GE E4H-CE, E8-CE User Manual

E4H-CE AND E8-CE SERIES

WATER PURIFICATION

MACHINES

3 m

/hr to 45 m3/hr

18,000 gpd to 288,000 gpd

Operation and Maintenance

Manual

INSTRUCTIONS FOR E4H-CE AND E8-CE

WATER PURIFICATION

OPERATION AND MAINTENANCE MANUAL

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

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

/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

/h (gpm or gph).

1.1.3 Feed Rate [Qf]

The Feed Rate is the flow rate of incoming water in Lpm or m

/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

1.1.5 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

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).

= Feed Concentration

= Permeate Concentration

= Concentrate Concentration

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:

Average Concentration (C

avg

) = [(Cf) + (Cc)]

= [(100 mg/L) + (375 mg/L)]

= 237.5 mg/L

Rejection = [(C

avg

) - (CP)] x 100

avg

)

= [(237.5 mg/L) + (8.3 mg/L)] x 100

(237.5)

= 96.5%

Passage = (C

) x 100

)

= (8.3 mg/L) x 100

(237.5)

= 3.5%

Recovery = (Q

) x 100

)

= (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.

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

/hour at 25°C (77°F)]

· 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

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

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

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

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

MODEL

E4H-CE-3

E4H-CE-5

E4H-CE-7

E8-CE-9

E8-CE-14

E8-CE-23

PUMP MODEL

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

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

/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

(85 ft2)

1500 MW*

E8-CE

FRP

98.0 - 99.5%

39.8 m

/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

(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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