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Second Edition
CONFIDENTIAL INFORMATION
CONFIDENTIAL AND SENSITIVE MATERIAL This is an internal and CONFIDENTIAL GE Water & Process Technologies manual and is not for distribution or release to non-GE entities. Contact Ed Habayeb or Technical Marketing Management with any questions about usage and restrictions. This is an evolving document that is continually updated based on formal workshops, meetings, and discussions with many global experts. Thanks to all of those who have contributed.
Second Edition: January 2008 Second Edition Authored by: Matthew Hunter, Anna Bandick, and Ed Habayeb
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Table of Contents 1. Membrane Elements ........................................................................................................1 2. Site Survey Data Required.............................................................................................3 3. Feed Water Quality Guidelines....................................................................................5 4. Water Source Characterization and Filtration Pretreatment Requirements ...................................................................................................................7 5. SDI Determination .............................................................................................................9 6. Media Filter Typical Operating Parameters (Carbon, Multimedia, Greensand)..............................................................................................................................11 7. Multi Media Backwash Practices.............................................................................15 8. Cartridge/Depth Filter Replacement .....................................................................17 9. Chemical Feeding Sequence.....................................................................................19 10. Coagulant Feed and Selection...............................................................................21 11. Feed Water pH Control..............................................................................................25 12. Antiscalant Selection..................................................................................................27 13. Argo Analyzer Software Program ........................................................................29 14. Bisulfite Feed and Dechlorination ........................................................................31 15. Microbiological Control .............................................................................................33 16. RO Normalization Data Collection/Interpretation........................................37 17. RO Troubleshooting Guidelines .............................................................................41 18. RO CIP Cleaning ............................................................................................................ 43 19. Calcium Carbonate Scale.........................................................................................47 20. Sulfate-Based Scale....................................................................................................49 21. Iron and Manganese Fouling .................................................................................51 22. Aluminum Fouling........................................................................................................53 23. Silica Scaling and Fouling.........................................................................................55 24. Colloidal Fouling ...........................................................................................................57 25. Microbiological Fouling .............................................................................................59 26. Organic and Chemical Fouling ..............................................................................61 27. Membrane Autopsy Results and Interpretation............................................63 28. RO Storage Practices and Procedures...............................................................65 29. Membrane Element Installation............................................................................67 30. Pressure Vessel Probing............................................................................................69 Appendix 1. Temperature Correction Factors (TCF) ...........................................71 Appendix 2. Sample Cleaning Procedure................................................................73 Appendix 3. Spacer Tube Installation .......................................................................77
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Forward
GE Water & Process Technologies has the unique position in the industry of being an OEM of RO systems, RO membranes, and cartridge filters, as well as a service provider of RO chemistries. This broad product and service offering has been achieved through the integration of various services and manufacturing entities. This allows us to offer a wide spectrum of solutions to meet our customers needs. A word of caution from the authors of this manual: Each of the organizations integrated into GE has brought with them unique design and operational philosophies. It is in our best interest and the interest of our customers to be accurate in our appraisal of their current systems for functionality and operational readiness. Part of that evaluation means understanding the original specifications and design intent under which the systems were sold and installed. We encourage you to familiarize yourselves with the equipment from all our heritage businesses and to understand that multiple system designs and operation philosophies are acceptable and optimal. We have put to paper the best practices as we see them. These are not the only way or last word in how to accomplish a given task, just the recommendations of where to start.
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1. Membrane Elements
Two types of commercial membranes are most commonly used in NF/RO membrane equipment: cellulose acetate (CA) and a family of polyamide (PA) thin film composite (TFC) membranes. Comparative Properties Commercial RO Membranes Note: These are typical ranges and limits; always consult membrane manufacturers specifications for actual tolerance limits.
CA Membranes Surface Charge Pressure Temperature (Max) pH (Operating) Chlorine Free
4. Less likely to foul- the relatively smooth, uncharged surface of a CA membrane is less likely to attract foulants compared to charged PA and polysulfone (PS) surfaces. CA Disadvantages 1. Hydrolysis- the acetyl groups on the polymer in the CA membrane will hydrolyze over time. The pH dependency of the hydrolysis mechanism limits the operational pH to the range of 4.0 to 6.0. As hydrolysis occurs, the membrane will lose salt rejection performance. 2. Potentially shorter life due to hydrolysis. Three years is a good estimate for the membrane life of both PA and CA membranes. CA membranes that are run outside of the recommended pH range will not last as long. Both types are capable of lasting up to 7 or 8 years. 3. Higher operating pressures- Must operate at ~400 psi to get reasonable permeate flow and salt rejection 4. Capital Equipment costs- higher equipment costs compared to PA membranes since the higher pressure requires bigger pumps. CA membranes are often more expensive. Salt Rejection The percentage of any individual ion rejected by a membrane depends on the size and electrical characteristics of the ion, with the following percentages typical for the general range of ions found in treated water. Note that gases are generally not rejected by RO membranes (e.g. CO2, NH3, etc.). Typical Salt Rejection for Membrane Performance
Ion Sodium Chloride Calcium Magnesium Sulfate Bicarbonate Conductivity Silica CA Membrane 85 99% 85 99% 90 99+% 90 99+% 90 99+% 85 99+% 85 99% 85 95% PA Membrane 96 99% 96 99% 98 99+% 98 99+% 98 99+% 96 99+% 97 99+% 98%
Note: 1. CA Membranes are typically used in municipal drinking water or beverage applications due to their tolerance for chlorine. 2. CA membrane cleaning: do not exceed pH 7.5 due to potential damage to membranes from higher pH (hydrolysis). PA Advantages 1. Overall lower operational cost 2. Lower operating pressure 3. Improved salt rejection 4. Significantly lower energy consumption. CA Advantages 1. Chlorine and oxidizer tolerant- CA membranes can tolerate up to 1 ppm free chlorine. Chlorine and oxidizers destroy PA membranes. 2. Good for high MB potential applications- oxidizer tolerance makes CA membranes a good choice for applications with potential for MB problems. An oxidizing biocide such as chlorine can be continuously fed without damaging the membrane. 3. Attractive for potable applications due to chlorine tolerance.
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Notes: 1. If RO feed water values are above the targets, or in the case of temperature, above or below the targets, additional engineering evaluation or design changes should be considered. In addition, pretreatment equipment will be needed. See section on water source and pretreatment equipment requirements. 2. Silica limits: The above silica limit was set so that the max silica concentration in the brine solution does not exceed 160 ppm at 75% recovery. New antiscalants have been developed that allow for running the RO at higher brine silica levels in excess of 300 ppm. In addition, HERO is a patented process that allows an RO to be run with much higher silica levels. GEWPT has rights for the patent in certain markets and geographies. Consult with GE Engineers for operating guidelines and antiscalant recommendations. 3. Parameters show Run Argo Analyzer because their effect on RO performance is determined by operating conditions such as pH, recovery, temperature, and the overall ionic make up of the water. All feed waters should be evaluated by running Argo Analyzer. Contact GE Technical Marketing if there are any questions.
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Pretreatment Equipment Selection is based on water source and turbidity. Pretreatment Equipment Selection Based on Water Source and Turbidity
Water Source Critical Water Parameter NTU > 25 River NTU 10-25 NTU <10 Surface water Lake Well Water Brackish Water Sea or Ocean Hard water and TOC NTU >25 NTU<25 Iron and manganese NTU < 10 NTU >10 NTU <10 NTU >50 NTU < 50 NTU <25 Suggested Treatment Equipment Clarifier + MMF or UF/MF MMF or UF or MF with Coagulant MMF or UF or MF (Coagulant may be needed) Lime softener + Clarifier MMF Clarifier + MMF or UF/MF MMF or UF/MF Chlorination + MMF Greensand Filter MMF or UF/MF MMF UF/MF or MMF Clarifier + MMF UF or MF Check with MF supplier UF/MF
Moderate to Moderate High High with seasonal variation Low Low Low Low High Moderate Low to Moderate Low to Moderate Low
>5
Definition of Characterization
Parameter/Values Turbidity NTU Color PtCO TOC ppm TDS-ppm Low 1-10 <10 <1 10-150 Moderate 10-25 15-30 2-10 150-2,500 High >25 >30 >10 > 2500 Brackish
TOC= Organics, MF= Micro filtration, UF= Ultrafiltration, MMF= Multimedia Filters Total suspended solids greater than 100 mg/L require clarification.
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5. SDI Determination
Silt Density Index (SDI) is a critical RO feed water parameter. It provides an indication of fouling potential caused by particulate matter. It is desired to have feed water that has SDI15 readings less than 3 to insure long membrane life, but less than 5 is acceptable. Readings higher than 3 indicate that improved pretreatment should be considered or that frequent cleaning may be required. SDI Measurement involves measuring the number of seconds it takes for 500 mLs of water at 30 psi to pass through a 0.45 micron filter at 0 (initial) minutes, 5 minutes, 10 minutes and 15 minutes. SDI is calculated with the following equation. SDITimex = [1-(initial T0 sec)/(Timex Seconds)] x 100 Timex Where TimeX can be 5, 10 or 15 minutes. Sample Calculation: The table below shows an example of the data that would be collected while running an SDI test. Measurement Time Interval Initial (T0) 5 minutes (T5) 10 minutes (T10) 15 minutes (T15) Time to pass 500 mL (sec) 31 45 67 106
SDI Equipment There are two devices that are commonly used to measure SDI: 1. Auto SDI Auto SDI is initially calibrated to a 500 mL flow. It has the convenience of automatically measuring the amount of time required for 500 mL flows at T = 0, 5, 10, and 15 minutes and calculating the individual SDI reading for each time interval. It has the disadvantage of shutting off once the flow through the instrument falls below 1.5 mLs per second. Of course, water with this low a flow level has a very high SDI reading.
The SDI for each time interval can be calculated using the equation above. The convention is to report the 15-minute SDI value. SDI5 = [1 (31/45)] x 100 = 6.22 5 SDI10 = [1 (31/67)] x 100 = 5.37 10 SDI15 = [1 (31/106)] x 100 = 4.72 15
2. Manual SDI Manual SDI is simply a pressure regulator and filter holder. It has the advantage of not shutting off. A disadvantage is that the 500 mL flow must be physically measured and timed for each time interval. Feed water source must be constant 30 psi for the test and the SDI test equipment should include a pressure regulator capable of maintaining 30 psi during the test. Use the SDI booster pump kit if the feed pressure is inadequate.
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Multimedia Filters are a combination, in descending layer order, of anthracite, sand and garnet. The density of the material determines the position in the layer. The combination of the three layers acts to remove a wide range of incoming solid contaminant particle sizes as small as 1015 micron. MMF Multi Media (Anthracite, Sand, Garnet)
Parameter Turbidity TSS Operation Loading flow rate Max allowable pressure drop Clean bed pressure drop Air scour (if equipped) Filter Backwash Backwash rate Backwash source Rinse source Backwash frequency Max Inlet Limit 50 NTU 50 mg/L 4-7 gpm/ft2 (160-290 L/min/m2) 15 psi 5 psi 3 SCFM/ft2 15-20 gpm/ft2 (610-820 L/min/m2) Feed or filtered RO brine Feed Delta P, Breakthrough on Turbidity
Multimedia filters can be used in concert with chlorine feed in front to oxidize and remove certain metals. Required chlorine dosages are in the following table:
Chlorine required for oxidation (ppm Cl2) Iron, Fe Manganese, Mn Hydrogen Sulfide, HS 0.6 3.5 8.5
Note: For polyamide (PA) membrane applications, all chlorine must be removed from RO feed water prior to contacting the membranes.
Note: Activated carbon removes incoming chlorine in the first several inches of media. This may result in the microbiological activity in the remainder of the bed. Periodic sanitizing is recommended.
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Greensand Filters are used to remove iron and manganese from RO feed waters. They function by oxidizing the iron and manganese to insoluble forms that are easily removed and held by the greensand media. Greensand filters require accompanying feed of potassium permanganate either with the feed or with the backwash. Chlorine is also use alone or in conjunction with permanganate in continuous feed applications. How they work: The surface of the sand is treated and coated with MnO2 groups that can change valence states. Upon contact, soluble Fe, Mn, and H2S are oxidized to an insoluble form. For example: 2(Z:MnO2) + 2Fe(OH)2 o Z:Mn2O3 + Fe2O3 + 2H2O [Fe2+ ferrous] [Fe3+ ferric] The media bed serves to capture and filter insoluble particles. Greensand Filter
Parameter Iron (Ferrous) Manganese H2S Alkalinity Operation Loading flow rate Bed depth based on Iron levels < 5 ppm Iron < 8 ppm Iron <15 ppm Iron Clean bed pressure drop (delta P) 15 ppm 2 ppm 5 ppm 125 ppm 2-5 gpm/ft2 (80-205 L/min/m2) 30 Greensand 36 Greensand 42 Greensand 3-5 psi Max Spec
Max allowable pressure drop (delta 15 psi P) KMnO4 demand rate (3% KMnO4) 1 ppm /ppm of Fe+ 2 ppm/ppm of Mn+ 5 ppm / ppm of H2S 12-15 gpm/ft2 (485-615 L/min/m2) Filtered feed water 2-3 bed volume Time or water flow or pressure drop 13
GreenSand Filter Backwash Backwash flow rate Backwash water source Rinse volume Backwash Frequency CONFIDENTIAL INFORMATION
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Note: Every system is different and individual system configurations may favor alternative feed points. For example, the chemical injection points on PRO-series machines are generally always upstream of the cartridge filter housing to maximize mixing and contact time and due to the proximity of other components. Acid: Feed point can vary greatly depending upon its primary function. It may be fed ahead of the multimedia filter to aid in coagulation and precipitation, or it may be fed in conjunction with the antiscalant for improved scale control in the RO machine. Antiscalant: Can be fed either upstream or downstream of the cartridge filters. On most machines, the injection point is upstream of the filters. Biocide: Can be fed either upstream or downstream of the cartridge filters when feeding in a continuous or intermittent mode. An advantage of upstream injection is disinfection of the cartridge filters, a common source of biogrowth. When feeding biocide continuously at low levels, ensure that the bisulfite is not being fed in excess. Excess bisulfite will deactivate non-oxidizing biocides. Bisulfite: Can be fed either upstream or downstream of the cartridge filters. An advantage of downstream injection is that chlorine residual is maintained through the filters and biogrowth within the cartridge filters is prevented.
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Streaming Current Detectors Some systems use streaming current detectors (SCDs) to monitor and control coagulant addition. These on-line electro kinetic analyzers essentially measure the net electrical charge of suspended solids after coagulant dosing. They provide a feedback signal to adjust the chemical feed pump in response to the degree to which the charge on the suspended particles has been neutralized. Warning Statements Controlling coagulant dosage is critical to prevent over/underfeeding. Underfeeding and overfeeding will both result in particulate build-up in membrane elements. Overfeeding can also result in membrane fouling. It is important to select a coagulant that is chemically compatible with the antiscalant specified in the RO pretreatment program. Cationic polymer coagulants should not be used in conjunction with antiscalants that contain anionic dispersing agents. Product Selection The selection guide on the following page can be used as a general guideline for coagulant application. Jar testing followed by online validation is always recommended for designing a coagulant program. Note: Each global region has a limited number of products available. Refer to your country's price book for product availability.
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Betz MPH5000
x x x x x x x x Citric acid-based formulation 50% Active Acid strength: Mild Typical dosage: 10 100 ppm (No max use limit for potable) Inhibits Fe and Al scaling Preferred for high sulfate water Additional cleaner functionality. Safe; non-toxic, noncorrosive
Betz MPH9300
x Sulfuric Acid-based formulation x 93% Active x Acid Strength: Strong x Cost-effective pH adjustment x Typical dosage: 5 50 ppm (Max use limit = 50 ppm for potable) x Preferred for use in large flow applications (economical)
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Note: Each global region has a limited number of products available. Refer to your country's price book for product availability
Hypersperse antiscalants are used to inhibit scaling and fouling in RO systems. The selection guide on the following page provides an overview of all Hypersperse products and shows which types of scale/deposit they effectively inhibit. Final selection and dosing requirements are determined using Argo Analyzer.
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This software uses the machine recovery to calculate the concentration factor. Based on the feed water analysis, the scaling potential in the system is then predicted. The user can compare the impact that each Hypersperse product has on saturation indices for a given feed water. Software outputs clearly specify the product, dosage, and additional operating guidelines such as pH adjustment (see illustration below). The software also contains many advanced features for skilled users as well as information about cleaner selection and cleaning procedures.
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Biocide Deactivation Sodium bisulfite-based products are also used to deactivate isothiazoline and DBNPA-based non-oxidizing biocides that are used to sanitize RO machines. Local regulatory authorities often require deactivation of these biocides prior to discharge or disposal. For deactivation, sodium bisulfite-based products can be fed directly to the concentrate discharge or they can be fed to a collection tank (such as the CIP tank after a biocide clean-in-place). Note that biocides are typically rejected by RO membranes (there will be some passage of actives depending upon several variables). Therefore, their increased concentration must be accounted for in the concentrate stream when designing a bisulfite program (e.g. 3 ppm biocide in the RO feed will translate to approximately 12 ppm in the concentrate stream at 75% recovery). The following table contains recommended dosages for biocide deactivation.
Deactivation Product BetzDearborn DCL30 / DCL32 BetzDearborn DCL95 Dosage required to deactivate 1 ppm Biocide Biomate MBC781 Biomate MBC2881 2.3 ppm 0.8 ppm 2.4 ppm 0.9 ppm
*Note: Generally sodium bisulfite is overfed at 0.5 to 1.0 ppm (active sodium bisulfite) to provide a margin of safety. For example, 6 ppm of DCL30 might be recommended for a feed stream containing 1 ppm total chlorine. No more than a slight overfeed is recommended, as excess sodium bisulfite can indirectly contribute to biofouling.
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Important: All biocide products must be used in compliance with federal, state, and local regulations. End users must strictly adhere to the instructions and restrictions on the EPA label. Biomate MBC nonoxidizing biocides must not be used in any application that is potable or where product water could be consumed by or injected into humans or animals. Contact the global Product Stewardship group for all questions and concerns related to biocide usage.
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Methods of Feeding Biomate MBC Biocides: Intermittent: This method of application is limited to DBNPAbased products due to their fastacting nature. The product should be injected into the RO feed for 30 to 60 minutes during normal operation of the RO machine, with permeate and concentrate directed to drain or neutralization tank in accordance with site regulations. This is done Microscopic image of a Biofouled periodically, from once or twice a Membrane at 1000X week to quarterly. Dosage must not exceed label limits.
Biocide Deactivation For systems where it is undesirable to discharge biocide-laden concentrate or CIP solution to municipal wastewater systems, BetzDearborn DCL30, DCL32, or DCL95 should be fed on the discharge side of the membrane equipment or directly to the CIP tank according to the guidelines in Section 14 Bisulfite Feed and Dechlorination of this handbook. Potable applications: Non-oxidizing biocides cannot be used in potable water RO systems. These products are not approved for applications where permeate water or products formulated with permeate water can be consumed by or injected into humans or animals. The use of peracetic acid is the most common method for sanitizing membranes in these applications. GE Water does not supply peracetic acid based products for technical and commercial reasons. Some general notes and guidelines are discussed below. Always follow the application guidelines and safety instructions of the chemical supplier: Peracetic acid is a strong oxidizer and it can damage membrane elements. The general industry recommended dosage is 400 ppm (mg/L) maximum, of peracetic acid in off-line CIP cleaning mode. The peracetic acid cleaning solution should be circulated/soaked for less than 1 hour of contact time to minimize the potential for membrane damage. Any residual transition metals in or on the membrane will catalyze the oxidation process and result in rapid membrane damage, so it is critical that the membranes are thoroughly cleaned (acid and alkaline) prior to a peracetic acid sanitization. The system should be thoroughly rinsed before returning to normal operation.
Clean-in-Place (CIP): Either DBNPA or isothiazoline-based biocides may be used. This method of application is often desirable for applications where an injection point is not available in the RO feed line, where discharge volume is limited, or where strict control and thorough deactivation of the biocide is required. The biocide solution is contained in the CIP tank and can be readily deactivated prior to discharge. Biocide CIP is most effective after an alkaline CIP cleaning but is sometimes conducted between cleanings, similar to intermittent treatment. Alkaline cleaning helps to disperse and remove biofilm. It is recommended that biocide CIP be conducted as a separate step in the cleaning sequence; contact a technical marketing expert to discuss options for combining with another cleaning step. Dosage must not exceed label limits. Note that a minimum of 4 hours contact time is recommended when using isothiazoline-based biocides in CIP Mode while 30 minutes to 2 hours is sufficient for DBNPA-based products. Continuous: Either DBNPA or isothiazoline-based biocides may be used for this method of application. Continuous feed is generally limited to small to moderately sized systems due to the elevated cost of treatment. This method is also used for systems with unique microbiological fouling conditions that require a constant biostatic environment. Biocide product should be fed continuously to an injection point prior to the cartridge filters. Typical treatment will require initially higher dosages that can be reduced over time. Dosage must not exceed label limits.
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affected. Typically, the rejection will remain somewhat constant and slowly decrease over time as the membranes age. Usually, when the rejection is graphed, we look for the steady decline from aging, or sudden changes that occur from mechanical leaks such as o-ring failures. Membrane fouling does not always cause an increase in salt passage and will sometimes improve rejection. Membrane scaling can, however, lead to increased salt passage. Permeate quality will not always be restored by cleaning and it may worsen. Data Collection Sheet (spreadsheet)
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Solving RO Problems
Possible Cause Verification Possible Corrective Action Analysis of metal ions in Improved pretreatment to Metal oxide fouling cleaning solution, current remove metals. Cleaning with water analysis acid cleaners. Colloidal fouling SDI measurement of feed. X-ray diffraction analysis of cleaning solution residue ICP metals? Optimize pretreatment system for colloidal removal. Clean with high pH, anionic detergent formulation
To aid in troubleshooting, use the next two charts to locate the problem (steps 1 & 2) and identify possible solutions (steps 3 & 4). Locating RO Problems
Symptoms Normalized Normalized Normalized Permeate Pressure Salt Passage Flow Drop Decreased Normal to increased Increased Normal to increased Increased Normal to increased Decreased Normal Location Possible Cause
Biological fouling
Shock or online treatment of Non-oxidizing Biocide. (Non Drinking water) Clean with Slime in pipes and vessels. alkaline (High pH) anionic Septic smell in the vessels surfactant. Chlorine dosage upstream with subs. or filter housings. Dechlorination. Replace cartridge filters. Check for SBS overfeed. Analysis of metal ions in cleaning solution. Check LSI of reject. Calculate maximum solubility for CaSO4, BaSO4, SiO2, in reject analysis. Destructive testing, e.g. FTIR analysis. Check flows and pressures against design guidelines. Increase acid addition and scale inhibitor for CaCO3 and CaSO4. Reduce recovery. Clean with an acid formulation for CaCO3, CaSO4 and BaSO4. Optimization of pretreatment system (e.g. coagulation process). Resin/activated carbon treatment. Clean with high pH cleaner. Reduce conversion rate. Calibrate sensors. Increase analysis and data collection. Replace O-rings. Replace elements. Check chlorine feed equipment and Dechlorination equipment. Improved pretreatment. Check all filters for media leakage.
Scaling (CaSO4, BaSO4, SiO2,) x Metal oxide fouling, First stage x Colloidal Fouling, x Biological Fouling Last bank All banks All banks Random x Scaling (CaSO4, BaSO4, SiO2,) x Organic fouling Recovery too high x Recovery too high x O-ring leaks, end or side seal glue leaks, backpressure damage Organic fouling
Decreased
Decreased or Decreased moderately increased Normal to low Normal to increased Increased Increased
O-ring leaks, end or Probe test. Vacuum test. side seal glue leaks Chlorine oxidant attack Chlorine analysis of feed. Destructive element test.
Increased
Increased
Normal
First bank, x Chlorine oxidant attack, slight x Abrasion of membrane second by crystalline material
Abrasion of Microscopic solids membrane by analysis of feed. crystalline material Destructive element test.
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The selection guide below can be used to identify specific cleaners, typical product dosages, and make-down pH and conductivity targets. Note: Each global region has a limited number of products available. Refer to your country's price book for product availability
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CIP System Design CIP system design can be either 1) high pressure, full machine or 2) low pressure, bank by bank cleaning. GE has standard platform equipment that incorporates each method. Appendix 2 contains a sample procedure for high pressure, full machine cleaning. Low pressure cleaning will follow similar steps. Specific procedures are included in O&M manuals. High pressure cleaning (up to 175 psi) employs a booster pump from the CIP tank and the high pressure skid pump to deliver the appropriate flow. The pressure is controlled by a throttling valve on the main pump discharge, and either a concentrate valve or a bypass valve (in the case of orifice plate back pressure control). This method cleans all banks of the skid simultaneously. There will be a lower capital cost for this equipment, and less cleaning chemical and time will be required to clean the system. Low pressure cleaning (40 to 100 psi) is typically available when the skid is piped to allow bank-by-bank cleaning. If the machine has three banks, the second and third banks are generally cleaned together. The primary pump for this cleaning is an independent CIP pump which bypasses the main pump, delivering cleaning solution directly to the feed manifolds. Bank by bank cleaning prevents the potential redeposit of particulate materials in subsequent banks by maintaining optimum flow velocities in each bank. The low pressure minimizes the generation of permeate which pulls foulant toward the membrane instead of across the membrane and out of the system. Higher flow velocities are achieved using this method and it can be more effective in cases of severe fouling.
Foulant-Specific Cleaning The next several chapters discuss common foulants in general terms. Generic cleaning strategies are discussed without specific reference to any GE Water performance products. Use the cleaner selection guide on the previous page and/or consult a Technical Marketing Expert to develop a site-specific cleaning strategy.
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Cleaning strategy Calcium carbonate scale can be readily dissolved in a low pH solution. A pH below ~4 is typically required to dissolve and prevent re-deposition. For severe cases, an overnight soak may be warranted. Cleaning solutions should be periodically circulated to introduce fresh cleaning solution to the scaled membrane surface. The pH of the cleaning solution should be checked frequently since the acid solution will be partially neutralized as scale is removed. Add additional acid as need to maintain the target pH. When calcium carbonate scale is identified as the primary foulant, the cleaning sequence should specify acid cleaning first, followed by alkaline cleaning. Chelating agents such as citric acid or EDTA may improve cleaning performance by removing the metal ions from complex foulant matrices and subsequently allow for other cleaning mechanisms to take place.
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Cleaning strategy Calcium sulfate may be removed by using an alkaline solution containing EDTA and elevated levels of bicarbonate. The mode of action for this method is believed to involve displacement of the sulfate with carbonate to form calcium carbonate and liberate sulfate ion into solution. The EDTA is present to chelate the calcium ions and keep them in solution. Extended soak times and elevated temperatures improve foulant removal. The alkaline cleaning step should be followed by an acid cleaning step to remove any insoluble calcium carbonate or calcium hydroxide that remains. Barium and strontium sulfate scales are very difficult to remove. It is critical that pretreatment steps be taken to prevent these types of sulfate scales.
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Cleaning strategy Effective cleaning is strongly correlated with pH. The pH of the cleaning solution should be less than 2.5 for ferric iron solubility (refer to previous solubility curve). It is critical that the membrane manufacturers limit for minimum cleaning pH (typically ~2) is not exceeded. Chelating agents such as citric acid or EDTA will improve cleaning performance.
When iron or manganese is identified as the primary foulant, the cleaning sequence should specify acid cleaning first, followed by alkaline cleaning. For severely fouled systems, strong reducing agents such as sodium bisulfite or hydrosufite (sodium dithionite) can be used to reduce the iron to a ferrous state. Sodium dithionite works very effectively in this application, but handling caution is required as it is a hazardous material with significant reactivity concerns.
In most water sources, iron is more prevalent than manganese. Most well water sources tend to have elevated levels of iron that must be addressed with pretreatment equipment and chemicals. Other sources of high iron levels include carbon steel pretreatment equipment and piping or overfeed of ferric-based coagulants. Ferrous iron is rapidly oxidized to colloidal ferric hydroxide in the presence of oxygen, permanganate, or chlorine. Low levels (>0.05 ppm) of iron or manganese in the oxidized state can foul an RO system if not treated by a suitable antiscalant. Precipitation of these metals tends to cause fouling in the first bank of multi-banked systems. Symptoms of metal precipitation are loss of flow and salt rejection and sometimes increased differential pressure. Since iron is so readily oxidized to an insoluble state, most systems specify upstream oxidation and filtration for removal prior to the RO. This can be accomplished with multi media filters or greensand filters, which are specifically designed for this purpose. Note that an alternative method of preventing iron fouling is to maintain a reduced environment via excess reducing agent (e.g. bisulfite). This approach has had some success, but it has not been extensively employed.
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Cleaning Strategy High or low pH cleaning solutions can be effective at removing aluminum-based foulants based upon the solubility of aluminum (see solubility curve above). Aluminum oxide and aluminum hydroxide are typically cleaned using an acidic cleaning solution. Aluminum that is complexed in a colloidal form is best cleaned with alkaline cleaning followed by acid cleaning. Chelating agents such as citric acid or EDTA will improve cleaning performance. High pH cleaners containing neutralizing amines are often most effective for removing colloidal aluminum.
In an RO application, aluminum fouling can occur via several mechanisms, therefore it is recommended that the aluminum level in the feed water be maintained below 0.1 ppm. Precipitation of aluminum tends to cause the greatest degree of fouling in the first bank of multibanked systems. Symptoms of aluminum precipitation are loss of flow and salt rejection and sometimes increased differential pressure. The increased differential can occur in the front of the system, due to blockage of the feed/concentrate channel, or in the back of the system due to increased flows caused by the fouling. In the latter case, differential pressure will be reduced when the foulant is removed from the front of the system.
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Cleaning Strategy When membranes are scaled by silica, the scale is almost impossible to remove. Some high pH cleaners applied with extended soak times (1224 hours) generally improve, but do not restore, the performance. More effective cleaning solutions are limited to dilute ammonium bifluoride or hydrofluoric acid. These chemicals are, however, extremely hazardous, and are not recommended for use. Deposits of colloidal silica can be removed by high pH cleaners, as long as soluble silica did not also deposit. Maximum pH and temperature will improve chances for success in cleaning. Alkaline cleaning should be followed by acid cleaning to remove any inorganic scale.
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For RO applications, the SDI test is widely used to predict the colloidal fouling tendency of feed waters. This test is not always a good predictor of fouling since it does not truly simulate the cross-flow hydraulics of spiral wound RO and NF elements. Cleaning Strategy When metal hydroxides are present with other colloidal foulants, such as clays, sequential cleaning is recommended, starting with acid. When metals are absent, clay (aluminum silicate) fouling generally can be cleaned with the alkaline solution alone. When systems are fouled by colloids, high velocities and high temperatures are essential for effective cleaning, especially if there are high differential pressures. Sometimes, alternating between soaking and recirculating the cleaning solutions can help dislodge particles caught in the feed spacer of RO elements. Overnight soaking of fouled elements in an alkaline cleaning solution may also be necessary.
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Cleaning Strategy A system that is fouled with biofilm and microbiological species should always be cleaned first with an alkaline cleaning solution. This is critical because exposure to strongly acidic conditions can cause biological foulants to crosslink, resulting in a hardened foulant layer that is very difficult to clean. The pH of the alkaline cleaning solution is strongly correlated to the ability to remove biofilm. Studies have shown that a pH=12 cleaning solution will be approximately 10 times more effective at removing biofilm than a pH=10.5 cleaning solution. In systems that have experienced or are prone to biofouling, a biocide or sanitizing program should be considered. Refer to Section 15 Microbiological Control for detailed recommendations and strategies for controlling and preventing microbiological fouling.
Biofouling affects membrane system performance in several ways including: x As bacteria colonize and multiply on membrane surfaces, they may exude slime (e.g., polysaccharides), which is a potent membrane foulant. x Bacteria and slime accumulations also affect boundary layer conditions above the membrane surface, thereby increasing the potential for colloidal fouling and scale formation. x Bacteria may colonize on the permeate side of elements and periodically slough slime and bacteria into the permeate stream. Because permeate is used for rinsing and process applications, many industries, including the electronics and biomedical, cannot tolerate even moderate numbers of bacteria in the permeate stream
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Cleaning Strategy Alkaline cleaners containing surfactants are best suited for most organic foulants. Maximum pH and elevated surfactant levels will generally improve cleaning performance by penetrating, breaking up, and/or emulsifying organic foulants. Cleaning with high pH cleaners first is critical since exposure to strongly acidic conditions can cause some organic foulants to crosslink, resulting in a hardened foulant layer that is very difficult to clean. Chemical contact time is important and extended soak time is highly recommended. Polymer fouling often presents a unique challenge for RO systems. In many cases, aggressive alkaline cleaning is not sufficient to remove the foulant and restore performance. In these situations a brine squeeze may be considered. A ~5% NaCl solution adjusted to pH 11 is circulated through the system in CIP mode at low pressure (<60 psi). Brine solutions can be very effective at removing chemical foulants. It is critical that a full-machine, high pressure cleaning is not attempted using a brine solution.
It is not always possible to predict whether specific organic chemicals will adsorb to membrane surfaces. For example, it is known that quaternary ammonium chloride surfactants bind irreversibly to PA type membranes, however some quaternary amine coagulants do not. Compatibility of all pretreatment chemicals should be verified.
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4. When the RO system is filled with this solution, close the valves to retain the solution in the RO. 5. Repeat Steps 2 and 3 with fresh solution every thirty days if the temperature is below 80F (27C), or every fifteen days if the temperature is above 80F (27C). 6. When the RO system is ready to be returned to service, flush the system to drain until the permeate water meets quality specifications, then return the machine to service. Important Note: Over time, sodium bisulfite will become oxidized and form sulfuric acid, lowering the pH. The pH of the lay-up solution should be monitored monthly and fresh solution added if the pH drops to pH=3 or lower, in order to safeguard the membranes.
An alternate procedure that requires less maintenance specifies the use of citric acid or a low pH cleaning solution to Pickle the system. The following procedure is recommended: 1. Clean the membrane elements via standard clean-in-place procedures, and thoroughly rinse the RO system. 2. Prepare the appropriate strength citric acid solution in the CIP tank by diluting with permeate water. 3. Circulate the solution through the RO system for 15 to 20 minutes. 4. Shut the RO system down. 5. Valve off CIP tank and drain tank. 6. Leave the acid solution in the RO machine. The elements can remain in the housings for over a year without any change in element performance, provided the storage temperature is below the maximum element operating temperature.
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forced to flow through the element feed spacer instead of bypassing the element. Membrane Element Loading Instructions 1. Load an element into the upstream or feed end of the pressure vessel. The brine seal should face the upstream end of the vessel to prevent feed bypass when the unit is in operation. Leave 6" of the element exposed beyond the end of the pressure vessel to facilitate loading succeeding elements. 2. Record the serial number and location of the element. 3. Apply glycerine to the O-rings of an interconnector. With a twisting motion, insert the interconnector into the central tube on the upstream end of the previously loaded element. Rotate the interconnector to insure that the O-rings have been seated. 4. Line up a second element with the interconnector of the first element. With a gentle pushing and twisting motion, insert the interconnector into the downstream end of the second element. 5. Push both elements forward until about 6" of the second element extends beyond the feed end of the pressure vessel. 6. Record the serial number and location of the second element. 7. Repeat the loading process for the remaining elements. 8. When all elements have been loaded into a pressure vessel, insert glycerine lubricated product end adaptors into the first and last elements in the vessel. 9. Connect the downstream pressure vessel end cap to the product end adapter and secure the end cap. 10. The following figure illustrates the correct placement of interconnectors and elements within a pressure vessel. Typical Installation
The element structure is usually contained in a hard casing (fiberglass wrap). Anti-telescoping devices (ATD) are present on both ends of the element and a brine seal is located on the feed end to prevent by-pass between the element and the wall of the housing. In some applications, for example in the beverage and food industries, full-fit membranes are used to eliminate the difficult-to-clean stagnant areas between the membrane casing and housing. Full-fit membranes do not have a hard outer casing. They are wrapped in netting material and have no brine seals. Element Housing is the tube in which the elements reside. Interconnectors are hollow plastic tubes with O-rings on each end. They are designed to fit into the countersunk permeate tube and to provide a sealed connection between elements. Solid interconnectors are used when spacer tubes are installed (see appendix 3). Brine Seal is the gasket on one end of the element that forms a barrier to concentrate flow around a membrane element so that the concentrate is
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General Probing Instructions x The 1-inch permeate plug should be removed from the end of the pressure vessel and replaced with a permeate port sample valve that will accommodate -inch tubing. x A suitable length of -inch tubing should be introduced through the sample valve and into the permeate collecting tube. The tubing should be pre-measured to ensure it reaches the far end of the vessel and spans the entire vessel length. x While the machine is running in normal operation, conductivity should be measured and recorded at regular intervals throughout the pressure vessel by extracting the -inch tubing incrementally between each measurement. x Measurements should be taken at the ends of the vessel, at the center of each element, and at each interconnector. The -inch tubing can be pre-marked for each interval or a tape measure can be used to accurately measure the length of tubing that is pulled out of the sample valve between each measurement.
Same-bank vessels should have a similar permeate conductivity. The average permeate conductivity will increase toward the back of the system. So, the second bank should have a higher average conductivity than the first bank. In 3-bank systems, the last bank will have the highest average permeate conductivity. If one of the vessels shows a higher conductivity than the rest of vessels in the same bank (shown in red in the image above), this vessel should be probed. This will help confirm possible O-ring leakage or membrane damage. By comparing probing results to expected conductivity values the root cause(s) of poor permeate quality can be identified.
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The above graph shows vessel probe profile data for a vessel containing an interconnector with an O-ring failure (red line) versus the expected profile (black line). Suspect elements should be unloaded for an O-ring inspection. If membrane degradation is confirmed, affected element(s) should be replaced.
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Note: This table is only to be used for PA (TFC) membrane elements. A Temperature Correction Factor (TCF) is used to predict what a membrane element will produce at a temperature different from the temperature specified by manufacturers flow rating. This TCF table relates flow at given temperature (T) to flow at 77F (25C). The table assumes 200 psig (13.7 bar) effective pressure. Corrected Flow at given T = Flow rating at 77F TCF at given T Example: An Osmo PRO 100 produces 100 gpm of product at 60F (15.5C). To determine what the machine will produce at 55F, the equation above is applied (correcting flow up from 60F rating, and then down for 55F actual temperature). The machine will produce: 100 gpm x 1.3958 (TCF @ 60F) = 89 gpm 1.4280 (TCF @55C)
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minutes. When cleaning with the high pH (alkaline) cleaner, recirculate until the solution temperature reaches 100F (38C). CAUTION: DO NOT EXCEED 110F (38C). The membrane elements can only handle temperatures in excess of 85F (29C) for short periods of time. If heat rise occurs too quickly, larger volumes of cleaning solution or the use of a heat exchanger will slow the temperature rise. (Soaking with recirculation can be an alternative.) 4.5 Turn the main OFF/AUTO/HAND/FILL switch to the OFF position. 4.6 Let the machine soak for 10 30 minutes. 5. Purge the dirty solution from machine. 5.1 Turn the OFF/AUTO/HAND/FILL switch to the HAND position and begin recirculating the solution. Recirculate the solution for 5 10 minutes. 5.2 Open the service concentrate valve (to drain) and close the CIP concentrate valve. Allow the permeate to return to the CIP tank. This action will purge the concentrated dirty cleaning solution from the system. 5.3 Watch the CIP tank level. When the level reaches 1/4 full, turn the main OFF/AUTO/HAND/FILL switch to the OFF position 6. Flush the cleaning solution from machine. 6.1 Close the CIP inlet valve. 6.2 Open the service inlet valve. 6.3 Open the CIP drain valve. This diverts the permeate and concentrate streams to drain. 7. Operate the machine as described in Step 6 for 1 hour and/or until the system pH and conductivity readings return to near normal operating levels. NOTE: After the high pH cleaning the conductivity of the permeate may actually increase temporarily due to the effects of higher pH and the nature of the surfactants. The rinse period for conductivity of the permeate to return to normal periods can be lengthy and unacceptable. To speed this process, repeat the cleaning procedure with the low pH cleaner at concentration for a few minutes. Then rinse to quality. 8. Turn the main OFF/AUTO/HAND/FILL switch to the OFF position.
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9. Install new pre-filters (Section 4.5.1). 10. Return machine to normal operation. 10.1 Open the service permeate valve. 10.2 Open the service concentrate valve. 10.3 Close the CIP permeate valve. 10.4 Close the CIP concentrate valve. The machine is now ready for operation.
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M1000EN Feb-08