FEDCO HPB-2800 Installation & Operation Manual
English Version
INSTALLATION & OPERATION MANUAL
HPB™
HYDRAULIC PRESSURE BOOSTER
Models: HPB-2800
www.fedco-usa.com
ONE COPY OF THIS MANUAL MUST REMAIN WITH THE EQUIPMENT AT ALL TIMES
HPB-2800 Installation Operation Manual, 01-28C-XXXXXX-0
HPBTM Series
REGISTERED
ISO
ISO
REGISTERED
FEDCO Certications
ISO 9001 and ISO 14001:
FEDCO has adopted the ISO 9001 standard to dene and develop our Quality Management System (QMS.) The QMS allows FEDCO to better serve our customers’ needs
through continuous improvement of the quality, delivery, and eciency of our products.
3 FEDCO achieved ISO 9001 registration in September 2017.
FEDCO has adopted the ISO 14001 standard to dene and develop our Environmental
Management System (EMS) to better protect our environment.
3 FEDCO achieved ISO 14001 registration in September 2017.
14001:2015
9001:2015
CE Stamp:
CE marking conrms that specic products are in compliance with European Union
requirements. This allows FEDCO’s product lines to be sold throughout the European
Economic Area. Most FEDCO products can be provided with the CE mark.
Compliant Test Systems:
Performance acceptance testing of FEDCO pumps and energy recovery devices are
measured using procedures and instrumentation tested by a third party NSF® auditing
company to be in accordance to the Hydraulic Institute’s H.I. 14.6 standards for cen-
trifugal pump testing and data recording.
www.fedco-usa.com
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HPBTM Series
Commitment to Quality & Success
Fluid Equipment Development Company (FEDCO)
was founded in 1997 to develop new uid machinery
to reduce the cost of reverse osmosis desalination.
The results included patented concepts, highly integrated design, superior production software, and
sophisticated manufacturing processes. Our eorts
culminated in multiple lines of energy recovery tur-
bines and pumps uniquely suited for seawater and
brackish RO desalination.
We are the developers of the HP-HEMI™ ERD and
control system for mega-scale SWRO systems, as
well as the world’s rst low-cost integrated pump-ERD
for brackish water RO. Additionally, our Monroe facility
operates the largest pump and ERD test system dedicated to SWRO systems in the world.
Our teams of talented and energetic engineers,
manufacturing specialists and systems experts have
created a fully integrated enterprise with one aim – to
provide our customers with customized uid machines
with exceptional eciency and low capital cost cou-
pled with customer service that exceeds their expectations. The results include new designs, technology,
manufacturing processes, and standards. Our pumps
and ERDs use bearings that are lubricated by feed or
brine to eliminate the numerous maintenance and logistics issues associated with oil or grease lubricated
bearing systems. We oer three materials of construction: Duplex SS, Super Duplex SS and 316 SS.
FEDCO pumps only cover ows and pressures found
in BWRO and seawater SWRO applications. They are
designed for clean uids and are optimized for typical
suction pressures in RO systems. Our ERDs include
variable area nozzles that meet typical brine pressure
variations. Our products eliminate external tubing carrying high pressure feed or brine that can fail creating
hazards to personnel and equipment. Our units are
designed for operation and maintenance by unskilled
personnel in the harshest of desert or marine environments.
With the longest warranty and the highest eciencies,
our product lines are unmatched in quality and per-
formance by any manufacturer in the RO equipment
market. FEDCO is a widely recognized supplier with
thousands of units installed around the world.
We design uid machines to take full advantage of the
technical characteristics of the membrane process.
FEDCO USA
FEDCO
800 Ternes Drive
Monroe, MI 48162, USA
Telephone: +1 (734) 241-3935
Fax: 734-241-5173
Email: sales@fedco-usa.com
Oce 1910 | Concord Tower
P.O. Box 282102 | Media City
Dubai, United Arab Emirates
Telephone: +971 (0)4 242 3856
Email: sales@fedco-usa.com
FEDCO UAE
Fax: +971 (0)4 242 3856
www.fedco-usa.com
For patent coverage visit patent.fedco-usa.com
© Copyright 2018 Fluid Equipment Development Company | www.fedco-usa.com
Eli Oklejas - FEDCO CEO
FEDCO SINGAPORE
(No Oce Address)
Telephone: +(65) 9784 3813
Email: sales@fedco-usa.com
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Table of Contents
HPBTM Series
Unpacking/ Inspection/ and Storage ...........5
HPB External Components ......................... 5
Inspection of Unit Upon Receipt ................. 5
Pump Storage Requirements...................... 6
Long-Term Storage (>6 Months) Checklist . 6
Theory and Operation ...................................7
HPB External Components ......................... 7
Installation Procedures .................................8
Warnings and Safety Precautions ............... 8
User Health and Safety .............................. 9
Booster Installation Requirements .............. 9
Lifting and Handling ................................. 10
Baseplate Installation ............................... 11
Installation Congurations......................... 12
Booster Piping Connections...................... 14
Recommended Instrumentation and
Operation With VFD .................................. 18
Upstream Filtration.................................... 18
Start Up Check List .................................. 19
Preparation For Booster Start Up ............. 19
Start Up Precautions ................................. 19
Booster Start Up ....................................... 19
Basic Troubleshooting ................................20
Visual Inspection ....................................... 20
Troubleshooting Chart ............................... 21
Specications ..............................................22
Fastener Torque Specications ................ 22
Lubricants and Compounds ...................... 22
Maintenance Schedule ............................. 23
Service Parts Kits...................................... 23
Ordering Parts........................................... 23
Service Policy ..............................................24
Return Material Authorization (RMA) ....... 24
Procedure ................................................. 24
Warranty Registration Form .......................27
HPB Unit Operating Conditions .................28
Notes.............................................................28
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HPBTM Series
Unpacking/ Inspection/ and Storage
HPB External Components
Inspection of Unit Upon Receipt
• Review the contents of the packing list to make sure all components have been included.
• Inspect all components for signs of damage which may have occurred during shipping.
• If damage is present or if the contents are incomplete, please contact your shipping company
or a FEDCO representative before proceeding.
6
5
4
3
2
1
13
7
5
8
3
9
10
11
14
12
Item Description Item Description
1 Brine outlet 8 Pump casing
2 Turbine end cap 9 Pump end cap
3 End cap lifting eye 10 Feed inlet
4 Turbine casing 11 Unit nameplate
5 Hoist ring 12 Base Feet
6 Feed outlet 13 Actuator assembly (optional)
7 Brine intlet 14 Foundation plate
Figure 1 - HPB-2800 Booster External Components
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Unpacking/ Inspection/ and Storage Continued
HPBTM Series
Pump Storage Requirements
• The HPB™ unit must be protected from
sand, grit, and other foreign matter. For
long-term storage, the booster and all
other components should remain in their
original un-opened state. Both the unit
and its actuator (if equipped) are wrapped
and sealed in water/humidity proof foil with
desiccant bags added. The unit may be
stored at a temperature of 5-50° C or less
and/or a humidity level or 75% or less for an
indenite period of time. Do not remove the
protective covers until ready to install.
PROTECTIVE COVERS
Long-Term Storage (>6 Months) Checklist
1. Check caps to ensure they have not been
damaged or allowed debris inside the unit.
• Check for debris (wood, slag, sand or any
dirt) and clean up with a clean, wet rag if
minor.
2. Check rotor:
• Turn manually (through feed inlet) and
check for ease of turning.
• Check for axial movement.
3. Seal check:
• Prime HPB with clean water and allow the
O-rings to soak for 1 hr before start-up.
Check for leaks at end cap and aux valve.
Figure 2 - Proper HPB Storage
(Actuator Shipped Separately)
NOTES: Actuator manual provided by its manufacturer. Actuator installation, operation and
maintenance is not included in FEDCO HPB manual.
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HPBTM Series
Theory and Operation
HPB External Components
The Hydraulic Pressure Booster™ or HPB™ is designed to provide brine energy recovery in
reverse osmosis (RO) systems. The HPB™ is energized by the high-pressure brine stream which
causes the HPB™ to generate a large pressure boost in the feed stream independent of the high
pressure feed pump.
The HPB™ is typically installed between the
high pressure feed pump and the membrane.
The feed passes through the pretreatment
system and then passes through the feed
pump which raises the feed pressure. The
pressurized feed passes through the HPB™,
which provides an additional pressure increase
before passing to the membrane. The high
pressure brine steam from the membrane is
directed back to the HPB™.
Motor
Throttle Valve
High Pressure
Pump
HPB™
The HPB™ recovers the pressure energy and
discharges the brine at low pressure for disposal. The HPB™ does not require a brine
disposal pump or gravity ow piping as the
brine can be discharged against a back pres-
sure. The HPB™ reduces feed pump energy
consumption and allows use of a smaller feed
pump, smaller motor, smaller motor starter,
electrical wiring, etc.
High Pressure Location
Feed
Brine
High Pressure
Brine Stream
Permeate
Product
Brine Outlet
Figure 3 - Hydraulic Pressure Booster Flow
Motor
Throttle Valve
High Pressure
Pump
Location
High Pressure
Feed
Brine
Permeate
Product
First Stage
Brine
Brine Outlet
HPB™
Brine
High Pressure
Brine Stream
Permeate
Product
Figure 4 - Interstage Boosting Pump Conguration
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Installation Procedures
Warnings and Safety Precautions
Safety practices and precautions for the operation
and maintenance of all FEDCO pump products
and energy recovery devices MUST BE FOLLOWED. This information supplements oral or
written instructions that may be received. Safety
MUST be practiced as part of the standard oper-
ating procedures for this equipment during any
installation and operation. To ensure that safe
operating and maintenance procedures are followed, operators should develop and keep up
a program of safety checks and current instructions. This manual contains certain operating and
maintenance procedures that involve exposure
to potentially hazardous situations. The levels of
hazardous situations are as follows:
HPBTM Series
DANGER
WARNING
CAUTION
ELECTRICAL
HAZARD
PUNCTURE
HAZARD
Hazards which are IMMEDIATELY ACCESSIBLE, and capable of
causing SEVERE PERSONAL INJURY OR DEATH.
Hazards which are NOT IMMEDIATELY ACCESSIBLE, but are
capable of causing SEVERE PERSONAL INJURY OR DEATH.
Hazards which are NOT IMMEDIATELY ACCESSIBLE, and can
cause PERSONAL INJURY.
Hazards which are related to Electrical Components and can
RESULT IN ELECTRICAL RISKS, SHOCK, ELECTROCUTION
OR DEATH if instructions are not followed properly.
Hazards which are NOT IMMEDIATELY ACCESSIBLE and can
RESULT IN SEVERE PERSONAL INJURY OR DEATH if instructions are not followed properly.
© Copyright 2018 Fluid Equipment Development Company | www.fedco-usa.com
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HPBTM Series
Installation Procedures Continued
WARNING
All HPB and safety precautions must be followed to prevent physical injury to the operator.
It is illegal to operate the equipment in an EU
member state if the manual(s) is not written in
that states language. Contact FEDCO if a translated copy is needed.
CAUTION
A hydraulic pressure booster (HPB) is a pressure-generating device with rotating parts that
can be hazardous. Any device containing generated pressure can rupture, explode or discharge
its contents if it is suciently over-pressurized
and may possibly result in personal injury, prop-
erty damage, environmental damage and death.
All necessary precautions must be exercised
to insure over-pressurization does not occur.
FEDCO will not accept responsibility for physical
injury, damage or delays caused by a failure to
observe the instructions in this manual.
WARNING
Installation, operation or maintenance of the
booster unit in any manner which is not covered
in this manual could cause damage to the equipment, serious injury or death. This includes any
modication to the equipment or the use of parts
not provided by FEDCO. If there is a question
regarding the intended use of the equipment,
please contact a FEDCO representative before
proceeding.
User Health and Safety
Safety equipment and PPE (Personal Protection Equipment) should be used in accordance with company regulations.
In the Work Area
• Always keep the work area clean and dry.
• Avoid all electrical dangers. Be aware
of risks from electric shock or arc ash
hazards.
• Utilize adequate lifting equipment and
methods.
Booster Installation Requirements
A rigid mounting surface is required for the
hydraulic booster assembly in order to prolong
the life of critical components. Mounting surfaces constructed of wood or other non-rigid
materials are NOT acceptable as they may
deect during operation. All anchoring fasten-
ers used should meet or exceed manufactur-
ers specications. All units must be mounted
on one of three types of substrates:
• concrete foundation.
• container with a suitable steel
substructure.
WARNING
Do not use the equipment for a dierent application than originally specied without the approval
of a FEDCO representative.
WARNING
FEDCO boosters are not intended for ammable or hazardous liquids. Solutions intended
for human consumption need proper purication
per product. FEDCO approval will be needed to
control slurry and particle size for this specic
product
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