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ALKHAFJI 60 MLD SWRO

DESALINATION PLANT
SWRO OPERATION PROCEDURES

Quality Control Sheet

PROJECT KHAFJI SWRO PLANT

DOCUMENT SWRO OPERATION PROCEDURES

DOCUMENT# 30801-

OPERATION AND MAINTENANCE MANUAL

ADVANCED WATER TECHNOLOGY

DATE 20-July-2017 REVISION 0

JULY 20, 2017

ADVANCED WATER TECHNOLOGY


P.O.BOX 6086 RIYADH 11442 SAUDI ARABIA
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Contents
1. FIRST PASS RO ........................................................................................................................................ 4
1.1. INTRODUCTION ................................................................................................................................................................... 4
1.2. CONTROL PHYLOSOPHY .............................................................................................................................................. 5
1.2.1. SEA WATER RO PLANT ............................................................................................................................... 5
1.2.2. BRACKISH WATER RO PLANT...............................................................................................................13
1.3. TECHNICAL INFORMATION ........................................................................................................................................18
1.3.1. FEED WATER CONDITIONS .....................................................................................................................18
1.3.2. DESIGN DATA ..................................................................................................................................................19
1.3.3. PROCESS DATA .............................................................................................................................................19
1.3.4. TECHNICAL DATA .........................................................................................................................................21
1.3.4.1. PUMPS ..................................................................................................................................................................21
1.3.4.2. EQUIPMENT .......................................................................................................................................................22
1.4. EMERGENCY SHUTDOWN CONDITIONS ............................................................................................................27
1.5. REVERSE OSMOSIS (RO) TRAINS OPERATIONS ..........................................................................................27
1.5.1. RO START-UP CONDITIONS ....................................................................................................................28
1.5.2. RO FLOW SET POINTS AND RECOVERY CALCULATION ......................................................29
1.5.3. RO START-UP SEQUENCE #1 (WITHOUT FEED PRESSURE IN RO) ................................30
1.5.4. RO START-UP SEQUENCE #2 (WITH FEED PRESSURE IN RO)- ON HOLD ..................32
1.5.5. PRESSURE VERSUS FLOW CONTROL .............................................................................................32
1.5.6. RO RUNDOWN SEQUENCE ......................................................................................................................32
1.5.7. RO SHUTDOWN SEQUENCE ...................................................................................................................34
1.5.8. FLUSHING SEQUENCE FOR OFFLINE RO .......................................................................................34
1.5.9. RO STANDBY CONDITIONS .....................................................................................................................37
1.6. CALCULATIONS ................................................................................................................................................................39
1.6.1. RECOVERY CALCULATIONS ..................................................................................................................39
1.6.2. NORMALISATION CALCULATIONS .....................................................................................................39
1.7. TRENDS..................................................................................................................................................................................39
1.7.1. RO TRENDS FOR EACH RO .....................................................................................................................39
1.7.2. QUALITY TRENDS 1 FOR ALL ROS .....................................................................................................40
1.7.3. QUALITY TRENDS 2 ......................................................................................................................................40
1.7.4. PRESSURE TREND 1 FOR ALL ROS ...................................................................................................40
1.7.5. PRESSURE TREND 2 FOR ALL ROS ...................................................................................................40
1.8. EVENTS ..................................................................................................................................................................................40
1.9. REPORTS ..............................................................................................................................................................................40
1.10. RO CHEMICAL CLEANING SYSTEM ......................................................................................................................41
2. BWRO ....................................................................................................................................................... 45
2.1. GENERAL ..............................................................................................................................................................................45
2.2. MAIN COMPONENTS ......................................................................................................................................................45
2.3. OPERATION OF BWRO .................................................................................................................................................45
2.3.1. MANUAL OPERATION .................................................................................................................................45

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2.3.2. AUTOMATIC OPERATION ..........................................................................................................................45


2.3.2.1. HMI MODE...........................................................................................................................................................46
2.3.2.2. PLC MODE ..........................................................................................................................................................46
2.3.2.3. START OF BWRO ...........................................................................................................................................47
2.3.2.4. OPEN PERMEATE VALVE AND FILL PRODUCT TANK .............................................................50
2.3.2.5. MONITORING OF BWRO IN OPERATION ..........................................................................................50
2.3.2.6. SHUT DOWN OF BWRO ..............................................................................................................................51
2.3.2.7. SHUT DOWN OF 2ND PFP .........................................................................................................................52

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1. FIRST PASS RO
1.1. INTRODUCTION
The aim of this document is the description of the function and design as well as description
of the operating and control philosophy of Reverse Osmosis plant for Al-Khafji Phase 1
SWRO.

The purpose of the RO is the production of good quality desalinated water for further
potabilization from pre-treated sea water. In the RO stage salt from the UF pre-treated sea
water is removed by means of reverse osmosis spiral wound membranes. To make the
separation process working, the osmotic pressure between brine (concentrate) and permeate
(desalinated water) has to be overcome by means of a high pressure feed pump. The system
operating pressure on the brine side is in the range of 60 to 75 bar, whereas the permeate
after passing the membranes is merely pressure-less (~1-1.5 bar).

To make the system more energy efficient, the remaining high pressure of the brine is used
to drive the PX (pressure exchanger), which is feeding additional raw water to the
membranes. The pressure difference between HP pump feed and PX feed is covered by a
frequency driven booster pump.

The reverse osmosis (RO) system consists of eight (6) individual trains, each one made up
from the membrane rack, the HP feed pump, the PX system with booster pump, a set of
valves and measurement instruments.

In order to avoid corrosion effects on the RO system after shut-downs, the remaining sea
water and brine will be flushed out by pumping permeate into the system, thus replacing the
concentrated salt water. During expansion of the plant to 90,000 m3 3 more units will be
installed.

After ramp down of the RO feed pumps the osmotic pressure will draw back permeate until
the differential osmotic pressure is in equilibrium. This phenomenon is not wanted as it
creates sudden osmotic shock. That is why non return valves are installed in permeate lines
from each individual RO train. To provide the required quantity of permeate for flushing, a
tank is located downstream of the RO trains serving as a reservoir for flushing and for
product water pumping.

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Components:

RO Feed Pumps RO Booster Pumps RO ERD

RO Membrane RO Dosing System RO CIP System

Racks

RO Flushing Compressed Air Neutralisation

System System

1.2. CONTROL PHYLOSOPHY

1.2.1. SEA WATER RO PLANT


The SWRO plant consists of the following units

Feed water quality monitoring


Chemical dosing
6 SWRO Trains
Permeate Flushing System
CIP System

Feed Water Quality Monitoring:

The quality of the feed water is continuously monitored by means of 2 pH meters, 3 ORP
meters, Turbidity meter, Particle monitor, conductivity meter and an SDI monitor. The shutoff

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valve 00GCK25AA001 in the sampling line feeding the instruments will be opened as soon
as at least one UF unit is in operation.

Chemical Dosing:

Three different chemicals can be dosed upstream of the SWRO:

Caustic soda dosing is controlled by the pH value.


Antiscalant is dosed proportional to the RO feed flow. It will be activated if dosing is pre-
selected by operator HMI input.
Sodium bisulphite dosing will be started automatically if ORP in the RO feed exceeds a
preselected limit and then dosed proportional to the RO feed flow.

Control of the dosing stations/dosing pumps follows the same pattern as all the other dosing
systems described above.

Process image of RO Feed Quality monitoring and conditioning

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Process image of SWRO Trains overview


The SWRO trains are operated continuously. Each train is controlled individually by an SFC.
If functional and available they can either be Offline (idle), Online (in operation), or
performing one of several different flushing processes.

When stopped they usually get flushed with permeated before being put offline. If a train has
been stopped without flushing or being offline for an extended period, different flushing
processes can be performed out of the offline mode, some of them are optional and can be
chosen by the operator. One is mandatory and performed automatically if a preset offline-
time is exceeded.

There is one common flushing system for all trains.

The operation and flushing of the units is managed by another logic function similar to the
ones described for the DMF and UF. This RO manager makes sure that always the correct
number of units is in operation. The RO manager detects which units are available for the
automatic control (SFC switched on, no faults of pumps, valves and instruments, unit filled
with water, etc.) as well as operating time of the running (online) units and the rest time of the
idle (offline) units, and the status of the counters and flags.

If the number of requested units deviates from the number of running units it automatically
corrects the number of running units by either starting additional units one after the other
beginning with the one with the longest rest time or stopping units beginning with the one
with the longest operation time.
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Possible reasons for correcting the number of operating units:

Operator reduces or increases the number of requested units


Superordinate control reduces or increases the number of requested units
Units become unavailable due to a fault of associated equipment (pumps, valves,
instruments)
Units have to be stopped because an insufficient number of upstream or
downstream process units (DMF, UF, BWRO, product water pumps) is available
Units are taken out of operation manually by operator
Additional unit(s) is (are) started manually (not by changing the number of required
filters)

As there is a common flushing system, the RO manager monitors the availability of that
facility as well.

For controlled stopping there are three procedures available. Run down with flushing (which
would be the default procedure), Run down without flushing (on operator request) and shut
down. The shutdown procedure can be seen as a controlled emergency stop. Which is
chosen if some error occurs that does not allow to continue operation but is not so critical
that the pumps have to be stopped immediately.

As soon as a unit is scheduled for run down it enters a sequencer step in which it continues
operation but is marked for run down and waits until the RO manager has issued the
approval to continue, i.e. to perform the flushing or go to offline mode. This approval is issued
if another unit has been started successfully (if another unit is required), the relevant
common system is available i.e. ready for operation, not occupied by another unit, sufficient
water available inside the flushing tank, etc.). If this approval is not issued within a preset
period of time (adjustable via HMI) the unit will be stopped anyway, and can be sent into
offline flushing later on manually or automatically.

Furthermore a unit can be marked as independent. This means that it is fully operational
but not available for the automatic function. If a unit is marked as independent it is not
counted. Like already described for the sea water intake pumps, DMF and UF, this can be
used for testing purposes or similar without interfering with the running system.

Like the pump manager the RO manager features an automatic time controlled switchover
function which can be activated or deactivated. This function might be useful as an
alternative to standby-flushing if the plant is not operated on full load for a longer period.

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Process image of one SWRO Train (membrane stacks and permeate)

Controllers:

The HPP Feed flow, ERD BP (energy recovery device booster pump) flow and Recovery
ratio are controlled during start-up, operation, rundown, shutdown and flushing. The setpoints
for the controllers and working principle (open loop, closed loop) are being changed
automatically by the SFC depending on the requirements of the current sequencer step.

The Recovery ratio can be varied between 40 and 44%. The value can be defined by the
operator via HMI input for each train.

The SWRO is built as split partial second pass. The low TDS permeate from the front end of
the pressure vessels can be fed directly to the product tank (while the high TDS permeate
feeds the BWRO plant). This feature can be activated or deactivated for each train via HMI
input. If activated it gets started automatically once the SWRO train is in operation, the LTDS
flow rate is controlled by flow controller 20GCF21CF001 and control valve 20GCF21AA101.
It gets either automatically switched off if LTDS conductivity is too high or can be deactivated

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any time by the operator. Once it has been deactivated during operation LTDS withdrawal
can only be restarted upon a restart of the SWRO train.

LTDS withdrawal will automatically be blocked if only one SWRO train is in operation,
because in that case the feed water supply to the second pass feed pumps would be less
than their allowable minimum flowrate. As soon as a second SWRO train has been started
the blocked control will be released.

After start-up of an additional SWRO train or if a BWRO train trips, the SWRO plant might
produce more HTDS permeate than the BWRO plant is able to process. For such phases the
flushing tank filling valve 20GCP30AA101 and the pressure offloading valve 20GCK36AA101
are used to keep the BWRO HPP feed pressure 00GCK40CP001 constant, i.e. the excess
permeate is used to fill up the flushing tank or (if tank is full and overflow to product tank is
deactivated) it gets dumped.

During operation it is possible to dump the high TDS permeate, e.g. for testing purposes. If
such a dumping of permeate is initiated by the operator, the plant control is going to stop one
BWRO train first to avoid a lack of supply to the BWRO plant.

Process image of one SWRO Train (pumps, pressure exchanger & recovery control)

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Permeate Flushing system:

The permeate flushing system mainly consists of a flushing tank and two flushing pumps,
incl. valves and instruments.

The pumps are controlled by another pump manager, that chooses which unit to be
operated, cares for emergency switch over, etc.

The flushing processes is controlled by the SWRO units SFC (request for pump, flow
controller, recycle valve, etc.). The coordination between the SWRO SFCs and the flushing
pump manager is done by the RO manager.

During flushing a biocide can be dosed. This chemical dosing is activated by operator input
at the HMI. If activated the chemical is dosed automatically proportionally to the flushing
water flowrate. Control of the dosing station/dosing pumps follows the same pattern as all the
other dosing systems described above.

The filling of the flushing tank is done with HTDS permeate via the control valve
20GCP30AA101. The valve is flow controlled by controller 20GCP30CF001.

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Process image of RO flushing system

RO CIP system:

The CIP system consists of a tank with electrical heater and two pumps incl. associated
instruments and valves.

A chemical cleaning (CIP) can be performed if necessary. The whole process is operated
manually. The SFC of the concerned SWRO or BWRO unit has to be switched off for this
process.

The only automatic functions are shutoff of mixer, heater and pumps at tank level low or
limits of temperature, pressure, flow, pH etc. exceeds the set value. Before or after starting
the pump(s) manually, the operator has the choice to activate a shutoff timer which stops the
pump(s) after it has elapsed.

The CIP system can be used for both SWRO and BWRO plant.

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Process image of RO CIP System

1.2.2. BRACKISH WATER RO PLANT


The BWRO plant consists of the following units

Chemical dosing
3 BWRO High pressure pumps (aka second pass feed pumps)
6 BWRO trains

Chemical Dosing:

Two different chemicals can be dosed upstream of the BWRO:


Caustic soda dosing is controlled by the pH value.
Antiscalant is dosed proportional to the RO feed flow. It will be activated if dosing is
pre-selected by operator HMI input.

Control of the dosing stations/dosing pumps follows the same pattern as all the other dosing
systems described above.

Second Pass Feed Pumps:

The second pass feed pumps are common for all 6 BWRO trains. For each two requested
BWRO trains one pump is required. The operation of the pumps is controlled by another
pump manager.

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This pump manager makes sure that always the correct number of pumps is in operation.
The pump manager detects which pumps are available for the automatic control (inlet
pressure above low limit, no electrical fault, pump in automatic mode, no error of the
correlated suction vent valve and discharge valve, etc.) as well as operating time of the
running pumps and the rest time of the idle pumps. If the number of requested pumps
deviates from the number of running pumps it automatically corrects the number of running
pumps.

If the number of running pumps is lower than the number of requested pumps, more pumps
will be started (one after the other). The pump manager chooses independently which of the
available pumps it has to start. The pump manager features the same functionalities like
already explained previously, i.e. it either starts a preselected pump or the one with the
longest rest time and stops either a not preselected pump or the one with the longest running
time.
This function works in any case no matter what the reason for the deviation between
requested and running pumps is. This could either be:

Operator reduces or increases the number of requested pumps


Superordinate control reduces or increases the number of requested pumps
Pump(s) trip or become otherwise unavailable
Additional pump(s) is (are) started manually (not by changing the number of required
pumps)
Also a pump can be marked as independent, for testing purposes or similar.

Flow/pressure control:
The pumps are equipped with VFDs. The main purpose of the process control of the pumps
is to feed the amount of HTDS permeate which is produced by SWRO plant (minus the
amount which is dumped via the pressure offloading valve 20GCK36AA101 and/or used to fill
the flushing tank) to the BWRO plant at the required pressure. On the other hand the pumps
require a minimum flow rate that must not be under-run.

During normal operation the BWRO plant inlet pressure 00GCK40CP001 works as the
master controller for the individual flow controllers of the second pass feed pumps
(00GCF11/12/13CF001). Hence these individual pump flow controllers receive their flow
setpoint from the master controller (i.e. the manipulated value of the pressure controller is the
setpoint of the flow controllers). In the course of the detailed controller design it will be
checked if it would be of advantage to execute the master controller as flow controller with

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the BWRO plant inlet pressure as disturbance variable. The flow setpoint of the individual
pump flow controllers is limited to the minimum allowable pump flow rate.

Process image of BWRO feed pumps and conditioning

BWRO Trains

Process image of BWRO Trains Overview

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The BWRO trains are operated continuously. Each train is controlled individually by an SFC.
If functional and available they can either be Offline (idle), Online (in operation), or
performing a start-up or rundown process.

The operation and start-up / rundown of the units is managed by another logic function
similar to the ones described for the DMF, UF and SWRO. This RO manager makes sure
that always the correct number of units is in operation. The RO manager detects which units
are available for the automatic control (SFC switched on, no faults of pumps, valves and
instruments, unit filled with water, etc.) as well as operating time of the running (online) units
and the rest time of the idle (offline) units, and the status of the counters and flags.

If the number of requested units deviates from the number of running units it automatically
corrects the number of running units by either starting additional units one after the other
beginning with the one with the longest rest time or stopping units beginning with the one
with the highest differential pressure.

Possible reasons for correcting the number of operating units:

Operator reduces or increases the number of requested units


Superordinate control reduces or increases the number of requested units
Units become unavailable due to a fault of associated equipment (pumps, valves,
instruments)
Units have to be stopped because an insufficient number of SWRO trains is in
operation
Units are taken out of operation manually by operator
Additional unit(s) is (are) started manually (not by changing the number of required
filters)

As soon as a unit is scheduled for run down it enters a sequencer step in which it continues
operation but is marked for run down and waits until the RO manager has issued the
approval to continue, i.e. to go to offline mode in a controlled way. This approval is issued if
another unit has been started successfully (if another unit is required), If this approval is not
issued within a preset period of time (adjustable via HMI) the unit will be stopped anyway.

Furthermore a unit can be marked as independent. This means that it is fully operational
but not available for the automatic function. If a unit is marked as independent it is not
counted. Like already described for the other process units, this can be used for testing
purposes or similar without interfering with the running system.

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Like the pump manager the RO manager features an automatic time controlled switchover
function which can be activated or deactivated. This function might be useful is not operated
on full load for a longer period, to avoid bacteria growth within the membranes, etc.

Process image of BWRO train

Controllers:

The Feed flow and Recovery ratio are controlled during start-up, operation and rundown. The
setpoints for the controllers and working principle (open loop, closed loop) are being changed
automatically by the SFC depending on the requirements of the current sequencer step.

The setpoint for the feed flow controller is deliverd by the same master controller that delivers
the setpoint for the second pass feed pump flow controllers.

The Recovery ratio can be varied between 80 and 90%. The value can be defined by the
operator via HMI input for each train.

After start-up of an additional SWRO train or if a BWRO train trips, the SWRO plant might
produce more HTDS permeate than the BWRO plant is able to process. For such phases the
flushing tank filling valve and the pressure offloading valve 20GCK36AA101 are used to keep
the BWRO HPP feed pressure 00GCK40CP001 constant, i.e. the excess permeate is used

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to fill up the flushing tank or (if tank is full and overflow to product tank is deactivated) it gets
dumped.

During operation it is possible to dump the permeate, e.g. for testing purposes.

1.3. TECHNICAL INFORMATION

1.3.1. FEED WATER CONDITIONS

Description Unit Data

SWRO Feed Water Condition

Max Feed TDS [mg/l] 47000


Seawater design pH range 8 8.3
Feed Temperature C 16 -40
SDI <3 at 100% of time
< 0.2 at 80% of the time at
Turbudity
< 0.5 at all time
Boron (measured by ICP method) [mg/l] 5.5
Calcium [mg/l] 520.7
Magnesium [mg/l] 1,718
Sodium [mg/l] 14,511
Potassium [mg/l] 499.9
Chloride [mg/l] 26,011
Sulfate [mg/l] 3,541
Bicarbonate [mg/l] 177.1
Fluoride [mg/l] 1.252
Silica [mg/l] 0.417

BWRO Feed Water Condition

Max Feed TDS [mg/l] 266.2

pH range 6.77

Feed Temperature C 16-38

Chloride [mg/l] 0.392 0.581

Boron [mg/l] 0.00

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1.3.2. DESIGN DATA

RO 1st Pass design

Number of trains - 6
Design conversion rate % 40
Maximum average flux rates l/m/h 14
Max. permissible temperature
continuous operation C 16-40
short time (cleaning etc.) C 16-40
during storage in standby C 16 - 35

RO 2nd Pass design

Number of trains No. 6


Design conversion rate % 90
Maximum average flux rates l/m/h 36
Max. permissible temperature
continuous operation C 16-40
short time (cleaning etc.) C 16-40
during storage in standby C 16 - 35

1.3.3. PROCESS DATA

Description Unit Data

General

Winter Summer
Seawater temperature C 16 40
Maximim Seawater Total Dissolved Solids g/l 38000-47000 38000-47000
Total permeate capacity at design conditions RO
m/d
plant 60341.76 @ 40% with 6 Racks
Maximum average membrane lifetime (AMLT) RO
year 3.32 3.32
1st Pass
Maximum average membrane lifetime (AMLT) RO
year 4.47 4.47
2nd Pass
Permeate Total Dissolved Solids mg/l 12.3 - 20 12.3 20
Permeate Chloride content mg/l 6.359 12 6.359 12

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Description Unit Data

Case 1: All (N) RO trains are in Operation

Feed flow rate of RO plant m/d 167616 167616


Permeate flow of RO 1st pass m/d 67046.6 67046.6
Feed flow rate per RO 1st pass train m/d 27936 27936
Permeate flow rate per RO 1st pass train m/d 11174.4 11174.4
Permeate 1st pass Total Dissolved Solids mg/l 164.3 - 206.9 605.1 - 751.1
Permeate 1st pass Chloride content mg/l 133.97 133.97
Operating pressure RO 1st pass bar 65.5 - 66.6 65.5 - 66.6
Feed flow rate of RO 2nd pass plant m/d 67046.6 67046.6
Permeate flow of RO 2nd pass plant m/d 60340.76 60340.76
Feed flow rate per 2nd pass train m/d 11174.4 11174.4
Permeate flow rate per 2nd pass train m/d 60340.76 60340.76
Permeate 2nd pass Total Dissolved Solids mg/l 85.8 - 220.9 85.8 - 220.9
Permeate 2nd pass Chloride content mg/l 0.392 0.581 0.392 0.581
Permeate 2nd pass Boron content mg/l 0.00 0.00
Operating pressure RO 2nd pass bar 18.3 20.7 18.3 20.7

Case 2: (N-1)RO trains are in Operation

Feed flow rate of RO plant m/d 152400 152400


Permeate flow of RO 1st pass m/d 67056 67056
Feed flow rate per RO 1st pass train m/d 30480 30480
Permeate flow rate per RO 1st pass train m/d 13411.2 13411.2
Permeate 1st pass Total Dissolved Solids mg/l 165.6 209.7 605.9 - 752
Permeate 1st pass Chloride content mg/l 115.7 377.3 115.7 377.3
Operating pressure RO 1st pass bar 70.02 72.87 62.9 65.52
Feed flow rate of RO 2nd pass plant m/d 67056 67056
Permeate flow of RO 2nd pass plant m/d 60360 60360
Feed flow rate per 2nd pass train m/d 13411.2 13411.2
Permeate flow rate per 2nd pass train m/d 12069.6 12069.6
Permeate 2nd pass Total Dissolved Solids mg/l 0.4 0.98 0.4 0.98
Permeate 2nd pass Chloride content mg/l 6.36 - 9.96 6.36 - 9.96
Permeate 2nd pass Boron content mg/l 1.43 1.77 1.43 1.77
Operating pressure RO 2nd pass bar 16.09 16.77 10.12 11.04

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1.3.4. TECHNICAL DATA

1.3.4.1. PUMPS

Description Unit Data

First pass high pressure pumps

Manufacturer of pump - Flowserve


Number of pump units No. 6
Rate of pump delivery (design point) m/ h 565
Total differential head (design point) m 735.4
Number of stages No. 4
Speed RPM 3350
Materials
Casing - A890 Gr 5A
Pump impeller - A890 Gr 5A
Pump efficiency (design point) % 84.5
94.6%-96% @ Output 50%-
Motor efficiency (design point) %
100%
Power consumption at coupling of pump kW 1380

Second pass high pressure pumps

Manufacturer of pump - Flowserve


Number of pumps No. 3
Rate of pump delivery (design point) m/h 1188
Total differential head (design point) m 204
Efficiency (design point) % 84.6
Materials
Casing - A890 Gr 5A
Pump impeller - A890 Gr 5A
Power consumption at coupling of pump kW 779
Driving motor rated power KW 900
Maximum Rate of pump delivery (design point) m/h 1400
Total differential head (design point) m 190
Efficiency (design point) % 85
Power consumption at coupling of pump kW 945

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Description Unit Data

ERD Booster pumps

Manufacturer of pump - Flowserve


Number of pumps No. 6
Rate of pump delivery (design point) m/h 756
Total differential head (design point) m 58.34
Efficiency (design point) % 86.5
Materials
Casing - A890 Gr 5A
Pump impeller - A890 Gr 5A
Power consumption at coupling of pump kW 143

Driving motor (Variable speed)


Rated power kW 185

1.3.4.2. EQUIPMENT

Energy Recovery System

Manufacturer of device - Energy Recovery Inc


Number of devices No. 6 Devices / 84 Units
Type of energy recovery device - PX-Q300
Delivery rate of device (at design point) m/h 45-68
High1200psi (82.7 bar)
Pressure at device inlet (at design point) Psi(bar)
Low145psi (10bar)
Pressure at device outlet (at design point) Psi(bar) 12 (0.8)
Efficiency (design point) % 97.2
Materials
Casing/Shell - GRP
Internals - Superduplex
Valves/piping Pipe Flexible Pipe Coupling
Energy recovery per unit kW 1390

RO 1st pass
- Cross Linked Fully Aromatic
Material of membrane
Polyamide Composite
Type of membrane/elements - TM820M-440
Membrane manufacturer - Toray
Quantity of pressure vessels per train No. 144

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Quantity of elements per vessel No. 7


Reserve space provided for installation of additional %
-
pressure vessels
Materials of construction

Low pressure feed piping - GRP


High pressure feed and brine headers - Superduplex
Connecting pipework feed/brine headers to
- Superduplex
pressure vessels
Product headers - UPVC / CPVC
Product piping - GRP
Piping for cleaning - GRP
Piping for shut-down flushing - GRP

RO 2nd Pass
Cross Linked Fully Aromatic
Material of membrane -
Polyamide Composite
Type of membrane/ elements - TM720D-400
Membrane manufacturer - Toray
Quantity of pressure vessels per train No. 54
Quantity of elements per vessel No. 7
Reserve space provided for installation of additional
% -
pressure vessels
Materials of construction
Low pressure feed piping - GRP
High pressure feed and brine headers - Duplex
Connecting pipework feed/ brine headers to
- Duplex
pressure vessels
Product headers - UPVC / CPVC
Product piping - GRP
Piping for cleaning - GRP
Piping for shut-down flushing - GRP

Antiscalent Dosing System

Chemial dose as 100% mg/L 2.5


Number of storage/dosing tanks No.
2 / 10 m3
Capacity of storage/dosing tanks m
Material
Body /ends - GRP
Pipes / valves - PVC

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Number of dosing pumps No. 2


Material of dosing pumps
Housing - PVC
Diaphragm / Valves - PVDF/PTFE
Capacity of dosing pump l/hr 42

NaHSO3 dissolving and dosing station (SBS)

Chemial dose as 100% mg/L 4


Number of dissolving/dosing tanks No. 2
Capacity of dissolving/dosing tanks m 10
Material
Body/ ends - GRP
pipes/ valves - PVC
Agitator - V2A-PP
Number of dosing pumps No. 2
Material of dosing pumps
Housing - PP
Diaphragm / Valves - PVDF/PVC/PTFE
Capacity of dosing pump l/hr 1400

Caustic Soda Dosing System

Chemial dose as 100% mg/L 35


Number of storage/dosing tanks No. 2
Capacity of storge/dosing tanks m 50
Material
Body/ ends - GRP
pipes/ valves - SS
Number of dosing pumps No. 2
Material of dosing pumps
Housing - PP
Diaphragm / Valves - PVDF/EPDM
Capacity of dosing pump l/hr 500

Instrumentation

Detection system for free chlorine


Number of analyzers No 4

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Potentiostatic 3 electrode
Type of measuring system
system
Manufacturer Siemens
Measuring range from ......to...... mgCl2/l 0 to 5
SDI Online measuring system of RO feed
Number of instruments No. 3
Manufacturer MABAT

Cleaning equipment

Number of cleaning tanks No. 1


Net volume of each cleaning tanks m 60
Material
Body /ends - GRP
Pipes / valves -
Agitator - 316 SS
Heating/cooling facility for the CIP solution
Yes / 2
Number of cleaning/flushing pumps No.
Rate of delivery m/ h 720
Number of cartridge filters No. 1
Material
Housing - GRP
filter elements -
Cartridge filter nominal pore size m 5

CIP procedure

appr. frequency of cleaning 1st pass No./a 2 to 4


duration per cleaning 1st pass h 16
appr. frequency of cleaning 2nd pass No./a N/A
duration per cleaning 2nd pass h N/A

Permeate storage/flushing tank

Number of permeate tanks No. 1


Net volume of permeate tank m 1800
Material Concrete
shell plate - N/A
roof plate - N/A
bottom / annular plate - N/A
girder / rafter - N/A

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column - N/A

Permeate Flushing pumps

Number of permeate flushing pumps No. 2


Rate of delivery m/ h 144
Material of pump
Housing - SS 1.4408
Impeller - SS 1.4408
Drive type
capacity kW 15.05

Emergency flushing pumps

Number of Emergency Flushing pumps No.


Rate of delivery m/ h
Material of pump Flushing pumps are used for
emergency flushing
Housing -
Impeller -
Drive type
capacity kW

Mode of cleaning, flushing and draw-back

Stationary system Yes Yes


Connection of cleaning pipe work to the RO lines fixed Removable GRP connectors
Flushing with product of RO pressure vessels, modules
and all stainless steel comprising pumps and piping Yes/No Yes
provided
Product draw-back facilities in case of shut-down
Yes/No No
provided

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1.4. EMERGENCY SHUTDOWN CONDITIONS


Any of the following conditions will initiate an Emergency Shutdown (ESD) of all the RO
Plant, both pre-treatment and all UF Racks. All devices will be set to their fail-safe state. This
is software ESD and is carried out in the PCS logic:

Plant Operator Station ESD Button


Low Pressure Compressed Air

On Emergency Shutdown, all sequences will go to their idle state. DCS failure and power
loss will also set all sequences to idle.

1.5. REVERSE OSMOSIS (RO) TRAINS OPERATIONS


The main components influencing the RO trains operations are as follows:

Instruments

ORP Analyzer 00GCK25CQ006/008/009

Conductivity Transmitter 00GCK25CQ001

Turbidity Transmitter 00GCK25CQ003

pH Transmitter 00GCK25CQ005/CQ007

Temperature Transmitter 00GCK25CT001

Level Transmitters & Switches


20GCP30CL001
Permeate & Flushing Water Tank LT

Tanks
Permeate & Flushing Water Tank xxx m 20GCP30BB001

Pressure Transmitters
00GCK25CP001
Main Header Pressure Transmitter
HPP Suction Pressure Switch 20GCF11CP006
Membrane Feed Pressure Transmitter 20GCF11CP004
Membrane Diff. Pressure Transmitter 20GCF21CP001/CP002
PX LP out Pressure Transmitter
20GCF11CP005
HPP discharge pressure S/W
20GCF11CP007
Flow Transmitters
20GCF11CF001
HPP Feed Flow Transmitter

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PX LP in Flow Transmitter 20GCF11CF002


PX HP out Flow Transmitter 20GCF11CF003
Permeate Flow transmitter 20GCF21CF002

Pumps
HP Pumps 20GCF11AP001
Booster Pumps 20GCF11AP002
Motor Frequency Controller 20GCF11GU001-16GU001
Flushing Pumps 20GCP31AP001/32AP001

Actuated Valves 20GCF11AA001


HPP Feed Valve
PX LP in Valve 20GCF11AA002
Feed Line Vent Valve 20GCF11AA002
PX LP out Control Valve 20GCF11AA003
HPP Flushing Valve 20GCF11AA401
PX Flushing Valve 20GCF11AA402
Permeate Vent Valve 20GCF21AA004
Permeate Forward valve 20GCF21AA001
Permeate Dump Valve 20GCF21AA002
RO trains will be brought Online & Offline by the Operator to meet production demands.

All trains operate in exactly the same way, for simplicity the RO train descriptions given in
this document are based on Train 1 Tag Nos.

Brine flow is regulated by flow control valve on the reject line by 20GCF11AA003, via ERD
feed flow controller 20GCF11CF002.

The Brine flow control valve 20GCF11AA003 has a minimum flow position of xx %, which
will be set both in software and mechanically on the valve.

1.5.1. RO START-UP CONDITIONS


Start-up is not enabled unless all associated rundown and shutdown conditions are healthy.
Intake must be in operation.
All pump data must be within limits (temperature, oil, power, current, flow rpm)
The minimum number of DMF lines shall be in operation (if not bypassed)
All pump data must be within limits (temperature, oil, power, current, flow rpm)
The minimum number of Strainers shall be in operation.
The minimum number of UF racks for operation of RO shall be in duty No other RO
train starting or ramping down or in shut down sequence.

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All the valves in the train should not have any fault.
Signal from ORP Analyzer 2 out of 3 analyzers shall not trigger alarm high or high
high.
Signal from pH Transmitter CQ005/007 shall not trigger alarm high or high high.
Signal from Turbidity Transmitter shall not trigger alarm high or high high.
Membrane Feed Pressure Transmitter 20GCF11CP004 must give signal that RO
train pressure is < 5 bar for startup sequence #1 without pressure.
If Membrane Feed Pressure Transmitter 20GCF11CP004 gives signal that RO
train pressure is > 5 bar for startup sequence #2 with pressure-ON HOLD.
Air pressure in air system must be above minimum value.

1.5.2. RO FLOW SET POINTS AND RECOVERY CALCULATION


The RO feed flow is calculated by 20GCF11CF001 + 20GCF11CF003
The recovery Y is calculated by permeate flow (20GCF21CF002 / RO feed flow) x
100
A face plate for each individual RO is available in the DCS to enter the set points of
control valves and flows:

SP for PX LP out valve 20GCF11AA003 (after opening PX LP in valve) e.g. 20 %

SP for HPP feed flow 20GCF11CF001 e.g. 483 m/h

SP for PX LP in flow 20GCF11CF002 e.g. 704 m/h

SP for PX HP out flow 20GCF11CF003 e.g. 704 m/h

Display the calculated recovery as per the setpoints:

(Consider for the permeate flow 8 m/h less than HPP feed flow SP, e.g 475 m/h
Y = 475 / (483 + 704) x 100 = 40,0 %
The same inputs shall be adjusted to meet 44 % recovery

No input shall be allowed which results in a recovery > 45 %


When increasing the flows the order of input must be:

1. SP for PX LP in flow 20GCF11CF002

2. SP for PX HP out flow 20GCF11CF003

3. SP for HPP feed flow 20GCF11CF001

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When decreasing the flows the order of input must be:

1. SP for HPP feed flow 20GCF11CF001

2. SP for PX HP out flow 20GCF11CF003

3. SP for PX LP in flow 20GCF11CF002

Display the actual recovery at each RO train if RO is in operation:

Y = 20GCF21CF002 / (20GCF11CF001+20GCF11CF003) x 100

1.5.3. RO START-UP SEQUENCE #1 (WITHOUT FEED PRESSURE IN RO)


This sequence shall be used if the membrane feed pressure 20GCF11CP004 is < 4 bar
Operator selects [ONLINE] icon (pulse) for respective train (assume 1)

Display following POP up:

Confirm pipes are water filled and all relevant manual valves are in correct position.
Operator to enter YES to proceed.

DCS sets valves associated with RO Train to correct position as follows:

Feed vent valve 20GCF11AA002 Open


Permeate dump Valve 20GCF21AA002 Open
Permeate Vent Valve 20GCF21AA004 Open
Permeate Forward valve 20GCF21AA001 Closed
Brine Flow Control Valve 20GCF11AA003 Closed
HPP Flushing Valve 20GCF11AA401 Closed
PX Flushing Valve 20GCF21AA002 Closed
Display following Popup (if the first RO is started)

Do you want to start ASC dosing?

Operator to enter YES or NO to proceed. Operator must be aware of possible consequences


if NO is selected.

LP flushing of RO system

Open the raw water feed valves 20GCF11AA001 & 20GCF11AA002 and start the
timer, e.g 300 sec.
Check for the flows-20GCF11CF001 and CF002 & CF003.
After xxx sec. close vent valves

After elapse of timer xxx sec.

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Start ERD Booster Pump

Start the booster pump with a frequency of xx hz.


keep the position of PX LP outlet valve at fully open position.
Wait for predefined time and start increasing the frequency of the ERD booster pump
until 20GCF11CF003 reaches the pre-defined value e.g 704 m3/hr.

Start HPP
If following conditions are fulfilled:
HPP inlet valve is open
Permeate forward valve is closed and dump valve is open.
Permeate vent valve is open.
PX LP in valve is open.
PX LP out valve is in preset position.
Pre-conditions for pretreatment are OK.
ERD Booster pump is running
Pump inlet pressure should be greater than or equal to 2 bars

Then:

Start HP Pump
Increase flow 20GCF11CF001 to set point of e.g. 704 m/h by increasing frequency of HP
Pump.
The speed of increase and system pressurization must not exceed pressure increase rate
of x.x bar/second measured on Membrane Feed Pressure Transmitter-20GCF11CP004
Continue ramping up the RO until the HPP feed flow setpoint is achieved flow set point
e.g. 483 m/h.
Start flow control for Control Valve 20GCF11AA003 with flow set point (Xyz) signal
from HPP Feed Flow Transmitter 20GCF11CF001
The RO is considered in operation if the feed pressure is > 40 bar.
Wait until the permeate conductivity reaches a predefined value.
Open the permeate forward valve 20GCF21AA001 and
Close the dump valve 20GCF21AA002.

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1.5.4. RO START-UP SEQUENCE #2 (WITH FEED PRESSURE IN RO)- ON HOLD

1.5.5. PRESSURE VERSUS FLOW CONTROL


Usually the flows are controlled to reach a certain production at a certain recovery. Once
the membranes are getting older and fouled the pressure may increase beyond the
allowable limits.

If feed pressure measured by Membrane Feed Pressure Transmitter 20GCF11CP004


exceeds the maximum allowed pressure related to the temperature of feed water for more
than 1 hour, then the HPP feed flow control is toggled to pressure control. The pressure set
point used is to prevent maximum permissible pressure from being exceeded.

e.g. at 30 C the maximum allowed feed pressure in [psi] is calculated


with 1250 5 x 30 = 1100 psi.

The maximum allowed feed pressure must be converted to bar by division with
14,504 P(max) = 1100 psi / 14,504 = 75,8 bar

Pressure control set point = maximum allowable pressure 1.0


High Alarm Setting = maximum allowable pressure 0.5

High High alarm setting = maximum allowable pressure (HH will initiate run down of the train
if duration exceeds time (T xyz) hours.

1.5.6. RO RUNDOWN SEQUENCE


Rundown is initiated by operator selecting [OFFLINE] icon, for respective train or any
rundown trip condition.

If the rundown is initiated manually by operator there are two options of rundown. With or
without flushing. The option is ticked prior to send RO to OFFLINE.

If the rundown is initiated by trip there is no flushing at all and the RO stops without flushing

RO RUNDOWN WITHOUT FLUSHING


If OFFLINE is initiated manually then display Popup:

Confirm Rundown of RO train

Operator to enter YES to proceed or NO to abort & return to Online.

DCS carries out following actions Run Down HPP:


Gradually reduce the frequency of HPP until feed flow reaches xx m3/hr.

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The speed of valve opening and system de-pressurization must not exceed pressure
decrease rate of 0.7 bar/second measured on Membrane Feed Pressure Transmitter.
If minimum flow is reached stop reducing the frequency and wait 10 sec.
Then stop HPP and open the permeate vent valve
If permeate vent valve is open continue to open the brine valve 20GCF11AA003 to
predefined position.
Open the dump valve 20GCF21AA002 and Close permeate outlet valve
20GCF21AA001 which may be controlled by permeate conductivity High limit. Dump
valve opens when Conductivity reached high limit and closes the permeate forward
valve.
Close the HPP inlet valve 20GCF11AA001
Reduce frequency of ERD booster pump to 50% o Wait 60 sec.
If time is elapsed then stop flow control for RO booster pump and reduce frequency to
the minimum of 20 Hz and stop RO booster pump
Close PX LP out flow control valve to predefined position and then close PX LP in
valve 20GCF11AA002.

RO RUNDOWN WITH FLUSHING


If OFFLINE is initiated manually then display Popup:
Confirm Rundown of RO train
Operator to enter YES to proceed or NO to abort & return to Online.
DCS carries out following actions Run Down HPP:
Gradually reduce the frequency of HPP until feed flow reaches xx m3/hr.
The speed of valve opening and system de-pressurization must not exceed
pressure decrease rate of 0.7 bar/second measured on Membrane Feed Pressure
Transmitter.
If minimum flow is reached stop reducing the frequency and wait 10 sec.
Then stop HPP and open the permeate vent valve
If permeate vent valve is open continue to open the brine valve
20GCF11AA003 to pre defined position.
Open the dump valve 20GCF21AA002 and Close permeate outlet valve
20GCF21AA001.
Open HPP flushing valve 20GCF11AA401

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if valve is open then close RO HPP inlet valve 20GCF11AA001 o Reduce


set point for PX LP flow control to 50 %
Open PX LP in flushing valve 20GCF11AA402
If valve is open then start one flushing pump 20GCP31/32AP001
If pump is running then close PX LP in valve 20GCF11AA002 o Start timer
flushing through PX (default 300 sec.)
If flow to HPP > 20 m/h AND HPP flushing valve 20GCF11AA401 is open
then reduce flow setpoint for PX LP out control valve to 40 %.
If time is elapsed then stop flow control for RO booster pump and reduce
frequency to the minimum of 20 Hz and stop RO booster pump.
Close PX LP out flow control valve to predefined position and then open
the vent valves.
Stop the flushing pump and wait for xx sec.
Close the flushing valves 20GCF11AA401 and 20GCF11AA402.

1.5.7. RO SHUTDOWN SEQUENCE


Shutdown is initiated by any valve fault, pump fault and certain instrument limits exceeded

DCS carries out following actions:

When the HPP feed flow is below the minimum flow of 209 m/h then stop HPP.
If the pump is stopped open permeate vent valve.
If the permeate vent vale is open then close permeate valve and open dump valve,
Close HPP Feed Valve
Close PX LP out control valve and ramp down RO Booster Pump and
stop the pump at minimum frequency and open the vent valve 20GCF21AA003.
Close PX LP in valve.

1.5.8. FLUSHING SEQUENCE FOR OFFLINE RO


If the RO train is stopped by operator without flushing or shut down by fault a timer will be
started (default time 240 minutes). If the RO train is not started before the expiry of this timer
a Popup is issued

Confirm RO Train #x Permeate Flushing

If the request is not confirmed and the Popup is removed it will reappear every 60 minutes.

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The OFFLINE flushing can be also initiated by the Operator via the face panel prior to the
expiry of the timer.

The permeate flushing sequence for the RO train which is OFFLINE depends on the
pressure in the system.

Flushing Preconditions

At least one flushing pump must be ready for operation.


Level in Permeate & Flushing Water Tank xxx m 00GCP40BB001 must be higher
than xx %.
Relevant valves required for flushing must be in healthy conditions

HPP Flushing Valve 20GCF11AA401


PX LP in Flushing Valve 20GCF11AA402
Permeate Vent Valve 20GCF21AA004
PX LP out Control Valve 20GCF11AA003
Feed vent valve 20GCF21AA004
SWRO to ERD Vent Valve 20GCF21AA003

Air pressure in air system must be above minimum value and RO booster pump must
be ready.

OFFLINE FLUSHING PROCEDURE WITH PRESSURE

If the membrane feed pressure 20GCF11CP004 is > 6 bar then this procedure will
apply.
The OFFLINE flushing is initiated either by timer and operator confirmation or by input
in the face panel.
Following valves to be positioned as follow:

HPP inlet Valve 20GCF11AA001 closed


PX LP in Valve 20GCF11AA002 closed
HPP Flushing Valve 20GCF11AA401 closed
PX LP in Flushing Valve 20GCF11AA402 closed
Permeate Vent Valve 20GCF21AA004 open
PX LP out Control Valve 20GCF11AA003 closed
Feed vent valve 20GCF11AA002 closed

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Brine vent valve 20GCF21AA003 open

DCS carries out following actions:


Open PX LP in Flushing Valve 20GCF11AA402.
Open PX LP out control valve 20GCF11AA003 to preset position (default 20 %)
Start duty flushing pump 20GCP31/32AP001.
Start RO booster pump 20GCF11AP002 and ramp up to flow setpoint of
20GCF11CF003.
Start timer (default 300 sec.).
If timer is elapsed OR feed pressure 20GCF11CP004 is < 4 bar continue, else
wait.
Open HPP flushing valve 20GCF11AA401.
Open feed vent valve 20GCF11AA002 and ERD vent valve 20GCF21AA004 and
brine vent valve 20GCF21AA003.
Reduce frequency of RO booster pump to 50 % flow set point.
Close PX LP out control valve 20GCF11AA003 and close PX LP in Flushing
Valve 20GCF11AA402.
If feed valve is fully open start timer (default 300 sec.) After 120 sec. close all vent
valves.
After elapse of timer ramp down the booster pump and stop.
Stop flushing pump and after xx sec close HPP flushing valve

OFFLINE FLUSHING PROCEDURE WITHOUT PRESSURE


If the membrane feed pressure 20GCF11CP004 is < 6 bar then this procedure will
apply.
The OFFLINE flushing is initiated either by timer and operator confirmation or by input
in the face panel.
Following valves to be positioned as follow:

HPP inlet Valve 20GCF11AA001 closed


PX LP in Valve 20GCF11AA002 closed
HPP Flushing Valve 20GCF11AA401 closed
PX LP in Flushing Valve 20GCF11AA402 closed
Permeate Vent Valve 20GCF21AA004 open
PX LP out Control Valve 20GCF11AA003 closed
Feed vent valve 20GCF11AA002 closed

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DCS carries out following actions:

Open PX LP in Flushing Valve 20GCF11AA402


Open PX LP out control valve 20GCF11AA003 to preset position (default 20 %).
Start duty flushing pump 20GCP31/32Ap001.
Start timer (default 60 sec).
If timer is elapsed continue, else wait.
Open HPP flushing valve 20GCF11AA401
Open feed vent valve 20GCF11AA002 and ERD vent valve 20GCF21AA004 and
brine vent valve 20GCF21AA003.
Start RO booster pump 20GCF11AP002 and ramp up to flow set point of
20GCF11CF003.
Close PX LP out control valve 20GCF11AA003 and close PX LP in Flushing
Valve 20GCF11AA402.
Start timer (default 300 sec.) After 120 sec. close all vent valves.
After elapse of timer ramp down & Stop RO booster pump.
If RO booster pump is stopped then close HPP flushing valve and stop flushing
pump
If feed control valve is closed procedure is finished.

1.5.9. RO STANDBY CONDITIONS


It is expected that SWRO plant should be kept in continuous operation, but it may
happen that due to some reasons train or trains may be placed in standby conditions.
Membranes which are loaded and not operated are subject to the standby conditions
what can be seen as:

a. Short Term Standby.

b. Long Term Standby.

Short-term storage is for periods where an RO plant must remain out of operation for more
than few hours, but fewer than thirty days, with the RO elements in place. Relevant RO train
in short term standby should be regularly flushed with pre-treated feed water - ultra filtrate,
while simultaneously venting any gas from the system. Flushing with RO permeate water
instead of pre-treated feed water has added benefits, and may help remove or keep under
control buildup of foulants.

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Long-term storage is for periods where an RO plant must remain out of operation for more
than thirty days with the RO elements in pressure vessels. The RO train in such conditions
should be cleaned and preserved using proper preservative solution.

It is very important for RO elements in a vessel or RO train that is not operating, the
temperature of the building should be such that the temperature of the water inside the
vessel does not exceed 45 C.

The DCS has built in logical sequence for safe Standby of RO trains. DCS considers
particular RO train in standby if HP Pumps and Booster Pumps not in operation for more
than timer {Txyz} default value 12 hours.

DCS displays OAR

Confirm RO Train Flushing

A. Filtered Feed Water Flushing or

B. RO Permeate Flushing

Operator selects required type of flushing and confirms it.

LP Feed Water Flushing of RO system


This procedure will work only if there is no pressure in the RO system and the brine vent
valve and permeate vent valve are open.

LP Feed Water Flushing of RO system


Open HPP Feed Valve 20GCF11AA001.
If RO Feed Valve is open then start RO booster pump with 50 % of the flow set point.
Open PX LP in Valve 20GCF11AA002.
Open PX LP out control valve 20GCF11AA003 to preset position (default 20 %).
If PX LP out control valve is in position start timer (default 60 sec.).
After the timer is elapsed, then close PX LP out control valve.
If the valve is closed, then close PX LP in Valve 20GCF11AA002.
If RO Feed valve is open start timer (default 300 sec.) If the timer is elapsed then:
Stop RO booster pump.
Close HPP Feed valve 20GCF11AA001
Permeate vent valve 20GCF21AA004 remains open during the LP Feed water
Flushing.

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RO Permeate Flushing of RO system

This procedure is identical with the flushing procedure without pressure in the system as
described above.

The DCS has built in condition that permeate flushing must be executed at least every
5 days AND the RO train is NOT in sanitizing condition. Operator cannot change this
condition! Permeate flushing will start independently on operators selection.

1.6. CALCULATIONS

The following calculations will be carried out for RO.

1.6.1. RECOVERY CALCULATIONS


Train recovery is measured by the conversion ratio, which is:
Y= Product Flow (20GCF21CF002) x 100 %
Feed Flow (20GCF11CF001+20GCF11CF003)
This will be carried out for all RO Trains and displayed.

1.6.2. NORMALISATION CALCULATIONS


Normalisation will be automatically available within the system, utilising the algorithm
contained in Normalisation Calculations Spreadsheet will be submitted later

1.7. TRENDS

1.7.1. RO TRENDS FOR EACH RO


0 1000
Individual RO train inlet flow HP
Individual RO train inlet flow PX
Individual RO train booster flow PX
Individual RO train product flow

0 2000
Individual RO train outlet conductivity

0 100
Individual RO train feed pressure
Individual RO train temperature

0 10
Individual RO train differential P

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Individual RO train brine discharge P

1.7.2. QUALITY TRENDS 1 FOR ALL ROS


0 2000
Individual RO train outlet conductivity

1.7.3. QUALITY TRENDS 2

0 10
RO Feed Water pH
RO Feed Water Turbidity

0 1000
RO Feed Water ORP
RO Feed Water Conductivity

1.7.4. PRESSURE TREND 1 FOR ALL ROS


0 100
Individual RO train feed pressure

1.7.5. PRESSURE TREND 2 FOR ALL ROS

0 10
Individual RO train differential Pressure

1.8. EVENTS

The following alarms/events will be date and time-stamped by the DCS and displayed on the
HMI system, these alarms/events will also be printed out on the event printer.

Alarm Initiated.
Alarm Acknowledged.
Alarm Cleared.
Device Failure Initiated.
Device Failure Acknowledged.
Device Failure Cleared.
Sequence Start (All sequences).
Sequence Stop (All sequences).

1.9. REPORTS

The following report functionality will be available in the system:

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Daily Report.
Monthly Report.

Each report shall contain the following information:

Production of each RO Train.


Running hours of each RO Train.
Average RO permeate quality of each RO Train.
Total production of permeate pumped to the product tank.
Total production of product pumped.
Average product chlorine.
Average product Ph.
Average product conductivity.
Overall plant power consumption.
Specific power consumption.

The reports shall be automatically printed out on the local report printer and can be printed
on the following day from the day before and in the following month from the month before.
The monthly report shall also be saved as a print file in suitable format.

1.10. RO CHEMICAL CLEANING SYSTEM

The main components influencing the RO CIP operations are as follows:


Instruments
CIP Temperature Transmitter 00GCP45CT001
pH /ORP Transmitter 00GCP45CQ001/003
RO CIP Tank LT 00GCP40CL001
RO CIP Tank 60.0 m 00GCP40BB001
Main CIP Header Pressure Transmitter 00GCP45CP002
Membrane Diff. Pressure Transmitter 20GCF21CP001/002
ERD Reject Pressure Transmitter 20GCF11CP005
CIP Feed Flow Transmitter 00GCP45CF001
CIP Pumps 00GCP41-43AP001

Heaters
CIP Heater 00GCP45AH001/002

Mixer
RO CIP Mixer 00GCP40AM001

Actuated Valves
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Permeate Vent Valve 20GCF21AA004


Permeate Forward valve 20GCF21AA001
As the performance of the membranes is decreasing with operation time because of build-up
of foreign matters, a chemical cleaning has to be performed to regain a proper membrane
performance.

The preparation of the cleaning solution as well as the execution of the cleaning process
involves many steps to be carried out manually, so there is no automatic operation of this
process, only the pumping of the cleaning solution should be handled via operator control
through the HMI. It shall be done also in local manual mode.

The Operator as required will carry out chemical cleaning. The automatic sequences
associated with operation of CIP system is limited to automatic opening of the permeate vent
valve if the CIP pump is stopped or tripped.

Operator should open and adjust all valves and run CIP pumps manually from local panels or
via HMI. Only two CIP pumps should normally run in parallel!

Cleaning solution is made up in tank 00GCP40BB001. Tank volume is 60 m. Tank feeds 3 x


50% CIP pumps. These are initially used to recycle cleaning solution through tank and then,
once chemicals are properly mixed and solution warm, recycle through the appropriate RO
train via manually set-up valves. Cycling the solution through the tank equipped with heater
via CIP pumps controls the correct cleaning solution temperature.

Indication of cleaning solution flow to the RO Trains is provided via 00GCP45CF001.

Indication of cleaning solution pH/ORP is provided via 00GCP45CQ001/003 with high and
low warnings and alarms.

Indication of cleaning solution temperature is provided via 00GCP45CT001 with high and low
warnings and alarms.

Brief description of manual CIP procedure is as follows.

Relevant RO train must be in standby and flushed with RO permeate (the RO train is
pressure less and the ERD vent valve and permeate vent valve are open).

Operator activates CIP mode via HMI displays following Popup

Operator Adjust All Relevant Valves For CIP!

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Circulate the cleaning solution through the pressure vessels for approximately half an
hour or the desired period of time. At the start, send the displaced water to drain so
you dont dilute the cleaning chemical and then divert up to 20% of the most highly
fouled cleaning solution to drain before returning the cleaning solution back to the RO
Cleaning Tank. For the first 5 minutes, slowly throttle the flow rate to 1/3 of the
maximum design flow rate. This is to minimize the potential plugging of the feed path
with a large amount of dislodged foulant.
For the second 5 minutes, increase the flow rate to 2/3 of the maximum design flow
rate, and then increase the flow rate to the maximum design flow rate. If required,
readjust the pH back to the target when it changes more than 0.5 pH units.
An optional soak and recirculation sequence can be used, if required. The soak time
can be from 1 to 8 hours depending on the manufacturers recommendations.
Preferred pattern is 30 minutes recirculation and 30 minutes soaking. Caution should
be used to maintain the proper temperature and pH.

Do not exceed maximum pH and temperature limits for specific elements. See Table
below.

Temperature 50C 45C 35C 30C

pH of CIP
Contact TORAY 2.0 11.5 2.0 12.0 2.0 12.5
solution

To prevent possible problems due to high pH and/or high temperature during the CIP
following alarms are generated by DCS:

If CIP solution temperature is <30C AND CIP pH is < 2.0 or pH > 12.5 Display
following Popup

Operator Adjust CIP Solution pH!

Same POP Up is displayed if

CIP solution temperature is 35C >T>30.1C AND pH is <2.0 or pH>12.0


CIP solution temperature is 45C>T>35.1C AND pH is <2.0 or pH>11.5
If CIP solution temperature is T>45C and pH of CIP solution is >11.5 following popup
is displayed:

Operator Immediately Stop CIP Recirculation - Adjust pH and temperature!

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The above messages are generated if CIP of the train is confirmed via HMI button and at
least one of CIP pumps is in operation.

To prevent damage of the heater or CIP pumps or mixer due to low level in the CIP tank a
level transmitter is installed. This means that any actions that trip the CIP pump will also trip
the mixer and the heater and the CIP pumps can only run if the LIT 00GCP40CL001 is above
L limit and LSL/LSLL 00GCP40CL002/CL003 are not active

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2. BWRO

2.1. GENERAL

The pretreated sea water is desalinated in reverse osmosis trains. The first pass SWRO
consists of 6 RO trains built as split partial 2nd pass SPSP. The low TDS permeate from
the front end of the 1st pass RO pressure vessels may be used directly for blending, whereas
the high TDS permeate from the brine end will be desalinated further in the 2nd pass BWRO.
The amount of blending water as well as the feed for the 2nd pass BWRO from the individual
RO trains is depending on the conductivity and may vary from train to train.

The BWRO consists of a set of 2nd pass feed pumps (2nd PFP) equipped with a VFD and 6
BWRO trains.

Each 2nd PFP has the capacity to feed two BWRO trains.

2.2. MAIN COMPONENTS

Three 2nd pass feed pumps with VFD.


Six membrane Trains in two stages each.
Header system with pressure unloading valve and Flushing system.

2.3. OPERATION OF BWRO

2.3.1. MANUAL OPERATION


Manual operation of a single RO train may be possible, but it is not advised to operate more
SWRO trains and / or BWRO trains in manual mode, as the control of flows and pressures
will be difficult to impossible.

If any equipment is operated manually only the hardwired protections are active and special
care must be taken.

The PLC will display only the status of equipment and analogue values on the VDU.

2.3.2. AUTOMATIC OPERATION


When the selector switch on the MCC is switched to position PLC, the control of the related
equipment via PLC system is possible.

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2.3.2.1. HMI MODE

In HMI Mode, individual equipment can be started and stopped, opened and closed from the
system. No PLC interlocks are active and special care must be taken as hardwired interlocks
are active only. When operating individual equipment, it must be assured that the relevant
portion is safe for operation and no pressure surges, water hammer or similar will occur.

2.3.2.2. PLC MODE

In PLC mode, the start-up of the individual BWRO train is initiated by an operator input and
will follow a certain sequence. All interlocks are active and the flows are controlled for
startup, operation and shut down. After selection of PLC operating mode from a tick box in
the control picture on the DCS, the PLC will start the RO according to predefined settings
within the SCL operation mode.

As the 2nd PFPs are separated and common for all 6 BWRO trains there will be a difference
in starting the first BWRO or another BWRO.

If a BWRO shall be started, this means that the permeate of one SWRO train is dumped
via the pressure offloading valve 20GCK36AA101 and one SWRO more is in operation
than BWRO.

Prior to start up all automatic valves are in the zero or fail safe position:

zero fail safe


Valve tag name
position position
2nd PFP suction vent valve 00GCF1xAA001 closed open
2nd PFP discharge valve 00GCF1xAA002 closed open
BWRO feed control valve 20GCF3xAA101 closed fail fixed
Feed vent valve 20GCF3xAA002 closed
Brine vent valve stage 1 20GCF3xAA003 closed
Brine vent valve stage 2 20GCF3xAA001 closed
Permeate vent valve 20GCF3xAA004 open
Brine control valve 20GCF3xAA102 open fail fixed
Permeate valve 20GCF3xAA005 closed fail open
Permeate dump valve 20GCF3xAA006 closed

Fail safe position is given if different than zero position.

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In addition, the manual train isolation valves are open for normal operation:

zero fail safe


Valve tag name
position position
BWRO isolation valve 20GCF3xAA201 open

2.3.2.3. START OF BWRO


Start condition (AND):
The RO train is selected for PLC (tick box) mode of operation
2nd PFP motor is ready and none of the following fault conditions for 2nd PFP apply:
dry-run protection through the pressure switch 00GCF1xCP001_PLM on the
suction side time delayed.
Emergency button active.
Restart lock-out time for the 2nd PFP: 10 minutes.
Manual BWRO feed isolation valve is open 20GCF3xAA201_OM.
Sufficient control air pressure (00GCX23CP001 or 00GCX23CP002).
All pneumatic valves have no fault ..._FM.
All electric ON/OFF valves and control valves have no fault ..._FM.
All electric ON/OFF valves and control valves are in auto Mode.
One more SWRO is in operation than BWRO.
The pressure for 2nd pass feed is not low 00GCK40CP001_PSLL
Start command Start BWRO 3x in VDU issued.

Note:
Only for start of the 1st, 3rd and 5th BWRO train an additional 2nd PFP is required and must
be available.
For start of the 2nd,4th and 6th BWRO train the frequency of the operational 2nd PFP(s) will
be increased only.
2nd PFP
Issue flag BWRO 3x starting
All BWRO related valves are in zero position Issue POPUP message

Confirm that manual 2nd PFP discharge valve is open and locked 00GCF1xAA202
Issue POPUP message

Confirm that manual Ph2 feed valve is open and locked 20GCK45AA201

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Issue POPUP message for BWRO to be started

Confirm that all three manual cleaning isolation valves on feed and brine side are closed
and locked (20GCF3xAA203/204/205)
If all POPUP messages are confirmed and valve positions are reached continue, else
wait.
If valve positions are not reached within allowed time limit issue fault message of
concerned valve and reset RO start command
If one 2nd PFP has to be started then continue, else go to step Start BWRO
Open suction vent valve 00GCF1xAA001_OC
If vent valve is open 00GCF1xAA001_OM start vent time for e.g. 10 sec.
If time is elapsed close suction vent valve and open pump discharge valve
00GCF1xAA002_OC.
If discharge valve is open 00GCF1xAA002_OM, then go to step Start BWRO

Start BWRO
Open BWRO feed control valve 20GCF3xAA101 to fixed position, e.g. 10%
Open feed vent valve 20GCF3xAA002_OC and start feed vent time for e.g. 30 sec.
If valve is open. Open 1st stage brine vent valve 20GCF3xAA003_OC and start 1st
stage brine vent time for e.g. 100 sec. if valve is open.
Open 2nd stage brine vent valve 20GCF3xAA001_OC and start 2nd stage brine vent
time for e.g. 150 sec. if valve is open.
Open permeate vent valve 20GCF3xAA004_OC and start permeate vent time for e.g.
200 sec. if valve is open.
Open permeate to dump valve 20GCF3xAA006_OC
Release brine control 20GCF3xAA102 and limit brine flow to 60 m/h After elapsed
time close feed vent valve / 20GCF3xAA002_OC
After elapsed time close 1st stage brine vent valve 20GCF3xAA003_OC
After elapsed time close 2nd stage brine vent valve20GCF3xAA001_OC
After elapsed time close permeate vent valve 20GCF3xAA004_OC
If all vent valves are closed start increase opening of feed control valve with a ramp
Start to calculate BWRO feed flow 20GCF3xCF005

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Feed flow = (1st stage permeate flow + 2nd stage permeate flow) + brine flow
20GCF3xCF005 = 20GCF3xCF004 + 20GCF3xCF003

Start to calculate BWRO3x recovery Y(BWRO3x)

Y(BWRO3x) = (20GCF3xCF004 / 20GCF3xCF005 ) * 100

Avoid at all times that the recovery Y(BWRO3x) is higher than 90% by limiting (opening)
brine control valve. The setpoint for the brine control valve is the permeate production, which
is 90% of the feed flow (default 90 %, adjustable 80 90 %)

During increasing the BWRO feed flow by opening the control valve 20GCF3xAA101 the
pressure on the 2nd PFP suction side 00GCK40CP001 is monitored and maintained by
control with the pressure offloading valve

20GCK36AA101. (please refer P&ID-018)

If the pressure offloading valve is completely closed 20GCK36AA101_CM then stop


increasing the feed to the starting BWRO.

During multi-train operation and may be the case that the blending flows from different
SWRO trains are different and as such also the high TDS permeate to the BWRO will be
different. The total high TDS flow shall be distributed equally to all BWRO trains in operation.

During the starting of any BWRO the flow to the other operational BWRO trains remains
unchanged, i.e. the feed flow setpoint will be frozen during the starting period of one BWRO
train. Once the start up is finished the feed flows through all operational BWROs will be
balanced again.

The starting BWRO is considered in operation if

The pressure offloading valve is closed and


The recovery is > 60%
Independent which permeate valve is open 20GCF3xAA005_OM or
20GCF3xAA006_OM

Then:

Reset flag BWRO 3x starting


Set flag BWRO 3x in operation

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2.3.2.4. OPEN PERMEATE VALVE AND FILL PRODUCT TANK

If the permeate conductivity of the starting BWRO train is within the limits then open the
permeate valve 20GCF3xAA005_OC.

Note: if n permeate valves are open also n product tank filling valves(00GCK36AA001/002)
must be open.

If both valves are open then close the permeate dump valve / 20GCF3xAA006_OC

2.3.2.5. MONITORING OF BWRO IN OPERATION

During RO operation, all parameters important for a safe operation are monitored and
recorded.

If values are beyond the limits of warning a message is initiated. If the parameter reaches the
alarm value the RO will mostly shut down.

All process values which lead to an alarm or warning are listed in the latest alarm list.

A shut down of any BWRO is initiated if one or more of the following conditions apply:

Any automatic valve position not as required by process.


Insufficient number of 2nd PFP in operation.
An operational 2nd PFP is on fault and no other pump available.
A shut down request for SWRO is given and more BWRO are in operation.

If a SWRO train is stopped a BWRO train shall be stopped as a consequence to have the
same number of BWRO than SWRO in operation.

The BWRO which is shut down for any reasons above shall be the one with the highest
differential pressure 20GCF3xCP002 OR 20GCF3xCP004 or a priority sequence shall be
selected by operator on which BWRO has to be shutdown in such cases.

A shut down of the individual BWRO is initiated if one or more of the following conditions
apply:

Operator input in DCS to shut down BWRO GCF3x.


Pressure switch 2nd PFP suction is low 0GCF1xCP001_PLLM
Pressure measurement 2nd PFP discharge is high high 00GCF1xCP002_PHHM
Pressure measurement 2nd PFP discharge is low low 00GCF1xCP002_PLLM

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after start up delay Flow measurement 2nd PFP discharge is low low
00GCF1xCF001_FLLM
after start up delay Conductivity measurement 2nd pass feed is high high
00GCK40CQ01_QHHM
after start up delay pH measurement 2nd pass feed is high high
00GCK40CQ02_QHHM
Any temperature measurement bearing of 2nd PFP is high 00GCF1xCT0xx_THHM
Any temperature measurement winding of 2nd PFP is high 00GCF1xCT00x_THHM
Any vibration measurement of 2nd PFP is high 00GCF1xCV0xx_VHHM
Any automatic valves are not in position
BWRO train isolation valve is not open 20GCF3xAA201_OM
Bursting disk on high TDS permeate side is broken 00GCK30CU502/505
Pressure 1st stage permeate is high high 20GCF3xCP003_PHHM
Pressure permeate is high high 20GCF3xCP005_PHHM
Conductivity permeate is high high 20GCF3xCQ001_QHHM
Flow brine is low low 20GCF3xCF003_FLLM
Recovery is higher than 91 % for more than 5 minutes

2.3.2.6. SHUT DOWN OF BWRO

If one or more of the above conditions are fulfilled the shutdown of the individual BWRO will
be initiated.

Reset flag BWRO GCF3x in operation Set flag shut down BWRO GCF3x
Open permeate dump valve 20GCF3xAA006_OC
If permeate dump valve is open then
close permeate valve / 20GCF3xAA005_OC and close one permeate to tank valve /
00GCK36AA00x_OC
Stop brine control and keep position of valve
Stop feed control and close feed control valve /20GCF3xAA101_OC to preset
position of e.g. 10%
Reduce frequency of all 2nd PFPs to maintain the max required pressure of any
BWRO in operation
If BWRO feed flow has reached 60 m/h then open brine control valve
20GCF3xAA102_OC

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If brine control valve is open 20GCF3xAA102_OM wait for 1 minute and then close
feed control valve completely / 20GCF3xAA101_OC
Open permeate vent valve to avoid pressurization from permeate side
20GCF3xAA004_OC

2.3.2.7. SHUT DOWN OF 2ND PFP

Each 2nd pass pump is meant for feeding 2 RO trains. If any BWRO unit will shut down the
pump with high running hours will have to reduce the frequency and for the next BWRO unit
the same pump will shut down.

The pump with the highest running hours shall reduce the frequency gradually.
The remaining pump(s) in operation shall increase the frequency to keep the
maximum required pressure of any operational BWRO
At the minimum flow the pump shall be stopped.
If the pump is stopped / 00GCF1xAP001_RM then close pump discharge valve
20GCF1xAA002_OC
If the pressure at the pump 00GCF1xCP001_PMV > 5 barg then open the suction
vent valve 00GCF1xAA001_OC
If the pressure at the pump 00GCF1xCP001_PMV < 1 barg then close the suction
vent valve 00GCF1xAA001_OC

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