Technologies
3239 Dundas Street West
Oakville, ON, Canada
L6M 4B2
Phone: 905-465-3030
Fax: 905-465-3050
Email: gewater.technicalsupport@ge.com
PROJECT: 200443
REVISION: 0
NOTICE
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200443 Town of Taos MBR GE Water & Process Technologies
ZeeWeed Wastewater Treatment System Operation & Maintenance Manual
TABLE OF CONTENTS
Preface
Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
Typographical Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
List of Effective Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv
Tagged Components Within This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
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Section 8 - Glossary
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
8.2 Acronyms & Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
8.3 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
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A.8 - Troubleshooting
A.8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-151
A.8.2 Troubleshooting Quick-Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-152
A.8.3 Permeate Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-154
A.8.3.1 Membrane Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-154
A.8.3.2 Cassette Seal Leakage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-154
A.8.4 Process Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-155
A.8.5 Backpulse Tank Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-156
A.8.6 Air Release Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-157
A.8.7 General Component Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-159
A.10 - Calculations
A.10.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-167
A.10.2 Unit Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-167
A.10.3 General Dosing Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-169
A.10.4 Calculating Membrane Permeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-170
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LIST OF TABLES
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LIST OF FIGURES
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Figure A.7.5 - Bottom Permeate Port (Left), Top Permeate Saddle (Centre) & Location of Port
& Saddle (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-142
Figure A.7.6 - Aerator Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-143
Figure A.7.7 - MIS Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-144
Figure A.7.8 - Locking Key Locked (Left) & Unlocked (Right) . . . . . . . . . . . . . . . . . . . . . . . . . A-144
Figure A.7.9 - Locking Pin Locked (Left) & Unlocked (Right). . . . . . . . . . . . . . . . . . . . . . . . . . A-145
Figure A.7.10 - Module Header, Showing Wear Location . . . . . . . . . . . . . . . . . . . . . . . . . . . A-145
Figure A.10.1 - Dosing Calculation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-169
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200443 Town of Taos MBR GE Water & Process Technologies
ZeeWeed Wastewater Treatment System Operation & Maintenance Manual
PREFACE
This manual provides installation, operation, maintenance, and
ownership information for the Town of Taos MBR ZeeWeed WWTP. It
should be read and internalized in its entirety by all operators.
TYPOGRAPHICAL CONVENTIONS
Typographical conventions used within this manual are defined as
follows:
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SECTION 1
GENERAL SAFETY
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1.1 INTRODUCTION
This section provides general personal and environmental safety
information that applies to all personnel required to work with or around
the system.
• At all times while in the plant operating area, wear safety boots
with steel toe and shank inserts.
1.2.2 CLEANLINESS
A water treatment plant poses a number of potential health hazards that
make consistent personal and site cleanliness practices essential.
Immunization protects against infection, but common sense and care
are required at all times when in the plant operating area.
Do not expose cuts or open sores to feedwater, and ensure that hands
are washed with an antibacterial soap on a regular basis, especially
prior to eating, drinking, or smoking.
• Ensure that all personnel have been made familiar with the
proper operating procedures described in this manual and the
accompanying Volume I - Vendor Data Manual. In particular,
procedures related to the handling of acidic or caustic chemicals
and the maintenance of pressurized lines or components with
rotating parts should be emphasized.
• Ensure that safety shower and eye wash stations are operational
and in close proximity to areas where chemicals will be used.
Consider installing an alarm (visible and audible throughout the
plant operating area) that will activate if an emergency shower or
eye wash station is used.
• Ensure that areas where chemicals will be handled are well lit
and that access is not restricted.
SERVICING ENERGIZED COMPONENTS: Even with the power switch in the OFF
position, certain components inside a control panel or other electrical
device may remain energized. No service work can be performed until
the power supply to the device is first disconnected.
Exposed rotating parts can catch clothing, fingers, or tools and cause
severe personal injury or death.
FALL HAZARDS: Fall hazards include any situation where the possibility of
either personnel or equipment falling from a significant height
(approximately 3 m (10 ft)) is present. Ensure that personnel exposed to
this risk are secured using a harness as described in 1.2.1 Personal
Protective Equipment, and that all equipment involved is stored and
handled in a way that prevents it from falling.
• Gas detector.
• Tripod.
2.1 INTRODUCTION
This section provides a high-level description of the Town of Taos MBR
ZeeWeed WWTP, including information about the system’s performance
specifications, structure, and production process.
2.3.1 PRETREATMENT
All components and processes included upstream of the system inlet
valve have been provided by others and cannot be accurately
documented within this manual.
This system uses sequential aeration process, wherein the valves cycle
air between the trains. This limits the amount of air required to operate
the system and so reduces operating costs. The plant control system
automatically determines which trains should run in 10/10 aeration and
10/30 aeration, based on the system performance
For more information about controlling the system through the HMI,
refer to Section 3 - Operating the System. For information about the
electrical connections within the control panel, or about the specific
components it contains, refer to Volume III - Drawings Binder or to
Volume I - Vendor Data Manual, respectively.
3.1 INTRODUCTION
This section provides general information regarding the standard
operating procedures (SOPs) used to start up and operate the various
subsystems and individual components that comprise this system.
3. After the HMI has been activated, the Login screen appears.
The first screen to appear is the Overview screen, which provides a high-
level display of the system and the current status of all subsystems and
major components. All other screens and menus can be accessed by
selecting the buttons and symbols displayed on this screen.
2. In the Graphics menu, select the HMI Legend button. The Legend
screen appears.
AIR COMPRESSORS: At the Motor Control Center (MCC), ensure that all air
compressor circuit-breakers are ON and that all air compressor selector
switches are set to AUTO.
TIP: Automatic valves 2. Ensure that pressure within the air compressor tank is at a high
may not function enough level to satisfy the operating requirements of all
properly if air
pressure falls below pneumatically actuated valves. For more information, refer to
this level. Volume I - Vendor Data Manual.
3. Set all manually operated valves in the proper position for normal
operation. For information regarding valve positioning, refer to
Volume III - Drawings Binder. For more on valve operation, refer
to Volume I - Vendor Data Manual.
4. In the Overview screen, select the symbol for the train that is to
be put into production. The Train screen for that train appears.
TIP: The train will first 6. To activate the train, in the Modes pop-up screen, select the ON
enter STANDBY mode button. The train begins operating in AUTO mode.
after being activated.
7. When finished, select the Exit button. The Modes pop-up screen
closes.
• An alarm sounds.
Because an emergency shutdown does not trigger the same cycles that
a normal shutdown would, resuming operation immediately may
damage the system. As a result, after an emergency shutdown has been
triggered, all system components must be inspected and reset for
startup before operation resumes. For more information, refer to 3.5
Resuming Operation Following an Alarm Shutdown.
When an alarm occurs, the Alarm Summary pop-up screen appears and
displays a list of alarms and their associated conditions.
The Active Alarms pop-up screen lists all alarms that are in the alarm
state, both acknowledged and unacknowledged.
The Alarm History pop-up screen lists all alarms that have occurred.
TIP: If an alarm 5. Resolve the alarm condition before proceeding. For information
condition remains on resolving alarms, refer to the CLC. Refer to the accompanying
when the operator
attempts to resume appendices for information regarding issues related to a specific
operation, the alarm subsystem, or to Volume I - Vendor Data Manual for information
will sound again and
this procedure will regarding a particular component.
need to be repeated.
6. The action required to reset an alarm depends in the type of
alarm that was triggered. After all alarm conditions have been
resolved, to reset the alarm, complete one of the following steps:
TIP: If the alarm 7. To prepare the ZeeWeed UF subsystem for operation, perform
condition involved a steps 1 - 7 under 3.3.2 ZeeWeed UF Subsystem.
component in LEAD
mode, the paired
component in LAG If an alarm sounds but does not trigger an emergency shutdown and
mode will
automatically enter
deactivates automatically, consult the Alarm History pop-up screen for
LEAD mode until an explanation. In most cases where this occurs, the condition that
manually switched triggered the alarm was resolved automatically. However, operators
back to LAG mode.
should confirm this in order to rule out the possibility of a faulty alarm.
The level of manual control that an operator has over the system
depends on his or her security level access. Many of the controls
outlined below will not be available (that is, they will not appear on the
screen) if the operator who has logged in does not have clearance to
override the automated settings already in place.
3.6.2 VALVES
Valves can be set in the following modes:
1. At the HMI, select the symbol for the valve. The valve’s pop-up
screen appears.
3.6.3 PUMPS
The controls used to adjust a pump’s settings can vary depending on the
type of pump in question.
A pump that has been taken out of AUTO mode must not be left
unattended.
1. At the HMI, select the symbol for the pump. The pump’s pop-up
screen appears.
2. In the pump’s pop-up screen, select either the box displaying the
Start Speed value or the one displaying the Runtime value, as
needed. The keypad control for the selected value appears.
3. Enter the new value, and then select the Reset button. The setting
is updated.
TIP: As membranes The process pump can be set to operate in the following modes:
become fouled, the
PLC will automatically
adjust VFD and feed • AUTO - the pump is controlled by the PLC.
flow settings to
maintain production. • STOP - the pump is stopped.
1. At the HMI, select the symbol for the pump. The pump’s pop-up
screen appears.
2. In the pump’s pop-up screen, select the Stop button. The pump
deactivates and the Start Forward and Start Reverse buttons
appear.
The mode buttons “Start Forward”, “Start Reverse” and “Stop” are
only available when the supervisory password has been entered.
1. At the HMI, select the symbol for the pneumatic valve associated
with the pump. The valve’s pop-up screen appears.
The mode buttons “Open” and “Close” are only available when the
supervisory password has been entered.
To adjust a pump’s stroke speed, use the controls found on the pump
itself. For more information, refer to Volume I - Vendor Data Manual.
TIP: The Plant 1. In the Overview screen, select the Plant Setpoints button. The
Setpoints button is Plant Setpoints pop-up screen appears.
also available from
most other screens.
2. In the Plant Setpoints screen, select the button for the required
setpoint subgroup. The setpoints included in that subgroup
appear.
3. From the setpoints listed, select the box that displays the current
value for the setpoint that will be updated. The keypad control for
the selected value appears.
4. Enter the new value, and then select the Reset button. The setting
is updated.
5. To close the Plant Setpoints screen, select the Exit button. The
Plant Setpoints screen closes.
This same procedure can be used to adjust the setpoint values found on
other screens as well.
1. In the Overview screen, select the LOG OFF button. The Confirm
Logout screen appears.
2. In the Confirm Logout screen, select the Yes button to logout the
screen, or the No button to return to the Overview screen.
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Table of Contents
1 Plant Overview
This document covers a general description of the controls by GE W&PT for the following unit
processes:
ZeeWeed® Trains,
Backpulse Equipment,
Aeration Equipment,
Clean-In-Place (CIP) Equipment,
Utilities Equipment.
2 General Information
The reader should refer to the Piping and Instrumentation Diagrams (P&IDs), Operations Sequence
Chart (OSC) and the Control Logic Summary Chart (CLSC) for a complete understanding of the plant
control scheme as described below.
The PLC follows specific steps to automatically control valves, pumps, etc. during the operating states
for the treatment plant. These steps are listed and described in the OSC.
Details of the control logic, setpoints, etc. that are required to operate the plant are given in the CLSC.
In the documentation, the Programmable Logic Controller is referred to as the PLC. The PLC provides
automated control of the ZeeWeed® equipment. All the programming for the control of the
ZeeWeed® plant is stored in the PLC.
Setpoints, alarms, and calculated parameters, etc., are assigned tags in the PLC code. When tags are
used in the Control Narrative, they are identified by an alpha-numeric label, for example, 20-P-301,
for a process pump.
Modes are a series of steps the train follows to perform various operations, such as a cleaning. A
specific mode discussed in this document is shown in capital letters, such as MAINTENANCE CLEAN.
Buttons displayed on the HMI screen that the operator can press to initiate a mode or other
operation are shown with the first letter capitalized. For example, one button that is used to put a
train to OFF mode is the Off button.
Each ZeeWeed® train has separate mode buttons. There are several modes for each train, these
modes are: OFF, POWER OFF, SHUTDOWN, STANDBY, PRIME, BACKPULSE, RELAX, PRODUCTION,
MAINTENANCE CLEAN, RECOVERY CLEAN and NEUTRALIZATION. Using the ZeeWeed® train mode
buttons on the HMI, the operator can put each ZeeWeed® train into a different mode. There are
some interlocks present to prevent the user from proceeding to one mode from another. These
interlocks are for membrane protection. Not all modes are selectable. Consult the CLSC and OSC for
further details on the modes.
For the plant to operate automatically, the operator needs to have all devices set to AUTO and the
Trains’ On button(s) selected. The On button is only active for a train if it is in either OFF or
SHUTDOWN. Pressing the Train’s On button places that train into PRIME and then STANDBY mode. If
there is a demand for the train to run, the train proceeds to PRODUCTION. The train continues in the
production cycle, alternating between PRODUCTION and either BACKPULSE or RELAX modes, until the
demand to treat wastewater decreases placing the train to STANDBY. A scheduled MAINTENANCE
CLEAN automatically interrupts this production cycle. An alarm may also place a train to STANDBY
or SHUTDOWN.
The operator may interrupt the production cycle by pressing the Maintenance Clean or Backpulse
button. The train will proceed to the selected mode once the resources are available. There are
interlocks preventing more than one train from entering the same mode at the same time. Consult
the CLSC and the OSC for details on the interlocks.
The operator may turn a train OFF at any time. Pressing the Off button will place the train into OFF
mode. It is the responsibility of the operator to ensure that if the Off button is pressed when a train is
in the MAINTENANCE CLEAN or RECOVERY CLEAN modes the tank’s contents are suitable for a train to
proceed to another mode. Neutralization may be required.
The flow setpoint for the PID loop which controls the process pump is based on the plant flow
demand or a manually entered flow setpoint.
4.3.1 Influent Flow, Membrane Feed Collection Channel Level & Permeate Flow Control
The influent flow signal is used for the plant flow demand. As the influent flow increases the plant
flow demand increases, causing the process pump(s) to speed up. To prevent standby and overflow
conditions, the level in the membrane feed collection channel is used to trim the plant flow demand.
Level control is accomplished with Proportional control. The PLC carries out these calculations. The
plant flow demand is the net permeate flowrate required from the GE W&PT system and does not
include additional permeate the system produces for non-production operations, such as
BACKPULSE.
The trim flowrate, which is a calculated flow, is added to or subtracted from the influent flowrate
according to the level in the membrane feed collection channel and the difference from the level
setpoint. As the level increases above the setpoint in the membrane feed collection channel, the trim
increases causing the overall plant flow demand to increase. When the plant flow demand increases,
the process pumps for the trains in operation are ramped up to increase the plant permeate
production which brings the level down in the membrane feed collection channel. Conversely, if the
membrane feed collection channel is below the setpoint, the calculated trim flowrate is a negative
flow and the overall plant flow demand decreases. The process pumps are ramped down, decreasing
the permeate production, and the membrane feed collection channel level increases as a result of
the decreased permeate production.
The flow setpoints for trains with a manual flow setpoint are added together and subtracted from the
plant flow demand which includes the level trim. This revised plant flow demand is then divided
equally to the trains in operation without a manually entered flow setpoint. This becomes the net
production flow setpoint for a train. A correction factor is calculated to account for the time when
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the train is not producing water (i.e. Relax or Backpulse) and to produce additional water required for
backpulsing the train, when trains are being backpulsed. The net production flow setpoint multiplied
by the correction factor is then used to calculate the instantaneous flow setpoint for the train. This
value controls the process pump speed through the flow PID loop.
A flow setpoint may also be entered for each train manually. The supervisor can do this by setting
the production flowrate for some or all of the trains on the HMI. The system will maintain the
operator entered production flowrate or PLC calculated production flowrate up to a maximum
TransMembrane Pressure (TMP) or a minimum tank level.
Figure 1: Influent Flow, Level Control & Permeate Flow Control Chart
Total of all
Measured Level
supervisory
entered train Actual train
Level flow from
flows
Setpoint transmitter
Trim
Subtract supervisory
Add Flow Revised Divide net control output Convert the production Process
Influent entered train flows
and Trim Plant Flow by the number of units in flow setpoint per train Pump
Flow from plant flow
Plant Demand a production cycle without to the instantaneous Speed
demand
Flow a supervisory setpoint production setpoint
Demand
The PLC continuously calculates the TMP value while in PRODUCTION. If the TMP is too low, (i.e., too
negative) the TMP low trigger is active and the flow control PID loop output is captured. This value
becomes the maximum value for the flow control PID loop output.
When the TMP low trigger becomes active, the PLC gradually reduces the maximum for the flow PID
loop output until the TMP low trigger is not active, (i.e., TMP is less negative). At the moment when the
TMP low trigger becomes inactive, the maximum value is then gradually increased until the TMP low
trigger is active again, or continues to increase until the maximum value for the flow control PID loop
output equals 100%. This control strategy allows the PLC to vary the pump speed to maximize flow
while avoiding excessive TMP across the membranes.
TMP is calculated by using the equation below. During PRODUCTION the value is negative, for
backpulses and CIP, it is positive.
TMP = Header Pressure + C x (A + B - Membrane Tank Level)
Where:
A is the height of the pressure transmitter above the top of the membranes.
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The number of trains in operation at any given time will vary depending on the plant flow demand.
As this demand increases the number of trains in PRODUCTION will increase. Start and stop train
triggers are used to determine when another train is to start or when a train is to be placed to
STANDBY. These triggers are defined in the CLSC.
Several triggers may cause a train to go to STANDBY rather than shutting it down. These triggers
include a low membrane tank level or a loss of compressed air. If a low membrane tank level occurs,
the train will immediately proceed to STANDBY. If the STANDBY triggers no longer exist and a start
trigger is active, the train proceeds to PRODUCTION.
Trains are automatically rotated from PRODUCTION to STANDBY when another train is in STANDBY
based on an adjustable cycle timer, typically set to 4 hours. As long as there is at least one train in
the Production cycle, the cycle timer operates and when the timer times out, a Standby request is
initiated to stop one train, the train that has operated the longest compared to the other operating
trains. This lead train is put to STANDBY at the end of its next Backpulse/Relax, and a train that is in
STANDBY starts in PRODUCTION. Train rotation allows each available train to operate as the lead train
for no more than the duration of the cycle timer, such as 4 hours, plus the time remaining in the
train's Production cycle when the train is triggered to proceed to STANDBY.
When the cycle timer times out and there is no train available in STANDBY to start in PRODUCTION,
the lead train continues in the Production cycle and the request to put a train to STANDBY is
maintained, waiting for a train to become available.
If permeate demand decreases and triggers a train to stop, the cycle timer resets and resumes
timing or when the train with the highest priority to stop is not in the Production cycle, timer resets
and resumes timing.
5 Backpulse Control
At this facility, the membranes are backpulsed using the process pump. Treated water is periodically
reversed back through the membranes to maintain stable transmembrane pressures.
The PLC controls the process pump speed to backpulse the trains at a set flow rate per train up to a
maximum TMP. A transmitter on the membrane header is used to calculate the BACKPULSE TMP.
This TMP limit provides membrane protection against over-pressurization. If the TMP is too high, the
TMP high trigger is active and the flow control PID loop output is captured. This value becomes the
maximum value for the output of the flow control PID loop.
When the TMP high trigger becomes active, the PLC gradually reduces the maximum for the flow PID
loop output until the TMP high trigger is not active, (i.e., TMP is less positive). At the moment when the
TMP high trigger becomes inactive, the maximum value is then gradually increased until the TMP
high trigger is active again, or continues to increase until the maximum value for the flow control PID
loop output equals 100%. This control strategy allows the PLC to vary the pump speed to maximize
flow while avoiding excessive TMP across the membranes.
The backpulse duration, production cycle duration, TMP setpoint and flow setpoint for all ZeeWeed®
trains can be set through the HMI. All ZeeWeed® trains in the plant share the same backpulse
duration and production cycle duration.
The PLC staggers the backpulses of the trains throughout each cycle to distribute the backpulses
evenly when all trains are in the Production cycle. Each train is given a fixed scheduled time in the
master Production cycle timer to begin a BACKPULSE and RELAX. Train 1 is assigned the first time
slot, train 2 is assigned the second time slot, and so on for all trains in the system. Regardless of the
number of trains in the Production cycle, each train is always backpulsed at the same time slot of the
Issued: October 4, 2010 Page 6 of 6 CN_200443_Taos_R00_04Oct10_JJ
Process Controls: J. Jackson
AO# 200443 Town of Taos MBR Printed:
master Production cycle timer. For example, when there are four trains in the system and the
Production cycle time is 12 minutes, the first time slot is at time 0 minutes and the second time slot,
to backpulse Train 2, is at 3 minutes of the master Production cycle timer.
The master Production cycle timer starts when there are no trains in PRODUCTION and one train is
requested to start PRODUCTION. The timer restarts every time it times out.
The operator can initiate a BACKPULSE from the HMI for any ZeeWeed® train by pressing the
Backpulse button. This button is disabled if any other train is in BACKPULSE or RELAX.
5.2 Relax
RELAX control is an alternative to backpulsing. If a backpulse failure occurs and no pump is available,
the PLC will place the trains into RELAX mode.
In RELAX mode, the PLC will stop permeating and the membranes will sit for an operator entered
duration before continuing production. During this time solids that have concentrated around the
membrane will be distributed away from the membrane surface by the aeration.
6 Sludge Wasting
The operator is required to waste sludge from the membrane basins in order to maintain good
membrane performance. The operator should analyze the sludge to ensure a mixed liquor
concentration of less than 10,000 mg/L, for example, to maximize membrane performance.
The blowers supply low pressure air into a common air header for all of the trains. This common air
header then divides into multiple air headers to the membrane tanks. The PLC calculates the
membrane aeration demand and communicates this value.
For further details on blower operation, refer to the OSC and CLSC for the occurrence of blowers to be
running at any given time and the required air flow.
Each train operates under sequential aeration. Valves will cycle air within a train, reducing both the
air required to run the system and the operating costs. See the OSC for steps with an aeration
demand. Cyclic aeration may be deactivated for a train by the PLC due to a cyclic valve failure.
The plant control system automatically determines which trains should run in 10/10 aeration (i.e.
sequential aeration) and 10/30 aeration, based on the system performance.
If a cyclic valve is requested to close and fails to close, cyclic aeration continues and the train does
not proceed to Standby due to an active Plant Permeate Demand Standby Trigger. An alarm would
be triggered to alert the operator. If an aeration valve fails to open, the train is shutdown to prevent
overfouling of the membranes due to inadequate air scouring.
The alternative aeration strategy is referred to as 10/30 Cyclic Aeration. 10/30 Cyclic Aeration is
accomplished by aerating a given membrane module for 10 seconds, then not aerating for 30
seconds. The only change with respect to the standard 10/10 aeration is the time between aeration
events increases from 10 to 30 seconds. The extension from 10 to 30 seconds of no aeration
significantly reduces the aeration requirement for the entire plant.
The plant controls automatically determine which trains should run in 10/10 and 10/30 operation
based on the system performance. The reduction in aeration is made possible by monitoring the
condition of the membranes and determining the level of fouling on the membranes. When
membranes are in a clean condition the trains will operate in the 10/30 aeration. If the membranes
become fouled, the aeration is returned to 10/10 aeration in order to increase the shear on the
membranes and remove any solids accumulation. Experience has shown that it is possible to
operate in 10/30 aeration for periods where the wastewater flow is at or below the average day
design value. During peak flow conditions the operating TMP will increase and call for the system to
switch to 10/10 aeration automatically.
The PLC aerates trains in Standby sequentially to limit the number of starts and stops on the
membrane aeration blowers. The trains in Standby are aerated starting with the first train followed
by the second train, then the third train, without stopping the membrane aeration demand. Trains
are aerated in the order of their train number. If, for example, train 2, and 3 are in Standby, train 2 is
aerated first, and then train 3. Sequential aeration involves an overlap of aeration to allow the
membrane aeration blower to continue to operate as one train completes its aeration and another
train begins its aeration.
Integrity of the plant is monitored with an on-line turbidimeter. Turbidity is monitored and displayed
when any train is in PRODUCTION.
There are three turbidity alarms used to assist the operator in running the system. One alarm is used
to detect a problem that is not a spike and will alert the operator of a critical problem. For example,
this alarm will occur when the turbidity is above the setpoint, 5 NTU, for 30 seconds.
A second alarm is used to detect a spike in turbidity and will set all trains that are in BACKPULSE
mode to RELAX mode. For example, the alarm is active when the turbidity is above the setpoint, 5
NTU, for 10 seconds. The alarm will also skip all scheduled MAINTENANCE CLEANS until the turbidity
alarm condition no longer exists. From this time on, MAINTENANCE CLEANS will again be completed
as scheduled, but the BACKPULSE Mode must be manually selected by the operators, if required.
The third alarm also detects turbidity spikes but at a lower setpoint and is used to notify the operator
of a potential problem which needs to be addressed. For example, the alarm is active when the
turbidity is above the setpoint, 1 NTU for 60 seconds.
The turbidity alarm setpoints and the time delays, before the alarms become active, are adjustable at
the HMI.
For further details consult the CLSC.
The membranes require cleaning to maintain peak performance. There are two types of cleaning
methods; MAINTENANCE CLEANS and RECOVERY CLEANS.
Sodium hypochlorite is used to remove organic contaminants from the membranes. The sodium
hypochlorite pumps 23-P-130-10 and 23-P-130-11 are air diaphragm pumps. The GE W&PT PLC
requests the sodium hypochlorite valve, 23-FV-131-2 for MAINTENANCE CLEAN and 23-FV-131-1 for
RECOVERY CLEANS, to open to run the pump in specific steps during the cleaning procedure. Consult
the OSC for these steps.
Citric acid is periodically used to remove inorganic contaminants from the membranes such as
calcium carbonate, manganese and iron compounds. The citric acid pumps 23-P-330-10 and 23-P-
330-11 are air diaphragm pumps The GE W&PT PLC requests a citric acid valve, 23-FV-331-2 for
MAINTENANCE CLEAN or 23-FV-331-1 for RECOVERY CLEAN, to open to run the pump in specific steps
during the cleaning procedure. Consult the OSC for these steps.
Maintenance Cleans are scheduled through the HMI and are automatically initiated by the PLC based
on a 24 hour clock. The operator may select to perform one scheduled Maintenance Clean a train
per day on the MAINTENANCE CLEAN schedule screen.
The operator selectable options:
Day of week for cleaning;
Time of day for cleaning;
Sodium hypochlorite for cleaning solution;
Citric acid for cleaning solution.
When it is time to carry out a MAINTENANCE CLEAN, the PLC compares the current plant flow
demand with the available capacity of the plant if one train is not in service. If the plant flow demand
exceeds this capacity, then scheduled MAINTENANCE CLEAN is skipped but the request remains
active and is started when this demand is lower. When a MAINTENANCE CLEAN is skipped or aborted,
an alarm occurs to inform the operator.
If the plant demand does not exceed this capacity, when it is time to carry out a MAINTENANCE
CLEAN, the train completes its current production cycle before starting the cleaning procedure. If a
train is in STANDBY it goes directly to MAINTENANCE CLEAN.
RECOVERY CLEANS can only be carried out for a train if it is in R. CLEAN mode. The operator is
required to turn the train OFF then select either R. Clean Acid or the R. Clean Hypochlorite button to
for the cleaning to begin. During a Recovery Clean there are several prompts which the operator
must address. Consult the OSC and CLSC for further details. As a result it is suggested to have the
operator present during the Recovery Clean so that these prompts can be responded to in a timely
manner.
RECOVERY CLEANS can be done with citric acid or sodium hypochlorite depending on which cleaning
chemical the operator selects at the beginning of the sequence.
The default steps for Recovery Clean are:
1. Aerates the membrane tank;
2. Drains the membrane tank, the operator required to manually align valves and start pump;
3. Manual drain and flush step. The PLC will proceed to the next step after a defined duration.
4. Steps 5 to 8 are repeated for a number of iterations and then proceed to step 9.
5. Backpulses the membrane tank for a defined duration then proceeds to next step or until the
tank is at a defined level then proceeds to step 7;
6. Relaxation period for all cassettes for a defined duration and then proceed to step 5.
7. Aerates the membrane tank for a defined duration;
8. Drains the membrane tank, the operator required to manually align valves and start pump;
Issued: October 4, 2010 Page 10 of 10 CN_200443_Taos_R00_04Oct10_JJ
Process Controls: J. Jackson
AO# 200443 Town of Taos MBR Printed:
9. Chemically enhanced pulse to all the cassettes for a defined duration then proceeds to next step
or until the tank is at a defined level then proceeds to step 11;
10. Relaxation period for all cassettes for a defined duration and then proceeds to step 9;
11. Final, extended relaxation period with intermittent aeration;
12. The operator selects the Neutralization button to proceed to NEUTRALIZATION mode.
The Neutralization button is available in OFF and in the last step of RECOVERY CLEAN. The default
steps for Neutralization are:
1. Fills the membrane tank to defined level with feed;
2. Aerates the membrane tank;
3. Relaxation period for all cassettes for a defined duration and then either proceed to next step if
the clean was with sodium hypochlorite or proceed to step 5 if the clean was with citric acid.
4. The operator manually checks the residual chlorine concentration. The operator selects the
Confirm Neutralization button to proceed to next step when the Cl residual is less than 10 ppm.
The operator selects the Resume Neutralization button when the chlorine residual is greater than
10 ppm. The PLC will proceed to step 3.
5. Non-chemically enhanced pulse to all the cassettes;
6. Proceeds to OFF.
Consult the OSC and CLSC for specific details on the steps and setpoints used in this mode.
Each train is provided with an ejector, which uses compressed air to operate and primes the process
pump during PRIME, at the beginning of BACKPULSE/RELAX and intermittently the trains in
PRODUCTION.
To prime the train’s ejector compressed air valve opens which also opens the permeate header
isolation valve. During this time, air in the permeate header is pulled up and out through the ejector,
which also pulls water into the membranes and process pump suction. Any water that is drawn into
the ejector drains out by gravity.
The operator can manually initiate the priming sequence by pressing the Prime button for the train at
the HMI. The operator can manually initiate priming only when the train is in STANDBY and OFF.
When low compressed air alarm is active, trains in PRODUCTION, BACKPULSE, RELAX, and
MAINTENANCE CLEAN proceed to STANDBY and trains in RECOVERY CLEAN and NEUTRALIZATION
proceed to SHUTDOWN.
A trigger is a normal event that can clear an alarm or be one of several points in a sequence of
events.
12.1 Alarms
Alarms are used to identify a problem with the system. Depending on the nature of the problem the
alarm may either shutdown the train(s), place a train to STANDBY, and initiate a callout to notify the
operator that there is a problem. It is understood that the operator will acknowledge the alarm and
address the situation. If the problem is not corrected, production quality and quantity will drop off
quickly.
An alarm that is activated by an instrument, pressure transmitter, flow transmitters, or level
instrumentation, typically requires a pump or certain device to be on to generate the required flow or
pressure. Otherwise, the alarm will be ignored if the device to be protected is off.
All alarms are indicated with a message on the screen. The operator cannot reset the alarm without
the correct password. All alarms and the time they occurred are recorded on the alarm history
screen.
Some alarms can shutdown a ZeeWeed® train(s). These alarms close appropriate valves and stop
pumps. The shutdown alarm puts the train to Shutdown mode. Restarting after a shutdown will
require the alarm to be reset.
Devices which are being controlled remotely cannot have their status changed by the PLC.
Consult the CLSC for details on specific alarms, the corresponding actions and reset procedures.
Typical alarms that shutdown a train and alarms that put a train to STANDBY are listed in the
following tables.
To accommodate the above operational requirements and all other control, display, and monitoring
requirements, this plant employs a Human Machine Interface (HMI) for access to plant controls. The
HMI communicates with the Programmable Logic Controller, which in turn controls the plant.
The ability to silence the horn and acknowledge alarms does not require a password, but alarms can
not be reset.
To gain access to make changes on the HMI, the operator is required to enter the correct password.
A screensaver blanks the screen after a set amount of time of inactivity. The screen is reactivated by
a single touch. Reactivation cannot select a device or operating mode.
In order to access the control screens, the individual must enter a correct password then press Enter.
There are three levels of password protection; Operator, Supervisor, & GE W&PT. The operator
password is factory set; consult the CLSC for the operator password. The supervisor password can
be modified from the HMI. There is no limit to the number of times another password can be
attempted. The password must be re-entered after a set amount of time of inactivity. For details of
password privileges consult the CLSC.
The color-coded -status indicates a device’s mode. The HMI uses the color-coding shown below.
Green Open On
The mode, step and in steps with a duration timer the time remaining in the step is displayed on the
train screen at the HMI.
When a loss of power occurs, the affected trains will immediately proceed to POWER OFF mode.
After power returns, the plant powers up and trains will start-up automatically as described in the
CLSC. The CLSC lists the order in which the common equipment and trains will power up; it also
specifies the mode that a train will proceed to from POWER OFF mode.
Legend
This column is for the GE W&PT Tags
T - Indicates that the valve is throttling in Auto.
ion
O - Indicates that the valve/motor is open/on in Auto.
lat
air
s
Iso
e
lve
M - Indicates that the valve is to be manually opened by the operator.
ite
ite
alv
tio
sed
lor
Va
rite
lor
X - Indicates that the valve/motor is closed/off in Auto.
d
nV
p
ola
an
on
um
ch
res
ch
clic
rai
t Is
C - Indicates that valve cycles though an open/close sequence.
al
l
em
i
po
h
lat
po
P
mp
ign
oc
Cy
al D
en
r to
Hy
-x - Indicates that there are multiple trains associated with this tag number.
Iso
nD
Hy
ci d
Operating Mode
yp
id
co
tS
rum
ion
u
de
Ac
m
LS - Indicates that the valve/pump will retain the last state it had (open/closed, on/off) to avoid damaging equipment.
tio
cid
cA
H
g
s
an
tor
ue
rat
diu
Ta
ea
diu
um
t
era
ric
ic A
s
-M
itri
jec
eq
- In
Ae
-H
GE
So
Cit
So
i
eA
d
pR
-E
NE
Cit
So
ne
N-
N-
Step Description Step #
y
TE
TE
N-
N-
ran
ela
um
UM
RA
bra
EA
EA
N-
N-
EA
EA
ss
LEA
LEA
pD
mb
MB
RM
RM
SP
ce
CU
CL
CL
m
EA
EA
p
R. C
R. C
Pro
Me
Ste
Ste
ME
Me
VA
RA
PE
CL
PE
CL
M.
M.
Manual
Tag Numbers Valves Chemical Pump Valves Drain Pumps & Blowers
For 20-E-801-
20-HV-501-x
23-FV-331-1
23-FV-131-1
23-FV-331-2
23-FV-131-2
20-FV-210-x
20-FV-211-x
20-FV-301-x
20-FV-320-x
23-FV-130-x
23-FV-330-x
20-FV-802-x
The Operations Sequence Chart (OSC), Control Logic Summary Chart (CLSC) and the Control Narrative (CN) should all be read to assist in the understanding of plant
20-P-301-x
20-B-200
MB-P-5
MB-P-x
operations.
The train remains in this step indefinitely until one of the following occurs:
If a start train trigger is active, defined in the CLSC, the train proceeds to the PRODUCTION - step 1.
STANDBY Step 3 CN1 X X X X X X X X X O
N4
X
N5,N6
O
N1
X 3
If the Backpulse button is pressed proceeds to BACKPULSE - step 1.
If the Maintenance Clean button is pressed proceeds to MAINTENANCE CLEAN - step 1.
If the Prime Train button is pressed proceeds to PRIME - step 1.
Only proceeds to the step indicated if the resources are available and the interlocks preventing the action are not present.
PRIME 8 8 Only one train can be in PRIME mode at a time but more than one train can be in a priming step.
Holds this step for step duration
If PRIME was initiated from STANDBY then proceeds to STANDBY - step 1.
Priming Train Step 1 X X X X X X X X X X O X X X 20-KQS-801D 1
If the Prime button was pressed in OFF, then train proceeds to OFF - step 1.
If the On button was pressed in Off or Shutdown, then proceeds to STANDBY - step 1.
PRODUCTION 14 14
Step 1 C O O X X X X X X X O O X X 6 1 Waits for step delay, then proceeds to the next step.
Permeates until the end of the current PRODUCTION cycle, then:
If there is a demand for the train to run and there is no MAINTENANCE CLEAN request noted below or if the train is unable to proceed to the MAINTENANCE CLEAN, proceeds to
either BACKPULSE - step 1 or RELAX - step 1.
Permeate Step 2 C O O X X X X X X X X O O O 2
If a MAINTENANCE CLEAN request is active proceeds to MAINTENANCE CLEAN - step 1. (A MAINTENANCE CLEAN requests refers to either a scheduled request or the
Maintenance Clean button is selected.)
BACKPULSE 20 20 Only one train can be in BACKPULSE or RELAX at a time.
Permeating Stops Step 1 C O X X X X X X X X O O LS X 6 1 Waits for step delay, and then proceeds to the next step.
Step 2 C O X X X X X X X X O O O X 6 2 Waits for step delay, and then proceeds to the next step.
Page 1 of 4
Issued: October 4, 2010
Process Controls: J. Jackson The enclosed materials are considered proprietary property of GE Water & Process Technologies. OSC_200443_Taos_R00_04Oct10_JJ
AO # 200443
GE Water & Process Technologies
Town of Taos, MBR
Operations Sequence Chart for Train Sequenced Equipment
Legend
This column is for the GE W&PT Tags
T - Indicates that the valve is throttling in Auto.
ion
O - Indicates that the valve/motor is open/on in Auto.
lat
air
s
Iso
e
lve
M - Indicates that the valve is to be manually opened by the operator.
ite
ite
alv
tio
sed
lor
Va
rite
lor
X - Indicates that the valve/motor is closed/off in Auto.
d
nV
p
ola
an
on
um
ch
res
ch
clic
rai
t Is
C - Indicates that valve cycles though an open/close sequence.
al
l
em
i
po
h
lat
po
P
mp
ign
oc
Cy
al D
en
r to
Hy
-x - Indicates that there are multiple trains associated with this tag number.
Iso
nD
Hy
ci d
Operating Mode
yp
id
co
tS
rum
ion
u
de
Ac
m
LS - Indicates that the valve/pump will retain the last state it had (open/closed, on/off) to avoid damaging equipment.
tio
cid
cA
H
g
s
an
tor
ue
rat
diu
Ta
ea
diu
um
t
era
ric
ic A
s
-M
itri
jec
eq
- In
Ae
-H
GE
So
Cit
So
i
eA
d
pR
-E
NE
Cit
So
ne
N-
N-
Step Description Step #
y
TE
TE
N-
N-
ran
ela
um
UM
RA
bra
EA
EA
N-
N-
EA
EA
ss
LEA
LEA
pD
mb
MB
RM
RM
SP
ce
CU
CL
CL
m
EA
EA
p
R. C
R. C
Pro
Me
Ste
Ste
ME
Me
VA
RA
PE
CL
PE
CL
M.
M.
Manual
Tag Numbers Valves Chemical Pump Valves Drain Pumps & Blowers
For 20-E-801-
20-HV-501-x
23-FV-331-1
23-FV-131-1
23-FV-331-2
23-FV-131-2
20-FV-210-x
20-FV-211-x
20-FV-301-x
20-FV-320-x
23-FV-130-x
23-FV-330-x
20-FV-802-x
The Operations Sequence Chart (OSC), Control Logic Summary Chart (CLSC) and the Control Narrative (CN) should all be read to assist in the understanding of plant
20-P-301-x
20-B-200
MB-P-5
MB-P-x
operations.
Page 2 of 4
Issued: October 4, 2010
Process Controls: J. Jackson The enclosed materials are considered proprietary property of GE Water & Process Technologies. OSC_200443_Taos_R00_04Oct10_JJ
AO # 200443
GE Water & Process Technologies
Town of Taos, MBR
Operations Sequence Chart for Train Sequenced Equipment
Legend
This column is for the GE W&PT Tags
T - Indicates that the valve is throttling in Auto.
ion
O - Indicates that the valve/motor is open/on in Auto.
lat
air
s
Iso
e
lve
M - Indicates that the valve is to be manually opened by the operator.
ite
ite
alv
tio
sed
lor
Va
rite
lor
X - Indicates that the valve/motor is closed/off in Auto.
d
nV
p
ola
an
on
um
ch
res
ch
clic
rai
t Is
C - Indicates that valve cycles though an open/close sequence.
al
l
em
i
po
h
lat
po
P
mp
ign
oc
Cy
al D
en
r to
Hy
-x - Indicates that there are multiple trains associated with this tag number.
Iso
nD
Hy
ci d
Operating Mode
yp
id
co
tS
rum
ion
u
de
Ac
m
LS - Indicates that the valve/pump will retain the last state it had (open/closed, on/off) to avoid damaging equipment.
tio
cid
cA
H
g
s
an
tor
ue
rat
diu
Ta
ea
diu
um
t
era
ric
ic A
s
-M
itri
jec
eq
- In
Ae
-H
GE
So
Cit
So
i
eA
d
pR
-E
NE
Cit
So
ne
N-
N-
Step Description Step #
y
TE
TE
N-
N-
ran
ela
um
UM
RA
bra
EA
EA
N-
N-
EA
EA
ss
LEA
LEA
pD
mb
MB
RM
RM
SP
ce
CU
CL
CL
m
EA
EA
p
R. C
R. C
Pro
Me
Ste
Ste
ME
Me
VA
RA
PE
CL
PE
CL
M.
M.
Manual
Tag Numbers Valves Chemical Pump Valves Drain Pumps & Blowers
For 20-E-801-
20-HV-501-x
23-FV-331-1
23-FV-131-1
23-FV-331-2
23-FV-131-2
20-FV-210-x
20-FV-211-x
20-FV-301-x
20-FV-320-x
23-FV-130-x
23-FV-330-x
20-FV-802-x
The Operations Sequence Chart (OSC), Control Logic Summary Chart (CLSC) and the Control Narrative (CN) should all be read to assist in the understanding of plant
20-P-301-x
20-B-200
MB-P-5
MB-P-x
operations.
Operator presses Confirm Neutralization to proceed to next step, or presses Resume Neutralization to return to NEUTRALIZATION step 5.
Page 3 of 4
Issued: October 4, 2010
Process Controls: J. Jackson The enclosed materials are considered proprietary property of GE Water & Process Technologies. OSC_200443_Taos_R00_04Oct10_JJ
AO # 200443
GE Water & Process Technologies
Town of Taos, MBR
Operations Sequence Chart for Train Sequenced Equipment
Legend
This column is for the GE W&PT Tags
T - Indicates that the valve is throttling in Auto.
ion
O - Indicates that the valve/motor is open/on in Auto.
lat
air
s
Iso
e
lve
M - Indicates that the valve is to be manually opened by the operator.
ite
ite
alv
tio
sed
lor
Va
rite
lor
X - Indicates that the valve/motor is closed/off in Auto.
d
nV
p
ola
an
on
um
ch
res
ch
clic
rai
t Is
C - Indicates that valve cycles though an open/close sequence.
al
l
em
i
po
h
lat
po
P
mp
ign
oc
Cy
al D
en
r to
Hy
-x - Indicates that there are multiple trains associated with this tag number.
Iso
nD
Hy
ci d
Operating Mode
yp
id
co
tS
rum
ion
u
de
Ac
m
LS - Indicates that the valve/pump will retain the last state it had (open/closed, on/off) to avoid damaging equipment.
tio
cid
cA
H
g
s
an
tor
ue
rat
diu
Ta
ea
diu
um
t
era
ric
ic A
s
-M
itri
jec
eq
- In
Ae
-H
GE
So
Cit
So
i
eA
d
pR
-E
NE
Cit
So
ne
N-
N-
Step Description Step #
y
TE
TE
N-
N-
ran
ela
um
UM
RA
bra
EA
EA
N-
N-
EA
EA
ss
LEA
LEA
pD
mb
MB
RM
RM
SP
ce
CU
CL
CL
m
EA
EA
p
R. C
R. C
Pro
Me
Ste
Ste
ME
Me
VA
RA
PE
CL
PE
CL
M.
M.
Manual
Tag Numbers Valves Chemical Pump Valves Drain Pumps & Blowers
For 20-E-801-
20-HV-501-x
23-FV-331-1
23-FV-131-1
23-FV-331-2
23-FV-131-2
20-FV-210-x
20-FV-211-x
20-FV-301-x
20-FV-320-x
23-FV-130-x
23-FV-330-x
20-FV-802-x
The Operations Sequence Chart (OSC), Control Logic Summary Chart (CLSC) and the Control Narrative (CN) should all be read to assist in the understanding of plant
20-P-301-x
20-B-200
MB-P-5
MB-P-x
operations.
GENERAL NOTES:
1 For operator protection, sodium hypochlorite pumps are interlocked at the PLC with the citric acid pumps to prevent them from running at the same time Mixing sodium hypochlorite and citric acid generates chlorine gas. Chlorine gas is toxic at levels greater than 1 ppm. Refer to CLSC for further information.
2 Devices will follow the start-up sequence in the CLSC when powering up.
Page 4 of 4
Issued: October 4, 2010
Process Controls: J. Jackson The enclosed materials are considered proprietary property of GE Water & Process Technologies. OSC_200443_Taos_R00_04Oct10_JJ
AO # 200443
GE Water & Process Technologies
Town of Taos MBR
Controls Logic Summary Chart
CLSC_200443_Taos_R00_04Oct10_JJ
Notification
ZenoTrac®
Shutdown
Range Range
Standby
Callout
Tag Type Description Component Equipment Setpoint Units Set Action or Derivation Reset Notes
Min Max
Page 1 of 18
Issued: October 4, 2010 The enclosed materials are considered proprietary property of GE Water & Process Technologies.
AO # 200443
GE Water & Process Technologies
Town of Taos MBR
Controls Logic Summary Chart
CLSC_200443_Taos_R00_04Oct10_JJ
Notification
ZenoTrac®
Shutdown
Range Range
Standby
Callout
Tag Type Description Component Equipment Setpoint Units Set Action or Derivation Reset Notes
Min Max
HEARTBEAT_LOST Alarm Loss of Heartbeat Settings Control IN ALL MODES: IN ALL MODES: IN ALL MODES: Y Y
When the "heartbeat" in the client's PLC is not - all steps, displays on alarm banner "Communication with other When the "heartbeat" in the client's PLC is
incremented in 5 seconds. PLCs has been lost." incremented.
Since GE is not providing the PLC the actions of this alarm cannot
be defined
CP_SURGE_SUPPRESSOR_"Y" Alarm Control Panel Surge Suppressor Needs Surge Control IN ALL MODES: When the control panel surge suppressor Y one tag for each surge
Replacing Suppressor - all steps, when the control panel surge contact no longer indicates a failure suppressor
suppressor contact indicates a failure
PLC_LOW_BAT_"Y" Alarm PLC Battery Low Control Control IN ALL MODES: When the PLC battery is normal. Y one tag for each battery
- all steps, when the PLC Battery is low
A. Info Buttons Interface Control After a button is pressed at the HMI, it is reset after one scan time.
LOG_OFF Button Log Off Security Control Returns Security Level to Viewer.
GENERAL_CALLOUT Alarm General Callout Interface Control IN ALL MODES: When the conditions requiring the callout Y
- all steps, when any condition requiring a callout are cleared.
is activated.
CLEAR_NOTIFICATION Button Clear Notification Interface Control Clears the notification signal.
ALRM_NOTIFICATION Digital Out Alarm Notification Interface Control When an alarm is initiated. Provides signal for device to notify the operator an alarm has When the Clear Alarm Notification or 10
occurred. minutes have passed since the signal was
Conditions requiring notification are identified by the activated.
"NOTIFICATION" column on the right side of the CLSC.
Feed System
Page 2 of 18
Issued: October 4, 2010 The enclosed materials are considered proprietary property of GE Water & Process Technologies.
AO # 200443
GE Water & Process Technologies
Town of Taos MBR
Controls Logic Summary Chart
CLSC_200443_Taos_R00_04Oct10_JJ
Notification
ZenoTrac®
Shutdown
Range Range
Standby
Callout
Tag Type Description Component Equipment Setpoint Units Set Action or Derivation Reset Notes
Min Max
15-FC-401 Derived Plant Flow Demand Level Feed The plant flow demand equals the average influent flow plus the This signal is communicated
plant flow demand trim. to the plant PLC.
15-FC-401 = 15-FCY-401+ 15-FXI-401
15-FI-401 Comm Plant Feed Flow Flow Feed 0 [MAX FEED gpm Displays value with engineering units on screen. The Plant Feed flow is the
FLOW] basis for permeate demand.
Actual instrument is 15-FE/FIT-401.
15-FXI-401 Derived Moving Average Plant Feed Flow Flow Feed 0 [MAX FEED gpm The moving average is for 15 minutes and the sample time is once A moving average is used to
FLOW] every 1 minute. prevent rapid changes and
These times can be adjusted if required. Unless GE W&PT Process equalize intermittent spikes in
Group provides the information use the default values. plant demand.
15-FAT-401 Alarm Plant Feed Flow Transmitter Out of Range Flow Feed 0 [MAX FEED gpm IN ALL MODES: When the transmitter is in range. Y Y
FLOW] When the transmitter is out of range by 2% of the
calibrated range for 2 seconds.
(i.e. calibrated range = range max. - range min.)
15-FQI2-401 Derived Today's Plant Feed Volume Volume Feed 0 1000000000 gal Totalize feed flow. At midnight after current value is put into 15
FQI3-401.
At midnight this value is stored at 15-FQI3-401.
15-FQI3-401 Derived Yesterday's Plant Feed Volume Volume Feed 0 1000000000 gal At midnight. Set valve to 15-FQI2-401 at midnight. Y
15-LC-401 Setpoint Membrane Feed Collection Channel Level Level Membrane 0 [MAX TBD in. Operator entered level setpoint. This level is used to calculate
Setpoint Feed Collection CHANNEL This level is used to calculate the Plant Demand Trim Flowrate. It is the trim plant flow demand. It
Channel LEVEL] in the middle of the maximum and minimum levels for the trim is in the middle of middle of
volume the maximum and minimum
levels for the trim volume.
15-LCH-401 Setpoint Membrane Feed Collection Channel High Level Membrane 0 [MAX TBD in. This is the maximum Membrane Feed Collection Channel level Typically set to about 12 in.
Level Setpoint Feed Collection CHANNEL setpoint where plant flow demand is at the maximum value. Used to above 16-LCL-401 setpoint.
Channel LEVEL] calculate the Plant Demand Trim Flowrate 15-FCY-401.
Operator entered value. It is in the middle of the operating band
15-FCY-401 Derived Plant Flow Demand Trim Flow Membrane -[MAX FEED [MAX FEED gpm Plant Flow Demand Trim Flowrate is proportional to Membrane Feed The plant trim is calculated to
Feed Collection FLOW] FLOW] Collection Channel level, as shown below. maintain a fairly constant level
Channel in the bioreactor.
15-FCY-401 = [Max. Peak Flow x (15-LI-401 - 15-LC-401) / (15-LCH-
401 - 15-LC-401)] This is added to a
communicated flow demand to
Where: establish the plant permeate
Maximum control level is 15-LCH-401 where permeate demand demand.
must equal the maximum peak flow for the entire plant.
Control level is 15-LC-401 is in the middle of the maximum and The trim can range between
minimum levels for the trim volume. the maximum plant demand in
PHF is the peak flow for the plant. This value may be less than the the positive and negative
peak flow. If the controls are erratic the value may be adjusted directions. This allows the
This is the plant permeate trim flow used to calculate the net trim to drive the plant demand
permeate flow for each train in PRODUCTION, 20-FCY-301A-x. to the maximum or zero,
despite the communicated
demand signal.
15-LAH-401 Alarm Membrane Feed Collection Channel Alarm Level Membrane 0 [MAX TBD in. IN ALL MODES: IN ALL MODES: When the level is below this setpoint. Y
High Feed Collection CHANNEL - all steps, when the level is above this setpoint - all steps, sets the plant flow demand equal to the peak flow for the
Channel LEVEL] for 8 seconds. plant
NOTE:
User is responsible for the use of this button to ensure that a
cleaning solution will be handled as required before proceeding to
production.
Page 3 of 18
Issued: October 4, 2010 The enclosed materials are considered proprietary property of GE Water & Process Technologies.
AO # 200443
GE Water & Process Technologies
Town of Taos MBR
Controls Logic Summary Chart
CLSC_200443_Taos_R00_04Oct10_JJ
Notification
ZenoTrac®
Shutdown
Range Range
Standby
Callout
Tag Type Description Component Equipment Setpoint Units Set Action or Derivation Reset Notes
Min Max
20-KQS-801D Setpoint Priming Duration Sequence ZeeWeed® 30 300 60 sec. IN PRIME: IN PRIME: When the timer times out.
step 1. - starts timer, when the timer times out proceeds as per the OSC.
20-KQY-301 Setpoint Production Cycle Timer - total time to Sequence ZeeWeed® 8 15 12 min. When a train enters the production cycle for the Value entered at the HMI, in minutes. When the full production duration has
complete one Production sequence plus first time and no other train is in the production expired.
one Backpulse sequence. cycle. Time remaining in the production cycle for each train, 20-KI-301-x, is
displayed, in seconds.
The timer keeps running through all of the valve alignment steps and
through backpulse.
If all trains are in OFF or POWER OFF the time is retained. When
trains enter the production cycle the timer resumes.
The aeration order is repeated for the trains in STANDBY every 20-
KQS-201D seconds.
A. Info Calculated 10/30 Aeration Status Sequence Membrane When a train is enabled for 10/30 aeration and its calculated status Details of 10/30 aeration
Aeration is 10/30 Aeration. triggers are not included in the
- when a train switches from Standby to Production, it is aerated in control documents.
10/30 if it has a partner.
- 10/30 aeration only occurs for trains in STANDBY, BACKPULSE,
RELAX, and PRODUCTION when they have a partner.
Page 4 of 18
Issued: October 4, 2010 The enclosed materials are considered proprietary property of GE Water & Process Technologies.
AO # 200443
GE Water & Process Technologies
Town of Taos MBR
Controls Logic Summary Chart
CLSC_200443_Taos_R00_04Oct10_JJ
Notification
ZenoTrac®
Shutdown
Range Range
Standby
Callout
Tag Type Description Component Equipment Setpoint Units Set Action or Derivation Reset Notes
Min Max
A. Info 10/30 Aeration Train Pairing Sequence Membrane IN STANDBY, PRODUCTION, BACKPULSE, & RELAX: The first two trains permitted
Aeration Trains in 10/30 aeration pair up based on the time that the aeration to enter 10/30 are paired
mode changed from 10/10 to 10/30 aeration. i.e. The first and together.
second trains to enter 10/30 pair in the sequencing. This does not
necessarily correspond to the train number.
If there is an odd number of trains in 10/30 aeration, the train with the
highest STANDBY priority is aerated in 10/10, with the other trains
pairing based on the time that their aeration mode changed as
above.
20-FY-301-x Trigger Net Permeate Flow Trigger, 10/30 Aeration Sequence Membrane 347 gpm IN STANDBY, BACKPULSE, RELAX, IN STANDBY, BACKPULSE, RELAX, PRODUCTION: This trigger clears when the flow is less 10/30 aeration is prevented
Aeration PRODUCTION: - the train's aeration status is switched to 10/10 aeration. than this setpoint. when the train's flow demand
- when 20-FCY-301A-x or 20-FCY-301B-x is - the number of blowers operating is adjusted as required. is higher than this level.
greater than this setpoint for 5 minutes.
A. Info Resistance Calculation for 10/30 Aeration Flow Membrane The resistance calculation will be run from the end of a BP/RELAX to Details of 10/30 aeration
Aeration the beginning of a BP/RELAX for every cycle for each train (i.e. triggers are not included in the
permeation cycle). The trigger to be in 10/10 or 10/30 (outputs from control documents.
Ri-resistance initial and Rc-resistance cake) will always be saved for
the last complete cycle.
20-HS-210A-x Button Enable/Disable 10/30 Aeration Flow Membrane IN ALL MODES: 10/30 Aeration will only occur
Aeration - the 10/30 aeration is enabled/disable when conditions permit.
20-FV-210-x Button Cyclic Valve , Mem. Tk. Mode Selection Valve Membrane Changes mode to selected mode.
20-FV-211-x "Auto, Open, Close" Aeration When the valve is manual 10/30 is prevented.
The modes "Open" and "Close" are only available when the
supervisory password has been entered.
20-ZAO-210-x Alarm Cyclic Valve , Mem. Tk. Failed to Open Valve Membrane IN ALL MODES: IN PRODUCTION, BACKPULSE & RELAX When the train's ON or OFF button is Y Y Y An aeration valve that fails to
20-ZAO-211-x Aeration - all steps, when the open limit switch is not - all steps, proceeds to SHUTDOWN step 1. pressed. open will prevent proper
activated for 7 seconds when the valve is asked aeration.
to open. IN MAINTENANCE CLEAN & RECOVERY
CLEAN/NEUTRALIZATION: The train must be shut down
- all steps, continues Maintenance Clean or Recovery to prevent over-fouling.
Clean/Neutralization without aeration. Once steps are complete, the
train proceeds to SHUTDOWN step 1.
20-ZAC-210-x Alarm Cyclic Valve , Mem. Tk. Failed to Close Valve Membrane IN ALL MODES: IN PRODUCTION & BACKPULSE: When the close limit switch is activated. Y Y An aeration valve that fails to
20-ZAC-211-x Aeration - all steps, when the close limit switch is not - all steps, continues to cycle valve. Displays on alarm banner "Train close will prevent the train
activated for 7 seconds when the valve is asked has a Cyclic Valve Failure, Inadequate Membrane Aeration may be from stopping aeration.
to close. Occurring". Train does not proceed to Standby due to an active
Plant Permeate Demand Standby Trigger, (i.e., 15-FSYL-401 has no The train is required to
effect for this train). continue PRODUCTION, but
the operator must address the
Maintenance Cleans and Recovery Cleans are prevented. failure before proper aeration
10/30 Aeration is disabled. is restored.
IN MAINTENANCE CLEAN:
- all steps, proceeds to MAINTENANCE CLEAN step 9. After the
last step of MAINTENANCE CLEAN proceeds to SHUTDOWN step
1. Displays on alarm banner "Maintenance Clean Aborted."
IN RECOVERY CLEAN:
- all steps, proceeds to SHUTDOWN step 1. Displays on alarm
banner "Recovery Clean Aborted."
IN NEUTRALIZATION:
-all steps, continue steps.
20-KQS-210 Setpoint Mem. Tk. Cyclic Valve Cycle Time for Valve Membrane 10 sec. Valves will alternate between open and close positions every 10
10/10 Aeration Aeration seconds. One valve will be open and another will be closed. For
example, when valve 20-FV-210-x is open for 10 seconds the PLC
opens valve 20-FV-211-x and then delays for 2 seconds before
closing valve 20-FV-210-x. This applies to all the cyclic aeration
valves.
20-KQS-201C Setpoint Train in Standby Aeration Duration Sequence Membrane 120 600 300 sec. IN STANDBY: IN STANDBY: When train is not in Standby step 3. Trains are periodically aerated
Aeration step 3. step 3, aerates the membrane tank for 20-KQS-201C seconds in STANDBY to prevent solids
every 20-KQS-201D seconds. Starts step with no mixing. settling.
20-KQS-201D Setpoint Train in Standby Aeration Frequency Sequence Membrane 1800 sec. IN STANDBY: IN STANDBY: When the timer times out.
Aeration step 3. step 3, aerates the membrane tank for 20-KQS-201C seconds
This setpoint is not adjustable. every 20-KQS-201D seconds. Starts step with no mixing.
Page 5 of 18
Issued: October 4, 2010 The enclosed materials are considered proprietary property of GE Water & Process Technologies.
AO # 200443
GE Water & Process Technologies
Town of Taos MBR
Controls Logic Summary Chart
CLSC_200443_Taos_R00_04Oct10_JJ
Notification
ZenoTrac®
Shutdown
Range Range
Standby
Callout
Tag Type Description Component Equipment Setpoint Units Set Action or Derivation Reset Notes
Min Max
20-FY-200 Comm Membrane Aeration Air Flow Flow Membrane 0 [MAX AIR SCFM Displays value with engineering units on screen.
Aeration FLOW]
20-FC-200-x Derived Mem. Tk. Membrane Aeration Air Flow Flow Membrane 0 1000 TBA SCFM Membrane Aeration Requirement Per Train Airflow requirement per train is
Requirement Per Train Aeration a fixed, constant value.
20-FQ-200 Derived Membrane Aeration Demand Flow Membrane 0 [MAX AIR SCFM 20-FQ-200 = Sum of 20-FC-201-x for the trains with an aeration
Aeration FLOW] demand.
20-FAH-200 Alarm Membrane Aeration Air Flow High Flow Membrane 0 100 110 % IN ALL MODES: When the aeration flow as a percentage of Y
Aeration - all steps when the aeration flow as a percentage the aeration flow setpoint is is below the
of the aeration flow setpoint is at or above the alarm setpoint.
alarm setpoint for 120 seconds.
20-FAL-200 Alarm Membrane Aeration Air Flow Low Flow Membrane 0 100 80 % IN ALL MODES: When the aeration flow as a percentage of Y
Aeration - all steps when the aeration flow as a percentage the aeration flow setpoint is is above the
of the aeration flow setpoint is at or below the alarm setpoint.
alarm setpoint for 120 seconds.
20-FALL-200 Alarm Membrane Aeration Air Flow Low, Low Flow Membrane 0 100 50 % IN ALL MODES: IN PRODUCTION, RELAX, BACKPULSE: When the aeration flow as a percentage of Y Y Y
Aeration - all steps when the aeration flow as a percentage - all steps, the train proceeds to SHUTDOWN step 1. the aeration flow setpoint is is above the
of the aeration flow setpoint is at or below the IN MAINTENANCE CLEAN, RECOVERY CLEAN, alarm setpoint.
alarm setpoint for 120 seconds. NEUTRALIZATION:
- all steps continue.
Membrane Tank
20-LI-201-x Analog In Mem. Tk Level Level ZeeWeed® 0 132 in. Displays value with engineering units on screen. Y
IN RECOVERY CLEAN:
- Displays on alarm banner "Recovery Clean Aborted."
IN NEUTRALIZATION:
- Displays on alarm banner "Neutralization Aborted."
20-LAHH-201-x Alarm Mem. Tk Level High High Level ZeeWeed® IN ALL MODES: When the level Alarm high is no longer Y Y This indicates that a high level
When the level Alarm high has been active for active. alarm was not solved by
more than 90 seconds. ramping up production.
20-LAH-201-x Alarm Mem. Tk Level High Level ZeeWeed® 0 132 130 in. IN ALL MODES: IN ALL MODES: When 20-LS-201A-x is active. Y The plant demand must be set
When the level is at or above this level for 8 - all steps, sets the plant flow demand equal to the peak flow for the to the maximum to prevent
seconds. plant possible overflow of mixed
liquor.
IN MAINTENANCE CLEAN:
- all steps, alarm only. This level is set above the
normal operating band, but
IN RECOVERY CLEAN/NEUTRALIZATION: below the overflow level.
- all steps, alarm only.
20-LS-201A-x Trigger Mem. Tk Level to Enable Membrane Tank Level ZeeWeed® 0 132 124 in. IN ALL MODES: Resets 20-LAH-201-x This level is below the LAH
Feed When the level is at or below this level for 8 level and placed within the
seconds. normal operating band.
20-LS-201C-x Trigger Mem. Tk Level 3 for Fill and Aerate Level ZeeWeed® 104 in. IN NEUTRALIZATION: IN NEUTRALIZATION: Target setpoint is a level
When the level is at or above this setpoint for 2 - proceeds to the next step. about 12 inches (300 mm)
seconds in the steps as indicated in the OSC. above the LY2-3426 setpoint
Target setpoint is a level about 12 inches above the 20-LS-201E-x but prevents the membrane
setpoint but prevents the membrane tank from flowing over the weir. tank from overflowing.
20-LS-201E-x Trigger Mem. Tk Level Above Membranes Level ZeeWeed® 0 132 92 in. IN ALL MODES: Resets 20-LAL-201-x. This level is the lowest point in
When the level is at or above this level for 8 the normal operating range.
seconds. The train will come out of standby and resume production if there is
a demand to produce water.
20-LAL-201A-x Alarm Mem. Tk Level Low Level ZeeWeed® 0 132 90 in. IN ALL MODES except RECOVERY CLEAN: IN PRODUCTION: When 20-LS-201E-x is active. Y Y Y Train is driven to STANDBY to
When the level is at or below this level for 8 - all steps, proceeds to STANDBY step 1. prevent membrane exposure.
seconds.
This level is just above the membrane fibers in the cassette. This level is just above the
membrane fibers in the
cassette.
20-LALL-201A-x Alarm Mem. Tk Level Low Low Level ZeeWeed® 20-LAL-201- in. IN ALL MODES: IN ALL MODES: When the level is above the setpoint. Y Y This alarm indicates that the
x When the level is at or below the setpoint for - all steps, displays on alarm banner "Membrane Tank 'X' Possible membranes have been
more than 3600 seconds. Membrane Exposure." exposed for an extended
duration and the operator is
required to immediately raise
the tank level.
20-LS-201S-x Trigger Mem. Tk Empty Tank Level ZeeWeed® 0 132 3 in. IN RECOVERY CLEAN: IN RECOVERY CLEAN: When the level is at or above this setpoint This level is very near the
When the level is at or below this setpoint for 2 steps as indicated in the OSC, proceeds to next step. for 5 seconds bottom of the tank, or bottom
seconds in the steps as indicated in the OSC. of level transmitter range.
Page 6 of 18
Issued: October 4, 2010 The enclosed materials are considered proprietary property of GE Water & Process Technologies.
AO # 200443
GE Water & Process Technologies
Town of Taos MBR
Controls Logic Summary Chart
CLSC_200443_Taos_R00_04Oct10_JJ
Notification
ZenoTrac®
Shutdown
Range Range
Standby
Callout
Tag Type Description Component Equipment Setpoint Units Set Action or Derivation Reset Notes
Min Max
20-LAL-201B-x Alarm Mem. Tk Level Low Level ZeeWeed® IN PRODUCTION: IN PRODUCTION: When the switch is no longer active. Y Y Y Train is driven to STANDBY to
- all steps, when switch is active for 5 seconds. - all steps, proceeds to STANDBY step 1. prevent membrane exposure.
This level is just above the membrane fibers in the cassette. This switch is just above the
membrane fibers in the
cassette.
20-LALL-201C-x Alarm Mem. Tk Level Low Low Level ZeeWeed® IN PRODUCTION: IN ALL MODES: When the switch is no longer active. Y Y This switch is set below the
- all steps, when switch is active for 5 seconds. - all steps, displays on alarm banner "Membrane Tank 'X' Possible below the operating band to
Membrane Exposure." protect the membranes from
exposure.
Permeate System
20-FAH-301A-x Alarm Instantaneous Permeate Flow, Flow High Flow Permeate 0 1500 864 gpm IN PRODUCTION: IN PRODUCTION: When the train's ON or OFF button is Y Y Y This alarm is usually set to
- all steps when the flow is at or above the - all steps, proceeds to SHUTDOWN step 1. pressed. 110% of the maximum
setpoint for 10 seconds. instantaneous flow setpoint to
This is a common setpoint with multiple Alarms. protect the membranes from
over-fluxing.
20-FCH-301 Setpoint Instantaneous Permeate Flow Maximum Flow Permeate 700 790 785 gpm This is the upper limit for 20-FC-301A-x This is the maximum
Flow Setpoint acceptable instantaneous flow
that does not exceed the
membrane flux requirements.
20-FCYH-301A Setpoint Net Permeate Flow Maximum Setpoint 1 Flow Permeate 600 695 695 gpm When all trains are available. This is the upper limit for 20-FCY-301A-x and 20-FCY-301B-x. This is the required net
All trains are available when there are no trains in permeate flow to achieve PHF
OFF, SHUTDOWN, MAINTENANCE CLEAN or with all trains available (N
RECOVERY CLEAN/NEUTRALIZATION. condition).
20-FCYH-301B Setpoint Net Permeate Flow Maximum Setpoint 2 Flow Permeate 400 463 463 gpm When there is one train, or more than one train, This is the upper limit for 20-FCY-301A-x and 20-FCY-301B-x. This is the required net
not in service. permeate flow to achieve PHF
A train is not in service when it is in OFF, without all trains available (N-1
SHUTDOWN, MAINTENANCE CLEAN or condition).
RECOVERY CLEAN/NEUTRALIZATION.
15-FSYH-401A Trigger Plant Permeate Demand Start Trigger for Demand Permeate 153 274 180 gpm When the plant flow demand is at or above this Puts one train to production that has the highest starting priority. Start & Stop triggers are
One Train Running setpoint for 10 seconds calculated based on process
requirements and generated
using a trigger generation tool.
15-FSYL-401A Trigger Plant Permeate Demand Standby Trigger - Demand Permeate 60 247 150 gpm When the plant flow demand is at or below this Puts one train to standby that has the highest standby priority. Y Y
One to No Trains Running setpoint for 10 seconds
15-FSYH-401B Trigger Plant Permeate Demand Start Trigger for Demand Permeate 247 434 340 gpm When the plant flow demand is at or above this Puts one train to production that has the highest starting priority.
Two Trains Running setpoint for 10 seconds
15-FSYL-401B Trigger Plant Permeate Demand Standby Trigger - Demand Permeate 213 400 300 gpm When the plant flow demand is at or below this Puts one train to standby that has the highest standby priority. Y Y
Two to One Train Running setpoint for 10 seconds
15-FSYH-401C Trigger Plant Permeate Demand Start Trigger for Demand Permeate 587 774 680 gpm When the plant flow demand is at or above this Puts one train to production that has the highest starting priority.
Three Trains Running setpoint for 10 seconds
15-FSYL-401C Trigger Plant Permeate Demand Standby Trigger - Demand Permeate 366 533 460 gpm When the plant flow demand is at or below this Puts one train to standby that has the highest standby priority. Y Y
Three to Two Trains Running setpoint for 10 seconds
15-FSYH-401D Trigger Plant Permeate Demand Start Trigger for Demand Permeate 927 1114 1020 gpm When the plant flow demand is at or above this Puts one train to production that has the highest starting priority.
Four Trains Running setpoint for 10 seconds
15-FSYL-401D Trigger Plant Permeate Demand Standby Trigger - Demand Permeate 519 706 612 gpm When the plant flow demand is at or below this Puts one train to standby that has the highest standby priority. Y Y
Four to Three Trains Running setpoint for 10 seconds
20-FCL-301 Setpoint Instantaneous Permeate Flow Minimum Flow Permeate 150 200 165 gpm This is the lower limit for 20-FC-301A-x This level is the minimum
Flow Setpoint stable flow that the process
pump can safely supply.
20-FAL-301A-x Alarm Instantaneous Permeate Flow, Flow Low Flow Permeate 100 200 150 gpm IN PRODUCTION: IN PRODUCTION: When the train's ON or OFF button is Y Y Y This alarm is usually set to
- all steps, when the pump is running and the flow - all steps, proceeds to SHUTDOWN step 1. pressed. 90% of the minimum
is at or below the setpoint for 10 seconds. instantaneous flow setpoint to
This is a common setpoint with multiple Alarms. protect the pump from under-
speed conditions.
20-FAT-301-x Alarm Permeate Flow Transmitter Out of Range Flow Permeate 0 1500 gpm IN ALL MODES: IN PRODUCTION, BACKPULSE, MAINTENANCE CLEAN, When the train's ON or OFF button is Y Y Y Trains must shut down if the
When the transmitter is out of range by 2% of the RECOVERY CLEAN & NEUTRALIZATION: pressed. permeate flow cannot be
calibrated range for 2 seconds. - all steps, the train proceeds to SHUTDOWN step 1. determined as there is no way
(i.e. calibrated range = range max. - range min.) to set pump speed.
20-FI-301A-x Analog In Instantaneous Permeate Flow Flow Permeate 0 1500 gpm Displays value with engineering units on screen.
Page 7 of 18
Issued: October 4, 2010 The enclosed materials are considered proprietary property of GE Water & Process Technologies.
AO # 200443
GE Water & Process Technologies
Town of Taos MBR
Controls Logic Summary Chart
CLSC_200443_Taos_R00_04Oct10_JJ
Notification
ZenoTrac®
Shutdown
Range Range
Standby
Callout
Tag Type Description Component Equipment Setpoint Units Set Action or Derivation Reset Notes
Min Max
20-FQIY-301B-x Derived Today's Permeate Volume Volume Permeate -10000 1000000000 gal Total Train Production Volume for Today = Totalized Permeate At midnight after current value is put into 20
volume during Production to the end of the cycle minus Total FQIY-301C-x.
Backpulse volume from process pump when backpulsing.
20-FFY-301-x Setpoint Net Instantaneous Production Flow Flow Permeate 1.00 1.3 The system recalculates then freezes this value in In Auto This adjustment factor is used
Correction Factor Production step 2 when 20-FIC-301A-x is set to 20-FFY-301-x = (20-KQY-301 + 20-FQI-301B-x/20-FCY-301A-x)/(20 to determine the
Auto. KI-301-x) instantaneous flow required to
In Sup deliver the desired net
20-FFY-301-x = (20-KQY-301 + 20-FQI-301B-x/20-FCY-301B-x)/(20 permeate flow.
KI-301-x)
Where: This value is calculated only
20-KI-301-x is the time remaining to next Backpulse, and, once per production cycle.
In Auto SP: 20-FC-301A-x = (20-FCY-301A-x) × 20-FFY-301-x
In Sup SP: 20-FC-301A-x = (20-FCY-301B-x) × 20-FFY-301-x
20-FCY-301A-x Derived Target Net Permeate Flow Calculated Flow Permeate 20-FCL-301 20-FCYH- When auto setpoint is selected. This is the value used in the calculation of 20-FC-301A-x. This is the Net Permeate each
301A train is required to produce to
Target Net Permeate Flow = (Plant Flow Demand - ∑ Supervisory meet the desired plant
Entered Flows) ÷ (Number of Trains In Production/Backpulse - production rate.
Number of Trains In Production/Backpulse with a Supervisory
Setpoint)
Initially:
20-FCY-301A-x = 20-FCY-301B-x when alternating between auto
and supervisory setpoint. This is a bumpless transfer.
20-FCY-301B-x Setpoint Target Net Permeate Flow Operator Flow Permeate 20-FCL-301 20-FCYH- ### gpm When supervisory setpoint is selected. This is the value used in the calculation of 20-FC-301A-x. The operator can use this
Entered 301A setpoint to override the
Initially: calculated permeate
20-FCY-301B-x = 20-FCY-301A-x when alternating between auto requirement.
and supervisory setpoint. This is a bumpless transfer.
20-FIC-301A-x PID Permeate Instantaneous Flow Proportional Flow Permeate IN PRODUCTION: PV is the permeate flow, 20-FI-301A-x This controller adjusts the
Integral Derivative Controller steps as per the OSC SP = 20-FC-301A-x pump speed to maintain the
CV is the speed of the process pump. required flow rate.
The minimum CV is 25% and the maximum CV is defined by 20-
PDSLL-301-x action.
Page 8 of 18
Issued: October 4, 2010 The enclosed materials are considered proprietary property of GE Water & Process Technologies.
AO # 200443
GE Water & Process Technologies
Town of Taos MBR
Controls Logic Summary Chart
CLSC_200443_Taos_R00_04Oct10_JJ
Notification
ZenoTrac®
Shutdown
Range Range
Standby
Callout
Tag Type Description Component Equipment Setpoint Units Set Action or Derivation Reset Notes
Min Max
20-HS-201Q-x Button Demand Override Enabled Button or Sequence Permeate Demand Override Enabled Button This button will force a train to
Demand Override Disabled Button IN ALL MODES: enter and stay in
- all steps, train will not be effected by the low flow demand trigger. PRODUCTION independent
Demand Override Disabled Button: of the plant and train demand.
IN ALL MODES:
- all steps, train will be effected by the low flow demand trigger. The train flow setpoint will still
be determined automatically
Note: This button does not affect the speed of the process pumps unless the supervisory
setpoint is also selected.
This button returns trains to
automatic start and stop
triggering.
20-YA-301A-x Alarm Process Pump Fail Pump Permeate IN ALL MODES: IN PRODUCTION & BACKPULSE MAINTENANCE CLEAN: IN PRODUCTION & BACKPULSE & Y Y Y
- all steps requiring the pump to run, when the - all steps, places pump into manual-stop. The train proceeds to MAINTENANCE CLEAN
MCC running confirmation is missing for 5 SHUTDOWN step 1. When the train's ON or OFF button is
seconds. IN BACKPULSE, MAINTENANCE CLEAN: pressed.
- all steps, proceeds to SHUTDOWN step 1. IN RECOVERY CLEAN &
IN RECOVERY CLEAN & NEUTRALIZATION: NEUTRALIZATION:
- all steps, places pump into manual-stop and proceeds to the next When process pump is placed into auto
step and waits in the step until 20-KQS-301W clears or times out. and Recovery Clean Fails Timer clears
- 20-KQS-301W starts then continue steps.
Displays, "Train will be Shutdown due to active alarm" (banner
counts down)
20-KQS-301W Alarm Recovery Clean Fails Timer Pump Permeate 120 min IN RECOVERY CLEAN: IN RECOVERY CLEAN & NEUTRALIZATION: IN RECOVERY CLEAN & Y Y Y Alarms that halt a
steps 1 to 20, when one of the following alarms - proceeds to SHUTDOWN step 1. NEUTRALIZATION: RECOVERY CLEAN or
are active 20-YA-301A-x 20-FAH-301B-x, 20- When all hold step alarms clear. NEUTRALIZATION will hold
FAL-301B, 20-PDAH-301B-x, 20-PAHH-601B-x, the train in that mode until this
20-LALL-301 is active for 120 continuous timer times out. This provides
minutes. a delay while the operator can
attempt to clear the alarm.
IN NEUTRALIZATION:
- all steps, when one of the following alarms are When this timer times out, the
active 20-YA-301A-x 20-FAH-301B-x, 20-FAL- trains will be shut down, and,
301B, 20-PDAH-301B-x, 20-PAHH-601B-x, 20- as a result, refilled with mixed
LALL-301 is active for 120 continuous minutes. liquor. This prevents the
membranes from drying out.
20-HA-301-x Alarm Process Pump MCC Not in Auto Pump Permeate IN ALL MODES: Pump control is removed from the PLC and the pump is placed in When the MCC is returned to Auto. Y
- all steps, when the MCC is no longer in Auto. the MCC control.
20-HS-301-x Button Process Pump Mode Selection "Auto, Start Pump Permeate Only the mode selected and the Stop button are Changes mode to selected mode.
Forward, Start Reverse, Stop" visible on the HMI. Other buttons are hidden from
view. The modes "Start Forward", "Start Reverse" and "Stop" are only
available when the supervisory password has been entered.
To change the pump operating mode, operator
must press the Stop button on the HMI for the
pump.
Page 9 of 18
Issued: October 4, 2010 The enclosed materials are considered proprietary property of GE Water & Process Technologies.
AO # 200443
GE Water & Process Technologies
Town of Taos MBR
Controls Logic Summary Chart
CLSC_200443_Taos_R00_04Oct10_JJ
Notification
ZenoTrac®
Shutdown
Range Range
Standby
Callout
Tag Type Description Component Equipment Setpoint Units Set Action or Derivation Reset Notes
Min Max
20-PDIR-301A-x Derived Backpulse Analysis TMP Prior to Last TMP Permeate IN PRODUCTION: Captures and Displays value and engineering units in Backpulse Y
Backpulse - when the Pre-Backpulse trigger, 20-KS-201A, is Analysis Chart:
active. - prior to last backpulse
- during last backpulse
- after last backpulse
- after previous backpulse
20-PDIR-301B-x Derived Backpulse Analysis TMP During Last TMP Permeate IN BACKPULSE & RELAX: Captures and Displays value and engineering units in Backpulse Y
Backpulse/Relax - when the During Backpulse/Relax trigger, 20-KS Analysis Chart:
201B, is active. - prior to last backpulse/relax
- during last backpulse/relax
- after last backpulse/relax
- after previous backpulse/relax
20-PDIR-301C-x Derived Backpulse Analysis TMP After Last TMP Permeate IN PRODUCTION: Captures and Displays value and engineering units in Backpulse Y
Backpulse - when the Post-backpulse trigger, 20-KS-201C, Analysis Chart:
is active. - prior to last backpulse
- during last backpulse
- after last backpulse
- after previous backpulse
20-PDIR-301D-x Derived Backpulse Analysis TMP After Previous TMP Permeate IN PRODUCTION: Move value of 20-PDIR-301C-x into 20-PDIR-301D-x. Y
Backpulse - when the Post-backpulse trigger, 20-KS-201C,
is active. Displays value and engineering units in Backpulse Analysis Chart:
- prior to last backpulse
- during last backpulse
- after last backpulse
- after previous backpulse
20-PDALL-301-x Alarm TMP Low Low TMP Permeate -8.0 0.0 -7.0 psig IN PRODUCTION: IN PRODUCTION: When the train's ON or OFF button is Y Y Y This alarm will shut down the
- all steps, when the TMP is at or below this - all steps, proceeds to SHUTDOWN step 1. pressed. train under cases of
setpoint for 5 seconds. uncontrollable TMP to prevent
membrane damage. Due to
issues with NPSH (permeate
pump elevation is close to
operating water level), the
max TMP will have to be
limited to-7 psi.
20-PDSLL-301-x Trigger TMP Low-Low TMP Permeate -8.0 0.0 -6.0 psig IN PRODUCTION: IN PRODUCTION: IN ALL MODES: This trigger allows the PLC to
- all steps, when the TMP is at or below this - all steps, captures the initial value for the maximum of the 20-FIC- -all steps, when the TMP is above the manage TMP by ramping
setpoint. 301A-x CV as: setpoint, then increases the maximum down the pump.
value for 20-FIC-301A-x CV by 0.25% This allows the train to
Initial value for the maximum CV = (CV value of 20-FIC-301A-x) - every second until it reaches 100%. maintain a reduced level of
0.25 production without shutting
down or damaging
Then reduces the maximum value for 20-FIC-301A-x CV by 0.25% membranes.
every second until it reaches to the its minimum of 25%.
20-PDILL-301-x Indicator TMP Low-Low Display TMP Permeate IN PRODUCTION: IN PRODUCTION: IN PRODUCTION: The operator is informed when
- all steps, when maximum value for 20-FIC-301A--all steps, the maximum value for 20-FIC-301A-x CV is limited to a - all steps, when the maximum value for 20- TMP limiting is occurring.
x CV is below 100%. value below 100% . FIC-301A-x CV is at 100%.
Displays "TMP at limit!" indication on the screen.
20-PDI-301-x Derived TMP TMP Permeate TMP = Membrane Header Pressure + Conversion Factor x (Height TMP (Trans Membrane
of the Pressure Transmitter Above the Top of the Membranes + Pressure) is a measurement
Height from the Bottom of the Tank to the Top of the Membrane of the pressure differential
Fibers - Membrane Tank Level) across the surface of the
membranes.
Consult Control Narrative for Further Details.
For WW deep membrane tanks where bottom of cassette is 30 in.) TMP is what drives water
WHEN 20-LI-201-x IS ABOVE 30 in.: (permeate) to cross the
20-PDI-301-x = 20-PI-301-x + C x (A+B - 20-LI-203-x) membrane. Excessive TMP
can damage the membranes.
WHEN 20-LI-201-x IS AT OR BELOW 30 in.:
20-PDI-301-x = 20-PI-301-x + C x (A+B - 30)
20-PAHH-301A-x Alarm Permeate Membrane Header Pressure Pressure Permeate -3.0 0.0 -0.3 psig IN PRODUCTION: IN PRODUCTION: When the train's ON or OFF button is Y Y Y This alarm will shutdown the
High High - all steps, when the process pump is running and - all steps, proceeds to SHUTDOWN step 1. pressed. train to prevent damage to the
the pressure is at or above this setpoint for 10 pump or membranes,
seconds.
20-PAT-301-x Alarm Permeate Membrane Header Pressure Pressure Permeate -15.0 15.0 gpm IN ALL MODES: IN PRODUCTION, BACKPULSE, MAINTENANCE CLEAN, When the train's ON or OFF button is Y Y Y Trains must shut down if the
Transmitter Out of Range When the transmitter is out of range by 2% of the RECOVERY CLEAN & NEUTRALIZATION: pressed. pressure cannot be
calibrated range for 2 seconds. - all steps, proceeds to SHUTDOWN step 1. determined, to protect the
(i.e. calibrated range = range max. - range min.) membranes.
20-PI-301-x Analog In Permeate Membrane Header Pressure Pressure Permeate -15.0 15.0 psig Displays value with engineering units on screen.
Page 10 of 18
Issued: October 4, 2010 The enclosed materials are considered proprietary property of GE Water & Process Technologies.
AO # 200443
GE Water & Process Technologies
Town of Taos MBR
Controls Logic Summary Chart
CLSC_200443_Taos_R00_04Oct10_JJ
Notification
ZenoTrac®
Shutdown
Range Range
Standby
Callout
Tag Type Description Component Equipment Setpoint Units Set Action or Derivation Reset Notes
Min Max
20-HS-301-x Button Permeate Header Valve Mode Selection Valve Permeate Changes mode to selected mode.
"Auto, Open, Close"
The modes "Open" and "Close" are only available when the
supervisory password has been entered.
Recirculation/RAS System
FC-MB-P-x Setpoint RAS Pump Flow Setpoint Flow Recirculation 0 3500 ### gpm IN PRODUCTION, BACKPULSE, RELAX: Recirculation is set to occur at
RAS Setpoint = Flow Factor multiplied by train flow demand a constant multiple of the
MC-MB-P-x = FFY-MB-P * 20-FC-301A-x production rate.
Flow setpoint is updated every 15 minutes.
KQI-MB-P-x Derived RAS Pump Pump Recirculation 0 30000 hours IN ALL MODES: IN ALL MODES: When the Reset Run Time button is
Accumulated Run Time When the pump is operating. Displays accumulated run time for the pump on the screen. pressed, run time resets to 0 hours.
HS-MB-P-x Button RAS Pump Mode Selection "Auto, Start, Pump Recirculation Changes mode to selected mode.
Stop"
The modes "Start" and "Stop" are only available when the
supervisory password has been entered.
KQS-MB-P-C-x Setpoint Standby RAS On Duration Pump Recirculation 2 20 5 min. IN STANDBY: IN STANDBY: When the timer times out or when the train
- steps as per OSC, when KQS-MB-P-D-x has - starts timer for KQS-MB-P-C-x is not in STANDBY.
timed out. - the pump starts without delay for KQS-MB-P-C-x minutes and
stops for KQS-MB-P-D-x seconds.
KQS-MB-P-D-x Setpoint Standby RAS Off Frequency Pump Recirculation 0, 10 30 30 min. IN STANDBY: IN STANDBY: When the timer times out or when the train
- steps as per OSC, when KQS-MB-P-C-x has - starts timer for KQS-MB-P-D-x is not in STANDBY.
timed out. - stops pump.
Pumps remain Off until timer KQS-MB-P-D-x times out.
When the value of KQS-MB-P-D-x is 0, the RAS is constant.
Backpulse System
20-KQS-301G Derived Staggered Backpulse Order Sequence Backpulse Staggered Backpulsing: Staggered backpulsing
The time slots to do backpulse are evenly distributed throughout one involves backpulsing each
production cycle. The distribution is based on the maximum number train separately and spreading
of trains installed in the plant. The production cycle is 12 minutes the backpulses evenly
and there are 4 trains. A backpulse is scheduled to occur every 3 throughout the global
minutes. Each train is assigned a time slot to do backpulse production timer.
according its train number, e.g., train 1 is backpulsed in the first time
slot, and train 2 is backpulsed in the second time slot, etc. Any train
that is not in a production cycle will be skipped.
20-KQS-301B Setpoint Backpulse/RELAX Duration Sequence Backpulse 5 200 30 sec. IN BACKPULSE: IN RELAX & BACKPULSE: When timer times out.
step 3. - starts timer. Proceeds as per OSC when timer times out.
IN RELAX:
step 2.
20-KS-201A Trigger Pre-Backpulse Snapshot Trigger Info Backpulse IN PRODUCTION: Y
- end of in permeate step.
20-KS-201B Trigger Backpulse/Relax Snapshot Trigger Info Backpulse IN BACKPULSE: Y
- 10 seconds into step 3.
IN RELAX:
- 10 seconds into step 2.
20-KS-201C Trigger Post-Backpulse Snapshot Trigger Info Backpulse IN PRODUCTION: Y
- 30 seconds into production steps.
20-FI-301B-x Derived Backpulsing Flow Info Backpulse 0 1500 gpm IN BACKPULSE, MAINTENANCE CLEAN, RECOVERY CLEAN,
NEUTRALIZATION:
- the flow measured by 20-FI-301
20-FC-301B Setpoint Backpulse Flow Setpoint Flow Backpulse 700 850 823 gpm Operator entered flow setpoint for backpulsing the entire train.
This is a plant setpoint.
Page 11 of 18
Issued: October 4, 2010 The enclosed materials are considered proprietary property of GE Water & Process Technologies.
AO # 200443
GE Water & Process Technologies
Town of Taos MBR
Controls Logic Summary Chart
CLSC_200443_Taos_R00_04Oct10_JJ
Notification
ZenoTrac®
Shutdown
Range Range
Standby
Callout
Tag Type Description Component Equipment Setpoint Units Set Action or Derivation Reset Notes
Min Max
20-FIC-301B-x PID Process Pump - Backpulse, Maintenance Flow Backpulse IN BACKPULSE: IN BACKPULSE: This controller adjusts the
Clean Recovery Clean and Neutralization steps as per the OSC PV is the Backpulse flow rate measured at 20-FIT-301-x. pump speed to maintain the
Flow Proportional Integral Derivative IN MAINTENANCE CLEAN: SP = 20-FC-301B. required flow rate for
Controller steps as per the OSC CV is the speed of the process pump, 20-SC-301-x. backpulsing in BACKPULSE,
IN RECOVERY CLEAN: The minimum CV is 25% and the maximum CV is defined by 20- MAINTENANCE CLEAN,
steps as per the OSC PDYH-301A-x action. RECOVERY CLEAN, and
IN NEUTRALIZATION: NEUTRALIZATION.
steps as per the OSC IN RECOVERY CLEAN and NEUTRALIZATION:
PV is the CIP flow rate measured at 20-FIT-301-x.
SP = 20-FC-301C.
CV is the speed of the process pump, 20-SC-301-x.
The minimum CV is 25% and the maximum CV is defined by 20-
PDYH-301B-x action.
IN MAINTENANCE CLEAN:
PV is the CIP flow rate measured at 20-FIT-301-x.
SP = 20-FC-301D
CV is the speed of the process pump, 20-SC-301-x.
The minimum CV is 25% and the maximum CV is defined by 20-
PDYH-301B-x action.
20-LI-301 Analog In Backpulse Tank Level Level Backpulse 0 [BP TANK in. Displays value with engineering units on screen.
HEIGHT]
Actual instrument is 20-LE/LIT-301.
20-LAH-301 Alarm Backpulse Tank Level High High Level Backpulse 0 [BP TANK TBD in. IN ALL MODES: When the backpulse tank level is below this Y Y
HEIGHT] - all steps, when the backpulse tank level is at or setpoint.
above this setpoint for 10 seconds.
20-LS-301A Trigger Backpulse Tank Level Trigger High Level Backpulse 0 [BP TANK TBD in. IN ALL MODES: IN ALL MODES: When 20-LS-301B is active. When this trigger is active,
HEIGHT] - when the backpulse tank level is at or above this - resets 20-LALL-301 permeate is no longer directed
setpoint for 3 seconds. IN RECOVERY CLEAN: to refill the backpulse tank.
-proceed according to the OSC
20-LS-301B Trigger Backpulse Tank Level Trigger High Level Backpulse 0 [BP TANK TBD in. IN ALL MODES: IN RECOVERY CLEAN: When 20-LS-301A is active.
HEIGHT] - when the backpulse tank level is at or below this -proceed according to the OSC
setpoint for 3 seconds.
20-LAL-301 Alarm Backpulse Tank Level Low Level Backpulse 0 [BP TANK TBD in. IN BACKPULSE: IN BACKPULSE: In the last step of Backpulse. Y When the level in the
HEIGHT] - all steps, when the backpulsing pump is running - auto stop the backpulse pump and continue steps. backpulse tank is low, the
and the backpulse tank level is at or below this pump is stopped for pump
setpoint for 10 seconds. protection.
Page 12 of 18
Issued: October 4, 2010 The enclosed materials are considered proprietary property of GE Water & Process Technologies.
AO # 200443
GE Water & Process Technologies
Town of Taos MBR
Controls Logic Summary Chart
CLSC_200443_Taos_R00_04Oct10_JJ
Notification
ZenoTrac®
Shutdown
Range Range
Standby
Callout
Tag Type Description Component Equipment Setpoint Units Set Action or Derivation Reset Notes
Min Max
20-LALL-301 Alarm Backpulse Tank Level Low Low Level Backpulse 0 [BP TANK TBD in. IN BACKPULSE, MAINTENANCE CLEAN, IN BACKPULSE: When the backpulse tank level is above the Y Y When the level in the
HEIGHT] RECOVERY CLEAN & NEUTRALIZATION: - all steps, proceeds to the next step. setpoint 20-LS-301A. backpulse tank is low, the
- all steps, when the backpulsing pump is running - switch the mode of all trains to RELAX IN RECOVERY CLEAN & pump is stopped for pump
and the backpulse tank level is at or below this IN MAINTENANCE CLEAN: NEUTRALIZATION: protection.
setpoint for 10 seconds. - all steps, proceeds to SHUTDOWN step 1. When process pump is placed into auto
IN RECOVERY CLEAN & NEUTRALIZATION: and Recovery Clean Fails Timer clears
- all steps, places pump into manual-stop and proceeds to the next then continue steps.
step and waits in the step until 20-KQS-301W clears or times out.
- 20-KQS-301W starts
Displays, "Train will be Shutdown due to active alarm" (banner
counts down)
20-LAT-301 Alarm Backpulse Tank Level Transmitter Out of Level Backpulse 0 [BP TANK in. IN ALL MODES: IN BACKPULSE: When the train's ON or OFF button is Y Y Y When the level in the
Range HEIGHT] When the transmitter is out of range by 2% of the - all steps, proceeds to the next step. pressed. backpulse tank cannot be
calibrated range for 2 seconds. - switch the mode of all trains to RELAX determined, the pump is
(i.e. calibrated range = range max. - range min.) IN MAINTENANCE CLEAN, RECOVERY CLEAN & stopped for pump protection.
NEUTRALIZATION:
- all steps, proceeds to SHUTDOWN step 1.
20-PDAH-301A-x Alarm Process Pump in Backpulse, TMP High TMP Backpulse 0.0 7.0 7.0 psig IN BACKPULSE, MAINTENANCE CLEAN & IN BACKPULSE, MAINTENANCE CLEAN: IN BACKPULSE & MAINTENANCE Y Y Y When the TMP is too high, the
RECOVERY CLEAN, NEUTRALIZATION: - all steps, proceeds to SHUTDOWN step 1. CLEAN backpulse pump is stopped to
- all steps, when the TMP is at or above this IN RECOVERY CLEAN & NEUTRALIZATION: When the train's ON or OFF button is protect the membranes. Due
setpoint for 5 seconds during backpulse. - all steps, places pump into manual-stop and proceeds to the next pressed. to issues with NPSH
step and waits in the step until 20-KQS-301W clears or times out. IN RECOVERY CLEAN & (permeate pump elevation is
This is a common setpoint with multiple Alarms. - 20-KQS-301W starts NEUTRALIZATION: close to operating water
Displays, "Train will be Shutdown due to active alarm" (banner When process pump is placed into auto level), the max TMP will have
counts down) and Recovery Clean Fails Timer clears to be limited to 7 psi.
then continue steps.
20-PDYH-301A-x Trigger TMP High TMP Backpulse 5.0 PDAH-8823 6.0 psig IN BACKPULSE, MAINTENANCE CLEAN & IN BACKPULSE, MAINTENANCE CLEAN & RECOVERY CLEAN, IN ALL MODES: This trigger allows the PLC to
RECOVERY CLEAN, NEUTRALIZATION: NEUTRALIZATION: -all steps, when the TMP is below the manage TMP by ramping
- all steps, when the TMP is at or above this - all steps, captures the initial value for the maximum of the 20-FIC- setpoint, then increases the maximum down the pump.
setpoint. 301B-x CV as: value for 20-FIC-301B-x CV by 0.25% This allows the train to
every second until it reaches 100%. maintain a reduced level of
Initial value for the maximum CV = (CV value of 20-FIC-301B-x) - backpulse without shutting
0.25 down or damaging
membranes.
Then reduces the maximum value for 20-FIC-301B-x CV by 0.25%
20-PDIH-301A-x Indicator TMP High Display TMP Backpulse IN BACKPULSE, MAINTENANCE CLEAN & IN BACKPULSE, MAINTENANCE CLEAN & RECOVERY CLEAN, IN BACKPULSE, MAINTENANCE CLEAN The operator is informed when
RECOVERY CLEAN, NEUTRALIZATION: NEUTRALIZATION: & RECOVERY CLEAN, TMP limiting is occurring.
- all steps, when maximum value for 20-FIC-301B--all steps, the maximum value for 20-FIC-301B-x CV is limited to a NEUTRALIZATION:
x CV is below 100%. value below 100% . - all steps, when the maximum value for 20-
Displays "TMP at limit!" indication on the screen. FIC-301B-x CV is at 100%.
20-PAH-601-x Alarm Process Pump in Backpulse, Switch 20- Pressure Backpulse IN BACKPULSE, MAINTENANCE CLEAN & IN PRODUCTION: Y
PSH-601-x Pressure High RECOVERY CLEAN, NEUTRALIZATION: step 1.
- all steps, when the switch is active for 5
seconds.
20-PAH-602-x Alarm Process Pump in Backpulse, Switch 20- Pressure Backpulse IN BACKPULSE, MAINTENANCE CLEAN & IN PRODUCTION: Y
PSH-602-x Pressure High RECOVERY CLEAN, NEUTRALIZATION: step 1.
- all steps, when the switch is active for 5
seconds.
20-PAHH-601B-x Alarm Process Pump in Backpulse, Pressure High Pressure Backpulse IN BACKPULSE, MAINTENANCE CLEAN & IN BACKPULSE, MAINTENANCE CLEAN: IN BACKPULSE & MAINTENANCE Y Y Y When the Backpulse Pump
High RECOVERY CLEAN, NEUTRALIZATION: - all steps, proceeds to SHUTDOWN step 1. CLEAN discharge pressure is high,
- all steps, when both backpulse pressure high IN RECOVERY CLEAN & NEUTRALIZATION: When the train's ON or OFF button is the pump is stopped for pump
switches 20-PAH-601-x & 20-PAH-601-x are - all steps, places pump into manual-stop and proceeds to the next pressed. and piping protection.
active at the same time on the same train. step and waits in the step until 20-KQS-301W clears or times out. IN RECOVERY CLEAN &
- 20-KQS-301W starts NEUTRALIZATION:
Displays, "Train will be Shutdown due to active alarm" (banner When process pump is placed into auto
counts down) and Recovery Clean Fails Timer clears
then continue steps.
Page 13 of 18
Issued: October 4, 2010 The enclosed materials are considered proprietary property of GE Water & Process Technologies.
AO # 200443
GE Water & Process Technologies
Town of Taos MBR
Controls Logic Summary Chart
CLSC_200443_Taos_R00_04Oct10_JJ
Notification
ZenoTrac®
Shutdown
Range Range
Standby
Callout
Tag Type Description Component Equipment Setpoint Units Set Action or Derivation Reset Notes
Min Max
20-KS-201D-x Setpoint Maintenance Clean Start/Enable Time Schedule Maintenance 0 2400 Determined hr. Operator entered value to start/enable Maintenance Clean on the Operator- entered time to start
Clean by Operator given day. M. CLEAN.
20-FSH-375 Trigger Maintenance Cleans Delay or Aborted whenSchedule Maintenance System calculates the plant capacity as if there was one currently When the required production
Plant Flow Demand is high. Clean available train not in service. is too high to be
WHEN: accommodated with a train in
Current plant permeate demand is at or above [Max. net flow for MAINTENANCE CLEAN, that
Train 1 x Total number of trains available less one train]. clean is blocked from
IF: occurring.
15-FC-401 ≥
[(20-FCYH-301B) x (NUM_TR_PROD + # of tr. in Standby step 3
+ # of tr. in Maintenance Clean - 1]
Page 14 of 18
Issued: October 4, 2010 The enclosed materials are considered proprietary property of GE Water & Process Technologies.
AO # 200443
GE Water & Process Technologies
Town of Taos MBR
Controls Logic Summary Chart
CLSC_200443_Taos_R00_04Oct10_JJ
Notification
ZenoTrac®
Shutdown
Range Range
Standby
Callout
Tag Type Description Component Equipment Setpoint Units Set Action or Derivation Reset Notes
Min Max
20-FAH-375-x Alarm Maintenance Clean Delay/Abort Alarm Schedule Maintenance When 20-FSH-375 is active and either the Prevents Maintenance Cleans from starting and aborts Maintenance When 20-FSH-375 is not active. Y Y
Clean Maintenance Clean is pending for train "X" or Cleans that are in progress.
train "X" is in a Maintenance Clean.
WHEN IN PRODUCTION, BACKPULSE, OR RELAX:
The Maintenance Clean request is blocked and remains active.
Alarms and displays on the alarm banner "Maintenance Clean
delayed".
When alarm 20-FAH-375-x clears at lower plant demands, 20-FSH-
375 is not active, trains that have a Maintenance Clean request
active will proceed to Maintenance Clean step 1 when no other train
is in a Maintenance Clean, as described in the OSC.
23-HS-101A-x Button Maintenance Clean Sodium Hypochlorite Sequence Maintenance Allows the operator to select Sodium Hypochlorite Maintenance , all MAINTENANCE CLEANS
Button Clean Clean for each scheduled Maintenance Clean. selected/scheduled for this
train will use SODIUM
HYPOCHLORITE.
23-HS-201A-x Button Maintenance Clean Citric Acid Button Sequence Maintenance Allows the operator to select Citric Acid Maintenance Clean for each , all MAINTENANCE CLEANS
Clean scheduled Maintenance Clean. selected/scheduled for this
train will use CITRIC ACID.
20-KQS-301C Setpoint Maintenance Clean Repeated Pulse Sequence Maintenance 5 200 30 sec. IN MAINTENANCE CLEAN: IN MAINTENANCE CLEAN:
Duration Clean steps as noted in the OSC. steps as noted in the OSC, this is the steps duration.
20-KQS-301R Setpoint Recovery Clean Soak Extended Soak Sequence Recovery 600 7200 1200 sec. IN RECOVERY CLEAN: IN RECOVERY CLEAN:
Mixing Frequency Clean - as per OSC. - setpoint is mixing duration with air in extended soak step.
- aerates the membrane tank for 20-KQS-301Q seconds every 20-
KQS-301R seconds. Starts step with no mixing.
Page 15 of 18
Issued: October 4, 2010 The enclosed materials are considered proprietary property of GE Water & Process Technologies.
AO # 200443
GE Water & Process Technologies
Town of Taos MBR
Controls Logic Summary Chart
CLSC_200443_Taos_R00_04Oct10_JJ
Notification
ZenoTrac®
Shutdown
Range Range
Standby
Callout
Tag Type Description Component Equipment Setpoint Units Set Action or Derivation Reset Notes
Min Max
20-HS-210C Button Extended Soak Mixing Enable/Disable Sequence Recovery Enable button: When selected, the cleaning
Button Clean When the button is selected there is intermittent aeration in the soak solution will be intermittently
step of Recovery Clean. mixed during the extended
Disable button: soak period of RECOVERY
When the button is selected there is no intermittent aeration in the CLEAN.
soak step of Recovery Clean
Neutralization System
20-KQS-201J Setpoint Neutralization Aeration Step Timer Sequence Neutralization 5 900 60 sec. IN NEUTRALIZATION: IN NEUTRALIZATION:
steps as noted in the OSC. steps as noted in the OSC, this is the steps duration.
Vacuum System
20-HS-802-x Button Vacuum Ejector Compressed Air Valve Valve Vacuum Changes mode to selected mode.
Mode Selection "Auto, Open, Close"
The modes "Open" and "Close" are only available when the
supervisory password has been entered.
20-PAH-301A-x Alarm Re-Priming Pressure High Pressure Vacuum 8.0 psig IN ALL MODES: IN ALL MODES: When the train's ON or OFF button is Y Y Y
- when the compressed air ejector valve is - closes the ejector valves then proceeds to SHUTDOWN step 1. pressed.
requested open and the pressure, 20-PI-301-x, is
at or above this setpoint with no time delay. Displays on alarm banner "Priming Aborted"
20-KQS-802A Setpoint Train Ejector Operating Frequency - Master Sequence Vacuum 4 120 8 min. Operator entered value used as a Master Ejector Cycle Timer. This is the duration between
Ejector Cycle Timer Setpoint sets the frequency for ejector operation for each train. ejector opening on a single
Ejector for train X operates every 20-KQS-802A seconds. train.
20-KQS-802B Derived Ejector Operating Interval - time between Sequence Vacuum sec. Derived setpoint is the ejector operation interval between any two This value is the time between
operating any two ejectors trains. successive calls to run an
This time is used to determine when to trigger an ejector to operate ejector.
in the Master Ejector Cycle Timer, as described in KY1-9200.
20-KQS-802C-x Setpoint Train Ejector Open Duration Sequence Vacuum 5 30 15 sec. IN STANDBY step 3, & PRODUCTION: Operator entered value. This is the length of time each
- When ejector is required to operate according to Ejector opens for this duration. ejector is open during the
the start time calculated in 20-KQS-802A master cycle. This is a train
This is a plant setpoint. setpoint.
20-TI-301 Analog in Plant Permeate Temperature Temperature Plant 32 122 deg. F Displays value with engineering units on screen. Y
Permeate
Actual instrument is 20-TE/TIT-301
Page 16 of 18
Issued: October 4, 2010 The enclosed materials are considered proprietary property of GE Water & Process Technologies.
AO # 200443
GE Water & Process Technologies
Town of Taos MBR
Controls Logic Summary Chart
CLSC_200443_Taos_R00_04Oct10_JJ
Notification
ZenoTrac®
Shutdown
Range Range
Standby
Callout
Tag Type Description Component Equipment Setpoint Units Set Action or Derivation Reset Notes
Min Max
20-HS-320 Button Plant Permeate Turbidity Meter Isolation Valve Plant Changes mode to selected mode.
Valve Mode Selection "Auto, Open, Close" Permeate
The modes "Open" and "Close" are only available when the
supervisory password has been entered.
20-AAT-320 Alarm Plant Permeate Turbidity Transmitter Out of Quality Permeate 0 10 NTU IN ALL MODES: IN ALL MODES: When the transmitter is in range. Y Y
Range When the transmitter is out of range by 1% of the - all steps, for all trains, changes to Relax mode and prevents
calibrated range for 2 seconds. scheduled Maintenance Cleans.
(i.e. calibrated range = range max. - range min.)
20-AI-320 Analog In Plant Permeate Turbidity Quality Permeate 0 10 NTU Displays value with engineering units on screen. Y
20-AAH-320B Alarm Plant Permeate Turbidity High 2 Quality Permeate 0 10 1 NTU When any train is IN PRODUCTION: When the turbidity reading is below this Y
- all steps, when the turbidity reading is at or setpoint.
above this setpoint for 20-KS-320B seconds.
20-AAH-320C Alarm Plant Permeate Turbidity High 3 Quality Permeate 0 10 5 NTU When any train is IN PRODUCTION , When the turbidity reading is below this Y Y
BACKPULSE & RELAX: setpoint.
- all steps, when the turbidity reading is at or
above this setpoint for 20-KS-320C seconds.
20-KS-320A Setpoint Permeate Turbidity High 1 Timer Quality Permeate 0 60 10 sec. When any train is IN PRODUCTION: Timer is used to trigger high Alarm. When turbidity reading is below 20-AAH-
- all steps, when turbidity reading is at or above When timer times out, 20-AAH-320A is active. 320A setpoint.
20-AAH-320A setpoint, timer operates.
20-KS-320B Setpoint Plant Permeate Turbidity High 2 Timer Quality Permeate 0 300 60 sec. When any train is IN PRODUCTION: Timer is used to trigger high Alarm. When turbidity reading is below 20-AAH-
- all steps, when turbidity reading is at or above When timer times out, 20-AAH-320B is active. 320B setpoint.
20-AAH-320B setpoint, timer operates.
20-KS-320C Setpoint Plant Permeate Turbidity High 3 Timer Quality Permeate 0 300 30 sec. When any train is IN PRODUCTION: Timer is used to trigger high alarm. When turbidity reading is below 20-AAH-
- all steps, when turbidity reading is at or above When timer times out, 20-AAH-320C is active. 320C setpoint.
20-AAH-320C setpoint, timer operates.
IN MAINTENANCE CLEAN:
- all steps, proceeds to STANDBY step 1.
Displays on alarm banner "Maintenance Clean Aborted."
IN RECOVERY CLEAN:
- all steps, proceeds to SHUTDOWN step 1.
Displays on alarm banner "Recovery Clean Aborted."
IN NEUTRALIZATION:
- all steps, proceeds to SHUTDOWN step 1.
Displays on alarm banner "Neutralization Aborted."
System Power
20-JAL-001 Alarm Plant Power Failure Plant System Power IN ALL MODES: All trains proceed to POWER OFF mode. When power is restored. Y Y
- all steps, when the system detects that power is
lost for 1.5 seconds. The system blocks all fail safe inputs that are normally closed (to
avoid nuisance alarms).
Page 17 of 18
Issued: October 4, 2010 The enclosed materials are considered proprietary property of GE Water & Process Technologies.
AO # 200443
GE Water & Process Technologies
Town of Taos MBR
Controls Logic Summary Chart
CLSC_200443_Taos_R00_04Oct10_JJ
Notification
ZenoTrac®
Shutdown
Range Range
Standby
Callout
Tag Type Description Component Equipment Setpoint Units Set Action or Derivation Reset Notes
Min Max
Interlock Startup Step 1 Startup System Power When the system detects that power is restored. This startup sequence shows the order in which the devices in the
plant are re-enabled after a power interruption or after an emergency
stop has been reset.
All trains proceed to POWER OFF until power is resumed and the
train is enabled.
Interlock Startup Step 2 Startup System Power 60 seconds after start of step 1 and 90-PSL-001 Re-enables all common, non-sequenced valves.
shows normal pressure.
Interlock Startup Step 3 Startup System Power 30 seconds after the start of the previous step. Allows train 1 to come out of POWER OFF mode. Y Y
There is no delay if the device in the previous step
is not required. Train proceeds to either STANDBY step 1 or SHUTDOWN step 1.
See start-up sequence step 1 for more details.
Interlock Startup Step 4 Startup System Power 30 seconds after the start of previous step. Allows train 2 to come out of POWER OFF mode. Y Y
Page 18 of 18
Issued: October 4, 2010 The enclosed materials are considered proprietary property of GE Water & Process Technologies.
SECTION 5
RECOMMENDED SPARE PARTS
LIST
This page has been
intentionally left blank
C = CRITICAL
RECOMMENDED SPARE PARTS LIST FOR Town of Taos PROJECT NO. 200443 R = RECOMMENDED
M = MAINTENANCE
CS = CONSUMABLES
Item Check
Item Qty GE WATER # Tag # Item Details C R M CS
No. List
PLEASE NOTE: THIS IS THE MOST CURRENT RECOMMENDED SPARE PARTS LIST BASED ON THE BILL OF MATERIAL AT THE TIME OF REQUEST. FOR A FULL CUSTOM PRICED LIST PLEASE ALLOW 1-2
WEEKS FOR GENERATION.
PUMPS
SPARES INCLUDE:
SCREW ROTOR TIP, FL 1036, CCW
SCREW ROTOR TIP, FL 1036, CW
T-PLUG FOR SCREW ROTOR TIP
COVER PROTECTION PLATE, HARDENED STEEL
20-P-301-1
AXIAL CASING PROTECTION PLATE, HARDENED STEEL
20-P-301-2
COUNTERSUNK SCREW; M8X20; STAINLESS STEEL
6 SPARES FOR PROCESS PUMP 1 PROCESS PUMP 20-P-301-3
20-P-301-4
MECHANICAL SEAL, CAST IRON; O-RING, BUNA-N X
O-RING; 1176 X 9
O-RING, 67 X 4
O-RING, 110 X 3
WITHDRAWAL TOOL FOR ROTOR BODY
SPECIAL TOOL FOR MECHANICAL SEAL
SPECIAL TOOL FOR HOLDING BUSH
VALVES
VALVE, BALL, 0.5", TRUE UNION, CPVC BODY, TEFLON SEATS, VITON O-RINGS,
23-FV-330-1
SOCKETWELD, Vented Ball , ASSEMBLY
23-FV-330-2
TYPE 233 C/W PA11 DOUBLE ACTING PNEUMATIC RACK AND PINION ACTUATOR
7 BALL VALVE 0.5" 1 1033661 23-FV-330-3
23-FV-330-4
ASSEMBLY C/W TYPE 5470 120VAC SOLENOID X
VALVE CSA WITH NAMUR PLATE AND MANUAL OVERRIDE, CSA/UL APPROVED.
VALVE, BALL, 0.5", TRUE UNION, CPVC BODY, TEFLON SEATS, EPDM O-RINGS,
23-FV-130-1
SOCKETWELD, , ASSEMBLY TYPE 233 C/W PA11 DOUBLE
23-FV-130-2
ACTING PNEUMATIC RACK AND PINION ACTUATOR, ASSEMBLY
8 BALL VALVE 0.5" 1 1033666 23-FV-130-3
23-FV-130-4
C/W CSA/UL A PPROVED SOLENOID PILOT VALVE 120/60 VAC TYPE X
5470
USA / ZENON Membrane Solutions
CAD / GE Water Process Technologies Canada RSPL200443XMR1 8/9/2011 AC 1 of 6
C = CRITICAL
RECOMMENDED SPARE PARTS LIST FOR Town of Taos PROJECT NO. 200443 R = RECOMMENDED
M = MAINTENANCE
CS = CONSUMABLES
Item Check
Item Qty GE WATER # Tag # Item Details C R M CS
No. List
VALVE, BUTTERFLY,, 8" CAST IRON LUG STYLE BODY,
20-FV-301-1
RATED VACUUM TO 50 PSI, UNDERCUT NYLON COATED DISC, SS SHAFT, EPDM
20-FV-301-2
SEAT, BRAY PNEUMATIC RACK AND PINION DOUBLE ACTING ACTUATOR SERIES
9 BUTTERFLY VALVE 8" 1 1041078 20-FV-301-3
20-FV-301-4
92/118, C/W NAMUR DIRECT MOUNT SOLEN OID 110VAC NEMA 4,4X S63 120V DIN X
WITH SPEED CONTROLS AND PLUG CONNECTOR;
VALVE, SOLENOID,
23-FV-131-1 2-WAY AIR/WATER 1/2" FNPT, SS BODY, VITON
23-FV-131-2 SEAL, NORMALLY CLOSED, 7/16" ORIFICE, Cv-3.3GPM (WATER) OR 110 SCFM
10 SOLENOID VALVE 1 1023781 23-FV-331-1
23-FV-331-2
(AIR), 0 PSI PRESSURE DIFFERENTIAL REQUIRED, 0-230 PSI PRESS URE RANGE,
C/W TYPE H ELECTRICAL CONNECTION, IDENTIFICATIONL AND 1/2"
X
FNPT CONDUIT RING ADAPTOR,
INSTRUMENTS
20-PI-302-1
PRESSURE GAUGE, 30PSI, SS CASE 100MM DIAL
20-PI-302-2
(4"), 0-30 PSI (DUAL SCALE PSI & kPa) 1/2" LOWER CONNECTION, GLYCERINE
13 PRESSURE GAUGE 1 1023430 20-PI-302-3
20-PI-302-4
FILLED, 3-2-3% ASME GR B ACCURACY, POLYCARBONATE WINDOW. X
20-PI-301-1 PRESSURE GAUGE, 30PSI, SS CASE, 100MM DIAL
20-PI-301-2 (4"), 30" MERCURY-30 PSI (DUAL SCALE IN MECURY & PSI/kPa) 1/2" LOWER
14 PRESSURE GAUGE 1 1023462 20-PI-301-3
20-PI-301-4
CONNECTION, GLYCERINE FILLED, 3-2-3% ASME GR B ACCURACY, POLYCARBONATE
WINDOW.
X
USA / ZENON Membrane Solutions
CAD / GE Water Process Technologies Canada RSPL200443XMR1 8/9/2011 AC 2 of 6
C = CRITICAL
RECOMMENDED SPARE PARTS LIST FOR Town of Taos PROJECT NO. 200443 R = RECOMMENDED
M = MAINTENANCE
CS = CONSUMABLES
Item Check
Item Qty GE WATER # Tag # Item Details C R M CS
No. List
23-PI-130-1
23-PI-330-1 PRESSURE GAUGE, 200PSI, SS CASE 63MM DIAL
DIAPHRAGM SEAL 1026673 TO BE (2.5"), 0-200 PSI (DUAL SCALE PSI & kPa) 1/4" LOWER CONNECTION,
15 PRESSURE GAUGE 1 1023435
ATTACHED TO PRESSURE GAUGES GLYCERINE FILLED, 3-2-3% ASME GR B ACCURACY, POLYCARBONATE WINDOW. X
23-PI-130-1 AND 23-PI-330-1
DIAPHRAGM SEAL FOR 23-PI-130-1 DIAPHRAGM SEAL, TYPE 300, ALL CLAMPED,
DIAPHRAGM SEAL FOR ABOVE AND 23-PI-330-1 PRESSURE 1/2" FNPT PROCESS CONNECTION, PVC HOUSING, TEFLON DIAPHRAGM, 1/4" FNPT
16
PRESSURE GAUGE
1 1026673
GUAGES GAUGE CONNECTION, GAUGE MOUNTED WITH GLYCERINE FILLING FLUID. X
20-PSH-601-1 20-PSH-601-2
20-PSH-601-3 20-PSH-601-4 PRESSURE SWITCH,
20-PSH-602-1 20-PSH-602-2 GENERAL PURPOSE MICROSWITCH, NEMA 4X ENCLOSURE, IP66, 15 AMP SPDT
20-PSH-602-3 20-PSH-602-4 CONTACT, Teflon DIAPHRAGM, 1/2" PROCESS CONNECTION, 0 TO 30 PSI NOMINAL
SP= RANGE (0.5 TO 1.5 PSI DE ADBAND ON POSITIVE PRESSURE), 500 PSIG PROOF
17 PRESSURE SWITCH HIGH 1 1033361 20-PSH-301-1 20-PSH-301-2
20-PSH-301-3 20-PSH-301-4
PRESSURE, FACTORY SET @ X PSIG (INCREASING/DECREASING), CSA APPROVED, X
20-PSH-302-1 20-PSH-302-2 PAPER TAG.
20-PSH-302-3 20-PSH-302-4
SP= 20PSIG INCREASING
sUPPLY AS 120VOLT
SWITCH, LEVEL, CABLE SUSPENDED 4" Ø FLOAT,
20-LSL-201B-1 20-LSL-201B-2 POLYPROPYLENE HOUSING, 39 FT LONG OIL RESISTANT PVC CABLE, 120VAC OR
18 LEVEL SWITCH LOW 1 1032157 20-LSL-201B-3 20-LSL-201B-4
20-LSLL-201C-1 20-LSLL-201C-2
220VAC, 1PH/60Hz, -20oC to 60oC OPERATING TEMPERATURE X
20-LSLL-201C-3 20-LSLL-201C-4
USA / ZENON Membrane Solutions
CAD / GE Water Process Technologies Canada RSPL200443XMR1 8/9/2011 AC 3 of 6
C = CRITICAL
RECOMMENDED SPARE PARTS LIST FOR Town of Taos PROJECT NO. 200443 R = RECOMMENDED
M = MAINTENANCE
CS = CONSUMABLES
Item Check
Item Qty GE WATER # Tag # Item Details C R M CS
No. List
TRANSMITTER, LEVEL, 316L 3"
150# ANSI FLANGE PROCESS CONNECTION, TRANSMITTER FOR HYDROSTATIC LEVEL
MEASUREMENT, TUBE (ROD) VERSION FOR MOUNTING IN TANKS, FLUSH MOUNTED
20-LIT-201A-1 CONTITE-SENSOR W/ METALLIC D IAPHRAGM ALLOY C4, HERMETICALLY WELDED.
20-LIT-201A-2 CSA, CL. 1, DIV 2, GROUP A-D. MEASURING RANGE: 0-15 PSIG. CELL W/
20-LIT-201A-3 LINEARITY < 0.2%, SILICON FILL & VITON SEAL. LOOP POWERED 4-20 mA W/
21 LEVEL TRANSMITTER 1 1030631 20-LIT-201A-4 DISPLAY, HART PROT. 316l SS NEMA 4X HOUSING W/ 1/2"" CON DUIT
CONNECTION.
X
ROD length = 132"
PLEASE STATE THE LENGTH OF THE PROBE, ROD LENGTHS AVAILABLE 16" to 160"
MISCELLANEOUS
STRAUB COUPLING, NON-RESTRAINT, FLEX 1L, F1L 3" IPS, E, 316L SS CASING,
LP & INSERT, 3.7" LONG, 3" NOM INNER DIAMETER (88.9
MM), 5.4" OUTER DIAMETER, 1 PC, PRESSURE RATING: 232 PSI,
316L SS FULL VACUUM RATED STRIP INSERT EPDM SEALING SLE EVE, 2 X BOLTS,
23 STRAUB COUPLING 3" 9 1027929
M8, 5.5 FT.LB, X
MAX PIPE GAP 1".
STRAUB COUPLING, NON-RESTRAINT, FLEX 1L, F1L 4" IPS, E, 316LSS CASING,
LP & INSERT, 3.7" LONG, 4" NOM INNER DIAMETER (114.3
MM), 5.4" OUTER DIAMETER, 1 PC, PRESSURE RATING: 232 PSI,
316L SS FULL VACUUM STRIP INSERT EPDM SEALING SLEEVE, 2 X BOLTS, M8,
24 STRAUB COUPLING 4" 3 1027930
5.5 FT.LB, X
MAX PIPE GAP 1".
STRAUB COUPLING, NON-RESTRAINT, FLEX 1L, F1L 6" IPS, E, 316L SS CASING,
LP & INSERT, 4.21" LONG, 6" NOM INNER DIAMETER (168.3 MM), 7.5" OUTER
DIAMETER, 1 PC PRESSURE RATING: 232 PSI, 316L SS FULL VACUUM RATED
25 STRAUB COUPLING 6" 2 1027931
STRIP INSERT EPDM SEALING SL EEVE, 2 X BOLTS, M10, 7.5 FT.LB. X
USA / ZENON Membrane Solutions
CAD / GE Water Process Technologies Canada RSPL200443XMR1 8/9/2011 AC 4 of 6
C = CRITICAL
RECOMMENDED SPARE PARTS LIST FOR Town of Taos PROJECT NO. 200443 R = RECOMMENDED
M = MAINTENANCE
CS = CONSUMABLES
Item Check
Item Qty GE WATER # Tag # Item Details C R M CS
No. List
ZW500D V2.1.3 KIT INCLUDES: INTERCONNECTION STRIP, O-RINGS, BOLTS, NUTS, WASHERS, MODULE RELEASE TOOL,
27
CASSETTE SPARE PARTS KIT
1 1029418
LOCKING KEYS. X
ZW 500D Module Permeate
28
Adapter
1 1028578 SINGLE MODULE ADAPTER FOR FLUSHING/BUBBLE TESTING X
29 ZW500D REMOVAL TOOL 1 1032836 ZW500D MDL REMOVAL TOOL(REV5-NOV2007) X
ZW500D, DUMMY ELEMENT, TOP AND BOTTOM FILLED WITH URETHANE
30 ZW500D Blank Header 1 1029083 X
( 4 ) 20cc SYRINGE, ( 10 ) NEEDLES (PURPLE), ( 5 ) 22G NEEDLES, SILICONE ( SHELF LIFE OF 6 MONTHS ),
31 Fiber Repair Kit 1 1022887
SCISSORS 4 1/2", ( 2 ) GLOVES. X X
32 Silicone Dispensing Gun 1 1025796 FOR USE WITH FIBER REPAIR KIT. X
Pneumatic Silicone Injection Tool Compressed Air Injection Gun (requires 10cc barrels)
33
(LITTLE JOE)
1 1028260 *Option to above Item* X
Membrane Maintenance Station -
34
Tank
1 1027906 PLASTIC WORK TANK WITH METAL STAND X
Membrane Maintenance Station -
35
Pump Kit
1 1027907 SKID MOUNTED - PUMP FOR FLUSHING/PRESERVING MODULES X
Membrane Maintenance Station -
36
Hose Kit
1 1027908 3 HOSE SECTIONS FOR CONNECTION PUMP KIT TO MODULES X
Membrane Maintenance Station -
37
Work Tray
1 1027985 SLIDING TRAY FOR TOP OF TANK X
PORTABLE INSTRUMENTS FOR TESTING THE INTEGRITY OF ZEEWEED MEMBRANES. THE UNIT
INCLUDES A HIGH ACCURACY DIGITAL PRESSURE DISPLAY, A PRECISION AIR REGULATOR WITH
38 Bubble/Pressure Decay Test Kit 1 1023613 PRESET UPPER LIMIT PRIMARY. PROTECTION AT 8 PSI, A SECONDARY AIR RELIEF PROTECTION VALVE,
COALESCING AIR FILTER, STAINLESS STEEL CASING WITH HANDLE, 20 FEET OF 1/4 TUBING, 2X3" AND
X
2X4" CAMLOCK END CAPS EACH WITH A 1/4" FEMALE QUICK CONNECT.
USA / ZENON Membrane Solutions
CAD / GE Water Process Technologies Canada RSPL200443XMR1 8/9/2011 AC 5 of 6
C = CRITICAL
RECOMMENDED SPARE PARTS LIST FOR Town of Taos PROJECT NO. 200443 R = RECOMMENDED
M = MAINTENANCE
CS = CONSUMABLES
Item Check
Item Qty GE WATER # Tag # Item Details C R M CS
No. List
TTF IS AN ANALYTICAL TEST PARAMETER THAT PROVIDES CRITICAL DATA ON THE FILTERABILITY
OF MIXED LIQUOR BIOREACTOR SLUDGE
LAB EQUIPMENT PACKAGE
(1) CERAMIC BUCHNER FUNNEL 100 MM DIAMETER (1) ERLENMEYER SUCTION 1000ML SUCTION
TIME TO FILTER KIT FLASK
39
LAB EQUIPMENT
1 1030547 FOR WASTE WATER
(1) FILTER PAPERS, GLASS MICRO-FIBRE, 9CM, BOX OF 100 (1) GRADUATED CYLINDER 100 ML PLASTIC X
(1) RUBBER STOPPER 1 HOLE, # 8, PACK OF 12 (1) BEAKER 250 ML, PLASTIC (1) POCKET THERMOMETER
0-120F
(1) STOPWATCH
TERMS:
QUOTATION #
USA / ZENON Membrane Solutions
CAD / GE Water Process Technologies Canada RSPL200443XMR1 8/9/2011 AC 6 of 6
SECTION 6
MATERIAL SAFETY DATA
SHEETS
This page has been
intentionally left blank
GLYCEROL Page 1 of 7
GLYCEROL
1. Product Identification
Synonyms: 1,2,3-propanetriol; glycerin; glycol alcohol; glycerol, anhydrous
CAS No.: 56-81-5
Molecular Weight: 92.10
Chemical Formula: C3H5(OH)3
Product Codes:
J.T. Baker: 2135, 2136, 2140, 2142, 2143, 2988, 4043, M778
Mallinckrodt: 0564, 5092, 5093, 5100
2. Composition/Information on Ingredients
3. Hazards Identification
Emergency Overview
--------------------------
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GLYCEROL Page 2 of 7
Inhalation:
Due to the low vapor pressure, inhalation of the vapors at room temperatures is unlikely.
Inhalation of mist may cause irritation of respiratory tract.
Ingestion:
Low toxicity. May cause nausea, headache, diarrhea.
Skin Contact:
May cause irritation.
Eye Contact:
May cause irritation.
Chronic Exposure:
May cause kidney injury.
Aggravation of Pre-existing Conditions:
Persons with pre-existing skin disorders or eye problems or impaired liver or kidney
function may be more susceptible to the effects of the substance.
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GLYCEROL Page 3 of 7
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GLYCEROL Page 4 of 7
Ventilation System:
A system of local and/or general exhaust is recommended to keep employee exposures
below the Airborne Exposure Limits. Local exhaust ventilation is generally preferred
because it can control the emissions of the contaminant at its source, preventing dispersion
of it into the general work area. Please refer to the ACGIH document, Industrial
Ventilation, A Manual of Recommended Practices, most recent edition, for details.
Personal Respirators (NIOSH Approved):
If the exposure limit is exceeded and engineering controls are not feasible, a half facepiece
particulate respirator (NIOSH type P95 or R95 filters) may be worn for up to ten times the
exposure limit or the maximum use concentration specified by the appropriate regulatory
agency or respirator supplier, whichever is lowest.. A full-face piece particulate respirator
(NIOSH type P100 or R100 filters) may be worn up to 50 times the exposure limit, or the
maximum use concentration specified by the appropriate regulatory agency, or respirator
supplier, whichever is lowest. Please note that N filters are not recommended for this
material. For emergencies or instances where the exposure levels are not known, use a full-
facepiece positive-pressure, air-supplied respirator. WARNING: Air-purifying respirators
do not protect workers in oxygen-deficient atmospheres.
Skin Protection:
Wear protective gloves and clean body-covering clothing.
Eye Protection:
Use chemical safety goggles. Maintain eye wash fountain and quick-drench facilities in
work area.
http://www.jtbaker.com/msds/englishhtml/G4774.htm 8/26/2005
GLYCEROL Page 5 of 7
--------\Cancer Lists\------------------------------------------------------
---NTP Carcinogen---
Ingredient Known Anticipated IARC Category
------------------------------------ ----- ----------- -------------
Glycerin (56-81-5) No No None
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GLYCEROL Page 6 of 7
http://www.jtbaker.com/msds/englishhtml/G4774.htm 8/26/2005
GLYCEROL Page 7 of 7
Mallinckrodt Baker, Inc. provides the information contained herein in good faith but
makes no representation as to its comprehensiveness or accuracy. This document is
intended only as a guide to the appropriate precautionary handling of the material by
a properly trained person using this product. Individuals receiving the information
must exercise their independent judgment in determining its appropriateness for a
particular purpose. MALLINCKRODT BAKER, INC. MAKES NO
REPRESENTATIONS OR WARRANTIES, EITHER EXPRESS OR IMPLIED,
INCLUDING WITHOUT LIMITATION ANY WARRANTIES OF
MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE WITH
RESPECT TO THE INFORMATION SET FORTH HEREIN OR THE PRODUCT
TO WHICH THE INFORMATION REFERS. ACCORDINGLY, MALLINCKRODT
BAKER, INC. WILL NOT BE RESPONSIBLE FOR DAMAGES RESULTING
FROM USE OF OR RELIANCE UPON THIS INFORMATION.
*******************************************************************************
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SECTION 7
SERVICE & SUPPORT
This page has been
intentionally left blank
200443 Town of Taos MBR GE Water & Process Technologies
ZeeWeed Wastewater Treatment System Operation & Maintenance Manual
7.1 INTRODUCTION
This section provides information regarding the various support services
offered by GE W&PT. All service bulletins associated with the Town of
Taos MBR ZeeWeed Wastewater Treatment System are to be inserted at
the end of this section.
PHONE: 1-866-439-8272.
EMAIL: GEWater.TechnicalSupport@ge.com.
7.3 MYZENON
TIP: In the event of a MyZENON (www.MyZENON.com) provides an information exchange
lost MyZENON location between GE W&PT and your facility. It is strongly recommended
password, contact the
Service Department that the contact information for all facility supervisors be posted and
immediately. regularly updated in order to allow for better support.
• Training programs.
• O&M agreements.
7.4.1 ZENOTRAC
ZenoTrac is a powerful plant support tool available to those system
owners who choose to subscribe. It provides fully automated process
data monitoring and trend analysis, and stores information in a
centralized database. This information is then presented as a series of
charts and provided to operators through email, a secure web site, or as
printed reports.
Emergency call-outs are invoiced based on the Field Services Labor Rate
Sheet, which can be found on MyZENON or obtained by contacting the
Service Department.
7.4.3 TRAINING
Training for all operators is provided at the time of plant commissioning.
Customized training packages are available. Contact the Service
department for more information.
8.1 INTRODUCTION
The following sections define acronyms, abbreviations, and terms used
within this manual and the water treatment industry in general.
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GFD Gallons per ft2 per Day VFD Variable Frequency Drive
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8.3 DEFINITIONS
AC MOTOR Consists of two basic parts: A rotating cylinder called a Rotor and a
stationary part called a Stator. The Stator surrounds the Rotor. It has
coil windings, which produce an alternating magnetic field. This
magnetic field causes current to flow through the Rotor conductors,
resulting in a rotational force. The Rotor spins at a speed proportional
to the frequency of the applied alternating current. The motor rotates
at a set rotation depending on the frequency of the winding
configuration.
ACID A solution having an excess of hydrogen (H+) ions (with a pH of less than
7.0).
ACTIVATED SLUDGE The floc produced in raw or settled wastewater due to the growth of
bacteria and other organisms in the presence of dissolved oxygen (DO).
ACTUATED VALVE Any valve with an actuator that is controlled by an external command.
ADVISORY ALARM A process alarm, which alerts the operator, that action is needed to
prevent an impending shutdown, or to restore the components to a
normal state.
AEROBIC BACTERIA Any bacteria requiring free oxygen for the metabolic breakdown of
material.
AIR COMPRESSOR Air compressors provide oil-free, pressurized air for the operation of the
actuated valves.
AIR DIAPHRAGM Air diaphragm metering pumps provide chemical dosing at measured
METERING PUMPS rates. This dosing is set manually and it is regulated either by the
amount of compressed air driving the pump or by setting the
backpressure of the pumps.
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AIR DRYER Air dryers protect pneumatic devices, like valves and air diaphragm
pumps, from damage due to condensation in the compressed air. The
controls on the air dryer allow for adjustment of dew point and
temperature setpoints.
AIR FLOW SWITCH Air flow switches, located in the membrane aeration piping or the
supplemental aeration piping, are used to indicate when a specific flow
rate has been reached for a blower. This flow rate identifies low
aeration to the membranes or bioreactor, triggering an alarm or alert.
AIR RELEASE VALVES Air release valves allow the air to separate from the permeate to
prevent air locks in the permeate piping.
ALARM BEACON A visible device for alerting an operator when a new alarm occurs, such
as a flashing or rotating light.
ALKALINE A solution having an excess of hydroxyl (OH) ions (with pH greater than
7.0).
ANAEROBIC Any bacteria that can survive in partial or complete absence of oxygen
BACTERIA by using molecular oxygen found in nitrates and sulfates.
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ANALOG An electrical signal that is proportional to the size of the variable being
monitored or controlled. Analog signals in our systems are exclusively
4-20 mA, but an analog signal can be 0-20 mA or 0-10 VDC.
AUTOMATIC FLOW Automatic flow valves are used when regular changes are required in
VALVE the state of the valve (fully open or fully closed only). They are controlled
by the PLC.
BACKWASH TMP The change in TMP over a permeation cycle that overrides the
TRIGGER permeation time in order to trigger a backwash.
BACKWASH TROUGH The trough on the side of the membrane tank that collects the water
during a backwash and discharges it to the backwash channel.
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CHEMICAL OXYGEN A test used to estimate the amount of organic matter within a sample.
DEMAND (COD) A strong chemical oxidizing agent is used to measure the amount of
organic matter that can be oxidized. The COD of wastewater is
generally higher than the BOD because more compounds can be
chemically oxidized than can be biologically oxidized. The units of COD
are mg/L. Generally the BOD/COD ratio varies from 0.4 to 0.8.
CHLORINE CONTACT The part of a water treatment plant where effluent is disinfected by
CHAMBER chlorine.
CIP MODE The system operating mode in which the unit is undergoing the CIP
procedure.
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COAGULATION The addition of inorganic coagulants into raw water prior to filtration.
This promotes clumping (aggregation) of dissolved or fine impurities.
CO-CURRENT FLOW Flow across and through a membrane where the feed/reject and
permeate flow in the same direction and parallel to the membrane
surface.
COLOR Color can occur as the result of decaying or organic debris in the water.
CONCENTRATE The portion of the feed solution that does not pass through the
membrane, in which solids or ions are at an increased concentration.
Also known as reject or retentate.
CONCENTRATE Portion of the feed stream added to the concentrate recycle stream to
MAKEUP (CMU) control ionic concentrations in the concentrate stream.
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CONTACTOR The electrical switch component of the motor starter. The contactor
protects the PLC by isolating it from the high currents and voltages
necessary to run most motors. A contactor operates as follows: an
output of 120 V or less from the PLC energizes a magnetic coil and/or
coils in the contactor. The magnetic field causes the contact(s) to pull
in, completing the motor’s circuit.
CONTROL STRATEGY The document, or set of documents, that defines the function of
programmable controllers and operator interfaces that will be used to
control a process system. Generally, a GE W&PT control strategy
includes a Control Narrative (CN), a Control Logic Chart (CLC), and an
Operations Sequence Chart (OSC).
CONTROL VALVE A valve with a positioning actuator (not an open/closed actuator) for
manipulating a process flow, or a self-actuated valve. Typically tagged
“FCV”, “LCV”, “PCV”, or “TCV” on a P&ID.
CORROSION The attack upon metals by chemical agents, converting them to non-
metallic products. Stainless steel has a passive film created by the
presence of chromium (and often other alloying elements) that resists
this process.
CRITICAL ALARM An alarm condition that requires the operator’s immediate attention to
allow the system to run at the necessary level of production, or to
investigate a potentially unsafe condition.
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CRITICAL FAILURE A condition that triggers a process alarm that causes the unit to shut
down immediately, because continued operation could present an
immediate hazard or cause damage to the system.
CROSS-FLOW Flow across and through a membrane where the feed/reject stream
FILTRATION flows parallel to the membrane while the permeate stream flows
perpendicular. The flow pattern reduces fouling on the media surface.
Cross flow filtration necessitates a certain amount of the feed being
lost to maintain flow.
CROSS LEAK Hydraulic transfer of water between manifolds in the stack (from the
demineralizing stream to the concentrate stream).
CYCLIC AERATION Cyclic aeration valves control the air flow to the ZeeWeed membrane
VALVES cassettes, typically in 10 second intervals. The PLC controls the
operation of cyclic aeration valves.
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DEMAND A dynamic setpoint that is typically used for controlling a system with
multiple process trains or units in parallel (example: an integer setpoint
for the number of trains or pumps that should be running or a flow
setpoint for the desired system production rate).
DISSOLVED OXYGEN The amount of free oxygen dissolved in water or wastewater. Dissolved
(DO) oxygen levels are measured to ensure that sufficient oxygen is
available for the biological population to degrade the wastewater
during aerobic digestion. DO is normally expressed in mg/L, ppm, or
percent of saturation. Oxygen dissolves into the mixed liquor by
diffusion across the water surface and aeration.
DIGITAL VS. ANALOG A digital (discrete) electrical signal is either on or off. This signal is used
SIGNALS for simple on/off control of devices or alarm/alert setpoints.
DILUTE FEED The stream that serves as the feed water source for demineralization.
DRY CONTACT An electrically isolated relay contact that is not directly connected to a
power source. Typically used for sending a contact closure to a remote
control circuit where the circuit power comes from a remotely located
controller.
EDUCTOR A jet pump for withdrawing a fluid or powdery substance from a space.
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ELECTROMAGNETIC Electromagnetic flow meters (mag meters) measure liquid flow rate.
FLOW METERS (MAG The PLC uses this information to regulate pump speed and to totalize
METERS) flow.
EMERGENCY STOP The manual stopping of operation as quickly and reliably as possible,
using a circuit that meets the requirements of NFPA 79, Chapters 9 and
10.
ENGINEERED UNITS A numerical data value that is correct for its unit of measure, so it does
not need to be scaled for use or display.
FAULT An abnormal condition that affects the ability of a device to perform its
normal function. “Fault” should generally be used instead of “failure”,
“failed”, or “faulted”, and should not be used where “alarm” would be
applicable.
FLOCCULANTS Materials that can precipitate into aggregates or flocs from finely
suspended particles. The suspended materials can then be separated
from the water.
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FLUX A measure of the rate at which permeate passes through the filtration
membrane, per unit surface area of membrane. Flux is usually
measured in GFD (gallons per ft2 per day) or LMH (liters per m2 per
hour). Flux = permeate flow rate / membrane surface area.
FOOD-TO- The mass (kg) of organic matter fed to the bioreactor each day per unit
MICROORGANISM mass of microorganism. Expressed as (kg BOD (or COD) / kg VSS - d).
RATIO (F:M)
FOULING The buildup of unwanted materials on the surface or within the pores
of the filtration membrane. Fouling reduces the active surface area of
the membrane and results in a reduction in permeability.
HAND VALVES FOR Hand valves are used to control flow in situations where regular
FLOW CONTROL changes in flow are not required. The valve is in the fully open or fully
closed position.
HAND VALVES FOR Hand valves for isolation are used in situations where regular changes
ISOLATION in the valve’s state are not required. The valve is in the fully open or fully
closed position. Types of hand valves used for isolation include ball
valves, butterfly valves, and gate valves.
HIGH A condition in which a process variable is greater than its normal value
or range of values. This condition is typically used for control and/or for
an advisory alarm.
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HUMAN MACHINE A typical panel-mounted operator interface, which allows the operator
INTERFACE (HMI) access and control of the various component functions of a system. An
HMI may be an operator interface with proprietary software or a
Windows-based industrial computer running SCADA software.
IMMEDIATE A shutdown alarm condition that causes the process unit to stop
SHUTDOWN ALARM immediately (because continued operation could damage the system)
instead of using the normal shutdown sequence that might include
flushing or cleaning.
INTERLOCK A control scheme for preventing a mechanism or action from being set
in motion when another mechanism or action is in operation, because
the two operating simultaneously might produce undesirable results.
ION EXCHANGE The process by which salts (cations and anions) are removed from
water by using electricity to replace undesirable ions with a certain
charge with desirable ions of the same charge.
ION EXCHANGE The process of restoring the ion exchange resin to its fully charged
REGENERATION state.
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LEVEL SWITCH Level switches are placed in tanks to indicate very high or very low tank
levels.
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LEVEL TRANSMITTERS Level transmitters measure the liquid level in membrane tanks. The PLC
uses these levels to calculate the permeate rate or the feed flow rate to
maintain appropriate tank levels.
LOW A condition in which a process variable is less than its normal value or
range of values. This condition is typically used for control and/or for an
advisory alarm.
LOW-LOW A condition in which a process variable is lower than the Low setpoint.
This condition typically causes an automated shutdown.
LUMEN The internal cavity within the hollow fiber of a ZeeWeed membrane
through which air and permeate flow.
MC-1 (CITRIC ACID) A proprietary cleaning chemical available from GE W&PT and designed
to remove inorganic foulants from membranes.
MEMBRANE BLOWER Membrane blowers provide aeration to recirculate influent and provide
turbulence to membrane surfaces to reduce membrane fouling.
MEMBRANE The ratio of the flux and the transmembrane pressure at that flux value.
PERMEABILITY Usually expressed in L/m2/h/kPa or GFD/psi.
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MIXED LIQUOR The liquid mixture present in the aeration tank of an activated sludge
system. The liquid is a mixture of activated sludge and water
containing organic matter undergoing activated sludge treatment. The
mixed liquor is a living ‘soup’ of microorganisms that requires food,
oxygen, nutrients, proper pH, and correct solids retention time.
MIXED LIQUOR A measure of the quantity of suspended solids in the aeration tank of
SUSPENDED SOLIDS an activated sludge treatment system. Mixed Liquor Suspended Solids
(MLSS) (MLSS) is usually measured in milligrams per liter (mg/L).
MIXED LIQUOR The portion of the Mixed Liquor Suspended Solids (MLSS) that vaporizes
VOLATILE when heated to 550ºC ± 50ºC (1022ºF ± 122ºF). This volatile portion is
SUSPENDED SOLIDS mainly organic material and thus indicates the biomass present in the
(MLVSS) aeration tank. The portion of solids that does not vaporize is mostly
inorganic substances.
MODULE FLOW RATE The fluid flow rate through the module, which is normally equal to the
sum of the permeate and concentrate flow rates. Measured in US gpm
or liters/minute.
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MOLECULAR WEIGHT The size of the molecule that determines whether or not the molecule
CUT-OFF is small enough to pass through the membrane’s pore.
MOTOR CONTROL The control panel that holds the motor starters and breakers for the
CENTER (MCC) various system components.
MOTOR ROTATION A pump may be severely damaged if started in reverse rotation. Three-
CHECK phase motors can run either clockwise or counter-clockwise
depending on how they are wired. It is essential to verify motor
rotation before operating a pump. Rotation should be checked each
time the motor’s three-phase power is disconnected. A coupled pump
should always be uncoupled before checking the rotation.
MOTOR STARTER A starter allows the PLC to operate a motor while remaining electrically
isolated from the motor circuit. A motor starter consists of a contactor
and an overload.
NO VS. NC A circuit is either open (off) or closed (on). A circuit is closed if current
SWITCHES flows through it; a circuit is open if there is no current.
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NON-CRITICAL An alarm condition that needs to be addressed but that does not
ALARM require immediate operator attention.
NON-CRITICAL A process alarm condition which starts an orderly shutdown of the unit.
FAILURE
NORMALLY OPEN The circuit is open when no forces are acting on the switch.
SWITCH (NO)
NORMALLY CLOSED The circuit is closed when no forces are acting on the switch.
SWITCH (NC)
OFF-SPEC PRODUCT Portion of product stream sent to the feed tank or waste tank for not
(OSP) meeting product quality standards.
OPERATOR Also called Human Machine Interface (HMI) or Man Machine Interface
INTERFACE (OI) (MMI). A display screen through which system conditions can be
monitored and controlled.
OPERATOR Also called Human Machine Interface (HMI) or Man Machine Interface
INTERFACE TERMINAL (MMI).
(OIT)
ORGANIC LOADING The mass of organic matter feed to the anoxic and aerobic reactors
RATE each day per unit volume. Expressed as kg of COD/m3 of nitrification
reactor/d or kg of BOD5/m3 of nitrification reactor/d. The organic
loading rate can be reported using the units of mg/L/min.
OVERLOAD Provides thermal overload protection to the motor. This occurs when
the motor is drawing a higher current than its full load amperage (FLA)
for an extended period. Common thermal overloads use bimetallic strip
switches or heater coils. Common features on an overload are as
follows:
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• A trip current dial (for bimetallic strip overloads) sets the current
(usually at or slightly above the FLA) at which the circuit will trip.
OXYGEN UPTAKE The rate of oxygen at which microorganisms consume food in the
RATE (OUR) bioreactor. The rate at which the microorganisms use oxygen (OUR)
can be a direct indicator of their biological activity. OUR is measured in
mg of O2 consumed/L of biomass/minute.
PANELVIEW HMI Provides an interface between the operator and the PLC. The
(HUMAN MACHINE PanelView screen enables the operator to monitor the system’s
INTERFACE) operation. The touch-screen controls and/or push buttons allow the
operator to control the system.
PARTICLE COUNTS The number of particles per 100 ml of filtrate water. Water can be
microscopically examined using a particle counter, which classifies
suspended particles by number and size.
PARTICLE COUNTER Particle counters are placed in piping to measure the particle count,
verify membrane integrity, and ensure the quality of the permeate.
PARTICULATES Very small suspended solids in water. They vary in size, shape, density,
and electrical charge, and can be gathered together by coagulation
and flocculation.
PERMEATE The portion of the feed solution that passes through the membrane.
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PERMEATE FLOW The permeate flow rate per unit of membrane area. This is used for a
RATE (FLUX) specific system with a fixed number of membranes. The term can be
used interchangeably with permeate flow rate. The most common
usage is in GFD (gallons of permeate per square foot of membrane
area per day) or in LMH (liters of permeate per square meter per day).
PERMEATE HEADER The piping running along the length of the membrane tank that collects
permeate from each of the permeate manifolds.
PERMEATE The piping running across the top of the cassette (parallel to the main
MANIFOLD axis of the cassette) that collects the permeate from the individual
stacks. The permeate is discharged to the permeate header.
PPM Parts per million. 1 ppm = 1 mg/L (assuming specific gravity = 1.0).
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PRESSURE GAUGE A device used for measuring the pressure of a gas or liquid.
PROCEDURE The strategy for carrying out a process. It may refer to a process that
does not result in the production of a product, for example a Clean-In-
Place (CIP) procedure.
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The integral control term Ti is the time during which the actuating
variable is changed for an existing deviation. The magnitude of Ti
determines the amount of memory that the PID control loop exhibits. A
large Ti value has a low effect on the setpoint deviation and vice versa.
Controllers that use 1/Ti have opposite effects on the deviation.
RATE The tuning parameter for the derivative control action of a PID
controller.
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REINFORCED FIBER GE W&PT-patented hollow fiber used in the ZeeWeed 500 series
modules, consisting of a polymeric membrane on a strong support.
RESET The process of using a manual reset button to clear an alarm condition
after it has been resolved. The tuning parameter for the integral control
action of a PID controller.
RESIDUAL CHLORINE Residual chlorine analyzers are placed in the recirculation piping to
ANALYZER electronically measure the level of chlorine present during Recovery
Cleans. The PLC uses this online chlorine measurement to control the
neutralizing chemical dosing pumps.
RUN TIME METER A run time counter for a motor or process unit, usually with units of
hours.
SEQUENTIAL A control function intended to set the states of the pumps, valves, and
CONTROL other control devices of a process unit for a series of operation steps.
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SETPOINT An adjustable value for a process variable, which is used for controlling
a process. A controller will vary the process to keep the process
variable at the setpoint, or a process alarm and/or control action will
occur when the process variable reaches the setpoint.
SHUTDOWN ALARM An alarm that alerts the operator that action is needed to recover from
a situation where either a component is unable to operate, or the
control system has determined that operation is unsafe or undesirable.
SLUDGE WASTING The excess volume of biological sludge wasted daily from the
RATE bioreactor. Usually measured in L/d or g/d.
SOLENOID VALVE Solenoid valves provide on/off control for low flow volume locations,
including air diaphragm chemical pumps and pneumatic valves. The
PLC controls the solenoid valves.
SOLIDS RETENTION The time required to remove the working volume of the bioreactor’s
TIME (SRT) mixed liquor by the average flow rate of waste sludge from the system.
SOLVENT Any material that acts to dissolve another. The solvent constitutes the
dissolving medium, or liquid portion, of a solution. Water is frequently
referred to as the universal solvent.
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SUPERVISORY A computer system that collects and records process data and alarms,
CONTROL AND DATA and provides a graphical user interface for a process system. It is
ACQUISITION typically a Windows-based desktop computer that runs a SCADA
(SCADA) software package. The SCADA, which is the center of the control
system, acts as a link between the PLC and the operator. It allows the
control of valves, pumps, and blowers. All electronic parameters are
displayed and setpoint values are stored.
SYSTEM RECOVERY The system recovery ratio is the ratio of water recovered as permeate
versus the amount of feed water supplied to the system. A high
recovery ratio means that a large percentage of the water is collected
as permeate; a low recovery ratio results in most of the feed water
going to the reject stream. As the recovery ratio increases, the
concentration of the reject stream increases and the permeate quality
decreases. As the recovery ratio is lowered, the proportion of feed
water that is rejected increases.
TANK HEATER A CIP tank heater increases the temperature of the cleaning solution.
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TOTAL SOLIDS (TS) A measure of the amount of material that is dissolved or suspended in
a water sample, by weight. Total Solids is determined by allowing a
known volume to evaporate and then weighing the remaining residue.
TOTAL SUSPENDED A measure of the solids (normally expressed in ppm) found in water,
SOLIDS (TSS) which can be removed by filtration.
TRANSMEMBRANE The difference in pressure across a membrane (that is, between the
PRESSURE (TMP) outer and inner surface of membrane). TMP is the driving force behind
cross-membrane filtration, and is created by either increasing pressure
or by creating a partial vacuum on one side of the membrane.
TURBIDITY METER Turbidity meters are placed in the permeate piping or the feed piping
(TURBIDIMETER) to measure turbidity. When registering high turbidity, the PLC will
trigger an alarm and shut down the ZeeWeed system.
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ULTRAVIOLET (UV) A light wave, at a specific wavelength, used to disinfect water. UV will
kill any viable bacteria, viruses, and parasites.
VACUUM DEGASIFIER A tower to which a vacuum is applied and through which water
droplets descend to remove dissolved gas.
VACUUM PUMP Vacuum pumps remove air from the system and ensure that the
permeate/process pump remains primed.
VALVE TEST The process in which the operation of motor-operated valves may be
manually tested.
VOLATILE SOLIDS The total content of suspended and dissolved solids in water, which are
(VS) volatile at 550ºC (1022ºF).
VOLATILE The suspended solids that can be filtered from a sample of water and
SUSPENDED SOLIDS are volatile at 550ºC (1022ºF).
(VSS)
ZENOGEM The trade name for GE W&PT’s process of using a ZeeWeed membrane
system to clarify effluent from a bioreactor.
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ZENOTRAC The trade name for GE W&PT’s powerful plant process support tool
which provides fully automated process data monitoring and trend
analysis.
ZEEWEED The trade name for GE W&PT’s immersible hollow fiber filtration
module.
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GE Water & Process
Technologies
APPENDIX A
ZEEWEED 500D
IMMERSED HOLLOW-FIBER
ULTRAFILTRATION TECHNOLOGY
NOTICE
The enclosed materials are considered proprietary property of GE Water & Process Technologies. No assignments, either implied or expressed, of intellectual
property rights, data, know-how, trade secrets or licenses of use thereof are given. All information is provided exclusively for the addressee for the purposes of
evaluation and is not to be reproduced or divulged to other parties, nor used for manufacture or other means, or to authorize any of the above, without the
express written consent of GE Water & Process Technologies. The acceptance of this document will be construed as an acceptance of the foregoing conditions.
* Trademark of General Electric Company; may be registered in one or more countries.
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A.1
CAUTIONS
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A.2.1 INTRODUCTION
TIP: The term The ZeeWeed 500D is a supported hollow-fiber ultrafiltration membrane
'supported' refers to system that consists primarily of a series of modules housed within one
the fact that the
membrane polymer or more cassettes.
coats a braided
material that
reinforces the fiber.
A module is the basic building block and smallest replaceable unit within
the subsystem. Modules are joined together to form a cassette, which is
the smallest operable unit within the subsystem. The number of modules
contained within a cassette will vary depending on system capacity and
configuration.
The ultrafiltration membrane fiber has a nominal pore size of 0.04 µ and
is capable of removing suspended solids, protozoa, bacteria, and most
viruses. As a result, high-quality permeate can be produced with
minimum chemical addition and treatment. For more information, refer
to Table A.2.1 - Module Specifications.
A.2.3 MODULES
TIP: A special key is Membrane fibers are arranged vertically between the membrane
used to lock the module’s two headers. Water is drawn through the fibers and into the
module in place when
it is installed in the permeate header. From here, it then exits the module via the permeate
cassette. spigot or saddle.
Module Weight
Maximum shipping weight (crated) 26 kg (58 lbs) (wastewater)
28 kg (62 lbs) (drinking water)
Lifting weight (varies with solids 26 - 75 kg (58 - 163 lbs) (wastewater)
accumulation) 30 - 74 kg (66 - 163 lbs) (drinking water)
Membrane Properties
Nominal surface area 31.6 m2 (340 ft2) (wastewater)
40.9 m2 (440 ft2) (drinking water)
Material PVDF
Nominal pore size 0.04
Surface properties Non-ionic, hydrophilic
Fiber diameter (outside/inside) 1.9 mm/0.8 mm
Flow path Outside-in
Operating Specifications
TMP range -55 - 55 kPa (-8 - 8 psi) (wastewater),
-90 - 90 kPa (-13 - 13 psi) (drinking water)
Maximum operating temperature 40ºC (104ºF)
Operating pH range 5.0 - 9.5
Cleaning Specifications
Maximum cleaning temperature 40ºC (104ºF)
Cleaning pH range 2.0 - 10.5
Maximum chlorine concentration 1,000 ppm
A.2.4 CASSETTES
Cassettes provide support to modules, and consist primarily of a
reinforced frame and permeate collection piping. When installed,
modules are connected in parallel into the top and bottom common
saddles, which are linked by a 5.08 cm (2 in.) PVC permeate downcomer
pipe. The top saddle connects into the 20.32 cm (8 in.) permeate
manifold. The cassette is then linked to an external permeate header on
the train using hard pipe or hose connections.
The cassette includes 7.62 cm (3 in.) aeration PVC downcomer pipes that
feed air into tube diffusers assembled into a grid at the bottom of the
cassette.
Tie-Points
Permeate connection 15.24 cm (6 in.) 316 L SS 20.32 cm (8 in.) 316 L SS
vertical pipe horizontal pipe
Air connection All ZeeWeed 500D cassettes include two 7.62 cm (3 in.)
PVC vertical spigots
Weights
Maximum shipping weight (crated) 1,730 kg (3,815 lbs) 2,040 kg (4,500 lbs)
Lifting weight (varies with solids 1,335 - 4,260 kg 1,425 - 4,535 kg
accumulation) (2,945 - 9,385 lbs) (3,140 - 10,000 lbs)
A.2.5.1 FILTRATION
Filtration is defined as the separation of one or more components from
a fluid stream. In conventional usage, it usually refers to the separation
of solid or insoluble particles from liquid or gaseous streams.
As the pore size is reduced (and the MWCO decreases), the pressure
applied to the membrane for separation generally increases. The water
treatment objectives of each system decide the basis on which a
process is selected and operated.
1. Membrane 4. Effluent
A.3.1 INTRODUCTION
This section provides information regarding subsystem installation,
initial testing, and maintenance procedures. This information must be
read and internalized in its entirety by the operators prior to installing or
operating the ZeeWeed subsystem.
• That all 3-phase motors have been wired for proper rotation.
• Shipping crates are moved only by lifting from the bottom with a
forklift.
If membranes are frequently, lightly misted (not sprayed with fire hoses
or pressure washers) from the time they have been taken out of the
water, they may be left exposed to the air for a maximum of 6 hours at
a temperature between 5 - 35°C (41° - 95°F).
Examples of common materials that can cause damage include, but are
not limited to, the following:
• Cable ties.
• Pieces of wire.
• Fish.
All loose shipped parts required for cassette installation must be located.
All guide brackets, permeate piping and air piping are to be installed as
per installation documentation supplied by GE W&PT.
• Four (4) 3/4 in. lifting safety hoist rings rated for 2268 kg (5000
lbs), material: 4140 aircraft quality carbon steel (recommended
manufacturer ACTEK, part #46018) c/w 8 3/4 in. diameter SS flat
washers and 4 3/4 in. diameter SS hex nuts (included with
shipment)
Before the crates or cassettes can be moved, ensure that the lifting
mechanism (fork lift and crane) are in good operating conditions and are
rated for the load.
While maneuvering the crate or cassette, ensure that no one is in its path
or out of sight of the crane/forklift operator.
• painting
• roofing
• grinding
• tinwork
• welding
• pipe flushing
• sandblasting
• drilling
The top of the crate is to be removed first followed by one of the sides.
TIP: Crate The ends will remain supported by the other side of the cassette. When
dimensions (LxWxH) removing the other side, care must be taken to ensure the remaining
are: 111 in. x 83 in. x
89 in. (2.82 m x 2.10 m ends of the cassette are supported. See Figure A.3.2 - Top of Crate
x 2.26 m). Removed.
Cut open the bag sealing at the top, then carefully roll it down to the
base of the crate. See Figure A.3.4 - Bag Sealing the Cassette.
Do NOT cut along the center of the cassette. Fibers can be damaged.
Once rolled down to the base of the cassette, cut the bag at the base and
discard.
There is a plastic wrap underneath the bag. The plastic wrap must
stay intact for the uprighting of the cassette.
Depending upon the version of the cassette, it may come equipped with
yellow shipping braces. If these braces are present, they need to be
removed prior to uprighting the cassette.
If the membranes have been in storage, check for any signs of mold
on the fibers. If mold is present, immediately rebag and contact GE
W&PT.
Lift the cassette by the factory-supplied lifting points on the top of the
cassette using the lifting module. If a lifting module is not available, a
spreader bar is required.
Do not attach ropes to the four hanger brackets and lift the hanger
brackets. The hanger brackets will not withstand the horizontal
(inward) loads produced by the ropes.
If there is contact with the fibers, the integrity of the membranes may
be compromised. Advise GE W&PT staff on site immediately so the
fibers can be inspected and repairs can be initiated before cassette is
installed. If fiber damage is not reported to GE W&PT staff, extra time
and effort will be required later to remove the cassette and make the
repairs.
• Ensure that the large holes on the aerators are facing down
relative to the cassette.
• Ensure that the correct type of aerators are used under the non-
permeating (“dummy”) headers (some aerators are “left” aerators
and some are “right” aerators depending on which side the small
side holes are on).
• Ensure that the two main aeration pipes are installed and secure.
Bring shipping crates into the staging area one at a time. Clear the area
of any material and provide the safe space required for both removing
the cassette from the wooden skid and uprighting it. The area for the
uprighting operation shall be at least 7.5 meters X 3 meters (25 ft X 10 ft).
Clearly mark the area and isolate it, so that access of unauthorized
personnel is prevented. The use of a perimeter fence, rope/chain
barriers, pylons, or other signalling and blocking means is highly
recommended.
• Ensure that the bushing of the hoist ring is sitting flush against
the frame.
• Verify that the hoist is free to swivel and pivot in every direction.
Ensure that the following steps are taken before performing the
uprighting procedure:
1. Place a 1 in. thick foam sheet on the clear and flat ground where
the cassette will be placed for uprighting.
2. Use a four point lift frame and spreader bar to uncrate and
upright a cassette. This lifting configuration is highly
recommended in conditions where overhead space is limited.
3. Ensure that the hoist rings do not touch or pry against any
surface of the cassette frame, in particular the vertical corner
post, except at the location of attachment. If a lift frame or
spreader bar is not available, an arrangement similar to what is
shown in Figure A.3.11 - Lifting a Cassette Without a Four-Point
Lift Frame and Spreader Bar is recommended. Follow these
recommendations:
• Use two slings on each lifting bracket. The sling closest to the
cassette should be a short nylon strap about 4 feet long. This
arrangement will prevent damage from the crane hooks. The
longer cables should be at least 20 feet long.
Figure A.3.11 - Lifting a Cassette Without a Four-Point Lift Frame and Spreader
Bar
4. Slowly lift the hoist until the cassette is at the minimum height
(not more than 2 in. or 5 cm) required to move the cassette off the
wooden skid.
5. Slowly and gently transfer the cassette to above the 1 in. foam
sheet, and gently lower the cassette to the ground.
8. Disengage the hoist and slings. Remove the two hoist rings
attached to the bottom side of cassette (the side that will be
placed on the ground).
1. Locate the crane on the side of the cassette where the cassette
moves horizontally during the uprighting.
2. Place another 1 in. foam sheet to the side of the cassette where
it will be placed on the ground.
4. Slowly lifting the cassette off the ground. The cassette will tilt as
it is lifted. The lifting device must be free to move laterally to
remain over the cassette’s center of gravity.
5. At all times, keep the hoist in vertical alignment with the lifting
points on the cassette. Failure to do so could result in the cassette
“kicking out”. Do not attempt to stop the cassette if it kicks out.
7. Lift the cassette until it pivots onto its side, then lower it until it
rests fully on the foam in its vertical position.
There are regular and mirror image versions of the arms. Ensure that the
correct arm is installed on the correct side of the cassette.
Note the position of the open end of the hanger arms and the position of
the small tab at the bottom. Also note that the hanger arms on the
diagonal from each other are identical and hanger arms adjacent to
each other are opposite in orientation (top slots are on different sides of
center).
Be sure to cut along the corner beam to prevent fibers from being
damaged. Do not cut plastic wrapper along the membrane area.
Before removing the foam, visually inspect the cassette for any tangled
fibers or fibers stuck to the foam. Pull the foam out from within the
cassette carefully and slowly.
• Verify that the module keys are in the locked position (vertical).
• Ensure that the top and bottom expander blocks are tight and
fully engaged and flush with the bottom surface of the key side
outer assembly.
There must be enough potable water in the membrane tank such that
no fibers will be exposed to air once the cassette is installed.
The lifting arm is moved using the crane to the overtop of the cassette.
The pins at its four corners slide into the hanger arm slotted hole facing
the inside of the cassette. Once the pins are through the slotted holes, a
hitch pin must be passed through the lifting bracket pins to secure the
lifting bracket to the cassette.
Using the hoist and lifting bracket, carefully lift the cassette and install it
onto the leveling pins inside the membrane tank. The outside slotted
holes on the hanger arms slide onto the leveling pins in the tank.
Do not allow any glue or solvent to fall onto the fibers or cassette as
irreversible damage may result. Protect fibers and PVC piping from
spills.
1. Just before dropping the cassette onto the leveling pins, mount
the coupling to the cassette header and the pipe spool that
connects to the other side of the coupling.
2. Tighten the coupling so that it can support the weight of the spool
piece.
While installing the remaining couplings and spool pieces after the
cassette is in the tank, make sure that the membrane modules are
not stepped on. Only step on the cassette header and frame.
For systems where the permeate header is installed through the wall of
the tank and is aligned with the cassette header, place the coupling on
the section of the permeate header sticking through the tank wall. Lower
the cassette onto the leveling pins, slide the coupling so that it catches
both pipes, and tighten.
The single 4 in. tee version is for installations with cyclic aeration (whole
cassette on-off air cycling). The twin 3 in. connection version is for
installations with sequential aeration (air is cycled first to half the
aerators on a cassette - and then the other half). If there is any
uncertainty as to which design is to be used, refer to the P&IDs.
1. Lower the cassette onto the leveling pins and remove the lifting
bracket, if necessary, to make room to work.
4. Connect the other end of the hose to the already installed (see
A.3.7.7 Installing Union to Cassette’s Main Aeration Pipes) fitting
on the cassette main aeration pipes.
Always connect the air hose to the main aeration header first and
then connect the other end to the cassette PVC aeration pipes. This
avoids stressing the PVC parts on the cassette.
A.3.9.1 FLUSHING
All ZeeWeed membrane modules and cassettes are shipped in a
glycerin solution with a pH of 3.5 to 4.5 to prevent the membranes from
drying. This glycerin solution has a high biochemical oxygen demand
(BOD) and is not suitable for discharge to surface water or as drinking
water.
If there are multiple trains, the glycerin flushing water can be reused.
GE W&PT will provide calculations to determine the volume of water
required.
1. Start the blower and ensure that air is being supplied to the
membrane cassettes.
4. Check the air pipe connections for leakage. If any leaks are found,
fix the piping immediately to ensure that the membrane
cassettes are receiving sufficient aeration.
5. With the aeration on, observe the airflow pattern in the various
membrane tanks. Determine if the difference in membrane tank
level while backpulsing has an effect on the airflow pattern.
TIP: If possible, 1. Reduce the water level in the membrane tank to a point below
remove the cassette the permeate connection, so that no water can get into the
from the membrane
tank and test in a cassette after the connection is removed. The membranes must
separate tank. be completely submerged.
3. Connect the 1/4 in. tubing from the adapter to the permeate air
connection, and then connect the 1/4 in. tubing from the
compressed air source.
5. Set the applied air pressure to just over half of the required
pressure.
6. Wait 5 minutes to ensure the air has purged the water, and then
increase the air pressure to just under the required pressure.
In cases where few leaks are present in a given module, and none of the
leaks are serious, the repairs should be made on site. If a module
requires difficult or numerous repairs, contact GE W&PT for further
information.
TYPE 4: Type 4 bubbles gather at the top of the cassette and release
when the bubble is sufficiently large. This type of bubble is usually
formed by accumulated Type 2 or Type 3 bubbles.
1. Lower the liquid level in the membrane tank to just below the
connections. Carry out a general shutdown of the whole system.
Isolate the cassettes using the manual valves at the permeate
and air headers.
If heavily weighted cassettes are completely removed from the tank for
inspection and cleaning, this could result in the cassette frame and
cassette lifting mechanism being subjected to excessive loadings. In
some cases, the resulting load may encroach on the design safety
factor of the cassette frame and lifting mechanism, as well as the
cassette support beam and grating in the location where the cassette is
set down.
2. Turn off the aeration and lift the cassette partially out of the tank.
Flush the exposed section with clean water (process effluent is
sufficient). Lift the cassette approximately 50 cm – 75 cm (20 in. -
30 in.) at a time and repeat the process. By lifting the cassette in
steps, the submerged sections will be partially supported by the
wastewater and will reduce the lifting loads. For a deep tank
application, where this process is not practical, wash off the
debris prior to lifting the cassette above the grating.
For optimal performance and long life of the equipment, all areas
must be kept clean. Remove any chemical spills immediately and
wipe down the maintenance equipment frequently.
i. Soak the module in the above solution and apply 0.34 bar
vacuum (0.66 bar absolute) for 30 minutes.
ii. Take the module out of the solution and place it on the
floor for 30 minutes to allow excess solution to drain off.
5. Bag the module using a 0.15 mm (6 mil) thick plastic bag. These
bags are available from GE W&PT. Seal the membranes in the
plastic bag, using either a hand held sealer or tape, so that they
will remain preserved and will not dry out. For the tape seal,
remove as much air as possible from the bag. Seal most of the
membrane bag with tape, then remove the excess air with a shop
vacuum.
6. Store in a cool, dry area, out of the direct sunlight and protected
from accidental contact that could damage the module or bag. It
is recommended that the membranes be double bagged or
enclosed in suitable cardboard cartons.
The membranes are now properly preserved, and the system can be
shut down.
6. Leave the cassette isolation valves on the air headers open, and
the header outlets capped with camlock caps.
7. Remove and store the membrane tank level transmitter from the
membrane tank.
A.4.1 INTRODUCTION
This section outlines the various maintenance procedures required to
ensure optimal membrane performance and lifespan, including
information related to membrane fouling, handling, inspection, and
repair.
Allowing the proper amount of fiber slack between the headers ensures
that the fibers move freely during operation, which improves the effects
of air scouring. Additionally, it is common for membranes to shrink
slightly during operation, and permitting the proper amount of slack will
accommodate this reduction in fiber length.
Figure A.4.2 - Correct (Left) & Incorrect (Right) Slack for ZeeWeed 500D
For example, a system operating at 35ºC (95ºF) will typically exhibit more
fiber shrinkage than a system operating at 30ºC (86ºF) over the same
period of time. Systems operating at temperatures below 25ºC (77ºF) are
not expected to exhibit significant fiber shrinkage, and the need for slack
adjustment is unlikely.
This procedure requires that the cassette be out of the membrane tank
for an extended period of time. Allowing the membranes to dry-out
during this time will cause irreparable damage, and must be avoided by
re-wetting the membranes with a low-pressure stream of water at least
once every 30 minutes. Systems located in arid environments with low
humidity may require more frequent spraying.
To ensure that the water pressure in the hose is not excessive, confirm
that the stream does not extend more than 1 m (3 ft) when the hose is
held at a height of 1 m (3 ft) (Figure A.4.3 - Water Pressure Test). If the
stream contacts the ground within 1 m (3 ft) of the hose, the pressure is
suitable for spraying the membranes.
When removing the cassette from the membrane tank, ensure that the
following information is adhered to:
• 17mm socket
• Rubber Mallet
• Coarse File
• Drill
• Apply food grade anti-seize to all bolts (for example: White Knight
Anti-Seize)
2. Unlock the module key (top and bottom) prior to continuing with
this procedure. The module is in the unlocked position when the
lock is horizontal (see Figure A.4.6 - Locked and Unlocked Module).
Do not force the lock into position.
Be aware that tubes must be placed back into their original position
in the cassette.
3. Remove the bolts from positions # 9, # 16, and # 23. Loosen but
do not remove the bolt in position # 2. This bolt will keep the Front
Bottom Adjustable Beam aligned with the holes (see Figure A.4.10
- Removing the Bolts).
4. Pry the end of the Front Adjustable Bottom Beam where the bolts
have been removed (see Figure A.4.11 - Front Adjustable Bottom
Beam).
Do not slide any of the modules back into the permeate saddles.
7. Remove the bolts located at the middle of the centre beam. Note
there is one bolt on either side of the beam (see Figure A.4.20 -
Remove Center Beam Bolts).
.
8. Adjust the center beam by removing the bolts from each side of
the centre beam at both ends of the beam - four bolts in total.
Retain all hardware for replacement (see Figure A.4.21 - Adjust
the Center Beam).
.
9. Use the jacking bolts to lift the centre beam to the desired height,
referencing Figure A.4.4 - Center Beam.
10. Once all four bolts have been installed at the ends, align the
appropriate middle bolt hole on each side of the middle of the
centre beam (see Figure A.4.22 - Align the Middle Bolt Hole).
11. Install and tighten the six center beam bolts as per torque
specification 247 inch lbs (see Figure A.4.23 - Torque the Bolts).
12. Reinstall modules and lock into position. Reinstall aeration tubes
in their original positions.
13. Tighten all top and bottom key side outer support expanders
using a 5 mm Allen Key or a hex wrench. The expander is fully
engaged when flush with the bottom surface of the key side
outer assembly. Max tightening torque not to exceed 5.0 Nm (3.6
FT-LBS, 44 IN-LBS) (see Figure A.4.24 - Tighten Support
Expanders).
.
14. Indicate on the membrane map the date of the slack adjustment
and the amount of slack adjusted. List the bolt positions used.
In all instances, attempt to install the module by hand. Only use the tool
for assistance, if required.
• Gloves
Do not use any other tools to remove or install the 500D module.
Part # 1032836 replaces all previous versions of the 500D Removal Tool.
3. If the cavities are filled with material clean them out so the Insert/
Removal tool will mate properly.
Be sure to keep tool flush against module face while locking into
position.
Hand manipulate the rotating ring. Do not use tools to gain leverage.
Breaking of the locking tabs could result if tools are applied to the
rotating ring.
The removal tool is not designed to fully remove the module from the
cassette. Remove the tool prior to hand removing the module.
The membrane cassettes are shipped with the modules installed. This
procedure is provided for membrane repair. See A.4.6 Repairing Fibers
for the fiber repair procedure. To remove modules from a cassette see
A.4.4 Module Removal from a Cassette.
• Step Ladder
2. Confirm the black EPDM #118 ‘s are present, intact and in proper
placement on the permeate spigot. O-rings must not be twisted,
cracked, or worn. Apply a water-soluble lubricant (such as Lubri-
gel or KY Jelly) to the O-rings (see Figure A.4.38 - Correct Position
of the O-rings on the Permeate Spigot).
Quality testing has shown that the majority of module failures can be
attributed to incorrect module installation. It is very important that
the following instructions are followed to prevent damage. Under no
circumstances should excessive force be used on the module to aid in
insertion or removal from the cassette.
Each module has one square-end header and one round-end header.
Modules are installed alternating square and round ends up.
Support the headers at all times. Do not allow the module headers to
bump up against the cassette frame or other modules.
Check that the desired end (round or square) is at the top. Use 2 people
to lift the module. Be careful not to let the fibers or the bottom header
contact the ground. While one person climbs the ladder to install the top
header, the second person must support the bottom header at all times.
1. To insert the module into the cassette, align the rail on the top of
the module with the cassette.
Figure A.4.42 - Aligning the Rail on the Module with the Cassette Frame
2. If space allows, wipe any visible debris from the rail and apply
lubri-gel to both the rail and rail support guides on the top of the
header to allow a smooth insertion.
3. Confirm the O-ring seal on the module is correctly made with the
bottom permeate collector.
4. With the spigot properly seated, slightly and gently lift the header
- do not put stress on the spigot connection – and slip the
locating nipples on the front of the header into the holes on the
cassette frame.
2. If space allows, wipe any visible debris from the rail and apply
lubri-gel to both the rail and rail support guides on the top of the
header to allow a smooth insertion.
If a module does not easily slide into the cassette, visually check for the
following:
Expander is fully engaged when flush with the bottom surface of the key
side outer assembly. Max tightening torque not to exceed 5.0 Nm (3.6 FT-
LBS, 44 IN-LBS).
Once the module(s) have been installed and final check has been
completed, it may be necessary to carry out a glycerin flush and
sanitization procedure.
Do not separate strands that are glued together at the header, as this
will cause damage to the membranes.
2. (20 mm gap) cut position for single fiber 4. Drawn potting material
Figure A.4.48 - Membrane Fiber Cut Positions
3. Apply light pressure when injecting the silicone. Fill the lumen
back to the header, as indicated by the darkened zone in Figure
A.4.50 - Axial Silicone Injection (Two of Four). Filling typically takes
15 - 45 seconds.
5. While still applying pressure to the syringe, use the tip of the
needle to spread silicone over the cut end of the lumen.
After the repair is complete, place the cassette back into the membrane
tank. Allow 10 minutes for curing before performing further membrane
testing.
4. Repeat these steps on the other side of the leak, positioning the
needle 5 - 10 mm (3/16 - 7/16 in.) from the leak on the opposite
side to the first injection point.
1. Leak
2. Injected silicone
Figure A.4.54 - Subjacent Silicone Injection (Two of Two)
After the repair is complete, place the cassette back into the membrane
tank. Allow 10 minutes for curing before performing further membrane
testing.
A.5.1 INTRODUCTION
This section provides information regarding the various procedures and
chemicals used to clean and maintain the membranes.
TIP: For more severe The type of cleaning chemical required depends on the type of fouling
fouling, GE W&PT that needs to be cleaned. An alkaline solution is used to remove
offers additional
cleaning chemicals biological fouling, while an acid solution is used for precipitative fouling
designed specifically caused by accumulated mineral scales, iron, or other metals.
for use with ZeeWeed
membranes. Contact
GE W&PT for more
information.
These chemicals are used during the Maintenance and Recovery Clean
procedures outlined in this section. Safety and handling instructions for
all chemicals which GE W&PT has supplied can be found in the
applicable MSDSs provided in Section 6 - Material Safety Data Sheets.
NOTES:
• * Backpulse concentration
• ** Soak concentration
Citric acid solubility is 500 g/L at 10ºC (50ºF). GE W&PT does not
recommend increasing the concentration beyond this amount.
% by weight (as
x density = amount (kg) required per liter of permeate
decimal)
EXAMPLE: For a 50% by-weight citric acid solution with a density of 1.24:
After the cleaning solution has been prepared, ensure that chemical
injection pumps have been set to dose the proper amount of solution
when activated. Refer to Table A.5.1 - Cleaning Summary for more
information regarding required chemical concentrations.
A.5.6.1 BACKPULSE
Backpulse cleans are initiated automatically during the normal
production cycle according to setpoint values defined by the operator.
Backpulse-related setpoints should be updated periodically to account
for changes in operating conditions and feedwater quality.
A.5.6.2 RELAX
When a train is in the RELAX state, the membranes sit inactive (no
permeation) for a duration specified by the operator, after which
production resumes. During this time, aeration disperses foulants that
have concentrated around the membranes.
A train is placed in the RELAX state either manually (operator presses the
Enable Relax button) or automatically (PLC triggers the transition to
RELAX if a Backpulse sequence fails and no pump is available).
TIP: Cleans should be The operator must ensure that there are sufficient cleaning chemicals
scheduled during available and must set the day and time when the Maintenance Clean is
periods when system
demand is at its to occur for each train.
lowest.
Before initiating a clean and while the train is still in PRODUCTION mode,
record the current water temperature, flux, and TMP level.
The Recovery Clean will proceed according to the steps outlined in the
OSC. The default steps are outlined in the Control Narrative.
After the final drain, the PLC advances the clean through various steps
including soaking the membranes in a chemical solution.
A.5.6.5 NEUTRALIZATION
Following a chemical clean, the solution must be neutralized before it
can be sent for disposal. Acid solutions are neutralized through the
addition of sodium hydroxide, whereas sodium bisulfite is required for
chlorine removal following an alkaline clean. Because dechlorination
decreases the pH, the subsequent addition of sodium hydroxide is also
required for complete alkaline neutralization.
The PLC advances through the remaining neutralization steps. For more
information, refer OSC in Section 4 - Control Documentation.
A.5.7 VENTILATION
If the subsystem is located indoors, the membrane tank must be
properly ventilated in accordance with all local regulations.
A.6.1 INTRODUCTION
TIP: Data must be This section provides information regarding membrane permeability
normalized before and the procedures used to test and monitor the physical condition and
evaluation. Refer to
A.10 - Calculations. performance of the membranes.
A.6.3 TURBIDIMETERS
Membrane integrity is monitored using a series of train-specific on-line
turbidimeters, each mounted downstream from the associated
permeate pump.
A.7.1 INTRODUCTION
This section provides general information regarding the regular
inspection and maintenance of various subsystem components.
NOTES:
• D (daily); W (weekly); M (monthly); Q (quarterly); S (semi-
annually); A (annually).
• * - Monthly initially until optimum interval is established.
• ** - Inspection frequency may vary. Refer to A.7.3.2
Inspection Frequency for more information.
• Site name.
• Inspector’s name.
• Inspection date.
• Train number.
• Cassette position.
TIP: After the first For systems with operating temperatures greater than 30ºC (86ºF), or
year of operation, where the possibility that suspended solids might accumulate within the
inspection frequency
can be adjusted based membrane tanks exists, it is recommended that the inspection
on past findings and procedure be carried out on a monthly basis, rather than every 3
recorded trends in
system operation. months.
HITCH PINS: Confirm that each of the cassette’s hitch pins are fitted
snugly and show no signs of wear.
CAMLOCKS & HOSES: Confirm that all camlocks and hoses connected to
the cassette are in good condition. Note any cracks or discolouration on
hoses and check that all hose clamps are tight.
A cassette that has been in service will weigh more than it did when
it was first installed. To avoid severe personal injury caused by a
collapse, confirm that the load limits of all lifting equipment and of
the surface that the cassette will be set on are sufficient.
Do not attempt to operate the lifting beam without first having read
and understood the operator’s manual.
• Do not: exceed the rated load of the lifting beam, or use it to lift
anything other than the cassettes it was designed for.
To reduce the amount of solids on the cassette before lifting, aerate the
cassette without permeation and use a garden hose with a low-
pressure stream to dislodge solids from the cassette.
To ensure that the water pressure in the hose is not excessive, with the
hose held 1 m (3 ft) above the ground, confirm that the stream does not
extend more than 1 m (3 ft) from the hose before reaching the ground
(Figure A.7.1 - Water Pressure Test). A stream that extends any further
with the hose held at this height is too strong to be used on the
membranes.
CASSETTE FRAME AND HARDWARE: Check the cassette frame welds for signs
of leaking or corrosion, and all connections for loose or missing
fasteners.
LEVELLING PINS: Check the cassette’s levelling pin assemblies for signs of
loosening or wear. Levelling pins that have loosened over time may
result in cassettes becoming misaligned, which will contribute to uneven
aeration and solids accumulation. Refer to Figure A.7.2 - Levelling Pins for
more information.
SHELLS: Check the cassette and membranes closely for signs of aquatic
life, particularly in the form of shells, which can be as small as 1 mm in
length.
Figure A.7.5 - Bottom Permeate Port (Left), Top Permeate Saddle (Centre) &
Location of Port & Saddle (Right)
AERATION TUBES: Clear any blockage found in the aeration tubes and note
the location of plugged or clogged aeration tubes on the inspection
template. To remove blockage, the aeration end caps will need to be
removed. These end caps are located on bottom of the back side of the
cassette. Recheck the aeration pattern after cleaning.
1. Visually inspect all of the MISs and verify they are attached.
2. Verify that all locking keys are tightly locked in the vertical
position.
3. Inspect the MIS locking pins. The locking pins should be in the
vertical (locked) position.
4. Check for wear on the MIS. Each locking pin should lock into
position tightly and securely. If the locking pins move freely, the
MIS is worn. Figure A.7.10 - Module Header, Showing Wear
Location shows typical wear location on a module header.
CLEAN REGULARLY: Piping and equipment should be kept clean and dry.
Keep potential contaminants (example: solvents, tools, and equipment),
away from stainless steel components.
A.8.1 INTRODUCTION
This section provides information regarding some of the most common
issues and frequently asked questions related to ZeeWeed membranes
and associated components.
Refer to A.3.9.4 Bubble Test in the appendix A.3 - Installation & Testing for
information regarding the bubble test procedure, A.3.10 Membrane
Inspection/Replacement in the appendix A.3 - Installation & Testing for
more about visually inspecting membranes, and A.4.6 Repairing Fibers in
the appendix A.4 - Membrane Care for fiber repair procedures.
PROBLEM: The process pump will not achieve prime due to air inside
permeate header.
• Excessive TMP.
• Determine if the air release valve rubber seat has become stuck.
If so, it will prevent air from being vented from the permeate
header.
• The higher the TMP, the greater the likelihood of air being pulled
across the membranes. If high TMP is suspected of causing
excessive entrained air within the permeate header, initiate a
Recovery Clean to restore TMP to an optimal level.
1. At the HMI, select the backpulse tank LIT setpoints button and
record each of the four setpoints (example: LAHH, LAH, LAL and
LALL).
2. Record the current level within the backpulse tank and compare
with the setpoints shown on the HMI.
PROBLEM: Backpulse tank level low low alarm. The pump is set in STOP
mode.
1. Check the level in the backpulse tank. If the level is not low, then
the transmitter is not functioning correctly. Refer to Volume I -
Vendor Data Manual for troubleshooting procedures.
3. Confirm that the flow valve and check valve are functioning
correctly.
• The seat is set too far away from the top side of the support arm.
• Shut down the train, remove the air release valve housing cover,
and inspect the interior surface of the air release valve. Ensure
that the valve fits snugly against the orifice and check for rust. If
rust is present, refer to Volume I - Vendor Data Manual for
additional troubleshooting information.
• Ensure that the float moves freely inside the air release valve
housing. If not, remove any obstructions preventing movement.
A.9.1 INTRODUCTION
This section provides information regarding the procedures, tools, and
schedules associated with gathering and tracking subsystem
performance data. This information is essential when assessing long-
standing performance issues, establishing trends, and determining the
durability of various components.
A.9.2 LOGSHEETS
Logsheets, which are provided as electronic copies, are used for
manually recording operational data and analytical results.
A.9.3 ZENOTRAC
ZenoTrac is a powerful system support tool available as an option for all
GE W&PT clients. Contact GE W&PT for more information about
ZenoTrac.
A.10.1 INTRODUCTION
This section provides calculations used to determine chemical quantities
required for cleaning, maintenance, and various other subsystem
procedures. These calculations are intended as general examples only;
additional information specific to your subsystem may be provided by
GE W&PT personnel during initial startup and commissioning.
NOTES:
• Before mixing solution, consult the applicable MSDS for
chemical purity.
Calculate the flow rate of 35% ferric chloride solution to dose to 60 ppm
in a 100 lpm stream.
The mass flow rate of ferric chloride in the feedwater stream equals the
mass flow rate of ferric chloride dosed.
Qf x Cf
Qc =
c x Cc x 106
Example:
100 x 60
= 0.0126 lpm
1.36 x 0.35 x 106
48 modules per
x 3 cassettes per train x 340 ft2 per module = 48,960 ft2 per train
cassette
Flow Number of
Flux at 59ºF = x
Membrane surface area per train minutes per day
868 gpm
x 1,440 minutes per day = 25.5 gfd
48,960 in.2 per train
viscosity at T1
Flux at T1 = Flux at T2 x
viscosity at T2
1.0049
25.5 gfd x = 22.47 gfd
1.1403
22.47 gfd
= 3.7 gfd per 1 psi
6 psi