Operation Manual for Reverse Osmosis Plant

Checks before installation 1

Caution 2

Operation cycles 3

Checks and log book maintenance during operation 4

Specifications of your plant 5

Faults and Immediate checks/remedies 6

RO membrane descaling procedure 8

P&I diagram -

Panel circuit diagram -

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Checks before installation:

Check whether the received material is according to the packing list or not.
If anything is missing or faulty immediately contact our dispatch authority,
Mr. Vijay (09904401981).
Check the raw water tank for any lumped dirt, such as pebbles, soil lumps or
animal dead bodies. It is suggested to go for primary cleansing of the tank if
possible.
Check whether the raw water tank on site has sufficient water to meet the
input requirement of the RO plant or not. If not, please fill it immediately.
Check whether the height of the over head raw water tank is enough to give
the required Net Positive Suction Head to the pump or not. If not it might
create problems in the pumping of the Feed pump. It is suggested to keep the
raw water tank nearer to the plant to be installed to reduce pressure losses. If
the level of raw water tank is below that of the plant then it must be
specified before the designing of the plant.
Check whether the water pipeline from the output of the raw water tank to
the input of the RO plant (not being in our scope of supply) has been
constructed properly along with all required supports and clamps as per the
given specifications or not.
Please ensure that the RO water storage tank (being in your scope) is under
normal atmospheric temperature and pressure. If this is not taken care of, the
non-metallic level sensors will get damaged which are replaceable only on
chargeable basis.
Please ensure that the place on site where the plant is to be installed is well
roofed. It must be noted that the feed pump and the high pressure pump in
the plant may get damaged if their motors come in direct contact with water.
Please ensure that the site is well-lighted before our company person reaches
there for installation.
Please ensure that the 3-phase mains connection is readily available near the
place where the plant is to be installed before our attendant comes to site for
installation. Delay due to the same will not be entertained.
Please ensure that there is 4-5 feet working space all around the plant. The
dimensions of the plant will be given very well in advance.
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Caution
This plant is a fully automatic plant, controlled by our Programmable Logic
Control unit, installed in our power panel. So no flow sensors or level
sensors should be bypassed. Doing this will trigger a fault and ring the
buzzer.
Also, for each arising fault buzzer will ring along with a message given on
the touch screen of our PLC. For each message the checks to be carried out
are given in the maintenance guide (page no. ). After performing the
checks, try restarting the plant. If still the same message remains on the
screen, immediately call our service attendants, Mr. Amrish (09904401985),
or Mr. Arjun (09904401982).
If tampering is found done with any of the components of the plant, without
getting consent of our personnel the warranty will not be applicable and the
charges for the remedial steps will be taken as actual.
The . Membranes are very expensive. Also no replacement is given for
any damage caused due to carelessness of the operator. So it is very essential
that the Dozing Chemical & its tank should be well prepared according to
the description in the maintenance guide for very less scaling and long life of
the membranes.
As the plant is a High pressure operating system if due to any cause there is
some leakage from the system piping, the plant should be stopped & our
service attendants should be contacted immediately.
If any spares are required, a PO must be sent to our office or else mailed on
advance.ahmedabad@gmail.com for faster processing. The spare no. in the
spare list (given at the end of the manual) must be very well mentioned in
the PO.
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Operation Cycles
There are four modes in which the plant will run.

1. Main RO cycle

Firstly the raw water is sucked by the Feed Pump, through the Y-strainer
filter, and is discharged (@ bar) into the primary disc filter of 200 micron
pore size.
Further the valve . & valve .(Refer to the P&I diagram) remain closed
and the valve .opens and water is made to flow into the big sand filter.
The water, exiting the sand filter from its bottom, flows through the 10
micron and 5micron filters sequentially passing through the valve.
This filtered water is pumped into the membranes by the vertical high
pressure pump(@.bar)
RO water is got from the central collection tube in the membrane where as
the reject water is got from the outer surface. For higher output rates
sometimes the reject of first membrane is given to the inlet of the second.
This RO water is collected in the RO collection tank and used for required
applications.

2. Backwash cycle

This cycle runs after each 8hrs. (Settable from the PLC touch screen itself)
of operation of RO cycle.
Basically this cycle is used to back flush (by reverse flow of water) the
surface dirt and dust residing in the sand filter. It is to be noted that
membranes are never to be given the back flushing treatment or the rinsing
treatment. So they do not come in picture at all during these processes.
Here the valves and get closed and valves open up
The raw water flows directly from the disc filter to the bottom of the sand
filter and rises up in there due to pressure of the feed pump.
This water carrying enough of dirt particles leave from valve..and is
drained away.
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3. Rinse cycle

After each 10 mins. (Settable from the PLC touch screen itself) of operation
of back wash, rinse cycle is carried out.
This cycle rinses away (time of this cycle is also settable from the PLC) the
dirt particles which are now loosely bonded to the sand particles, due to the
back wash cycle. Thus the sand gets cleaned up and ready for reuse.
Here valves andget closedand valves.and open up
The raw water flows from the disc filter into the top the sand filter vessel
and leaves from the bottom, carrying all the suspended dirt particles.
This water is drained away passing through the valve

4. Membrane Restoration Process {MRP}

This is one of the unique features of our RO plant.

After their use, if the membranes are kept in no-load condition without any
treatment they may get dried up. Once dry, they cannot be re-used.
To avoid this mishap, after each break in the RO cycle, we have developed
this process where in, the valves and close and the valvesandopen
remain open. The feed raw water flows to the membranes and is drained
away, some part of it remaining inside the high pressure membrane tube.
This helps in getting rid of the suspended particles in the water present in the
tubes, after the RO cycle, and also keeps the membrane wet increasing its
useful life.

Checks & Log Book Maintenance

It is very much essential to keep a regular check on the pressure drop
readings across the sand filter and other primary filters. Their choking may
result into damaging of the membranes.

Higher pressure drop across the membranes than the allowable pressure
drop, as per given in the Membrane Specs. further in this manual , may lead
to reduction in efficiency of the plant, or sometimes may lead to membranes
failure.
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It is advisable to keep checking the level of liquid in the Dozing chemical

tank at regular intervals. As such this tank is equipped with level float which
rings the buzzer if the level goes too low and stops the plant. No appropriate
dozing of chemical straight away results into impairment of the membranes
which is irreversible.

Input water TDS and output water TDS values from the RO plant should be
checked regularly. Note that, not all membranes have different values of
input TDS values which they can withstand. For details see the Membrane
specs.

Also, the ratio of the permeate flow rate of RO water to the reject flow rate
of drain water should be nearer to the given allowable value.

It is advisable to keep a history record in form of a log book (as illustrated

below)for all the above parameters.It helps in keeping a watch over these
parameters and if any of these are found out of their range, quick remedial steps
can be taken.

LOG BOOK FORMAT:

Date DP(sand f) DP(bag f) DP (membs.) R Ratio I/P TDS O/P TDS Remarks

Specifications of your Plant:

1. GENERAL SPECIFICATIONS Date of Installation:______

Operating Voltage: 440V

Operating Frequency: 50HZ

Allowable P drop across sand filter (psi):______

Allowable P drop across disc filter (psi):______

Allowable P drop across bag filter (psi):_____

(*Note that P drop values are given for 1 no. of filter only)
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2. MEMBRANE SPECIFICATIONS

Model Input TDS Needed P Drop per membrane Output TDS

ESPA less than 1500 6-8 psi less than 50

CPA less than 3000 6-8 psi less than 100

(**Sea Water Application special design and hence special type of membranes, not listed above.)

3.CAPACITYWISE SPECIFICATIONS OF YOUR PLANT

Dozing Input
RO plant No. of Chemical water
capacity No.of df+sf+wf (ltrs. to be R Qty. FP HPP DP Total
(Ltrs./hr) memb. set added) ratio (Ltrs./hr) (kW) (kW) (kW) (kW)

(*FP-Feed pump, HPP-High Pressure Pump, DP-Dozing Pump, R ratio-Ratio of Permeate to

Reject Flow Rates, df-disc filter, sf-sand filter, wf-wound filter)

Faults and Immediate checks/remedies

1. FB FAULT FOR FEED PUMP :
This means Feedback Fault for Feed Pump.
Check the voltage and current drawn. Higher than the required current drawn by
the pump results to the trip of the corresponding pump MPCB provided in the
electric panel.
2. FB FAULT FOR HP PUMP:
This means Feedback Fault for High Pressure Pump.
Check the voltage and current drawn. Higher than the required current drawn by
the pump results to the trip of the corresponding pump MPCB provided in the
electric panel.
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3. MCB TRIP FOR DO PUMP:

This means Dozing pump has stopped working.
Contact our attendant immediately.
4. MCB TRIP FOR SOL VALVE:
This means one of the installed solenoid valves has failed due to some reason. It
may be high current drawing.
5. PRESSURE SW TRIP:
This means the pressure switch provided after the feed pump is tripping due to low
inflow pressure.
Check the amount of water in your raw water tank.
Check for any blockage in the filter strainer. It is preferred to open and clean it
regularly.
Check whether the feed pump is working properly.
6. CHEMICAL LOW LEVEL TRIP:
This indicates that the level of dozing chemical in the storage tank is lower than
needed.
Add the dozing chemical after dilution. Extent of dilution depends on the present
condition of your plant. Contact our attendant to get the details.
7. RAW WATER TANK EMPTY:
Your Raw water tank level has gone below the needed and the plant will not work.
(Note: There is no way to bypass these faults to run the machine. Please do not try
the same.)

The reverse osmosis membranes when clog due to high amount of scaling, it is
seen from the pressure drop and the lowered recovery. So at this point of time it is
needed that the membranes should be descaled systematically for further proper
operation as per the method given on the next page. For any assistance you may
contact our attendant.
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R.O. MEMBRANE DESCALING PROCEDURE

Use 40-45 lit. water for one membrane .

Step-1 :
(a) Make 2 % solution of colloid-O-clean and add Alk. Clener-2 to maintain
pH 10.0-10.5.
(b) Circulate it for 45 min.
(c) Soak it for 45 min.
(d) Repeat step (b) and ( c ) for two time.
(e) Drain cleaning solution.
(f) Flush the system with R.O. permeate water up to normal pH.(6.0-7.0)

Step -2 :
Make 4 % solution of Alk.cleaner 1 and add alk. Cleaner -2 to maintain pH
10.0-10.5

(a) Circulate it for 45 min.

(b) Soak it for 45 min.
(c) Repeat step (b) and (c) for two time
(d) Drain cleaning solution.
(e) Flush the system with R.O. permeate water up to normal pH(6.0-7.0)
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Step-3 :
(a) Make 4 % solution of Acidic cleaner . (pH 4.0-4.5)
(b) Circulate it for 45 min.
(c) Soak it for 45 min.
(d) Repeat step (b) and (c) for two time.
(e) Drain cleaning solution.
(f) Flush the system with R.O. permeate up to 5.5-6.0 pH.

Step-4 :
(a) Make 500 ppm (500 gms/ 1000 lit) of bio cleaner.
(b) Circulate it for one hour.
(c) Soak it for 08-12 hours.
(d) Circulate it for one .
(e) Drain the system.
(f) Flush the system for one hour.