Commissioning Procedures

CONTENTS
1.0.0 INTRODUCTION
1.1.0 Summary of requirements
1.2.0 Preconditions
1.3.0 Auxiliaries
2.0.0 FLUSHING & COMMISSIONING

2.1.0 Commissioning & manual operation
3.0.0 FLUSHING & COMMISSIONING OF INTAKE SYSTEM
3.1.0 Preconditions
3.2.0 Preparation for startup of the Bar Screen
3.3.0 Procedure
3.4.0 Preparation for startup of the Band Screen
3.5.0 Preliminary Test
3.6.0 Procedure
3.7.0 Preparation for startup of the Seawater Intake Pumps
3.8.0 Startup of the Seawater Intake Pumps and Flushing of the
Intake System
4.0.0 FLUSHING & COMMISSIONING OF THE RF ROUGHING FILTERS
4.1.0 Flushing and Commissioning of the RF Backwash
System
4.2.0 Procedure
4.3.0 Flushing and Commissioning of Dual Media Filters
(RF's)
4.4.0 Commissioning of the Air Scour Blowers and Air
Distribution Test
4.5.0 Procedure
4.6.0 Installation of Filtration Media Into RF's
4.7.0 Filling of Supporting Layer and Filtration Sand
4.8.0 Removal of Sand-Fines, Manual Backwash Sequence
No. 1
4.9.0 Procedure to continue
4.10.0 Filling of the Pumice
4.11.0 Backwashing of the Sand and Pumice - Manual
Backwash Sequence No.2
4.12.0 Air scouring
4.13.0 Backwashing of the Pumice with Water
4.14.0 Production of the Filtered Sea Water for Backwash of
other RF's
4.15.0 Procedure
5.0.0 FLUSHING & COMMISSIONING OF ULTRA FILTRATION

BLOCKS
5.1.0 Overview Process Commissioning XIGA System

5.1.1 Pre-commissioning activities
5.1.2 Process Commissioning XIGA - UF System Configuration
5.1.3 Stages Process Commissioning
5.1.4 Stage 1 Commissioning without Membranes
5.1.4.1 Temporary Facilities
5.1.4.2 Filtration Program Testing
5.1.4.3 Backwash and CEB Program Testing
5.1.4.4 Overall Plant Operation
5.1.4.5 Software Functionality Testing
5.1.4.6 UF System
5.1.4.7 Strainers
5.1.4.8 Filling Chemical Dosing Units
Stage 2
5.1.5 Membrane Element Loading
2
5.1.6 Stage 3 Membrane Element Flushing
5.1.7 Stage 4 Commissioning with Membranes

Final disinfection 5.1.7.1
5.1.7.2 System start-up, Auto-run and
Fine-tuning
5.1.7.3 Training
5.1.8 Stage 5 Take-over
5.2.0 Process Commissioning XIGA – Wet

Testing without Membranes
5.2.1 Operations to be done before starting of Wet Testing
5.2.2. Water Supply and Routing
5.2.2.1 Chlorination
5.2.2.2 Stagnant Water
5.2.2.3 Strainers
5.2.3 Commissioning without Membranes

5.2.4 Start up Auto Run
5.2.4.1 Determine and set initial settings
5.2.5 Active Section Testing
3
4
5
6.2.0 Flushing & Commissioning of Anti scalant Dosing
System
6.2.1 Precondition for flushing of the Filling pumps
6.2.2 Procedure
6.2.3 Pre-condition for flushing
6.2.4 Procedure
6.2.5 Pre-condition for commissioning
6.2.6 Procedure
6.2.7 Coagulant Dosing and Preparation
6.2.8 Solution preparation - determination of
concentration
6.3.0 Flushing & Commissioning of Non-Oxidising Biocide

Dosing System
6.3.2 Procedure
6.3.4 Procedure
6.3.5 Biocide Dosing and Preparation
6.4.0 Flushing & Commissioning of Sodium Bi-sulphite Doing

System
6.4.2 Procedure
6.4.4 Procedure
6.4.5 Coagulant Dosing and Preparation
6.4.6 Preparation of SMB solution for the first filling
6.4.7 Preparation of SMB solution during normal
operation
6.5.0 Flushing & Commissioning of the Chlorine Dosing

System
6.5.1 Precondition for flushing
6.5.2 Procedure
6.5.3 Procedure for PRE chlorination
6.5.4 Procedure for CEB 1 chlorination
6.5.5 Procedure for POST chlorination
6.5.6 Preparation of the Chlorine Storage Room
6.6.0 Flushing & Commissioning of Hydrochloric Acid

Dosing System
6
6.6.1 Precondition
6.6.2 Procedure for commissioning
6.7.0 Flushing & Commissioning of the NaOH Dosing System

6.7.1 Precondition for commissioning of the Filling
Pumps
6.7.2 Procedure 6.7.3 Precondition for commissioning of
the NaOH
Dosing System
6.7.4 Procedure
6.8.0 Flushing & Commissioning of the Anionic Polymer R
Dosing System.

6.8.2 Procedure 6.8.3 Pre-condition for
commissioning 6.8.4 Procedure
6.8.5 Coagulant Dosing and Preparation 6.8.6 Solution
preparation - determination of concentration
6.9.0 Flushing & Commissioning of the CO2 Dosing System
6.9.1 Precondition
7.0.0 FLUSHING & COMMISSIONING OF THE LIME MAKE UP &

DOSING SYSTEM
7.0.1 Start up of the Lime Make up and Dosing System
7.0.2 Procedure
8.0.0 FLUSHING & COMMISSIONING OF THE NEUTRALIZATION

SYSTEM
8.0.1 Preconditions 8.0.2
Procedure
9.0.0 FLUSHING OF THE RO CLEANING SYSTEM AND PRESSURE

VESSELS
Procedure 9.0.3 RO CIP Flushing Procedures – Low pressure
flushing 9.0.4 Flushing & Commissioning of the
RO CIP System 9.0.5 Flushing of the RO Trains Feed and Brine
Manifolds, Brine Headers and High Pressure
Pumps
7
Flushing Procedure 9.0.8 Low Pressure
Flushing 9.0.9 High Pressure Flushing
9.0.10 Procedure 9.0.11 Flushing and
st
Commissioning of 1 Pass RO
Flushing System
9.0.12 Procedure 9.0.13 Flushing of the 2nd Pass RO Train Feed
and Brine
Manifolds, Headers and HPP
9.0.14 Procedure 9.0.15 Low Pressure Flushing 9.0.16
High Pressure Flushing 9.0.17 Procedure
10.0.0 FLUSHING & COMMISSIONING OF THE RO FLUSHING

SYSTEM
Procedure
11.0.0 FLUSHING AND COMMISSIONING OF THE SERVICE WATER

SYSTEM.
11.0.1 Preconditions
11.0.2 Procedure for flushing and commissioning
12.0.0 COMMISSIONING OF THE PLANT AIR SYSTEM

12.0.1 Pre-condition
12.0.2 Procedure
13.0.0 FLUSHING & COMMISSIONING OF THE PRODUCT WATER

PUMPING STATION
13.0.2 Procedure 13.0.3 Pre-condition for
commissioning 13.0.4 Procedure
APPENDIXES
8
1.0.0 INTRODUCTION
The following document summarizes the procedures required for Al Jubail SWRO
Desalination plant-Phase 2, plant flushing & process commissioning. It assumes a
number of pre-conditions (which are listed in each section) and is based on the
possibility of proper flushing & commissioning the plant. Detailed plant sequences
are not included in this document as they are in the single equipment Operating &
Maintenance Manual, produced by equipment manufacturers. These procedures
are referred to throughout this document.
1.1.0 SUMMARY OF REQUIREMENTS 1.2.0 Preconditions
Pre-commissioning should be completed and signed off by the designated

Commissioning staff and client as appropriate. It should include the following
as a minimum:
• power supply in operation

• motor tests
• MCC tests
• Signal tests
• all plant and equipment inspected and systems confirmed as complete
• all hydraulic tests carried out, confirmed as complete and no leaks remaining
• Alarm and trips roughly adjusted (fine adjustment is possible only when the
continuous availability of process liquid.)
1.3.0 Auxiliaries
To enable efficient flushing as well as commissioning the following list of auxiliary
temporary equipment if required:
• Temporary pipe connections for the flushing
• Hand held laboratory equipment necessary for commissioning
• Walkie - talkie set
• Set of commissioning tools for single equipments
9
2.0.0 FLUSHING AND COMMISSIONING
Once all necessary preparations have been made and the required temporary
equipment is available flushing of the equipment & commissioning can
commence.
Detailed stepwise procedures for the manual flushing and commissioning of each sub-
system are provided in the manufacturer’s single equipment O & M, and to be
strictly followed.
A full logbook of activities and difficulties encountered should be maintained. This
should be supplemented by the completion of the relevant datasheets and test
record sheets which require signing by the commissioning engineer and
the client.
Any errors in the manufacturers O&M manual shall be noted and corrected to
submission of the final document.
2.1.0 COMMISSIONING & MANUAL OPERATION

Note: In order to avoid repetition, the operating descriptions are provided in a
general form in relation to replicate Plant systems. For example, where an
instruction is given to start one of a number of Pumps the instruction may be “Start
intake pump”. Where Pump ‘A or B’ is started, it is expected that its associated
valves and instruments are also operated.
All centrifugal pumps shall be started against closed or only crack opened
discharge valve when downstream pipes are only partially full or completely
empty. It is recommended to fill the pipes with water by small pump or service
water system prior start up of the pumps.
3.0.0 FLUSHING AND COMMISSIONING OF INTAKE SYSTEM
3.1.0 Preconditions
• MCC is commissioned, energized and in correct working condition
10
• Local control station and pushbutton pendant connections are checked,
commissioned and energized
• All electrical connections are checked and energized
• PLC and VDU is working (preferred operation is via PLC and VDU, but the
flushing process will be carried out manually due to temporary connections in
place for circulation process).
• All VFD drives and motors are set and tested, ready for operation
• Seawater Intake including Distribution Chamber are inspected for presence of

any larger debris before, it shall be perfectly cleaned from erection debris
before it is flooded!!!
• Use of temporary strainer on Intake Pumps suction is recommended for this

procedure to protect the pumps.
Attention: Consider safety instructions and good operational practice.

Where the procedure is executed from MCC room, bear in mind that
alarms and trips are not active. When the PLC is available, always start
devices using the PLC and VDU. When you start any device via VDU and
PLC, all alarms and trips are active and device should be secure.
Each actuated valve can be operated manually from local panel.
3.2.0 Preparation for start up of the Bar Screen

Note: Study and be familiar with installation, operation and maintenance manual
of Bar Screens and Drum Screens.
Preconditions
• Bar screens are to be pre-commissioned in dry intake Screens are aligned,
tension of the chains adjusted and checked
• Manual test run with disconnected motor (turning just motor cooling fan) shall
be carried out, (few turns) to check alignment and manual run without load.
11
• All electrical connections and wiring is checked
• Seawater Intake is flooded with flooding valve
• Seawater Intake stop gate is removed
• Gear unit for the screens is correctly fitted, the solid plugs has been removed
from the filler point and the correct filler/breather are fitted
• Gearbox oil level is correct
• Personnel are aware that Bar Screen and Drum Screen are about to start
3.3.0 Procedure
• carry out one manual raking operation
• Check that it operates smoothly and correctly
• Repeat the test under automatic control via PLC
3.4.0 Preparation for start up of the Drum Screen

Note: Study and be familiar with installation, operation and maintenance manual
of Drum Screen and Wash Water Pumps.
Preconditions
• Drum screen assembly is complete and have been pre-commissioned in dry
intake
• Screen wash pumps have been installed pre-commissioned following

manufacturers O&M instructions.
• All grouting is complete

• Seawater intake is flooded and water is available for wash water pumps
• Wash water manual valves are opened
• Wash water PIS are calibrated
12
• Level transmitters in Screening Area and forebay have been commissioned •
Seawater intake stop gate is removed
Gear unit is correctly fitted, the fixings plug has been removed from the filler
point and the correct filler/breather is fitted
• Gearbox oil level is correct

• All tools and loose material have been removed
• Personnel are aware that screen is about to start
3.5.0 Preliminary Test

Note: This test can be performed also in dry intake, but small stream of water
(1/2” hose) directed to the screen chain & seals to reduce friction
• First carry out manual test run with disconnected motor (turning just motor
cooling fan) one round to check alignment and manual run without load.
• If OK , than start the screen on low speed (if double speed motor) and check
that it rotates smoothly and in the correct direction
• Allow the screen to run for 10 minutes
• Check that the drum is rotating aligned and no excessive friction appears
towards the civil works.
• Check that the motor Amps do not exceed those quoted on the motor
nameplate
• Repeat these checks at high speed if screen is equipped with double speed
motor
• Re-fit and secure all covers

3.6.0 Procedure
• Start the screen on low speed and check that it runs smoothly
13
• Turn on wash water pumps and check that all wash water jets nozzles operate
correctly and that jet pipe pressure is correct as per manufacturer and design
recommendation
• Change to high speed operation and run for next 15 minutes. Check that
screen runs smoothly
• Check correct automatic / PLC operation
Screen is ready for operation.
3.7.0 PREPARATION OF START UP OF THE SEAWATER INTAKE PUMPS.
Note: Study and be familiar with the installation, operation and maintenance
instructions for Seawater Intake Pumps and Motors provided by pumps
manufacturer.
Pre-conditions
• Seawater Intake including Distribution Chamber is cleaned and flooded.
• Intake pumps cooling water supply unit (strainers) is installed and tested as per
manufacturer / vendor package recommendations and ready to use. Use of
temporary pump for pipe filling before Intake pump start up is
recommended!
• Cooling water temperature measurement is tested and ready for use
• Self-cleaning strainers for cooling water are pre-commissioned and ready to

use.
• The Intake pumps motor and rotor rotation by hand has been checked
• Mechanical seal has been checked if applicable as per O&M.
• All pump set components have been checked as per manufacturer

documentation
14
• All guards preventing accidental contact has been mounted in areas of coupling
and thrust bearing.
• Check if bearings have been filled with specified level of lubricant, if applicable.
• Motors for Intake pumps shall be greased prior to start up, tested and direction
of rotation checked as per motor Instruction Manual.
• All Intake motors & pumps temperature and vibration measurement shall be
checked and adjusted
Intake Oil, Particle, Algae Analyser to be pre-commissioned at later stage, all

valves are closed.
15
Sea water stop gates in Screening area, Forebay and Distribution Chambers are
reoved.
• Intake Level Transmitters have been commissioned.
• Sea water Bar Screens and Drum Screens have been commissioned
• Seawater Intake Pump discharge butterfly valves are closed.
• Seawater Intake Pump suction butterfly valves are opened.
• Main header towards Roughing Filters shall be filled with sea water prior to
start up of the Intake Pumps (VFD) by use of Wash Water pumps with
temporary connections, or any other temporary pump and all shall be vented.
DN100 by pass line valves to be used for filling.
• Surge Vessel shall be installed and Air compressors pre-commissioned as pre

manufacturers O&M Instruction Manuals.
• Surge Vessel to be pressurized/charged by air to required pressure.
• Inlet valves to Surge Vessel and Pressure transmitter shall be opened.
• Safety valve at the top of the Surge vessel shall be set and tested. • All Drain
valves at main piping are closed
• All vent valves (aeration / de-aeration) at main piping are opened
• Pressure transmitter primary isolation valves are opened.
• Seawater Intake Pump Discharge Header drain are closed.
• Seawater Intake Pump Discharge Header vent are opened.
• Non Return Valves if hydraulic type, are to be preliminary set; final setting will
be carried out during commissioning.
• All electrical connections have been checked and are energized.
16
•
• Ferric dosing to be cold commissioned before the start up which is explained in
detail in other section – Dosing Systems. Ferric dosing system will be used
during commissioning ONLY and shall not be used with seawater intake pumps
flushing procedure.
• Check that the shut – off elements in the discharge pipe is closed.
• All isolation valves at main header are opened to receive water
• All valves at RF are tested (open/close signal) and ready for operation
• All drain valves at roughing filters are open
• All BW outlet valves from Roughing Filters to culvert are opened.
3.8.0 START UP OF THE SEAWATER INTAKE PUMPS AND FLUSHING OF THE

INTAKE
SYSTEM.
• As a preferred pump to be started one of the VFD driven Intake pumps. Start
Seawater Intake pump via the Seawater Intake screen on the VDU or, if
necessary, under ‘local’ control from the MCC with set VFD for minimum flow.
Prior to start up discharge valve shall be slowly opened to app. 10 %.
• Slowly open recirculation valve to its operational position and check the
discharge pressure of the running pump. Pump shall be now running at
minimum flow as per pump curve.
• Check piping for proper venting. When system is vented, close the Seawater
Intake Discharge header manual vent valves.
• Water is directed into inlet piping and subsequently via RF BW outlet valves to
Culvert, following the DN800 line and finally dumped back to the sea. Water
from RF rinsing valves is passing into a culvert.
Observe the behavior of the Intake pump for unusual sounds, vibrations,
discharge pressure or leaks
17
• Flush the system and run trial run for 2 hours for each pump. Check for lubricant
level, bearing temperature, tightness, and vibrations and sliding noises of the
shaft seals.
• Stop the running Intake pump. Start the second pump (VFD), repeating the set
procedures as outlined. When system is vented, close the Seawater Intake
Discharge header manual vent valve.
• Start third and fourth Intake pumps (SS), if possible for necessary period of the
time, flow shall be limited with control valves downstream of the SS pumps.
• Observe the behavior of the pumps for unusual sounds, vibrations, discharge
pressure or leaks.
• Stop all running Seawater Intake pump when testing and flushing is completed
• Close the Seawater Intake Pump discharge valves
• Stop the chlorine dosing if it was started to sterilize the system
• Let water drain from the filters (and Settling tank).
• After all flushing has been completed; all RF shall be opened and cleaned above
and under the nozzle floors from GRP piping parts, dust and or possible debris
forgotten in the piping during erection.
• Settling tank shall be also inspected and cleaned.
4.0.0 FLUSHING AND COMMISSIONING OF THE ROUGHING FILTERS.
• RF filtration system consists from 12 nos. of roughing filters, each with capacity
of 1000 m3/h.
• Each RF filter is having 3 layers of supporting / filtration material. Layer 1 - 150

mm of gravel, layer 2 – 400 mm of sand and layer 3 – 600 mm of pumice.
Operating pressure shall be 6 bars.
18
•
Note: Study and be familiar with the installation, operation and
maintenance instructions for BW pumps and motors. Check all
requested points as they are described in these instructions.
• Study and be familiar with the operation manuals water and air flow meters at
the RF’s inlet lines.
• Study and be familiar with the operation manuals for butterfly valves and
actuators from BRAY.
• Upon initial start up or following works or periods where any access may have
been gained to upstream pipe work, temporary rough strainers should be
installed to the backwash pump suctions to prevent possible ingress of debris.
Familiarize yourself with exact location of all emergency stop push buttons and
safety showers.
4.1.0 FLUSHING AND COMMISSIONING OF THE RF BACKWASH SYSTEM

Preconditions
• Back wash tank shall be water seal painted, perfectly cleaned from civil and
erection debris prior to receive the water. Water used, shall be filtrated sea
water from near by plant or if available service water could be used for first use
and flushing.
• Use of temporary strainer on backwash pumps suction is recommended for this

procedure to protect the pumps. Backwash tank shall be inspected for
presence of any larger debris before it is filled with water.
All valves at RF are tested (open/close signal) and ready for operation
• Air scour blowers are commissioned and ready for operation.
• Pressure and flow transmitters are ready for operation
• BW tank level transmitter is calibrated and ready for operation
• Dry run protection for BW pumps is set and tested
19
• Drain system for backwash outlet water is ready and connected to Settling tank
/ brine outlet pipe.
• Backwash Pumps Flow Control Valves are set to minimum required backwash
flow (525 m3h)
• Install temporary Backwash Pump suction strainer if required.
4.2.0 Procedure
• Fill the Backwash Tank with Service Water or Filtered Seawater.
As the tank fills:
• Open Backwash Flow Control Valve. Open Backwash Pump Header Vent
isolation valve and observe until Backwash header is correctly vented. Then
close.
• Close Backwash Flow Control Valve and open RF Backwash Outlet valve for 2
nos. of RF
• Open RF Backwash Inlet Valve at least for 2 nos. of RF
• Open RF Vent valves.
Note: It is recommended that the Roughing Filters are flushed in the

following order, from back side (phase 3 RF) towards UF station.
• Start one of the Backwash Pump
• Crack open Backwash Pumps discharge valve and Backwash Flow Control
Valve
• Continue with opening of Backwash Pump outlet isolation valve until flow is ~
800 m³/hr. Flush for 15 minutes.
• Gradually close BW Pump Flow Control Valve
• Stop running Backwash Pump
20
•
• Close RF Backwash Inlet isolation valve
• Repeat the above procedure for the remaining RF’s using both of the
backwash pumps in turn.
• Upon completion of the flushing of all RF, drain down the Backwash Tank, the
Backwash Pumps and the associated backwash header pipes, and remove the
temporary Backwash Pump suction strainers and check for any possible debris
inside of the filters brought by flushing water.
• RF are now ready for air distribution test and filtration media filling.
4.3.0 FLUSHING AND COMMISSIONING OF ROUGHING FILTERS (RF’s)

Preconditions
• Intake System has been pre-commissioned
• Pressure indicator transmitters PT for BW pumps and PT for BW blowers have

been pre-commissioned
• Flow meter for BW pumps have been pre-commissioned
• Backwash pumps are pre-commissioned and ready for operation
• Air scour blowers are pre-commissioned and ready for operation
• Pre-chlorination is available for operation - injection at intake pumps discharge

header into dosing point
Check again the internals of the backwash tank to ensure that it is free of
debris
• All relevant valves and pipe work have been commissioned
• Close lower manhole of all RF if opened for inspection
4.4.0 Commissioning of the Air Scour Blowers and Air Distribution Test
Note: Filtered seawater may be used for this operation, however
service water is preferred. If seawater is used, filter must be flushed
21
with service water after test completion to avoid formation of salt
deposits in filter vessel.
Preconditions
• Air scour blowers are pre-commissioned as per manufacturer O&M Instruction
Manual and ready for operation.
• All related pipes and valves are installed and commissioned.
• Ensure all the air distribution nozzles have been installed, leveled (plus – minus
2 mm) and the retaining nuts tightened using the recommended torque limits.
4.5.0 Procedure
• Close the lower manhole for the selected RF.
• Install temporary water connection on one of the RF vessel outlet nozzles if

permanent pipes and valves are not installed or start filling filter by gravity
from BW tank via permanent piping.
• Open Air Scouring line drain valves
• Open RF Lower vent valve until water passes without interruption , then close
the valve
• Observe the level of the water within the RF through the top manhole and
close water inlet when the water covers the air distribution nozzles up to
50100 mm above the nozzles.
• Open Air Scour Blower discharge valve
• Start Air Scour Blower, and close drain valve
• Open RF Air inlet valve
• As the air enters the underside of the nozzle plate the water level will gradually
rise until the air has cleared a sufficient volume to allow it to pass via the
nozzle shafts. The water within the upper section should be observed to
ensure an even distribution of air across the nozzle plate. If there are any
22
•
blank areas the test should be stopped, the filter drained, the nozzles suitably
adjusted and the test repeated.
• On completion of the test, or where the nozzles require adjustment
• Open Air Scour Header Drain valve and at the same time close RF Air inlet valve
• Open Air Scour Header Gooseneck drain isolation valve
• Stop Air Scour Blower
• Open Drain/Rinse isolation valve and rinse header drain valve until the filter is
empty, and then close. Use temporary drain connection if necessary.
• Flush filter vessel with service water if seawater was used for test
• Repeat the above as necessary on all remaining RFs

• After Air Distribution test has been completed, RF are ready to start filling of
the first layer of supporting material – gravel followed by backwash of the
gravel, than fill filtration material-sand, followed by backwash and at the end
fill pumice. After soaking of the pumice backwash shall be carried out.
4.6.0 INSTALLATION OF FILTRATION MEDIA INTO RF’s.

Preconditions
• All filter nozzles are installed and aligned
• Air distribution test on RF’s was performed successfully
• A water collection trough inside of the RF’s adjusted.
• Supporting layer and filtration media sand / pumice of proper size and quantity
are available.
23
4.7.0 FILLING OF SUPPORTING LAYER AND FILTRATION SAND.
• Insert supporting layer of the fine gravel through the upper manhole by means
of a crane or by using man power and fill up to 150 mm above nozzle floor.
Level and start backwashing with flow 1500 m3/h of the gravel layer, until
water from BW outlet is clear.
• Insert sand through the upper RF manhole by means of a crane, any available
device or man power.
• Level sand roughly inside chamber by using manual man power and check
beneath nozzle floor if sand drops through nozzles.
• If sand leaks through nozzles remove affected nozzles and reinsert having
checked their quality. Replace if necessary.
• Continue with sand filling up to level 150+400 mm above nozzle floor in all RF
filters.
4.8.0 REMOVAL OF SAND-FINES, MANUAL BACKWASH SEQUENCE No.1.

Preconditions:
• Intake Pumps have been pre-commissioned
• Local pressure indicator transmitters and flow meters have been

precommissioned
• RF Backwash pumps and flow meter have been pre-commissioned and are
ready for operation
• Air scour blowers have been pre-commissioned and are ready for operation
• (Pre-treatment chlorination dosing system has been pre-commissioned and is

available for operation. Injection points are located at Backwash pipes.
• All relevant valves and instrumentation have been commissioned and are ready
for operation
24
• All relevant pipe work (from Intake to RF’s and Backwash Tank to RF’s) have
been commissioned, flushed and is ready for operation.
4.9.0 Procedure to continue

• Close the lower manhole for the selected RF
• Open RF Upper Vent valve
• Fill the Backwash Tank with Service Water or Filtered Seawater up to the
half of its volume. As the tank fills:
• Open Backwash Pump Inlet Isolation valve
• Open Backwash Pump Outlet Isolation valve
• Open fully Backwash Pump Outlet Flow Control valve
• Open Backwash Pump Header Manual Vent isolation valve and observe until
Backwash header is correctly vented. Then close.
• Open RF Backwash Inlet valve and allow the water to pass from the
Backwash Tank via the Backwash Pumps, and into RF. Continue to fill the
backwash tank with service water to maintain the level.
• Open RF nozzle floor vent valve until water passes without interruption ,
then close
• Observe the level of the water within the RF and close Backwash Inlet valve
when the water starts to overflow through the RF Backwash outlet valve.
Close Backwash Pump Outlet Flow Control valve
• Start Backwash Pump
• Open RF Backwash Inlet valve
• Open Backwash Pump Outlet Flow Control valve and adjust flow to 1500
m3/hr. Check flow at FT.
Attention: The removal of sand fines should be observed both via the
upper manhole and within the RF trench in the discharge flow. Adjust
25
the backwash water flow such way that only sand fines are flushed
out and not sand.
• After ~15 minutes from commencement of the backwash close the
Backwash inlet valve
• Stop Backwash Pump
• Open Rinse valve
• When the water level drops to just under the upper surface of the sand,
close RF rinse valve
• Open Air Scour header valve
• Start Air Scour Blower
• Close Air Scour Gooseneck drain isolation valve
• Close Air Scour Drain valve and at the same time open RF Air inlet valve
• As the air enters the underside of the nozzle plate the water level will
gradually raise until the air has cleared a sufficient volume to allow it to pass
via the nozzles. The water within the upper section should be observed to
ensure an even distribution of air across the nozzle plate.
After ten minutes of air scouring:

• Open Air Scour Drain valve and at the same time close RF Air inlet valve
• Open Air Scour Gooseneck drain isolation valve

Return to the start of Section 4.10 and repeat the backwashing and air scouring
of RF at least four-five times or until fines are flushed out.
Initially the discharge from the RF will be cloudy. This will clear over the course
of the backwash as the water starts to channel within the sand. The purpose of
the Air Scour is to break up the channeling and resettle the bed in preparation
for the next backwash. Gradually the time taken for the backwash discharge to
clear will reduce. A period of 2 to 3 minutes to clear is required before
commencing pumice installation.
26
The effluent should be checked on a regular basis during the backwash. The
quality of the discharge can be checked visually for quality. Where required
turbidity meter should be used, where levels of 5 NTU and less would be
deemed acceptable. When sufficient backwashing has been completed, such
that the final discharge meets the above parameters, go to next step.
On completion of the final backwash, air scouring is not required. The

backwash tank should be allowed to fill and the service water supply closed
thereafter.
4.10.0 FILLING OF THE PUMICE

Preconditions
• Requirements of Section 4.9 have been completed.
• Install / fill in Pumice of delivered size by means of a mobile crane or any other
filling device or man power. Pumice should be leveled to 1150 mm, (150 mm
gravel + 400 mm sand + 600 mm pumice) above the nozzle floor.
NOTE: as not all pumice may be watered there might be an initial loss of
material for app. 50 mm.
• Take regular samples of Pumice and mark them for reference and possible
laboratory investigation.
Note: The installation and leveling of pumice should be undertaken

with care. Filter masks and protective clothing should be worn at all
times.
The RF shall be filled with water via gravity feed from the Backwash Tank by
opening of the backwash inlet valve app. 300 mm above the sand layer.
• Fill the pumice and then raise the water level until the pumice is raised to 100
mm below the BW channel again from the backwash tank
27
Caution: Do not overfill the RF with water as Pumice will float prior to proper
wetting.
• Remove the inspection pipe and close over the upper manhole
• Keep pumice 3-5 days depending from quality covered under water for soaking
• When only a view cm are left floating careful BW may be started with reduced
flow of 800 m³/h.
4.11.0 BACKWASHING OF THE SAND AND PUMICE – MANUAL BACKWASH

SEQUENCE No.2
Preconditions
• Pumice has been kept minimum 3-5 days (depending from quality) under water
or the time until is completely soaked and settled down.
• Backwash tank is filled with service water or filtered seawater
• Water level in the RF has been raised until overflowing into the discharge
trough the Backwash outlet valve
• Upper manhole of relevant RF is open.
• Backwash Pump Outlet Flow Control valve is closed
4.12.0 Air scouring

• Open air scour goose neck drain valve
• Open air scour header drain valve, air scour inlet isolating valve, RF rinse/drain
valve
• Observe the lowering level of the water within the RF and record the time
taken to lower to 200 mm below the upper surface of the media. This level can
be observed by digging a small crater into the media. Close RF rinse valve and
air scour header drain valve to maintain this level.
• Wait until water has lowered through the goose neck drain and water flow has
stopped
28
• Close air scour goose neck drain valve and air scour inlet valve
• Open air scour header drain valve and wait 2 minutes
• Open air scour header isolating valve
• Start air scour blower
• Open RF air scour inlet valve and close air scour drain valve
Note: During this period may the blower relief valve shortly lift and pass
• Air scour for ten minutes
• Close air scour inlet valve, open air scour drain valve , open air scour goose
neck drain valve and close air scour valve
4.13.0 BACKWASHING OF THE PUMICE WITH WATER

Note: Check level of water in backwash tank during backwashing.
(Dry run protection of backwash pump IN THIS STAGE possibly may
not be activated!!!)
• Open nozzle floor vent valve to release the air from air scouring
• Open RF upper vent valve
• Open Backwash outlet valve
• Open Backwash inlet valve
• Open water (filtered seawater or service water) supply to Backwash Tank
• Start Backwash Pump
• Adjust Backwash Pump Flow Control valve to achieve flow of ~500 m3/hr.
Check flow. Keep backwashing until water started to be clear. Over the period
of time increase backwash flow gradually (600-700 m3/h) by adjusting Flow
Control valve and also higher as long as no pumice is carried over to the BW
channel.
• Close and open RF backwash inlet isolating valve 10 times during backwash
time of 15 min. After a couple of open/close cycles,
29
• During the backwash, the effluent water should be monitored and PUMICE IS
NOT CARRIED OUT BY BACKWASH FLOW!!! The level of the expanded pumice
should be observed through the upper manhole. Where the top of the
expanded media bed is high or low, adjust the Backwash Pump Flow Control
valve to increase or reduce the flow.
Note: The purpose of this exercise is to provide sufficient flow to

expand the media bed and wash out particles of filter material while
having insufficient flow to wash out the Pumice. On achieving this
flow the Pump Flow Control valve will be in its optimum flow position
and will be suitable for temperature variations of ±5°C. Valve position
should be marked for future resetting.
Initially the discharge from the RF will be cloudy. This will clear over
the course of the backwash as the water starts to channel within the
sand. The purpose of the Air Scour is to break up the channeling and
resettle the bed in preparation for the next backwash. Gradually the
time taken for the backwash discharge to clear will reduce. A period
of 1 to 2 minutes to clear is acceptable.
• Check the effluent water by taking samples regularly
• Continue with air scour and backwash cycles until acceptable results are
obtained
If the effluent is unacceptable during backwash:

• After the 15 minutes backwash period or when the level of the Backwash Tank
becomes low, close the backwash inlet valve
• Stop Backwash Pump
• Return to Section 4.14. and commence air scour followed by backwash
If the effluent is acceptable during backwash, than continue as follows:
30
• Ensure that upper manhole is secured before commencing final backwash
• Close RF backwash outlet valve
• Wait until water starts to pass through RF upper vent valve
• Close RF upper vent valve
• Close backwash water inlet valve
• Switch off backwash pump
• Close seawater supply valve to Backwash Tank

The first RF is now in stand by condition and ready for operation.
If there is sufficient amount of service water/sea water, backwash of remaining
RF’s should be carried out in the same way. Where seawater must be used the
following procedure should be used for the rest of the RF’s:
4.14.0 PRODUCTION OF THE FILTERED SEA WATER FOR BACKWASH OF OTHER RF's
Precondition
• All pre-treatment systems and equipment have been commissioned
• Intake chlorination or pre-treatment chlorination or

backwash tank
chlorination is available
• Coagulant dosing is available
• Intake Pumps discharge header manual vent valve is opened
• Two – three RF filled with sand and pumice is backwashed and in standby
condition
• Intake Pump Discharge valves ready for operation
• Coagulant dosing set is calibrated and ready for use (if required by seawater
quality). JAR tests executed and preliminary specific dose evaluated
• All impulse line primary and local isolating valves for pressure transmitters and
gauges are opened
31
• RF Dump valve is open and set to approximately 60% of opening to keep
required back pressure in the system, to be re-set if required.
• Analyzers inlet isolation valve are closed

4.15.0 Procedure
• Open Backwash Tank inlet actuated valve
• Switch on Intake Pump and operate at minimum flow through recirculation

valve.
Warning: Remember basic rule for start of centrifugal pump - start the pump
against closed or very slightly opened discharge valve if the pipes are empty!!! It
is recommended to fill the pipes with water prior start up of the pumps.
• Once the pump is running - slowly open the Intake Pump discharge valve
• Check if water is passing from Intake Pumps discharge header manual vent
valve. If yes, check the color of the water from the pipe - it should be colorless
and transparent. A milky or white color indicates air in the system.
• Check system pressure via pressure gauge. Adjust the system pressure to ~ 4.0
bar by opening the intake pump discharge valve
• Open RF inlet valves “first" RF’s which has been filled with dual media and
backwashed.
• Ensure that water is passing from the RF’s top vent valve. If not, wait until
water appear on the valve outlet and leave it flow for ~ 3 minutes. Check the
color of the water for air presence.
• Open RF rinse/drain valve and rinse RF for 30 minutes. During this time the
vent valve should be closed
• Close RF rinse/drain valve
• Once you are sure that the pipes are filled with water, complete the opening of
RF’s treated water outlet valve
• Than open and then close RF Outlet valves on the remaining RFs filled with
media to vent the pipes
32
• Close vent valve
• Check production of filtered seawater at overflow of the backwash tank
• Intake equipment and RF’s have been commissioned and at least 2-3 RF are in
operation running to drain through rinse line
The first RF is now producing filtered water. To improve the quality of filtered
water, start sulphuric acid and coagulant dosing (if required by seawater quality)
and chlorination (intake and/or pre-treatment) for disinfection of the system.
5.0.0 FLUSHING & COMMISSIONING OF ULTRA FILTRATION BLOCKS.

Note: Study and be familiar with the installation, Operation and
Maintenance instructions for UF Strainers & Pentair UF skids supplied
equipment and Technical Bulletins. Check all requested points as they
are described in these instructions.
Familiarize yourself with exact location of all emergency stop push

buttons.
All membrane housings are closed without membranes.
5.1.0 Overview Process Commissioning XIGA System

In this document a basic overview of process commissioning of a XIGA UF system is
presented. For the main stages of the process commissioning the applicable
activities, basic guidelines and points of attention are described. Special attention
is paid to temporary facilities required and routing of the waste water. This
document is for information only and can be used for preparation of the detailed
process commissioning plan and program.
5.1.1 Pre-commissioning activities

Prior to the start of process commissioning, all starting conditions for process
commissioning shall be completed during the precommissioning period. A
brief description of the activities involved is presented below:
Software is tested (off-site);
33
Functionality of the UF system software is tested by means of a Factory
Acceptance Test (FAT) and complies with the functional requirements.
UF system is mechanically and electrically complete;
All associated pipe work and equipment is installed, connected, pressure tested
and flushed. All electrical devices are installed and cabled and power is on the
MCC.
Automation system, I/O’s are tested. This includes amongst others:
• All I/O connections are checked (including any associated external signals).
• All instruments are calibrated.
• SCADA and PLC software is loaded and operational.
• All initial software parameter set-points, alarms, PID loop settings, timers,
etc… are set.
• Set-up of the PLC/SCADA configuration is checked.
• Trending and alarm logs are available.
• Rotation of the pumps and compressors is checked
• Temporary facilities are available;

All temporary facilities required during execution of process commissioning
are available on site. In this document examples of typical temporary facilities
will be presented.
• Drinking water is available;
Drinking water (or water with similar quality) is required for membrane
element flushing and optional during commissioning without membranes.
• UF membrane elements are available;
• UF membrane elements are available on site or delivery has been planned.
Membrane elements will be required during membrane element loading.
• CEB / Neutralization chemicals are available;
• Chemicals for CEB and neutralization (if applicable) are available on site or
delivery has been planned. Chemicals will be required during commissioning
with membranes.
34
• UF system filling, venting and flushing;
Water is introduced into the UF system and the complete UF system is filled,
vented and flushed. In principle UF feed water can be used for this purpose.
Since low-grade UF feed water is (normally) available already, this is generally
the most convenient water source. However, disadvantage of UF feed water is
that the complete permeate section of the UF system (UF units, backwash
tank, backwash pumps/strainers, permeate/backwash pipe work) need to be
drained and flushed with drinking water quality after commissioning without
membranes. This is required for thoroughly cleaning this section prior to
membrane loading. For this reason it may be considered to use drinking water
(or water with similar quality). In order to limit drinking water consumption,
circulation loops may be established during commissioning without
membranes. For filling, venting and flushing the chemical dosing units,
drinking water (or water with similar quality) should be available.
• Membrane integrity testing:

After membrane loading, the UF unit assembly can be tested for integrity for
checking if the membrane elements have correctly been loaded. For this
purpose, a pressure decay test can be carried out.
5.1.2 Process commissioning XIGA – UF system configuration

A typical XIGA™ UF system is presented below:
35
The following main process units can be distinguished:
UF feed unit : feed strainer(s)
UF unit(s) : skid(s) with membrane housings filled with membrane
elements, feed flow control valves, airflow integrity test
equipment 1)
Backflush unit: backflush tank, variable speed backflush pump(s),
backflush strainer(s), CEB chemical dosing units
Neutralization unit 1) : neutralization tank, pump(s), chemical dosing unit(s)
1) If applicable
In this document, explanation of process commissioning is based on the above

typical XIGA™ UF configuration.
5.1.3 Stages process commissioning

Process commissioning of a XIGA™ UF system consists of the following
5 main stages:
Stage 1: Commissioning without membranes;
Functionality of the UF system is tested by automatic plant
operation with water, without the UF membranes loaded. After
successful completion, the UF system is ready for membrane
loading.
36
Stage 2: Membrane element loading;
The membrane elements are loaded into the membrane

housings.
Stage 3: Membrane element flushing;
The preservation chemicals present in the membrane elements

are flushed out.
Stage 4: Commissioning with membranes;
The UF system is disinfected and taken into automatic

operation. Plant performance is monitored and reviewed and
operational settings are fine-tuned.
Stage 5: Takeover;
The plant is taken over by the customer.

The stages described above are in chronological order. At the end of the
process commissioning period the UF system shall be completely
operational and perform within the required specifications.
5.1.4 Stage 1 - Commissioning without membranes
• Main objective of this stage is to ensure that the overall functionality of

the UF system complies with the requirements as detailed in the project
related functional specification documents (Process Control Philosophy,
Functional Design Specification, etc…). Only after successful completion of
this stage, the UF membranes can be loaded.
• A brief description of the activities involved is presented below. For

detailed description of the commissioning without membranes, reference
is made to the related documents (section 1.2).
5.1.4.1 Temporary facilities
For enabling functionality testing of the UF system, it is advised to provide
temporary facilities. Depending on UF system design and modes of operation
(filtration, backflush, CEB, etc…) different temporary facilities apply.
In order to save drinking water during testing, temporary facilities can
be provided for recirculation of the water. Examples are:
5.1.4.2 Filtration program testing:
5.1.4.3 Backflush and CEB program testing:
37
Return of concentrate back to the backwash tank, making use of
temporary connections between the normal backflush concentrate and
CEB concentrate line and the backflush tank.
5.1.4.4 Overall plant operation:
Produced permeate is collected in the backflush tank and backflush waste is
returned to the UF feed tank. Change settings to allow continuous UF system
operation.
During some of the backflushes, concentrate leaving the UF unit will be
discharged to the culvert. During CEB, chemically loaded concentrate leaving
the UF unit is discharged to the Neutralization tank (if applicable) and finally
discharged to the culvert. Backwash and CEB duration and flow can be reduced
to limit concentrate production and the loss of water.
5.1.4.5 Software functionality testing
• All initial software parameter set-points, alarms, PID loop settings, timers, etc,
are set and software functionality and controls are tested by running and
checking the automatic programs. This is done to check and debug the
software and set-up and tune the initial settings that have to prevent flow and
pressure peaks. This includes the following main activities:
• All applicable automatic UF programs (filling, filtration, backwash, CEB,

Air integrity test, draining) are tested
• All PID control loops are set/tested (e.g. Pump ramping-up and down and FCV
controls)
• Valve operating times are set/tested

• Chemical dosing sets are tested with water only
• Duty-standby and duty rotation handling are set/tested
• Handling of emergency stop and power/air failures is tested
• Alarm handling is tested

• Data logging/trending is tested
• Initial software parameters are set and optimized as much as possible

• Surge tests, if applicable
38
5.1.4.6 Cleaning UF system
The water used during software functionality testing can be chlorinated (2-5
ppm chlorine) to prevent growth and perform a limited disinfection.
After software functionality testing the UF system has to be cleaned. Backflush
tanks are typically cleaned with a power washer and used to store clean water
that will be used to flush and clean the remainder of the UF system. UF system
disinfection is not mandatory at this stage, but is advised.
5.1.4.7 Strainers
At the end of software functionality testing all feed and backflush strainers
have to be inspected and cleaned. Damaged strainers have to be repaired or
replaced. Debris from damaged strainers can cause damage to the
membranes.
5.1.4.8 Filling chemical dosing units
After successful software testing, the chemical dosing units are filled with
chemicals. Once the membranes have been loaded, these chemicals are
required for CEB and neutralization (if applicable).
5.1.5 Stage 2 - Membrane element loading
• Only after successful completion of commissioning without membranes, the

membrane elements can be loaded into the membrane housings. For detailed
description of membrane element loading, reference is made to the related
documents (section 1.2).
• Membrane element loading is a labor intensive activity for which a relatively

clean environment is required. Loading of individual UF units shall be
completed (all membrane housings closed) at the end of the day, to prevent
insects or small animals from going into the UF unit.
• After completion of membrane element loading, the UF unit assembly can be

tested for integrity to check if the membrane elements have correctly been
loaded.
5.1.6 Stage 3 - Membrane element flushing
39
• Membrane element flushing is required for flushing out the preservation
chemicals (sodium bisulphite / glycerine = BOD) and expelling air from the UF
unit. For detailed description of membrane element flushing, reference is
made to the related documents (section
1.2)
Main points of attention during membrane element flushing
are listed below:
• UF unit filling:
After membrane element loading, an automatic or manual filling program shall
be executed for smoothly filling the UF unit with water and expelling the air
from the membranes. UF unit filling is performed at minimum feed flows, i.e.
app. 50 m3/h with the filling valve.

• UF unit flushing:
The UF unit shall be flushed from both feed and backwash sides with
drinking water, according to the standard Pentair membrane flushing
procedure (see related documents, section 1.2).
• Temporary facilities during flushing:

• During flushing, the bisulphate / glycerin loaded water will leave the UF via
permeate and concentrate lines. To avoid contamination, the permeate waste
cannot be collected into permeate / backflush tank. Therefore a temporary
connection is required between the permeate line and concentrate line. Final
destination of this BOD loaded waste is determined by the customer. An
indication of BOD waste concentrations is included in the
commissioning
5.1.7 Stage 4 - Commissioning with membranes
• During this period, final disinfection of the UF system is performed after which
the UF system is taken into automatic operation and fine-tuned.
5.1.7.1. Final disinfection
40
• The permeate side of the UF system (UF units, backwash tank,
backwash pumps/strainers, permeate/backwash pipe work) is
disinfected after membrane flushing:
• Disinfection is executed according to the customer requirements.
• Requirements and routing of disinfection waste water is determined

by the customer. Last disinfection step shall be execution of a normal
chlorine CEB program.
5.1.7.2 System start-up, auto-run and fine-tuning
• The UF system is taken into automatic operation. This means that operation of
the UF system is controlled by the automation system. During this period the
most relevant process data are collected and reviewed and the UF settings are
fine-tuned to optimize system performance.
5.1.7.3 Training
• The UF system operators have to be trained before handing over the UF

system to the customer. For this purpose an operator training will be given,
covering both the Pentair XIGA™ Ultra filtration technology in general and
operation of the specific UF system commissioned.
• Beside this training session, it is recommended to have the operator(s)
working together with the Pentair commissioning team throughout the
process commissioning period.
5.1.8 Stage 5 - Take-over
• At the end of the process commissioning period, the UF system is taken over
by the customer. Specific details will be discussed and agreed between the
customer and Pentair. A process commissioning report will be generated
covering the process commissioning period.
5.2.0 Process Commissioning XIGA – Wet testing without membranes.

• The wet-testing period is the start of commissioning and is one of the most
important activities. After this period the UF plant will be ready to receive
membranes and the state of the UF plant is such that:
41
• No pressure and/or flow peaks, that can damage the membranes, are
expected. All program functionality’s, e.g. CEB’s, are working.
• Responses to external failures are properly handled.

• After loading the membrane plant can be taken on-line without the need for
reprogramming or fixing of UF software for which tests have to be
performed. Software changes after membranes are installed can cause
membrane damage.
• To achieve this state the functionality, stability and consistency of the

software will be checked, certain scenarios, power failure and air-pressure
failure, will be tested and all initial settings will be set during this intensive
testing period.
• The bases for these tests are derived from the control and design
documents, Process description and Process Control Philosophy or
Automation System Description.
5.2.1 Operations to be done before starting of wet testing
• Pre-commissioning has to be finished before the start of the wet

commissioning. When precommissioning is finished the entire UF plant is
available for wet commissioning.
• Finishing the pre-commissioning is a milestone and hold point after which the
actual commissioning starts. A pre-commissioning document has to be made.
For this the Process commissioning checklist can be used.
• This document has to contain the following items:

• Mechanical works are finished.
• No more works such as grinding, cutting and welding on parts of the plant
that involve or affect the UF plant.
• All pressure tests have been done and finished.
• Check on completion and check according the P&ID’s
• Electrical works are finished.
42
• I/O tests are finished.
• All valves, pumps (motor rotation) and instrumentation is tested and

calibrated. Software
• Software is installed
• All I/O loop tests are done.
• Initial software tests are done, the plant can run on software. Trending and
alarm logs are available
• PLC communication network is healthy.
• PC communication is healthy.
• All supporting systems such as, backwash unit, chemical dosing and
neutralization are commissioned. (tested, calibrated and operative)
• The software FAT has been completed satisfactory and all comments on the
FAT are worked out / implemented.
5.2.2. Water supply and routing
• During wet testing without membranes water is pumped through the UF

plant. A lot of water will be needed if normal routings, for filtration and
backwashes, will be used during testing.
• The water demand during testing can be reduced by:

• Recycling the water by allowing permeate to flow back into the UF feed tank.
• Choose creative settings that will reduce water use and / or optimize the re-
use of water.
5.2.2.1 Chlorination
• If the water is circulated it is advised, if possible, to add 2 to 5 ppm of chlorine to
the water. This prevents microbiological growth and work as a “disinfecting
step”.
5.2.2.2 Stagnant water
• Although all units have to be tested it is possible to save water by performing

the tests after each other instead of all at once. Avoid stagnant water
43
because will allow microbiological growth in the piping and membrane
housings!!!
5.2.2.3 Strainers
• At the start of the ‘wet commissioning without membranes’ period the

strainers have to be installed. These strainers are:
Feed strainers (automatic strainers shall be operable)
Backflush pump strainers
• The strainers will catch off a lot of matter, such as sand and cutting and
grinding debris, which has to be removed from the system.
• When the wet testing without membranes period has finished the
strainers have to be checked for any damages that could have occurred
during the tests.
5.2.3 Commissioning without membranes
• When the wet commissioning without membranes takes place

the software FAT has already been completed satisfactory. This
means that all functionalities and sequences are available.
• Therefore the purpose of the wet commissioning without
membranes is:
Finding unmentioned or during FAT unseen software errors
Checking equipment operation, e.g. valve operations
Setting up initial settings
Smooth operation without water hammer and pressure and flow peaks
Checking for correct error handling, e.g. no freezing programs or water

hammer and pressure and flow peaks.
Testing equipment on their specifications e.g. pumps

Achieve this UF system has to run in auto during the entire wet
commissioning without membranes period.
44
5.2.4 Start up auto run
For large plants it would not be possible to just push the start button and start
running in auto. Too much would happen at the same time and errors might not
be traceable and / or cause start-up problems.
The following start-up sequence will be helpful in avoiding

this problem:
• Start the system in filtration only.
• Set-up feed flow control.
• Activate backflushes.
• Set-up backflush flow control.
• Activate chemical enhanced backflushes. Set-up neutralization system.

• Set-up post dosing flush times or volumes and check pH.
• Start and set-up drain program.
• Start and set-up venting/filling program. Start and set-up Air-flow test
program.
• The plant is running in auto and all programs are available and testing can
begin.
Before starting to run in auto the system (test) settings have to be
determined and set.
5.2.4.1 Determine and set initial settings
• PLC settings, such as given below, must be set: Valve delay

timers
Step delay timers Alarm
delay timers
• SCADA settings, such as:
Filtration time
Filtration volume
Flow rates PID
settings Etc.
Most of these settings can be extracted from design documentation such as,
45
Process Description, Process Control Philosophy or Automation System
Description.
All start settings have to be listed in a setting list. The setting list will leave
space for filling in settings changes during commissioning.
5.2.5. Active section testing

• The system running in auto is a test for the system, but during the wet
testing period not all- possible scenarios will pass. Therefore these possible
scenarios have to be introduced to the system, e.g. simulating high TMP
alarm. This is the active testing period.
5.2.5.1 UF feed section
The UF feed station consist out of:
• Unit control valves

This section is very important, since it controls the feed flow to the units. The
following items are of attention for testing the UF feed section:
• Preventing pressure and flow peaks; Feed flow control. (PID set-up, starting
and stopping pumps)
• Preventing excessive variations in flow distribution; control valve set-up,

hydraulically balancing. Steady flow control.
5.2.5.2 Tank level set-up
• The BF tank is equipped with level transmitters and switches. The level
transmitters and switches are used to protect the BF pumps and prevent air
ingress into the UF units.
• The level switch has a fixed height and will cause immediate pump and
possible plant shutdown. A level switch cannot be used for controlling. It is a
safety feature.
• A level transmitter can be used for controlling and avoid plant shutdown on
the level switch.
46
• The tank levels have to be set-up. The level settings have to be set such that
a vortex is avoided and the system can react fast enough to avoid plant
shutdown.
5.2.5.3 Feed flow control
• Feed flow control takes place with intake pumps and it is on plant level.
• Duty / Stand-by pumps connected to a common header and unit control
valves.
• Independent from the feed flow is the available number of membrane
units. Taking units off-line and on-line is a good test for changing the
maximum plant capacity. These tests have to be done.
5.2.5.4 Feed flow distribution
Feed flow distribution is the flow distribution between UF units with

dedicated flow control valves
• Flow control valves are more difficult to set-up. The control valve throttles
a flow, valve positions change. If one control valve changes position on a
common header with several control valves, it will cause the other valves
to react / control as well.
• The flow has to be limited to the max. flux and should be distributed within
a dead band over all the units. This can be affected by the hydraulic profile
of the UF plant. At large plant this can mean that maximum valve open
position differ 20%, e.g. from 60 % open to 80 % open.
• To make a plant with large hydraulic differences controllable the maximum

open positions have to be set. The maximum open position for all control
valves has to be between 70 and 80 %. If the valve starts at 100 % open,
the first 20 % closing has no effect on the flow causing slow flow control
which can result in flow peaks.
• Control valves have to be set to 70 to 80 % maximum open.
47
5.2.5.5 Duty / stand-by
• The duty / stand-by changeover of pumps, if applicable, has to be tested. If
the feed system is set-up with assist pumps the change over is more
difficult and feed flows can change very rapidly if stand-by pumps are
started or stopped when taking over from an assist or duty pump. The
changeover has to be smooth, starting and stopping the pump has to be
tested thoroughly. The control must be set up avoiding erratic control
causing pressure and flow peaks.
5.2.6. Backflush section

UF feed section consist of:
• Backflush water holding tank
• Backflush
pumps
• The backflush flow is generally 2.5 times higher than the filtration flow.
Most of the times backwash systems are relatively easy to set-up, no assist
pumps and flow distribution and they are servicing just one unit at a time.
The following items are of attention for testing the backflush section:
• Air ingress; due to drawing air from the backflush tank. (vortex, low level
setting) Preventing pressure and flow peaks; Feed flow control.
(PID set-up, starting and stopping, BF-stream)
5.2.6.1 Tank level set-up
• The backflush tank is equipped with level transmitters and switches. Air ingress
into the backflush lines and UF units must be avoided.
• The level switch has a fixed height and will cause immediate pump and unit
shutdown. A level switch cannot be used for controlling. It is a safety feature.
• Level transmitter has adjustable settings and can be used for more adequate
control.
• The tank levels have to be set-up. The level settings have to be set such that a
vortex is avoided.
48
5.2.6.2 Backflush flow control
• Backflush flow control takes place with VFD driven backflush pumps. A
backflush pump will only wash one unit at a time. The set-point can differ,
regular backflush, CEB in or venting backflush.
• The backflush flow control has to be set up to avoid pressure and flow peaks
and erratic control of flow. The ramp-up and -down times have to be in the
range of 5 to 10 seconds.
• In case of a stream backwash (multiple units are backwashed consecutively

within one wash cycle), backflush control requires more attention. The key
attention points are:
• The intermediate step where two units change over from one unit to the next.
The unit coming out a backflush closes its route and the recirculation valve
opens. Only then the next unit can do a backflush and the route through the
unit is open (open signals from the valves).
• Flow rate changes during change over.
The duty / stand-by of changeover of pumps, if applicable, have to be tested.
5.2.7. Chemical dosing systems
The chemical dosing systems are calibrated and ready to run. The dosing
systems are used for: Chlorinating pre or post membranes, pre-dosing can
have ammonia oxidizing function:
• Coagulant dosing
• Dosing CEB chemicals
• Dosing CIP chemicals
These systems can cause (indirect) membrane damage, due to:
• Upsetting flow meters, if dosing is too pulsating
• Unsatisfactory chemical strength causing high Trans Membrane
Pressure and unstable running.
• Tank levels have to be set and checked.
49
• The dosing systems have to be calibrated, by measuring the chemical
concentration in the stream in which it has been dosed.
• The changeover to these dosing systems or pumps has to be tested.
5.2.8. Membrane integrity test unit

The membrane integrity test unit consists of:
• Air supply
• Air flow measure panel
The following items are of attention for setting up and testing the MIT unit:
• Air pressure used for the test.
• Test set up of air flow panel
5.2.8.1 Air supply
• The air supply consists out of a filter set and an air-pressure regulator. The
air-pressure has to be set at 1 bar (g). The maximum pressure offset of the
air-pressure is plus or minus 0.2 bars. The air pressure has a direct relation
with the air-flow rate. Therefore the air-pressure has to be monitored.
Besides monitoring the pressure for checking the results the air pressure
is monitored for membrane protection.
5.2.8.2 Air-flow measurement panel

• On the air-flow measure panel the air-flow rate is measured.
• The air-flow panel is equipped with a manual valve which has to be

throttled during an air-flow test. The valve has to be throttled, for testing
purpose, so that the flow to the panel limited to a pre-set setpoint for
checking fail and pass conditions. After membrane loading the valve has
to be opened.
• The larger plants are equipped with stand-by air-flow measure panels.
The changeover to these panels has to be tested.
50
5.2.9. Sequence and functionality test
Testing the different sequences has to be done with the Process Control
Philosophy or Automation System Description. In the document each sequence
and functionality is described.The sequences have to be tested, but at the
same time settings for these sequences are optimized.
• The sequences and functionality’s are the basis for the plant, but it all has
to work as one. To see if it works as described, one has to pay attention to:
• Reliability
• Proper handling of priorities

• Consistent handling of priorities
5.2.9.1 Filtration
• In the Process Control Philosophy or Automation System Description all

software functionalities are described such as: valve sequence start, stop
and step conditions controls, venting and alarm parameters.
• All of these have to be tested and settings optimized. If the plant is

equipped with turbidity control the different turbidity levels have to be
tested. Using a mA signal generator that simulates the output of the
turbidity meter can do this. Alternatively the settings for HH/H/L/LL level
can be adjusted to trigger a response.
5.2.9.2 Backflush
• In the Process Control Philosophy or Automation System Description all software

functionalities are described, such as: valve sequences, start, stop and step
conditions, controls and alarm parameters.
All of these have to be tested and settings optimized.
5.2.9.3 Chemical enhanced backflush

51
Conditions, controls and alarm parameters. (Refer to this section)
All of these have to be tested and settings optimized.
5.2.9.4 membrane integrity test
conditions, controls and alarm parameters. (Refer to this section)
• All of these have to be tested and settings optimized.

functionalities are described such as: valve sequences, start, stop and step
conditions, controls and alarm parameters.
• All of these have to be tested and settings optimized.

5.2.9.5 Filling and venting
• In the Process Control Philosophy or Automation System Description all

software functionalities are described, such as: valve sequences, start,
stop and step conditions, controls and alarm parameters.
• All of these have to be tested and settings optimized. Optimization of the

filling/venting settings without membranes is very difficult. Therefore it is
best to keep working with very safe settings that can be optimized with
membranes.
5.2.9.6 Active testing general control functions - Emergency stop
• The goal of the emergency stop is to stop the plant as quick and safe as
possible. This means that even with an emergency stop not all valves should
be shut directly. Shutting valves could also cause dangerous situations, such as
water hammering.
• Therefore the emergency stop sequence has to be set-up such that no other
dangerous situations are created.
• An emergency stop has to be tested.
52
5.2.9.7 Power failure
• A power failure is an undesired stop and can happen at any time. The system
design and software have to be able to coop with these power failures without
causing pressure and flow peaks.
• A power failure is a partially controlled shut-down sequence. Control can be

maintained by using suited equipment and an uninterrupted power supply
(UPS) for the PLC.
• The plant has to be brought back on-line after a power failure. This is the
second part of testing power failures. There are two different scenarios for
this:
• A power failure with UPS and the PLC has been on-line for the duration of the
power-failure.
• A power without a UPS or the UPS power supply died and the PLC did not stay
on-line during the power failure.
• Both situations have to be tested.
• An emergency stop has as goal to stop the plant as quick and safe as possible.
This means that even with an emergency stop not all valves should be shut
directly. Shutting valves could also cause dangerous situations, such as water
hammer.
• Therefore the emergency stop sequence has to be set-up such that no other
dangerous situations are created.
• An emergency stop has to be tested.
5.2.9.8 Instrument air-supply failure
• If the instrument air-supply fails the plant has to be shut-down in the same
way as an emergency stop. A pressure switch monitors the instrument air
pressure.
5.2.9.9 Data collection changes - Trending and logging
• Trending and logging, of process data and alarm messages, is needed for
monitoring the plant during testing, membrane flushing and running with
membranes.
53
• The trending and logging system helps fault finding during the wet
commissioning without membranes. Wet testing without membranes can only
be started if trending and logging is available.
• At the start, preferably before the start, of wet commissioning without

membranes a telemetry connection has to be established with the Pentair
office.
5.2.9.10 Recording Changes
• During wet commissioning without membranes all set-point changes have to

be recorded. All
• Start settings have to be listed in a setting list. The setting list will leave space
for filling in settings changes during commissioning.
• Complete software modifications through which functionality changes have to
be approved by the Process Engineer of Pentair. These changes have to be
properly documented, so that they can be used to up-date the as build
Automation System Design or Process Control Philosophy.
5.3.0 Process Commissioning XIGA - UF Membrane Element

Loading.
This is a general membrane element loading procedure. It can be membrane
part commissioning or membrane element replacement of existing membrane
plants. The procedure describes what needs to be done before and during
membrane element loading.
5.3.1 Start conditions

The following conditions have to be met before starting membrane element
loading or its preparations:
• Commissioning without Membranes’ is finished, see related documents.
• UF plant permeate piping, backwash piping and backwash tank are clean, no
debris, sand or organic sediment, etc.
• Strainers are in place.
54
• Membrane elements and loading materials and facilities are available at site.
• Water for membrane element flushing will be available. For water quality, see
‘Procedure Membrane Element Flushing’ in related documents.
5.3.2 Order of activities
Membrane element loading is consists of several activities. These

activities are split in preparation and membrane element loading. Table 1-
1: Preparations
Item Activity
1 Fitting O-rings on connectors
2 Facilities
3 Cleaning membrane loading area
Table 1-2: Membrane element loading

Item Activity
1 UF unit Draining
2 Membrane housing dismantling
3 Membrane housing cleaning
4 Membrane elements loading
5 Membrane housing assembling
5.3.3. Time span
Time activity of membrane element loading of one membrane housing with

two persons can be found in table below.
Table 1-3: Time span for membrane element loading.

Item Activity Duration Comments
1 Membrane housing dismantling 5-10 min. Both end-caps from membrane

housing
55
2 Membrane housing cleaning 5 Using water hose and foam
cleaning pig.
3 Membrane housing loading 5-10 Loading of membrane elements
4 Membrane housing assembling 5-15 Both end cups of membrane

housing
1. Preparation and other supporting activities are not supported
5.3.4 Preparing for membrane element loading
5.3.4.1 Connector O-rings
The membrane elements and membrane housing end-caps are connected

through inter- and end-connectors. Membrane elements are connected with
each other by inter-connectors. Inter- connectors legs are of equal length.
Membrane elements and housing end-caps are connected with
endconnectors. End-connectors have a long leg and a leg with the same length
as one of an inter-connector. See figure below. The long leg provides space for
adding shims. Shims will prevent the membrane elements from shifting in the
membrane housings.
Figure 2-1: Connectors and shims
56
Newly delivered connectors are not fitted with O-rings. The O-rings have to be
fitted before membrane element loading. All connectors have to be checked
for cracks when the O-rings are fitted. Cracked connectors cannot be used.
Before usage the connectors must be cleaned and kept in a bucket with 10 to
20 ppm free chlorine solution for disinfecting.
NOTE: Read sodium hypochlorite material safety data sheet 5.3.4.2 Materials and
facilities
Materials and facilities needed for membrane element loading can be found in
the tables below.
Table 2-1: Preparations

Item Activity Material and equipment
1 Fitting O-rings on connectors Inter-connectors, end connectors and O-rings
2 Loading facilities installation Scaffolding and/or ladder
3 Membrane loading area Broom, rubber mop, water hose

cleaning
Table 2-2: Membrane element loading

Item Activity Material and equipment
1 UF unit draining n.a.
2 Membrane housing dismantling Spanners and Allen-keys
3 Membrane housing cleaning Foam cleaning pig, pig support, rope ,bucket and
water hose
4 Membrane element loading Membrane elements, glycerin. Sodium

hypochlorite, buckets, record sheets, pallet truck
or forklift, hammer, flat head screw driver, pair
of thongs and pair of scissors or knife
57
5 Membrane housing assembling Spanners, Allen-keys, shims and glycerin
• The materials and facilities should be available before membrane element

loading will start.
• Membrane elements are packed in cardboard boxes (one element per box) or
wooden crates (Maximum 20 elements per crate). A Pallet-truck or fork-lift
truck is needed to move the wooden crates.
NOTE : Store membrane elements following “STORAGE & SHIPMENT

INSTRUCTION: see related documents for this matter.
• For membrane loading the crates should be positioned as close as possible to

the UF unit. For opening the wooden crate a pair of thongs, a flat-head
screwdriver and hammer is needed. The individual membrane elements are
vacuum sealed in thick plastic. For removing the plastic a pair of scissors or
knife is needed.
• Scaffolding and ladders could be required during dismantling and assembling

of membrane housings and membrane element loading. Tools used during
dismantling and assembling membrane housings are spanners and Allen-Keys,
check membrane housing manufactures installation instructions.
• For cleaning of the membrane housings a foam pig is required. A rope with
foam pig support is needed to pull the pig through the membrane housing.
The foam pig support will be pushed through the foam pig after which a rope
will be connected to the front of the foam pig. The foam pig needs to be
wetted before pushing it in the membrane housing. The foam pig has to be
cleaned after it has been pulled through the membrane housing. A large
bucket can be used for wetting and cleaning of the foam pig. A water-hose is
needed to re-fill the bucket and flush-out the membrane housings.
Figure 2-2: Foam pig and foam pig support
58
59
• Each membrane element has its own serial number, see figure below. The
serial number is used for recording the position of each membrane element in
the UF unit. During membrane element loading glycerin is used to lubricate
connector O-rings. This will prevent damage or displacement of O-rings.
Figure 2-3: Membrane element code
• Membrane housings have to be reassembled after membrane element loading

is finished. When the membrane housings are reassembled the membrane
elements position will be fixed with shims. Shims are used to fill the open
space between end-cap and membrane element.
NOTE : Shims and end-connectors are normally part of scope of supply of

the membrane housing manufacturer!!
5.3.5 UF Membrane element loading
5.3.5.1 UF unit draining
• The UF unit has to be drained before dismantling. The UF unit can be drained
manually or automatically, if drain program is part of the plant software.
NOTE: Make sure that UF units are isolated after draining!!
• If the UF unit is drained all manual drain valves have to be closed, the UF
unit has to be made inactive/off-line in SCADA and instrument air supply to
the UF unit has to be disconnected.
5.3.5.2 Membrane housing dismantling
60
• After UF unit draining and isolation the membrane housing end-caps can be
removed. A 90° elbow is connecting the membrane housing end-cap with
the permeate header. The membrane housing end-cap and the 90°elbow
have to be removed as one piece. Both membrane housing endcaps (from
both sides) have to be removed.
• The instructions for removing and replacing membrane-housing end-caps

are described in the manufacturer installation instructions.
PLEASE NOTE: Membrane housing end-cups must be repositioned on
their original position!!
5.3.6 Membrane housing cleaning

• The membrane housings have to be cleaned before membrane
elements loading. Cleaning is required to remove all sediment from
the inside of the membrane housings.
• Start cleaning at the top membrane housings of the UF unit.

Sediment from the top membrane housings will flow through feed
piping to the lower membrane housings. Cleaning is done in 3 steps:
• Pre-flush membrane housings with clean water.
• Pull a wet foam pig through each membrane housing. A foam pig can
be used for approximately 40 membrane housings.
• Flush membrane housings with clean water after swab or foam pig
cleaning.
5.3.6.1 Membrane element loading

• The weight of 1 new membrane element is approximately 25 kilograms.
Hence, it is advised to handle membranes with 2 persons.
NOTE : It is the client’s responsibility that membrane element loading
shall be executed in accordance with local health and safety regulations.

NOTE : Membrane element package has to be checked for damage,
ripped bags, damaged boxes.
All damages have to be recorded on ‘membrane element loading record
61
sheet’.
• Each loaded membrane element position has to be recorded. An example

of a ‘membrane element loading record sheet’ can be found in annex I.
• Membrane housings can hold one to four membrane elements. The

following procedure describes loading of membrane housing for four
membrane elements. The same procedure applies for loading membrane
housings for one, two or three membrane elements.
Step 1: Insert the first membrane element
• Record membrane element serial

number
• Remove membrane element packing
• Insert up to 4/5 of the membrane
element into membrane housing.
Leave 1/5 of the membrane element

•
outside the membrane housing.
• Lubricate the inter-connector O-rings on both sides with Glycerin.

• Keep the newly loaded membrane element in place and insert the
lubricated inter-connector into membrane element; make sure that the
connector nipples touch the membrane element.
Note: In case the membrane housings can hold a maximum of one

membrane element, continue with step five. Do not insert the last
mentioned inter-connector.
Step 2: Insert the second membrane element
62
• Record membrane element serial number.
• Remove membrane element packing.
• Keep the previously loaded membrane in
place and slide the second membrane
element over the lubricated inter-
connector, make sure that the connector
nipples touch the membrane element.
• Note: Keep the membrane elements aligned, to prevent the connector from
breaking.
• Insert up to 4/5 of the membrane element
into membrane housing.

• Take an inter-connector and lubricate O-
rings on both sides with Glycerin.
• Keep the newly loaded membrane element
in place and insert the lubricated
inter-connector into membrane element;
make sure that the connector nipples touch the membrane element.
Note: In case the membrane housings can hold a maximum of two

membrane elements, continue with step five. Do not insert the last
Step 3: Insert the third membrane element

place and slide the third membrane
Note: Keep the membrane elements aligned, to prevent the connector from
breaking.
63
• Insert up to 4/5 of the membrane element into membrane housing.
• Take an inter-connector and lubricate O- rings on both sides with Glycerin.
• Keep the newly loaded membrane element in place and insert the lubricated
inter-connector into membrane element; make sure that the connector nipples
touch the membrane element.
Note: In case the membrane housings can hold a maximum of three

membrane elements, continue with step five. Do not insert the last
Step 4: Insert the fourth membrane element

place and slide the fourth membrane
Note: Keep the membrane elements aligned, to prevent the connector from
breaking.
Insert the membrane element completely into

membrane housing.
Step 5: Install the first set of membrane housing end-caps, both sides of
membrane housing.
64
• Position one, two, three or four membrane
elements in the centre of the membrane
housing. Make sure that the distance from
the edge of the membrane housing to the
first membrane element is more or less equal
for both sides of the membrane housing.
• Remove O-rings from end-connector and membrane housing end-caps.

• Put shims on the end-connectors of each side of the membrane housing, one on
both sides.
• Test if two, total, shims are enough to fix the membrane elements in the
membrane housing. While being able to install the end-caps.
• Add more shims, one by one, if needed. Continue until one too many has been
added. (end-caps can not be installed)
• Remove the excess shim.
• Make sure that shims are equally divided over the end-connectors and make sure
that the number is recorded in the loading records.
• Reposition O-rings on end-connectors and membrane housing caps.
• Place shims on the long leg of the end- connector and lubricate end-connector O-
rings.
• Push long leg of end-connector, with shims, into membrane housing end- cap.
• Make sure that the connector nipples touch the membrane housing end-cap.
Note: Keep the membrane housing end- cap aligned, to prevent the end-
connector from breaking.
Step 5: Install remaining membrane housings end-caps, both sides of

membrane housing.
• Divide total number of shims needed, see

step five, over both end-connectors.
• Place shims on the long leg of the end-
connector and lubricate end-connector
Orings.
65
• Push long leg of end-connector, with shims, into membrane housing end- cap.
• Make sure that the connector nipples touch the membrane housing end-cap.
Note: Keep the membrane housing end- cap aligned, to prevent the end-
connector from breaking.
5.4.0 Process Commissioning XIGA - UF Membrane Flushing.

This membrane flushing procedure is a non site-specific flushing procedure
that describes membrane flushing and other works involved with membrane
flushing.
Membrane flushing is done for 2 reasons, venting the UF unit and flushing
out the preservative. The membranes are preserved in order to prevent
bacterial growth and form dehydration of the fibers.
The flushing procedure is KIWA and DWI approved and has to be done when
new membrane elements are installed.
NOTE: It is best to start membrane flushing directly after loading. The

maximum delay time for starting with flushing is 100 hours.
5.4.1. Before membrane flushing
Software testing, operation of the plant with water has been completed.
Membranes are loaded.
No mechanical, electrical and / or software changes are scheduled and needed.
Especially mechanical changes can be hazardous for membrane damage due to
foreign matter. Software changes can impact on plant operation and undo
completed software test results. Tank cleaning and inspection is completed
and if necessary action has been taken.
Flush water is available.
Temporary connections are available and installed.
5.4.2 Man power and set-up
Man-power required and team set-up depends on the amount of manual

actions required to flush the system as well as available time, water and
discharge capacity.
66
The duration of flushing 1 unit continuous and uninterrupted is approximately
1 hour.
Table 1: Man power
Flushing team
Supervisor Norit 1
Software engineer 1
Commissioning engineer 1-3
Note: The table is a reflection of what can be achieved. It will depend

on factors such as available tools, team-work, discipline, available
water, working hours etc.
Flushing requires good teamwork between the members of the team. The
software engineer operates the system, the supervisor controls the flushing
and the others will perform the manual actions.
5.4.3 Water supply and discharge
NOTE : Membranes have to be flushed with good quality water. Good

quality water is potable water or equal with a maximum turbidity of
1 NTU. Good quality of flush water is used to prevent the membranes
from fouling during flushing.
Flush water will dissolve the membrane preservative (water / glycerin /

Nabisulphite) and therefore, amongst others, the BOD level in the water will
increase. This means that produced permeate, during a flushing, can not go to
the feed tank or backwash tank. The same applies for backwash concentrate
5.4.4 BOD levels
The average BOD level increase of the total flush water volume will be
between 20 and 30 mg/l. See Table 2:
If the average BOD level increase is too high to discharge, it is advised to insert
a minimum soak period of 2 hours after step 1 and arrange separate discharge
for step 2 and 3. During step 3 an average BOD level of 300 mg/l can be
67
reached. The average BOD level will be between 3 and 7 mg/l of the totaled
flush water volume after step 3 taking into account the initial flush water does
not contain BOD.
NOTE : Effluent from a membrane flush step can not be used for
other membrane flushing steps.
5.4.5 Temporary connections
Preventing flush water to be re-used and supplying the plant with fresh flush
water generally requires temporary connections and piping and / or hoses.
Possible water routing problems, that might require temporary

connections, are:
• Re-filling the feed tank
• Discharging filtration effluent (permeate line)
• (Re-filling) the backwash tank
• Discharging Backwash concentrate
5.4.6 Flushing Procedure

In Table 2 the flush procedure is written down. The flush water quantities
mentioned in Table 2 are based on 10 UFC-M5 membrane elements with 40
m². The flush volume is a linear ratio with the number of membrane elements.
Each step volume must be met. Fluxes can be lowered if the times are
extended. Therefore the water quantities for flushing are fixed as volume per
module.
The flushing procedure exists of two subsequent parts:
Mandatory part with a BOD removal of >95% (always performed during

commissioning) Recommended part with complete BOD removal The
recommended part is an extension to the mandatory part. Whether or not
the recommended part of the flushing protocol is performed must be
discussed with, and agreed on by, the client.
68
Table 2: Characteristics of membrane flushing
No. Stage Flux Duration Volume

Filtr. BW
[-] [-] [lmh] [min] [m³] [m³]
Mandatory steps of X-flow flush procedure (BOD removal >95%)

1 Unit fill See note 1)
2 Filtration 50 5 1.7
3 Backwash 125 1 0.9
Subtotal mandatory steps 4.4 2.3
Recommended additional steps X-flow flush procedure (complete BOD

vFiltrational) 100 5 3.4
r6e
mo
11 CEB with NaOCl
11a Backwash 250 1 1.7
11b BW + NaOCl (200 125 1 0.9
ppm)
11c CEB soak 0 10
11d Backwash 250 2 3.4
Subtotal recommended steps 10.2 9.4
14.6 11.7
Total (mandatory + recommended steps)
Notes:
1. according to the Process Control Philosophy, unit fill has to e performed at 20
50m³/h. Independent of unit size.
2. The table is based on flushing 10 UFC M5 membranes with 40 m² each.
3. There are no safety margins in this table, adding 10% extra volume is
recommended.
Following table 2, the following overall water volumes are required membrane
flushing:
69
Mandatory step (1-5) 0.67m3 / element
Mandatory + recommended (step 1-11): 2, 6 m3/ element
5.4.7 Flushing stages
NOTE : Check all valves positions before starting with membrane

flushing.
Stage 1: Unit filling

The unit is completely empty and therefore the unit needs to be filled
carefully. The unit has to be filled with a maximum flow rate of 20 to 50 m³/h.
For this purpose the venting/filling program can be used (part of Process
Control Philosophy).
When no automatic venting/filling program is available, perform the actions
described below. If the manual vent valves are used the following sequence
can be followed:
Open feed vent valves and permeate vent valves
Open feed to the unit
Open feed to the unit and limit the feed flow to 20 - 50 m³/h
When the first water flows over the top, close one of the feed vent valves
After 1 minute with 1 feed vent valve closed, open the closed feed vent valve
and close the open feed vent valve.
The unit has to be filled for at least 5 minutes. It is no problem if this stage
takes longer, to increase the effectiveness of the stage.
Stage 2, 4, 6, 8 and 10: Filtration (50 - 100 lmh)

During filtration water is pushed from the feed side through the membrane
and discharged on the permeate side. The filtration flow rate for each stage
can be found in Table 2.
During filtration the vent valves have to be operated, in automatic operation or
manually, for venting of air. This has to be done several times during the
filtration period.
Stage 3, 5, 7, 9, 11a till 11d: Backflush (125 - 250 lmh)
The backflush takes place in the opposite direction to filtration. The water is
pushing water from the permeate side through the membrane and discharge
on the feed side.
During the backflush the vent valves have to be operated, in automatic
operation or manually, for venting of air. Since the backflush has a short
70
duration the vent valves should be opened halfway of the backflush and just
for 10 seconds.
Vent valves have to stay closed during steps with chemicals (11a – 11d).
NOTE : Be aware of chlorine washout of stage 11d and make sure that it
is routed to the right tank or sewer, were it can be either neutralized or
disposed.
Stage 11b and 11c: Chemical dosing and chemical soak
With stage 11b a 200 ppm chlorine mixture has to be washed into the unit. The
backwash is performed at 125 lmh, and chlorine has to be dosed into the
backwash stream. It is no problem if the concentration is higher, as long as
chlorine concentrations are below 500 ppm.
The dosing time and backwash time is 60 seconds. If the dosing system is not
close to the unit(s) the backwash time has to be extended. By extending the
backwash time the chemicals will be transported into the unit.
During the backwash with chemicals the vent valves should not be opened.
When the chemicals are washed into the unit, step 11c, soak, is started.
During the soak a sample has to be taken from the unit. The sample is taken
to determine the concentration of chlorine in the unit.
The chemicals are washed out with stage 11d. Concentrate from this backwash
has a high chlorine concentration.
5.4.8 Calculations
Volume for flushing - Site situation (example):

• 3 skids with 11 membrane housings each
• Each membrane housing is 6 meters long and can hold 4
membrane elements.
• Membrane elements are UFC-M5 with 40 m2, also used in

table 1.
Number of membrane elements on the plant:
71
=>> 3 (skids) x 11 (membrane housings) x 4 (elements per housing) = 132
membrane elements
Filtration volume needed (complete flushing process):
=>> (132 / 10) x 14.6 m³ (total filtration volume from table 1) = 193 m³
Add 20 % safety margin = 232 m³
Backwash volume needed:
=>> (132 / 10) x 11.7 m³ (total BW volume from table 1) = 154.4 m³
Add 20 % safety margin = 186 m³
5.4.9 Flush flow rate
Site situation (example):

Same as used in volume calculation (see section 2.2.1).
For calculating the flush flow the membrane area of the unit needs to be
calculated first.
Unit membrane area:
=>> 11 (membrane housings) x 4 (elements per housing) x 40 m² = 1760 m²

For stage no 4 of table 1:
=>> Filtration stage no 4 at 80 lmh
Flush flow = 80 lmh x 1760 m² = 140800 [l/h] = 140.8 [m³/h]
In general, the flow (m3/h) for the various stages is calculated as:
=>> (flux x available area) /1000
72
5.4.10 Flushing instructions and restrictions - Venting
It is very important that the unit is regularly vented during the different flush
stages. Especially for units with the flush outlet on the bottom. If the vent
valves are not used air will accumulate and compress in the top of the unit.
Air in the top of the unit reduces the effective membrane area. With a
reduced membrane area and compressed air in the unit can lead to possible
membrane damage.
NOTE : Vent valves on feed or permeate side can only be opened if the
minimum pressure on that side, in the top of the unit, is 0.05 bar.
If pressure in the top of the units isn’t high enough there is a possibility
that air is introduced into the unit.
The vent valves can be operated manually or automatically, as long as the

minimum pressure condition is met.
5.4.11 Flow control
During flushing the units are filled with a water / air mixture. It is therefore
very difficult to control a pump or control valve on a flow set point. It is
advised to use a fixed pump speed or
Hand / control valve conditions.
NOTE : All flow rates, for filtration and backwashing, have to be manually
controlled.
e.g. fixed pump speeds and fixed, control, valve positions.
5.4.12 Pressure shocks and flow peaks
Pressure shocks and flow peaks have to be avoided at al times. Pressure shocks
and flow peaks can occur when:
• A unit flush is started
• A unit flush is stopped
• Pump rump-up
• A fast flow set-point change
73
NOTE : Avoid pressure shock and flow peaks with proper operation
during the flush steps.
Pressure shocks and flow peaks can damage the membranes.
NOTE : Operations to avoid pressure shocks and flow peaks can increase
the chance of, partially, unit draining. This has to be avoided, since
reintroducing air from flush step to flush step will make the flush less
effective and the chance of membrane damage increases with the
increasing flows.
5.4.13 Cavitations and flow ranges

Usually the UF plant not specially designed to accommodate for the full flush
flow range per UF unit. If the required flush flow can not be achieved it would
not be a problem, since flushing with lower flows is allowed.
In systems with high pump capacities, the maximum flush flow per step shall
not be exceeded. Most of the times this can be solved with temporary
connections, such as bypasses, bleeds or by using other available pump (e.g.
CIP pump) and hydrants.
In some cases throttling a valve directly behind a pump can control and reduce
the flow. Cavitations must be avoided as much as possible, because it could
damage the valve and could lead to air ingress into the unit by the local under-
pressures which is undesirable.
Throttling a valve behind the unit is not allowed. This situation will lead to
pressurizing the UF unit with an increasing chance of pressure shocks and flow
peaks.
NOTE : The maximum flow for a flush stage shall not be exceeded. A
lower flow for a flush stage is allowed. This will result in longer
stage duration to meet the required flush volume.
NOTE : Air ingress, e.g. due to cavitations, can cause membrane damage.
Units can not be pressurized, flow control has to take place upstream of
the unit.
74
5.4.14 Trans membrane pressure
NOTE : During flushing the maximum filtration TMP of 1.0 bar and the
maximum backwash TMP of 2.0 bar shall not be exceeded.
Exceeding the TMP’s during flushing can seriously damage the

membranes.
It is unusual that the maximum TMP values are exceeded during flushing, since
relatively clean water is used. Normally high TMP are expected when the fouling
load of the water is very high or when air ingress takes place. Exceeding the high
TMP is therefore a very good indication that flushing is not done properly.
5.4.15 Permeability
During the last filtration stage of (mandatory and / or recommended)

membrane flushing, the filtration TMP and water temperature has to be
recorded. The flux, TMP and water temperature will be used for determining
the permeability.
5.4.16 Flushing record
Each flush stage has to be recorded. Normally a SCADA system will log the
data, but a written record is required as well.
On this log sheet the following has to be recorded:
Location and name of plant

• Supervisor name
• Flush date
• Flush water turbidity
• For each flush stage the flow rate and the start and stop time
• Active chlorine concentration of step 11c
An example of a log sheet can be found in annex I.
NOTE : A flush record has to be generated for warranty and is sometimes

also required by the authorities
75
5.4.17 Flushed units
When a unit is flushed the unit can be taken into operation. If the unit is not
taken directly in to operation the unit has to be flushed, with flush water,
every 24 hours. This can be repeated as long as needed.
If the unit has to stay off-line for a long period, due to circumstances, it might
not be desired to keep flushing the units. For these cases a Shutdown and
Storage procedure is available.
NOTE : Flushed membrane units can not be kept isolated for more than
24 hours.
Optionally the permeate side of the UF system (UF units, backwash tank,
backwash pumps/strainers, permeate/backwash pipe work) is disinfected
after membrane flushing:
Disinfection is executed according to the customer requirements.
Requirements and routing of disinfection waste water is determined by the
customer. Last disinfection step can be execution of a normal chlorine CEB
program.
Annex I: Membrane flushing sheet
Plant location & name: Supervisor:
Date: Flush water turbidity:
Stage Required Actual Start time Stop time

Flow rate Flow rate
[m³/h] [m³/h] [hh:mm:ss] [hh:mm:ss]
Unit fill 20 - 50
Filtration
Backwash
76
Filtration
Backwash
Filtration
Backwash
Filtration
Backwash
Filtration
Backwash
Backwash + Cl-
dosing (100 ppm)
Soak period Chlorine concentration:

[mg/l]
Backwash
Filtration*
Backwash
(*) Permeability data
Feed pressure 1 [bar] Permeate pressure 1 [bar] Water temperature [°C]
Feed pressure 2 [bar] Permeate pressure 2 [bar] Unit flow [m³/h]
Comments:
5.5.0 Process Commissioning XIGA – Wet testing with membranes

The plant will be taken in automatic operation after the membrane elements
are loaded and flushed. During the initial phase of automatic operation the
plant has to be monitored and fine tuned.
77
The goal of this period is to get the plant to operate according design
specifications. This means that plant operation has to be monitored and plant
data will be used to review and change settings, if needed.
Main plant performance parameters that need to be monitored are:
• Filtration permeability
• Chemical Enhanced Backwashes
• Coagulation process
• Feed and permeate quality
• Membrane integrity
5.5.1 Process control and optimization - Data collection

The below listed data has to be collected
on unit level:
• Feed pressure (feed pressure transmitter(s))
• Permeate pressure (permeate pressure transmitter(s))
• Unit feed flow rate
• Unit backwash flow rate
• Feed water temperature
With above measurements (and the applicable membrane area) the flux, TMP,
permeability etc can be calculated in the SCADA system. Calculations are
described in the Process Control Philosophy or Automation Document.
Membrane unit performance can vary, due to either membrane fouling or feed
water temperature. Both will result in increase or decrease of Trans
Membrane Pressure, head-loss over the membrane. The throughput, unit flow,
also affects the Trans Membrane Pressure.
For monitoring and evaluating the performance of the UF unit(s) the

throughput is normalized. This normalized throughput called permeability is
corrected for temperature and Trans Membrane Pressure.
78
The permeability is normally automatically calculated and logged. The logged
permeability data is used for plant performance evaluation. The representative
permeability data is measured 3 minutes after the start of the first filtration
cycle after a primary CEB, the most frequent CEB.
5.5.2 Sample frequency

For proper long-term plant evaluation the data has to be recorded during a
predetermined period with a fixed frequency. The sample frequency for all the
parameter is described in the Process Control Philosophy or Automation
Document.
5.5.3 Chemical enhanced backwash

Chemical Enhanced Backwashes are needed to clean the membranes. If the
CEB’s are not properly set and therefore not effective in cleaning the
membranes the membrane plant will slowly foul. Fouling of the unit can cause
capacity problems in the long-term.
For an effective CEB the chemical concentration and the position of the
chemical cloud in the UF unit are important.
The chemical concentration has been set-up according the design

specifications. The design specifications for acid CEB’s are based on achieving
pH 2 to 2.2 and the caustic CEB’s are based on achieving pH 11.8 to 12. If other
chemicals are used, oxidizers such as NaOCl or H2O2, chemical concentrations
have to be checked as well. For these chemicals the concentration on the
projection has to be met.
The chemical cloud has to be washed into the unit. The chemical cloud is
transported into the unit by setting the post dosing time. If the post dosing
time is too short the chemical cloud will not reach or completely reach the
unit. If the post dosing time is too long the chemical cloud can pass the unit.
The dosing time also has to be properly set; otherwise the chemical cloud can
be too small or large.
79
During the soak period of a CEB the pH or the chemical concentration has to be
checked. Measuring the chemical concentrations in both the concentrate and
permeate can be used to check the position of the chemical cloud.
5.5.4 Sample frequency

During the first week after start-up the CEB will be sampled regularly and CEB
settings have to be adjusted, if needed.
After commissioning operators are advised to verify dosing pump performance
by checking and recording on a weekly basis the pH or chlorine concentration
of a unit during CEB soak.
In case of deviation to the specification the relevant dosing pump has to be
calibrated, as per instructions of the relevant sections of the O&M manuals.
Checks on operation and maintenance shall be recorded in operating and
maintenance logs.
5.5.5 Coagulation process

For an UF plant with a coagulation system it is very important that the
coagulation process is operating properly. A proper working coagulation
process will result in the desired flocks and consequently stable plant
operation with good performance.
An indication for an ineffective coagulation system is the presence of
coagulant, soluble Al or Fe, in permeate.
Factors that can influence the coagulation process are:

• Coagulant concentration
• Initial mixing into the water
• Retention time
• Coagulation pH
• Temperature
Therefore the following parameters have to be monitored:
• Coagulant dosing concentration, measured in the coagulated feed water.
80
• Coagulated feed water pH.
• Coagulant passing the membrane, permeate samples have to be taken from a
unit and not from a tank collecting permeate
• The flow output of the chemical dosing pumps has to be checked weekly.
5.5.6 Sample Frequency

In the first week after start-up the parameters for monitoring the coagulation
have to be monitored on a daily basis. After the first week, if the coagulation
system is operating as should be, the sample frequency can be reduced to once
per week.
5.5.7 Feed en permeate quality
Important, contractual, feed and permeate water quality data, for plant
operation, that is not logged automatically has to be manually analyzed and
logged.
Examples of possible water analysis are:
• Feed water:
• Turbidity
• TOC
• Total suspended solids
• Color
PERMEATE
• Bacteriology
• Color
• Al or Fe concentration
Water quality data results can be used as a reference for plant performance
evaluation, for future optimization, reacting on water quality changes and
trouble-shooting.
81
Parameters that are not measured in-line have to be sampled on daily basis
during the first week after start-up. After the first week without excursions in
the sample results, the sample frequency can be reduced to once per week.
5.5.9 Membrane integrity

Monitoring of the membrane integrity can be performed manually as well as
automatically.
Some UF units are equipped with an automated integrity test. Settings

for monitoring the membrane integrity have to be optimized to
reduce down-time of a unit.
When the unit is not equipped with an automated integrity test, a pressure
decay integrity test can be performed, see related documents.
A pressure decay membrane integrity test shall be performed when the

permeate quality is not according to the water quality expectations.
Automatic membrane integrity testing frequency must be discussed and
agreed upon with the client.
5.5.11 Settings
Optimizing the system can only be done by changing settings. Setting changes
have to be recorded. Setting records can be used to evaluate the effects of
setting changes.
When settings are changed the old and new settings have to be recorded with
the time, date and person who changed the setting.
Settings changes have to be recorded in a dedicated log book that is available
for everybody who is allowed to change settings.
When, after take over by client, uncontrolled changes to operating conditions,
software functionality or software settings might negatively impact UF plant
performance and consequently performance and membrane lifetime. If the
customer proposes to make changes to operating conditions, software
functionality or software settings which might impact performance of the
82
UF/NF membrane units, Pentair shall be informed about the intended change.
This shall be done preferably prior to, but not more than 24 hours after the
change by fax.
Pentair will advise the Customer that the change is or is not accepted.
5.5.12 Preconditions for flushing
• Local control station and push button pendant connections are checked,
commissioned and energized.
• Whole UF system including UF BF tank is cleaned and free of debris.
• All electrical connections are checked and energized.
• Intake, RF and Self Cleaning strainers shall be commissioned & operational.
• Required pipe work and instrumentation are pre-commissioned and ready

for operation
• The Compressor system is commissioned & operational to provide oil free

air for integrity testing.
• Back flush tank and back flush pumps are pre-commissioned
• CEB system is pre-commissioned
• UF Cleaning In Place (CIP) system is commissioned
• The vent valves at the self cleaning strainers, UF inlet & outlet headers to
be in open position.
• All drain valves shall be in closed position.
• Drain and Neutralization Systems are commissioned to receive waste water
• All pressure transmitters, level switches primary valves shall be in open

position.
• Temporary connection (GRP or PVC) between UF inlet & outlet headers DN

300 to be installed.
• All High pressure pump inlet valves in RO building shall be in closed

position.
83
• The UF feed flow meter FIT shall be pre-commissioned.
• Ultra filtration strainers dPTI instruments has been pre-commissioned.
• UF Strainer motors and pneumatic valves has been pre-commissioned and

checked for function and rotation.
5.5.13 Procedure
• One pump at Intake station and few Roughing filters are in operation
• Filtrated water is passing via dump valve into a culvert
• Open inlet valves at the UF strainers following manufacturer O&M
Instruction manual. Take care for proper de-aeration.
• When the priming is completed, close all manual vent valves.
• Monitor the diff pressure of self cleaning strainers. If the DP crosses its
allowed limit, manually start strainer back flush sequence from local control
panel.
• Water is now passing via UF inlet and outlet headers by pass spools and via
DN 450 dump line to culvers.
• Increase the flow and pressure to maximum possible to increase efficiency of

flushing.
84
•
Flush the piping for at least 5 ~ 10 hours.

• Repeat for all UF racks piping.
NOTE: Before the UF module installation remove temporary

interconnection spools between UF inlet & outlet header and install
blank flanges!
NOTE : For commissioning of the UF Moduls follow procedure from

Norit O&M Instruction Manual with help of Chapters 5.1, 5.2, 5.3, 5.4,
and 5.5 from above.
5.6.0. FLUSHING & COMMISSIONING OF THE UF CHEMICAL CLEANING

SYSTEM
5.6.1 Preconditions
• UF Cleaning tank is cleaned, flushed and filled with RO permeate water by
flushing pumps.
• All system instrumentation has been commissioned.
• Pipe system and associated valves have been commissioned.
• Cartridge Filter elements are not installed in UF Cartridge Filter.
• CF dPI and all instrumentation is pre-commissioned
• UF Cleaning Pumps are pre-commissioned and ready for operation (dry run
protection is activated).
• Flushing spools for UF CIP inlet and UF CIP outlet are installed.
• UF Cleaning Flow Meter is pre-commissioned.
• CIP tank mixer is tested and pre-commissioned
85
•
• Dry run protection for CIP mixer and CIP pumps is set and tested
• Water heater has been wired and pre-commissioned
CIP flow meter has been pre-commissioned

• Neutralization to be ready and pre-commissioned
5.6.2 Procedure
The following valves are closed:

• UF Chemical Cleaning Pump inlet isolation valve.
• UF Chemical Cleaning Pump discharge isolation valve.
• UF Chemical Cleaning Pump recirculation valve.
• UF Cleaning Cartridge Filter outlet isolation valve.
• UF rack Cleaning inlet isolation valve.
• UF rack Feed isolation valve.
• UF rack Feed drain valve.
• UF rack waste water drain valve.
• UF rack Air inlet valve.
• Or if UF rack are still not installed use temporary GRP spools to re-connect
the CIP system
Warning: Always start the centrifugal pumps against closed or
very slightly opened discharge valve if downstream pipes are
empty.
• Open UF Chemical Cleaning Pump suction isolation valve.
• Open UF Chemical Cleaning Pump discharge isolation valve.
• Crack open UF Chemical Cleaning Pump recirculation valve.
• Slowly open UF Cleaning Cartridge Filter inlet isolation valve.
86
•
• Check UF Cleaning Cartridge Filter vent valve
• Close inlet / outlet piping of UF rack to be flushed and set the following
valves:
Note: The UF rack to be flushed should be the one, which is most far
from the UF Cleaning System. The purpose of such selection is to flush
full length of the feed and return cleaning pipes.
Check level of UF Chemical cleaning tank and refill if necessary by opening

permeate inlet valve from Flushing pumps.
Note: This part of the flushing sequence will allow the cleaning pipes
and UF block (feed and concentrate side, if installed) to fill with water
and thus reduce the amount of air within the system at pump startup.
During this period and the subsequent flushing, all joints and
connections should be checked and sealed as required.
• Close permeate water inlet isolating valve.
• Close manual vent valve on line between UF Cleaning Cartridge Filter and UF
rack.
• Close UF rack filtrate return valve.
• Close UF Cleaning Cartridge Filter outlet isolation valve.
• Close UF Chemical Cleaning Pump discharge isolation valve. This valve can
be left crack opened.
• Start the UF Chemical Cleaning Pump/Slowly open Cleaning Pump discharge

isolation valve to its fully open position.
• Slowly open Cleaning Pump recirculation valve and adjust pump discharge
pressure to xx bars as stated at the pump name plate
• Re-circulate water for 10 minutes back to the tank
87
•
• Slowly start to open UF Cleaning Cartridge Filter outlet isolation valve and at
the same time start to close Cleaning Pump recirculation valve.
• Adjust flow to 150-200 m3/h. Check flow on flow meter.
• After 2 minutes slowly open UF Cleaning Tank concentrate CIP return valve.
• Increase the flow to 300 m3/h, either using UF Cleaning Cartridge Filter
outlet isolation valve or UF Cleaning Tank outlet return valve.
Note: During recirculation, observe behavior of the pump and check

for unusual noise, vibrations or leaks.
88
• Re-circulate water for 60 minutes and then:
Warning: Do not close UF Cleaning Tank outlet return valve fully!!! Flow
through UF filtrate CIP return line shall not exceed 30m3 / hr.
• Follow with recirculation for next 10 minutes
• At the end of recirculation period stop the CIP pumps and close the UF rack
Cleaning Product return valve.
• Open UF Cleaning Tank outlet dump valve and at the same time close UF
Cleaning Tank outlet return valve.
• This will allow the content of the UF Chemical Cleaning Tank to be drained
down. The level of the tank should be observed and the following actions
undertaken prior to the pump tripping on low level:
Note: Take sample of water from Cleaning Tank via drain valve before
the Cleaning Pump is stopped. If the sample is particularly dirty,
consideration should be given to draining the system completely and
repeating flushing.
• Close UF Chemical Cleaning Pump inlet isolation valves, discharge isolation

valves (can be left crack opened) and open UF Cleaning Tank drain valve to
neutralization. Refill the UF Cleaning Tank and repeat flushing with second
UF Cleaning Pump for flushing the other UF racks.
5.7.0 FLUSHING OF THE UF BACKFLUSH SYSTEM

Attention: Consider safety instructions and good operational practice. Where
the procedure is executed from MCC room, bear in mind that alarms and trips
are not active.
5.7.1 Preconditions
• Drain system (culvert) is commissioned and ready to take waste water
89
• UF Back wash tanks and Pump Chambers are clean from any construction
debris and filled with service water or filtered seawater.
• Temporary suction strainer is installed on UF Back wash pump suction line.

• Level transmitter is commissioned and ready for operation.
• Pressure transmitters and are commissioned and ready for operation.
• Flow meter is commissioned and ready for operation.
• Associated pipe work and valves are commissioned and ready for operation.
• UF Back wash pumps are pre-commissioned.
• Temporary spools between backwash inlet and backwash outlet lines are
installed.
• Isolation valve at the outlet line to culvert is open
The following valves are opened:
• Back wash pump inlet isolation valve

• UF rack back flush inlet valve.
• Back wash line manual vent valve.
• Instrumentation isolation valves.
• Back wash Tank drain isolation valve.

• Back wash Tank inlet valve.
• Back wash Pump discharge isolation valve.
5.7.2 Procedure
Warning: start the pump against closed or very slightly opened
discharge valve if the pipes are empty!!!
Note: Study and be familiar with the installation, O&M Instruction

Manual from pump manufacturer for UF Back wash Pumps and
Motors.
• Crack open the back flush Pump discharge isolation valve.
90
• Start back flush Pump.
• Slowly open the pump discharge isolation valve and adjust to the
predetermined flow. Check the flow on flow meter.
• Check the pump discharge pressure on pressure transmitter.
• Check the water flow from back wash line manual vent valve. It should be
clear without of air bubbles. Cloudy water indicates air presence in the water.
Close the valve if water is clear and system free of air.
• Flushing water is passing now via BW piping and temporary spool to the
culvert
• Check the pump for vibrations and any unusual noise
• Stop the pump before water level in the Back flush Tank drops to minimum
• Refill the Back flush Tank and repeat the procedure with second Back flush
Pump
• Repeat flushing procedure for all UF racks

Upon completion of the flushing:
• Drain down the back flush Tank, the back flush Pumps and the associated back
flush header pipes, and remove the temporary back flush Pump suction
strainers.
6.0.0 FLUSHING & COMMISSIONING OF CHEMICAL DOSING SYSTEMS

Important Note: Observe safety regulations when working with chemicals. Always
use Personal Protection Equipment (PPE) like gloves, glasses, shield, rubber suit
etc., when working with chemicals!!!!
Ensure that utility water is available for operation of safety showers.
Study and familiarize yourself with Chemical Safety Data Sheets of all chemicals
used on site. Chemical data sheets are at the end of file as enclosure.
6.1.0 FLUSHING & COMMISSIONING OF THE FERRIC CHLORIDE DOSING SYSTEM.
For safety of the work study and follow attached ASC safety data sheet.
91
6.1.1 Precondition for flushing of the Filling pumps.
• Connect suction of the Filling pumps to the clean Temporary tank
• Fill Tank with Service water to the top of the Tank.
• Filling pumps are pre-commissioned as per manufacturer O&M Instruction

Manual, all piping is connected and pressure indicators are connected.
• Discharge piping from Filling pumps to the Ferric Dosing Tanks is opened
6.1.2 Procedure:
• Read and consider O&M Instruction Manual from Filling pumps manufacturer.
• The pumps are pre-commissioned, oil level checked, power supply and control
cables connected and tested.
• Open Temporary tank outlet valve
• Open suction valves for Ferric Filling Pumps
NOTE: There is no DRY RUN PROTECTION FOR THE FeCl3 FILLING PUMPS
AVAILABLE. Dry run protection depend from operator, to switch off the filling
pumps in right time, immediately when Tanker is empty or latest when suction
of the pump will be aerated.
• Start Filling pump and open discharge valve at discharge piping to the NaOH
Dosing Tanks. Run the pump as per operational curve, obtained in the O&M
Instruction Manual.
• Observe the behavior of the Filling pump for unusual sounds, vibrations,
discharge pressure or leaks. When everything is OK, stop filling pump and
repeat the test with second filling pump.
Filling pumps are Commissioned and ready to receive NaOH solution
6.1.3 Precondition for flushing of the Ferric dosing system:
• Ferric dosing tanks are cleaned & level indication is pre-commissioned.
92
• Potable water is available in ferric storage tank.
• Read and consider operation manual from dosing pumps manufacturer.
• The dosing pumps are pre-commissioned, oil level checked, power supply and
control cables connected and tested.
• The piping to the dosing location is pre-commissioned (upstream of Roughing

Filters & UF dosing Point) and opened.
• Dampeners at the discharge piping of the Ferric Dosing pumps are

precommissioned and charged with air or nitrogen to required operational
pressure.
• Pressure indicators (PI) are installed and tested.
• The dosing pump inlet/suction strainers are installed.
6.1.4 Procedure
• Open Ferric storage tank outlet valve
• Disconnect the suction piping from both dosing pump and flush the line.
Connect piping back and open Dosing Pump inlet isolation valves.
• Open dosing pump outlet isolation valve, vent the pump.
• Start one dosing pump, adjust its stroke (refer to supplier instructions) and
speed slowly to 25% capacity and flow and allow pump to prime. Afterwards
increase capacity and speed to 50%, 75% and to the 98-100% setting. This may
require the discharge pipe to be vented by unscrewing a connection of the
discharge pipe.
• Run the pump in maximum stroke and speed for 2 hours observe for unusual
sound and behavior.
93
• Ensure that pressure relieve valve back to the tank and pressure sustaining
valve at dosing line are properly set to required pressures to avoid damage/
overloading of the pumps.
• When completed, stop the pump and start the next unit. Ensure on completion
that all connections are secure.
• Ensure that the flushing water from the dosing pump, piping & from the
storage tank is drained completely.
• Ensure that dry run protection for the pumps has been tested during test and
minimum level is set.
Warning: Stroke length of the pump can be adjusted only when the
pump is in operation !!!!!
• Ferric dosing tank is cleaned & pre-commissioned.
• Process liquid is continuously available for the feed headers & carrier water
piping for the commissioning.
• Ferric chloride is available in ferric storage tank.
• The dosing pumps are flushed and calibrated as per manufactures O&M
instruction manual.
• The piping to the dosing location is flushed (upstream of Roughing filters and &
upstream of UF dosing point).
• All instruments and signals from Roughing Ph2 and RF turbidity are installed,
checked & pre-commissioned.
• The dosing pump inlet strainer is installed.
• Whenever low level alarm (LL) in solution tank is indicated, the tank must be
re-filled with fresh solution immediately.
94
6.1.6 Procedure
• Open Ferric storage tank outlet valve
• Open Dosing Pump inlet isolation valves.
• Open dosing pump outlet isolation valve.
• Start one dosing pump, adjust its stroke and speed (refer to supplier
instructions) Taking to consideration also operational conditions of the plant
(dosing rate and media flow) and allow pump to prime. Keep in operation in
automatic mode of operation for required time.
• Observe for proper operations of the pump, PRV and PSV.
• Once first pump is commissioned, stop the pump and start the next unit.
Ensure on completion that all connections are secure.
6.1.7 Coagulant Dosing and Preparation.
• Ferric chloride may be used and dosed as a coagulant to improve removal of

suspended solids and colloidal matters by filtration. FeCl3 is used also during
algae bloom season to enhance efficiency of RF’s. The dosing system is based
on FeCl3 industrial chemical and is equipped with duplicate dosing tanks and 2
x 100% dosing pumps. Ferric Chloride (FeCl3) is delivered in plastic drums (200
liters – 280 kg) of FeCl3. Commercial liquid technical ferric chloride is supplied
with concentration of 40% w/w and liquid density of 1.4 kg.
• Chemical: Ferric chloride FeCl3 40% solution

• Dosing concentration: 40 %
• Design Dosing rate: 3 g Fe / m³ or 8,7 g FeCl3 / m³
• Adjustment of dosing rate – for manual plant operation

Specific dosing rate: 3 mg/l as Fe
Flow rate: 1480 m³ / hour
95
Concentration in tank: 40 % = 567, 2 g/l as FeCl3
the factor for recalculation Fe / FeCl3 is 2, 9
1480 m³/ h × 3 g / m³ × 2,9

Dosing rate: = 22,70 l / h
567,2 g /l
If 3 mg/l Fe shall be dosed in the process flow of 1480 m³/h the dosing pump flow shall
be adjusted with up and down arrows to 22, 70 l/h.
The dosing rate has to be checked regularly and adjusted when the water
condition is changing.
6.2.0 FLUSHING & COMMISSIONING OF ANTI_SCALANT DOSING

SYSTEM.
For safety of the work study and follow ASC safety data sheet received
from ASC suppliers!
6.2.1 Precondition for flushing of the Filling pumps.
• Connect suction of the Filling pumps to the clean Temporary tank
• Fill Tank with Service water to the top of the Tank.

Manual, all piping is connected and pressure indicators are pre-commissioned.
• Discharge piping from Filling pumps to the ASC Dosing Tanks is opened
6.2.2 Procedure:
• Open Temporary tank outlet valve
• Open suction valves for ASC Filling Pumps
96
NOTE: There is no DRY RUN PROTECTION FOR THE ASC FILLING PUMPS
pumps in right time, immediately when Tanker is empty or latest when suction
of the pump will be aerated.
• Start Filling pump and open discharge valve at discharge piping to the ASC
Instruction Manual.
• Filling pumps are Commissioned and ready to receive ASC solution.
• The anti scalant tank (ASC) is thoroughly cleaned and filled with service water.
• Potable water is available in the storage tank.
• ASC tanks mixers are wired, oil level is checked and are pre-commissioned
• Dry run protection level indicators at the ASC tanks are installed and tested
• Dampeners at the discharge piping of the ASC Dosing pumps are

pressure.
• Pressure indicators (PI) and flow switches (FS) are installed, wired and tested.
• The piping to the dosing location is pre-commissioned (upstream of SWRO feed

& BWRO pumps).
97
6.2.4 Procedure
• Start ASC tank mixer in both tanks, observe for unusual noise and vibration
• Disconnect the suction piping from both dosing pump, flush the lines, and
check the strainers.
• Connect piping back and open ASC storage tank outlet valve
increase capacity and speed to 50%, 75% and to the maximum setting. This
may require the discharge pipe to be vented by unscrewing a connection of the
discharge pipe.
• Run the pump in maximum stroke for 2 hours observe for unusual sound and
behavior.
• Ensure that dry run protection for the pumps has been tested and minimum
level set.
Warning: Stroke length of the pump can be adjusted only when the pump is in
operation !!!!!
98
• ASC dosing tanks are is cleaned & pre-commissioned.
• Process liquid is continuously available for the SWRO and BWRO feed headers
for the commissioning.
• ASC is available in ASC storage tank.
• The dosing pumps are flushed.
• The piping to the dosing location is flushed (upstream of SWRO feed & BWRO
pumps).
• All instruments are installed & pre-commissioned.
refilled with fresh solution immediately.
6.2.6 Procedure
• Open dosing tank outlet valve
• Open the dosing Pump discharge isolation valves.
• Open Dosing Pump suction isolation valves.
automatic mode of operation for required operational time.
operation !!!!!
99
• The dosing of Anti scalant (ASC) shall ensure that the scaling potential in the RO
brine is below the solubility limits of sparingly soluble salts in case of no acid is
dosed in the pre treatment. At pH values of below 7, 5 usually no ASC is
required.
• Anti scalant is usually delivered as a liquid in the plastic drums or barrels is size
depending from its manufacturer and order. If using a powder trade product,
dosing of ASC requires the operation of the utility water pumps – one in operation,
the second standby, which feed the mixing tanks with permeate from the permeate
tanks.
In manual mode, the dosing of the chemicals is controlled by adjustment of the dosing
rate from the operator panel on the relevant dosing pump.
Mixers in the dosing tanks are only operated manually during preparation of the
solution. Usually ASC is overdosed by approx. 20% for safety reason.
6.2.8 Solution preparation - determination of concentration.
• The ASC is usually dosed as trade product undiluted, but also powder-trade
products are available, for with a dilution with permeate by carrier water
pumps is necessary.
Adjustment of dosing rate - Example Calculation

Specific dosing rate: 2 mg/l as Na2S2O5
Concentration in tank: 100 %
1480 m³/hour*2 g/m³ liter
Dosing rate: = 2,96
1000 g/liter hour
6.3.0 FLUSHING & COMMISSIONING OF NON-OXIDISING BIOCIDE DOSING

SYSTEM.
For safety of the work study and follow Non-Oxidising Biocide Safety data
sheet received from Biocide suppliers.
100
• The Biocide tanks are thoroughly cleaned and filled with service water.
• Service Water is available in the storage tank.
• Read and consider O&M Instruction Manual from dosing pumps manufacturer.
• Biocide tanks mixers are wired, oil level is checked and are pre-commissioned
• Dry run protection level indicators at the Biocide tanks are installed and tested
• Dampeners at the discharge piping of the Biocide Dosing pumps are

pressure.
• Pressure indicators (PI) are installed tested.
• The piping to the dosing location is pre-commissioned (Flushing Pumps, BW

lines Ph2+Ph3).

6.3.2 Procedure
• Start Biocide tank mixer in both tanks, observe for unusual noise and vibration
• Connect piping back and open Biocide storage tank outlet valve
101
may require the discharge pipe to be vented by unscrewing a connection of
the discharge pipe.
• Run the pump with maximum stroke adjustment for 2 hours observe for
unusual sound and behavior.
• When completed, stop the pump and start the next unit. Ensure on
completion that all connections are secure.
level set.
• Biocide dosing tanks are is cleaned & pre-commissioned.
• Process liquid is available for the Flushing Pumps and Back wash line Ph2+Ph3
• Biocide is available in Biocide storage tank.
• The piping to the dosing location is flushed
102
•
All instruments are installed & pre-commissioned.
The dosing pumps inlet strainers are installed and free of debris.
6.3.4 Procedure
instructions) as per process requirement taking to consideration operational
conditions of the plant (dosing rate and media flow) and allow pump to prime.
Keep in operation in automatic mode of operation for required operational
time. When required change specific dosing rate and frequency at VFD when
in manual mode.
• Change to automatic mode of operation, and observe how system is working.
6.3.5 Biocide Dosing and Preparation.
The Biocide is dosed normally once per week in order to prevent bio-fouling
caused by the effects of chlorination.
103
• Dosing is carried out for a certain time period (some minutes - hours) with a
concentration of 15 – 20 ppm (for detailed info see data of trade-product
manufacturer).
• The dosing-rate of Biocide is determined by calculation programs, which are

available from the suppliers of Biocide.

Specific dosing rate: 20 mg/l
Dosing rate: = 29,6
1000 g/liter hour
6.4.0 FLUSHING & COMMISSIONING OF SODIUM BI-SULPHITE DOSING

SYSTEM.
For safety of the work study and follow attached Sodium-Bisulphite
Safety data sheet.
• The SMB tanks are thoroughly cleaned and filled with service water.
• Service Water is available in the Storage tank.
• Read and consider O&M Instruction Manual from dosing pumps

manufacturer.
• SMB tanks mixers are wired, oil level is checked and are pre-commissioned
• Dry run protection level indicators at the SMB tanks are installed and tested
104
•
•
• Dampener at the discharge piping of the SMB Dosing pumps are
pressure.
• The piping to the dosing location is pre-commissioned (Dosing Point

downstream of UF and Neutralization System).
The dosing pump inlet/suction strainers are installed.
Ventilation above the dosing and preparation tanks is installed and

precommissioned.
6.4.2 Procedure
• Start SMB tank mixer in both tanks, observe for unusual noise and vibration
• Connect piping back and open SMB storage tank outlet valve
may require the discharge pipe to be vented by unscrewing a connection of
the discharge pipe.
• Run the pump with maximum stroke adjustment for 2 hours observe for
unusual sound and behavior.
105
level set.
operation !!!!!
• SMB dosing tanks are is cleaned & pre-commissioned.
• Ventilation above the dosing and preparation tanks is active and working.
• SMB solution was prepared as per required concentration and is available in

SMB Dosing tank.
• The piping to the dosing location is flushed
• The dosing pumps inlet strainers are installed and free of debris.
6.4.4 Procedure
106
•
•
instructions) as per process requirement taking to consideration operational
conditions of the plant (dosing rate and media flow) and allow pump to prime.
Keep in operation in automatic mode of operation for required operational
time. When in manual mode of operation and required, change specific dosing
rate at dosing pump and frequency at VFD manually.
Change to automatic mode of operation, and observe how system is working.
Observe for proper operations of the pump, pressure relive valves (PRV) and
pressure sustaining valves (PSV).
• Once first pump is commissioned, stop the pump and start the next unit
following above mentioned procedure. Ensure on completion that all
connections are secure.
operation !!!!!
• The dosing of Sodium-Meta-Bisulfate (SMB) = Na2S2O5 shall ensure that the
free chlorine content does never exceed 0.1 mg/l or a corresponding value of
ORP of the feed water.
When dissolved in water SMB gives a solution of sodium-hydrogen sulfite Na

(HSO3):
Na2S2O5 + 2OH− ⇔ 2 Na+ + 2 SO32− + H2O
For elimination of 1 mg of chlorine approx. 1, 4 mg of SMB are required

according to
SO32− + Cl2 + 2OH− ⇔ SO24− + 2Cl− + H2O
107
Free oxygen content is reduced according to the reaction
2 SO32− + O2 ⇔ 2 SO24−
6, 25 mg of SMB per 1 mg of oxygen is consumed. However this reaction is

much slower than chlorine reduction.
• Usually SMB is overdosed by approx. 20% for safety reason
• The SMB is dosed flow proportional to the sum of the flow of RO 1st pass Trains
• SMB – dosing is required only when a pre-chlorination system is in operation.

It shall be started at the time when chlorine dosing is started and SMB shall
remain in operation at least 2 hours at full load when chlorine dosing in the
pre treatment is stopped. If the pre treatment is in operation at partial load,
SMB shall remain in operation correspondingly longer. The ORP measurement
downstream of the cartridge filters shall be at all times below 350 mV.
6.4.6 Preparation of SMB solution for the first filling
• Fill the clean tank with 500 liter water. Start the mixer and add the content of 2
bags SMB (25 kg each) for a solution of 10%.
• Continue mixing for about 15 minutes until the SMB is dissolved completely.
Stop the mixer and the solution can be used.
6.4.7 Preparation of SMB solution during normal operation.
• At level alarm low the tank shall be changed over to the standby tank which
was prepared as described before.
• Add the necessary amount of water to have the tank filled with 500 liters. Start
the mixer and add the content of x bags SMB (25 kg each) in order to get a 10%
solution. (E.g.: If 400 liters added, 40 kg SMB shall be added.)
• Continue mixing for about 15 minutes until the SMB is dissolved completely.
Stop the mixer and the solution can be used.
• Table 3: Properties of SMB- Solution (MW g/mol)
108
•
•
Concentration Concentration Solution
SMB SMB density in
in [%] in [kg/l] [g/l]
5% 0,051 1,03
10% 0,106 1,06
15% 0,165 1,10
109
Specific dosing rate: 5 mg/l as Na2S2O5
Concentration in tank: 10% = 106 g/l

Dosing rate: = 69,81
106 g/liter hour
6.5.0 FLUSHING & COMMISSIONING OF THE CHLORINE DOSING SYSTEM

For safety of the work study and follow attached chlorine safety data sheet.
The chlorine dosing system is divided into three parts and shall be commissioned
before start up of the Sea Water Intake pumps:
1. Chlorine dosing into Sea Water Intake Pre-chlorination,
2. Chlorination CEB-1
3. Chlorine dosing for Post-chlorination in Product Water Tank
6.5.1 Precondition for flushing
• Service water to the Pre-chlorination, Chlorine storage room showers Chlorine
detection leak sensors and extraction fans are ready and pre-commissioned •
Filtered water is available for Pre-chlorination booster pumps

• MCC is commissioned, energized and in working condition
• Local control station and push button pendant connections are checked,
commissioned and energized
• PLC and VDU is working
110
• Automatic change over device is wired, tested and ready for operation
• Vacuum regulators are installed and ready for operation
• Neutralization system shall be ready and pre-commissioned to receive

chlorinated water from chlorine storage room in case of any malfunction.
• The pre-chlorination booster pumps are installed and ready for

precommissioning as per manufacturer O&M Instruction Manual.
• The post-chlorination booster pumps are installed and ready for

precommissioning as per manufacturer O&M Instruction Manual.
• The CEB 1 booster pumps are installed and ready for pre-commissioning as per
manufacturer O&M Instruction Manual.
• The dosing piping is installed, flushed & pre-commissioned.

• All valves and instrumentation are connected and ready for operation
6.5.2 Procedure
Note: Be familiar with operation and maintenance manuals of the Service Water
System as per manufacturer O&M Instruction Manual.
• All Booster Pumps suction isolation valves.
• All Booster Pumps discharge isolation valves
• Inlet valves for injectors
• Filtrated water inlet valve • Service Water Hydro pore inlet
• Hydro pore vent valve.
6.5.3 Procedure for PRE chlorination
• Crack open PRE chlorination booster water pump suction inlet isolation valve.
111
• Slightly unscrew the BOOSTER Pump vent screw and observe water flow
through the vent. When there is no air in the water, tight the vent screw.
• Reinstall the plug and fully open the Booster Water Pump suction inlet isolation
valve. Repeat above procedure on remaining Pre-chlorination /
Postchlorination (POST) Booster Water Pumps
• All pumps are de-aerated
• Slowly open Pre-chlorination (PRE) Booster Water Pumps discharge isolation

valve.
Depending on the pressure in RF outlet line, the system will be filled with
filtered water and air removed from pipes.
• Open motorized valve at DN 160 line to Sea Water Intake
• Open both isolation valves for inlet/outlet to ejectors
• Start the PRE Booster Water Pump.
• Observe the vacuum regulators and adjust when required
• Run the pump for 2-3 hours and check for unusual noise, vibrations,
temperature.
• Repeat the same for other second PRE booster pump.
• The PRE-chlorination booster pump system is now checked and ready for
operation.
6.5.4 Procedure for CEB 1 chlorination
• The same procedure is applicable for CEB 1 Chlorination Booster pumps
• CEB 1 chlorination booster pumps open isolation valve from UF Filtrate line •
Open CEB 1 Booster Pumps suction isolation valves, vent pumps both pumps
• Start the CEB 1 Booster Water Pump.
112
• Slowly open the CEB 1 Booster Water Pumps discharge isolation valve and
adjust discharge pressure.
• Check vacuum at Vacuum regulator
temperature.
• Repeat the same for other second CEB 1 booster pump.
• The CEB 1 chlorination booster pump system is now checked and ready for
operation.
6.5.5 Procedure for POST chlorination
• Open isolation valve for Permeate water from Product water pump station •
Open Booster Water Pumps suction isolation valves, vent pumps both pumps
• Start the POST Booster Water Pump.
• Slowly open the POST Booster Water Pumps discharge isolation valve and
adjust discharge pressure.
• Check vacuum at Vacuum regulator and adjust when required
temperature.
• Repeat the same for other second POST booster pump.
• The POST chlorination booster pump system is now checked and ready for
operation.
6.5.6 PREPARATION OF THE CHLORINE STORAGE ROOM.
• MCC is commissioned, energized and in working condition
113
• Local control station and Change over device are checked, commissioned and
energized
• PLC and VDU is working
• The chlorine dosing piping is installed, flushed & pressure tested with
nitrogencommissioned.
• All valves, catch pot / expansion chamber and instrumentation are connected
and ready for operation
• Chlorine scales are commissioned and tested
• Chlorine drums are available at scales ready for operation
• Vacuum regulators are installed and ready for commissioning
• All chlorinators are installed, valve limit switches adjusted, energized, ready
for commissioning.
• Service water system, chlorine detector, extraction fans and sprinkling system
are ready for commissioning.
• Neutralization system is commissioned
6.5.7. Pre-condition for commissioning
• If previous chapters are successfully completed, keep all equipment in

operation and follow instruction below to start commissioning of the Chlorine
dosing system
• PRE, CEB 1 a POST Booster pumps are in operation as required by process
• Vacuum from ejectors is sufficient
• All piping and valves is ready for operation
• Injection points are opened
• Chlorine drums are in position ready to be opened
• Change over valves is in position for one of the drums No.1 or No2.
114
• Open outlet valve from selected drum, check pressure at PI
• Automatic chlorine controllers are installed, wired and set
• Open inlet and outlet valves at selected Pre-chlorinator and adjust flow of
chlorine gas to required process flow.
• Open inlet and outlet valves at selected CEB 1 chlorinator and adjust flow of
• Open inlet and outlet valves at selected Post-chlorinator and adjust flow of
• Repeat the same for all remaining chlorinators for Pre-chlorination, CEB 1
chlorination and Post-Chlorination.
Adjustment of chlorine dosing rate.
Chlorine is dosed proportionally to the sea water inlet flow, CEB 1 flow to UF
and product water flow for post-chlorination.
Example Calculation for Pretreatment
Specific dosing rate: 2 mg/l as Cl2
Dosing Rate: 2.96 kg/hour
6.6.0 FLUSHING & COMMISSIONING OF HYDROCHLORIC ACID DOSING SYSTEM.

For safety of the work study and follow attached Hydrochloric Acid safety
data sheet.
6.6.1 Precondition:
• Hydrochloric acid is mainly used for CEB of the UF plant. Acid is directly drawn
from delivery IBC’s tanks. Since the Hydrochloric acid is 31% concentrated,
make sure that all piping is completed & pre-commissioned.
115
• It is not recommended to flush the acid with potable water due to the
chemical properties of hydrochloric acid and exothermic reaction. Therefore,
flushing with potable water cannot be carried out. For cleaning purposes
instrument or service air shall be used and all piping shall be blow up for at
least 20 minutes.
• Hydrochloric acid shall be available in IBC’s storage tank.
• The dosing piping from dosing pumps to RO CIP, UF CIP, Neutralization, and UF
units 1-13 is pre-commissioned.
• HCL absorption filter is installed and level measurement instrumentation

(LI,LSL, LSLL) for dry run protection of the pumps is commissioned.
• Review the O&M Instruction Manual from piston dosing pump manufacturer.
• Neutralization pit and neutralization dosing pumps are pre-commissioned.
6.6.2 Procedure for commissioning.

• Open the outlet valve of hydrochloric acid storage tank
• Start one of piston dosing pump (UF_RO CIP + Neutralization), adjust its
stroke and speed (refer to supplier instructions) as per process requirement
taking to consideration operational conditions of the plant (dosing rate and
media flow) and allow pump to prime using personal protection equipment.
On completion of priming ensure that all connections are secure.
• Change to in automatic mode of operation with pH control for required

operational time. When in manual mode of operation is required, change
specific dosing rate at dosing pump and frequency at VFD manually.
• Observe for proper operations of the pump, pressure relive valves (PRV) and
pressure sustaining valves (PSV).
116
• Once first pump is commissioned, stop the pump and start the next unit
following above mentioned procedure. Ensure on completion that all
connections are secure.
• Make sure the pump stops automatically when the IBC tank level reaches LSLL
level. If not, immediately stop the pump manually.
• Confirm no leak in the piping by checking the leak detectors.
• When pumps to CIP and Neutralization are commissioned follow the same
procedure for HCL dosing pumps with second set of the dosing pumps for CEB
to UF Units 1-13 (CEB).
operation !!!!!
6.7.0 FLUSHING & COMMISSIONING OF THE NaOH DOSING SYSTEM.

For safety of the work study and follow attached Caustic Soda safety data
sheet.
The caustic have to be dosed in RO feed line if the RO feed pH is less than 8.0 for
the proper boron rejection. The caustic soda (NaOH) is also used for the cleaning
processes of UF & RO system.
6.7.1 Precondition for commissioning of the Filling pumps.
• Since the NaOH is 49-50% concentrated, make sure that all piping is
completed & pre-commissioned.
• It is not recommended to flush the acid with potable water due to the
chemical properties of NaOH and exothermic reaction. Therefore, flushing
with potable water cannot be carried out. For cleaning purposes instrument or
service air shall be used and all piping shall be blow up for at least 20 minutes.
• NaOH is available in IBC’s storage tanks.
• The dosing piping from dosing pumps to RO CIP, UF CIP, Neutralization, and UF
units 1-13 is pre-commissioned.
117
• Review the O&M Instruction Manual from dosing pump manufacturer.
• Neutralization pit and neutralization dosing pumps are pre-commissioned.

Manual, all piping is connected and pressure indicators are connected.
• Discharge piping from Filling pumps to the NaOH Dosing Tanks is opened
• Safety showers are pre-commissioned
6.7.2 Procedure:
• Open IBC tank outlet valve
• Open suction valves for NaOH Filling Pumps
• NOTE: There is no DRY RUN PROTECTION FOR THE NaOH FILLING PUMPS
pumps in right time, immediately when IBC is empty or latest when suction of
the pump will be aerated.
• Start Filling pump and open discharge valve at discharge piping to the NaOH
Instruction Manual and continue with filling of the NaOH tanks.
• Filling pumps are commissioned and ready for operation
6.7.3 Precondition for commissioning of the NaOH Dosing System.
• Read and consider O&M Instruction Manual from dosing pumps manufacturer.
118
• NaOH tanks mixers are wired, oil level is checked and are pre-commissioned
• Dry run protection level indicators (mixers – dosing pumps) at the NaOH tanks
are installed and tested
• Dampener at the discharge piping of the NaOH Dosing pumps (if installed) are
pre-commissioned and charged with air or nitrogen to required operational
pressure.
• Heating system in the NaOH Dosing Tanks is installed, wired, tested and ON.
• The piping to the dosing location (UF CIP, RO CIP, Neutralization) is

precommissioned
6.7.4 Procedure
• Start NaOH tank mixer in both tanks, depending from level of NaOH in the
tans, observe for unusual noise and vibration
• Connect piping back and open NaOH storage tank outlet valve
speed slowly to 25% capacity and flow and allow pump to prime. This may
require the discharge pipe to be vented by unscrewing a connection of the
discharge pipe Afterwards increase capacity and speed to 50%, 75% and to the
119
maximum setting. Run pump for certain time, if all OK set pump to operational
conditions controlled by neutralization and CIP pH and continue operation,
observe for unusual sound and behavior.
level set.
• When RO CIP, UF CIP and Neutralization NaOH dosing system are flushed
continue with Dosing to SWRO fee line, BWRO feed line UF unit 1-13 and UF
unit 14-26, following instruction above.
operation !!!!!
6.8.0 FLUSHING & COMMISSIONING ANIONIC POLYMER DOSING SYSTEM.

For safety of the work study and follow Anionic Polymer safety data sheet
received from Anionic Polymer supplier!!
• Anionic Polyelectrolyte (AP) causing severe irritation.
• Wear protective clothing.
• Do not swallow.
• Avoid contact with eyes, skin, and clothes.
• At contact, wash thoroughly with water.
• The Anionic polymer tank (AP) is thoroughly cleaned and filled with service
water.
120
• Permeate water is available in the storage tank.
• AP tanks mixers are wired, oil level is checked and are pre-commissioned
• Dry run protection level indicators at the ASC tanks are installed and tested
• Pressure indicators (PI) and flow switches (FS) are installed, wired and tested.
• The piping to the dosing location Settling TANK is pre-commissioned
6.8.2 Procedure
• Start AP tank mixer in both tanks, observe for unusual noise and vibration
• Connect piping back and open APE mixing tank outlet valve
may require the discharge pipe to be vented by unscrewing a connection of the
discharge pipe.
• Run the pump in maximum stroke for 2 hours observe for unusual sound and
behavior.
• Ensure that pressure relieve valve back to the tank is properly set to required
pressures to avoid damage/ overloading of the pumps.
121
level set.
operation !!!!!
• AP dosing tanks are is cleaned & pre-commissioned.
• Process liquid is continuously available for the SWRO and BWRO feed headers
• AP is available in AP storage tank.
• The piping to the dosing location Settling Tank is flushed • All instruments (PIS,
TS, LIT) are installed & pre-commissioned.
6.8.4 Procedure
• Prepare AP solution as per procedure described below
122
automatic mode of operation for required operational time.
operation !!!!!
6.8.5 ASC Dosing and Preparation.
• The dosing of Antiscalant (ASC) shall ensure that the scaling potential in the
RO brine is below the solubility limits of sparingly soluble salts in case of no
acid is dosed in the pre treatment. At pH values of below 7, 5 usually no ASC is
required.
• Antiscalant is usually delivered as a liquid in the plastic drums or barrels is size

depending from its manufacturer and order. If using a powder trade product,
dosing of ASC requires the operation of the utility water pumps – one in operation,
the second standby, which feed the mixing tanks with permeate from the permeate
tanks.
In manual mode, the dosing of the chemicals is controlled by adjustment of the dosing
rate from the operator panel on the relevant dosing pump.
Mixers in the dosing tanks are only operated manually during preparation of the
solution. Usually ASC is overdosed by approx. 20% for safety reason.
6.8.6 Solution preparation - determination of concentration.
• The ASC is usually dosed as trade product undiluted, but also powder-trade
products are available, for with a dilution with permeate from Flushing Tanks
by Service Water pumps is necessary.
123
• In manual mode, the dosing of ASC is controlled by adjustment of the dosing
rate from the operator panel on the relevant dosing pump. The mixers in the
dosing tanks are also operated manually during preparation of the solution.
• For automatic operation via PLC system the relevant dosing pump has to be
set for remote control from the switchboard first. Furthermore one out of two
dosing tanks has to be selected for operation by a selector switch on the
dosing on the control PC screen. The PE is dosed flow proportional to the inlet
flow.
• Refill the relevant APE vessel when level alarm low shown on PLC / SCADA.
Solution preparation / determination of concentration
AP is dosed usually at a concentration of 0, 2 % with a rate of 2 mg/l.
The AP is either available as liquid or powder trade – product. The APE is

diluted with utility water from the permeate tank in order to prepare a 0,2 %
solution.
• Adjustment of dosing rate - Example Calculation Specific dosing rate: 2 mg/l
Design flow rate: 480 m³ / hour

Dosing rate: =
0,96 1000 g/liter
hour
6.9.0 FLUSHING & COMMISSIONING OF CO2 DOSING SYSTEM.

6.9.1 Precondition
• CO2 tanks, evaporators, and CO2 piping up to the booster pump injection
point is pre-commissioned.
• Booster pumps and inlet & outlet piping, flow meters are installed &
precommissioned.
• Mass flow controllers are installed and pre-commissioned.
124
• The flushing of booster pump & associated piping can be performed by the
same procedure mentioned for carrier water flushing.
• CO2 gas in the CO2 storage tank is required to perform the above
commissioning.
• Please refer to manufacturers O&M Instruction manual for the details of
flushing & commissioning of CO2 storage tanks and its associated
equipments.
• For commissioning, Permeate transfer pumps shall be in operation to
identify the dosing requirements.
7.0.0 FLUSHING & COMMISSIONING OF THE LIME MAKE UP &

DOSING SYSTEM
7.0.1 Start up of the Lime Make up and Dosing System
Be familiar with manufacturer’s O&M Instruction Manual for Lime Silos, Lime
Milk Pumps, Lime Circulation Pumps and Lime Saturated Water Pumps
following
Preconditions
• Check if hydrated lime is available in Lime Silos

• Lime silos, feed conveyors, tank mixers, lime milk pumps, sludge pumps and
saturated lime water pumps are pre-commissioned and ready for operation
• All interconnecting piping, valves and instruments are installed
• Flow meter is ready for operation
• Service water is available
Note: Service water for Lamellae Separators is required only for first
start up of the system. When RO Trains are in operation, permeate
will be used to feed the Separators.
• Dosing line is connected to dosing point at Static Mixer
• Permeate water is available
• VFD for the Lime Slurry pumps is set and tested
7.0.2 Procedure:
125
• Open permeate water suction and discharge isolation valves for circulation
pumps
• Open permeate water isolation valves to Slurry make up tanks and to Lime
Mixing tanks
• Adjust permeate water flow to Lime Slurry Make-up Tank to e.g. 5 m3/h via
manual valve, fill all tanks ,

• Start all mixers when minimum level is reached and test the equipment
Note: Mixer must be in operation continuously as long as there is
lime slurry in the tank!!!
• Start Lime slurry pumps to Lime mixing Tanks and to Lamella Clarifier, flush
the piping
• Water is passing via Lamella Clarifiers to Saturated Lime Water Tanks
• When tanks are full and flushed start, lime water pumps to injection point in
Product Water System
• Lime System is flushed now.
• Start lime Screw Conveyor
• Start lime Feeder and add required kg of hydrated lime into the tank.
(Feeder has capacity of ___ kg/h)
• Close the permeate service water inlet solenoid when tank is full. Do not
stop the mixer!!!
• Stop the lime Feeder when required amount of hydrated lime is added to
the tank
• Open the Slurry Tank outlet manual isolation valve

• Open Lime slurry pump inlet isolation valve
• Open Lime slurry pump discharge isolation valve
Note: Discharge valve must be always opened prior start up of
Lime Milk Pumps as they are of progressive cavity type !!!
• Open lime milk inlet valve to Lime Mixing Tank
126
• Open Mixing Tank inlet flow control valve and adjust service water flow to
tank to e.g.~ 25 m3/h
• Start Mixer when water level in Mixing Tank reaches minimum

• Open Lime Milk circulation Pump inlet isolation valve and start Lime Milk
Pump
• Run the pump in the following way – 1 minute ON and 4 minutes OFF
Note: Lime Slurry Pumps are oversized by factor 5, therefore

pump is in operation for 1 minute and in standby for 4
minutes, depending from equipment design and
manufacturer. Frequency of “charging” of Lamellae Separators
must be adjusted based on lime slurry concentration, water
temperature and permeate flow.
Water is now passing through the Lamellae Separators where it is being
saturated with lime.
Note: Lime Milk circulation pumps discharge lines must be
flushed on regular basis (each 4 hours) to keep them clean and
avoid build up of lime scale. Automatic service water flushing
connections with solenoid valves are provided for this purpose.
• Open Saturated Lime Water Pumping Tank outlet valve

• Open Saturated Lime Water Pumps inlet isolation valves
• Remove vent plug from the Saturated Lime Water Pumps and leave the
pump body to be filled with Lime Saturated Water from the Saturated Lime
Water Pumping Tank
• Reinstall the plugs when all air is removed and the pump body flooded.
• Close Lime Saturated Water flow control valve and then adjust its position
to 10% open
• Crack open the Saturated Lime Water Pump discharge valve
• When water level in the Saturated Lime Water Pumping Tank reaches
minimum, start the Saturated Lime Water Pump
127
• Slowly open the Saturated Lime Water Pump discharge valve
• Check lime saturated water flow on FIT and adjust it to e.g. ~ 25 m3/h via
flow control valve
Note: Over the time of operation, lime sludge will be formed in Lamellae
Separators. Sludge quantity depends on purity of hydrated lime (90 –
95%) and lime solubility in water. Lime solubility is a function of water
temperature. The lower the temperature, the higher the solubility. Each
Lamellae Separator has conical bottom where sludge will be collected.
Volume of sludge section is approx. 4.5 m3. Lime Circulation Pump is

installed below each Lamellae Separator for sludge removal and
recirculation back to the Separator inlet. Set of actuated valves allows to
divert sludge flow either back to Separator or to Sludge Skip for disposal.
Expected volume of sludge is 0.8 m3/day. Sludge Circulation Pumps
should be in operation each 2 hours for 5 minutes in recirculation mode
and once per day in disposal mode e.g.
Worked Example:
Permeate water flow 1,118 m3/h
Lime dosing rate 32 mg/l
Lime purity 95%
Lime slurry concentration 105.7 g/l (10% slurry)
Lime solubility 1.47 g/l @ 35 degC
Required flow of lime saturated water:

(1,118 m3/h * 32 g/m3 / 0.95)/(1.47 g/l*0.001 m3/l) = 25.6 m3/h
Required lime slurry inlet to Lamellae Separator:

(1,118 m3/h * 32 g/m3 / 0.95)/105.7 = 356 l/h
Slurry Pump capacity 2,500 l/h
128
Slurry pump running time 356 l/h / 2,500 l/h = 0.14 h x 60 = 8.5 min/h
Number of running cycles 60/5 = 12 (each 5 minutes)
Running time per cycle 8.5 / 12 = 0.7 min
8.0.0 FLUSHING & COMMISSIONING OF THE NEUTRALIZATION SYSTEM

Note: Be familiar with O&M Instruction Manual for Neutralization Pumps and
Motors provided by pump manufacturer.
8.0.1 Preconditions
• Neutralization chamber is ready to receive dumping water.
• Neutralization Sump is commissioned, clear of any construction debris and
filled with service water or filtered seawater.
• Neutralization Pumps are pre-commissioned as per O&M manual and ready
for operation.
• Drain system is commissioned and ready to receive waste water
• Submerged recirculation pumps are pre-commissioned
• pH analyzers are commissioned
• Caustic dosing pumps are commissioned

• Acid dosing pumps are commissioned
• Level transmitter is commissioned
8.0.2 Procedure
• Submerged Neutralization pumps recirculation valve.

• Neutralization pumps dump valve.

• Neutralization pumps discharge valve.
• Neutralization pumps discharge pressure gauge isolation valves.
• Crack open Neutralization pumps discharge valve.
• Start the Neutralization Pump
• Slowly open the discharge valve to its fully opened position.
129
• Slowly open Neutralization pumps discharge pressure gauge isolation
valves and check discharge pressure. Release air if necessary.
• Observe the behavior of the pump for unusual sounds, vibrations,

discharge pressure or leaks
• Slowly open Neutralization pH analyzers isolation valve and check flow of
sample through electrode sample cells.
• Check water quality (pH) and start alkali or acid dosing if necessary.
• Continue with dosing until water quality is within prescribed limits
• When water quality is acceptable for disposal, then:
• Open Neutralization pumps dump valve and divert water to culver
• Close Neutralization pumps recirculation valve
• Stop the Neutralization Pump when sump is empty
• Repeat above operation under automatic mode and check system
performance.
• Neutralization system is commissioned and ready for operation.
9.0.0 FLUSHING OF THE RO CLEANING SYSTEM AND PRESSURE VESSELS.
Attention: Consider safety instructions and good operational practice. Procedure

can be executed from MCC room, and bear in mind that alarms and trips are not
active. Manual operation from MCC is not recommended. When the PLC is
available, always start devices using the PLC and VDU. When you start any device
via VDU and PLC, all alarms and trips are active and device should be secure.
Each actuated valve can be operated manually from local panel via dedicated
pneumatic solenoid valve.
9.0.1 Preconditions
Note: Study and be familiar with operation and maintenance instruction manual
for RO Chemical Cleaning Pumps and Motors provided pump manufacturer.
130
• Culvert is ready to receive the dumping water from RO cleaning, RO permeate
overflow tank.
• Overflow piping is available, RO Cleaning tank is cleaned, flushed and fully filled
with Flushing water or RO permeate.
• Important Note: Observe safety regulations when working with chemicals.

Always use Personal Protection Equipment (PPE) like gloves, glasses, shield,
rubber suit etc., when working with chemicals!!!!
• Ensure that flushing water is available for operation of safety showers.
• Study and familiarize yourself with Material Safety Data Sheets of all
chemicals used on site.
9.0.2 Procedure
• RO Cleaning tank 60m3 is cleaned, flushed and filled with Flushing water or RO
permeate (do not use water from Treated Water Tank which contains free
chlorine, which will cause oxidation of RO membranes!!! If used always add 25
kg of Sodium Metabisulphite (SMB) to the tank during filling with service
water. Or use Cleaning Chemicals Preparation System to transfer SMB solution
to Cleaning Tank)
• Cleaning Chemicals Preparation Unit is commissioned
• All system instrumentation has been commissioned
• CIP pipe system and associated valves have been commissioned
• Cartridge Filter elements are not installed in RO Cartridge Filter
• Cleaning Water Heater is commissioned
• RO Cleaning Pumps A/B/C are pre-commissioned and ready for operation (dry
run protection is activated.) Follow O&M Instruction manual for RO CIP
pumps!
131
• All RO pressure vessels are connected (plugs are installed at feed & permeate
side of the pressure vessels??)
• Cleaning Cartridge Filter is checked
• RO Cleaning Flow Meter is pre-commissioned
• CIP isolation valve to 1st Pass RO Trains is opened
• CIP isolation valve to 2nd Pass RO Trains is opened
• Cleaning feed movable spool pieces are installed or if valves installed all must
be opened on 1st Pass Feed Branch
• Both CIP valves at inlet side / Feed side ( from CIP system) of the RO train are
opened
• Both CIP plug valves at inlet side / Feed side of the RO train are closed
• Cleaning reject return movable spool pieces are installed on 1 st Pass Brine
Branch
• CIP valve at inlet side / Brine side (Brine CIP return) of the RO train is opened
• CIP plug valve at outlet side / Brine side of the RO train is closed
• Permeate return CIP valve is opened on 1st Pass Product Branch
• CIP by pass isolation valve for the 2nd pass is closed
• 1st Pass RO brine CIP return valve to CIP tank is opened.
• 1st Pass RO permeate CIP return valve to CIP tank is opened
• 2nd Pass RO brine CIP return to CIP tank is opened
• 2nd Pass RO permeate CIP return valve to CIP tank is opened
• Both valves from 1st and 2nd Pass to Neutralization are closed
• All vent valves are opened
132
9.0.3 RO CIP Flushing Procedures – Low pressure flushing
• Flushing / Permeate water is filled in the CIP tank.

• Do not operate the mixer until the tank is filled with liquid medium to avoid
bending of mixer spindle.
• Open circulation valve from CIP pumps discharge to RO CIP tank

• Open suction valves, vent the RO CIP pumps and start one pump.
• Gradually open pump discharge valve and carry out short circulation to the
tank.
• Start and stop one by one all three pumps with short circulation.
• Open vent valves at cartridge filter.
• Start again one of the pumps, open slowly open discharge valve and start filling
of the Cartridge Filter and CIP piping with pressure vessels. Slowly start closing
short circulation valve to CIP tank.
• Close vent valves when air is completely removed from the system.
• Start second RO CIP Pump, slowly open discharge valve to increase flow and
pressure.
• Flushing water is now circulating from CIP tank via pressure vessels of the 1st
and 2nd pass trains back to the CIP tank, keep in operation for 1 hour, or time
required to properly clean the CIP system.
• Open both valves from 1st and 2nd pass to neutralization and dump all dirty
water
• When pumps are stopped by CIP Tank dry run protection, drain / empty CIP
tank to neutralization
• Repeat procedure one again if required

• One by one repeat similar procedure for all five 1st and 2nd pass RO trains.
133
9.0.4 Flushing & Commissioning of the RO CIP System
• Difference between the flushing and normal operation / cleaning of the train is:
Cartridge filters are installed in both CF and flushed with permeate water
• Chemical cleaning solution is prepared in the RO CIP Tank depending from kind
of cleaning procedure used or recommended by membrane manufacturer,
acidic or alkaline.
• Heater is switched on when required
• pH measurement and conductivity instrumentation is in operation
• All other procedure is the same as per flushing
9.0.5 FLUSHING OF THE RO TRAINS FEED AND BRINE MANIFOLDS, BRINE

HEADERS AND HIGH PRESSUE PUMPS.
Attention: Consider safety instructions and good operational practice. Procedure
can be executed from MCC room, and bear in mind that alarms and trips are not
active. Manual operation from MCC is not recommended. When the PLC is
available, always start devices using the PLC and VDU. When you start any device
via VDU and PLC, all alarms and trips are active and device should be secure.
Each actuated valve can be operated manually from local panel via dedicated pneumatic
solenoid valve.
Note: Study and be familiar with O&M Instruction manuals of the following
equipment:
• 1st Pass RO High Pressure Pump and Electric Motor
• Lube Oil System for 1st Pass HPP
• High Pressure Booster Pump and Electric Motor

• Variable Speed Drive for 1st Pass RO High Pressure Pump Electric Motor
• Energy Recovery Turbine
• Pressure Vessels
• Membrane service bulletin for flushing of the pressure vessels
134
9.0.6 Preconditions
WARNING : Variable Speed Drives are located in High Voltage area

with access restricted to authorized personnel only !!!!!
Preconditions
• High pressure piping within 1st Pass RO Train is clean and free of dirt
• Temporary in-line strainer is installed on the suction of the HP pumps
• Lube Oil System is commissioned
• Cooling water supply is available for Lube Oil System and HPP Motor
• Pretreatment is commissioned and in operation
• All instruments, valves and piping have been commissioned
• Permeate outlet ports of membrane pressure vessels are plugged using special
PVC plugs
• Remove vent and drain plugs from HP Pumps and from HP Booster Pumps
Note: If starting the pump set for the first time after installation or overhaul,
disconnect the flexible coupling between the pump and motor and turn the pump
by hand to ensure freedom of rotation. Than re-connect the coupling.

• HP Pump feed valve
• HP Pump discharge isolation valve
• Permeate Flush inlet valve
• Product Retain valve
• Product outlet valve to Permeate tank
• Redox 001 Primary isolation valve
The following valves are open:

• 1st Stage feed vent valve
• HP Booster Pump discharge control valve
• 2nd Stage feed (1st Stage brine) vent valve
135
• Intake station is in operation
• RF filtration, and dosing system are in operation
• UF system is in operation or permeate / potable water is in Permeate tank
• Culvert is ready to receive the reject/dumping water/overflowing water
• RO train will be flushed directly with product water from UF skids or by

permeate water from existing plant. First way is preferable due to bigger water
volume and higher pressure.
• RO Flushing system is pre-commissioned and ready for operation
• Instrument air is available to open pneumatic valves
• All valves on instrumentation system are closed.
• All RO pressure vessels are connected and plugs at feed & permeate side
installed
• RO Flow Meters are pre-commissioned

• All Super duplex and GRP piping is installed, pressure tested and
precommissioned
• High pressure piping within RO Train is clean and free of any dirt.
• Temporary in-line strainer is installed on the suction of the HP pumps, if

required
• Permeate outlet valve from the train shall be closed.
9.0.7 Flushing Procedure
• ‘Crack’ open HP Pump inlet valve. Care must be taken in opening this valve to
prevent water surge
• This will allow the seawater to pass into the HP Pump. The flow should be
controlled such, that a generous flow is seen from each of the vent and drain
ports on the pump. The pump shaft should be rotated few times to release
136
trapped air and dirt. The plugs should be gradually installed and the flow
reduced accordingly.
9.0.8 Low pressure flushing
• Crack open HP Pump discharge isolation valve
• This will allow the seawater to pass into the membrane stages and through
the HP Pump. The flow should be controlled such, that a generous flow is seen
from each of the vent and drain ports on the pump. The pump shaft should be
rotated few times to release trapped air and dirt. The plugs should be
gradually installed and the flow reduced accordingly.
• When HP Pump is de-aerated, set the inlet flow to ~ 150 m3/hr. Check flow on
flow meter.
• Check the pressure on the suction of the HP pump. It should be approx.~ 2.0 –
2.5 bar.
• Check the flow from feed vent valve. When this is clear and without
interruption the vent valves should be closed.
• Flush the train using low-pressure seawater for 30 minutes. As the Train
flushes, pass over the system opening and closing all the sample points
• Once low pressure flushing is over, proceed to the next step – high-pressure
flushing.
9.0.9 High pressure flushing

Preconditions
RO Chemical Cleaning Tank is filled with service water or RO permeate
Note: Don’t forget that service water from Treated Water Tank contains free
chlorine, which will cause oxidation of RO membranes!!! Always add 20 litres of
15% SMBS solution to the tank during filling with service water. Use Cleaning
Chemicals Preparation System to transfer SMBS solution to Cleaning Tank.
137
• The actions and preconditions set out in Section 9.0.7 have been complied with

• Product Retain valve
• Permeate Flush inlet isolation valve
• Product outlet valve to product water tank
• HP Pumps feed sample isolation valve
The following valves are open:

• HP Pump discharge isolation valve
• feed vent valve
• brine vent valve
• Permeate vent valve
• Brine control valve
• Product Dump valve to culvert
9.0.10 Procedure
The train is now ready for first start of HP Pump and high pressure flushing.
• Check that MCC is set for local/manual operation of the HP Pump and VFD
• Start the main lube oil pump and check pressure is greater than 1.5 bar g
• Start HP pump and slowly increase speed of the motor via VFD to ~ 2,500 –
2,900 RPM
WARNING : Variable Speed Drives are located in High Voltage area with access
restricted to authorized personnel only. Only authorized person can operate the
drive !!!!!
• Once the pump is running at above speed, check the flow at FT‘s . The flow
should be adjusted as per pump capacity and curve.
138
• Observe the behavior of the HP Pump and ensure there are no leaks on pipe
connections or valves
• After 10 minutes close the feed vent valve
• Check the feed pressure and flow. If necessary re-adjust flow.
• Check the feed pressure
• Slowly increase the flow, but do not exceed maximum flow. The flow is limited
by brine pipe sizing and ERT
• Continue with flushing for 4 hours. Observe behavior of the HP Pump, electric
motors and VFD.
• Slowly reduce HP Pump speed via VFD to 0 RPM
• On completion of flushing return to Section 9.0.7 and repeat flushing on the

next 1st Pass RO Train until all trains have been flushed.
9.0.11 Flushing and commissioning of 1st Pass RO Flushing System
Note: Study and be familiar with operation and maintenance manual

for Flushing Tanks and Flushing Pumps and Motors .
Preconditions
• Flushing Tank is commissioned, flushed and filled with service water

(temporary service water connection to flushing tank will have to be provided
for this exercise)
• Flushing Pumps are pre-commissioned and ready for operation
• Associated pipe work, valves and instrumentation are commissioned and ready
for operation
• Temporary drain connection is provided between future RO train flushing

connection and ERT trench
139
Warning: Remember basic rule for start of centrifugal pump -
start the pump against closed or very slightly opened discharge
valve if downstream pipes are empty.

• Flushing Pumps discharge isolation valves
• Flushing Pumps discharge header drain valve
• Flushing Tank inlet valve
• Flushing Tank drain valve
• 1st Pass RO Trains flushing inlet valves
• UF Chemical Cleaning Tank permeate water inlet valve
• RO Chemical Cleaning Tank permeate water inlet valve

• Flushing Tank outlet valve
• Flushing Pumps inlet isolation valves
• 1st Pass RO Trains permeate retain valves
• 2nd Pass RO Trains feed valves
9.0.12 Procedure
• Slowly open the Flushing Pump discharge isolation valve
• Open vent valve on Flushing Pumps discharge header
• Leave system to fill with water under hydrostatic pressure from Flushing Tanks
and check flow through vent valves. When flow is steady without air bubbles,
close the vent valve.
• Close the Flushing Pump discharge isolation valve (the valve can be crack
opened)
• Refill the Flushing Tanks with service water if necessary
• Start the Flushing Pump
140
• Slowly open the Flushing Pump discharge isolation valve and adjust discharge
pressure to pump curve performance data.
• Check flow on FT
• Slowly increase the flow
• Check the pump discharge pressure on PT.
• Continue with flushing for 30 minutes
• Observe pump behavior for unusual noise, vibrations and system leaks
At the end of flushing period:
• Reduce flow by throttling the Flushing Pump discharge isolation valve
• Stop the Flushing Pump
• Fully Close the Flushing Pump discharge isolation valve

• Refill the Flushing Tanks with service water and repeat flushing with the second
Flushing Pump.
• Flushing system is now commissioned and ready for use with 1st Pass RO
Trains.
• Flush out all the salty water from 1st pass train with fresh water or permeate
and drain the system.
• It is very important for protection of the high-pressure pipe work. Stagnant

seawater at high temperature is very aggressive against stainless steel and
should always be displaced.
9.0.13 Flushing of the 2nd Pass RO Trains feed and brine manifolds, headers and
high pressure pumps
Note: Study and be familiar with operation and maintenance manuals

of the 2nd Pass RO High Pressure Pump and Electric motor
Preconditions
• High pressure piping within 2nd Pass RO Train is clean and free of dirt
141
• Pretreatment and UF are commissioned and in operation
• 1st Pass RO Train is commissioned and in operation
• Flushing Tanks are commissioned
• Temporary dump line is installed to allow dumping of combined permeate from

one 1st Pass and one 2nd Pass RO Trains
• Temporary in-line strainer is installed on the suction of the HP pumps
• All instruments, valves and piping have been commissioned
142
Permeate outlet ports of membrane pressure vessels are plugged using special
PVC plugs
• Remove vent and drain plugs from HP Pumps

• 1st Pass RO permeates valves (One of the 1st Pass RO Trains is in operation.
Product water from running train flows through the Flushing Tanks and to drain
via temporary dump connection on combined product line)
• 1st Pass RO permeate dump valve to drain
• 2nd Pass RO Train 1st stage feed vent valves
• 2nd Pass RO Train permeate vent valves
• 2nd Pass RO Train 2nd stage brine vent valves
• 2nd Pass RO Train brine control valves
• 2nd Pass Trains brine dump valve
• 2nd Pass Trains permeate retain valves
• Flushing Tank outlet valve
• Flushing Tank outlet valve to Flushing Pumps suction header

• 1st Pass RO permeate dump valve
• 2nd Pass Trains brine return valve
143
•
• 2nd Pass HP Pumps inlet isolation valves
• 2nd Pass RO feed control valve
• Permeate line isolation valve

9.0.14 Procedure
• “Crack” open 2nd PFP outlet valve. Care must be taken in opening this valve to
prevent water surge
• Open 2nd PFP
• This will allow 1st Pass permeate to pass into the 2nd Pass FP. The flow should
be controlled such, that a generous flow is seen from each of the vent and
drain ports on the pump. The pump shaft should be rotated few times to
release trapped air and dirt. The plugs should be gradually installed and the
flow reduced accordingly.
• Slowly open 2nd PFP outlet isolation valve until sufficient flow is established
9.0.15 Low pressure flushing
• Open 2nd PFP discharge flow control valve and adjust flow
• Check flow and pressure
• This will allow the seawater to pass into the membrane stages
• Check the pressure on the suction of the 2nd PFP. It should be at least 1.5 bar.
• Check the flow from 1st Stage feed vent valve and 2nd Stage feed vent valve.
When this is clear and without interruption the vent valves should be closed.
Flush the train using low-pressure seawater for 30 minutes. As the Train
flushes, pass over the system opening and closing all the sample points
144
• Once low pressure flushing is over, proceed to the next step – high-pressure
flushing.
9.0.16 High pressure flushing
Preconditions
• RO Cleaning system is commissioned
• Neutralization system is commissioned
• 2nd PFP is pre-commissioned and ready for operation
• Temporary orifice plate is installed in spool piece on cleaning reject return line
from 1st stage pressure vessels (Orifice must be installed to limit the flow and
reduce pressure in reject return line)
• 1st Pass RO permeate retain valves (One of the 1st Pass RO Trains is in
operation. Product water from running train flows through the Flushing Tanks
and to drain via temporary dump connection on combined product line)
• 1st Pass RO permeate dump valve to drain
• 2nd Pass HP Pumps inlet isolation valves
• 2nd Pass RO Train 1st stage feed vent valves
• 2nd Pass RO Train permeate vent valves
• 2nd Pass RO Train 2nd stage brine vent valves
• 2nd Pass RO Train brine control valves
• 2nd Pass Trains brine dump valve
• 2nd Pass Trains permeate valves
145
•
Flushing Tank outlet valve
• Flushing Tank outlet valve to Flushing Pumps suction header
• Combined permeate line isolation valve
• RO cleaning reject return valve to RO Cleaning Tank
• Isolation valve between UF and RO Cleaning Tank
• RO Cleaning Tank drain valve
• UF Cleaning Tank drain valve

• 1st Pass RO permeate dump valve
• 2nd Pass Trains brine return valve
• 2nd Pass HP Pumps discharge valve
• Permeate line isolation valve
9.0.17 Procedure
• Fully close 2nd PFP Discharge valve. The time between fully closed and fully
opened position of the valve check with C&I engineer. It is recommended that
the operator practice the gradual opening and closing of the valve at this time.
Adjust the valve afterwards to 15 % open position.
• The train is now ready for first start of the 2nd PFP and high pressure flushing.
• Check that MCC is set for local/manual operation of the HP Pump
• Start HP pump
Once the pump is running at full rotations check and adjust the flow at FT.
146
• Gradually open 2nd PFP Discharge valve.
Observe the behavior of the pump and ensure there are no leaks on pipe
connections or valves.
• After 10 minutes close the Train feed vent valve.
Important Note: Always close the feed vent valve before brine
vent valve when starting the Train !!!
• Check the feed pressure and flow. Increase the flow if necessary.
• After 10 minutes close the Train brine outlet vent valve
Note: Do not exceed maximum flow. The flow is limited by

temporary orifice and brine pipe sizing
• Continue with flushing for 4 hours - test of the 2nd PFP and motor
• When the flushing is over, reduce the flow by throttling of HP Pump discharge
valve.
• Once the flow is low, open the Train brine outlet vent valve
Important Note: Always open the brine vent valve before the
feed vent valve when stopping the Train !!!
• Once the brine outlet vent valve is open, open the feed vent valve.
• Stop the 2nd PFP
• Repeat the procedure for the next Train until all 2nd Pass Trains have been
flushed
11.0.0 FLUSHING AND COMMISSIONING OF THE SERVICE WATER SYSTEM.
11.0.1 Preconditions
• Permeate water, chlorine free water is available in Flushing Tank.
147
•
• Service Water Pumps are pre-commissioned as per O&M Instruction manual
and ready for operation.
• Water Accumulator tank is installed charged to working pressure and

precommissioned.
• Instrumentation is ready (PI, PIT), set and commissioned

• All pipes, valves and instrumentation are connected and ready for operation.
Note: Be familiar with O&M Instruction Manuals of the Service Water System
provided by suppliers.
• Utility Water Pumps suction isolation valves.
• Utility Water Pumps discharge isolation valves.
• All utility water valves at user points
• Permeate Water Tank outlet valve.
• Service Water Accumulator tank inlet / outlet valves
11.0.2 Procedure for flushing and commissioning
• Crack Open Service Water Pump inlet isolation valve.
• Slightly unscrew the Service Water Pump vent screw /vent valve and observe
water flow through the vent. When there is no air in the water, tight the vent
screw.
• Reinstall the plug/ or close the valve and fully open the Service Water Pump
inlet isolation valve. Repeat above procedure on remaining Service Water
Pumps
Slowly open the Service Water Pumps discharge isolation valve.
148
• Depending on the water level in Product Water Tank, the system will be by
gravity filled with service water and air removed from pipes.
• Slowly open utility water valve on each user point (one at a time) and leave
water flow for necessary minutes to de-aerate piping
• Close all utility water valves on user points
• Close utility Water Accumulator Tank vent valve ( if available) when water is
free from air bubbles
• Partially open Service Water inlet valves for filling of the Chemical Dosing tanks
and Settling tank
• Start one of the Service Water Pump.
• Slowly open the Service Water Pumps discharge isolation valve and adjust
discharge pressure as per pump manufacturer curve.
• Run the pump for 1-2 hours and check for unusual noise or vibrations and
problems.
• Check all piping for leakages
• During operation, slowly open service water valve on all 27 user points (onetwo
at a time) and leave water flow for necessary time until piping is not properly
de-aerated.
• Repeat the same for other Service Water pump.
The Service Water System is now flushed, commissioned and ready for operation.
12.0.0 COMMISSIONING OF THE PLANT AIR SYSTEM
12.0.1 Pre-condition
• Please familiarize with air compressors O&M Instruction Manual

commissioning the compressors,
• All Air receivers and air piping are installed and pressure tested
149
•
• The compressor system is installed and pre-commissioned as per O&M.
• Power supply and control cables are connected
• Compressors shall have sufficient oil level.
• The air-receivers on plant are pre-commissioned, cleaned.
12.0.2 Procedure
• Close the manual condensate drains

• Open the air outlet valve
• Press the compressor start button
• When automatic LEF is alight the compressor regulator is automatically
controlling the compressors. Compressor is operating under the load and air
delivery is transferred into Air Receivers.
• After reaching of the operational pressure in the air receiver, open drain
valves from the receivers and blow out all dust / rust from receivers
• Afterwards open all air delivery points and blow them one by one for
minimum 30 minutes to clean Instrument air piping
• Instrument air system is ready for operation
150
13.0.0 FLUSHING & COMMISSIONING OF THE PRODUCT WATER
PUMPING STATION
• The product Water tanks) are pre-commissioned and are filled with product
water.
• All related pipe work is installed & pre-commissioned.
• The PWFPS main header vent valve is open
• All inlet & outlet valves for Product Water Pumps are in closed position.
13.2.0 Procedure
• Open the inlet valve of VFD driven pump & crack open its discharge valve.
• Start the pump
• Gradually increase frequency and slowly open the discharge valve
• Monitor any abnormal behavior of pumps such as sound, vibration, high
temp etc.
• Flush the system for 3 ~ 4 hrs
• If the flushing process is satisfied, stop the pump and close the inlet & outlet
valve.
• Repeat the above for the remaining pumps.
• Apply the same procedure for all Product water pumps.
13.0.3 Pre-condition for Commissioning:
• The Product water tanks (PWT) are pre-commissioned & flushed.

• All related instruments are installed & pre-commissioned.
• PWT level transmitters are installed & pre-commissioned.
151
• All dosing sets as a Lime dosing , Chlorine dosing and CO2 dosing are
precommissioned
• Product Water Pumps are pre-commissioned.
13.0.4 Procedure:
• All inlet & outlet valves of Product Water pumps are in closed position.
• Open the inlet valve for VFD driven product water pump & crack open its
discharge valve.
• Start the pump
• Gradually increase frequency and open the discharge valve
• Start all dosing skids one by one, CO2, Lime and chlorine and adjust specific
dosing rate in accordance with flow
• Check pH and conductivity at the instrumentation, if the values are not

within the design re-adjust dosing rates
• If the pump performance is matching with the pump curve, stop the pump
and close the inlet & outlet valve.
• Apply the same procedure for all remaining pumps.
Please refer also to reference documents listed below.

1. Chemicals Hazardous Substance Fact Sheet, NaOH, SMB, Ca(OH)2, FeCl3, HCl attached.
2. Mechanical equipment test sheets formats, sample for each kind of equipment.
152

Commissioning Procedures

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Commissioning Procedures

Uploaded by

Copyright:

Available Formats

CONTENTS

2.0.0 FLUSHING & COMMISSIONING

5.0.0 FLUSHING & COMMISSIONING OF ULTRA FILTRATION

5.1.0 Overview Process Commissioning XIGA System

5.1.7 Stage 4 Commissioning with Membranes

5.1.8 Stage 5 Take-over

5.2.0 Process Commissioning XIGA – Wet

5.2.3 Commissioning without Membranes

6.3.0 Flushing & Commissioning of Non-Oxidising Biocide

6.4.0 Flushing & Commissioning of Sodium Bi-sulphite Doing

6.5.0 Flushing & Commissioning of the Chlorine Dosing

6.6.0 Flushing & Commissioning of Hydrochloric Acid

6.7.0 Flushing & Commissioning of the NaOH Dosing System

6.8.1 Pre-condition for flushing

7.0.0 FLUSHING & COMMISSIONING OF THE LIME MAKE UP &

8.0.0 FLUSHING & COMMISSIONING OF THE NEUTRALIZATION

9.0.0 FLUSHING OF THE RO CLEANING SYSTEM AND PRESSURE

10.0.0 FLUSHING & COMMISSIONING OF THE RO FLUSHING

11.0.0 FLUSHING AND COMMISSIONING OF THE SERVICE WATER

12.0.0 COMMISSIONING OF THE PLANT AIR SYSTEM

13.0.0 FLUSHING & COMMISSIONING OF THE PRODUCT WATER

1.1.0 SUMMARY OF REQUIREMENTS 1.2.0 Preconditions

Pre-commissioning should be completed and signed off by the designated

• power supply in operation

• Set of commissioning tools for single equipments

2.1.0 COMMISSIONING & MANUAL OPERATION

3.0.0 FLUSHING AND COMMISSIONING OF INTAKE SYSTEM

• All electrical connections are checked and energized

• Seawater Intake including Distribution Chamber are inspected for presence of

• Use of temporary strainer on Intake Pumps suction is recommended for this

Attention: Consider safety instructions and good operational practice.

3.2.0 Preparation for start up of the Bar Screen

• Seawater Intake is flooded with flooding valve

• Seawater Intake stop gate is removed

• Check that it operates smoothly and correctly

• Repeat the test under automatic control via PLC

3.4.0 Preparation for start up of the Drum Screen

• Screen wash pumps have been installed pre-commissioned following

• All grouting is complete

• Wash water PIS are calibrated

Seawater intake stop gate is removed

• Gearbox oil level is correct

3.5.0 Preliminary Test

• Allow the screen to run for 10 minutes

• Re-fit and secure all covers

3.7.0 PREPARATION OF START UP OF THE SEAWATER INTAKE PUMPS.

• Cooling water temperature measurement is tested and ready for use

• Self-cleaning strainers for cooling water are pre-commissioned and ready to

• Mechanical seal has been checked if applicable as per O&M.

• All pump set components have been checked as per manufacturer

Intake Oil, Particle, Algae Analyser to be pre-commissioned at later stage, all

• Intake Level Transmitters have been commissioned.

• Seawater Intake Pump discharge butterfly valves are closed.

• Seawater Intake Pump suction butterfly valves are opened.

• Surge Vessel shall be installed and Air compressors pre-commissioned as pre

• Surge Vessel to be pressurized/charged by air to required pressure.

• Inlet valves to Surge Vessel and Pressure transmitter shall be opened.

valves at main piping are closed

• All vent valves (aeration / de-aeration) at main piping are opened

• Pressure transmitter primary isolation valves are opened.

• Seawater Intake Pump Discharge Header drain are closed.

• Seawater Intake Pump Discharge Header vent are opened.

• All electrical connections have been checked and are energized.