BANGGAI AMMONIA PLANT (BAP) PROJECT Boustead Salcon Water Solutions

Pte Ltd
PROGRAM

 DAY 1
 Introduction
 Pretreatment (Ultrafiltration)
 Desalination (Seawater Reverse Osmosis)

 Day 2
 Desalination (Brackish Water Reverse Osmosis)
 Mixed Bed Polisher
PROGRAM

 Fundamentals
 Design Basis
 Process Flow Diagram
 System Description
 Operation Philosophy
 Daily Operation, Monitoring and Maintenance
 Start Up
 Shut Down
 Troubleshooting
 Safety Precaution
FUNDAMENTALS OF
REVERSE OSMOSIS
(RO)
Filtration Spectrum
Typical Operating Pressure of
Different Driven Processes
Reverse Osmosis (RO) Definition

Osmosis Reverse Osmosis

A spontaneous process of A pressure driven process

water flow across a
semipermeable membrane
barrier from the solution of
low concentration to the
solution of higher salt
concentration.
of water flow across a
semipermeable membrane
from the solution of high
concentration to the
solution of lower salt
concentration.

Applied Pressure

Flow

Concentrated
Solution Membrane Dilute Solution
Reverse Osmosis (RO) Definition

 Membrane
The semi-permeable barrier manufactured from
polymeric materials: cellulose acetate or
polyamide.

 Separation Process
During the reverse osmosis process both water
and salt passes through the membrane. Water
passes at a high rate. Salt ions passes at a lower
rate. The difference in passage rates result in a
separation of water from salt.
Basic Definitions

Permeate flow
Recovery (%) =  100%
Feed flow

Salt Passage (%) = Permeate salt conc

 100%
Feed salt conc

Salt Rejection (%) = 100 - Salt Passage

Permeate flow (m3 / h)

Permeate Flux (lmh) = 2
100
Total Membrane area (m )
Reverse Osmosis (RO) Membrane

 Comparison between Cellulose and Polyamide

Membranes
Reverse Osmosis (RO) Membrane
Reverse Osmosis (RO) Vessel
Fundamentals of RO

What RO can do:

 Obtain purified water from a feed stream (permeate)
 Extract constituents from a feed stream (concentrate)
 Selectively separate small ions and molecules
Fundamentals of RO

What RO cannot do:

 Cannot concentrate to 100%
 Cannot separate to 100%
 Not always the most cost effective method
Simple RO System

10 to 40 bar (Brackish Water)

55 to 76 bar (Seawater)
RO Feed Water Quality

 SDI < 5.0, preferably < 3.0

Treatment method:
 Turbidity < 1 NTU • Dosing SBS
• Using AC Filter
 Al, Fe, and Mn concentrations
< 0.05 ppm
 Chlorine residual < 0.1 ppm
 LSI in the brine stream slightly negative or
< +1.5 if antiscalant is used to control CaCO3
scale
SDI Test Kit

Feed
𝑇𝑖
100 𝑥 (1 −
𝑇𝑓 )
Ball valve or 𝑆𝐷𝐼 =
𝑇𝑡
1st stage
regulator

Ti = Time to collect 500 ml sample

Pressure
regulator Tf = Time to collect 2nd 500 ml
30 psi sample after Tt
Tt = 15 minutes
Pressure gauge

0.45 m Bleed
filter
O-ring
 Pre-treatment of RO System

To increase efficiency and life span of RO membrane, proper

pretreatment to minimizing:
 Scaling
 Fouling
 Membrane Degradation

To Prevent Scaling
 Acid Addition
 Antiscalant Addition

To Prevent Colloidal Fouling

 SDI Measurement
 Media Filter or Cartridge Filter or Ultrafiltration

To Prevent Biological Fouling

 Chlorination
 Dechlorination
Factors Affecting Membrane
Performance
 Feed Water
 Concentration
 Temperature
 Osmotic Pressure
 pH

 Operation Parameters
 Pressure
 System Recovery
Effect of Feed Water Pressure on
Flux & Salt Rejection

Assuming temperature, recovery and feed concentration

are constant
Effect of Feed Water Temperature on
Flux & Salt Rejection

Assuming feed pressure, recovery and feed

concentration are constant
Effect of Feed Water Concentration
on Flux & Salt Rejection

Assuming temperature, feed pressure and recovery are

constant
pH Influence on Salt Rejection

Assuming temperature, feed pressure and fee

concentration (TDS) are constant
Factors Affecting Membrane Performance -
Summary

RO Permeate Flow increases with:

 Higher Flux / Lower Pressure Membrane
 Higher Feed Pressure
 Higher Feed Temperature
 Lower Feed / Concentrate TDS
 Damaged Membrane
Factors Affecting Membrane Performance -
Summary

RO Permeate Quality improves with:

 Higher Rejection Membrane

 Colder Feed Temperature

 Lower Feed/Concentrate TDS

 Lower % Recovery

 Divalent Cations and Anions

 DESIGN BASIS OF
SEAWATER
REVERSE OSMOSIS
(SWRO)
Design Basis
Feed Water Characteristic:

Source: Filtrate from UF System

SWRO Configuration: (2 Duty, 1 Standby) x 50%
Design Flow Rate:
Feed of SWRO System 464 m3/h

Feed Water Quality (UF Filtrate):

SDI15 <3
Turbidity < 0.1 NTU
Total Dissolved Solids (TDS) 35720 mg/L

Treated Water Quality (After SWRO System):

pH 6.5 – 8.5
Total Dissolved Solids (TDS) Max. 600 mg/L
Boron 2.4 mg/L
PROCESS FLOW DIAGRAM
&
SYSTEM DESCRIPTION
FOR SWRO SYSTEM
Process Flow Diagram

Chemical for SWRO System

SWRO
Module

SWRO Feed Pump

SWRO Product Tank

Location of Equipment for SWRO System

SWRO Feed
Pump

UF Filtrate
Tank

SWRO Cartridge Filters

SWRO HP Pump

SWRO Product
Tank

SWRO Skid
RO CIP Pump

RO CIP Tank

Biocide SBS Antiscalant

System Description

SWRO Feed Pump

 To transfer UF Filtrate from UF Filtrate Tank into
SWRO system
 Configuration: 3 x 50%
 API 610 Standard
 Capacity: 232 m3/h @ 4 barg

SWRO Cartridge Filter

 Serve as guard filter for SWRO to remove any
suspended solids may have go into water, either
through UF Filtrate Tank or Chemical Dosing
 Configuration: 3 x 50%
 Housing Material: Carbon Steel Rubber Lined
 Cartridge: PP Material with 5 micron size
System Description

SWRO High Pressure Pump

 To raise up feed water pressure to its required
operating pressure
 Configuration: 3 x 50%
 API Standard
 Capacity: 232 m3/h @ 34 barg
 Due to variation in operating conditions such as water
temperature and TDS, membrane age, degree of
fouling, etc., RO feed pressure is adjusted by
controlling pump speed by VFD to achieve required
permeate flow ( 104m3/h).
System Description:
SWRO Cartridge Filter & SWRO HP Pump
System Description

SWRO ERD
 To improve the energy recovery of SWRO system.
Discharge pressure from SWRO HP Pump is boosted
by using residual pressure from SWRO reject
 Type of ERD used is hydraulic turbocharger from
FEDCO
 Configuration: 3 x 50%
 Material: Duplex Stainless Steel
 Integral brine control valve that can adjust the brine
flow and pressure within the approximate range
required.
SWRO Energy Recovery Device (ERD)
SWRO Energy Recovery Device (ERD)

Feed Outlet Feed Inlet

Brine Outlet

Brine Inlet
SWRO Energy Recovery Device (ERD)

A short video to understand more about the turbocharger.

Equipment Video\HPB
Video.mp4
System Description

SWRO Modules
 Design Recovery: 45%
 Each train of SWRO consists of 25 nos. of pressure
vessel ( 7 elements long)
 8 inch diameter spiral wound polyamide RO
membrane
 Membrane used is Toray’s seawater RO membrane,
model TM820M-440.
System Description

Chemical Dosing
 Following chemicals shall be injected to SWRO feed water
Normal
Chemical Purpose Remark
Dosage
SBS For dechlorination 3 ppm Continuous dosing
Antiscalant To prevent scaling 1.75 ppm Continuous dosing
Biocide To prevent biofouling 30 ppm Intermittent dosing

 NaOH is dosed into SWRO permeate to raise its pH to 8.2 Dose once
every 5 days.
for better rejection in downstream system (BWRO) Duration: 1
hour

Permeate Water (PW) Flushing

 SWRO system must be flushed with permeate water to
remove high salt concentration from Pressure Vessel.
 Flushing is done at low pressure
 Flushing facility (RO CIP Tank & RO CIP Pump) is available
System Description: Chemical System for
SWRO
Biocide
1 x 100% Storage
Tank & 2 x 100%
of Dosing Pump

SBS/Antiscalant
1 x 100% Storage
Tank & 3 x 50%
of Dosing Pump
 SWRO SKID

Feed water inlet to SWRO Low pressure SWRO Permeate

modules after boosted by SWRO reject
ERD PFD

High pressure
SWRO Reject

Feed from SWRO

HP Pump SWRO Off Spec
Flushing Reject
Permeate
SWRO SKID PHOTO
Cleaning In Place (CIP) for RO

 Elements must be cleaned before fouling is fully developed.

Fouling of the membrane surface will result in a
performance decline, i.e. lower permeate flow rate and/or
higher solute passage and/or increased differential pressure
loss from feed side of a stage to the brine side.

 CIP process to be conducted manually by operator

Cleaning In Place (CIP) for RO

Commence cleaning when

1. Normalized differential pressure increases more than 20%

OR
2. Normalized permeate flow rate decreases by more than 10%
OR
3. Normalized salt passage increases by more than 20%.
Cleaning In Place (CIP) for RO

 RO CIP System including 1 no. RO CIP Tank, 1 no. RO CIP

Cartridge Filter and 3 nos. of RO CIP Pump
 RO CIP Pump is also used for Permeate Water Flushing for
SWRO Module
 Both SWRO & BWRO share 1 CIP System
OPERATION PHILOSOPHY
OF
SWRO SYSTEM
Overview of SWRO System

SWRO Cartridge SWRO Cartridge

Filter Differential Filter Outlet ORP
Pressure Indicator Analyzer
Switch

UF Filtrate Tank
ORP/pH/Conductivity
Analyzer
 Overview of SWRO System

SWRO HP Pump SWRO Module Feed SWRO Module SWRO Module

Suction Pressure Pressure Switch Permeate Flow Permeate Conductivity
Switch Transmitter Analyzer

SWRO Module Feed SWRO Module Reject

Pressure Transmitter Pressure Transmitter
 Operation Parameter

 SWRO Feed Water (UF Filtrate) Quality:

 Alarm when high/low ORP (detected by AIT-23008)
 Alarm when high conductivity (detected by AIT-23009)
 Alarm when high/low pH (detected by AIT-23009) & prohibit
SWRO system to operate if HH/LL pH is detected

 SWRO Module in Auto Operation: Maximum 2

 Common SWRO Operation Parameter shall be set:

Membrane
acceptable range:
2 to 11
Adjust SWRO
permeate to
higher pH, to Enable for dosing
enhance once timer is up
alkalinity
rejection in
BWRO
Operation Parameter

 Individual SWRO Operation Parameter shall be set:

Shall apply same
value for all train

Parameter Set Point Remark

SWRO Feed ORP 238 mV Monitoring the oxidant component in
SWRO feed water. Control the SBS
dosing rate
Product Flow 104 m3/h Designed Capacity. Set point value for
SWRO HP Pump VFD to modulate
pump speed.
Differential Pressure HH: 4 kg/cm2 Reference value for below action:
H: 1.5 kg/cm2 HH: Shutdown SWRO Operation
H: Initiate “CIP Cleaning” message
H Permeate Conductivity 1000 µS/cm SWRO Treated Water Quality:
Maximum 600 ppm of TDS

Standby Timer 48 hours Reference value for SWRO train switch

over for duty
 Operation Philosophy: Service

Step 1: Pre-Service Dump & Check ORP Measure ORP

when pre-service
dump timer is up.

1. Start SWRO Dosage adjusted

Feed Pump corresponded to
2. Drain to ORP value.
Outfall
3. Dose SBS
4. Continue
until preset
pre-dump
timer is up
 Operation Philosophy: Service

Step 2: Service (Start High Pressure System) SWRO

permeate will
be dumped to
Outfall. After 5
mins, check
conductivity

1. Open
Cartridge
Filter Outlet
Valve, and
This flushing
Flushing
valve is closed
Valve
when SWRO
2. SWRO HP HP Pump start
Pump start
ramp up
after 5 mins
delay
3. Start dose
antiscalant
 Operation Philosophy: Service

Step 2: Service (Conductivity below Set Point)

Permeate
conductivity
below set point,
permeate water
will be directed
to SWRO
Product Tank

Start NaOH
Dosing Pump to
increase pH of
SWRO
1. Dosage of
permeate before
SBS is
pumping to
corresponded
BWRO System
to ORP value
2. Antisclant
dosage is
fixed
Operation Philosophy: Shutdown

 In case of Abnormal Critical Operation occurs, SWRO

will proceed to shutdown.
Parameter
SWRO Cartridge Filter Outlet ORP > HH
SWRO HP Pump Suction Pressure Switch
Activated
SWRO Module Feed Pressure Switch
Activated
SWRO Module Feed Pressure > HH
Instrumentation
Detected by AIT-23016 A/B/C
Detected by PS-23017 A/B/C
Detected by PS-23019A/B/C
Detected by PIT-23021 A/B/C

SWRO Module Reject Pressure > HH Detected by PIT-23023 A/B/C

Permeate
Dumping,
Differential Pressure of SWRO Module > HH PIT-23021 A/B/C – PIT-23023 A/B/C recheck
conductivity

SWRO Module Product Conductivity > H Detected by AIT-23015 A/B/C

UF Filtrate pH < LL or > HH Detected by AIT-23013 A/B/C

Note: Shutdown procedures will proceed automatically without activation

by operator
 Operation Philosophy: Shutdown

Step 1: Shutdown (SWRO HP Pump Ramp Down)

1. Open
Permeate Off
Spec Valve and
close Permeate
Outlet Valve.

2. SWRO HP
Pump ramp
down slowly

3. Antisclant
Dosing Pump
stop when
SWRO HP Pump
start ramp down.
 Operation Philosophy: Shutdown

Step 2: Shutdown (SW Flushing)

2. SW Flushing:
SWRO Feed
Pump continue
running until pre- 1. Flushing
set SW Flushing Valve open
timer is up. after SWRP
HP Pump
fully stop
 Operation Philosophy: Shutdown

Step 3: Shutdown (Completion of SW Flushing)

2. Valve close
after SWRO
Feed Pump stop
1. SW Flushing:
SWRO Feed
Pump Stop when
timer is up

3. SBS Dosing
Pump stop
when SWRO
Feed Pump
Stop
Operation Philosophy: PW Flushing

Step 4: PW Flushing
Valve open
1. Valve for
open
PW Flushing
for PW
Flushing

2. Pump run after

Flushing Inlet Valve
& Flushing Valve are
Opened. Continue
until preset PW
Flushing timer is up
Operation Philosophy: PW Flushing

Step 5: Completion of PW Flushing

3. This valve
always remains
in OPEN
position until
next service
cycle starts

1. Pump stop when

2. Valve
Valve close
close pre-set PW Flushing
after pump stop timer is up
SWRO CIP Operation

 CIP operation shall be conducted manually by

operator
 Frequency: Every 3 months or High Differential
Pressure alarm is activated
 At all time, only 1 train of SWRO modules can be put
to cleaning
 Run 2 RO CIP pumps in parallel ( 2 x 100m3/h)
SWRO CIP Procedures

1. Update SWRO status to CIP “In Process”

2. Isolate from other system

3. Connect the CIP Inlet/Outlet by flexible hose
SWRO CIP Procedures

4. Prepare chemical, mixing by recirculating RO CIP Pump

discharge flow
5. Load new cartridges into RO CIP Cartridge Filter
6. Start RO CIP Cleaning steps. There is 5 steps of cleaning
7. After completion of CIP, dismantle the flexible hose
8. Update SWRO Status to “Completed”
SWRO CIP Procedures

Cleaning Chemicals:
CIP Chemical Condition
Calcium scale Citric acid 1 –2 %, adjust pH value: 2 – 4
Metal hydroxides with ammonia (NH3)
Inorganic colloids
Organic matter, Dodecyl Sodium Sulfate pH value : 7 – 11,
bacterial matter (DSS, Sodium Lauryl adjust with
Sulfate), sodium hydroxide,
0.03 - 0.2% with alkaline
solution

Acid insoluble SHMP 1 % pH value 2;

Scaling Sodium adjust with
CaF; BaSO4; hexametaphosphate hydrochloric acid
SrSO4;CaSO4
SWRO CIP Cleaning Steps

Step 1: 1st Recycle

Running 2 RO CIP Pump in

parallel for 30-60 minutes.
Cleaning all 25 nos. of vessels
SWRO CIP Cleaning Steps

CIP Inlet

Must close this SWRO Permeate

Isolation Valve (BUV-
0703/0803/0903)

Open this SWRO

Permeate Drain Valve
(BAL-
0701/0801/0901), to
drain out CIP chemical
waste

CIP Outlet
SWRO CIP Cleaning Steps

Step 2: Soak
 RO CIP Pump Stop, allow membrane to soak overnight for
10 to 15 hours
Step 3: 2nd Recycle

 Repeat as per Step 1.

Step 4: Drain
 Discharge chemical via Cartridge Filter Drain Valves (BAL-
1033 & BAL-1034). Close the CIP Cartridge Filter Outlet
Valve (BUV-1315).

CLOSE
`

OPEN
SWRO CIP Cleaning Steps

Step 5: Flushing
 Top up BWRO Permeate into RO CIP Tank. Flushing the
membranes by running 2 nos. of RO CIP Pump for 60 to 120
minutes
 Check pH (AIT-23051) to ensure chemical is fully flushed
out
SWRO Operation: Biocide Dosing

 Biocide is dosed intermittently to prevent biofouling.

 Recommended duration is every 5 days of service duration.
 There is pre-set & counter timer available for Biocide Dosing
 Upon timer is up, operator enable to start Biocide Dosing
and dosing duration shall be set by operator
 Upon completion of biocide dosing, the counter will reset

If preset timer is up, enable

biocide dosing

Dosing duration is adjustable

SWRO Operation: Biocide Dosing

Biocide dosing
happen when
the SWRO train
is in service
DAILY OPERATION
MONITORING &
MAINTENANCE
FOR SWRO SYSTEM
Daily Operation Monitoring

 It is important for operators to follow daily

operation schedule

 Small issues can be detected earlier and

rectification work can be done before problem
develop into major problem

 Ensure proper operation of plant to achieve

performance

 Instrument data or trending should be checked

if abnormal reading/trend is found

 Maintain a log look where all relevant

operational events are recorded.
Daily Operation Monitoring

Parameter Instrumentation Action/Remark

pH of UF Filtrate AIT-23013 To ensure feed water quality do

ORP of UF Filtrate AIT-23008 not exceed design limit
Conductivity of UF AIT-23009
Filtrate
High Differential DPS-23015 A/B/C As indication where cartridge
Pressure for SWRO replacement is required
Cartridge Filter
SWRO Cartridge Filter AIT-23016 A/B/C To ensure oxidant content in
Outlet ORP SWRO Feed Water do not
exceed limit
SWRO Module Feed PIT-23021 A/B/C To ensure operation of SWRO
Pressure system is smooth.
SWRO Module Permeate FIT-23024 A/B/C To ensure SWRO system is
Flow operating as per designed.

SWRO Module Permeate AIT-23025 A/B/C To confirm water quality of

Conductivity SWRO Permeate meet
requirement
Note: For others parameter, please refer to Alarm Set Point List for details.
SWRO System Maintenance

 Perform SDI test at Cartridge Filter Outlet weekly

 Replace SWRO Cartridge Filter when differential

pressure across filter > 1 bar

 Monitor flow, pressure, ORP, conductivity

 Perform RO CIP when

 Pre-set High differential pressure alarm is activated
 Normalized permeate flow drop by 10%
 Normalized salt passage increase by 20%
System Performance Normalization

 As discussed, RO system is influenced by the feed

water composition, feed pressure, temperature and
recovery

 Measured Permeate Flow and Salt Passage have to be

normalize to distinguish the performance change

 The initial performance data shall be used as reference.

 This procedure is strongly recommended because it

allows an early identification of potential problems
when the normalized data are recorded daily
TorayTrak

 To assist in RO System performance data

normalization. TORAY developed a RO Performance
Data Normalization Program called TorayTrak.

 TorayTrak is available as free download at the Toray

web site www.toraywater.com.
 START UP OF
SWRO SYSTEM
Start-up of SWRO System

 Before Start-up Operation, ensure that:

 Sufficient chemical in SBS Storage Tank (2301-L9F),
Antiscalant Storage Tank (2301-L11F) and NaOH
Storage Tank (2301-L8F)
 UF Filtrate Tank (2301-L2F) is filled with UF Filtrate
 Final Check Basin is ready to receive SWRO brine
 Ensure all the manual isolation valves and
instrument isolation valves along the flow paths are
opened
 Ensure that SWRO Cartridge Filter (2301-L3LA/B/C)
are loaded with cartridges
Chemical Storage & Dosing System

 Top up chemical into Chemical Storage Tanks

 Calibrate Dosing Pump according to design dosage
 Determine the dosage of chemical required
 Calculate the dosing rate as following

 For Manual Stroke Pump, adjust pump stroke

manually to achieve the required dosing rate
Chemical Storage & Dosing System

Chemical Dosage
Antiscalant for SWRO 3.5 ppm
Biocide for SWRO 30 ppm

Note:
1. Dosage to be confirmed during commissioning.
2. Antiscalant dosage to be confirmed by chemical supplier as the
dosage may vary between different suppliers.
3. Chemical program to be reviewed when there is significant change
in feed water quality.
Chemical Storage & Dosing System

 For Auto Stroke Pump, the dosing rate will be

adjusted automatically corresponding to feedback
from dedicated analyzer

Chemical Dosage
SBS for SWRO Feed Dosing rate is adjusted
corresponding to feedback from
SWRO Cartridge Filter Outlet ORP
(AIT-23016 A/B/C) to maintain DO ≤
238 mV

NaOH for SWRO Dosing rate is adjusted

Permeate corresponding to SWRO Permeate
Combine Outlet pH Analyzer (AIT-
23026) to maintain pH of 8.2.
Start-up Procedures

1. At the HMI, select “AUTO” mode for below equipment:

 All On-Off Valves corresponding to SWRO system
 SBS Dosing Pump (2301-L13JA/B/C)
 Antiscalant Dosing Pump (2301-L15JA/B/C)
 NaOH Dosing Pump for BWRO (2301-L11J/JA)
 SWRO Feed Pump (2301-L3JA/B/C)
 SWRO High Pressure Pump (2301-L4JA/B/C)

2. Select SWRO Module to “Service” under “Auto” mode.

3. Service shall be started. Check for any abnormalities.

4. Collect a sample after SWRO Cartridge Filter to confirm

SDI < 3. If otherwise, check for contamination in UF Filtrate
Tank or the UF performances.
Start-up Procedures

5. Throttle integral brine control valve at SWRO ERD (2301-

L5JA/B/C) to achieve 45% recovery

6. If membranes is newly loaded or start-up after long term

shutdown, activate the “Hold” button at permeate stream to
extend flushing period. (Minimum 4 hours of flushing)

7. Continue until all operating parameter reading are stable.

Monitor the conductivity of SWRO product and others
operation data, for e.g.: Recovery, Salt Rejection

8. After 24 hours operation, take sample from individual SWRO

vessel and check conductivity. All conductivity shall same.
(Out of specification is a sign of leaking of O-ring, Stop the
system and reload the membrane for that particular vessel).

9. After 1 week operation, review if shimming is required.

 Shimming Procedures

 It is normal to have some movement of the RO element in the

RO Vessel. This is due to pressure drop across the element
can cause them to compress.

 Movement can cause rubbing across the interconnector O-

rings, and over time and break it.

 Potential of movement shall be minimized by ensuring that

elements are fit tightly in the RO vessel. Any unwanted gap
shall be eliminated by using shim.
 Shimming Procedures

 To shim, simply place PVC “washers” of varying thickness

(1/8” to 3/8”) over the FEED side inboard adapter. Add as
many shims as necessary until the end plate fits snugly
against the shims. If necessary a shim may be removed if the
end cap is difficult to reinstall. A gap of 1.4 inch between the
end plate and the shims will not cause problems in
performance.
Shimming Procedures

After installing all membranes, check distance “A”.

If distance “A” is bigger than the thickness of shim provided
by the pressure vessel manufacturer, use the shim to fill the
excess distance. Remained distance should be smaller than
the thickness of shim. Shims must be positioned on the
upstream end of the vessel.
SHUT DOWN OF
SWRO SYSTEM
 Shutdown Procedures

1. From the HMI, select “Off” to shutdown SWRO from

service.

2. At MCC, switch to “Off” mode for all the motor that are
stopped to prevent accidental start during shutdown
maintenance.

3. Check all pressure gauges. If some point is still pressurized,

open the sampling/vent/drain valve along the line to
release pressure.

4. Ensure SWRO Permeate Off Spec Valve (BUV-053/063/073)

is kept in open position to prevent permeate backpressure
acting on membrane
Shutdown Procedures

5. SWRO system can be stopped for 48 hours without

preservation but precautions like daily flushing is needed to
prevent microbiological fouling.

6. Daily flushing: Conduct Permeate (PW) Flushing under

“Manual” mode.

7. If the SWRO system has to be shutdown for extended period

of time longer than 48 hours, take care below:
 The elements do not dry out. Dry elements will irreversible
lose flux
 RO membranes are flushed with RO permeate every 24
hours
 If no flushing is done, chemical preservation is necessary.
Shutdown Recommendations

Preservation of RO Membranes shall be as follow:

 Type of chemicals: Formaldehyde, Sodium Bisulfite,
Hydrogen Peroxide
 Recommended: 1000 ppm of Sodium Bisulfite Solution
 Run the RO CIP Pump to replace the water in RO Module
with preservative.
 Close all valves to retain the chemical in the RO Module.
This is to prevent oxidation of chemical, rendering it
ineffective.
 Preservative solution shall > 3.2 , if pH srop, replace fresh
solution
 Check the permeate pressure is not greater than feed
pressure.
 Repeat the procedures to replace fresh solution:
 Every 15 days if temperature > 27oC
 Every 30 days if temperature < 27oC
TROUBLESHOOTING
OF
SWRO SYSTEM
Troubleshooting

 Potential problem in RO System can be recognized by early

monitoring the changes of Permeate Flow, Salt Passage and
Differential Pressure of RO system.

 Recommend that operator record and review operation

data frequently.

 Basic steps of troubleshooting:

Check Calibration of Instruments

Review Daily operation data, maintenance logs,
normalized data, comparison of current
performance to design specification
Investigate Reason of performance changes and
possible causes
Troubleshooting Initiate corrective action e.g. chemical
cleaning, replacement of defective parts
RO Vessel Probing Procedures

 Probing: Inserting a semi-rigid tubing into the permeate

channel of the pressure vessel to measure water quality at
different length of RO vessel.

 Probing is required to check whether there is a problem in

a particular vessel.

 Possible Problem: O-ring leak, cracked adaptor, or poor

performance of membrane
RO Vessel Probing Procedures

1. Obtain a piece of 3/8 inch SS316 tubing, the tubing shall be

several feet longer than the length of RO vessel
2. Close the Vessel Sampling Valve. Start SWRO system and
let it run for 15 minutes.
3. Insert tubing into the RO vessel and push the tubing until
it reaches the last element.
4. After 1 minute, measure the conductivity come out from
the tubing.
5. Recheck several time to make sure the values are constant.
6. Pull the tubing out one membrane length as guide, wait for
1 minute and check conductivity.
7. Repeat step 4 to 6 until the tubing come outs of the RO
vessel.
8. Chart the value of permeate conductivity versus length of
vessel.
RO Vessel Probing Procedures
Interpreting Probing Data

 Normal conductivity profile shows steady increase of the

permeate conductivity at feed side of the pressure vessel
toward the end of the RO vessel.

 Sudden increase of permeate conductivity at junction

between element indicate O-Ring Problem or disconnect
between the elements. (Replace O-ring or ensure the
connections are in order).

 Sudden increase conductivity outside this region, indicate

element problem. (Replace RO membrane).
Troubleshooting

Lost of salt rejection or loss of permeate are the most common

problem encountered in RO system.
Salt Permeate Differential Direct Indirect Corrective
Passage Flow Pressure Cause Causes Measure
↑ ↑ ↔ Oxidation Free Chlorine, Replace
Damage ozone, KMnO4 membrane
↑ ↑ ↔ Leaking of Improper Replace O-ring
O-ring installation
↑ ↑ ↔ Leaking of Permeate  Replace
membrane backpressure, damaged
abrasion membrane
 Check
pretreament
↑ ↓ ↑ Colloidal Failure of  Check SDI
Fouling Fouling Control of feed water
at regular
basis.
 Clean RO
membrane.
 Improve
pretreatment
Troubleshooting

Salt Permeate Differential Direct Indirect Corrective

Passage Flow Pressure Cause Causes Measure
↑ ↓ ↑ Scaling Insufficient  Scale
scale control control
 Cleaning
↔ ↓ ↑ Biofouling Contaminated  Disinfection
raw water  Improve
pretreatment
Insufficient
pretreatment
↓ ↓ ↔ Membrane Water hammer/  Replace
compaction high feed damage
temperature/ membrane
pressure
↔ ↓ ↔ Organic Oil, cationic  Cleaning
Fouling polyelectrolytes  Improve
pretreatment

↑ Increasing ↓ Decreasing ↔ No Changing

SAFETY PRECAUTION
Safety Precaution

IN USING ANY CHEMICALS, FOLLOW ACCEPTED SAFETY

PRACTICES. ALWAYS WEAR EYE PROTECTION AS
MINIMUM, IN CASE OF HANDLING CORROSIVE
CHEMICALS, WEAR FULL FACE COVER AND PROTECTIVE
CLOTHING. REFER TO RELEVANT MATERIAL SAFETY
DATA SHEETS AS SUPPLIED BY CHEMICALS
MANUFACTURERS.

BEFORE DRAINING ANY CHEMICALS FROM STORAGE

TANKS, RUN SERVICE WATER TO THE CHEMICAL DRAIN
POINT. SLOWLY OPEN THE CHEMICAL DRAIN VALVE AND
FLUSH GENEROUSLY WITH SERVICE WATER.
Safety Precaution

ALWAYS WEAR SAFETY HELEMT AND BOOSTS

AT ALL TIME WITHIN PLANT AREA
QUESTIONS ??
QUIZ
 Quiz: SWRO
1. There is how many SWRO train in BAP plant?

2. In BAP Plant, what it the method to remove free chlorine?

3. What is the SDI requirement for RO feed water?

4. How to calculate RO Recovery %?

5. How to measure SDI?

6. Which device is used to recover the energy from SWRO reject?

7.
8. Which chemical is dosed to prevent membrane scaling?

9. During PW Flushing, how many RO CIP pump is running?

10. How to initiate RO CIP?

11. When cartridge replacement is required?

12. How to check which RO vessel has problem?

13. Which chemical is dosed intermittent? And what is the purpose?

THANK YOU