Reverse Osmosis Calculation and Survey Instructions

1) Enter the required data on the each worksheet.

- All required data is shown in light red cells and may be changed.
- All assumptions are shown in light green cells and may be changed. (Assumptions are based upon accepted rules of thumb.)
- All equations are shown in light blue cells and cannot be changed.

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section.)

4) This file is a read-only file. This is to protect the integrity of the original file. When you enter your data and try to save the file, you will need to rename
the file.

Worksheet Descriptions

Data Collection Form: Print this form for manually recording data.

Data: Enter reverse osmosis operational data in this spreadsheet to trend and compare the data.

Data Charts: Pertinent reverse osmosis data plotted in charts for analysis.

Cleaning: Recommendations on when membrane cleaning may be warranted.

Troubleshooting: General advice to help solve reverse osmosis operational issues.

SDI: Silt Density Index calculation form.

SDI Instructions: Silt Density Index instructions.

Boiler Pretreatment: Economic, mass, and energy balance of using reverse osmosis for boiler pretreatment. The model compares a current boiler system
with softened water makeup to that of using reverse osmosis makeup.
Data Collection Form: 2-Stage RO (Print this form for logging data by hand.)

Location:

RO Name:
Chemical Inventory
Feedwater
Free Feed Interstage Permeate Concentrate Permeate Concentrate Feed Permeate Concentrate Runtime Antiscalant Dechlor Acid
Date Time Operator Unit Chlorine Temp (F) Pressure Pressure (psig) Pressure Pressure (psig) Flow (gpm) Flow (gpm) Conductivity Conductivity Conductivity (hours) (gallons) (gallons) (gallons)
(psig) (psig) (mmhos) (mmhos) (mmhos)
(ppm)
Performance Tracking Data: 2-Stage RO
RO Name:

Baseline Data (Enter new baseline data when new membranes are installed.)
Net
Feed Interstage Permeate Feed Permeate Concentrate
Concentrate Permeate Concentrate Driving Salt Rejection Recovery
Date Temp (F) Pressure Pressure Pressure Conductivity Conductivity Conductivity
Pressure (psig) Flow (gpm) Flow (gpm) Presure (%) (%)
(psig) (psig) (psig) (mmhos) (mmhos) (mmhos) (psig)
5/13/11 77 201 185 5 170 40 12 200 4 800 177.1 98.0% 76.9%

Tracking Data

Normalized 1st Stage 2nd Stage Net

Feed Interstage Permeate Feed Permeate Concentrate Salt
Concentrate Permeate Concentrate Runtime Pressure Pressure Driving Recovery
Date Temp (F) Pressure Pressure Pressure Conductivity Conductivity Conductivity Permeate Flow Rejection
Pressure (psig) Flow (gpm) Flow (gpm) (hours) Drop Drop Pressure (%)
(psig) (psig) (psig) (mmhos) (mmhos) (mmhos) (gpm) (%)
(psig) (psig) (psig)

5/14/11 77 200 185 5 170 40 12 200 4 800 1432 40.1 15 15 176.6 98.0% 76.9%
5/15/11 77 201 186 5 171 41 13 198 4 795 1456 40.9 15 15 177.6 98.0% 75.9%
5/16/11 78 204 189 5.1 173 41 13 204 4.1 806 1480 39.7 15 16 179.9 98.0% 75.9%
Performance Tracking Data Charts: 2-State RO

Normalized Permeate Flow (gpm)

41.0

40.8

40.6

40.4

40.2

40.0

39.8

39.6

39.4

39.2

39.0
5/13/11 5/14/11 5/14/11 5/15/11 5/15/11 5/16/11 5/16/11

98.0% Salt Rejection (%)

98.0%

98.0%

98.0%

98.0%

98.0%

98.0%

98.0%

98.0%
5/13/11 5/14/11 5/14/11 5/15/11 5/15/11 5/16/11 5/16/11

Recovery (%)
77.0%

76.8%
 Recovery (%)
77.0%

76.8%

76.6%

76.4%

76.2%

76.0%

75.8%

75.6%

75.4%
5/13/11 5/14/11 5/14/11 5/15/11 5/15/11 5/16/11 5/16/11

1st Stage Pressure Drop (psig)

16

14

12

10

0
5/13/11 5/14/11 5/14/11 5/15/11 5/15/11 5/16/11 5/16/11

2nd Stage Pressure Drop (psig)

16.2

16

15.8

15.6

15.4
 16

15.8

15.6

15.4

15.2

15

14.8

14.6

14.4
5/13/11 5/14/11 5/14/11 5/15/11 5/15/11 5/16/11 5/16/11
5/16/11

5/16/11
5/16/11

5/16/11
5/16/11
Cleaning Tips
Chemical cleanings are typically recommended when one or more of the following changes have occurred.
Normalized Permeate Flow (NPF) decreases by 10-15%
Pressure drop across a stage increases 15-25%
Percent salt rejection drops 10-15%

Cleanings need to be on time for long enough and hot enough (if applicable).
Waiting too long to clean will result in reduced membrane life and reduced RO performance.
The two graphs below illustrate the effects of cleaning on time versus waiting too long.
Normalized Permeate Flow

NPF
Properly Cleaned at 10-15% Drop
120

100

80
Cleaning Points
60

40

20

Time
0
Normalized Permeate Flow

NPF
Improperly Cleaned at >20% Drop
120

100

80

60

40 Cleaning Points

20

Time
0
Troubleshooting
Advice
Determine the nature of the decline.
- Rapid, gradual, steady, or intermittent?
Check instrument calibration.
Isolate location of decline.
- Uniform, front end, tail end, single vessel, single element?
Investigate potential causes of the problem.

Problems
Loss of Normalized Permeate Flow
- Fouling due to scale, microbiological or organic fouling, or particulate fouling.

Loss of Salt Rejection (often accompanied by increase in NPF)

Front end decline
- Missing or damaged O-ring.
- Acid siphoning in CA elements.
- High temp extremes from heat exchanger.
- Damage from water hammer.
Tail end decline

- Scaling from too high feedwater pH, insufficient scale inhibitor, system
recovery too high, biological or organic fouling.

Isolated decline
- Missing or damaged O-ring or brine seal.
- Manufacturing defect in element.
- Damaged end caps, stub tubes, or interconnectors
- System draining when off.
Uniform decline
- Chlorine damage.
- Antiscalant siphoning.
- Changes in feedwater composition.
- Severe fouling.

Increase in Membrane Bank Pressure Drop (often with decrease in NPF)

- Instrumentation error.
- Physical blockage.
- Fouling from various causes.
- Scaling from various causes.
- Bypass in cartridge filter.
- Shavings from plastic pump impeller or PVC piping.
- Telescoping from water hammer.
- Carbon fines trapped in elements.

SDI too high

- Note: Guidelines indicate SDI15<5. To minimize fouling, SDI15<3 is recommended.
- Investigate upstream treatment to remove suspended solids (e.g., filters, clarifiers).
- Check for changes in raw water quality.
 Silt Density Index
Note: Guidelines indicate SDI15<5. To minimize fouling, SDI15<3 is
recommended.

Initial Time Final Time Test Time SDI15

Date (minutes) (minutes) (minutes)
11/12/2009 2 3 15 2.22
Silt Density Index Instructions

- The Silt Density Index (SDI) is a commonly used test to measure water quality for RO application.

- The test is based upon the time required to filter a known volume of feedwater through a 0.45 m
filter pad at a 30 psig feed pressure.

SDI Equipment Setup

1 Assemble SDI equipment per Figure 1.
2 Install test equipment on feedwater sample tap.
3 With filter pad installed, adjust pressure regulator to achieve 30 psig.

SDI Procedure
1 Place a 500 mL graduated cylinder under the filter and open the valve fully.
2 Measure the time required to to collect 100 and 500 mL from the time the valve is opened.
3 Record these times.
4 After 5 minutes, measure the time required to collect 100 and 500 mL.
5 Record these times.
6 Repeat at 10 and 15 minutes and record times.
7 Enter the recorded times into the SDI Worksheet.

Notes

1 Record temperature of the feedwater. (The temperature should not vary more than + 1 C
between the start and end of the test.)
2 Bleed entrained air in filter holder before starting test.

3 If it takes more than about 60 seconds to collect a 100 mL sample, the pluggage is nearly 90% and
test should be stopped. The SDI is too high for RO.

4 Used filter papers may be saved in plastic bags or mounted on paper for future reference.

5 If necessary, 5 or 10 minute SDI's can be calculated.

6 Avoid touching filter with fingers
7 Use dull tweezers when positioning filter paper to prevent puncturing.
8 Ensure O-ring is clean, in good condition, and properly conditioned.
9 Flush apparatus to remove any contaminants.
10 SDI = P30 / Tt = 100 * (1 - Ti / Tf) / Tt
P30 = % pluggage at 30 psig feed pressure**
Tt = Total test time in minutes (usually 15 minutes, but may be less if 75% pluggage** occurs in
less than 15 minutes).
Ti = initial time in seconds required to obtain sample.
Tf = time required to obtain sample after 15 minutes (or less).
Boiler Pretreatment Analysis
Scope: Can apply to RO and Nanofiltration

Client Name: ABC Widgets

System Data
Boiler Pressure 250 psig
Steaming Rate 80,000 lb/hr
Current Cycles 10 cycles
Boiler Efficiency 80%
Operating Days/Year 250 days/year
BD Heat Content 381.4 BTU/lb
BD Heat Recovery Efficiency 0%
Fuel Type Natural Gas
Fuel BTU Content 1,000,000 BTU/unit

Makeup Conductivity 250 mmhos

Makeup Temperature 60 F

Condensate Conductivity 20 mmhos

% Condensate Return 65%

Feedwater Conductivity 100 mmhos

Water Cost $1.50 /1,000 gallons

Wastewater Cost $3.00 /1,000 gallons
Fuel Cost $7.50 /unit
Electrical Cost $0.04 $/kWh

RO % Reject 25%
Expected Boiler Cycles on RO Makeup 50 cycles
RO Design Permeate Flowrate 50 gpm
RO Pump Horsepower 30 hp

Scenario Comparisons
Current Proposed
Softened RO
Water Water Savings
Makeup Makeup
Operation Operation

Steam Production 480,000,000 480,000,000 0 lb/year

Feedwater 533,333,333 489,795,918 43,537,415 lb/year
Condensate Return 347,826,087 347,826,087 0 lb/year
Blowdown 53,333,333 9,795,918 43,537,415 lb/year
% Blowdown 10% 2.0% 8.0% %
Makeup 185,507,246 141,969,831 43,537,415 lb/year
Makeup 22,256,418 17,032,973 5,223,445 gal/yr
Makeup to Pretreatment 185,507,246 189,293,109 -3,785,862 lb/year
Makeup to Pretreatment 22,256,418 22,710,631 -454,213 gal/yr
Pretreatment Wastewater 0 47,323,277 -47,323,277 lb/year
 Blowdown Heat Content 20,341 3,736 16,605 MMBTU/year
RO Pump Energy Consumed 0 127,066 -127,066 kWh/year

Blowdown Heat Value $141,360 $25,964 $115,396 $/year

Blowdown Wastewater Value $19,196 $3,526 $15,670 $/year
Pretreatment Water Value $33,385 $34,066 -$681 $/year
Pretreatment Wastewater Value $0 $17,033 -$17,033 $/year
RO Pump Electrical Value $0 $5,083 -$5,083 $/year
Total Savings $108,269 $/year

Other Costs to Consider Current Proposed RO Savings

Antiscalant Chemical Cost $0 $2,000 -$2,000 $/year
Chlorine Destruct Chemical Cost $0 $1,000 -$1,000 $/year
Non-Oxidizing Biocide Cost $0 $0 $0 $/year
Acid Cost $0 $0 $0 $/year
Clean-In-Place Chemical Cost $0 $0 $0 $/year
Grand Total Savings $105,269
Supplement to RO Spreadsheet:
Sodium Zeolite Water Softener
Water Usage Calculations
Total Hardness 200 ppm as CaCO3
Iron 0 ppm as Fe
Cubic Feet of Resin 40 ft3
Exchange Capacity 27,000 gr/ft3
Expected % Capacity 90% %
Softening Capacity 83,106 gallons
Softener Diameter: 2 ft

Current System:
Backwash: Your System: Typical:
flow rate: 24 18.84 gpm
time: 10 10 min.
sub-total gallons: 240 188 gallons
Regeneration:
salt dosage: 10 8 #/ft3
flow rate: 40 40 gpm
time: 20 20 min.
sub-total gallons: 800 451 gallons
Slow Rinse:
flow rate: 40 40 gpm
time: 20 20 min.
total gallons: 800 451 gallons
Fast Rinse:
flow rate: 240 240 gpm
time: 10 10 min.
sub-total gallons: 2,400 2,400 gallons
Totals:
Total gallons per regen: 4,240 3,490
Regen Gallon per Day: 3,073 gpd
# Days Operation: 250 days per year
Regen Gallons per Year: 768,361 gals./year
Water Cost (to buy + to sewer): $0.0045 $/gallon
$3,458 Annually
Salt Cost: $0.150 per pound
$10,873 Annually
Annual Regeneration Cost: $14,331 Annually
If Implementing RO After Softeners:
% Reject for RO: 25% %
Revised Regen Water Requirement: 960,451 gals./year
Water Cost (to buy + to sewer): $0.0045 $/gallon
$4,322 Annually
Salt Cost: $0.150 per pound
$13,591 Annually
Annual Cost: $17,913 Annually

Extra Costs for Regens for RO: $3,583 Annually

Make-up water requirement: 500,000 pounds per day
Make-up water requirement: 60,241 gpd 42 gpm
Regenerations per day: 0.72 per day 1.0 gpm/ft3 resin
Make-up water requirement if RO after softener: 75,301 gpd 3.1 ft2 resin
New regenerations per day: 0.91 per day

typically 6 gpm/ft2 resin

typically 8 pounds salt/ft3 and 8% brine (0.71 # salt/gal)

typically 1 gpm/ft3 resin

same as regenrant flow rate

2 to 10 gpm/ft3 resin
gpm/ft3 resin
References
Technical Reference and Training Manual, 2nd Edition, Association of Water Technologies (AWT), 2009
Handbook of Industrial Water Conditioning, 9th Edition, Betz Laboratories, 1991
Reverse Osmosis Training Manual, Crown Solutions
Procedure for Measuring Silt Density Index (SDI), Technical Service Bulletin, TBS113.02, Hydronautics, May 1998
FilmTec Reverse Osmosis Membranes Technical Manual, Dow, 2004
Reverse Osmosis: A Practical Guide for Industrial Users, 2nd Edition, Wes Byrne, Tall Oaks Publishing, 1995
Drop by Drop: Articles on Industrial Water Treatment, James McDonald, Crown Solutions, 2009

Contributors
Name Company Name
Allan Bassett, CWT Bassett Air Quality, Inc.
Les Davis, CWT All Phase Consulting, LLC
Chris Golden, CWT Taylor Technologies, Inc.
Clive Ling, CWT Cascade Water Services, Inc.
James McDonald, PE, CWT, Crown EG, Inc.
Pretreatment Chair
Casey Walton, CWT Walton Technologies, LLC
tics, May 1998
Glossary

Plastic or metal device attached to ends of a spiral wound cartridge to prevent

Antitelescoping Device movement of cartridge leaves in feed flow direction due to high feed flows.

Arrangement of devices connected to common feed, product, and reject

Array headers (e.g., 2:1 array).

Clean In Place. Cleaning membranes in situ in RO membrane housing using CIP

CIP cleaning equipment (e.g., cleaning solution tank, recirculation pump)

Stream exiting a crossflow membrane device which has increased concentration

of solutes and particles as compared to the feed stream. The portion of feed
Concentrate stream which does not pass through membrane. The stream in which dissolved
solids and/or particulates are concentrated in a membrane separation process.

Plastic netting between membrane leaves which provides a flow channel for the
Feed Spacers fluid passing over surface of membrane and increases the turbulence of feed-
brine stream.
Reduction of flux due to a build-up of solids on the surface or within the pores
Fouling of membrane. The result is changed element performance.

Specialized, thin, semipermeable film which serves as a barrier permitting the

passage of materials only up to a certain size, shape, or electro-chemical
Membrane character. Membranes are used as the separation agent in reverse osmosis,
electrodialysis, ultrafiltration, nanofiltration, and microfiltration, as disc filters in
laboratories, and as pleated filter cartridges, particularly for microfiltration.

A treatment step or one of multiple treatment steps producing in a membrane

Pass system a product stream.
The portion of the feed water that passes through the membrane (also called
Permeate product).
The ratio of permeate flow rate over the feed flow rate given as fraction or
Recovery percent.

Portion of the feed stream which does not pass through the membrane. The
Reject brine or concentrate stream from a desalination device.

The build-up of precipitated salts on membranes, pipes, tanks, or boiler

Scale condensate tubes.
Silt Density Index. An index calculated from the rate of plugging of 0.45 m
SDI membrane filter at 30 psig. It is an indication of the amount of particulate
matter in a feed water.

Movement of the outer layers of a spiral wound cartridge in the direction of the
Telescoping feed flow. It is caused by excessive pressure drop through the feed channel
spacer.