OPERATING MANUAL

ULTRA FILTRATION
Capacity : 5 m3/Hour

1/1/2018

Prepared by :
Hydromaster Harmoni Nusantara,pt
Kompleks Inkopal Ruko KTC F/58 | Jl. Bulevar Barat Raya, Kelapa Gading, Jakarta 14240
T. (62-21) 4585 1435 | F. (62-21) 4585 1662 | E. contact@hydromaster-indonesia.com
www.hydromaster-indonesia.com
1. Content
Pages

1 Content 1
2 Brochures and Information 2
3 Process Description 8
3.1 Process Diagram 9
3.2 Filtration Diagram 10
3.3 Forward Wash Diagram 11
4 Installation Description 12
4.1 Mechanical System Schematics 12
4.2 System / Electrical Control & Schematics 13
5 System / Electrical Control & Schematics 14
5.1 Basic Controls on Starting and Stopping the System with Automatic Operating 15
5.2 Basic Controls on Starting and Stopping the System with Manual Operating 15
5.3 Basic Controls on Starting and Stopping Maintenance Cleaning (MC) the
System with Automatic Operating 16
5.4 Basic Controls on Starting and Stopping Recovery Cleaning (RC) the System
with Automatic Operating 16
5.5 Inverter Settings, Changing Filtration Pump Frequency Setting 17
5.6 PLC Diagram 18
6 Chemical Cleaning Solution 19
7 Storage and Usage 19
8 Trouble Shooting 20
9 System Parameter Record Chart 21

Page 1 of 21
2. Brochures and Information Model No: U686

Table 1 Specification of Hydromaster Ultra Filtration Membrane Cartridge

Parameter Hydromaster Ultra Filtration Membrane

Material of UF membrane PVDF
Membrane surface area 38 m2
Inlet / outlet size DN32
Number of permeate outlet 2
Pore size < 0.1 micron
Fibre ID / OD 0.6 mm / 1.2 mm
Filtration System Outside - In
Diameter 6" (160 mm)
Length 68" (1730 mm)
Capacity per module 1.5 - 5 m3/hour (depending on feed water quality)

Table 2 Feed Water Quality Required

Parameter Allowed Range
Feed water Tap water, ground water, surface water, sea water, treated waste water
pH 1 - 10
TSS < 100 ppm (mg/L)
TOC < 10 ppm (mg/L)
Oil & grease < 2 ppm (mg/L) otherwise pretreatment is required for removal of excessive oil
Hardness(CaCO3) < 150 ppm (mg/L) depending on pH, temperature and overall fouling potential
Allowed particle size in feed water < 0.5 mm

Table 3 Recommended Operation Parameter

Parameter Recommended Operation Parameter
Module capacity 1.5 m3/hour
Maximum feed pressure 2 Bar
Maximum Trans-Membrane Pressure (TMP) 1 Bar
Maximum air pressure 3 Bar
Operation Temperature 5 - 45 oC
pH range (cleaning) 0 – 12
Operation Mode Dead - end or Cross flow
Operation Pressure < 1 Bar
Air scouring cycle every 10 - 60 minutes
Duration of air purge 20 - 60 seconds
Quality of compressed air Oil free
Frequency of on-line chemical cleaning (per month) 1 - 6 times or more, depending on TMP indication
Duration of on-line chemical cleaning 10 - 60 minutes
Required when TMP > 1 Bar and on-line cleaning is no longer
Frequency of off-line chemical cleaning
effective
Duration of off-line chemical cleaning 60 - 120 minutes
Flow of system circulation 5 - 20% ( 0 when functioning as dead-end filtration )

Table 4 UF Permeate Quality

Parameter Value
Turbidity  0.1 NTU
TSS  1 mg/L
Bacteria removal 99.9 %
SDI <3

Skid size is modular and

flexible to requirement.

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BASICS OF ULTRA FILTRATION

1. UF Membrane Modules are the key to Ultra Filtration.

UF membrane
UF hollow fibers module - U686

One UF membrane module consists of many UF hollow fibers with fiber ID 0.6 mm2 and OD 1.2 mm2 with
pore size 0.1 – 0.01 m.

The UF machine is made up of UF membrane modules / skids, air scouring system, chemical cleaning system,
electrical and control system, pumping and piping system and the supporting frames. A P&ID of the UF
membrane system is shown in a separate page.

Hydromaster pressurized membrane module U686 is an “outside-in” PVDF hollow fibers. Four (4) pcs of U686
module is installed in your HMU04-06 unit.

For best result, an activated carbon system can be combined with UF. Activated carbon is normally added
prior to UF to get better quality and taste of drinking water.

1.1 Description

Your HMU04-06 Ultra Filtration machine is a durable piece of equipment which, with proper care, will last
for many years. These instructions give operation and maintenance details vital to the sustained
performance of the machine. Please read completely before operating your machine.

1.2 Definitions

The operating definitions provided below will help you further understand your machine and this manual.

1.2.1 Ultra Filtration (UF) is a variety of membrane filtration in which forces by pump lead the feed
stream to a separation through membrane pores. Suspended solids and solutes of high molecular
weight are retained in the so-called retentate, while water and low molecular weight solutes pass
through the membrane in the filtrate (permeate). This separation process is used in industry and
research for purifying and concentrating macromolecular. Ultrafiltration is not fundamentally
different from microfiltration. Both of these separations are based on size exclusion or particle
capture. Your Ultrafiltration is applied in dead-end mode.

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 The feedwater is hereby pressed into the module by a pump, and permeates
through the membrane due to the transmembrane pressure (TMP) difference.

1.2.2 Trans Membrane Pressure (TMP)

The pressure that is needed to press water through a membrane is called Trans Membrane
Pressure(TMP). The TMP is defined as the pressure gradient of the membrane, or the average
feed pressure minus the permeate pressure. The feed pressure is often measured at the initial
point of a membrane module. Max TMP allowed is 1 bar. Whenever TMP reaches 0.5 bar,
Maintenance Cleaning (MC) should be carried out.

1.2.3 Dead End Operation Mode

This Ultrafiltration membranes is operated in a continuous concentrate flow, which

is the so called “Dead End” mode, in which all feed water is pressed through the
membrane and concentrate is taken out of the system only during forwardwash
sequences.
In both cases, the ratio of feed and filtrate is called “Recovery” and is calculated as:

Flow filtrate
R = Flow
feed

Ultrafiltration membranes, applied in regular drinking water treatment processes

are usually operated in Dead - End Mode due to increased Recovery.
(shown in Graph 2 below)

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 Graph 2 : Dead End process schematics

Process Details:
When operating in the Dead-End-mode, no circulation of the water takes place. The
total quantity of the feed water is pressed through the membrane.
This mode is mainly used with raw water of high quality and less turbidity (e.g.
ultrafiltration for drinking water pre-treatment
Dead-End-mode is preferred due to improved profitability of the system. It provides
lower operation costs (less pump energy required) and higher recovery rates.

1.2.4 Cleaning in Forward Wash Mode

It is already proved that a short forward wash right significantly enhances the performance of the
membrane after dead-end operation mode for filtration cycle. Graph 3 shows the schematics of a
forward wash. This process is not carried out with filtrate but regular feed water and it does
influence the overall recovery of the system.

Forward wash of the UF machine is designed to allow automatic periodic cleaning of UF

membranes without any chemicals and fully controlled by Programmable Logic Controller.

Graph 3: Forward Wash process schematics

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1.2.5 Chemical Cleaning

Depending on the type of fouling, a forwardwash does not remove the fouling
layer completely. Therefore, filtration performance decreases over time.
To recover the systems original filtration performance, chemical cleanings are
performed in intervals of days and 2 - 3 months. Taking into consideration the type of
foulant, the appropriate chemical substance is chosen, e.g. Citric Acid, Caustic
(Sodiumhydroxide) or Sodium Hypochlorite as disinfection and cleaning.

1.2.5.1 Maintenance Cleaning (MC)

MC is cleaning of UF membranes with chemicals and is required when your UF machine

shows evidence of fouling after several forward wash. MC is carried out every 1 to 3 days
operation to get the UF permeate flow back to normal again.

1.2.5.2 Recovery Cleaning (RC)

Recovery Cleaning (RC) is required when feed pressure rises to 12mH2O or after 2 – 3
months of operation whichever occurs first. Each RC requires 90 min of soaking and
air scouring.

The cleaning chemical used is dependent on the type of pollutant. The RC process is
progressed after a MC process.

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System includes:

 Hydromaster Membrane Cartridges

 Feed Pump and Chemical Pump
 Control Valves (Motorized Valve)
 Feed, Air and Permeate Pressure Gauges
 Permeate Flow Meter
 Air-Scouring Configuration
 UF Frame
 PVC Piping, Hoses and Quick couplings
 Electrical Control Panel with PLC
 UV Lamp

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3. Process Description

( Refer to the filtration and forward wash diagram on pages 10 & 11 )

Start process in ‘Auto’. Select SS to “Auto”, depress PB “System On/Off” once to start. The system will go
through the following sequence.

1. Filtration Cycle
Aim : Produce filtered water

Outside to inside flow, on a dead-end configuration.

Filtration cycle will pump feed water to the membrane cartridges.
Filtered product water will flow through the flow-meter to the Permeate Tank.
Filtration Pressure (P1 – P3 = TMP1), maximum at 1 bar (Default setting below 0.5 bar)

Filtration Pressure / product flow rate can be increase or decrease by adjusting from the frequency controller
VFD, “3-10” (refer to inverter operating manual pages 17).
( Start filtration at low pressure first, example at 1 psi for a few cycles and records
down the parameters before increasing to higher pressure/flow.)

Time duration is set in the PLC, ‘Filtration’ (T1). (Default is at 10 minutes)

2. Forward Wash Cycle

Aim : Dislodge Suspended Solids from membrane and Membrane regeneration

Air scouring is a process of releasing of air bubbles in the membrane cartridge.

* Compressed Air -This is a pulsing mode controlled by the solenoid valve (SV). Air scouring pressure gauge
(P2) should read 0.1 ~ 0.2 kg/cm2 above the gauge reading.

This will dislodge Suspended Solids from the membrane surface. Time duration is set in the PLC. (Default is at
30 seconds)

Important Notes:

System startup procedure:

Start operating this system with clean water (normal city water supply) in the feed tank.
Operate the system for 30 minutes with this feed water. Record the operating parameters and keep this as the
reference for this plant.

Long term usage:

During long term usage, it will be useful to add a shock level of Biocide into the feed water on a once a day
basis. Chlorine can be applied at a dosage below 20 ppm. Other forms of non-oxidizing Biocide can be applied
at higher levels.

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3.1 Process Diagram

Page 9 of 21
3.2 Filtration Diagram

Page 10 of 21
3.3 Forward Wash Diagram

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4. Installation Instruction

4.1 Mechanical System Schematics for Initial Connection

Please carry out initial connection for the four pipe lines as follows :
Connect uPVC pipe (DN 65) as UF feed pipe from feed Tank (or incoming raw water line)
Connect uPVC pipe (DN 50) as UF permeate pipe to permeate Tank (or UF product line)
Connect uPVC pipe (DN 50) as UF permeate drain pipe to drainage
Connect uPVC pipe (DN 50) as UF drain pipe to drainage

UF Permeate Pipe
(DN 50)

UF Feed Pipe
(DN 65)
UF Permeate Drain Pipe
(DN 50)

UF Permeate Pipe
(DN 50)

UF Drain Pipe
(DN 50)

UF Feed Pipe
(DN 65)

Page 12 of 21
4.2 System / Electrical Control & Schematics

Termination of Power Incoming

Connect three phase power to incoming terminal (as shown below)

Termination of Water Level Control

Connect water level switch as Feed Tank Low Level to terminal 06S and DC+24S
Connect water level switch as Permeate Tank High Level to terminal 07S and DC+24S

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5. System / Electrical Control & Schematics

Page 14 of 21
 5.1 Basic Controls on Starting and Stopping the System with Automatic Operating
No Action Step Lamp Indicator
Release “EMERGENCY STOP” Switch Connect power supply to PLC,
1
(turn red knob clockwise) Control Valves, Flow-switches, etc

Turn the Selector Switch to “AUTO”

2
position

3 Press “ON/OFF SYSTEM” button ONCE Step 1 : Valve Filtration

(Start process) Step 2 : Permeate Drain Filtration
Step 3 : Filtration Filtration
Step 4 : Valve Forward Wash
Step 5 : Air Scouring only Forward Wash
Step 6 : Air Scouring and Water Drain Forward Wash
Return to Step 1

Press “FORWARD WASH” button

4 Jump to
ONCE
(enabled only during Filtration cycle) Step 4 : Valve Forward Wash
Step 5 : Air Scouring only Forward Wash
Step 6 : Air Scouring and Water Drain Forward Wash
Return to Step 1
Note :
Forwardwash process will be return to Step 1 only during Filtration Cycle.
Forwardwash process will stop at the end of process (not return to Step 1) if pressed when machine off.

5.2 Basic Controls on Starting and Stopping the System with Manual Operating
Switch Up
No Action Step Duration
SW
Release “EMERGENCY STOP” Switch Connect power supply to PLC,
1
(turn red knob clockwise) Control Valves, Flow-switches, etc

Turn the Selector Switch to “MAN”

2
position

3 Filtration Step 1 : Valve MV1, MV5 10 sec

MV1, MV5,
Step 2 : Permeate Drain 10 sec
FEED
MV1, MV3,
Step 3 : Filtration 10 min
FEED

4 Forward Wash Step 4 : Valve MV4, 10 sec

MV4,
Step 5 : Air Scouring only 30 sec
BLOWER
Step 6 : Air Scouring and Water MV2, MV4,
40 sec
Drain BLOWER

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 5.3 Basic Controls on Starting and Stopping Maintenance Cleaning (MC) the
System with Automatic Operating
No Action Step Lamp Indicator
1 Press “MC Man” button ONCE Step 1 : Valve MC Cycle
Step 2 : Water Fill MC Cycle
Step 3 : Valve MC Cycle
Step 4 : Air Scouring only MC Cycle
Step 5 : Air Scouring and Water Drain MC Cycle
Step 6 : Valve MC Cycle
Step 7 : Air Scouring and Chemical Fill MC Cycle
Step 8 : Chemical Soak MC Cycle
Step 9 : Valve MC Cycle
Step 10 : Air Scouring only MC Cycle
Step 11 : Chemical Soak MC Cycle
Step 12 : Valve MC Cycle
Step 13 : Air Scouring and Chemical Drain MC Cycle
Step 14 : Valve MC Cycle
Step 15 : Water Fill MC Cycle
Step 16 : Valve MC Cycle
Step 17 : Air Scouring only MC Cycle
Step 18 : Air Scouring and Water Drain MC Cycle
Step 19 : Valve MC Cycle
Step 20 : Water Fill MC Cycle
Return to Step 1
Note : MC process will be return to Step 1 only during Filtration Cycle.
MC process will stop at the end of process (not return to Step 1) if pressed when machine off.

5.4 Basic Controls on Starting and Stopping Recovery Cleaning (RC) the System
with Automatic Operating
No Action Step Lamp Indicator
1 Press “RC Man” button ONCE Step 1 : Valve RC Cycle
Step 2 : Water Fill RC Cycle
Step 3 : Valve RC Cycle
Step 4 : Air Scouring only RC Cycle
Step 5 : Air Scouring and Water Drain RC Cycle
Step 6 : Valve RC Cycle
Step 7 : Air Scouring and Chemical Fill RC Cycle
Step 8 : Chemical Soak RC Cycle
Step 9 : Valve RC Cycle
Step 10 : Air Scouring only RC Cycle
Step 11 : Air Scouring and Chemical Drain RC Cycle
Step 12 : Valve RC Cycle
Step 13 : Water Fill RC Cycle
Step 14 : Water Drain RC Cycle
Step 15 : Valve RC Cycle
Step 16 : Water Fill RC Cycle
Step 17 : Water Drain RC Cycle
Step 18 : Valve RC Cycle
Step 19 : Water Fill RC Cycle
Return to Step 1 RC Cycle
Note : RC process will be return to Step 1 only during Filtration Cycle.
RC process will stop at the end of process (not return to Step 1) if pressed when machine off.
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 5.5 Inverter settings, changing Filtration pump frequency setting
Warning : Do not change other parameters or settings, except for 3-10

No Action Display

Inverter (VFD)

Setup1

 HZ
Status Quick Main
Menu Menu
Menu

Back
OK


Setup1
Main Screen
 HZ

1 Press [ Menu ] twice

Setup1


2 Press [ ▼ ] three times

Setup1


3 Press [ OK ]


Setup1


4 Press [ ▼ / ▲ ] until "status" value shown 3-10


Setup1 +


INDEX
%

5 Press [ OK ]


Setup1 +


INDEX
%

6 Press [ OK ] frequency value will blink

7 Press [ ► ] to shift number
8 Press [ ▼ / ▲ ] to increase or decrease the frequency value
9 Press [ OK ] if finish setting value of frequency
10 Press [ Back ] to return back to main screen

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5.6 PLC Diagram

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6. Chemical Cleaning Solution

Maintenance Cleaning (MC)

Description Parameter Remarks
Cleaning frequency 1 time/1-3 days Depend on feed water quality
Concentration of cleaning solution 200 ppm 10-12% of Sodium Hypochlite (NaOCl)
Min. pH 4 Citric acid
Max pH 10 Caustic soda (NaOH)

Recovery Cleaning (RC)

Description Parameter Remarks
Cleaning frequency 1 time/one month Depend on feed water quality
Concentration of cleaning solution 500 ppm 10-12% of Sodium Hypochlite (NaOCl)
Min. pH 2 Citric acid
Max pH 12 Caustic soda (NaOH)

7. Storage and Usage

Storage
• Long term storage, the membrane element should be filled (10% v/v) and locked up with a 1 %
Sodium Meta Bi-Sulphite (SMBS) solution.

Usage
Avoid the following situation in order to prevent membrane damage:
• Do not allow the membrane to Dry out under all circumstances.
• Do not allow the membrane to operate beyond stipulated Trans-Membrane
Pressure (TMP).

Warning!!!
This membrane product contains preservative (Sodium Meta Bi-Sulphite) in liquid form.
Ensure thorough flushing before usage.

This membrane product (fibers in the membrane cartridge) should be kept moist at all times. That is;
during storage, installation, usage or any form of stoppage during any point of usage.

Page 19 of 21
8. Trouble Shooting

Your UF system is equipped with automatic start and stop function

If your UF does not function properly or does not function at all, check the following before you call for our
assistance.

Diagnosing Problem

No Symptoms / Indication Reason Trouble Shooting

1 UF suddently totally shut Electrical power
down, no power. supply may be down
or circuit breaker
tripped or a power
outage has occured
2 Inverter / VSD of feed Fuse blown / circuit
pump wont run. breaker tripped or a
power outage has
occurred
3 Motorized valves will not Problem of relay or
open or close. valve electricity
trouble
4 Machine off (Feed Pump
Mechanical error
Overload lamp indicator is
or problem on
On)
pump
5 Machine off (Feed Pump Hi
One of valve is not
Press lamp indicator is On)
open as required
6 Flowmeter and pressure at Water product
P1 wont go up. problem
7 When feed water is low WLC has
level / product water malfunctioned
overfill and machine will
not stop automatically
8 Water leakage Water drops along
pipe / tank / UF
system
9 Flow of UF product keeps UF is clogging
dropping more than 15%
and any MC procedures
dont help
Water feed quality is
worsening.
Check power supply in the UF control panel.
If Voltage out of power supply is less than 24
V DC or min 20 V, replace the power supply.
If Voltage out of the power supply is 22 –
24V, then check each relay if there is any
trouble (burn/disconnected).
Check relay of starting inverter / VSD.
Check electrical current of the valves.
Check the relay in UF panel.
If both above are ok, then replace the valve
with new one.
Do maintenance or repair pump.
Refer to trouble shooting No 3 above.
Check strainer at feed pump or check valve
of feed pump. If clogged or dirty, clean with
clean water.
Check the WLC of low and high level.
Replace when broken.
Repair the installation.
Do RC cleaning procedure
If RC cleaning procedures dont help, contact
UF supplier.
Check the quality of water supply. Please
refer to page 2.

Water supply is not Check the water supply.

adequate
Pump is having
trouble

Page 20 of 21
9. System Parameter Record Chart

Filtration Cycle Requirement

Filtration pressure (P1-P3) kg/cm2 < 1 kg/cm2

Inverter frequency hertz

Forward Wash Cycle

Air-scouring pressure (P2) kg/cm2 0.1 ~ 0.2 kg/cm2

- Thank You –

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