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INSTALLATION MANUAL
P.I. La Grela Bens - Gutenberg, 32 15008- La Corua- Espaa Telfono: +34 981250111 Telefax: +34 981258439
09-01
GUARANTEE
Products of GEFICO ENTERPRISE, are designed and produced according to highest international standards. Each component was tested before assembly, each plant was tested on quality and function before leaving works, in order to guarantee trouble less and efficient service to owners on site of application for many years. GEFICO ENTERPRISE trust that operator/shipyard installs the concerned plant according to its best technical standard of workmanship in an appropriate site, connecting it with qualified piping material and correct power supply. Damages occurred to GEFICO ENTERPRISE Products due to mishandling, wrong installation or negligence of operator or his delegate are excluded from any warranty. GEFICO ENTERPRISE guarantees for the period of 1 year on date plant leaving works to replace any part of the supplied plant free of charge to the owner subject the concerned applicant supplies the faulty part free of charge to the GEFICO ENTERPRISE works to be examinees, proving the part has not been damaged by force or other misuse. GEFICO ENTERPRISE reserves the right to apply technical alternations to their products according to developments of technical researches. Nevertheless GEFICO ENTERPRISE guarantees to owners to hold stock of spare parts according to international standards. The efficiency of the GEFICO ENTERPRISE Product will be guaranteed if the designed and described technical parameters are met.
Limited Warranty
GEFICO ENTERPRISE warrants the equipment of its manufacturer to be free from defects in workmanship and materials for a period of 12 months after first start up, or 18 months after shipment, whichever occurs sooner. This warranty applies only to the original BUYER and for new and unused equipment and cannot be altered or changed by GEFICO ENTERPRISE employees or its representatives. Warranty related repairs attempted and/or executed by our authorized representative shall only apply and extended when supported in writing by GEFICO ENTERPRISE.
GUARANTEE
03-03
Where equipment sold hereunder is used with attachment and/or modifications which have been not recommended or approved by GEFICO ENTERPRISE in writing, such use shall not be considered normal and this Warranty shall not apply. GEFICOs liability is limited to the replacement or repair of defective parts returned, freight prepaid by BUYER to a location to be specified by GEFICO ENTERPRISE. Repaired parts shall be returned to BUYER F.O.B. shipping point. When circumstances permit, GEFICO ENTERPRISE will invoke for the benefit of BUYER, the guarantee or warranty of GEFICOs vendor for equipment or materials furnished, but not manufactured by GEFICO ENTERPRISE. This warranty does not extend to, and GEFICO ENTERPRISE assumes no liability for, consequential and secondary damages, or losses of any kind sustained directly or indirectly as a result of any defect in any equipment, material, or installation. GEFICO ENTERPRISE shall in no event be liable in an amount exceeding the purchase price on the equipment and transportation charges thereon.
GEFICO ENTERPRISE MAKES NO WARRANTIES REGARDING EQUIPMENT MANUFACTURED BY IT OR NO OTHERS (INCLUDING WITHOUT LIMITATION, WARRANTIES AS TO MERCHANTABILITY AND FITNESS FOR A PROPOSE), EITHER EXPRESSED OR IMPLIED, EXCEPT AS PROVIDED HEREIN. THE FOREGOING SHALL CONSTITUTE THE EXCLUSIVE REMEDIES OF BUYER FOR ANY BREACH BY GEFICO ENTERPRISE OR IT WARRANTIES HEREIN.
All information contained herein is based on data believed to be accurate, however, errors and/or design changes are possible. It is the BUYERs responsibility to determine suitability for his own use of the products described. The information presented in this proposal supersedes all previous information published or presented about the Electric Fresh Water Generators.
GUARANTEE
03-03
INSTALLATION
Before installation of the plant, operators should be aware of the contents of this manual. Suitable facilities, for example lifting equipment, must be provided to enable the plant to be installed safely. Mechanical installation must be completed before electrical connection; remember that the mixture of water and electricity can prove fatal. Electrical installation must only be undertaken by persons suitably experienced and qualified. Suitable arrangements must be provided for the storage of spare parts, lubricants, preservatives and chemical cleaning materials.
OPERATION
The control and safety system provided is necessary for the safe operation of the plant. Any device removed or adjusted to facilitate maintenance must be replaced and/or readjusted before the plant is returned to service. Operators who are likely to be in contact with the machine lubricants, or the chemicals used for protection or cleaning must be provided with, and wear, suitable protective clothing.
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01-05
MAINTENANCE
Electrical maintenance must only be undertaken by persons suitably experienced and qualified. Ensure that electrical supplies are properly isolated before undertaking any maintenance procedure. The supply should be disconnected by operation of the main switch, circuit breakers, removal of fuses or other acceptable method. A notice should be placed at the point of isolation showing:
Place a free space surrounding the unit to facilitate the working. Make sure that you have a clear path of retreat. Check the explosion risk before using welding equipment or electrical hand tools. When working in confined spaces, make sure that no dangerous gasses are present.
CHEMICALS
Read and observe the Health and Safety instructions provided on chemical containers or data sheets. Take normal precautions to avoid skin contact and the inhalation of vapours. Provide adequate ventilation. If a chemical substance comes into contact with the skin take immediate and appropriate first aid action and seek medical attention.
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SECTION 1 DESCRIPTION
1.1. Principle of Reverse Osmosis
Reverse Osmosis Works
The phenomenon of osmosis occurs when pure water flows from a dilute saline solution through a membrane into a higher concentrated saline solution. The phenomenon of osmosis is illustrated in Figure 1. A semipermeable membrane is placed between two compartments. Semipermeable means that the membrane is permeable to some species, and not permeable to others. Assume that this membrane is permeable to water, but not to salt. Then, place a salt solution in one compartment and pure water in the other compartment. The membrane will allow water to permeate through it to either side. But salt cannot pass through the membrane. As a fundamental rule of nature, this system will try to reach equilibrium. That is, it will try to reach the same concentration on both sides of the membrane. The only possible way to reach equilibrium is for water to pass from the pure water compartment to the salt-containing compartment, to dilute the salt solution. Figure 1 also shows that osmosis can cause a rise in the height of the salt solution. This height will increase until the pressure of the column of water (salt solution) is so high that the force of this water column stops the water flow. The equilibrium point of this water column height in terms of water pressure against the membrane is called osmotic pressure. If a force is applied to this column of water, the direction of water flow through the membrane can be reversed. This is the basis of the term reverse osmosis. Note that this reversed flow produces a pure water from the salt solution, since the membrane is not permeable to salt.
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The following graphs show the impact of each of those parameters when the other three parameters are kept constant. In practice, there is normally an overlap of two or more effects.
Not to be neglected are several main factors which cannot be seen directly in membrane performance. These are maintenance and operation of the plant as well as proper pretreatment design. Consideration of these three parameters, which have very strong impact on the performance of a reverse osmosis system, is a must for each OEM (original equipment manufacturer) and end user of such a system. Pressure With increasing effective feed pressure, the permeate TDS will decrease while the permeate flux will increase as shown in Figure 3. Temperature If the temperature increases and all other parameters are kept constant, the permeate flux and the salt passage will increase (see Figure 4). Recovery The recovery is the ratio of permeate flow to feed flow. In the case of increasing recovery, the permeate flux will decrease and stop if the salt concentration reaches a value where the osmotic pressure of the concentrate is as high as the applied feed pressure. The salt rejection will drop with increasing recovery (see Figure 5).
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Feed Water Salt Concentration Figure 6 shows the impact of the feedwater salt concentration on the permeate flux and the salt rejection. Table 1 shows a summary of the impacts influencing reverse osmosis plant performance. Table 1: Factors influencing reverse osmosis performance Permeate Flow Decreasing: Salt Passage
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Start up
First at all always check that all valves are in their correct position. Electrical control panel include pump starters. High pressure control valve must be always full open during start-up and must be slowly closed (1 bar per second) until to reach the requires capacity increasing the pressure on the membranes.
Pre treatments
As the seawater enters the skid the temperature of the incoming water is monitored by a temperature gauge (T). If seawater temperature is below 25C, the capacity is reduced a 3% for each degree. For operation in low seawater temperatures a heater with automatic control temperature must be placed In seawater treatment the limiting factor is of a physical nature, i.e. the osmotic pressure caused by high TDS. So, only in very special cases, a dose of a chemical scale inhibitor may be injected into the feed line to reduce the formation of scale. A level sensor must be incorporated into the dosing tank to protect the dosing pump from running dry. Should the level sensor detect a low level in the tank, the dosing pump will stop, and an alarm signal will be sent to both the local control panel
Media Filtration
The removal of suspended and colloidal particles by media filtration is based on their deposition on the surface of filter grains, while the water flows through a bed of these grains (filter media). The quality of the filtrate depends on the size, surface charge and geometry of both suspended solids and filter media, as well as on the water analysis and operational parameters. With a well designed and operated filter, a SDI<5 can usually be achieved.
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The most common filter media in water treatment are sand and anthracite. The effective grain size for fine sand filter is in the range of 0.35 to 0.5 mm, and 0.7 to 0.8 mm for anthracite filter. In comparison to single sand filter media, dual filter media with anthracite over sand permit more penetration of the suspended matter into the filter bed, thus resulting in more efficient filtration and longer runs between cleaning. The design depth of the filter media is normally about 0.8 m (31 inches) minimum. In the dual filter media, the filters are usually filled with 0.5 m (20 inches) of sand covered with 0.3 m (12 inches) of anthracite. There are two types of filters employed, gravity and pressure filters. As the filter vessel for pressure filtration is designed for pressurization, a higher pressure drop can be applied for higher filter beds and/or smaller filter grains and/or higher filtration velocities. The design filtration flow rates are usually 10-20 m/h, and the backwash rates are in the range of 40-50 m/h. For feed waters with a high fouling potential, flow rates of less than 10m/h and/or second pass media filtration is preferred. The available pressure is usually about 5 m of head for gravity filters, and 2 bar (30 PSI) to more than 4 bar (60 PSI) for pressure filters. During operation, influent water to be filtered enters at the top of the filter, percolates through the filter bed, and is drawn off through the collector system at the bottom. Periodically, when the differential pressure increase between the inlet and outlet of the filter is 0.3 to 0.6 bar (4 to 9 PSI) for the pressure filter, and about 1.4 m for the gravity filter, the filter is backwashed and rinsed to carry away the deposited matter. Backwash time is normally about 10 min. Frequent shut-downs and start-ups should be avoided, because each filter velocity increase will release previously deposited particulate matter.
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10
The rate of chlorine attack depends on various feedwater characteristics. Under alkaline pH conditions, chlorine attack is faster than at neutral or acidic pH. An acidic pH is anyhow preferred for a better biocidal effect during chlorination. Chlorine attack is also faster at higher concentrations of heavy metals (e.g. iron), which catalyze membrane degradation, and at higher temperatures. By comparison, some other polyamide RO membranes have essentially zero chlorine tolerance. The superior chlorine tolerance of the FT30 membrane can be attributed to the thicker barrier layer (about 2,000 Angstrom) and the fact that the polyamide is crosslinked. If dechlorination upsets occur in a FT30 RO system, and if corrected in a timely manner, membrane damage can be minimized. For chloramine the tolerance of the FT30 membrane is 300,000 ppm-h, which implies that dechlorination is not required. However, since chloramines are formed by adding ammonia to chlorine, it is possible that free chlorine will be present. Since this free chlorine can be damaging to the membrane, dechlorination should still be considered. Residual free chlorine can be reduced to harmless chlorides by activated carbon or chemical reducing agents. An activated carbon bed is very effective in dechlorination of RO feed water according to following reaction: C + 2 CI2 + 2 H2O -------4 HCI + CO2
Cartridge Microfiltration
A cartridge filter with a pore size of less than 10 m is the minimum pre-treatment required for every RO system. It is a safety device to protect the membranes and the high pressure pump from suspended particles. Usually it is the last step of a pre-treatment sequence. We use a pore size of 5 m on second cartridge group. First cartridge group pore size is 60 m. The better the prefiltration is, the less cleaning of the RO membranes is required.
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11
When the silica concentration in the concentrate stream exceeds the theoretical solubility ,cartridge filtration with 1 m pore size is recommended in order to minimise the interaction with iron and aluminium colloids. The filter should be replaced before the pressure drop has increased to the permitted limit, but latest after 3 months. Back flushable filters are not recommended because of their lower efficiency and higher bio-fouling risk. The cartridge filter should be made of a synthetic nondegradable material; e.g. nylon or polypropylene and equipped with a pressure gauge to indicate the differential pressure drop and thereby indicating the extent of its fouling. Regular inspections of used cartridges provide useful information regarding fouling risks and cleaning requirements. If the differential pressure across the filter increases rapidly, it is an indication of possible problems in the raw water supply or in the pretreatment process. The filter provides some degree of short-term protection for the membranes while corrective action is taking place. Replacing cartridge filters more often than every 1 to 3 months usually indicates a problem with the pre treatment. However, the cartridge filter is not meant to be a major component for the removal of high amounts of filterable solids. This would not only be an inefficient use of rather expensive filters, but would probably lead to premature failure of the membrane system due to the high probability that some of the unwanted material will break through. It may be considered however, to use upstream a second cartridge with larger pore size. The feed then passes through cartridge filters (FP1 and FP2). These units remove particles down 60 microns (first set) and down 5 microns (second set), which is an acceptable level for entry into the RO pressure vessels. These filters are also monitored by pressure gauges. When pressure drop is higher than 3 bar, the cartridge must be replaced.
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Pressure Gauges and Pressure Switches (P2, PB, PA,) are positioned to monitor any problems that could arise from over pressurisation or low pressure feed. Pressure switches and gauges monitor low pressure on the suction side to prevent the pump running dry, and to minimise the problems of cavitations, and high pressure on the discharge side to protect the high pressure system. In some cases (as option) a pressure relief valve (VSA) set to operate at a pre-defined limit is installed downstream of the discharge pulsation damper as an extra protection. Maximum suction pressure for High Pressure Pump is 10 bar (g).
Permeate
The good quality permeate (<500 ppm) will now flow to the skid edge for distribution by the client. A permeate production meter is installed on the panel to check the unit production.
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13
When dynamic permeate backpressure is employed during plant operation, the limiting component is the permeate port which is made of PVC. The permeate pressure rating is a strong function of temperature, as shown in Table 2. Note that at static conditions, i.e. with the high pressure pump shut down, the permeate back pressure must never exceed 0.3 bar (5 PSI). If so, always open sample valve V-15 before stopping Table 2: Maximum Dynamic Permeate Backpressure
For FILMTEC Pressure Vessels
Maximum Dynamic Permeate Back Pressure (bar) (PSI) 10.0 12.4 15.1 17.7 20.6 23.3 145 180 219 257 299 338
Chlorination
A chlorination unit (as option) can be mounted on the fresh water generation unit, and designed to dose to an accepted level, for a flow rate of 50 m3/24hrs, or 2.08 m3/hr. This is achieved by a Variable rate dose pump that can be controlled by a production meter.
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14
Internal Cable connections: Terminals 2-10: Terminals 3-4: Terminals 1-6: Terminals 6-11: Terminals 5-8-9: High Salinity Alarm:
solenoid
Adjusting the Knob wheel trimming potentiometer accessible by hand in the front of the salinometer box can change the alarm level. (See enclosed data sheet). The display reads the salinity in ppms of sea salt. If salinity exceeds the alarm set point it is indicated by external red lamp and an internal two colours led changing from green to red. Scale 0 to 1000 ppm of chlorides.
Range:
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15
1-15
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16
SALINITY ALARM VALUE P.P.M. NaCl 30 60 120 170 320 360 400 450 700 900
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17
From time to time verify the alarm system. Rotate the set point control until the point at which the alarm lamp lights red. Check that the bilge solenoid valve is opened and the remote high salinity alarm is activated. When the water purity level is worse than the alarm set point, the salinometer activates the alarm relay. In this moment, the solenoid valves are de-energised and dump valve opens, meanwhile tank solenoid valve is closed. When water quality is better than alarm set value, the solenoid valves are energised. This system continually monitors the purity of the distillate. The meter indicates the quantity of salts in the water reflected by the degree of its conduction. The salinometer recalibration must be done as follows: The salinity indicator should be at approximately mechanical zero with power off. If not, turn the external knob in the indicator with a screwdriver until the zero will be marked by the needle. Clean the salinity cell electrodes, as is described in maintenance chapter. Controller (salinometric unit) calibration is accomplished by rotating the meter calibrates control on the PC board (inside the box), so that the meter reads correctly. Cell test resistor simulates the appropriate input, and it's applied across the cell electrodes. It is available from factory.
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18
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Permeate circuit
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1.5
STANDARD VALVES
Several valves are included in AQUAMAR RO units module for proper operation. There are other valves that must be placed on the installation by fitter, like: Inlet / Outlet valves to shut down the cleaning tank. Inlet / Outlet valves to shut down the activate carbon filter (dechlorinator). Inlet valve to shut down the seawater booster pump. Outlet check valve to shut down and control flow of the booster pump. Inlet / Outlet valves to shut down the chemical dosing tank. Overboard check valve. Check valve and atmospheric drain valve on permeate line to prevent the permeate pressure from exceeding the feed pressure. Valve in the permeate line to provide permeate drain during cleaning and start up. Safety valves on the circuits can be installed
1.6
CONTROL INSTRUMENTS
To ensure proper operation of the RO AQUAMAR ELECTRIC Module a number of control instruments are placed. The accuracy of all instruments are guaranteed to obtain correct readings. Pressure gauges to measure the pressure drop across the cartridge filter, the pressure on the pump inlet line and discharge line, the feed pressure to the membrane elements and the pressure in the permeate line. Stainless steel pressure gauges with glycerine are installed on the module. Flow meters to measure concentrate and total permeate flow rate. Hour meter to log the total operating time is placed on electrical panel. When pH control is required, a pH meter in the feed line after acidification to control carbonate scaling potential can be install Conductivity meters in the permeate line to determine permeate quality .
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1.7. TANKS
Storing water in tanks should be generally kept at a minimum. When tanks are used, the inlet and outlet should be placed so that no stagnant zones are permitted. The tanks should be protected from dust and microbiological contamination. In critical applications tanks are closed and vented through a HEMA-filter. A feed tank is needed to provide the reaction time (20-30 min.) when chlorine is used. The free volume of media filters can be used for this purpose as well. Feed tanks are also frequently used as a buffer to allow continuous operation of the RO section (e.g. during backwash of filters). A permeate tank is typically employed, when the permeate is the product. Plant start-ups and shutdowns can be initiated by low level and high level from the permeate tank. The system capacity and the tank size should be designed so that the RO plant is allowed to run for some hours continuously. The less frequently the plant is shut down, the better is the system performance. A draw-back tank is a small tank in the permeate line that provides enough volume for natural osmosis backflow when the system shuts down. A missing draw back tank can cause air to be sucked into the FILMTEC elements. This may create the following problems: Contamination of the permeate side of the membrane by airborne microbes and fungi. Hydraulic shocks and slugs of air upsetting meters and set point controllers when the air is expelled from the system on the next start up. Drying of the membrane (flux loss). lf the feedwater is in a reduced status and contains H2S, Fe2+, Mn2+ , etc., the air intrusion may cause fouling of the membrane by oxidized and precipitated colloidal matter. lf the product water from an RO system is chlorinated, care must be exercised to ensure that the chlorine does not migrate back to the membrane. Air breaks should be employed appropriately. lf a draw-back tank is used, its water level should be higher than the highest pressure vessel, but not exceeding 3 m from the lowest vessel. To prevent contamination, the flow is in at the bottom and out the top, and the tank must be covered. Post-chlorination if performed must be done downstream of this tank.
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The volume of the draw-back tank can be sized as follows: VDBT = 25 NE -VPP VDBT: Volume of draw-back tank NE: VPP: Number of installed element Volume of permeate piping between pressure vessels and draw-back tank (in litre) (in litre)
Dechlorination filter (carbon filter) can be placed between the hydrosphere fresh water tank and the inlet valve V3 to provide fresh water free of chlorine for osmosis backflow when the system shuts down or for chemical dosing tanks refillings. So, the draw back tank is not needed. Dosing tanks are required when chemicals are added to the feed water. They should be sized typically for a daily refill (if possible). Cleaning tank is required for cleaning procedure. The pH of cleaning solutions used with FILMTEC elements can be in the range of 2 to 12, and therefore non-corrosive materials should be used in the cleaning system. The mixing tank should be constructed of polypropylene or fibreglass reinforced plastic (FRP). The tank should be provided with a removable cover and a temperature gauge. The cleaning procedure is more effective when performed at an elevated temperature. It is not recommended to use a cleaning temperature below 15C (59F) because of the very slow cleaning rate at low temperatures. In addition, some chemicals, such as sodium lauryl sulphate might precipitate at low temperatures. Cooling may also be required to avoid overheating, so heating / cooling requirements must be considered. A rough rule of thumb in sizing a cleaning tank is to use approximately the empty pressure vessel volume and then add the volume of the feed and return hoses or pipes. For example, to clean three 8-inch diameter pressure vessels with one elements per vessel, the following calculations would apply.
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23 A . Volume in Vessels V1 = r^2 x L = 3.14(4 in)^2 X (1 x 40 in) V1 = 31,1 I / vessel V3 = 31,1 x 3 = 93,4 l B. Volume in Pipes Assume 50mm pipe with a length of 30 metres, SCH 80 Pipe Vp = r^2 x L = 3.14 (50 mm)^2 X (30 m) = 236 l Vct = V8 + Vp = 93,4 l + 236 l = 329,4 l Therefore, the cleaning tank should be about 330 litres. Appropriate valves, flow meters, and pressure gauge should be installed to adequately control the flow. Service lines may be either hard piped or portable hoses. In either case, the flow rate should be less than 3 m/sec (10 ft / sec).
DESCRIPTION A B C D
REV DATE DESCRIPTION PROJ ENG BY CHK ENG MNGR
NOTICE
DES:
SCA LE
JOB NO:
DATE:
DRAWING NO:
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24
1.8. PRE-FILTERS
As was mentions in point 1.3.1. as option, sand filter and/or carbon filter can be supplied. Grooved disc filter is installed inside the module.
WORKING PROCESS VALVE FILTRATION BACK-FLUSHING FLUSHING BY-PASS NO: OPEN NC: CLOSE
V1 NO NC NO NC
V2 NO NO NO NC
V3 NO NC NC NO
V4 NC NO NC NO
V5 NC NO NC NC
V6 NC NC NO NC
V7 NO NO NO NC
W
CONTRALAVADO BACK-FLUSHING
B X
SALIDA OUTLET
A
ENTRADA INLET
M H
E
DRENAJE DRAIN
GROOVED FILTER
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Power supplies
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2.2
EQUIPMENT SPECIFICATION
CAUTION
The information included here is for reference purpose only. Spare or replacement parts should be ordered from GEFICO ENTERPRISE quoting the information provided here and in Section Spare-Parts List, in order to ensure compatibility with the original equipment supplied.
Sand Filter
Model Total capacity Bottle diameter Filtration surface Bottle empty weight Gross grain sand weight Fine grain sand weight Anthracite weight Max. Flow rate Backwash flow rate Cleaning pressure drop Operating pressure Drw. N FAP19047/2 570 litres. 896mm 0,63 m2. 115 kg. 100 kg 400 kg 90 kg 12,6 m3/hr 20 m3/hr 1 bar(g) Between 2 and 6 bar(g) 09.60.04.FAP-2
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Pulsation damper
Supplier Model Type Maximum operating pressure: Gas filling: Admissible max.pressure ratio: SPECK TRIPLEX LAV-INOX. series LAV-0,5 150 bar Nitrogen exclusively, max. 90% of operating pressure. < 6/1
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5 Max. dynamic pressure differential Operating temperature range Mounting Body Diaphragm Gas Valve 125 bar -15C to 80C at will AISI 316 NBR 5/8" UNF, version 1
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6 Dosing rate Recharge period Mixer 0,7 l/hr 3 days CH-1 (Manual)
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2.3
CAUTION: The information included here is for reference purposes only. Spare or replacement parts should be ordered from GEFICO ENTERPRISE quoting the information provided here and in Section 6 - Parts List, in order to ensure compatibility with the original equipment supplied.
NOTE
For key to abbreviations and location of the instruments refer to P & I diagram in Section 7 - Drawings of this manual.
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Salinometer
Supplier Type Model Cell model Range Power supply GEFICO ENTERPRISE SALTEST OS-1 009-AQE-00 0 1000 ppm 24Vac
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10
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SECTION 3 INSTALLATION
3.1 GENERAL
14 STORAGE TANK 15
DN25
SOLENOID VALVE P1 8
SAFETY VALVE VSP SALINITY CELL FLOW METER F2 PRESSURE REGULATING VALVE 4
BY-PASS 5
SAMPLE
10
OVERBOARD
13
DN20
P1 FP2 FILTER 5 um
P1
PB
FLOW METER F1
1 1/4"G DN40
1"G
DN20 DN65
FILTER
P1
DRAIN DN25
TQL
MEDIA FILTER
TQL PRE-TREATMENT CHEMICAL TANK V2 DN50 DRAIN 12 DN40 T P C F PI THERMOMETER PRESSURE GAUGE COMPOUND GAUGE FLOWMETER PRESSURE SWITCH DRAIN BACKFLUSHING TO OVERBOARD
BACKFLUSHING BY-PASS
DISC FILTER FL
V3
AQUAMAR ELECTRIC
GEFICO SCOPE OF SUPPLY
FLOW DIAGRAM
A.FERNANDEZ AFL A.FERNANDEZ A.LINARES
09.60.01.004
Flow diagram
Service Seawater inlet Potable water outlet Brine discharge Fresh water/chemical inlet Chemical cleaning outlet Electrical supply Control voltage Drawing legend 1 8 6 3 7 Nominal size (ND) 40 25 40 40 40 380V / 50Hz / 3Ph 440V / 60 Hz / 3 Ph 24V / 50HZ-60hz Connection type DIN 2576, PVC DIN 2576, PVC DIN 2576, PVC DIN 2576, PVC DIN 2576, PVC Control panel Control panel
OSMOSIS AQE-60/35
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The Reverse Osmosis plant is a self contained unit which requires positioning to allow access as shown on the General Arrangement drawing. The unit should then be suitably mounted before connection to the above showed services: All water supply and discharge lines should be of a suitable material for the application (see list of recommended materials). The sea water supply should be free from contaminants which would effectively shorten the life of the inlet filters.
CAUTION
A operation sea water supply of 8,32 m3/hr is required. Take into consideration for pipe calculations, that a high flow is required for filters back-washing (at least 20m3/h). Seawater booster pump must be always installed below seawater level and very close to the cross-over or sea chest due to it is a not self prime pump. Special care must be taken to avoid pressure losses on this suction pipe and interferences from other pumps. The pipe work should contain no tight bends or other restrictions. All fittings and joints should be secure and free from leaks. The brined water discharge lines should be piped so that the back-pressure is not greater than 2 bar. A suitable isolator should be provided in the electrical supply to the system; that is, additional to the isolator on the control panel door. All electrical connections should be made to the relevant approved standard. When plant containing a new reverse osmosis membrane is first started, product water should be diverted to discharge for at least 60 (sixty) minutes before it is collected for storage. When the plant is being re-commissioned or started up after chemicals have been used for storage or cleaning, product water should be diverted to discharge for at least 30 (thirty) minutes before it is collected for storage. Water used in contact with the membranes must not have any chlorine content. When dynamic permeate back pressure is employed during plant operation, the limiting component is the permeate port which is made of PVC. The permeate pressure rating is a strong function of temperature, as shown in Table 2.
OSMOSIS AQE-60/35
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Table 2: Maximum Dynamic Permeate Backpressure For FILMTEC Pressure Vessels Temperature (C) 45 40 35 30 25 20 (F) 113 104 95 86 77 68 Maximun Dynamic Permeate Back Pressure (bar) (PSI) 10.0 145 12.4 180 15.1 219 17.7 257 20.6 299 23.3 338
Note:
Static conditions, i.e. with the high pressure pump shut down, the permeate back pressure must never exceed 0.3 bar (5 PSI) the brine pressure. So, sample valve must always be fully open before stopping.
For pressure vessel descriptions and installation recommendations refer to corresponding section.
OSMOSIS AQE-60/35
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OSMOSIS AQE-60/35
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Pitting means localized attacks that result in holes in the metal. Pitting occurs where the passive film formed by chromium oxides breaks and chlorides can attack the bare metal. Crevice corrosion is pitting associated with small volumes of stagnant water caused by holes, gasket surfaces, deposits and crevices under bolts, etc. In order to avoid pitting and crevice corrosion in the RO water desalination plant the following recommendations must be followed:
Besides the above recommendations general precautions must be taken during design, construction and installation, such as: Minimum of crevices and dead ends. Design the piping so that the flow velocity is above 1.5 m/s (5 ft/s). It promotes the forming and maintenance of the passive film. Use backing gas when welding in order to avoid the weld oxide film forming base for crevice corrosion. Pickle and passivate the pipe system as this gives the optimum safety against chloride attack. Flush the plant with low TDS water before a shut-down period.
OSMOSIS AQE-60/35
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3.3
INSTALLATION
Enough space must be let around the unit for maintenance and disassembly of elements. It is good idea to let a passage of at least 500 mm surrounding the unit. In order to remove membranes, 1000 mm in both sides of the module must be free. External connection flanges are made in PVC. No greater force is required to tighten bolts. A torque wrench should be used to tighten the bolts on a flanged joint with flat gaskets in order to prevent damage to the flanges and the adaptors . Hereunder table contains approximate torque values required for the various pipe diameters.
O.D. pipe mm 16 20 25 32 40 50 63 75 90 110 125 140 160 200 225 280 315 Nominal bore 10 15 20 25 32 40 50 65 80 100 110 125 150 175 200 250 300 mm Torque Nm 6 7 9 10 20 25 30 35 40 45 50 50 60 75 75 75 75
Flat gasket are used as a rule with flanged joints. Flat gaskets in EPDM (d20-d225), FPM (d20-d110) and IIR (d90-d225) are used.
OSMOSIS AQE-60/35
4-37
03-03
38
Sand filter must be installed in a place were they are accessible for minerals refilling and back-flushing procedure can be easily done. Before the filling with minerals, the filters must be filled with water until the middle of the vessel to avoid damage on filter elements and reduce the formation of dust. Filling must be done only 2/3 total height, 1/3 must be left as free space. Enough space must be let around the filters for maintenance and operation. The filling is done unthread the top register and the draining is done unthread the bottom register. So, enough height must be left on top and bottom.
OSMOSIS AQE-60/35
4-38
03-03
FILTERS
DISC INLET (bar) OUTLET (bar) INLET (bar) 60 m OUTLET (bar) 5 m INLET (bar) OUTLET (bar)
FEED
S.W. TEMP (C )
SEA
FEED FLOW (Lpm)
WATER
HIGH PRESS (bar) FLOW (Lpm)
PERMEATE
PRESSURE (bar) SALINITY (ppm)
DATE
4-39
03-03
SECTION 7 DRAWINGS
7-1
03-03
7-2
03-03
TDQ2 POST-TREATMENT CHEMICAL TANK (OPTION) STORAGE TANK 15 SAMPLE DUMP VALVE SAFETY VALVE VSS 13 9 SAL.1 SOLENOID VALVE 14 DN25 8 P1 SALINITY CELL
BY-PASS 5
10
OVERBOARD
P1 FP2 FILTER 5 um
P1
PB
FLOW METER F1
1"G
DN20 DN65
FILTER
P1
MEDIA FILTER
TDQ PRE-TREATMENT CHEMICAL TANK (OPTION) V2 DN50 DRAIN 12 DN40 T P C F PI THERMOMETER PRESSURE GAUGE COMPOUND GAUGE FLOWMETER PRESSURE SWITCH DRAIN BACKFLUSHING TO OVERBOARD
DN50
V7
BACKFLUSHING BY-PASS
DISC FILTER FL
V5 V6 DN50 P P1
V3
AQUAMAR ELECTRIC
GEFICO SCOPE OF SUPPLY
FLOW DIAGRAM
7-3
A.FERNANDEZ AFL A.LINARES A.FERNANDEZ
03-03
09.60.01.005
7-4
03-03
WORKING PROCESS VALVE FILTRATION BACK-FLUSHING FLUSHING BY-PASS NO: OPEN NC: CLOSE
V1 NO NC NO NC
V2 NO NO NO NC
V3 NO NC NC NO
V4 NC NO NC NO
V5 NC NO NC NC
V6 NC NC NO NC
V7 NO NO NO NC
55,00
920,00
140,00
605,00
760,00
55,00
40
,0 0
985
A B C D
GEFICO ENTERPRISE, S.L. GUTENBERG, 32 LA CORUA-15008 SPAIN Tfno: +34-981250011 Fax: +34-981258439 E.Mail: gefico@gefico.com
DESCRIPTION DESCRIPCIN FEED FRESH WATER ENTRADA AGUA DULCE CHEMICAL RETURN RETORNO QUIMICA PUMP SUCTION ASPIRACION BOMBA DRAIN PURGA
10 0, 0 0
Fecha
Creado Revisado Norma
N O T ICE.
Nombre
TH IS DR AWING HAS NO T B EEN PU BLIS HED AN D IS TH E S OLE PR OPER TY OF G EFICO ENT ERPR ISE A ND IS LENT T O T HE BO RR OWER FO R HIS CO NFIDE NTI AL US E ON LY AN D IN CON SID ER ATI ON OF THE LO AN OF T HIS D RAWIN G, T HE BOR R OWER P RO MIS ES AND AG REES TO R ETU RN IT UP ON R EQU ES T AND AGR EES TH AT I T S HALL NO T BE REP ROD UCED , COP IED , LENT O R OT HER WIS E DIS PO SED O F D R ECTLY OR IN DEREC TLY, NO R USE D I N AN Y WAY DET RIMENT AL T O T HE INT ER EST O F THIS COMPANY. I
Estado
Cambios
Fecha
Nombre
NOTES
7-1
03-03