In the Name of ALLAH The Most

Beneficent, The Most Merciful

Pre-Treatment Failure- A case study for

Shuaibah Independent Water Expansion Project
By
Shah Muhammad Tanweer (Ex-PGM SQIWPP)
Two day Course on
“Membrane Desalination - Drinking and Industrial Water Treatment”
(5th and 6th September 2016)
Organized By
Center for Continuing Engineering Education (CCEE)
NED University of Engineering & Technology
 Introduction for SIWEP
Location & capacities of Plant
 The seawater reverse
osmosis (SWRO) plant
has capacity to produce
150,000 m3
 In this plant, Permeate
SHUAIBAH
Quality to be maintained
are
 Chloride conc..< 20 mg/L
 TDS < 35 mg/L
 Boron conc.. < 0.5 mg/L
 Owner – SWEC– ACWAPI
 EPC – Doosan
 COD – November 27th 2009
 O& M – NOMAC 2
 Introduction for SIWEP
Birds Eye View of Reverse Osmosis (RO) Plant

CARTRIDGE FILTERS
1st and 2nd Pass RO units

PERMATE

OUTFALL

LIME PLANT

SEA WATER INTAKE

DUA MEDIA FILTERS

CHLORINATION SYSTEM

BACKWASH WATER TANK

DIRTY WASH
Industrial Water CO2 Gen Plant WATER TANK
Treatment Plant
 Introduction for SIWEP
Main Plant Units
7 3
6 5 4
OUTFALL CARTRIDGE FILTERS
PERMATE 2nd Pass RO units 1ST Pass RO units

SEA WATER INTAKE 1

DUA MEDIA FILTERS
 Introduction for SIWEP
Auxiliary Units
CHLORINATION SYSTEM
LIME PLANT BACKWASH WATER TANK

CO2 Gen Plant

waste Water COMPRESSOR DIRTY WASH WATER TANK CHEMICAL DOSING SYSTEM
Treatment Plant AIR
 Introduction for SIWEP
Process Flow of Desalination Plant
Caustic
Soda
ANTI
SCALANT
Polymer
ANTISCALANT 1St PASS RO UNIT 2nd PASS RO
1St PASS HP (10+0) UNIT (10+0)
coagulant SBS PUMPS (10+0)

Shock
chlorination ACID
ERD 2nd PASS FEED
BOOSTER PUMPS (10+0)
MEDIA FILTERS (32) PUMPS
(10+0)
CARTRIDGE
FILTER (9+1)
SEA WATER
SUPPLY Shock
chlorination ERD
SEAWATER
INTAKE
PUMPS

DIRTY WASH BACKWASH

WATER PUMP(2+1) PUMPS
(1+1)
AIR
BLOWER

DIRTY WASH BACKWASH WATER

WATER TANK TANK
INDUSTRIAL WASTE WATER
TREATMENT FACILITY

IWPP OUTFALL CHANNEL

IWPP OUTFALL CHANNEL

SWCC SHUAIBAH II POTABILIZATION

STORAGE TANK PLANT

PREMATE
TRANSFERE
PUMP (4+1) PREMATE
 Introduction for SIWEP
PRE-TREATMENT SCHEME
Screening Filtration

Screens Traveling Screens Dual Media Filters Cartridge Filters

Chemical
Shock/ Continuous SBS
Cleaning
Chlorination
Ferric
Chemical Dosing

Chloride
Reverse Osmosis

H2SO4
Anti Scalant

Post- Treatment Storages Disinfection

Lime CO2 ClO2 7

Introduction for SIWEP
PRE-TREATMENT SCHEME

8
 Introduction for SIWEP
Sea Water Intake
 Sea water Inflow
 By an intake channel
through gravity by the
intake pipe from the off-
shore location below
sea level.
 Two additional
channels

 Screens
 Bar Screen
 Travelling screen
 Screen wash pump
 Stop logs
 Introduction for SIWEP
Sea Water Intake
 Disinfection
Sodium Hypo-Chlorite is
added for disinfection of
the incoming seawater
as well as to prevent
growth of marine
organisms on the intake
pipe.
 Pumps
 Three intake Pump Channel
 Vertical turbine pump.
 Introduction for SIWEP
Dual Media Filter (DMF)
 Quantity and Placement
 Thirty two (32) Numbers of
DMF is placed in two lines.
 Design Parameters
 Size : 4 m O.D. x 12.5 m L
 Design Pressure: 7 Bar
 Under-drain Type:
Header/Lateral with Drilled
Orifices
 Normal Filter Rate: = 497 m3/hr
 NFR (One out): = 522 m3/hr
 Max. Filter Rate: = 626 m3/hr
 Backwash Rate: = 3128 m3/hr
 Design Air Wash Flow Rate: = 11
2800 m3/hr @ 0.41 bar
 Introduction for SIWEP
Cartridge Filter (CF)
 Construction & Operation
 10 #s of Cartridge Filters with
each having 572 #s of 5 μ
cartridges 70 inches in length
 Designed press is 6.5 barg
 Int. Dia = 2200mm x 3620mm L
 Flow rate = 1,878 m3/hr
 Feed is from DMF and 2nd pass
RO concentrate

 Dosing before CF
 Anti-Scalant
 Sodium Bi-Sulphite
12
 Introduction for SIWEP
Reverse Osmosis (RO) System
 Two Stage Passes  1st Pass RO (10 Trains)
Vessels/Train 189
RO Element Model TM820E-400
Material Aromatic Polyamide Composite
Elements/Vessel 7 elements /Vessel
Total Elements 13,230
Recovery Ratio 41.5%
Feed Sea Water TDS – 44,460 mg/l,
Quality Chloride – 25,044
Feed Water Flow 1,687 m3/hr per Train
SDI -- < 4 , 95% and < 5, 100%
pH – 3 to 8, Temperature 25 to
Maximum Feed
350C
water Quality
Residual Chlorine – Not
Detectable
Salt Rejection 99.75%
Permeate Quantity 16,800 m3/day per Train
Operating condition Max 67.5 bar(g), Min 501.1 bar (g)
Vendor TORAY 13
 Introduction for SIWEP
Reverse Osmosis (RO) System
 2nd Stage RO (10
Trains) Two passes

Vessels/Train 49 in 1st pass & 20 in 2nd Pass

RO Element Model TM720-430
Elements/Vessel 7 elements /Vessel
Total Elements 4,830
Recovery Ratio 90%
Salt Rejection 99.7
Feed Permeate from 1st Stage, pH -7
Feed Water Flow 700 m3/hr per Train Max Temp 45oC
Permeate Quantity 630 m3/hr per Train
Operating condition Max 13.5 bar(g), Min 10.5 bar (g)
TDS Maximum 35 mg/l
Permeate Quality Chloride Maximum 20 mg/l
Boron Maximum 0.5 mg/l
Vendor TORAY

14
 Dual Media Filters
Main Parts prone to Failure

Upper Collector

Drain Down

Filter
Media Air Wash
Sub-Fill

Under drain 15
 Dual Media Filters

Section Views
 Dual Media Filters
Section View

Plan View

17
 Dual Media Filters
Filter Bed Media
 Function
 The filter material which allows 1092
mm anthracite - e. s. 1.0 - 1.1
passage of effluent and retains the (43”) mm.
particulate material.
 Media is selected for desired
physical characteristics such as 305 mm silica sand - e. s. 0.45 - 0.55
size, specific gravity, and gradation. (12”) mm.

 The filter media for a particular application is specified in

terms of “effective size” and “uniformity coefficient”.
 Effective size (E.S.) is defined as the size of the grain in
millimeters, of which 50% or the material is larger.
 Uniformity coefficient (U.C.) is calculated by determining the
size of a grain of which 60% of the material is larger and
dividing by the effective size.
18
 Dual Media Filters
What to Look for in Filter Media
 Cracks & separation of Wall
 When the filter bed becomes excessively
dirty, it compacts, causing small cracks in
the bed and separation of the media from
the filter walls
 Water flows rapidly through the resulting
cracks, receiving little or no filtration.
 Larger cracks occur when the filter media is compacted, then
backwashed without using air scour. The media tends to heave
upward as a unit, then crack. The backwash water then flows
through the crack rather than acting to agitate the media.
These problems are best corrected by backwashing at a
low rate (8-10 GPM/SF) for 5-10 minutes. The backwash
rate is then increased to the normal high rate for an 19
additional 5-10 minutes.
 Dual Media Filters
What to Look for in Filter Media
 Mud Balls
 They are formed when grains of filter
media are not cleaned thoroughly; the
sticky floc residue forces the grains to
clump together.
 As the mud balls grow, their weight
causes them to sink into the filter bed
during backwashing.
 Mud balls clog the filter bed, altering normal filtration.
 As water continues to flow through the filter, the filtration rate
in areas that are not clogged by mud balls increases to make
up for the inactivity in the clogged areas.

20
 Dual Media Filters
What to Look for in Filter Media
 Mud Balls
 The water that is forced through the
filter at an accelerated rate is not
filtered as effectively as it would be at
the optimum filtration rate.
 This causes poor effluent quality,
early floc breakthrough and short filter
runs.

• Smaller mud balls can usually be seen on the surface of a filter

after backwashing, especially when the problem is severe.
• A periodic check should be made for mud balls lodged
beneath the surface of the filter.

21
 Dual Media Filters
What to Look for in Filter Media
 Holes
 Holes The appearance of holes in the surface of a filter
following a backwash is an indication of serious sub fill or
under drain damage.
 Holes usually occur when media is lost to the under drain
through a displaced area of the sub fill or through a break in
the under drain.
 The hole will disappear after the next backwash, then
re-appear during the service run.
 This must be investigated immediately or serious water
quality problems may result.
• This type problem may be prevented by always beginning
the backwash flow at a very low rate, and then gradually
increasing the flow over 1-2 minutes to the correct rate.
22
 Dual Media Filters
Sub-Fill
 Function
 These are the support material, usually several grades of
gravel, installed between the filter media and the under drain.
 Silica gravel and each layer supports everything above it
 The sub-fill does not effect filtration. Its function is to improve
backwash flow distribution and to prevent loss of filter media
through the effluent.
 It helps in Backwash distribution for an evens flow at base of
media
3/16’ X 1/10” (4.687 mm X 2.5 mm)
3/8” X 3/16” (9.375 mm X 4.687 mm)
5/8” X 3/8” (15.625 mm X 9.375 mm)
76 mm [3”] 1” X 5/8” (25 mm X 15.625 mm)

23
 Dual Media Filters
Under Drain
 Function Laterals
 Under drain are the filtered
water collection system
located beneath the filter
media and /or media support
gravel.
 This same system is also
employed for distribution of
backwash water. Because the
flow during backwash is
generally 3 to 7 times that of
service conditions
• The hydraulic design of the under drain
system is governed by backwash
conditions. 24
 Dual Media Filters
Under Drain
 Plan View

25
 Dual Media Filters
Under Drain
 Causes of Failure
 Air in Back wash water
• Evidence of “slugs” of air being released from the filter
bed during back wash can not only damage the under-
drain, if violent enough, but can cause the loss of filter
media by carrying it to waste.
• Air can be introduced into the under-drain if the
backwash header is permitted to drain between
backwashes or it can be introduced by the backwash
pump

 Excessive solids build-up in the filter

 Operating to an excessively high head loss
26
 Dual Media Filters
Under Drain
 Causes of Failure
 Excessive solids build-up in the filter
• If an excessive amount of solids is permitted to build up in the
filter bed due to insufficient backwash flow or high carry-over
of chemical precipitates or biologically active matter, portions
of the filter bed can become permanently clogged.
• When this occurs, areas of high and low velocity are created in
the filter bed during backwash
 Operating to an excessively high head loss
• Operating to an excessively high head loss can not only
contribute to clogging of the filter bed but can produce a
negative (below atmospheric) pressure.
• A negative head will cause air which is dissolved in the water
to escape, resulting in air binding and the violent release of air
27
during backwash.
 Pre- Treatment Failure Observation
Flushing of RO Vessels
 Before insertion of Element in Vessel, the flushing
through normal route of pretreatment was carried
 On 22nd March 09, Traces  To check the same
of anthracite and sand was Cartridge Filter # 8 Dome
observed from vessels for was opened by EPC in the
1st pass R.O Train # 6 same evening

28
 Pre- Treatment Failure Observation
Observation through Cartridge Filter # 8

 Filters found displaced,  Filters, ruined ,brownish

floating, up-side down and traces of Anthracite

29
 Pre- Treatment Failure Observation
Observation through Cartridge Filter # 8
 Debris, Cloth Pieces  Ample quantity of Anthracite
and other materials on the base plate
found

30
 DMF Failure Observation
Observations for DMF # 16 on 30th March-09
 Laterals found Damaged and deteriorated

Could this be only real cause?

31
 DMF Failure Observation
Observations for DMF # 20
on 02nd April-09
 Channeling
 Cracks
 Holes
 Media Up-Set

32
 Modifications for Cartridge Filter
First Modification on Trial Basis started on 4th April-09
 Springs (S.S 316-L)were
put on each filter so that it
holds & restricts the filter
from falling
 Compression Plate to hold
spring was added
Result of First
Modification
 Filter Displaced
 Spring Broken
 Rust on Springs

33
 Modifications for Cartridge Filter
Second Modification on 27th April-09
 A cage was inserted to hold the individual Filters at its
place
 Springs and compression plate were put as earlier

34
34
 Modifications for Cartridge Filter
The Result of the 2nd Modification
 It was observed
that the cage is
damaging the
rubber lining
 Rust on Cage

 Since cartridge Filter 8 was experimented with old filter

the results were not promising

35
 Modifications for Cartridge Filter
The Result the 2nd Modification
 All cartridge Filter were opened to
check its health.
 Plenty of sand and anthracite and
gravel had been found at the
supporting (bottom) plate
 Top cover for some of the cartridge
elements were found broken, which
made a pavement for sand, anthracite
and even gravel to reach HP pump

36
 Modifications for Cartridge Filter
The Result the 2nd Modification
 Most important was that the S.S
Rod supporting the cage (holding
elements filters) was found broken
 Element found Ruptured and
broken and springs found displaced
and broken
 Material utilized for modification
needed to be checked again

37
 Modifications in Filter Element
A new patented Filter Element was
introduced
The Result of the Modification
 The compression plate and the springs,
which showed to be a problem were
removed
 The cage along with safety guards of
Poly propylene remained

The Second Line of Defense Now Seems to be Intact 38

Final Modifications for Cartridge Filter

39
 Inviting Catastrophe
Feeding Water to First Pass Unit

 On 22nd April 2009, EPC started feeding water to first

pass RO
 A long list of concerns were shared with the owner to
restrict the activity but in-vain

40
 Catastrophe Begins
Observation for Membrane
 The DMF failure was causing extra load on C.F
 First pass R.O train #s 1,5, 8,10 to check the health of
Membrane and to see if cartridge filters that passed sand
and anthracite is effecting element

41
 Most Suspected DMF
Back Wash Observations
 Backwash problems CAUSE OF
 Backwash line drain down FAILURE---- ???
 Accumulation of air in
effluent
 Sudden eruption of air at
start of wash
 Displacement of sub-fill
 Water hammer

42
 Most Suspected DMF
Air Bubbling Test

DMF-11 DMF-12 DMF-15 DMF-16

on 31-7-2009 on 01-8-2009 on 01-8-2009 on 01-8-2009

DMF-27 DMF-28 DMF-30 DMF-11

On 01-8-2009 on 01-8-2009 on 01-8-2009 on 31-7-2009
43
 Most Suspected DMF
Man Hole Opening of DMF-30 and Observation
 The Service inlet header was found tilted, resting on the media
bed as most of the supports were found broken
 The media condition was very bad i.e. media completely mixed
(bed shape completely destroyed)
 As per visual observation, 40% media (Mostly anthracite) were
lost. Sand and Gravel mixed and little anthracite was present
 After displacing some media, the air scoring header of DMF#3
0 also found bulged at approximately 3/4th distance (of the
total DMF length) from the sea side manhole cover
Time for Action
Complete inspections of DMF#30
(i.e. by removing all media) should be
performed to assess the actual
condition of the internals 44
(MAIN SERVICE INLET HEADER (MAIN SERVICE INLET HEADER (AIR SCORING HEADER VISIBLE AND
SUPPORT DETACHED) TILTED AND SUPPORT DETACHED) SAND & ANTHRACITE MIXED)

45
 Inspecting Internals of DMF
Media Removal and inspection
 DMF # 30
 The Air scoring pipe were found
broken to pieces
 Main Service header was down
without any support

46
 Inspecting Internals of DMF
Media Removal and inspection
 DMF # 14
 The Air scoring pipe were found
broken to pieces
 Bulging of pipes was noticed at
several places

47
 Inspecting Internals of DMF
Media Removal and inspection
 DMF # 23
 The Air scoring pipe were found
broken to pieces
 Bulging of pipes was noticed at
several places

48
 Inspecting Internals of DMF
Inlet spool for Air scouring
Header

 DMF # 3
 Lot of mixed sand and
anthracite were found
 Spools were found choked

 DMF # 17
 Spools were found
completely choked with
sand and anthracite
49
 Membrane Deterioration
SWRO Train # 10 for Inspection
 On 10th December, these membrane elements were removed
from the top side. Membranes for inspection were removed
from Top, where as the bottom is subjected to first thrust
 Vessel # A-02 1st (lead) & last (Rare) two membrane elements
 Vessel# A-03, the 1st from feed side (lead) one membrane
First Vessel, Last
 All the membranes were found in Membrane Element
brownish colour
 Lot of Anthracite particles were found
on the Membrane
First Vessel, First Membrane Element

50
 Modification of DMF
Modification Work Summary
 Removal of Concrete
 To achieve desired plenum space
 For maintenance of nozzles for under-drain
 Installation of air header pipe through the filter
 Install new support for false bottom plate and internal
material for damp and hardware (Duplex grade)
 Install fixed welded plate for false flooring
 Re-work of Rubber lining for the false floor bottom
 Installation of air water Nozzles
 Re-Location of Air header inlet piping
 Filling of Media
 Perform Air Bubble Test, Skim the re-bed area,
Disinfection and taking in service 51
 Modification of DMF
Summary of Design Changes
 Construction material of floor … Carbon steel rubber lining
 Internal material for support and hardware … Carbon Steel
Rubber lining
 Air header pipe material … Sch. 80 PVC pipe or equal
 Media Configuration;
 No gravel layer
 305mm sand
 610mm anthracite
 Concurrent air and water backwash
 Air scoured cycle and values remained same
 Back wash (Low rate/unit area) and (Low rate / Vessel
remained unchanged
 Back Wash (High rate/unit area) and (High rate / Vessel)
decreased from 61.0 m/hr (25 GPM/Sq ft) to 50.2 m/hr (205
GPM/Sq ft) and from 3128.3 m3/hr (13775) GPM to 2575 52
 Modification of DMF
Design Details
 Filter Plates Support
 Supported on 8” x 6” joints (“I” beam)
spaced to suit the filter plates. Duplex
grade
 False Deck Installation
 1200 mm high from
bottom of vessel
 Carbon Steel plate with
rubber lining (R/L)
 Plate section is 500 ~ 600
mm smaller than man-
hole size.
 Welded with vessel after
removal of R/L
53
 Modification of DMF
Design Details
 False Deck Installation

 Under-Drain Plan View

54
 Modification of DMF
Design Details
 Air Header and Air Lateral Configuration
 The air supply pipe DN250 Sch. 80 PVC with DN75 nozzles
 Air and water nozzle with 0.2 mm slot
 The hole diameter in the plate for the nozzle is around 28.0
and 29.5 mm. Nozzle density is 50/m2, around 2528 / vessel
 Nozzles is manufactured from PPH (High grade
Polypropylene) . Nozzles are fitted using the expanding type

55
 Modification of DMF
Design Details
 Air and Water Nozzle
 Air and water nozzle with 0.25~0.30 mm slot
 Nozzle which is installed using a back nut,
complete with tailpipe to suit flows of both
backwash water and air scour.
 Nozzle density is 50/m2, around 2528 /
vessel
 The hole diameter in the plate for this nozzle
is around 26.0mm.
 Nozzles Material is PPH which is high grade
polypropylene

56
 Modification of DMF
Schedule for Completing the Work

57
 Consequences of Pre-Treatment Failure
Burden on Cartridge Filter
 Condition after two years.
(Photo of 5th March 2011)
 Changing Frequency
Deterioration of Lead
Membranes

58
 Consequences of Pre-Treatment Failure
Performance of Membranes
 Position of FCV/MOV  Increased in Feed Pressure

 Change of Lead Membrane  Rear Membrane affect

59
 Lesson Learned

 Commissioning activity should be given due respect

 Records for EPC works and timely intimation to

Owner
 Design review should be given proper time and
should be checked for its implementation at other
projects
 Operators should frequently observe filters during
backwash
 Chemical cleaning should be conducted before
normalized flow rate declined more than 15 percent.
Any Question ?

smt@sitechinternational.com

61
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63
19-11-2009
It has been observed that Doosan operators are manipulating the discharge valves of CF outlet
(every time when fresh CF taken in to service) in order to control the flow rates and thereby
controlling the dP across the cartridge filters. The maximum range of CF discharge flow at the
scale is 2200 m3/hr. It has been also observed that CF discharge flow (especially those taken in
to service) went on as much as 2700 m3/hr if their discharge valves became full open (which is
out of limit). The practice of CF discharge valve manipulation is not desirable during plant
normal operation and especially during RTR. At present, following is the status of CF discharge
valves and respective flows in the field:

Discharge V Flow Rate(m3/

CF# alve positio hr)
n (%)
1 100* 1194
2 65 2121
3 60 2134
4 60 2172
5 60 2160
6 100 1696
7 60 2152
9 55 2165
10 100* 1261
64