GFPS products in Seawater

Desalination Units

1 Adv-M4 Water Treatment Fundamentals | 12/2014 | Daniel Friedrich

Sea Water Desalination -
Basic Plant Configuration
Raw Water Pumps &
Storage Tank
Ultrafiltration
Chemicals for Backwashing UF
and Cleaning RO
Dissolved Air Flotation

Reverse Osmosis

MultiMediaFilter

Chemicals for
Water Blending

Pure Water Storage Tank

Chlorine disinfection
and Blending

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Product range for sea water
desalination plantsPlastic pipes & fittings

ecoFIT PVC-U / PVC-C PROGEF CONTAIN-IT / Double See

Polyethylene Polyvinylchloride Polypropylene Double-Wall

Manual and automatic valves

563 / 567 / 568 543 / 546 / 375 514 / 515 / 517 582 / 586

Plastic Butterflyvalves Ball Valves Diaphragm Valves Pressure Retaining

Valves

Couplers & accesories

Tangit ELGEF plus

Welding machines for
Solvent butt fusion and Large dimension
Cement elctrofusion couplers

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Instrumentation for sea water
desalination plantsInstruments & transmitters

U1000 2551 / 2552 335 / 350 2536 / 2537

UltrasonicFlow Magmeters Rotameters Paddle-Wheel

27xx 28xx 4150

pH / Orp-sensors Conductivity-sensors Turbidity

2260 / 2270 2281 2280 2285

Level Switch Swing Fork
Ultrasonic Level Conductive Level Switch Floating Switch

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Raw Water Pumps & Storage Tank

Process Conditions
• Medium salt water -> highly corrosive
• Sea Water atmosphere -> corrosion outside pipe
system
• Flow rates: 4.800 m³/d – 600.000 m³/d
• Piping inside and outside of buildings -> temperature
peaks and UV-impact on piping
State of the Art equipment
• SS and FRP pipes
• Butterfly Valves with Super Duplex
Discs
+GF+ solution/ advantages
• HDPE – piping systems
• Even large dimensions available/ more flexible onsite than FRP/ saddles reduce
required space and save costs
• Less weight than SS and definitive no corrosion inside & outside
• Even duplex discs of butterfly valves will corrode after some years – plastic ones do
not and we now have the possibility to offer butterfly valves up to d1200

5 Adv-M4 Water Treatment Fundamentals | 12/2014 | Daniel Friedrich

Raw Water Pumps & Storage Tank

ELGEF plus 563 / 567 / 568

Large dimension Plastic
couplers Butterflyvalves

543 / 546 / 375

HDPE / ELGEF
Ball Valves
Polyethylene

2280
Swing Fork
Level Switch
2260 / 2270 2285 2551 / 2552
Ultrasonic
Levelsensor Floating Switch Magmeters

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Pumping Station examples

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Dissolved Air Flotation

Process Conditions
• Medium salt water -> highly corrosive
• Dosing of Ferric Chloride, Caustic Soda
and Polymer solution
• Addition of compressed dried air (CDA)
• Sea Water atmosphere -> corrosion outside pipe
system
• Flow rates: 4.800 m³/d – 600.000 m³/d
• Pressure 2-6 bar , 6 bar on CDA side
• Piping inside and outside of buildings -> temperature
peaks and UV-impact on piping
• Vessels made of concrete, CS and SS
Process goal and special requirements
• Removal of nearly all suspended solids (outlet normally 10-15 ppm conc.),
• Removal of large impurities incl. small crabs, fish, algae ….
• Problems with deposits inside pipes due to pH adaption (precipitation of
carbonates)
• Problems with dosing of several chemicals
• Need for reliable CDA-system
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Dissolved Air Flotation

State of the Art equipment

• SS and FRP pipes
• Butterfly Valves with Super Duplex Discs
• Diaphragm valves of CS and SS
• Pressure sensors of SS
• pH sensors installed directly in the vessels

+GF+ solution/ advantages

• HDPE piping system – one material for all pipes – even double containment
systems available, nor corrosion , less tendency for deposits than SS or FRP
• Wall penetration sealing system available (normally done with SS nozzles -> very
expensive)
• CDA system made from +GF+ - easily extendable during operation (weld on tapping
valves)
• Butterfly valves (large dimension), diaphragm valves for process media and ball
and PRV-valves from +GF+ available – one package
• On site welders training, rental welding machines

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Dissolved Air Flotation
335 / 350

Rotameters

ELGEF plus
582 / 586
PE for CDA Pressure Retaining Valves

HDPE / ELGEF

Polyethylene CONTAIN-IT / Double See

Double-Wall

563 / 567 / 568 2551 / 2552 514 / 515 / 517 543 / 546 / 375
2260 / 2270 27xx
Plastic Ultrasonic pH / Diaphragm Valves Ball Valves
Magmeters
Butterflyvalves Levelsensor Orp-sensors

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MultiMediaFiltration
Process Conditions
• Medium salty water -> highly corrosive
• pH adapted to neutral slightly acidic
values
• Only few bigger particles left
• Flow rates: 4.800 m³/d – 600.000 m³/d
• Pressure 2-4 bar , filters normally
operated at max. 1 bar Dp
• Piping inside and outside of buildings ->
temperature peaks and UV-impact on
piping
• Vessels made of concrete, CS and SS

Process goal and special requirements

• Removal of all suspended solids bigger than 0,05 mm
• Preparation step for Ultrafiltration unit
• No difficult media left, only salt content generates corrosion issues

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MultiMediaFiltration
State of the Art equipment
• SS and FRP pipes, often prefabricated
face piping (skids)
• Butterfly Valves with Super Duplex
Discs
• Ball valves of CS and SS
• Pressure sensors of SS for differential
pressure and blocking
• Mag meters detection of flow velocities
and blocking

+GF+ solution/ advantages

• Prefabrication of filter piping in all +GF+ systems possible
• Plastic versus Steel less weight – for transport
• Assistance with workshop welding machine no matter where prefabrication is done
• Signet instruments for installation directly inside pipe for pH & flow
• More than 100.000 open/close cycles with our pneumatic actuators possible
• For solid containing media use butterfly valves or diaphragm -> no ball valves

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MultiMediaFiltration

PROGEF PVC-U
Polyvinyl-
Polypropylene chloride

563 / 567 / 568

HDPE / ELGEF Plastic
Polyethylene Butterflyvalves

335 / 350 514 / 515 / 517 563 / 567 / 568

2551 / 2552 543 / 546 / 375

Rotameters Diaphragm Automatic

Magmeters Ball Valves
Valves Butterflyvalves

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MultiMediaFiltration

14 Adv-M4 Water Treatment Fundamentals | 12/2014 | Daniel Friedrich

Ultrafiltration

Process Conditions
• Medium salt water -> highly corrosive
• Only few bigger particles left
• Flow rates:
inlet 4.800 m³/d – 600.000 m³/d
filtrate: 4.320 m³/d – 540.000 m³/d
• Pressure 2-4 bar , filters normally operated at max. 1
bar Dp
• Several different cleaning chemicals to be applied after
each filtration cycle
(approx. 10 minutes length)

Process goal and special requirements

• Removal of tiny particles down to size of bacteria and even viruses
water is normally crystal clear after an UF-step
• Problems with deposits and fouling on membranes -> periodically cleaning required
• Problems with quick blocking of the system if the mediafilters in front are not
working properly

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Ultrafiltration
State of the Art equipment
• Both plastic and steel piping
• Several automatic butterfly or
diaphragm valves required per UF unit
• Instrumentation:
- flow
- pressure
- temperature
- turbidity
- pH

+GF+ solution/ advantages

• Prefabrication of filter piping in all +GF+ systems possible
• Customizing for the headers possible (PE-Pipe with weld on saddles – space and
money saving or even for special customers special headers – e.g. Inge T-Rack)
• Complete package of sensors (flow, pH, turbidity and pressure, temperature)
• Complete package of valves
• Complete plastic double wall system for CIP-stations (cleaning in place) – at least 4-
5 chemcials used

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Ultrafiltration

PVC-U
Polyvinylchloride

543 / 546 / 375

Ball Valves

PROGEF
Polypropylene

514 / 515 / 517

HDPE / ELGEF
Diaphragm
Polyethylene Valves

27xx 2551 / 2552 4150 CONTAIN-IT / Double See

pH / Orp-sensors Magmeters Turbidity Double-Wall

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Ultrafiltration

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Reverse Osmosis
 Process Conditions
• Medium salt water -> highly corrosive
• No particles left
• Flow rates:
inlet 4.320 m³/d – 540.000 m³/d
outlet 2.400 – 300.000 m³/d
Pressure 45 - 55 bar
permeate flow by gravity
brine/concentrate flow ->
inlet pressure – 2 bars (43-53 bar)
• Several different cleaning chemicals
from time to time to be applied
(depends on scaling and fouling)

Process goal and special requirements

• Demineralisation / Desalination of the Sea or Brackish Water
• Problems with deposits and fouling on membranes -> periodically cleaning required
• Problems with high salt concentrations on brine/concentrate outlet

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Reverse Osmosis
State of the Art equipment
• Both FRP and steel piping on Inlet and
Concentrate Side
• Thermoplastics only on permeate side
• Instrumentation:
- flow
- pressure
- temperature
- conductivity – low range
- pH

+GF+ solution/ advantages

• Prefabrication of filter piping in all +GF+ systems possible
• Customizing of permeate collectors and sampling units possible – 3-way ball valve
with connected piping spool
Complete plastic double wall system for CIP-stations (cleaning in place) – at least 4-
5 chemcials used

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Reverse Osmosis

PROGEF 543 / 546 / 375

Polypropylene Ball Valves

CONTAIN-IT / Double See

Double-Wall
Customised Permeate
Headers

27xx 2551 / 2552 28xx

pH / Orp-sensors Magmeters Conductivity-

sensors

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Reverse Osmosis

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Chlorine disinfection / blending
Process Conditions
• Pure Water, no salts, not possible for
human consumption
Process goal and special requirements
• Dosing of minerals like fluoride
• Dosing of chlorine for disinfection

State of the Art equipment

• SS pipes
• Butterfly Valves with simple SS discs
• Double wall plastic pipes for chemical
dosing
• Several measurements like flow, pH …

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Chlorine disinfection / blending

Flow 2280
Swing Fork
Level Switch

UltrasonicLevel

UltrasonicLevel

Chlorine / pH

conductivity

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Additional +GF+ services &
customers’ benefits
Online Tools www.gfps.com
• Chemical resistance table
• Flow calculator
• Design basis for plastic piping system available
• CAD library for Solidworks, Catia, AutoCad, Pro engineer online
available
• New: first PDMS-CAD library for Thermoplastics on request available
• Smart logistic concepts
Installer and engineering trainings
• Engineering training for basic calculation and design of thermoplastic
piping systems
• Training on +GF+ products and installation technology for customers in
GF+ headquarter in Schaffhausen Switzerland
• Onsite training for installation staff on welding machines

Customized products
• Headers for UF-skids
• Permeate collectors for RO-skids

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Reference Case 1 - Fujairah
Object Name Fujairah II Water Production Plant
(UAE)

Type of Object Hybrid plant : RO Desalination / MED

Basic Data 150 000M3/day Water production

Sea Water Reverse osmosis

Place of Fujairah: United Arab Emirates

installation,
Country

Owner, Country Abu Dhabi Water & Electricity

Authority

Date of Installation 2009

GF Piping Material HDPE, PVCU, PVDF, Sygef PFA

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Reference Case 2 - Adelaide
Object Name Adelaide Desalination Project
(AUS)

Type of Object RO Desalination

Basic Data 150 000M3/day Water production

Sea Water Reverse osmosis

Place of Adelaide; Australia

installation,
Country
Owner, Country Adelaide Aqua Consortia

Date of Installation 2010 - 2011

GF Piping Material HDPE, PVCU, PVDF, Sygef PFA

27 Adv-M4 Water Treatment Fundamentals | 12/2014 | Daniel Friedrich

Reference Case 3 – Llobregat
Object Name Desalination Plant Llobregat,
Spain

Type of Object Electro Dialysis reverse EDR

desalination Plant

Basic Data 200 000M3/day Water production

Place of Abrera city along the Llobregat River

installation, Spain
2 RACKS OI 2 º PASO REMINERALIZACION
15 500 m3 /d - Conversión 85% 32 FILTROS CALCITA
12 km IMPULSION AL
DEPOSITO de
Country
Conversión Total 44% FONTSANTA
10 RACKS OI 1 er PASO DEPOSITO Y (Ø 1400)
20 500 m3 /d - Conversión 45% 5 BOMBAS AGUA POTABLE

Owner, Country Aigües Ter-Llobregat ATLL

10 BOMBAS MP DESCARGA de SALMUERA
Y EFLUENTES
20 FILTROS SEACLEANTM 2 DENSADEGTM
CLARIFICADOR y ESPESADOR
10 Racks ERI x 22 PX

12 BOMBAS AGUA FILTRADA 10 BOMBAS AP y BOOSTER

A DESCARGA
Date of Installation 2009 -2010
18 FILTROS CARTUCHOS EDAR LLOBREGAT

DESHIDRATACION FANGOS
Y SILOS
DEPOSITO AGUAS LAVADO Y
FANGOS GF Piping Material Progef , PVCU, PE
TAMIZADO
20 FILTROS MEDIAZUR GH TRATAMIENTO EFLUENTES
10 SeaDAF TM

6 BOMBAS AGUA de MAR

SDT= 39 700 mg/l

TOMA AGUA de MAR Temperatura= 12 – 25 0 C
(2 Ø 1800) (h= - 25 m)

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Reference Case 4 Infra Leuna –
Process Water Treatment Plant
SC: Germany

responsible Frank Friedrichs

Customer: Infra-Leuna

Engineering Consultant: n.a.

EPC: WAT Membratec , Erkrath

Installation Site: Chemical Complex, Leuna

Germany

+GF+ Market Segment: WT / CPI

Year of Installation 2013

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Reference Case 4 Infra Leuna –
Process Water Treatment Plant
Installation Conditions
Medium:
inside, prefabricated pumping stations
/ UF and RO-racks – interconnecting
piping on site
existing service water quality to be
treated in order to achieve demin-
quality 15-25°C

+GF+ pipe material (MOC) & +GF+ products

Product Qty Net selling price
(Anzahl) (Netto
Auftragsvolumen)

PVC-U pipes & fittings DN15-DN200

ISO-standard

PP-H pipes & fittings DN25-DN100

ISO-standard

Metal butterfly valves 038/039 (with

pneumat. actuators, limit swtches…)

546 ball valves DN15-25

Diaphragm valves 514/Diastar

Total Project Amount 120 k€

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Reference Case 4 Infra Leuna –
Process Water Treatment Plant
Project Description:

Greenfield Process Water plant at the petrochemical site of Leuna /

Germany by WAT Membratec. Water from existing service water
system of the chemical plant is treated in order to achieve demin-
quality for several consumers on site. The process water plant
consists of an UF/RO-system, inclduing required heat exchanger
systems and different chemical dosing units for cleaning in place
(CIP) of the membrane equipment.

WAT Membratec is a medium-sized German EPC-company for any

kind of water treatment plants. WAT is a longterm +GF+ customer
relying on +GF+ quality in order to meet the high requirements
regarding safety and up-time of chemical industry.

31 Adv-M4 Water Treatment Fundamentals | 12/2014 | Daniel Friedrich