ARUBA CONSTRUCTION PHASE N: 135 22 013 FLUSHING PROCEDURE SWRO AND BWRO SKIDS WITH FLUSHING AND CLEANING

G SYSTEM

Ref.: ARU-1-OTV-WMM-2600000-0015 Rev. : A1 Page: 1 / 13 Status : PRE

Prepared by: Emilie BANCEL Position:

Checked by: Loc BONNET Position:

Approved by: Eric Saez Position:

SWRO AND BWRO SKIDS MEMBRANE LOADING

A1 Rev

First Issue Description

EBA Prepared by

27/03/12 Date & Sign.

LBT Checked by

27/03/12 Date & Sign.

ESA Approved by

27/03/12 Date & Sign.

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ARUBA CONSTRUCTION PHASE N: 135 22 013 FLUSHING PROCEDURE SWRO AND BWRO SKIDS WITH FLUSHING AND CLEANING SYSTEM

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TABLEOFCONTENTS
1. 2. 3. 4. 5. 6. 7. EQUIPMENT SAFETY:................................................................................................................................3 REQUIRED TOOLS AND EQUIPMENT ......................................................................................................3 BEFORE THE LOADING: PRECONDITIONS.............................................................................................3 LOADING PLAN ..........................................................................................................................................4 PROCEDURE FOR MEMBRANE LOADING 1ST PASS: ...........................................................................6 PROCEDURE FOR MEMBRANE LOADING 2ND PASS: ..........................................................................9 CONTROL OF LOADING SCHEDULE......................................................................................................13

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ARUBA CONSTRUCTION PHASE N: 135 22 013 FLUSHING PROCEDURE SWRO AND BWRO SKIDS WITH FLUSHING AND CLEANING SYSTEM

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1. EQUIPMENT SAFETY:
Pumps should be started against closed or very slightly opened discharge valves when the downstream pipes are empty or partially filled. It is recommended to fill the pipes with water A/ BEFORE MEMBRANES LOADING, MAKE SURE THE SAFETY PROCEDURE IS APPLIED Before starting the loading of membranes, it will be compulsory that the RO area is complied with the safety procedure done by the commissioning manager. Keeping the Safety as 1st priority, it is important to note that this document requires some considerations: - No pressure activities in the RO area during the loading of membranes - Make sure the skid is drained after the flushing - The skid in loading will be restricted and exclusion zone under permit to work - All personnel have to wear personal protective equipment and have to be trained

2. REQUIRED TOOLS AND EQUIPMENT

Glycerine Pure silicon lubricant as Dow corning 111 Permeate or de-chlorinated potable water PVC pipe (DN40 DN 50) about 8.5 m long with connexion Sponge (to be fixed at one end of the PVC pipe) Membrane positioner (length to be the same as product end cap assembly) Membrane insertion tool (PVC pipe as shown in diagram below) Shims (sizes of 1, 2 and 5 mm thickness recommended) Scaffolding and/or scissor lifts Personal Protective Equipment (gloves, safety glasses, harness, shoes, safety helmet) Drinking water in RO Building for the workers

3. BEFORE THE LOADING: PRECONDITIONS

1) The commissioning engineer will carry out all the required tasks will be done in accordance with the safety procedure of plant. 2) Before starting the flushing, have a look inside of vessel, some pieces can be inside temporary. Remove them and install the o-ring on the end-plate. 3) The flushing of inlet lines (pipes, pumps, ERI and vessels) will be done. 4) Scaffolding installed and secured 5) Check the pressure vessel and the Victaulic interconnections (to ensure the connection does not protrude too far inside the vessel blocking the insertion of the membrane). 6) Remove end caps both sides if necessary of Pressure Vessel and HDPE pipe 7) On the permeate end cap remove the blind plug and fit the permeate adaptor ensuring all seals are in place and lubricated with silicon grease.

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ARUBA CONSTRUCTION PHASE N: 135 22 013 FLUSHING PROCEDURE SWRO AND BWRO SKIDS WITH FLUSHING AND CLEANING SYSTEM

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8) Flush out and clean down the Vessel tube with the sponge dipped in Permeate water and glycerine. 9) Wash the feed side tube entrance with one cup of glycerine/permeate mixture (50/50) 10) Identify the different membranes with colour stickers (for example) 11) The recording tool of membranes is ready. 12) The identification of vessels is done. 13) The over-head crane will be ready to transfer the crates

4. LOADING PLAN
The RO building is very compact. A loading plan has to be defined properly including the safety procedure. The loading of membranes has to be done skid by skid. Below, different views showing the access plan. In blue, scaffoldings will be installed from each side of skid. For the 1st pass and 2nde pass, third scaffolding will be installed closed to the scaffolding from feed side where the commissioning team will put the membranes before loading. For the 2nde pass, the loading has to be done from the both side (2 stages). From the door side, a forklift will be appropriate.

SCAFFOLDING NO ACCESS ENTER

SCAFFOLDING

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ARUBA CONSTRUCTION PHASE N: 135 22 013 FLUSHING PROCEDURE SWRO AND BWRO SKIDS WITH FLUSHING AND CLEANING SYSTEM

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WAY FOR HAND PALLET

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ARUBA CONSTRUCTION PHASE N: 135 22 013 FLUSHING PROCEDURE SWRO AND BWRO SKIDS WITH FLUSHING AND CLEANING SYSTEM
5. PROCEDURE FOR MEMBRANE LOADING 1ST PASS:

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2 types of membranes will be loaded inside of vessel: 1ST STAGE: Membranes are loaded and recorded from the feed side of the pressure vessels to the brine side.

For the correct control of the loading pattern 1 person is nominated to control the position of each membrane. He identifies the position of the membrane and ensures that it is placed in the correct location. He only releases a membrane for loading when he is satisfied that the membrane is going in the correct position & has recorded the vessel ID & Train. Each vessel has a reference with 8 positions/membranes for the 1st pass. The recorder will use a file (please find below a model) in order to control the position of each of them. A15

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ARUBA CONSTRUCTION PHASE N: 135 22 013 FLUSHING PROCEDURE SWRO AND BWRO SKIDS WITH FLUSHING AND CLEANING SYSTEM

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The different steps of the 1st STAGE

1. Lubricate membrane brine seal with glycerin and gently slide membrane into pressure vessel up to 2/3rd of element length ensuring the flow direction arrow is pointing into the vessel. Be careful with bisulfite sodium inside of bag before removing the membrane from it. 2. Interlock encaps for coupling membranes elements. Ensure the seal is installed on the Ilec TM. 3. Lift and place the next membrane, wash down the end of the two joined membranes with the 50/50 mix and push the membranes into the vessel until the last membrane is again protruding about 1/3rd of its length. Repeat the above with all other membranes. *Note: - Be careful, it is very important to support the membrane so as not to damage or displace the brine seal.

5. When installing the last element, push all elements completely inside the pressure vessel until the first element is properly installed with end plate.

6. Re-fit the brine side end cap assembly with permeat HDPE Pipe.

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ARUBA CONSTRUCTION PHASE N: 135 22 013 FLUSHING PROCEDURE SWRO AND BWRO SKIDS WITH FLUSHING AND CLEANING SYSTEM

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ARUBA CONSTRUCTION PHASE N: 135 22 013 FLUSHING PROCEDURE SWRO AND BWRO SKIDS WITH FLUSHING AND CLEANING SYSTEM
6. PROCEDURE FOR MEMBRANE LOADING 2ND PASS:

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7 membranes will be loaded with 1 spacer in the last position of loading. 1ST STAGE: Membranes are loaded and recorded from the feed side of the pressure vessels to the brine side. Each skid has 2 stages.

For the correct control of the loading pattern 1 person is nominated to control the position of each membrane. He identifies the position of the membrane and ensures that it is placed in the correct location. He only releases a membrane for loading when he is satisfied that the membrane is going in the correct position & has recorded the vessel ID & Train. Each vessel has a reference with 7 positions for the 2nde pass. The recorder will use a file (please find below a model) in order to control the position of each of them.

A13

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ARUBA CONSTRUCTION PHASE N: 135 22 013 FLUSHING PROCEDURE SWRO AND BWRO SKIDS WITH FLUSHING AND CLEANING SYSTEM

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The different steps of the 2nde Pass: Follow the steps above for membrane loading 1st pass. One more step will be added in this procedure. Only 7 membranes will be loaded instead of 8 membranes. This means an element spacer has to be installed: This element spacer, also called a dead man, is simply a standard product water tube without permeate holes. Proper installation is critical to both performance and safety. Only one element spacer has to be installed per pressure vessel, and it must always be installed in the first or lead element position. If placed in any other position it may crack or break due to the force being put on the product water tube. To install the spacer: 1. After loading the 7 membranes, insert the interconnector in the spacer and push the spacer with interconnector into the membrane. 2. Insert the adapter and then replace the pressure vessel head. It may be helpful to only partially insert the interconnector and adapter to leave room to line up the parts. Alternately, a guide stick can be inserted through the permeate port on the vessel head to hold the spacer in line while the parts are pushed together.
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ARUBA CONSTRUCTION PHASE N: 135 22 013 FLUSHING PROCEDURE SWRO AND BWRO SKIDS WITH FLUSHING AND CLEANING SYSTEM
VESSEL SHIMMING PROCEDURE FOR 1ST AND 2NDE PASS 1st method:

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To reduce the risk of the elements being disconnected within a pressure vessel, it is advisable to shim the vessel properly. The procedure is the same for the 1st pass and Second pass.

Thrust cone only for the brine side

1. Remove the end plate with adapter (6) 2. Push, if necessary, the membranes to ensure that they are correctly positioned with a specific fabricated tool.

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ARUBA CONSTRUCTION PHASE N: 135 22 013 FLUSHING PROCEDURE SWRO AND BWRO SKIDS WITH FLUSHING AND CLEANING SYSTEM

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3. 4. 5. 6.

Remove seal from adapter (5) and seal end cap (3) from end cap (4). Lubricate the adapter seal (5) with Molykote 111 Insert adapter (6) into element permeate tube Gently slide end cap on adapter (5) until the bearing plate is in line with the retaining ring grove

7. Gently remove the end cap assembly from the pressure vessel and measure the gap between the adapter (6) and the blind port 8. Insert the required quantity of shims over the adapter (6) to completely fill the gap

Desalination Project 9. Insert the adapter (6) into the end cap port 10. Re-install PWT O-rings and head seal (3). Lubricate PWT O-rings with silicon grease (Molykote 111) and head seal (3) with glycerin. Install feed end cap assembly. 11. Repeat the above procedure on all other pressure vessels 12. Finally install retaining rings 13. Re-install all permeate pipe work

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ARUBA CONSTRUCTION PHASE N: 135 22 013 FLUSHING PROCEDURE SWRO AND BWRO SKIDS WITH FLUSHING AND CLEANING SYSTEM
2nde method:

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Place the shims by trial and error method over the adapter and then replace the endplate. Shims should be added until the endplate will not fit entirely in place. Then remove a shim so that the total thickness of the shims is just enough to allow the endplate to fit. Repeat this procedure for all vessels.

Note: Shimming must be performed as tight as possible, (A maximum 2 mm gap is recommended), to avoid excessive movement of elements inside the pressure vessel during operation, particularly start up and shut down. Loose shimming will lead to adaptor O-rings being damaged and will compromise permeate quality.

7. CONTROL OF LOADING SCHEDULE

Management and Control for loading A team leader from NAWS must supervise all tasks: Manpower = 12 persons estimated One person records the position of membranes One team prepare the skid One team prepare the identification of the membranes One team prepare the transfer of the crates from containers to RO building + cleaning One team load the membranes One team shim/close the end caps

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