ENERGY RECOVERY, INC.

Installation and Operation Manual

PX(TM)-300 Energy Recovery Device
P P

© Energy Recovery, Inc. 2010 ERI Document Number 80197-01 Rev 01

ERI, PX and PX Pressure Exchanger are trademarks of Energy Recovery, Inc., registered in the U.S.
and other countries.
 PX-300 Device Installation and Operation Manual
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TABLE OF CONTENTS

1.
TU UT ABOUT THE PX DEVICE .............................................................................................. 3
TU UT

1.1.
TU UT About this Manual................................................................................................... 3
TU UT

1.2.
TU UT Device Basics .......................................................................................................... 3
TU UT

1.3.
TU UT PX Device in RO Systems ...................................................................................... 3
TU UT

1.4.
TU UT Circulation Pump with PX Devices ........................................................................ 3
TU UT

1.5.
TU UT PX Operational Limits ............................................................................................ 4
TU UT

2.
TU UT SAFETY ............................................................................................................................. 4
TU UT

2.1.
TU UT High Pressure Remains After Shutdown ................................................................ 4
TU UT

2.2.
TU UT Low Pressure Isolation and Over-Pressurization .................................................... 4
TU UT

3.
TU UT STORAGE, HANDLING AND INSTALLATION........................................................ 4
TU UT

3.1.
TU UT Storage and Handling Information.......................................................................... 4
TU UT

3.2.
TU UT Installation............................................................................................................... 5
TU UT

4.
TU UT OPERATION .................................................................................................................... 5
TU UT

4.1.
TU UT Feedwater Supply.................................................................................................... 5
TU UT

4.2.
TU UT Start and Stop Procedures ....................................................................................... 5
TU UT

4.2.1. Start Up Sequence ........................................................................................... 5

TU UT TU UT

4.2.2. Short Term Shutdown Sequence ..................................................................... 6

TU UT TU UT

4.2.3. Long Term Shutdown Sequence ..................................................................... 6

TU UT TU UT

4.3.
TU UT Feedwater Filtration ........................................................................................ 6
TU UT

4.4.
TU UT Flow Control ........................................................................................................... 6
TU UT

4.4.1. Lubrication Flow Rate .................................................................................... 6

TU UT TU UT

4.4.2. High- and Low-Pressure Flow Rates .............................................................. 7

TU UT TU UT

4.4.3. Flow Balance .................................................................................................. 7

TU UT TU UT

4.5.
TU UT Flushing................................................................................................................... 7
TU UT

4.6.
TU UT Purge Air ................................................................................................................. 7
TU UT

5.
TU UT SERVICE ........................................................................................................................... 8
TU UT

5.1.
TU UT Spare part and tool kits ........................................................................................... 8
TU UT

5.2.
TU UT Disassembly procedure ........................................................................................... 8
TU UT

5.2.1. Basic disassembly procedure .......................................................................... 8

TU UT TU UT

5.2.2. Disassembly procedure for the PX-300 device on the rack or piping .......... 13
TU UT TU UT

5.3.
TU UT Asembly procedure ............................................................................................... 13
TU UT

6.
TU UT TROUBLESHOOTING ................................................................................................. 19
TU UT

Troubleshooting Guide ..................................................................................................... 20

TU UT

7.
TU UT LEARNING MORE AND CONTACTING ERI ......................................................... 21
TU UT

8.
TU UT REVISION LOG ............................................................................................................. 21
TU UT

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1. ABOUT THE PX DEVICE

6B

1.1. About this Manual

14B

This manual contains instructions for the installation and operation of Energy Recovery, Inc. (ERI) PX-300 energy
recovery devices for Reverse Osmosis (RO) systems. This information is provided to ensure the long life and safe
operation of your PX energy recovery device. This manual is intended for use by personnel with training and
experience in the installation and operation of fluid handling systems. For additional information regarding using the
PX device in RO systems refer to ERI’s website: www.energyrecovery.com or contact ERI customer service.
HTU UTH

1.2. Device Basics

15B

The PX-300 energy recovery device transfers pressure energy from the RO high-pressure concentrate reject stream
to a low-pressure feedwater stream. It does this by putting the streams in direct, momentary contact in the ducts of a
rotor. The rotor is fit into a ceramic sleeve enclosed between two ceramic end covers with precise clearances that,
when filled with high-pressure water, create an almost frictionless hydrodynamic bearing. The rotor spinning inside
the hydrodynamic bearing is the only moving part within the device.

1.3. PX Device in RO Systems

16B

Figure 1 illustrates a typical flow schematic for a RO system equipped with a PX device. There are two independent
flow paths in the PX device, low-pressure (LP) side [B to H] and high-pressure (HP) side [G to D]. The reject
concentrate from the RO membranes [G] passes through the PX device or an array of devices operating in parallel.
The pressure of the concentrate reject is transferred directly to a portion of the incoming feedwater at up to 98%
efficiency. This pressurized feedwater stream [D], which is nearly equal in volume and pressure to the concentrate
reject stream [G], passes through a circulation pump. The circulation pump propels flow in the high-pressure loop
[E-F-G-D] at a rate controlled by either a variable frequency driver on the motor or a control valve at the discharge
of the circulation pump. Fully pressurized feedwater from the circulation pump merges with flow from the high-
pressure pump discharge [C] to feed the membranes [F].

MEMBRANES

PERMEATE

CIRCULATION
PUMP

HIGH
PRESSURE
PUMP

PX DEVICE
OR ARRAY

Figure 1 - Typical Flow Path of a RO System with PX Technology

1.4. Circulation Pump with PX Devices

17B

In the typical RO system illustrated in Figure 1, a circulation pump is required to move water through the
membranes and PX device or array. The high-pressure flow through the PX unit(s) is controlled by either a variable
frequency drive operating the circulation pump or a flow control valve at the circulation pump discharge.
Recommended practice is to use a slightly oversized circulation pump to accommodate for the projected range of
concentrate flow and head requirements. The head requirements are a sum of the pressure losses from the
membrane, piping, and PX device differential pressure (head). Seasonal variations, membrane fouling, and other

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process variations should also be considered when sizing your Circulation Pump. ERI carries a line of Circulation
Pumps with capacities from 20 gpm (4.5 m3/hr) up to 2,200 gpm (500 m3/hr). ERI Circulation Pumps can be
P P P P

manifolded to run in parallel to achieve higher capacities.

1.5. PX Operational Limits

18B

Successful operation of the PX-300 energy recovery device requires observation of some basic operating conditions
and precautions. The PX unit must be installed and operated in accordance with this manual and good industrial
practice to ensure safe operation and a long service life. Failure to observe these conditions and precautions can
result in reduced service life, damage to the equipment and/or harm to personnel. For operational conditions refer to
the Technical Data Sheet of the product. Table 1 provides a summary of system performance limits.

Parameter Operational values limits

English Units Metric Units
Maximum high pressure (HP IN or HP OUT) 1,200 psig 82.7 bar
Maximum feedwater inlet pressure (LP IN) 150 psig 10.3 bar
Storage, Operating and Feedwater temperature range 33-120 ºF 1-49 ºC
pH range 1-12 (short term at limits)
Table 1 - System Performance Limits

2. SAFETY
7B

The PX device is designed to provide safe and reliable service; however, it is used in a high pressure industrial
process. Operations and maintenance personnel must follow the basic safety rules associated with high-pressure
equipment and seawater RO processes. Proper installation and maintenance of shutdown devices and over-pressure
and over-flow protection equipment are an essential part of any RO system. Operation of the PX device outside of
the designed operating range can result in damage and may be unsafe.

2.1. High Pressure Remains After Shutdown

19B

The high-pressure section of a RO system equipped with a PX energy recovery device can remain pressurized after
shutdown. Pressure decreases as water slowly flows through the hydrodynamic bearing of the PX unit. If more rapid
system depressurization during shutdowns is required, the system should be designed with accommodating valves
and piping. Always make sure the RO system is fully depressurized before disconnecting any piping or equipment.

2.2. Low Pressure Isolation and Over-Pressurization

20B

If the low-pressure side of the PX energy recovery device is isolated before the high-pressure side is depressurized,
the PX unit or the low-pressure piping may be damaged by over-pressurization. High-pressure water will seep
through the PX device’s hydrodynamic bearing to low-pressure regions in the PX unit. To prevent this over-
pressurization scenario, use appropriate pressure relief valves, rupture disc and/or depressurization procedures.

3. STORAGE, HANDLING AND INSTALLATION

8B

3.1. Storage and Handling Information

21B

PX devices are packed with plugs installed on the connection ports and have been tested with a diluted biocide
solution to minimize the possibility of biological growth during shipment and storage. Keep the plugs in place until
the unit is to be fitted to the piping. This will keep the inside of the unit clean and prevent the biocide from drying
out.

Follow these guidelines to reduce the potential for damage:

• The PX units must never be exposed to temperatures below 33ºF (1ºC) or above 120ºF (49ºC) during
storage or operation. If possible, store in a climate-controlled building or warehouse
• Avoid direct sunlight, rain or weather
• Never lift or support the units with the end ports or side ports

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• Use a crane for lifting whenever one is available

3.2. Installation
2B

PX devices can be installed and operated in any orientation. Each unit has four connections labeled HP IN, HP
OUT, LP IN, and LP OUT.
• HP IN is the high-pressure concentrate inlet.
• HP OUT is the high-pressure feedwater outlet to the circulation pump.
• LP IN is the low-pressure feedwater inlet.
• LP OUT is the low-pressure concentrate outlet.

The PX unit must be supported by its housing and not by the pipe fittings. Prevent the PX unit from supporting
piping or manifolds.

The PX device should be kept in its original packing until the initial start up of the RO train. Proper piping, piping
support, and housing support must be employed to minimize external stresses on all pipe fittings. Use shims to
support and align the housing. Suitable flexible couplings should be used for joining fittings and piping. Use only
water-soluble lubricants such as glycerin on coupling gaskets; do not use grease. Please request dimensioned
drawings of a PX device and a piping detail for use for piping, manifold, and support rack design.

Prior to installation of the PX device, all associated piping should be thoroughly flushed to assure that no debris
enters and/or damages the PX unit. Temporary installation of basket strainers at both inlets to the PX device or PX
device array can be used.

Warning: Thoroughly flush associated piping with clean water before installing the PX unit. Foreign
material entering the unit may cause damage.

4. OPERATION
9B

4.1. Feedwater Supply

23B

Standard RO process chemicals are not harmful to the PX.

4.2. Start and Stop Procedures

24B

The following procedures are general guidelines for the startup and shutdown of PX unit systems. Procedure details
will vary by plant design. Contact ERI if your process design significantly differs from that shown in Figure 1.
Always ensure that the operating limits listed in Section 1.5 are followed.

4.2.1. Start Up Sequence

32B

1. All valves should be in their normal operating positions.

2. Start the feedwater supply pump. The feed flow through the PX unit(s) may or may not cause the rotor to begin
to rotate. Rotation will produce a humming sound that is audible at close proximity to the PX unit(s).
3. Adjust the feedwater flow to the desired flow rate using the low-pressure outlet flow control valve (FCV).
4. Open air vent valves to vent the high-pressure piping. This is necessary to allow air to escape the system and to
allow the high-pressure piping to fill with water pushed through the high-pressure pump by the feedwater
supply pump.
5. After the high-pressure piping is full of water, start the circulation pump. Rotor speed will increase. Bleed any
remaining air from the system.
6. Adjust the high- and low-pressure flows to the PX unit to make them equal.
7. After the feedwater supply and circulation pump have run for sufficient time to purge all air from the system
start the high-pressure pump. The RO system pressure will increase to the point where the permeate flow will
approximately equal the flow from the high-pressure pump. The sound level from the PX unit will increase.
Small variations in sound level and rotor speed are normal.

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8. Close the air vent valves.
9. Verify that pressure at the device low pressure outlet exceeds minimum requirements.
10. Verify the high- and low-pressure flow rates. Adjust flows as necessary to achieve balanced flow to the PX
units.

4.2.2. Short Term Shutdown Sequence

3B

1. Throttle the LPOUT FCV to avoid overflow in the LP side of the unit when the High Pressure Pump is turned
0B

off.
2. Shut off the main high-pressure pump.
1B

3. Wait until the system pressure drops to the osmotic pressure of the sea water, e.g. 400 psig (28 bar).
2B

4. Shut off the circulation pump.

3B

5. Shut off the feedwater supply pump.

4B

6. If necessary, open a purge valve to expedite depressurization.

5B

4.2.3. Long Term Shutdown Sequence

34B

If the process is to be shut down for long term (the time frame depends on the characteristics of the RO system and
feedwater), the RO system including the PX units must be thoroughly flushed with fresh water to remove any salt,
and precautions should be taken to inhibit biological growth. The high-pressure and low-pressure sides of the PX
unit must be flushed separately. The low-pressure side should be flushed with fresh water through the feedwater
feed line to the PX unit and to the concentrate drain. The high-pressure flush is typically performed by circulating
water through the PX unit and the membranes using the circulation pump. Lubrication flow for the PX device rotors
must be provided through the high-pressure pump or some other injection point in the high-pressure loop during
fresh water flushing. The PX units should receive a final flush with the same solution used to preserve the RO
membranes.

4.3. Feedwater Filtration

35B

Like the RO membranes, the PX device requires filtered water. Particulates entering the PX device are passed
through to the membranes. Particles entering the PX device may also prevent the rotor from spinning and can effect
performance, resulting in the need to service the device. The PX device filtration requirement applies during
commissioning, normal operation as well as, the membrane CIP process; refer to the technical data sheet for
filtration requirements.

4.4. Flow Control

25B

Flow rates and pressures in a typical RO plant will vary slightly over the life of a plant due to temperature
variations, membrane fouling, and feed salinity variations. The PX unit’s rotor is turned by the flow of fluid through
the device. The speed of the rotor is self-adjusting over the PX unit’s operating range. The ratio of the high- and
low-pressure flow rates affects the degree of mixing between the feedwater and concentrate streams that occurs
within the unit.

4.4.1. Lubrication Flow Rate

36B

In a PX device, some of the high-pressure water flows through the hydrodynamic bearing to low-pressure regions in
the assembly. The lubrication flow rate varies with system pressure according to the PX’s performance curves. If the
PX device has a damaged o-ring or is damaged by debris, overflow or insufficient discharge pressure, excess
lubrication flow may occur. Monitoring lubrication flow is a good way to check the integrity of an operating PX
unit. Lubrication flow can be determined using any of the following three methods:

• Measure the flow rate of the low-pressure feedwater to the high-pressure pump and the flow rate of the
permeate. The difference is the lubrication flow rate.

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• Measure the flow rate of the high-pressure concentrate to the PX unit and the high-pressure feedwater from
the PX unit. The difference is the lubrication flow rate.
• Measure the flow rate of the low-pressure concentrate from the PX unit and the low-pressure feedwater to
the PX unit. The difference is the lubrication flow rate.

4.4.2. High- and Low-Pressure Flow Rates

37B

The high-pressure flow through the PX unit is set by adjusting the circulation pump with a variable frequency drive
or with a flow control valve and verified with a high-pressure flow meter. The flow rate of the high-pressure
feedwater out of the PX unit equals the flow rate of the high-pressure concentrate to the PX unit minus the bearing
lubrication flow.

The low-pressure flow through the PX unit is controlled by the feedwater supply pump and a control valve in the
concentrate discharge from the PX unit(s). This valve also adds backpressure on the PX device required to prevent
cavitation. The low-pressure flow rate must be verified with a flow meter. The flow rate of the low-pressure
concentrate from the PX unit equals the flow rate of the low-pressure feedwater to the PX unit plus the bearing
lubrication flow rate.

4.4.3. Flow Balance

38B

The high- and low-pressure flows to and from the PX device should be equal or ‘balanced” for optimum RO
operation. Operating the PX unit with unbalanced flows can result in higher contamination of the feedwater feed by
the concentrate reject. Balanced flows help limit the mixing of concentrate with the feed. A feedwater inlet flow that
is much less than the feedwater outlet flow will result in lower quality permeate, increased feed pressure, and higher
energy consumption. For more information refer to ERI document 80088-01 Mixing Technical Bulletin or contact
ERI customer service.

4.5. Flushing
26B

There are two types of flush: Feed Water Flush and Fresh Water or Permeate Flush. Regardless of the flush water
used, all parts of the PX device must be flushed, i.e. low-pressure flow channels, high-pressure flow channels, and
lubrication channels.

Feed Water Flushing is part of a normal shutdown sequence as described in Section 4. After both permeate and
concentrate production have ceased, flow on both the high-pressure and low-pressure sides of the PX devices
continues. The flow path of the Feed Water Flush, with reference to Figure 1, is B-D-E-F-G-H driven by the feed
water pump and the circulation pump. A Feed Water Flush is typically continued until conductivity measurements at
process locations G and H are satisfactory (TDS close to feedwater TDS).

A Permeate Flush or fresh water flush is performed on a partially- or fully-depressurized system. This is
accomplished by introducing permeate simultaneously to the PX device low-pressure inlet [B] and either to the
high-pressure pump inlet [A] or through some other injection point such as a clean in place (CIP) connection.
Permeate may be produced during this flushing process. If so, it may be necessary to block permeate flow to divert
lubrication flow through the PX devices. The circulation pump must be run to flush HP side of the PX device (s).

For more detail information refer to relevent ERI technical bulletins

4.6. Purge Air

27B

Entrained or trapped air or other gases must always be purged from the RO system before pressurizing the system.
Entrained air in a pressurized system can result in damage to the PX unit. Prior to pressurizing the RO system vent
or flush for sufficient time to allow for the removal of all air from the RO system.

Warning: Entrained or trapped air must be purged from the RO system before every pressurization.

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5. SERVICE
10B

5.1. Spare part and tool kits

28B

The PX-300 energy recovery device needs no scheduled periodic maintenance. However, in the event that
disassembly is desired or required, the PX-300 unit is designed so that it can be assembled and disassembled in the
field with only basic tools and equipment. These tools are listed in Table 2. These tools, with the exception of the
hoist and torque wrench, are included in the PX-300 tool kit (ERI Part Number 20037-01). In addition, the PX-300
unit can be mounted on a stand or on blocks to facilitate service or the LP connection port can be unthreaded in
order to support the unit on the housing.

Table 2 - Tools and Fixtures Required for Assembly and Disassembly

EQUIPMENT PURPOSE
Lifting strap (typically supplied with order) to attach to housing for lifting
lifting eye (typically supplied with order) to attach to tension rod for lifting cartridge assembly
hoist, capacity: 500-pound (227 kg) for lifting housing or cartridge assembly
for removing 5/16-inch hex screws from securing rings
1/4 – inch Allen wrench
or port-bearing plates
to assemble and disassemble the ceramic cartridge
2 3/4-inch box wrenches
assembly
Torque wrench to assemble the ceramic cartridge assembly
water-soluble lubricant such as glycerin or abrasive-
for lubricating o-ring mating surfaces
free liquid soap
Tool designed to screw and unscrew LP connection
Strap wrench
ports
Dow Corning 111 Valve Lubricant and Sealant For pre-lubricating new o-rings prior to installation
Head puller Tool designed to facilitate removal of head.

Replacement seals and alignment pins are included in ERIs standard spare parts kits (ERI Part Number 20033-01).
One spare parts kit should be used each time a PX unit is opened for service.
Replacements for other components in the PX assembly are available. Refer to assembly drawing for PX component
descriptions, part numbers and the bill of materials.

5.2.Disassembly procedure
29B

Warning: Metal objects can chip or crack ceramic. Use caution when handling ceramic components
to avoid damage.

If a PX unit must be disassembled, the procedures provided in this section should be followed carefully. The tools
and fixtures listed in Table 2 are required. The procedures provided in this subsection are for complete disassembly
and subsequent assembly of a PX unit. Depending upon the reason for the maintenance work, complete disassembly
may not be required.

The following procedure is for the disassembly of a PX-300 device and inspection of the ceramic components. The
internal ceramic components can be reached through either end of the housing.

There are two recommended disassembly procedures for the PX-300 device, removing it from the piping and
disassembly in the rack.

5.2.1. Basic disassembly procedure

39B

1. Remove PX-300 unit from RO system. Ideally use an overhead crane to lift the unit by threading ERI lifting
strap into threaded hole in the bearing plate

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2. Optionally unscrew and remove the LP OUT port (Fig 5.1 and 5.2). Otherwise use blocks or a stand to support
the unit by the LP OUT end of the fiberglass housing (fig 5.3). Do not support the unit or apply stress to the
PVC low pressure port.

Fig 5.1. Port removal Figs 5.2. or 5.3. Support unit by fiberglass shell

Fig 5.4 Typical wood work stand dimensions

3. Remove all the 5/16-inch socket-head cap screws from the top of the PX unit using a 1/4-inch Allen wrench as
shown in Figure 5.5. Remove the fiberglass securing rings. (Fig 5.5)

4. Tap down on the port bearing plate to loosen the lock ring segments as shown in Figure 5.6. Remove the three
segmented lock rings.

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Fig 5.5. Remove 5/16 inch socket head cap screws Fig 5.6. Tap down on the port bearing

5. Extract the port bearing plate assembly from the housing using an ERI-supplied head puller tool or a hoist as
shown in Figures 5.7. and 5.8. Take care not to apply stress to the PVC LP port if it is still in place. Always use
a wood block to protect the edge of the housing if force is necessary to remove the head assembly.

Fig 5.7. Use a hoist and Lifting Strap Fig 5.8. Using Head Puller Tool

6. Remove the thrust ring and LP interconnectors. See Figures 5.9 and 5.10.

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Fig 5.9. Inside of the housing after removing head Fig 5.10. Remove Trust ring and LP interconnectors

7. Extracting the ceramic cartridge assembly:

a. Either:
i. Attach head puller tool onto the end of the tension rod. See figure 5.11
ii. Or attach the lifting eye onto the end of the tension rod. Attach a hoist to the lifting eye. See
figure 5.12
b. Clean the inner diameter of housing to remove any salt build up or biofouling present.
c. Lubricate the inside of the housing with a water-soluble lubricant such as glycerin or nonabrasive
liquid soap.
d. Extract the ceramic rotor subassembly of the housing. It may be necessary to apply downward force to
the edge of the housing while hoisting to get the ceramic rotor subassembly to slide out of the housing.
Always use a wood block to protect the edge of the housing if force is necessary to remove the rotor
subassembly. Be careful not to hit the rotor subassembly.

Fig 5.11. Head Puller Tool Fig 5.12. Using Lifting Eye & Hoist Fig 5.13. Removing cartridge

8. The ceramic rotor subassembly must be returned to the housing in the same orientation it was removed. Mark
the housing and the ceramic cartridge with a pencil or marker to assure that correct orientation is retained upon
reassembly. Note the endcovers are marked either "feedwater" or "concentrate" and should be oriented to the
appropriate side of the housing.

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9. Follow these steps to disassemble the ceramic cartridge:

a. Stand the ceramic rotor subassembly on blocks allowing clearance for the tension bolt and nuts on the
bottom of the assembly. See Figure 5.14 which illustrates correct rotor subassembly orientation.

Feedwater Endcover

Rotor / Sleeve Assembly

Concentrate Endcover

Fig 5.14. Ceramic cartridge

b. Remove the hex nuts and washers from the top end of the tension rod.
c. Lift the endcover off the rotor and sleeve, be careful not to loose the alignment pins or replace as
required.

Fig 5.15. Lift ceramic endcover

d. Lift the rotor and sleeve off the bottom endcover. DO NOT ALLOW THE ROTOR TO COME OUT
OF THE SLEEVE.
e. If the rotor comes out of the sleeve, the following procedure should be applied:
i. Clean the rotor and sleeve. Rinse liberally.
ii. Inspect rotor and sleeve. Remove all debris. Avoid getting lint or dirt onto the ceramic.
Re-rinse if necessary.
iii. Identify the end of the rotor marked “CHK”. Place the rotor on a flat clean surface with
the end marked “CHK” oriented upward.
iv. Identify the end of the sleeve marked “CHK” and orient it upward. If the sleeve is
marked “CHK SWP” orient the "CHK SWP" end downward.
v. Hold the sleeve over the rotor. Slowly slide the sleeve onto the rotor. This is a very tight
fit and requires a gentle touch. Do not force the sleeve on by pressing or hitting it. The

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sleeve should slide on easily. If the rotor and sleeve become bound, use hot water on the
sleeve to loosen it from the rotor.
vi. Contact Energy Recovery, Inc. if problems are encountered.

Thoroughly flush all PX components with clean water before assembling PX unit. Foreign
material may inhibit rotor movement.

5.2.2. Disassembly procedure for the PX-300 device on the rack or piping
40B

1. Depressurize all high-pressure and low-pressure piping to and from the PX unit.
2. Close all valves to and from the PX-300 unit or PX-300 rack or drain system.
3. Disconnect and remove the low pressure piping from the upward facing end of the unit. See Figures 5.16 and
5.17
4. Proceed with disassembly as directed in section 5.2.1 above.

Fig 5.16. PX device on array rack Fig 5.17. Access head and cartridge while unit
remains on array rack

5.3. Asembly procedure

30B

This assembly procedure assumes that the PX-300 unit has been disassembled per the previous section. All parts
should be carefully cleaned with clear water prior to assembly to ensure that no dirt or debris contaminates the PX
device. All parts should be thoroughly inspected for damage and/or debris prior to reassembly. O-rings should be
replaced by new set of orings. Do not attempt to reassemble a PX unit with damaged or broken parts.

For best results pre-lubricate all new o-rings with a very thin coating of Dow Corning 111 Valve Lubricant and
Sealant prior to installation. Wipe off any excess lubricant using a lint free cloth. O-rings should appear wet but not

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feel sticky or have any excess lubricant on the surface. See Figure 5.18. Dirt and debris can stick to pre-lubricated
o-rings. Use appropriate precautions to keep them clean during handling and storage.

Always lubricate all o-ring mating surfaces immediately prior to assembly with a suitable water soluble lubricant
such as glycerine or liquid soap

Improperly lubricated
o-ring showing
excess lubricant

Properly lubricated
o-ring
Fig 5.18. O-Ring Comparison

To assemble the cartridge, follow these steps:

1. Replace both tension rod o-rings.

2. Lubricate the tension-rod o-rings and the inside of the center hole of both endcovers.
3. Insert the tension rod through the ceramic endcover.
4. Insert dowel pins into the 3 holes on the face of the endcover as shown in Figure 5.19. Make sure the dowel pins
are fully seated in the endcover and the sharp ceramic edge has not created a burr. If a pin binds, remove and
clear the pin and hole of any debris.
5. Carefully place the assembled rotor and sleeve onto the endcover. Make sure that the dowel pins in the
endcover line up with the 3 holes in the sleeve as illustrated in Figure 5.20.

6. Install both washers and one hex nut finger tight. The fiberglass washer should be against the ceramic followed
by the metal washer and then the nuts. See Figure 5.21.

Fig 5.19. Insert dowel pins Fig 5.20. Assembly Fig 5.21. Washer Sequence

7. Carefully inspect the contact lines between the sleeve and the endcovers to be sure there are no gaps. See Figure
5.22. Occasionally, the assembly process will shave one or more of the pins and the debris that is generated will
prevent the sleeve and the endcover from coming into intimate contact. If this occurs, remove the rotor and
sleeve assembly, rinse ceramics, and remove all debris. Repeat assembly.

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Inspect the point of contact

between the sleeve and the
endcovers to be sure there are no
gaps

Fig 5.22. Assembled Cartridge

8. Tighten the nut closest to the cartridge assembly and torque to 15 ft-lb (20 N-m)
9. Thread the second nut onto the tension rod. This nut will act as a lock nut. Torque to 40 ft-lb (56 N-m) while
holding the adjacent nut. Make sure that the tension the inner nuts apply on the cartridge does not change. See
Figure 5.23.
10. Verify that the rotor can spin freely. Use a wooden or plastic dowel to advance rotor as illustrated in Figure
5.24.

Fig 5.23. Tightening Lock Nut Fig 5.24. Verify The Rotor Spins Freely

11. Lubricate all o-rings on the LP interconnectors as well as their receiving holes on the seal plate. Insert and fully
seat LP interconnectors into seal plate
12. If it was removed re-install the thrust ring as shown in Figures 5.25 and 5.26. Make sure it is oriented such that
the key engages with the seal plate and the side port is not blocked.

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Fig 5.25. Trust Ring Orientation Fig 5.26. Seated Trust Ring

13. Lubricate the cartridge o-rings, the 4 LP interconnect holes and the inside of the housing.
14. Attach the lifting eye to the cartridge assembly and attach to hoist.
15. Lower the cartridge assembly into the housing as shown in Figure 5.27. Make sure that the ceramic LP opening
are lined up with the LP interconnectors. This can be done by using the cartridge installation tool from the
toolkit as shown in Figure 5.28.

Fig 5.27. Insert the ceramic cartridge Fig 5.28. Cartridge installation tool.
into the housing.

16. Disconnect the hoist from the rotor subassembly.

17. Lubricate the o-rings of the LP interconnects and insert into the endcover.
18. Insert a thrust ring into the housing as shown in Figure 5.29. The ring must be compressed slightly during
insertion.

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Thrust ring must

not block Step of the
sideport thrust ring
towards head

Cartridge
fully seated

Fig 5.29. Insert thrust ring into the

housing.

19. Assemble the ports, the securing ring, the port bearing plate, the port locking rings, the seal plate and the O-
rings as shown in the assembly drawing. A completed port bearing plate subassembly is shown at the end of this
section. Be sure to lubricate all O-rings with a water-soluble lubricant or a non-abrasive liquid soap.

20. Lubricate the quad ring on the head assembly and the inside of the housing.
21. Insert the head assembly into the top of the housing. Make sure the low-pressure port lines up with the low-
pressure nipple. This can be verified by looking down through the low-pressure port while inserting the port
bearing plate subassembly. If the head does not insert fully, the low-pressure interconnects may not be correctly
aligned with their corresponding holes. Look down into the low-pressure port as illustrated in Figure 5.30. to
verify alignment. If the low-pressure port, low pressure interconnector, and endcover are not aligned, remove
the port bearing plate assembly completely, remount the quad ring, and try again.

Fig 5.30. LP interconnectors aligned

22. Insert the 3-part segmented lock ring into the space between the port bearing plate and the housing as shown in
Figure 5.31. If the lock ring segments will not fit into the gap, make sure the segments are correctly oriented. If
the segments still do not fit, this may be an indication that the low-pressure nipple is not correctly aligned. If so,
remove the port bearing plate and repeat the previous step.
23. Insert the fiberglass securing ring. Bolt down the securing ring with three 5/16-inch socket-head cap screws.
See Figure 5.32

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Fig 5.31. Insert 3-part segmented lock ring Fig 5.32. Bolt down securing ring

24. If removed thread LP connection port onto the bearing plate using the strap wrench (if necessary). See
Fig 5.33.

Fig 5.33. Installing the LP port

25. To assemble the head, follow these steps:

1. Lubricate o-ring and insert it inside the seal plate

2. Line up the seal plate thread holes with bearing thread holes

3. Bolt down the bearing plate with two 5/16-inch socket-head cap screws.

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Fig 5.34. Insert o-ring into seal plate Fig 5.35. Align holes on seal and bearing plates

6. TROUBLESHOOTING
1B

This section is designed to guide the operator in identifying and correcting most of the problems that could occur in
the PX energy recovery device. The instructions provided below are intended for use by personnel with general
training and experience in the operation and maintenance of fluid handling systems. This is not intended as a
comprehensive maintenance guide. Conditions not covered in this section may be resolved by contacting ERI’s
Service Department.

Preliminary procedures:
• Always check for proper valve configuration for the operation mode selected.
• Always inspect and test equipment or apparatus for possible causes of malfunctions before performing
replacements.

Instrumentation:
The following list of instrumentation is useful in monitoring and diagnosing the operation of PX devices.
• ERI requires that one flowmeter be installed in the PX unit(s) HP flow circuit and one in the LP flow path.
• ERI requires a pressure instrument be installed between the low pressure outlet and any control valve to
monitor device backpressure.
• ERI recommends that high flow and pressure alarms/shutdowns be incorporated into the system design to
protect the PX unit(s) from potential damage by high flows.
• ERI suggest using a TDS meter to check the conductivity of the streams entering and exiting the PX device
to monitor device performance.

When using this troubleshooting guide, please read all the probable causes before taking any action. Use common
sense and select the cause that seems to best fit the given situation.

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Troubleshooting Guide
31B

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

A. Excessive sound 1. Operating PX unit(s) above rated
levels flow rates
2. Operating PX unit(s) below
minimum back-pressure
3. Air in system
4. PX unit or ceramic cartridge
installed upside down
5. Damaged ceramic
B. Excessive high 1. Membrane fouling or scaling
pressure
2. Excessively high recovery in the
RO system
3. HPP is operating at too high of a
flow rate
4. Low pressure flow is less than
high-pressure flow, resulting in
mixing and high RO feed water
salinity
5. Stuck rotor
C. High salinity in 1. Unbalanced system
high-pressure
2. A stalled rotor
feedwater stream
D. Stalled rotor - no 1. Foreign debris or biological
audible rotation growth lodged in device
2. Operating system above rated
pressure or below rated flow
capacity
E. Low permeate flow 1. Membrane fouling or scaling
2. High pressure leak
3. HPP problem
Immediately reduce flow rates.
To increase system capacity, add PX unit(s) in
parallel to existing units.
Increase feedwater supply pressure. Re-balance the
system as described in Section 4.
Bleed air.
Verify that the PX unit has been installed with the
end marked “HPIN” oriented toward the concentrate
inlet. If service was performed, verify the orientation
of the ceramic cartridge by removing the concentrate-
side port bearing plate assembly. The endcover
marked “Concentrate” should be oriented toward the
concentrate inlet/outlet.
Contact the ERI Service Department
Contact membrane manufacturer for cleaning
recommendations.
Reduce recovery by increasing and balancing flows
through the PX unit(s). Do not exceed recommended
maximum PX unit flow rates.
Adjust flow rates
Adjust flow rates. See Section 4.
See Symptom D.
Check flow rates. See Section 4.
See Symptom D.
Conduct a fresh water flush.
Disassemble PX device per manufacturer procedure
and remove foreign debris.
If problem persists, contact the ERI Service
Department.
Check flow rates and pressures. See section 1.5.
Contact membrane manufacturer for cleaning
recommendations.
Identify and fix leak in RO system or inside PX
device.
Contact HPP manufacturer or service HPP

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7. LEARNING MORE AND CONTACTING ERI

12B

More information about PX technology is available on ERI’s website: www.energyrecovery.com, by emailing ERI’s
HTU UTH

service department at support@energyrecovery.com or by telephoning ERI at +1-510-483-7370. Refer to Technical

documents for PX device component names and the bill of materials for the PX unit assembly. Refer to Products
section in ERI website for recommended spare parts and tool kits.

ERI’s Technical Services staff offers commissioning service for all ERI products during field installation and/or at a
RO system manufacturer’s location. Service rate quotes are available upon request.

8. REVISION LOG
13B

Revision Description Date

0 Initial release 04/10
1 Updated pictures, added lubrication notes 09/10

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