DRINKING WATER SYSTEM

Presentation tailored for

Bharat Electronic Limited

By
KAMAL CHOKSHI
Of
KOMAL INDUSTRIES
 PRE
SOURCE TREATMENT
PURIFICATION

INSTRUMENTS
STORAGE &
USE &
DISTRIBUTION.
CONTROL
 WATER PURIFICATION
EQUIPMENT

REGULATORY STANDARD

DESIGN

STORAGE AND DISTRIBUTION

INSTRUMENTS

SYSTEM CONTROL AND MONITORING

QUALIFICAION
 Basic Regulatory
Requirements

IS 10500
Rules and Guidance (GMP)
BIS
Common Concerns of the
Regulator

Poor microbial control

Poor water quality test procedures
Poor SOP adherence
Lack of trending and validation
 Water Purification
Equipmen
Source: Water Quality defined
Process not define
Treated Quality as per IS 10500
Weight and size restriction
 Good Manufacturing
Practices
Series of rules ensuring that
products are manufactured in a
CONSISTENT and CONTROLLED
manner and will be FIT for their
intended purpose
GMP maintains a Company’s
reputation and product integrity.
Design Considerations
Capital Equipment Cost
Operating Cost
Life cycle Cost
Chemical Handling
Reliability / Uptime
Maintenance
Water Consumption / Discharge
Utility Requirements
Space Limitations
DESIGNING WATER
SYSTEM
DESIGN CRITERIA OF PURIFICATION

STORAGE AND DISTRIBUTION

EQUIPMENT STANDARDS & SPECIFICATION

MAINTENANCE
 Goals for Water Systems

Maintain the water quality within

acceptable limits
Deliver the water to the points-of-
use at required flow & quality
Minimize capital & operating
expense
WATER IMPURITIES

SUSPENDED SOLIDS

DISSOLVED IMPURITIES

TURBIDITY
BACTERIA
IRON
ORGANICS
 DESIGN RANGE

ALLOWABLE OPERATING RANGE

NORMAL OPERATING CONDITIONS

DESIGN RANGE

ALERT ALERT
LIMIT LIMIT
ACTION ACTION
LIMIT LIMIT
Drinking Water Standrard
Turbidity :< 5 NTU
pH : 6.5 – 8.5
T.D.S. : 500ppm
Total Hardness: 200 ppmas CaCO3
Iron : 0. 3ppm
Sodium : 180 ppm
Chlorine : 0.6 ppm
Sulphate : 250ppm
WATER QUALITY
SURVEILLANCE

Turbidity
Iron
Bacteria and Viruses
Total Dissolved Solid
 SYSTEM DESIGN

PRETREATMENT OPTION

TURBIDITY AND PARTICULATE

Iron

ORGANICS AND MICROBIOLOGICAL

IMPURITIES
 DISINFECTION

CHLORINE

OZONE

MEMBRANE

UV RADIATION

SILVER

HEATING
 PRE-TREATMENT
EQUIPMENT DESIGN

CHEMICAL DOSING
MULTIMEDIA FILTER
IRON REMOVAL MEDIA
MICROFILTRATION
ULTRAFILTRATION
PURIFICATION EQUIPMENT DESIGN

REVERSE OSMOSIS
 Election Microscopy Optical Microscopy Visible to Naked Eye

Macro Molecular Macro Particle Range

Ionic Range Molecular Range Micro Particle Range
Range
Micrometers 10-3 10-2 10-1 1 10 100

Angstrom 10 102 103 104 105 100

Mol.Wt.range 100 200 1,000 20,000 10,000 500,000

Latex Emulsions

Oil Emulsions

Sugars Carbon Black Paint Pimento

Endoloxins (Pyrogen) Yeast Cells

Virsus Bacteria

Soluble Salts Mycoplasm

(Ions) Red
Colloids Blood Cells Sand

Metal Ions Proteins / Enzymes Human Hair

REVERSE OSMOSIS MICROFILTRATION

NANOFILTRATION

ULTRAFILTRATION PARTICLE FILTRATION

Note : 1 Angstrom Unit = 10-10 Meters = 10-4 Micrometers (Microns)

PROPOSED WATER SYSTEM
MEMBRANE FILTRATION
Ultrafiltration
Reverse Osmosis
 Benefits of Membrane
Technology
Pressure driven separation giving
high value product
Established technology
Robust, reliable and easily
maintained
Selective and consistent
separation
Small footprint and lightweight
compared with other technologies
Modular, allowing for expansion in
capacity
Can be used in a wide variety of
applications
The Principles
Classification of
membranes
Membrane Material

Polymers
Ceramic membranes (metal oxide,
carbon, glass)
Liquid membranes
 Membrane Modules
Plate and frame - flat sheets stacked
into an element
Tubular (tubes)
Spiral wound designs using flat sheets
Hollow fibre - down to 40 microns
diam. and possibly several metres long ;
active layer on outside and a bundle
with thousands of closely packed fibres
is sealed in a cylinder
 Design Aspect
Crossflow (as opposed to ‘dead end’) –
cross flow velocity is an important
operating parameter
Sub-micron particles
Thermodynamic driving force (P, T, c
etc) for transport through membrane is
activity gradient in membrane
Flux (kg m-2 h-1)
Selectivity
Membrane area
 Filtration
Microfiltration (bacteria – potable water,
0.5 – 5 microns). Pore size specified.
Ultrafiltration (macromolecules, molecular
mass 1000 – 106, 0.5 – 10-3 microns).
Cut-off mol. wt. specified
Nanofiltration (low molecular weight, non-
volatile organics from water e.g. sugars).
Cut off mol. wt. specified.
Reverse osmosis (salts)
RO Membrane
Spiral membrane
UF Membrane Types
Polyacrylonitrile (PAN)
PVC/PAN copolymers
Polysulphone
PVDF (polyvinylidene difluoride)
PES (polyethersulfone)
Cellulose acetate (CA)
Hollow Fibre UF
UF Modules
Ceramic UF Nembranes
UF Operation
Normal Service
Fast flow
Back wash
Cleaning
Sanitisation
 UF membranes
Cleaning Sanitization
Citric Acid
Sodium Metabisulphite
Sod. Hydroxide
PAA
Hydrogen peroxide
Chlorine
RO Membrane Material
Asymmetric cellulose acetate
Polyamides
Sulphonated polysulphones
Interfacial composite membranes
Composite membranes
Nanofiltration membranes (lower
pressure, lower rejection; used for
lower feed solution concentrations)
 COMPARISON OF MEMBRANE SEPARATION
PROCESS

Separation Process Rating Production

Pure size or Mot Wt C.O.
Micro Filter 0.05-2 m 100%
Ultra Filter 1000-500000 D 95-98%
(MWCO)
Nano Filter 180-10000 kD 85%
Reverse Osmosis 150 kD 15%-85%
 Hollow fiber UF
Produce PW of Consistent high
Quality
Removes Bacteria, Endotoxins,
Viruses, dust colloidal silica
Chemical cleaning /Sanitisation
Possible
Compact modular design
Uniform rate of Flow
Small Qty. of Reject
Low energy consumption
Reverse Osmosis
Microbial concerns
Most systems cannot tolerate
chlorine in feed water at it tends to
hydrolyse the membranes
Significant bio-film and planktonic
counts can occur
Frequent sanitization is often required
Pretreatment system performance is
significant factor
 Preventing Biological
Fouling
Utilize proper membranes
Sound sanitization plan
Minimize incoming challenge
Feed disinfectant (Cl2, O3, etc.)
HWS Carbon Filters
Ultraviolet Lights to reduce
challenge
Lower unit recovery targets
RO Cleaning / Sanitization
Peracetic acid
Sodium hydroxide
Formaldehyde
Hydrochloric acid
Citric Acid
Hot water - 800C
FOUR BASIC ELEMENTS
of GMP: “4Ms”
Men: adequate training
Materials: raw materials,
products, reagents, Water
Machinery: facilities, systems,
equipment
Methods: manufacturing, control,
validation, documentation
STEPS INVOLVED in
VALIDATION
Validation master plan

Validation protocol

Execution of validation

Validation report

Preparation of SOPs
 Qualification
Performance Qualification verify that
the process perform effectively and
reproducibly
Operational Qualification verify that
the process operates as intended
throughout the operating range
Installation Qualification verify that the
process are correctly installed
Qualification and validation
Qualification and Validation
Planning for Validation
Documentation
Qualification
Process Validation
Cleaning Validation
Change Control
Revalidation
 Standard Operating
Procedures
Should be drafted early as possible
Should include :
start-up/shut-down (normal/emergency)
Sanitisation/cleaning
Operation (including log)
Sampling/testing
Specific procedures
Chemical addition, etc.
KOMAL INDUSTRIES
WATER PURIFICATION EQUIPMENT

108, CREATIVE IND. CENTER,

12, N.M. JOSHI MARG, LOWER PAREL (E),
MUMBAI - 400 011, INDIA.

TEL.: 91-22- 2309 1174 / 2309 1090

FAX.: 91-22- 2306 2711
E-mail : komalindustries@vsnl.com