GE E4H-CE, E8-CE User Manual

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E4H-CE AND E8-CE SERIES
WATER PURIFICATION
MACHINES
3 m
3
/hr to 45 m3/hr
18,000 gpd to 288,000 gpd
Manual
INSTRUCTIONS FOR E4H-CE AND E8-CE
WATER PURIFICATION
OPERATION AND MAINTENANCE MANUAL
T
ABLE OF CONTENTS
Page
1.0 DESCRIPTION 1
1.1 Definitions 1
1.1.1 Permeate Rate 1
1.1.2 Concentrate Rate 1
1.1.3 Feed Rate 1
1.1.4 Reverse Osmosis 1
1.1.5 Membrane Elements 2
1.1.6 Clean-In-Place 2
1.1.7 Flow Control Center 2
1.1.8 Average Pressure 2
1.1.9 Concentration 2
1.1.10 Salt (Ionic) Passage 3
1.1.11 Recovery 3
1.1.12 Salt (Ionic) Rejection 3
1.2 Machine Nomenclature 5
1.3 Features 5
1.4 Specifications for E-CE Series Machines 7
1.4.1 Feed Water Specifications 8
1.4.2 Permeate Flow Rate 8
1.4.3 Concentrate Flow Rate 8
1.4.4 Pressure Range 8
1.4.5 Reverse Osmosis Membrane Element Rejection 9
2.0 INSTALLATION 10
2.1 Feed Water Requirements 10
2.2 Mounting 10
2.3 Plumbing 11
2.4 Power and Electrical Requirements 11
3.0 PREPARATION FOR START-UP 12
3.1 Pretreatment for Water Purification 12
3.2 Initial Start-Up 12
3.3 Daily Start-Up 16
Page
4.0 MACHINE OPERATION AND MAINTENANCE 17
4.1 Daily Log Sheets 17
4.2 Pre-Filter Cartridge 17
4.3 Cleaning 17
4.4 Draining Machine for Shipment 19
4.5 Membrane Element Replacement 19
4.6 Membrane Element Removal 21
5.0 FIELD INSTALLED ACCESSORIES 22
5.1 Pretreatment Shutdown 22
5.2 Permeate Flush 22
5.3 Chemical Pump 24
5.4 Clean-In-Place Installation 24
6.0 TROUBLESHOOTING 25
7.0 FORMS 33
7.1 Return Goods Authorization (RGA) 33
7.2 Start-Up Data Sheet 34
7.3 Daily Log Sheet 35
8.0 WARRANTY/GUARANTEE 36
8.1 Warranty Terms 36
8.2 Warranty Commencement Date 36
8.3 Warranty Service 36
8.4 Voidability of Warranty 37
8.5 Limitations and Exclusions 37
Page
LIST
OF
FIGURES
Figure Title
1.1 Normal Versus Cross Flow Filtration 1
1.2 Membrane Element With Interconnectors 2
1.3 Principles of Operation 3
LIST
OF T
ABLES
Figure T
itle
1.1 Flow Specifications for E-CE Reverse Osmosis Machines 7
1.2 Minimum/Maximum Boost Pressure 8
1.3 Membrane Element Specifications 9
2.4 Feed Water Requirements 10
2.5 Connections 11
1.0 DESCRIPTION
E-CE Series Reverse Osmosis (RO) machines are durable pieces of equipment, which, with prop­er care, will last for many years. These instructions give operation and maintenance details vital to the sustained performance of the machine. Please read completely before operating your machine.
1.1 Definitions
The operating definitions provided below will help you further understand your machine and this manual.
1.1.1 Permeate Rate (Product Water Rate) [Qp]
The Permeate Rate is the flow rate of purified water that passed through the mem­brane element and out of the membrane element in liter/min (Lpm), cubic meters/hour (m
3
/h), gallons/min (gpm) or gallons/hour (gph). Specified perme­ate rates are based on a feed water temperature of 25°C (77°F). Permeate rate will vary with temperature.
1.1.2 Concentrate Rate (Wastewater Rate) [Qc]
The Concentrate Rate is the flow of incoming water in Lpm or m
3
/h (gpm or gph).
1.1.3 Feed Rate [Qf]
The Feed Rate is the flow rate of incoming water in Lpm or m
3
/h (gpm or gph).
Feed water rate equals permeate plus concentrate rate.
1.1.4 Reverse Osmosis
Reverse Osmosis (RO) is the separation of one component in a solution from another component of a solution from another component by means of pressures exerted on a semi-permeable membrane element. The feed solution is separated into two streams, permeate and concentrate, and collected from both sides of the membrane element.
Figure 1.1
Normal Versus Cross Flow Filtration
1
1.1.5 Membrane Elements
Membrane elements are interleaved layers of semi-permeable membrane, spacer, and permeate carrier spiraled around a central permeate tube make up the mem­brane element.
Figure 1.2
Membrane Element with Interconnectors
1.1.6 Clean-In-Place
The abbreviation for Clean-In-Place is CIP.
1.1.7 Flow Control Center
The Flow Control Center features a concentrate flow control valve, a recycle flow control valve, and a pressure gauge. It is located directly behind the control enclo­sure.
1.1.8 Average Pressure
P
AV G
(Average Pressure) = [(P
PRIMARY
+ P
FINAL
) ÷ 2]
1.1.9 Concentration
Concentration equals the Total Dissolved Solids (TDS) concentration of a solution expressed as conductivity (µS/cm) or parts per million (ppm).
2
C
f
= Feed Concentration
C
p
= Permeate Concentration
C
c
= Concentrate Concentration
C
avg
= Average Concentration in Machine
1.1.10 Salt (Ionic) Passage
Ionic Salt Passage equals the percent of dissolved salts passed through the mem­brane element or 100% minus rejection.
1.1.11 Recovery
Recovery equals permeate rate divided by feed rate and is expressed as a per­centage. For example, 75% recovery means that out of a given feed rate, 75% is produced as purified water (permeate).
1.1.12 Salt (Ionic) Rejection
Ionic Salt Rejection equals the percent of dissolved salt rejected by the membrane element, calculated from an average concentration over the membrane element.
An example of how to calculate salt rejection and recovery is below:
Figure 1.3
Principles of Operation
Given the system case in Figure 1.3:
3
Average Concentration (C
avg
) = [(Cf) + (Cc)]
2
= [(100 mg/L) + (375 mg/L)]
2
= 237.5 mg/L
4
Rejection = [(C
avg
) - (CP)] x 100
(C
avg
)
= [(237.5 mg/L) + (8.3 mg/L)] x 100
(237.5)
= 96.5%
Passage = (C
P
) x 100
(C
f
)
= (8.3 mg/L) x 100
(237.5)
= 3.5%
Recovery = (Q
P
) x 100
(Q
f
)
= (18 gpm) x 100
(24gpm)
= 75%
1.2 Machine Nomenclature
E-CE Series water purification machines are numbered in such a way as to indicate the permeate flow you can expect from the machine and other specifications:
Example: RE, E8-CE-9, 400, 5, 66 - 75
1.3 Features
E4H-CE and E8-CE water purification machines have all the features necessary for safe, continuous production of high-purity water. This assumes properly pretreated feed water with a TDS 2000 ppm and regular operator maintenance.
· Sixty-six (66) - 75% recovery (E8-CE) or 50 -75% recovery (E4H-CE). Adjust con-
centrate and recycle flows to obtain desired recovery.
· Epoxy-coated carbon steel frame.
· Three hundred fifty (350) square foot or 85 square foot (E4H-CE) membrane ele-
ments with stainless steel (SS) membrane element housings.
5
RO E8 - CE - 9 400 5 66 - 75
Machine Type Recovery Range
(Reverse Osmosis) 66 - 75% E8-CE
50 - 75% E4H-CE
Machine Series Hertz Operation
CE-E Series 5 = 50 Hertz (E8: 8-inch housings/membrane elements) (E4H: 4-inch housings/membrane elements)
CE Marked 400 VAC
3-Phase Starter
Rated Permeate Flow
[9 m
3
/hour at 25°C (77°F)]
6
· Multi-stage centrifugal pump, SS construction (SS end castings and wetted parts,
Noryl* internals) on the 3 to 3 to 34m3/hr and AS (all Stainless Steel components) on the 45m3/hr.
· Electrical package includes Programmable Logic Controller (PLC), IEC66 control
enclosure with a 24VDC control circuit, Siemens TP070 operator interface terminal, and a Siemens S7-200 PLC.
· Twenty (20)-inch, 30-inch, or 40-in SS pre-filter housing, including 5-micron car-
tridge filters, GS05-20-XK, GX05-30-XK, GX05-40-XK for the E8-CE and 20-inch PVC pre-filter housings, including 5-micron cartridge filters for the E4H-CE.
· Pre-filter, post-filter, primary, pump discharge, and final pressure gauges.
· Concentrate and permeate flow meters.
· Digital conductivity monitor, panel-mounted, for permeate quality monitoring with
high conductivity alarm.
· Gauges, valves, and rigid plumbing of SS or plastic.
·
Stainless Steel concentrate and recycle valves.
· External control capabilities (level control, pretreatment lockout).
· ALARMS included: low inlet pressure, high permeate pressure, high conductivity,
high pH, starter overload trip, and high temperature.
· Permeate purge capability.
·
High permeate pressure shutdown.
·
Low inlet pressure shutdown.
* Noryl is a trademark of General Electric Company.
1.4 Specifications for E-CE Series Machines
The machine flow specifications listed, Table 1.1 below, are based on 25°C (77°F) and 2000 ppm NaCl.
Table 1.1
Flow Specifications for
Reverse Osmosis
E-CE Machines
7
MODEL
Recovery
Units
Permeate
Rate
Concentrate
Rate
(50-66%)
Concentrate
Rate
(75%)
Feed Rate
(50-66%)
Feed Rate
(75%)
Recycle
Rate
(55-66%)
Recycle
Rate
(75%)
E4H-CE-3
50-75%
LPM/GPM
47.4/12.5
47.4/12.5
15.8/4.2
94.7/25.0
63.1/16.7
15.1/4.0
46.6/12.3
E4H-CE-%
50-75%
LPM/GPM
78.9/20.9
78.9/20.9
26.3/7.0
157.8/41.7
105.2/27.8
0.0/0.0
46.2/12.2
E4H-CE-7
50-75%
LPM/GPM
126.3/33.4
126.3/33.4
42.1/11.1
252.5/66.7
168.4/44.5
0.0/0.0
81.5/21.5
E4H-CE-9
66-75%
LPM/GPM
151.4/40.0
75.7/20.0
50.5/13.3
227.1/60.0
201.9/53.3
68.1/18.0
93.4/24.7
E4H-CE-14
66-75%
LPM/GPM
227.1/60.0
113.6/30.0
75.7/20.0
340.7/90.0
302.8/80.0
107.3/45.0
208.2/55.0
E4H-CE-23
66-75%
LPM/GPM
378.5/100.0
189.3/50.0
126.2/33.3
567.8/150.0
504.7/133.3
56.8/15.0
119.9/31.7
1.4.1 Feed Water Specifications
The feed water requirements listed in Table 1.1 must be met to ensure quality per­meate and extended membrane element life.
1.4.2 Permeate Flow Rate
Stated in Table 1.1 and on the machine serial number label (assumes no permeate back pressure, 2000 mg/L Total Dissolved Solids (TDS) maximum feed concen­tration, and rated temperature).
To estimate permeate output with back pressure, use the formula below. Maximum permeate back pressure is 80 psig (5.5 bar).
(Specified Permeate) x [(Operating Pressure) - (Permeate Back pressure)]
(Operating Pressure)
1.4.3 Concentrate Flow Rate
Stated in Table 1.1 and factory-set as stated on the serial number label.
1.4.4 Pressure Range
The Pressure Ranges listed below (Table 2.1) are boost pressure:
Boost Pressure = [(Primary Pressure - (Post-Filter Pressure)].
Table 1.2
Minimum/Maximum (Min/Max)
Boost Pressure
8
MODEL
E4H-CE-3
E4H-CE-5
E4H-CE-7
E8-CE-9
E8-CE-14
E8-CE-23
PUMP MODEL
Tonkaflo, SS2823G-50
Tonkaflo, SS2823G-50
Tonkaflo, SS2823G-50
Tonkaflo, SS2823G-50
Tonkaflo, SS2823G-50
PRIMARY PRESSURE
RANGE bar (psi)
8.6 - 15.5 (125 - 225)
7.6 - 15.5 (110 - 225)
6.6 - 14.4 (100 - 210)
6.6 - 12.8 (95 - 185)
5.2 - 9.3 (75 - 135)
1.4.5 Reverse Osmosis Membrane Element Rejection
E8-CE RO machines use Fiberglass Reinforced Plastic (FRP). E4H-CE RO machines use tape wrapped membrane elements. For more information, refer to the Spare Parts List (P/N 1233377).
Table 1.3
Membrane Element
Specifications
9
Specification
Outer Cover Material
Typical Ionic Rejection (TDS)
Nominal Permeate Flow Rate
[at 7.6 bar (110 psi)]
Typical Feed Water
Temperature Range
Maximum Temperature Range
Short-Term Cleaning
Temperature
pH Range
Chlorine Tolerance
Active Membrane Area
Average Molecular Weight
Cutoff*
E4H-CE
Tape
98.0 - 99.5%
8.3 m
3
/d (2200 gpd)
10° - 29°C (50° - 85°F)
0° - 40C (32° - 104°F)
< 43°C (110°F)
3.0 - 11.0
< 0.1 ppm
7.9 m
2
(85 ft2)
1500 MW*
E8-CE
FRP
98.0 - 99.5%
39.8 m
3
/d (10500 gpd)
10° - 29°C (50° - 85°F)
0° - 40°C (32° - 104°F)
< 43°C (110°F)
3.0 - 11.0
< 0.1 ppm
32.5 m
2
(350 ft2)
1500 MW*
* The Molecular Weight (MW) cutoff is based on the pore size of membrane elements and the
nature (size/shape) of the organic molecule.
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