04N Sodium Carbonate, a few drops at a time with gentle stirring until a
pale pink colour is produced which persists for one minute. Take the buretter
reading :
Interpretation of result :
Free CARBON DIOXIDE, as ppm CaCO3 = Burette reading(ml) x 10
99

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
5.13 EQUIVALENT MINERAL ACIDITY (E.M.A.) :

Reagents :
AMBERLITE IR-120 strongly acidic cation exchange resin
Approximately 2N hydrochloric acid
Screened methyl orange indicator
0.02N sodium hydroxide solution
Method :
Measure under water, 50 ml. settled volume of AMBERLITE IR- 120 into a
chromatographic tube. The tube should be fitted with an outlet tap or screwclip at
the bottom. If an ordinary glass tube is used, above this outlet a plug of glass wool
to support the bed of ion exchange resin is required. Backwash the ion exchange
resin in an upward direction with distilled or deionised water to loosen the bed, allow
the bed to settle, drain water down to the resin surface and pass 250 ml. of 2N
hydrochloric acid in a downward direction through the column at a rate of 3-5 ml/min.
Rinse the column with distilled or deionised water until the effluent is alkaline to
screened methyl orange. Pass 50 ml. of sample and discard the effluent. Pass two
100 ml. aliquots through the column at the same rate collecting the respective
effluents separately. Titrate each of the effluents in turn with 0.02N sodium
hydroxide using screened methyl orange as indicator.
Calculation :
EMA, as ppm CaCO3 = ml of titration x 1000
ml of sample
Note :
The column prepared in the above manner may be used for several determinations
before it is exhausted. It is capable of exchanging the equivalent of 5000 mg. of
calcium carbonate. When exhausted it need simply be washed, regenerated and
rinsed again.
When the figure for E.M.A. (or FMA) is used to calculate the total Anion load (TA) for
an anion exchange resin unit, the following method of calculation is to be used. This
applies when Screened Methyl Orange is used as the Indicator.
a = volume of sample (ml)
b = volume of titration (ml)
E.M.A., as ppm CaCO3 = [b + {0.008 (a+b)}] x 1000
a
100

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
This test actually determines the acidity equivalent to the dissolved neutral salts in
the water (Sulphate + Chloride + Nitrate)
101

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
5.14 SILICA 1-20 PPM :

BDH Lovibond Nessleriser.
Disc with colour standards 0.05 mg. to 1.0 mg. SiO2.
10 % w/v Aqueous solution of Ammonium Molybdate.
2N Sulphuric Acid Solution.
Method :
Fill one of the Nessler glasses to the 50 ml. mark with the sample and place in the
left hand compartment of the Nessleriser.
Fill the other Nessler glass with the sample, at 25-30 Deg C.
Add 4 ml. of 2N Sulphuric Acid and 2 ml. of the Ammonium Molybdate solution. Mix
thoroughly, place in the right hand compartment and allow to stand for 10 minutes.
Fit the standard disc of silica in the hinged lid.
Stand the Nessleriser facing a uniform source of light, looking north if possible, and
compare the colour of the sample with the colours in the disc. Rotate the disc until
the colours are matched.
Interpretation of result :
SILICA as ppm SiO2 = disc reading x 20.
If the colour in the test solution is deeper than the deepest standard, a fresh test
should be carried out using a smaller quantity of sample and diluting to 50 ml. with
distilled water before adding the reagents. Necessary correction to be made for
dilution of sample in calculating the silica content.
Note :
Most colourless salts, even when present in relatively large quantities, are without
influence upon the colour produced in the test provided the concentration of free
acid is not unduly disturbed. Phosphates, however, must be absent, since they
respond to the test and yield a yellow colour similar to that produced by silica.
Phosphates may be removed by treating 100 cc of the solution under test with 50 ml.
of Sorensen's borate buffer solution (pH 10.0) and 2 ml. of 2N calcium chloride
solution; after mixing and allowing to stand for 2 hours the mixture is filtered. The
test is made on 50 ml. of the filtrate by the method described above. As Sorensen's
borate buffer invariably contains silica derived from the glass bottle, a blank test
102

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
should be carried out and the necessary correction made. The result be multiplied by
1.5.
5.15 SILICA 0-1 PPM-MOLYBDENUM BLUE METHOD :
Reagents :
Acid Molybdate Solution :
75 gms of Ammonium Molybdate analar grade are dissolved in 500 ml. of distilled
water. 322 ml. of 10/N Sulphuric Acid are added gradually with constant shaking.
The solution is then made up to one litre with silica free water.
10 % w/v Oxalic Acid solution.
Reducing Agent :
90 gms. Sodium Metabisulphite are dissoved in 800 ml. of
silica-free water.
7 gms anhydrous Sodium Sulphite are dissolved in 100 ml.

silica free water,
together with 1.5 gm. of 1 - amino, 2 - naphthol, 4 -Sulphonic acid. The two
Solution are mixed and the total volume made up to one litre with silica-free
water.
Apparatus :
Lovibond Nessleriser
Disc for Silica 0.2-1.0 ppm
Two 50 ml. graduated tubes of Nessleriser.
Pipettes
Alternatively a spectrophotometer may be used at the wave length corresponding to
a maximum absorption (but the exact wave length will have to be checked on each
individual instrument).
Method :
50 ml. of the water under test is treated with 2.0 ml.Acid Molybdate solution and
allowed to stand for 5 mins. at a temperature of 20-30 Deg C. If a tinge of yellow
appears in the sample there is more than 1 ppm Silica present, and the test
described for 1-20 ppm Silica should be carried out on a fresh aliquot. If no tinge of
yellow appears, 4 ml. of 10% Oxalic acid is added to the sample followed by 1.0 ml.
of reducing agent and the sample allowed to stand for 20 mins. The blue colour of
103

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
the sample is compared with that of a blank solution prepared by adding reagents to
Silica free water, using either a B.D.H. Lovibond Nessleriser or a previously
calibrated absorption meter.
Note :
Silica free Water :
Prepare and store in a polythene bottle a large batch of water containing not
more than 0.005 ppm silica. Determine the Silica content of the water by treating it
as a sample as under `Method'. This water is used to prepare reagents and
standards, and to dilute samples when necessary. Distilled water from an all metal
`Still' or water which has been passed successively through a mixed bed dionisation
unit and strongly basic anion exchanger unit regenerated with NaOH at a level of
320 gms/litre has been found to meet this specification.
104

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
5.16 OXYGEN ABSORBED IN 4 HOURS :

Outline of the Method :
This is determined by estimating the amount of standard potassium permanganate
solution consumed by the sample in 4 hours under specified conditions.
Test Temperature :
This determination is carried out at a temperature of 37 Deg C.
Reagents :
Stock Potassium Permanganate Solution :
Dissolve 3.951 g of potassium permanganate (dried at 105 Deg C) in distilled water
and make up to 1000 ml. This solution must be kept in the dark and its strength
must be checked periodically.
Standard Potassium Permanganate Solution N/80 :
This solution should be prepared immediately before use by suitable dilution of stock
potassium permanganate solution. One millilitre of this solution is equivalent to 0.1
mg of oxygen.
Dilute Sulphuric Acid :
Add slowly 50 ml of concentrated sulphuric acid to 130 ml of distilled water, cool and
make up to 200 ml with distilled water. Add standard permanganate solution until a
very faint pink colour persists after 4 hours.
Potassium Iodide :
Stock Sodium Thiosulphate Solution :
Dissolve 31.2 g of sodium thiosulphate and 6 g of sodium bicarbonate in water and
make up to 1000 ml.
Standard Sodium Thiosulphate Solution N/80 :
This should be prepared by suitable dilution of stock sodium thiosulphate solution.
Before using the solution the strength must be checked by titration with standard
potassium permanganate solution.
105

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
Starch Indicator Solution :

Dissolve 1 g of starch in 100 ml of warm (80 Deg C - 90 Deg
and add a few drops of formaldelyde
solution.
C) distilled water
Procedure :
Place 250 ml of the well-mixed sample into a clean, glass- stoppered bottle of 400 ml
capacity. Add 10 ml dilute sulphuric acid, followed by an accurately measured
volume (see note) of standard potassium permanganate solution. Mix by gentle
rotation and place in a water-bath or incubator at 37 Deg C for 4 hours. If the sample
contains much suspended matter, it should be mixed by gentle rotation several times
during the period of incubation. At the end of 4 hours, cool to about 15 Deg C, add a
few crystals of potassium iodide and titrate in the bottle with standard sodium
thiosulphate solution, using a few drops of starch indicator soltuion. A blank for
oxygen absorbed in 3 minutes shall be carried out. Express the result to the nearest
0.05 mg/l.
Note :
The measured volume of standard potassium permanganate solution taken must not
be less than 10 ml, but should be such that at the end of 4 hours, the amount
remaining unchanged is between 5 and 15 ml. If it is found that the volume required
was anticipated incorrectly, the determination must be repeated.
Calculation :
Oxygen absorbed in 4 hours, mg/l = 0.4V
Where,
V = Volume in ml of standard potassium permanganate solution
consumed in reaction with the sample.
106

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
SECTION 6
TROUBLE SHOOTING
107

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
6.1 UF TROUBLE SHOOTING
6.1.2
LOW PERMEATE FLOW RATE

Check unit for proper operation and make sure operating pressures are at the
appropriate values. Clean the system using appropriate cleaning chemicals.
6.1.3
HIGH BACTERIAL LEVELS

Sanitize the system after appropriate cleaning.
6.1.4
HIGH PERMEATE FLOW RATE

a) System specifications are for a minimum flow rate using clean membranes
and prefiltered water at 50 psid and 25 deg. C. Flux (permeate) rates may
exceed the operating flux rate printed herein. Some UF cartridges may
exceed minimum specifications and hence produce slightly higher
permeation rates. This is not to be confused with membrane by-pass.
b) Check with IEI for permeate flow vs temperature correction factor to
determine appropriate flow for the operating temperature. Also check system
feed pressure.
108

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
6.2 TROUBLE SHOOTING FOR RO PASS-1 AND PASS-2:

This section gives the symptoms, likely causes and corrective actions required for the
RO unit. For smooth operation of the plant, continuous attention must be given to feed
water quality, operating parameters and routine maintenance.
Sr.
No
Symptom
1.
Increase
SDI at
outlet
Likely cause
Consequences if
not corrected
in Change in quality of
CF raw water
Coagulant
Flocculant
malfunction
Fouling
membranes
leading
/ reduction
dosing product flow
of
High/Low pH
Acid level low /

Blockage in acid line
Residual
chlorine
at
Cartridge
filter outlet
Use right quality of

chemicals.
Give
sufficient
backwash to the
filters.
Fouling
membranes
Damage to
membranes
Change in quality of
raw water.
Maloperation
of
sodium hypochlorite
109
water
Check sand filter
Feed water quality /

flow change
3.
Check raw
quality
to
in Check coagulant /
Flocculant dosing
system.
Carry out fresh jar
test if required.
Channeling in the
sand filter.
Inferior quality of
chemical.
Inadequate
backwash of filter
2.
Corrective action
of
the
Refill acid / Check

acid pump suction
and discharge.
Check feed water
flow, adjust dosage
as needed.
Damage to
membranes
(decrease in
rejection)
RO Check raw water

quality.
Adjust
salt dosing rate.
Repair the pump.

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
dosing pump.
Change in raw water
flow
4.
Low pressure
at H.P. pump
suction
Raw water pump

malfunction.
Excessive pressure
drop at MGF/CF
Adjust
flow.
water
H.P. pump may get

damaged due to
cavitation.
Check raw water

pump.
Give backwash to
MGF,
change
cartridges.
Recalibrate
pressure gauge /
pressure
switch.
Check
solenoid
valve/auto
feed
water valve.
Malfunction of auto
feed
water
valve/solenoid valve.
5.
Auto
water
does
open.
Solenoid
valve
malfunction.
Wrong installation of
this valve.
RO unit will not

function.
Check
solenoid
valve.
Check installation
of auto feed water
valve.
6.
Increase
in Increase in RO feed
RO
feed conductivity
pressure
Fouling / Scaling of
membranes
Reject
valve
maloperation
Pressure
gauge
malfunction
Lower product flow

Lower membrane
life
Check raw
quality / SDI
Membrane
cleaning.
Low
flow.
Scaling / fouling of
membrane.
7.
feed
valve
not
raw
reject RO
flow
and
pressure imbalance.
H.P.
pump
malfunction.
Incorrect reject flow
indicator.
8.
Increase
pressure
drop.
9.
Decrease
water
Adjust recovery
Check
pressure
gauge.
Adjust reject control
valve.
Check pump.
Calibrate reject flow

indicator.
in Pressure
gauge Decrease
in Check
pressure
malfunction.
product flow. Lower gauge.
Membrane scaling / membrane life.
Clean
the
fouling.
membranes.
Entry of particulate
Check SDI and
materials.
particulate content.
in Scaling /fouling of Lower product flow. Check raw water
110

normalised
permeate flow
NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
membranes.
Increase in
feed pressure
RO
Malfunction
of
permeate
flow
indicator
Change
in
temperature of water
10.
Decrease in O ring leakage.

normalised
Membrane damage.
salt rejection.
Use
suitable
temperature
correction factor.
Inferior
product
quality
(high
product
conductivity)
12.
High pressure
at HP Pump
discharge
ORP
dump
valve
does
not open
Probing / profiling
to find O ring
leakage
/
membrane
damage. Replace
damaged
membranes / O
rings. Eliminate the
cause of damage.
Clean
the
membranes.
Recalibrate product
cond. indicator.
Membrane
scaling
/fouling.
Product
cond.
indicator malfunction.
11.
quality / SDI. Clean

the membranes
Check
permeate
flow indicator
Reject / Recycle
valve closed
Membrane
damage
may Check the valves

Check fouling on
membranes
Membrane
fully HP pump may get Any blocks / foreign
choked / fouled
damaged
particles
water
passage
through
Leakage of joints / pressure tubes /
connectors
pipes
Solenoid
valve
malfunction.
Wrong installation of
this valve.
RO unit will not

function.
Check
solenoid
valve.
Check installation
of auto feed water
valve.
6.3 MIXED BED TROUBLE SHOOTING

Sr.
No.
DEFECTS
CAUSES
111
REMEDIES

1.
Decrease
in
capacity
between
regenerations.
NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
1. Flow
instrument
defective.
2. Plant being used

intermittently.
Check the instrument.

Avoid this situation.
Check. For the consumption.
3. Insufficient
chemicals used.
in ionic
load.
5. Resin
quantity
insufficient.
6. Channeling in bed
7. Resin dirty.
4. Increase
8. Resin fouled.
Check analysis.
Check & top up.
Check the distribution.
Give the prolonged backwash
If Cation giveHCL wash or if
Anion
give
alkali
brine
treatment
Check the conditions.
Treated
water
quality not upto
the standard.
1. Softener
Treated
water
quality not upto
the standard.
2. Unit idle.
3. Unit
insufficiently
3.
Unit rinse takes

long time.
1. Flow rate too low.

2. Unit exhausted.
3. Backwash
valve
passing
Increase the flow rate.

Regenerate the unit.
Check & rectify.
4.
Flow
low.
1. Choked
Check.
2.
rate
too
resin
exhausted.
rinsed.
4. Excessive flow rate.
5. Resin deteriorated.
valve &
suction of the pump.
2. Cavitation in the
pump
3. Distribution
&
collecting
system
choked.
112
Check.
Rinse
the
unit
till
the
satisfactory quality is achieved.
Adjust between min.& max.
flow rate.
Check resin quality & replace if
necessary.
Check the pump design &

operating conditions.
Check.

Sr.
No.
DEFECTS
5.
Pressure
drop
across the bed
increasing.
NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
CAUSES
6.
Resin being lost

from the unit.
7.
Ejector
working.
not
REMEDIES.
1. Defective pressure
gauge.
2. Defective valves.
3. Packed resin bed &
resin fines.
4. Collecting system
choked.
1.Excessive
backwash pressure.
2. Faulty
collecting
system.
1.Low power water
pressure.
2. Air lock in the
unit.
3. Choked or defective
valves.
4. Ejector
nozzle
choked.
much back
pressure from the
unit.
5. Too
8.
Incorrect reading
from rotameter..
1.Choked orifice or
sub
orifice
or
impulse line.
2.Dirty glass & float.
113
Check & calibrate the pressure gauge.

Check.
Give extended backwash with open
manhole and scrap off the finesand top
it up with fresh resin.
Check & give the backwash.
Check the inlet pressure and reduce if
necessary.
Check the collecting system by opening
the resin trap outlet valve.
Check the pressure.
Open the air release and backwash
outlet valves.
Examine & rectify.
Open & check the ejector nozzle.
Check for the collecting system.
Check & rectify
Check & rectify.

Clean the glass

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
DEFINITIONS OF TERMS
CONCENTRATE
The portion of the feed stream which does not pass through the membrane. It contains
retained dissolved or suspended materials at a concentration higher than that of the
feed stream. Also known as RETENTATE.
CONCENTRATION POLARISATION
The condition which results when the retained dissolved materials become concentrated
in the thin boundary layer adjacent to the membrane surface. The gel layer thus formed
presents a barrier to fluid migration to the membrane and reduces overall flux. Proper
design of cross flow filtration and cleaning techniques minimizes the effect.
DIAFILTRATION
The continuous exchange of process solution with fresh solvent, thereby removing
membrane permeating species from the batch.
ENDOTOXINS
Generally refers to the lipopolysaccharides coming from the cell walls of dead bacteria.
Frequently used interchangeably with pyrogen.
FEED
The influent stream to the ultrafiltration system, which is then split into a permeate
stream and concentrate stream.
FLOW DEPENDENT
UF feed streams where fouling mechanisms must be controlled to allow predictable
permeation rates through the membrane.
FLUX
Rates at which fluid permeates or flow through the membrane, usually expressed in
gallons per square foot of membrane per day (GSFD).
GEL LAYER
A layer of highly concentrated or precipitated solids, usually of high molecular weight
species, adjacent to the active surface of an operating ultrafiltration membrane. The gel
layer permeability rather than membrane permeability often controls ultrafiltration flux.
HUMIC ACID
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Any of various organic acids that are insoluble in alcohol and organic solvents and are
obtained from humus.
HUMUS
A brown or black complex and varying material formed by the partial decomposition of
vegetable or animal matter the organic portion of soil.
LAL
Limulus Amebocyte Lysate is a chemical, which is sensitive to the presence of pyrogenic
material (endotoxin). The LAL test measures the concentration of pyrogens which is
reported as endotoxin units (EUs) in a specified volume.
MEMBRANE ANISOTROPIC
A synthetic polymeric membrane composed of a very tight thin skin on one side
supported by a sponge like layer. The skin or active membrane, functions as the semipermeable barrier to solute flow causing rejection of macromolecules in solution and any
colloidal or suspended material.
MOLECULAR WEIGHT CUTOFF
The membrane specification describing the normal rejection of a known molecular
species dissolved or suspended in the feed stream.
PERCENT RECOVERY
Ration of permeate flow to feed flow
PERMEATE
Portion of the feed stream, which passes through the membrane, essentially free of
colloidal, particulate and microbiological species.
POINT-OF-USE SYSTEM
A filtration system which is installed very near to the location where the water is
consumed. this is in contrast to a central water system or loop, which is generally,
located a considerable distance from the point where the water is used.
POLYETHERSULFONE
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An engineering thermoplastic polymer from which ultrafiltration membranes having

desirable properties of toughness, chemical resistance and thermal stability can be
formed.
PPB
Parts Per Billion, refers to the concentrations by weight of a material relative to fluid in
which it is placed.
PRESSURE DEPENDENT
UF feed streams where fouling or concentration polarization is relatively unimportant.
PYROGEN
Any substance, which causes a temperature rise when, injected. A common source is
bacteria fragments. See endotoxin.
RECOVERY RATE
The amount of fluid (permeate) collected which has passed through the membrane
expressed as a percent of the feed stream.
REJECTION RATE
One (1) minus the ratio of a specific solute concentration in the permeate to the
concentration of the solute in the feed expressed as a percentage.
RETENTATE
See CONCENTRATE, Reject from Ultrafiltration System,
REVERSE OSMOSIS
By application of pressure (above osmotic pressure) on a salt solution against a semipermeable membrane, pure water is forced through the membrane leaving behind salts.
SOLUTE REJECTION
A measure of the ability of the ultrafilter to block the passage of material dissolved or
suspended in the feed stream.
SOLUTE
The constituents of a solution which are dissolved in the solvent.
TIC
Total Inorganic Carbon is similar to TOC but measures inorganic carbon.
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TOC
Total Organic Carbon or Total Oxidizable Carbon measures the total organic material by
high temperature oxidation or carbon dioxide. Detects presence of organic material
down to parts per billion.
ULTRAFILTRATION
A membrane separation process similar to reverse osmosis in which relatively higher
molecular weight materials are separated from a feed stream.
18 MEG-OHM WATER
Water which has been treated to remove conductive materials. For pure water, the
theoretical value for resistivity is 18 meg-ohm at 25 deg. C.
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SECTION 7
MAINTENANCE
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7.1 PRETREATMENT
The recommended pretreatment is a prefilter (100 micron strainer). The life of
the filter is a function of the degree of cleanliness of the feed water. The life
times given below must be considered as a maximum, this could be much
shorter if the feed water is highly contaminated with particles and colloids.
Strainer Prefilter cleaning differential pressure exceeds 20 psi (whichever is
sooner)
7.2
SANITIZATION
In order to preserve the performance of the UF cartridge as well as to maintain a
low bacteriological count in permeate water, it is necessary to sanitize the system
on a regular basis (once a week minimum). The most efficient sanitization is
achieved through injection of diluted chlorine bleach into the feed water line with
an accessory injection pump. The average chlorine concentration measured on
permeate line is 200 to 250 ppm.
During sanitization cycle the permeate flow is diverted to the drain.
7.3
WEEKLY CHECKING
We recommend to sanitize the UF system once a week minimum. The weekly
checking required is pump performance and permeate flow rate.
Permeate flow rate should be in accordance with figure 3.2 section.
7.4
PROLONGED SHUTDOWN
If the system is used once or twice a week, we recommend to sanitize it before
using the water. If the system is shut down for more than one week, it is
necessary to remove the UF cartridge and to store it immersed in a 3%
formaldehyde or caustic chlorine solution or follow long term membrane storage
procedure (6.4)
7.5
PUMP INSPECTION
Once in a week, pump should be checked for any mechanical damage, current
drawn. Necessary steps, as given in attached manual, should be carried out in case
of any performance deterioration.
7.6
CARTRIDGE REPLACEMENT AND CLEANING

Basket / Conical filter (prefilter) should be cleaned or replaced as
suggested.
119

7.7
NUMBER.
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LOG BOOK
Logbook of UF system should be maintained and recorded properly.
7.8 Integrity Testing :
Integrity testing of Hollow Fiber membrane modules is recommended prior to water

processing to ensure an integral membrane. The three procedures listed below give a gross
indication of membrane integrity. They are not intended as an absolute check of membrane
integrity.
A. Permeate Side Pressurization Test

1.
2.
3.
4.
Install the module on a system.

Fill the feed side of the module with clean water.
Close off the inlet valve (bottom side) to the system and open the outlet side.
Connect a clean air or nitrogen line to the permeate port. Air or nitrogen pressure just be
regulated to 2-3 psi. Inject air or nitrogen into the cartridge.
5. Watch for bubbles in the clear elbow on the top side of the cartridge, or bubbles exiting
the outlet line. The presence of large bubbles indicates a broken fiber. Some diffusion of
air may occur during this process, and should not be confused with a membrane failure.
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B. Feed Side Pressurization
1. Cap or close the valve on the top side of a hollow fiber cartridge. Cap the low permeate
port.
2. Attach a clean air or nitrogen line to the other feed side of the cartridge.
3. Fill the permeate side with as much water as possible until it pours out the top port
permeate.
4. Inject 2-3 psi of air or nitrogen into the feed side of the cartridge and watch for bubbles
on the permeate side. If a fiber is damaged, large bubbles can be seen through the clear
plastic housing. Some diffusion of air may occur during this process, and should not be
confused with a membrane failure.
5. Invest the cartridge and repeat the procedure to check the portion of the cartridge that
was on filled on the permeate side.
C. Pressure Hold Test

1. Install cartridges on system and fill with water.
2. Pressurize the feed side of the system with 15psi clean air or nitrogen. Higher pressures
may be applicable for some membrane types.
3. Monitor the pressure decay with a diffusion monitoring instrument over time (usually 5
minutes or less).
7.9
DOS AND DONTS
121

1.
2.
3.
4.
NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
DOS
DONTS
Do check the water level 1.

in Feed tank, so that the
pump suction is fully
flooded
Check water temperature 2.
regularly and shut off the
system immediately if
feed water temperature is
greater than 50 deg. C.
Dont run the system dry or

without sufficient water in the
buffer
Clean the prefilter when

pressure drop across it
exceed 15 psi
Do flush the system
sufficiently for about 30
min. at rated capacity
before taking samples
3.
4.
122
Dont run the system with feed

water temperature more than 50
deg. C continuous. Exception
during hot water sanitization
when temperature is at 90 deg.
C max. for 20 min. at a time.
Dont run the system when
pressure drop across prefilter
exceeds 15 ~20 psi
Dont take sample without
proper flushing of dead zones in
the system.

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
7.10 Precautions
Read and understand the following precautions. Personal injury and/or premature failure
could result if these precautions are not followed.
1. DANGERPRESSURIZED DEVICE The membrane modules and piping provided
with this system may cause loss of life, severe bodily injury and/or property damage
if not properly installed, operated and maintained. Read and understand all
equipment guidelines given before attempting to open, operate or service the
system. Failure to follow these instructions and observe every precaution may result
in malfunction and could result in catastrophic failure; Misuse, incorrect assembly or
use of damaged or corroded components can result in high velocity release of
hardware.
2. Do not perform any system or Module maintenance unless the system control power
is OFF, the pump starters are OFF and LOCKED-OUT and INTERNAL PRESSURE
HAS BEEN RELIEVED from the system. Failure to do so may result in serious injury.
3. The UF membranes must not be allowed to dry out. The membranes must remain
wet any time the system is shutdown for any reason, including maintenance.
Membrane dry out is irreversible, and will damage membrane permanently.
4. The UF membranes must not be allowed to freeze. Freezing will permanently
damage the membranes.
5. Do not expose the UF membranes to acidic pH chlorine. Always adjust water to >pH
8 prior to chlorine addition. It is recommended that the chlorine concentration not
exceed 250 ppm.
6. If the system is to be shutdown for a period exceeding one week, arrangements
must be made to clean the membranes to eliminate possible biological fouling. See
Membrane Protection section.
7. No anti-foam agents of any kind are to be introduced into the Koch Ultrafiltration
Membranes system without prior review.
8. No silicone based materials, including any waterproofing sprays, lubricating or
cutting fluids or greases, etc. are to be used in or around the Ultrafiltration System.
Using these materials in the Ultrafiltration Systems may cause complete and
irreversible membrane fouling.
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7.2 RO PASS 1&2 MAINTENANCE

7.2.1 INDUSTRIAL REVERSE OSMOSIS UNIT & CLEANING SYSTEM
This section describes in detail mechanical maintenance aspects. There is an extensive
discussion regarding the various foulants affecting the RO membranes and regarding
membrane cleaning.
7.2.2 Mechanical Maintenance
Regular maintenance of Reverse Osmosis unit is required for a long troublefree
performance. It will also enable the operator to pinpoint the causes of defective
performance quickly.
In general, since the Reverse Osmosis unit involves high pressure, it is necessary to
ensure that there are no leaks and to attend to them immediately should they occur. It is
also necessary to keep an inventory of essential spare parts so that problems can be
attended to as soon as they occur.
7.2.3
Change of filter cartridges
(Normally done when the pressure drop across the filter exceeds 1 kg/cm 2)
1. Turn the RO unit main switch to OFF position.
2. After ensuring that the pressure in the cartridge filter pressure gauge is zero, open
the cartridge filter cover and unscrew the nuts holding the cartridge filter elements.
Remove the existing cartridge filter elements and discard them.
3. Observe the particulates to see if there is any abnormal carryover of sand, or
activated carbon or any other material.
4. Drain the cartridge filter body and wash it with water.
5. Install new cartridges/filter elements and refix the covers tightening the bolts evenly.
6. Turn the main switch to AUTO and restart operations.
7.2.4
Lubrication of high pressure pump
1. Turn the main switch to OFF position.

2. Insert two strokes of lubricant from the hand operated becoming lubricant pump into
the grease filling near the motor end of the pump.
3. Turn the main switch to AUTO position.
124

7.2.5
NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
Maintenance schedule
Sr.
No.
Activity
Frequency
Inspect and attend leaks
Daily
Change filter cartridges
Once in 3 months or when the

pressure drop > 1.0 kg/cm2
whichever is earlier
Lubrication of high pressure pump
Once in 6 months
RO membrane cleaning
See Note 1 below.
RO membrane replacement
See Note 2 below.
Instrument calibration
Refer instrument manuals.
Note 1
When the "normalised" productivity rate is more than 15% below that for clean
membrane, or
When the RO feed pressure is 2.00 kg/cm2 higher than that with clean membrane.
Note 2
When after repeated cleaning performance is not restored to the desired extent.
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7.2.6 Membrane Cleaning

This section provides general information about the usual foulants affecting the
performance of Composite Polyamide Reverse Osmosis (RO) membrane elements and
the removal of these foulants. The information in this section applies to 4 inch and 8
inch diameter RO membrane elements.
Note
The Composite Polyamide type of RO membrane elements may not be exposed to
chlorinated water under any circumstances. Any such exposures will cause irreparable
damage to the membranes. Absolute care must be taken following any disinfection of
piping or equipment or the preparation of cleaning or storage solutions to ensure that
NO trace of chlorine is present in feed water to the RO membrane elements. If there is
any doubt about the presence of chlorine, perform chemical testing to make sure.
Neutralise any chlorine residual with sodium bisulphite solution, and ensure adequate
contact time to accomplish complete dechlorination.
It is recommended that all RO membrane cleaning operations should be closely coordinated with Ion Exchange (I) Ltd., during RO membrane element warranty period. IEI
Ltd field service personnel should be on site, at least for the first cleaning event.
The use of cationic surfactant should be avoided in cleaning solutions, as irreversible
fouling of the membrane elements may occur.
7.2.7
RO membrane element foulants
During normal operation over a period of time, RO membrane elements are subject to
fouling by suspended or sparingly soluble materials that may be present in the feed
water. Common examples of such foulants are calcium carbonates scale, calcium
sulphates scale, metal oxides scale, silica coating and organic or biological deposits.
The nature and rapidity of fouling depends on the condition of the feed water. Fouling is
progressive, and, if not controlled early, will impair the RO membrane element
performance in a relatively short time.
Monitoring overall plant performance on a regular basis is an essential step in
recognising when membrane elements are becoming fouled. Performance is affected
progressively and in varying degrees, depending on the nature of the foulants. Table 7.1
provides a summary of the expected effects that common foulants have on performance
of the RO system.
7.2.8
Foulant removal
Foulant removal is achieved by cleaning and flushing. Further fouling is avoided by

changing the operating conditions. As a general guide, foulant removal is required when
any of the following conditions occur:
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1. Permeate flow has dropped to 10-15 percent below rated flow at normal pressure.
2. Temperature corrected feedwater pressure has increased 10-15 percent to maintain
rated product water flow.
3. Product water quality has decreased 10-15 percent, salt passage has increased 1015 percent.
4. Applied pressure has increased about 10-15 percent.
5. The differential pressure across RO stage has increased noticeably (instrumentation
may not be available to monitor this indication).
The following paragraphs provide a discussion of the common foulants and their
removal:
Calcium carbonate scale
Calcium carbonate may be deposited from almost any feed water if there is a failure in
the inhibitor addition or in the acid injection of pH control system that results in a high
feed water pH. An early detection of the resulting calcium carbonate scaling is
absolutely essential to prevent the damage that crystals can cause on the active
membrane layers. Calcium carbonate scale that has been detected early can be
removed by lowering the feed water pH to between 3.0 and 5.0 for one or two hours.
Longer resident accumulations of calcium carbonate scale can be removed by
recirculating a citric acid solution of 2 percent strength and a pH of no less than 4.0
through the RO membrane elements.
Ensure that the pH in any cleaning solution does not fall below 4.0 otherwise, damage
to the RO membrane elements may occur, particularly at elevated temperatures. The
maximum pH should be less than 10.0. Use sodium hydroxide to raise the pH, or
sulphuric or hydrochloric acid to lower it.
Calcium sulphate scale
Solution 2 is the best choice for removal of calcium sulphate scale from the RO
membrane.
Metal oxides scale
Precipitated hydroxides (e.g., ferric hydroxide) can usually be removed by using the
techniques described above for calcium carbonate scale.
Silica scale
A silica coating not associated with either metal hydroxides or organic matter will usually
respond only to very specialised cleaning methods. Contact Ion Exchange (I) Ltd., for
instructions related to a specific problem.
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Organic deposits
Organic deposits (e.g. microbiological slimes and moulds) are best removed by using
solution 3. To inhibit additional growth, recirculate and soak the membranes with a IEI
Ltds approved biocide solution. This requires extended exposures to be effective; a
biocide solution is best employed when an RO block or train is to be left in a standby
condition for more than three days. Contact Ion Exchange (I) Ltd., for the biocide best
suited for specific conditions.
Cleaning solutions
The following chemical solutions are recommended for cleaning the RO membrane
elements. The appropriate solutions to use can be determined by chemical analysis of
the fouling material. A detailed examination of the results of the analysis will provide
additional clues as to the best method of cleaning. Keeping records of the methods
used and results obtained will provide data useful in developing the methods and
solutions that work best under the feed water conditions at hand.
Solution 1 is recommended for inorganic fouling. Solution 2 is recommended for calcium
sulphate and organics. Solution 3 is recommended for high organic fouling. All solutions
are to be used the highest available temperature up to 40 0C or upto 60 minutes of
cleaning. The quantities given are as per 100 litres of water. Prepare the solutions by
proportioning the amount of chemicals to the amount of cleaning water to be used. Use
chlorinefree permeate to mix the solutions. Mix thoroughly.
If additional information is needed, please contact Ion Exchange (I) Ltd.
RO membrane element cleaning and flushing
The RO membrane elements in place in the pressure tubes are cleaned by recirculating
the cleaning solution across the high pressure side of the membrane at low pressure
and relatively high flow. A cleaning unit is needed to do this.
The general procedure for cleaning the RO membrane is as follows:
1. Flush the pressure tubes by pumping clean, chlorinefree product water from the
cleaning tank (or equivalent source) through the pressure tubes to drain for several
minutes.
2. Mix a fresh batch of the selected cleaning solution in the cleaning tank, using clean
product water.
3. Circulate the cleaning solution through the pressure tubes for approximately one
hour or the desired period of time, at a flow rate of 133 to 151 l / min per pressure
tube for 8.0 and 8.5 inch pressure tubes, or 34 to 38 l / min for 4.0 inch pressure
tubes.
4. After completion of cleaning, drain and flush the cleaning tank; fill the cleaning tank
with clean product water of the same pH as that of cleaning solution for rinsing. This
is done to avoid precipitation of the matter which was dissolved during cleaning.
5. Repeat above step with permeate at neutral pH.
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6. After the RO system is rinsed, operate it with the product dump valve open until the
product water flows clean and is free of any foam or residues of cleaning agents
(usually 15 to 30 minutes).
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Table 7.2.9
RO Membrane Element Foulant Symptoms
Foulant
1.Calcium precipitates
(carbonates
and
phosphates, generally
found
at
the
concentrate end of the
system.
2. Hydrated oxides
(iron, nickel, copper
etc)
3. Mixed colloids (iron,
organic and silicates)
4. Calcium sulphates
(generally found at the
concentrate end of the
system)
5. Organic deposits
6. Bacterial fouling
General Symptoms
A marked decrease in salt rejection
and a moderate increase in pressure
between feed and concentrate. Also a
slight decrease in system production.
Response
Chemically clean the
system with solution
1.
A rapid decrease in salt rejection and

a rapid increase in pressure between
feed and concentrate. Also a rapid
decrease in system production.
A slight decrease in salt rejection and
a gradual increase in pressure
gradual decrease over several weeks
in system production.
A significant decrease in salt rejection
and a moderate increase in pressure
slight decrease in system production.
Possible decrease in salt rejection
and a gradual increase in pressure
gradual
decrease
in
system
production.

1.
Possible decrease in salt rejection

and a gradual increase in pressure
gradual
decrease
in
system
production.

2.
2.
2.
For heavy fouling,
use Solution 3.

system with either of
the
solutions,
depending
on
possible compound
fouling.
The detailed trouble shooting guidelines and suggested treatment are attached herewith
to be followed .All problems require the cause of the fouling to be corrected. Contact Ion
Exchange (I) Ltd., for assistance.
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Table 7.2.10
Summary of Recommended Cleaning Solutions
Solution
Ingredients
Quantity
pH adjustment
Citric Acid
RO product water
(chlorine free)
1.0 Kg
100 litres
Adjust to 4.0 with

sodium
hydroxide
(NaOH)
Sodium
tripolyphosphate
Tetra sodium EDTA
RO product water
(chlorine free)
2.0 kg
Adjust to 10.0 with

sulphuric
acid
(H2SO4)
Sodium
tripolyphosphate
Sodium
Dodecylbenzene
RO product water
(chlorine free)
2.0 kg
0.84 kg
100 litres
0.26 kg
100 litres
131
Adjust to pH 10.0
with sulphuric acid
(H2SO4)

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
INSTRUCTIONS FOR RO PLANT SERVICING / MEMBRANE CLEANING

1)
Collect the details of particulars of client like previous field service report,
contact person, address etc.
2)
Discuss and review the operation of the plant with contact person/operator. Note
down the problems if any.
3)
Refer the logbook for product flow, reject flow, water quality and system
pressure.
4)
Check the pre-treatment and confirm the system is working as per

design/requirements.
5)
Identify the type of membrane.
6)
Identify the plant problem from the trouble shooting guidelines.
7)
Apply the appropriate treatment program as per guidelines .
8)
Carry out the membrane cleaning.
9)
Compare the product flow, reject flow, system pressure, treated water quantity.
Collect all the details and put it in the log sheet.
10)
Prepare field service report giving details of job carried out, list out essential
spares required and the suggestions on plant monitoring and control. Propose
the next servicing schedule and get it signed by the client. Forward the copy of
the report to Branch in-charge/service in-charge.
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7.3 MAINTENANCE OF MB UNIT

7.3.1 General Maintenance
The Water Treatment Plant should be inspected externally every six months and any
damaged paintwork on vessels, pipework and valves renewed.
An internal inspection of vessels is also recommended every six months, although
this period can be extended if service experience indicates that a longer period
would not jeopardise the performance.
When carrying out external examination of pipework, valves and vessels bear in
mind that evidence of external corrosion may be due to underlying causes such as a
damaged lining in a vessel or pipe subjected to hydrochloric acid or Caustic Soda.
Consequently when removing scale on such items (e.g. bulk storage tanks,
measuring tanks) exercise caution. If there is any possibility of a break-through
consult the Water Treatment Plant Chemist or Engineer. If the internal and external
inspections are carried out systematically at regular intervals, and a record kept of
any work carried out, there will be little likelihood of the unexpected happening.
In addition to the items specifically mentioned in the MAINTENANCE section, rectify
leaking valves and joints immediately by loosened nuts and bolts or changing
sealing joints (gasket). Replace gland packing when required. Don't let leaks persist.
Keep the Water Treatment Plant dry and well swept.
If it is necessary for maintenance personnel to enter any of the treatment units,
rubber or soft soled shoes must be worn and great care taken to avoid damage to
any rubberlining and internal lateral systems. The feet should be placed on the
lateral clamping bars, not on the laterals themselves and every effort taken to avoid
standing on the small plastic strainers.
Entry into the vessels should be
discouraged, but if unavoidable, must be carried out under the supervision of the
Water Treatment Plant Chemist or Engineer.
Valve should be inspected regularly and gland packing where used should be
replaced regularly. Valves of the plug type and some diaphragm type which require
lubrication should be attended to regularly.
Refer to the auxiliaty manuals for Maintenance instructions on other equipment that
may be supplied such as pumps, blowers, instrumentation.
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7.3.2 CATION, ANION & MIXED BED UNITS :

Inspect all units externally every 6 months including connecting pipework and
valves. Chip away any loose paintwork, scale and make good with fresh paint.
When the unit has been removed from service for internal inspection, close the
manual inlet and outlet isolating valves as a safety measure and then open the AIR
RELEASE and DRAIN Valves.
Remove the manhole cover and examine the internal lining in the unit. If the lining is
damaged and shows signs of bulging or lifting, or is suspect, carry out a spark test
and rectify. Check procedures involved with your maintenance department or refer
the matter to this Company. If the condition of the lining below the level of the resin
is suspected, the resin will have to be removed as described in the MAINTENANCE
sheet entitled RESIN REMOVAL AND REPLACEMENT.
Carry out an extended backwah with the manhole cover open and observe the bed
performance. The water should break through evenly. If it breaks through from one
side of the vessel and floods over the bed surface, or the bed breaks into lumps,
(indicating packing and channelling) backwash at the fastest possible flow rate
without bringing resin over, and stir with a stout rod until the bed is level and of a
consistent density. Remove any 'fines' etc. by skimming the top surface and then
shovelling out.
After backwashing, drain the unit down and then note and record the bed level to
some convenient point. Refer to the MAINTENANCE sheet entitled BED DEPTH.
Compare this measurement with the last recorded level as a check for resin loss.
Note that in order to obtain an accurate bed measurement, the level must always be
taken immediately following a backwashing operation. If the condition or
performance of the resin is suspected take samples (approximately 150 mm and
again 450 mm and arrange for the samples to be analysed.
Refil the cation or anion unit by backwashing and double check bed depth, then refit
the manhole cover.
On Mixed Bed units, carry out an air mix operation (see relevant sections in the
OPERATION section) and observe the surface of the bed. The whole of the top
water and resin should be in a fairly vigorous 'bubbling' stage.
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7.3.4 BED DEPTH :

An ion exchange plant is designed to give a specified treated water quality when run
on a particular raw water, the analysis of which has been used for the design. An
economical quantity of resin required is decided upon and also an economical
quantity of regenerant to achieve the required quality of treated water and capacity
between regenerations.
The resin volume is a very important factor. If this is less, then a reduced capacity is
obtained. A procedure is given below for measuring the ion exchange resin bed
depth from which, by knowing the cross- section area of the pressure vessel, the
resin volume can be computed.
Equipment :
A scale long enough to measure the distance from the bottom of the unit to the top
flange of the manhole. A length of 25 mm x 25 mm wood may be used.
Alternatively a length of PVC, GI or , MS pipe.
Note:
For rubber lined units, GI or MS pipes should not be used as they might cause
damage to the lining or to the collecting systems.
If a pipe or length of wood is used, a separate scale is required to measure distance.
Method :
Open top manhole.
Open WASH OUTLET, then slowly open WASH INLET Valves. This will fluidise the
resin bed.
After 3-5 minutes carefully insert the measuring pipe into the unit, through the resin
until it reaches the bottom.
Note:
Where a SILEX underbed is employed, the pipe is to be inserted down to this level.
Where no SILEX is used, the collecting system may be one of several types-Header
and lateral, strainer on plate-in both cases polypropylene strainers are employed.
Hence care should be taken to see that no damage occurs to these or other
components. This pipe should be carefully manoeuvred so that it reaches the bottom
plate.
Hold the pipe vertical. Mark off the distance to a convenient reference point such as
the manhole flange.
Remove the pipe and repeat procedure to check the depths at two other points, then
remove pipe.
135

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
Measure the distance marked-off on the pipe (A).

Continue backwashing for 10 minutes then close WASH INLET Valve. This results in
the resin settling down under gravity.
After 5 minutes of settlement, slowly open the RINSE OUTLET Valve and let the unit
drain slowly at a flow rate not exceeding 4.5 m3/hr/m2 of bed area.
When the water drains down to the resin bed level, close the RINSE OUTLET Valve.
Re-insert the measuring pipe through the manhole down to the bed surface and
mark off the depth up to the same reference point. Repeat this at two other points.
Remove the pipe and measure this distance (B).
Open the WASH INLET Valve slowly and allow the unit to fill up. When water comes
out from the wash outlet pipe, close the WASH INLET and WASH OUTLET valves.
Close the manhole.
Knowing the cross-sectional area of the pressure vessel and the depth of resin (AB), calculate the resin volume and check that it is as per the TECHNICAL DATA
SHEET
Note :
The bed depth of both the strong acid cation and strong base anion resins are
measured in the exhausted form of these resins.
7.3.5 AIRSCOUR & EXTENDED BACKWASH :
Introduction
Due to prolonged use under varying pressure and flow conditions, the ion exchange
resin tends to break up. Normal annual loss, known as attrition loss, is about 5%.
The particles thus formed are known as 'fines'. These fines if allowed to remain in
the resin bed tend to choke up the bed thus increasing the pressure drop across the
bed and reducing the flow through it. Some of these particles thus formed are
normally eliminated during backwash but those which go down deep into the resin
bed are not removed. Hence it is advisable to remove these fines. RECOMMEND
THIS TO BE DONE ONCE IN THREE MONTHS
Equipment
An Air hose of sufficient length to reach the bottom of the resin bed. The hose
should be weighed at end to facilitate its reaching the bottom of the resin bed.
Air supply at 0.5 kg/cm2 g
A bucket to remove the fines
136

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
Method
Open the BACKWASH OUTLET Valve
Open the manhole
Close the Backwash OUTLET valve and open the RINSE OUTLET valve.
Drain the water till level is about 300 mm above the resin bed.
Insert the air hose halfway into the resin bed taking care to see it does not reach the
bottom of the bed and disturb the under bed if any.
Connect the hose to air supply and start the air.
Move the hose thoroughout the resin.
Continue this operation for 15 minutes.
Cut off air supply and remove the air hose.
Open BACKWASH OUTLET valve and slowly open BACKWASH INLET valve taking
care that the effluent water does not carry good resin beads.
After the Backwashing is over, close the BACKWASH
BACKWASH OUTLET Valve.
INLET Valve and the
Open RINSE OUTLET Valve and drain the water to slightly below the resin bed level.
Scrap off 6 mm (1/2") layer from the top of the resin bed and discard these (see
note).
Close the manhole cover.
The unit is now ready for further use.
Note:
In case a ladder is to be used for reaching the resin bed, care should be taken that
there is no damage to rubberlining if the vessel is rubber lined.
7.3.6 RESIN SAMPLING :
For softeners, cation, anion exchange units
Equipment :
One pipe (25 mm diameter) of sufficient length (with stopper or cork at one end) to
dip at least 500 mm into the resin bed.
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REV:1 DT 25.12.2010
Polyethylene bag to hold approximately 300 mls. of resin.

Procedure :
Do a normal backwash of the unit.
Allow the resin bed to settle under gravity for 3-5 mins.
Open the manhole.
Open RINSE OUTLET Valve and allow the water to drain slowly down to the resin
bed (5-10 mins.)
Insert the pipe piece corked at one end into the resin bed. The pipe piece should
go into the bed to a depth of about 300 mm. (IMPORTANT - SEE NOTE).
Release the cork for a minute or so. Then record the pipe.
Quickly withdraw the pipe and hold the polyethylene bag at the open end i.e.the end
which was dipped inside the resin bed.
Release the cork and tap the pipe.
If no resin falls into the bag, blow into the pipe from the other end.
See that the resin sample so collected is about 300 mls.
Drain water from the bag if any and seal the bag so that the resin is kept in a most
condition.
Close the manhole and use the unit as per requirement.
Despatching Samples :
Pack the samples securely and despatch it to our Bombay Office labelled with the
following particulars. Please note that the RESIN SAMPLE SHOULD ALWAYS BE
SENT IN A MOIST CONDITION.
Our Contract No - (see note).
Senders name and address to which analysis report is to be sent.
Type of resin (see note).
Unit from which resin was taken.
State of resin i.e. exhausted or regenerated.
138

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
Total quantity of water passed through the resin since use, and number of
regenerations carried out.
Note :
Contract No. and type of resin can be checked from the operation manual.
Some treatment units such as ones operating on Counterflow regeneration have a
collecting system near the resin surface. Extreme care should be taken when
inserting the pipe so that no damage is done to this.
Care is required to see that no damage is done to any rubber covered and plastic
items.
139

7.3.7
NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
RESIN REMOVAL & REPLACEMENT :
The performance of the Ion Exchange Resins used in the treatment units will
gradually deteriorate and therefore will need to be replaced at varying intervals
depending upon service conditions and the type of resin being used. When it is
necessary to remove the resin either for replacement or to gain access to the vessel
for repair purpose the following procedure should be adopted.
Necessary Equipment :
Mild steel rubberlined spool piece approximately 100 mm long and with flanges
suitable to match the resin outlet pad dimensions.
Cast iron rubberlined diaphragm valve suitable for
above.
connecting the spool piece
Mild steel rubber lined bend with suitable flanges at one end for connecting the
above valve.
Sufficient hessian sacks to contain the resin. These must be quite clean and without
any torn areas.
Resin Removal :
Isolate the unit and open the air release valve.
Remove the unit manhole cover and open the rinse outlet valve.
Drain the water completely.
Open the blind from resin outlet pad and fit the spool piece, valve and bend, in that
order. Use rubber gaskets at joints and required fasteners.
Close rinse outlet valve and open the unit inlet valve
the unit.
partially to admit water into
Throttle the valve connected to the resin outlet pad to control the resin flow and
collect the resin in the hessian bags.
When all the resin upto the resin outlet pad has been removed, close the unit inlet
valve and open unit backwash inlet valve to fluidise the bed and to remove resin
below the level of the resin pad.
Close all the valves.
Resin Replacement :
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NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
Opportunity may be taken at this stage to thoroughly inspect the vessel, internal
fittings and repairs may be carried out
Fill 3/4 of the unit with water by opening the wash inlet valve.
Pour the correct quantity and type of resin.
Check the resin bed (refer separate maintenance sheet).
Replace the manhole cover
7.3.8 RESIN STORAGE :
Ion Exchange resins are a very costly item and consequently require proper
maintenance at all times. These resins when dry have a tendency to swell up once
put in water. Hence it is imperative that the resin, whether in a vessel or during
storage should always be kept in moist condition. THE RESINS MUST NEVER BE
ALLOWED TO BECOME DRY.
Resin are supplied in moist condition in drums containing polyethylene liner bag.
Check the condition of drums upon receipt.
Open the top cover and the polyethylene bag.
Feel the resin from the top, if not moist then for :
CATION RESIN -Add a little water (clean and colourless) shake the drum. Check
again the top layer. Repeat the procedure till the resin is in moist condition.
Close the bag tightly and replace the lid and screw up the lip.
KEEP THE RESIN DRUM UNDER SHADE, PREFERABLY INSIDE THE SHED.
Once a month roll the drum, bring the top down and bottom up, keep in this
condition for one to two hours and reverse the position.
Once in three months check the condition of resin. If the resin has becom dry,
repeat theabove procedure to wet it.
141

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
SECTION 8
SAFETY
142

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
8.0 SAFETY
8.1 CAUSTIC SODA SOLUTIONS :
Protective Clothing:
When handling caustic soda solutions, care should be taken to prevent splashing or
contact with the skin. It is particularly necessary to protect the eyes, and the wearing
of comfortable goggles or eyeshields should be insisted on during all stages in the
discharge of road and rail tankers into bulk storage vessels and the subsequent
handling and use of the liquor.
Wool is readily attacked by caustic soda, so cotton overalls should be worn. Rubber
gloves and Wellington boots, give good protection to hand and feet.
First aid treatment for caustic burns:
Wherever there is a risk of caustic burns occuring by spillage, splashing, spurting or
any other means, a 5% solution of ammonium chloride (sal-ammoniac) should be
readily available in such quantities that skin or clothing may immediately be
drenched with it. If this action is taken without delay it is unlikely that serious
damage will occur. The ammonium chloride solution is stored most effectively in a
vessel holding 5 gallons. The vessel has a bottom outlet and is fitted with a length of
rubber tubing and a pinch-cock.
If there has been such delay in the application of the solution that some destruction
of the epidermis has taken place and there is actually a burn, the part affected
should be drenched with ammonium chloride for 10-15 minutes and then washed
continuously with running water or saline/boracic lotion for a period of an hour. The
burn should then be dressed with a four fold pad of lint soaked in Bonney"s blue
paint.
This dressing should be left undisturbed until it drops off without aid, when the burn
will be found to have healed completely. No infection can possibly take place if the
tissues have been thoroughly dyed by the blue paint.
Caustic soda in the eyes:
If the caustic soda gains access to the eye, theeye should be washed immediately
with the complete contents of one eyewash bottle (8-16 oz.) of 5% ammonium
chloride solution. Such bottles should be placed conspicuously in boxes in the plant
so as to be immediately available when needed. This treatment should be carried
out on the spot by one of the man's mates. The man should then be removed to the
works
surgery or other convenient place and the eye irrigated with running
saline/boracic lotion, or failing this, clear water preferably at body temperature,
continuously for one hour, taking special care that the lotion reaches the corners of
the lower sulous. This prolonged irrigation is of extreme importance and must be
done at once.
If such a case is sent to hospital without this preliminary
143

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
irrigation,irrepairable damage will have been done. This can only be prevented at
the time of the accident by the procedure.
An alternative first aid treatment for eye burns which is less painful than the
application of 5% ammonium chloride solution is as follows:
The eye should be immediately washed out with the complete contents of one eyewash bottle (8-16 oz) of a buffered phosphate solution made up to the following
formula:
Potassium dihydrogen phosphate (KH2 PO4) 27.22 gm
Dibasic sodium phosphate (Na2HP0412H2O) 71.63 gm
Distilled water
1 litre
Brilliant Green
0.01 gm
This treatment must be followed by the prolonged irrigation treatment with
saline/boracic lotion as described above, under medical supervision.
In order to prevent eye burns, the most satisfactory precaution is to insist on the use
of efficient goggles.
Note:
Saline/boracic lotion is made up in double strength as follows:
Sodium chloride
Boric acid
45 gm
50 gm
The double strength lotion should be stored in Winchester bottles. At the time of
using it shouldbe diluted with an equal volume of warm water in a wash- bottle to
make a lotion at about body temperature. The temperature is correct when a little of
the lotion poured on the back of the hand feels just warm and no more.
Bonney's blue paint. Blue paint is prepared by dissolving Crystal Violet and Brilliant
Green, 0.15% s/v of each in equal parts of alcohol and water. (see Martindale. The
Extra Pharmacopoeia, 1952, 23rd Ed., 1242 "Pigmentum Tinctorium" )
The contents of this Safety Sheet are given in good faith but without warranty.
144

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
8.2 SAFETY PRECAUTIONS FOR ACID USERS:

When corrosive acids are used, consideration must be given to the provision of
suitable protection for personnel working with them. The chief hazards are splashes
in the eyes, burns and damage to clothing. In some instances noxious fumes are
evolved. In order to minimise the risk of these hazards, certain precautions must be
taken and accordingly recommendations of precautions and suitable equipment are
described below.
Safety measures:
There are a number of precautionary measures which are commom to all acids.
These are as follows:
Personnel should be aware of the character of the acids and their hazards.
Avoid contact with the eyes, skin and clothing.
Goggles must always be worn during the handling of corrosive acids.
Protective clothing should be worn, rubber boots or clogs for the feet, apron for the
body, and gauntlets or gloves for the hands.
A plentiful supply of water must always be available. A bath or shower of water
adjacent to the working area is an advantage.
Tepid water should be supplied so that any possibility of shock is reduced to a
minimum. The shower must be equipped with foolproof and easily-operated valve.
An eye wash bottle, containing clean water, should be readily available.
Smoking or naked lights should be prohibited in the vicinity containing acid.
Acid supplied in mild steel drums may liberate hydrogen. The bung should, therefore,
be carefully slackened to release any excess pressure before removal, and this
should be done on receipt and after that at frequent intervals or at any time when
bulging of the drum is noticeable.
Do not discharge drums or carboys by the application of pressure to the containers.
Discharge by pouring, siphoning or by means of an approved discharged device.
Spillage:
Protective clothing, but with face shields preferably instead of goggles must be worn
when dealing with spillage. Any person not engaged in clearing the spillage should
be kept from the area.
145

NUMBER.
DATE : 21.07.2009
REV:1 DT 25.12.2010
The most satisfactory method of removing any acid which has been spilled is to hose
it down with water. The stream should be directed to the edges of the spillage and
not to the centre.
The diluted acid solutions are corrosive and, if necessary, may be neutralised with
hydrated lime or soda ash.
Hydrochloric Acid:
First Aid
In case of contact or spillage, drench with water. For eyes, give prolonged irrigation
with water and get medical attention immediately.
The contents of this Safety Sheet are given in good faith but without warranty.
146

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SUBJECT : PT.

OPERATION AND MAINTENANCE MANUAL

SUBJECT : PT. MENAMAS

SUBJECT : PT. MENAMAS

SUBJECT : PT. MENAMAS

SUBJECT : PT. MENAMAS

1.20 FUNDAMENTALS OF WATER TREATMENT:

SUBJECT : PT. MENAMAS

1.20.2 ULTRAFILTRATION PROCESS

SUBJECT : PT. MENAMAS

1.20.3 REVERSE OSMOSIS PROCESS

SUBJECT : PT. MENAMAS

SUBJECT : PT. MENAMAS

1.20.5.1ULTRA FILTRATION SYSTEM DESCRIPTION

Set of pipes/fittings (SS316 / PVC)

SUBJECT : PT. MENAMAS

1.20.5.2 REVERSE OSMOSIS PASS-1 SYSTEM DESCRIPTION

SUBJECT : PT. MENAMAS

3.1 Wet panel

SUBJECT : PT. MENAMAS

1.20.5.4 MIXED BED UNIT:

SUBJECT : PT. MENAMAS

SUBJECT : PT. MENAMAS

saving of overall time of regeneration

The injection concentrations are indicated below

SUBJECT : PT. MENAMAS

SUBJECT : PT. MENAMAS

TECHNICAL DATA SHEET

FEED WATER SPECIFICATIONS

B. Fast flush Pump

: 114 m3/hr @ 2.0 kg/cm2.

C. Back flush pump

SUBJECT : PT. MENAMAS

Motor speed RPM

1.3.3.2 Micron Cartridge Filter

Filter Element /Type

1.3.3.3 RO PASS-1 HIGH PRESSURE PUMP

Motor speed RPM

1.3.3.4 Reverse Osmosis Pass-1

SUBJECT : PT. MENAMAS

Number of pressure tubes

Pressure tube rating psi

Make of pressure tube

Size of pressure tubes

Maximum feed flow

Maximum permeate flow

Maximum reject flow

Reject recycle flow

1.3.3.4 RO PASS-2 HIGH PRESSURE PUMP

Motor speed RPM

1.3.3.5 Reverse Osmosis Pass-2

SUBJECT : PT. MENAMAS

Number of pressure tubes

Pressure tube rating psi

Make of pressure tube

Advanced Composites - Goa

Size of pressure tubes

Maximum feed flow

Maximum permeate flow

Maximum reject flow

4.9 m3/h (TO RO-1 FEED)

1.3.3.6 DEGASSER TOWER, TANK WITH BLOWER:

Degasser tower Height On Straight