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E4H-43K

GE E4H-16K, E4H-21K, E4H-27K, E4H-38K, E4H-43K Operation And Maintenance Manual

OPERATIONS AND MAINTENANCE MA
NUAL
E4H Series Water Purification Machines
16,000 GPD to 43,200 GPD
60.6 m3/day to 163.5
m3/day
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.
NOTICE
Operations and Maintenance Manual
E4H Series Water Purification Machines
Table of Contents
1. DESCRIPTION ...................................................................................................................................................................... 5
1.1 Definitions .......................................................................................................................................................................... 5
1.1.1 Permeate Rate (Product Water Rate) [Qp] ...................................................................................................... 5
1.1.2 Concentrate Rate (Reject Rate) [Qc] .................................................................................................................. 5
1.1.3 Feed Rate [Qf ] .............................................................................................................................................................. 5
1.1.4 Reverse Osmosis (RO) ............................................................................................................................................... 5
1.1.5 Membrane Elements ................................................................................................................................................ 6
1.1.6 CIP ...................................................................................................................................................................................... 8
1.1.7 Average Pressure [PAVG] ....................................................................................................................................... 8
1.1.8 Concentration ............................................................................................................................................................... 8
1.1.9 Salt (Ionic) Passage .................................................................................................................................................... 8
1.1.10 Recovery ....................................................................................................................................................................... 8
1.1.11 Salt (Ionic) Rejection ................................................................................................................................................ 8
1.2 Flow Description .......................................................................................................................................................... 10
1.3 Machine Nomenclature ............................................................................................................................................ 10
1.4 Economy (ECN) Model and Deluxe (DLX) Model Options .......................................................................... 11
1.4.1 ECN Model ................................................................................................................................................................... 11
1.4.2 DLX Model .................................................................................................................................................................. 12
1.5 Specifications for E-Series Machines ................................................................................................................. 13
1.5.1 Feed Water Specifications .................................................................................................................................. 13
1.5.2 Permeate Flow Rate ............................................................................................................................................... 14
1.5.3 Concentrate Flow Rate ......................................................................................................................................... 14
1.5.4 Operating Final Pressure ...................................................................................................................................... 14
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Operations and Maintenance Manual
E4H Series Water Purification Machines
1.5.5 Pump .............................................................................................................................................................................. 14
1.5.6 RO Membrane Rejection ....................................................................................................................................... 14
2. INSTALLATION ................................................................................................................................................................ 16
2.1 Mounting .......................................................................................................................................................................... 16
2.2 Piping ................................................................................................................................................................................. 17
2.3 Electrical........................................................................................................................................................................... 17
2.3.1 ECN Electrical System ............................................................................................................................................ 17
2.3.2 DLX Electrical System ............................................................................................................................................ 18
3. PREPARATION AND START-UP................................................................................................................................ 19
3.1 Pretreatment for Water Purification .................................................................................................................. 19
3.2 Start-Up ............................................................................................................................................................................ 20
4. OPERATION AND MAINTENANCE .................................................................................................................................... 26
4.1 Daily Log Sheets ..................................................................................................................................................................... 26
4.2 Pre-Filter ..................................................................................................................................................................................... 26
4.3 Flushing ...................................................................................................................................................................................... 27
4.4 Cleaning ..................................................................................................................................................................................... 28
4.4.1 CLEANING PROCEDURE FOR DLX AND ECN
4.5 Draining Machine for
4.6 Membrane
4.7 Membrane
5. OPTIONAL
5.1 Standard
I
nstallation ............................................................................................................................................... 30
Replacement
A
CCESSORIES
Options ........................................................................................................................................................... 33
Storage/Shipment
........................................................................................................................................... 32
................................................................................................................................................... 33
......................................................................................................... 30
MODELS:
...................................................................... 28
5.2 External
5.3 Filters and Water
5.4 Storage
Controls ........................................................................................................................................................... 34
Softeners .................................................................................................................................... 34
Tanks .................................................................................................................................................................. 34
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Operations and Maintenance Manual
E4H Series Water Purification Machines
6. TROUBLESHOOTING
7. SPARE PARTS
8. RETURN GOODS AUTHORIZATION (RGA)
9.
WARR
ANTY/GUAR
9.1 Machine
Warranty/Guarantee .............................................................................................................................. 46
9.2 Desal* Membrane Element Workmanship
10. OPERATING
LOGS
10.1 START-UP
............................................................................................................................................................. 35
LIST .................................................................................................................................................................. 42
PROCEDURE ...................................................................................... 44
ANTEE ................................................................................................................................................... 46
Warranty
............................................................................... 47
................................................................................................................................................................ 50
DATA
............................................................................................................................................................. 50
10.2 DAILY LOG FOR GE WATER & PROCESS TECHNOLOGIES MEMBRANE
List of Tables
Table 1. 1: Flow Specifications for E4H Machines, 50-75% Recovery
.................................................................. 13
MACHINES .................... 51
Table 1. 2: Feed Water Requirements
Table 1. 3: Membrane Element Specifications –
..................................................................................................................................... 13
AG4040F
......................................................................................... 15
*
Table 2. 1: Connection Schedule ................................................................................................................................................. 17
Table 6. 1: Troubleshooting Guide .................................................................................................................................................. 35
List of Figures
Figure1. 1: Normal vs. Crossflow Filtration ............................................................................................................................... 6
Figure1. 2: Membrane Element with Interconnectors ............................................................................. ............................ 7
Figure1. 3: Cross-Sectional View of Membrane Element ................................................................................................... 7
Figure1. 4: Principle of Operation .................................................................................................................................................. 9
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Operations and Maintenance Manual
E4H Series Water Purification Machines
1. DESCRIPTION
Your E-Series reverse osmosis (RO) machine is a durable piece 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 this manual completely before operating your machine.
1.1 Definitions
The operating definitions provided below will help you further understand yo this manual.
1.1.1 Permeate Rate (Product Water Rate) [Qp]
The flow rate of membrane
meters/hour (m (25°C). Permeate rate will vary with temperature.
purif
ied water, which has passed through the membrane and out of the
element
, expressed in gal/min (gpm) or gal/hr (gph) or liter/min (lpm) or cubic
3
/h). Specified permeate rates are based on a feed water temperature of 77 °F
1.1.2 Concentrate Rate (Reject Rate) [Qc]
The flow rate of water containing rejected solids to drain in gpm or gph (lpm or m3/h).
1.1.3 Feed Rate [Qf ]
The flow rate of incoming water in gpm or gph (lpm or m3/h). Feed water rate equals permeate rate plus concentrate rate.
ur
machine and
1.1.4 Reverse Osmosis (RO)
Reverse osmosis is the separation of one component of a solution from another component by means of pressure exerted on a semipermeable membrane. In other words, reversing the natural passage of a liquid from a concentrated solution to a more dilute solution by using external pressure. Removal of ionic, organic, and suspended /dissolved impurities occurs during the RO process. Unlike a filter, which separates by “normal” filtration, the membrane element separates using a process called cross flow filtration. Feed water solution is separated in to two streams, permeate and concentrate, and collected from both sides of the membrane. A semipermeable RO membrane, under sufficient pressure, allows passage of purified
water while rejecting and concentrating dissolved and suspended solids.
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Operations and Maintenance Manual
E4H Series Water Purification Machine
Figure1. 1: Normal vs. Crossflow Filtration
1.1.5 Membrane Elements
Membrane elements are the key to reverse osmosis. Interleaved layers of semipermeable membrane, spacer and permeate carrier spiraled around a central permeate tube make up
element
the the permeate carrier carries the purified water out of the membrane Process Technologies manufactures a patented spiral wound membrane element with a turbulent flow design. This membrane module collects the purified water within the central tube, the permeate tube. elements.
. The spacer allows for movement of the concentrate past the membrane, and
element
. GE Water &
The E4H RO machine utilizes between 9 and 24 membrane
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Operations and Maintenance Manual
E4H Series Water Purification Machine
Figure1. 2: Membrane Element with Interconnectors
Figure1. 3: Cross-Sectional View of Membrane Element
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Operations and Maintenance Manual
E4H Series Water Purification Machine
1.1.6 CIP
The abbreviation for clean-in-place.
1.1.7 Average Pressure [PAVG]
(
P
Primary
+ P
Final
)
2
1.1.8 Concentration
Concentration equals the Total Dissolved Solids (TDS) concentration of a solution expressed as parts per million (ppm) or conductivity (microSiemens/cm).
= Feed Concentration
C
f
= Permeate Concentration
C
p
C
= Concentrate Concentration
c
C
= Average Concentration in Machine
avg
1.1.9 Salt (Ionic) Passage
The percent of dissolved salts passed through the membrane or 100% minus rejection.
1.1.10 Recovery
Permeate rate divided by feed rate, expressed as a percentage. For example, 33% recovery means that for a given feed rate, 33% is produced as purified water (permeate).
1.1.11 Salt (Ionic) Rejection
The percent of dissolved salt rejected by the membrane, calculated from an average concentration over the membrane.
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Operations and Maintenance Manual
E4H Series Water Purification Machine
An example of how to calculate salt rejection and recovery is given below.
Figure1. 4: Principle of Operation
Given the system case in the figure above:
CC
Average Concentration,
CC
Rejection
Passage
Recovery
C
C
Avg
Q Q
C
Avg
p
237.5mg/L
p
100
f
pAvg
8.3mg/L
C
Avg
100
18gpm 24gpm
cf
2
237.5mg/L
375mg/L100mg/L
TDS 237.5mg/L
2
8.3mg/L237.5mg/L
%5.96100
%5.3100
%75100
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Operations and Maintenance Manual
E4H Series Water Purification Machine
1.2 Flow Description
The feed water passes through a replaceable 5-micron cartridge filter, which removes bulk suspended solids. Filtered water then flows to the inlet control valve.
This solenoid-controlled diaphragm valve is wired to the on/off switch and opens when the machine is turned on, allowing water to flow to the pump off, the valve closes, preventing non-turbulent flow through the membrane elements, which would lead to shortened membrane life.
The pump feeds water to the membrane housings arranged in parallel and serial combinations. A throttling valve is included on the pump discharge for manual adjustment of the pump pressure. The direction of water flow is indicated by an arrow on each housing. Water is separated by the membrane within the membranes and leaves the housings in two streams: permeate and concentrate.
Permeate from each membrane housing is collected in a common manifold. The permeate then flows through a flow meter and to the outlet point of the machine.
inlet.
When the machine is turned
The concentrate leaves the last membrane housing and flows to the flow control center (recycle/concentrate manifold). At this point, the recycle valve channels a predetermined amount of concentrate into the pump inlet. Recycle increases recovery while maintaining adequate cross-flow through the membranes. The other two ports of the flow control center lead to the concentrate valve and final pressure gauge. The concentrate valve has three functions: It controls the amount of concentrate flowing to the drain; it controls the pressure within the machine; and it helps control the system recovery. A feed flush solenoid is added to the flow control center with an additional tee. The concentrate then flows through a flow meter and to the outlet point of the machine.
1.3 Machine Nomenclature
E-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.
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Operations and Maintenance Manual
E4H Series Water Purification Machine
Example: RO,E4H-21K-DLX, 460, 6, 50-75
• RO indicates the machine is a reverse osmosis machine.
• E4H indicates the machine series (E) and 4-inch housings/membrane elements
• H indicates horizontal membrane element housing configuration
• 21K indicates the rated permeate flow in thousands of gallons per day at 77°F (25°C), i.e. 21K = 21,000 gallons per da
y
• DLX indicates the deluxe model and ECN indicates the economy model
• 460 indicates 460 VAC, 3-phase voltage to starter. Standard models offer 460 VAC, 60 Hz, 3-phase, 230 VAC, 60 Hz, 3-phase, and 380 VAC, 50 Hz, 3-phase.
• 6 indicates 60 Hz operation, (50 Hz operation is also available and is indicated b place of the 6.
• 50-75 indicates a recovery range of 50 to 75%.
1.4 Economy (ECN) Model and Deluxe (DLX) Model Options
1.4.1 ECN Model
E-Series ECN model water purification machines have all the features necessary for safe, continuous production of high purity water. This assumes good quality feed water, adequate pretreatment and regular operator maintenance, each shift or dai sy
stem.
• 50% to 75% recover
• Multi-stage centrifugal pump, SS construction (stainless steel castings with Noryl* Stages)
• Base model electrical package includes NEMA-1 enclosure with a 110 VAC, 60 Hz or 220 VAC, 50 Hz single-phase control circuit; applies to all ECN models
y
y
a 5 in
ly
, to the operation of the
• Automatic inlet shutoff valve
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Operations and Maintenance Manual
E4H Series Water Purification Machine
• Pre-filter housing and 5-micron cartridge filter
• Pre-filter, post-filter, primary and final pressure gauges
• Concentrate and permeate flow rotameters
• Pump throttling valve
• Digital conductivity monitor, panel-mounted, for permeate quality monitoring
• Feed flush System - programmable, automated high-velocity membrane flushing for the longest membrane life; set at the factory and adjustable in the field
• Gauges, valves and rigid piping of stainless steel or plastic
• Fiberglass reinforced plastic (FRP) membrane housing, with Noryl end caps
• Stainless steel concentrate and recycle valves
• All components in contact with the purified water (permeate) are either FDA­acceptable plastic (nylon, Noryl, polypropylene, PVC) or stainless steel materials.
• All high pressure fittings are 304 stainless steel.
• Alarms included: low inlet pressure and motor fault
1.4.2 DLX Model
The DLX package contains all of the above ECN standard features along with an AccuTrak® RO solid state controller.
• Electrical package includes AccuTrak® RO controller
• Chemical dosing system for antiscalant or pH adjustment
• Clean-In-Place (CIP)
• Digital flow meter and conductivity sensor
• Analog pH sensor on inlet
sy
stem
• Alarms included: low inlet pressure, high permeate pressure, high/low inlet pH, high temperature, high permeate conductivity, f ill-time exceeded, and motor fault
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Operations and Maintenance Manual
E4H Series Water Purification Machine
1.5 Specifications for E-Series Machines
The machine flow specifications listed in Table 1.1 below are based on 77°F (25°C) and 2,000 ppm NaCl.
Table 1. 1: Flow Specifications for E4H Machines, 50-75% Recovery
Mode
l
U
nit
s
Permeate Rate
C
oncentrat
Rat
e
Feed Rate
E4H-16K
gpm (m3/h) gpm (m3/h) gpm (m3/h) gpm (m3/h) gpm (m3/h)
11.2 (2.56) 15 (3.4)
11.2-3.7
e
(2.5-0.8)
22.4-14.9 (5.1-3.4)
1.5.1 Feed Water Specifications
The feed water requirements stated in the following table must be met to ensure quality permeate and extended membrane element life.
Temperatur
Inlet Pre
e
ssure
E4H-21K
15-5 (3.4-1.1)
30-20 (6.8-4.5)
E4H-27K
18.8 (4.3)
18.8-6.3 (4.3-1.4)
37.6-25.1 (8.5-5.7)
Table 1. 2: Feed Water Requirements
Typical: 50-85°F (10-29°C)
Maximum: 32-104°F (0-40°C)
Minimum 30 psig (2.1 bar)
Maximum 60 psig (4.1 bar)
E4H-38K
26.2 (5.9) 30 (6.8)
26.2-8.7 (5.9-2.0)
52.4-34.9 (11.9-7.9)
E4H-43K
30-10 (6.8-2.3)
60-40 (13.6-9.1)
Chlorine (continuous feed)
Operating
p
H
Silt Density Index (SDI
0 ppm
For soft water (less than 1 grain per gallon (gpg) or 17 mg/L hardness), acceptable pH is 4.0-11.0.
For unsoftened water contact factory with water analysis, acceptable pH is 5.5-6.0.
For short term (cleaning) a pH range of 2-12 is acceptable.
)
Less than or equal to 3 to minimize membrane fouling and extend cleaning intervals. Refer to ASTM standard D4189.
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Operations and Maintenance Manual
E4H Series Water Purification Machine
1.5.2 Permeate Flow Rate
Stated in Table 1.1 above and on the machine serial number label (assumes no permeate backpressure, 2000mg/L TDS maximum feed concentration, and rated temperature).
To estimate permeate output with backpressure, use the formula below:
Maximum permeate backpressure is 80 psig (5.5 bar).
re)Backpressu (Permeate-Pressure) (Operating

Label) on Flow (Permeate
Pressure) (Operating
1.5.3 Concentrate Flow Rate
Stated in Table 1.1 and factory set as stated on serial number label.
1.5.4 Operating Final Pressure
Minimum - 200 psig (13.8 bar) Maximum - 235 psig (16.2 bar)
1.5.5 Pump
Multi-stage centrifugal; approximate primary operating pressure of 190 psig (13.1
bar) excluding line pressure.
1.5.6 RO Membrane Rejection
E4H reverse osmosis machines use GE fiberglass reinforced plastic (FRP) covered
AG4040F membrane elements. For ordering information refer to the attached Spare
Parts List. See Table 1.3 below for details.
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Operations and Maintenance Manual
E4H Series Water Purification Machine
Table 1. 3: Membrane Element Specifications –
Outer Cover Materia
l
FRP
AG4040F
*
Typical Ionic Rejection (TDS)*
Nominal Permeate Flow Rate at 225 ps
i
Typical Feed Water Temperature Range
Maximum Temperature
pH Range
Chlorine Tolerance
Active Membrane Are
a
99.0 – 99.5%
2,200 gpd (8.
50 – 85°F (10-29.4C)
122°F (50C)
4.0 – 11.0
< 0.01 ppm
85 ft2 (7.9 m2)
3m3/day)
*Specification is based on a 2,000 mg/L NaCl solution at 225 psi (1,551 kPa) operating pressure, 77°F (25°C), pH 7.5 and 15% recovery. Individual flux may vary +25%/-15%. Average salt rejection after a minimum of 24 hours of continuous operation.
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Operations and Maintenance Manual
E4H Series Water Purification Machine
2. INSTALLATION
2.1 Mounting
E4H Series machines are equipped with a stand-alone frame, which supports the machine. At least 45 inches (114 cm) of space should be allowed on each end of the membrane element housings for removal and loading of membrane elements. If 45 inches (114 cm) are not available, the entire membrane element housing may need to be removed for membrane element replacement.
WARNING!!
Avacuumbreakermustbeinstalledatthehighestpointalongthe
concentrateline.Failuretodosomaycauseavacuumtoformwithinthis
lineaftershutdown.Thismayinturncausenumerousproblems,
includingbiologicalfouling,waterhammer,leaksfromROhousingside‐
ports,andthe
siphoningoftreatmentchemicals.
WARNING:
Connect the concentrate line to the RO machine’s concentrate outlet. A vacuum breaker must be installed at the highest point along the concentrate line. This provides an atmospheric break upstream from where the flow enters the drainage system. For systems which include multiple RO machines, install check valves along each machine’s concentrate line prior to connecting the lines to a common manifold.
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