320PRJ1201007-10-201 - O&M MANUAL - Rev 0

DOC. No.
320PRJ1201007-10-201
OPERATION & REV. NO. 0
MAINTENANCE MANUAL SHEET Page 1of 164
DATE 02-Oct-2013

Operation & Maintenance Manual

PROJECT NAME : LUBUK GAUNG REFINERY

OWNER : PT LVO MAS TUNGGAL.

SITE : NORTH EAST SUMATRA

SUPPLIER : (OVERSEAS) LTD

0 02/10/2013 Issued For Information CT PA TM
Rev. Date DESCRIPTION PREPARED CHECKED APPROVED
THIS DOCUMENT CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF METITO COMPANY. DO NOT DISCLOSE OR DUPLICATE WITHOUT PRIOR WRITTEN CONSENT OF METITO COMPANY

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PREFACE
This manual covers the operation and maintenance instructions of the Water Treatment Plant at PT
Smart Indonesia. In order to ensure that the plant operates under optimal conditions, it is
recommended that the users familiarize thoroughly this O & M Manual and all instructions herein are
carefully followed.
The Water Treatment Plant has been designed to treat sea water to render it suitable for usage. The
quality of main equipment, which is essential for proper operation, such as choice of equipment,
instruments, materials, sizing etc., have been carefully reviewed, selected and controlled during the
design, manufacturing & installation stages.
Should there be a requirement for maintenance assistance or spare parts, our Customer Services
Department may be contacted at the following address:
(OVERSEAS) LTD.
P.O Box 22701
Sharjah
United Arab Emirates
Phone:(06) 556 1818
Fax: (06) 556 4777
E- mail: metito@emirates.net.ae

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Table of Contents
1. USE OF THE O & M MANUALL ............................................................................................ 9

1.1 General ................................................................................................................................... 9
1.2 Glossaries of Terms ............................................................................................................ 10
2. INTRODUCTION ................................................................................................................... 16
2.1. Scope .................................................................................................................................... 17
2.2. Water Treatment System ..................................................................................................... 17
2.3. Reference Document ........................................................................................................... 18
3. DESIGN BASIS AND WATER QUALITY ............................................................................. 19
3.1 Feed Water Analysis ............................................................................................................ 20
3.2 DAF Product Water Quality ................................................................................................. 20
3.3 UF Product Water Quality ................................................................................................... 21
3.4 Design Product Water Quality ........................................................................................... 21
4. EQUIPMENT AND PROCESS DESCRIPTION..................................................................... 22
4.1 Sea Water Intake Pumps (1007-P101A/B) .......................................................................... 23
4.2 Dissolved Air Floatation system (1007-DAF101) ............................................................. 23
4.3 Static Mixer (1007-SM101) ................................................................................................... 24
4.4 Clarified Water Tank (1007-T102) ....................................................................................... 24
4.5 Oily Sludge Tank (1007-T102) ............................................................................................. 24
4.6 UF Feed Pumps (1007-P103A/B)......................................................................................... 25
4.7 Self Cleaning Filter (1007-SCF 101).................................................................................... 25
4.8 Ultra Filtration System (1007-UF 101) ................................................................................ 27
4.9 RO Feed / UF Backwash Tank (1007-T103)....................................................................... 32
4.10 UF Backwash Pumps (1007-P105 A/B) .............................................................................. 32
4.11 Static Mixer (1007-SM102) ................................................................................................... 33
4.12 SWRO Feed Pumps (1007-P104 A/B) ................................................................................. 33
4.13 Static Mixer (1007-SM103) ................................................................................................... 33
4.14 SWRO Cartridge Filter (1007-CF101).................................................................................. 33
4.15 SWRO High Pressure Pump (1007-P-106 A/B) .................................................................. 34
4.16 Pressure Exchanger (1007-PX-101A/B) ............................................................................. 35
4.17 ERD Booster Pump (1007-P-107A/B) ................................................................................. 36

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4.18 SWRO System (1007-RO101) .............................................................................................. 36

4.19 SWRO Permeate Tank (1007-T104) (By others) ............................................................... 40
4.20 BWRO Feed Pumps (1007-P108 A/B) ................................................................................. 40
4.21 BWRO Cartridge Filter (1007-CF-102) ................................................................................ 41
4.22 BWRO High Pressure Pumps (1007-P106 A/B) ................................................................. 41
4.23 BWRO System (1007-RO-102) ............................................................................................ 42
4.24 BWRO Permeate Tank (1007-T106) (By others) ............................................................... 45
4.25 BWRO Reject Water Tank (1007-T105) (By others).......................................................... 45
4.26 Coagulant Aid Tank (1007-DT101 A/B)............................................................................... 45
4.27 Coagulant Aid Dosing Pumps (1007-DP101 A/B)............................................................ 455
4.28 Sodium Hypochlorite Dosing Tank (1007-DT102) ............................................................. 46
4.29 Sodium Hypochlorite Dosing Pump (1007-DP102 A/B) .................................................... 46
4.30 Caustic Soda Dosing Tank (1007-DT103) .......................................................................... 47
4.31 Caustic Soda Dosing Pump (1007-DP103A/B) .................................................................. 47
4.32 Sulphuric Acid Dosing Tank (1007-DT104)....................................................................... 48
4.33 Sulphuric Acid Dosing Pump (1007-DP104A/B)................................................................ 48
4.34 Sodium Hypochlorite Dosing Tank (1007-DT105) ............................................................. 48
4.35 Sodium Hypochlorite Dosing Pump (1007-DP105A/B) ..................................................... 49
4.36 Ferric Chloride Dosing Tank (1007-DT106) ....................................................................... 49
4.37 Ferric Chloride Dosing Pump (1007-DP106 A/B/C/D) ....................................................... 49
4.38 Antiscalant Dosing Tank (1007-DT107).............................................................................. 50
4.39 Antiscalant Dosing Pump (1007-DP107A/B)...................................................................... 51
4.40 Sodium Bisulfite Dosing Tank (1007-DT108)..................................................................... 51
4.41 Sodium Bisulfite Dosing Pump A/B (1007-DP108 A/B) .................................................... 52
4.42 Caustic Soda Dosing Tank (1007-DT109) .......................................................................... 52
4.43 Caustic Soda Dosing Pump (1007-DP109A/B) .................................................................. 53
4.44 CIP Tank (1007-T-112) ......................................................................................................... 53
4.45 CIP Pumps (1007-P-112A/B) ............................................................................................... 54
4.46 CIP Cartridge Filter (1007-CF-103)...................................................................................... 54
5.0 ALARM LIST ......................................................................................................................... 54
6.0 PRECOMMISSIONING CHECKS ......................................................................................... 57
6.1 General. ................................................................................................................................ 58
6.2 Preparation for Initial Start-Up............................................................................................ 58
6.3 General Check-Up. ............................................................................................................... 58

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6.4 Line Flushing ....................................................................................................................... 58

6.5 Leak Testing ......................................................................................................................... 58
6.6 Electrical Checks ................................................................................................................. 59
6.7 Instrumentation Check ........................................................................................................ 59
6.8 Pump Pre-Start Check ......................................................................................................... 59
6.9 Availability of Utilities ......................................................................................................... 59
6.10 Availability of Chemicals .................................................................................................... 60
6.11 Chemical Injection System ................................................................................................. 60
6.12 Valve Check & Dry Test ....................................................................................................... 60
6.13 Dissolved Air Flotation (1007-DAF101)……………………………………………………..…..61
6.14 Self Cleaning Filter (1007-SCF 101)……………………………………………………………..61
6.15 UF System (1007-UF 101)…………………………………………………………………………61
6.16 Pressure Exchanger (1007-PX 105 A/B)……. …………………………………………………61
6.17 Pressure Exchanger (1007-PX 105 A/B)……. …………………………………………………61
7.0 INITIAL START UP ............................................................................................................... 62
7.1 Preparation for Initial Start-up .......................................................................................... 633
7.2 RO Plant Operation .............................................................................................................. 64
7.2.1 General ........................................................................................................................ 64
7.2.2 Routine Checks .......................................................................................................... 65
7.2.3 R.O Plant Shutdown .................................................................................................. 65
7.2.4 Duties of Plant Operator ............................................................................................ 66
7.2.5 General Operating Requirements ............................................................................. 66
7.3 Data Logging……………………….………………………………………………………………..667
7.3.1 General ........................................................................................................................ 64

7.3.2 Routine Checks .......................................................................................................... 65
7.3.3 R.O Plant Shutdown .................................................................................................. 68
7.3.4 General Operating Requirements ............................................................................. 68
7.3.5 Summary Preliminary Checks .................................................................................. 68
7.4 Start-Up Procedure .............................................................................................................. 69
7.5 Normal Maintenance ............................................................................................................ 70
7.6 SBS Dosing System ............................................................................................................ 70
7.7 Cartridge Filter ..................................................................................................................... 71
7.7.1 General ........................................................................................................................ 71
7.7.2 Start-up ....................................................................................................................... 71

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7.7.3 Shutdown .................................................................................................................... 72

7.7.4 Normal Operation ....................................................................................................... 72
7.7.5 Cartridge Filter Changing .......................................................................................... 72
7.8 SWRO Unit ........................................................................................................................... 73
7.9 MEMBRANE CLEANING PROCEDURE ............................................................................. 74
7.10 Instructions for SDI Kit ....................................................................................................... 87
8.0 GUIDELINES FOR DATA RECORDING .............................................................................. 90
8.1 General ................................................................................................................................. 90
8.2 Purpose of Record Keeping................................................................................................ 90
8.3 Operation Logs .................................................................................................................... 91
9.0 O&M JOB DESCRIPTION .................................................................................................... 90
9.1 General ................................................................................................................................. 93
9.2 Operation Schedules ........................................................................................................... 93
10.0 PLANT SERVICE LOG SHEET .......................................................................................... 117
11.0 CHEMICAL REQUIREMENT .............................................................................................. 118
11.1 Chemical Consumption ..................................................................................................... 119
11.2 Chemical Loading Procedure ....................................................................................... 11919
12.0 QUALITY OF CHEMICAL REQUIRED ............................................................................... 121
12.1 Ferric Chloride ................................................................................................................... 122
12.2 Sodium Hypochlorite ......................................................................................................... 122
12.3 Sodium Bisulphite Powder ............................................................................................... 122
12.4 Coagulant Aid .................................................................................................................... 122
12.5 Sulphuric Acid ................................................................................................................... 122
12.6 Caustic Soda ...................................................................................................................... 123
13.0 URGENCY PLAN FOR PREVENTATIVE MEASURES...................................................... 124
13.1 Emergency Shutdown Procedure and Probable Causes ............................................... 125
13.2 Conservation Instructions for Long Shut-Down ............................................................. 126
13.3 Trouble Shooting ............................................................................................................... 126
14.0 EQUIPMENT SHUTDOWN & PREPARATION FOR SHUTDOWN .................................... 128
14.1 Normal Shut Down Procedure ...................................................................................... 12929
14.2 Preservation Measures for long plant shut down....................................................... 12929
14.3 Plant Maintenance ............................................................................................... 12929
14.3.1 Safeguards ............................................................................................................... 129
14.3.2 General Prevention .................................................................................................. 130

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14.3.3 Personnel Protective Equipment ............................................................................ 130

14.3.4 Protective Apparatus ............................................................................................... 130
14.3.5 Regular and Preventative Maintenance ................................................................. 130
14.3.6 Inspection and Regular Maintenance..................................................................... 131
15.0 SAFETY ..................................................................................................................... 132
15.1 General ...................................................................................................................... 133
15.2 Kinds of Hazards ...................................................................................................... 133
15.2.1 Physical Injuries ....................................................................................................... 134
15.2.2 Chemical Burns ........................................................................................................ 134
15.3 Fire Prevention ......................................................................................................... 138
15.4 Safety Equipment...................................................................................................... 138
15.5 Housekeeping........................................................................................................... 138
15.6 First Aid Kit ............................................................................................................... 139
15.7 Emergency Notification ........................................................................................... 139
15.8 Chemical Handling & Safety ................................................................................... 139
15.8.1 Hazards Identification .............................................................................................. 139
15.9 Ferric Chloride.......................................................................................................... 141
15.10 Sodium Hypochlorite ............................................................................................... 142
15.11 Sodium Bisulphite ................................................................................................... 143
15.12 Caustic Soda ............................................................................................................ 144
15.13 Sulphuric Acid .......................................................................................................... 143
16.0 DUTIES OF PLANT OPERATOR ................................................................................ 146
17 TROUBLE SHOOTING GUIDELINES…………………………………………………..…..148
17.1 TROUBLESHOOTING GUIDE ..................................................................................... 149

17.2 Overview...................................................................................................................... 149

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ATTACHEMENTS:
 ANNEXURE-I_ALARM LIST
 ANNEXURE-II_VALVE SEQUENCE CHART
 ANNEXURE-III_P&ID
 ANNEXURE-IV_ PLANT SERVICE LOG SHEET
 ANNEXURE-V_ CHEMICAL CONSUMPTION LIST
 ANNEXURE-VI_UTILITY CONSUMPTION LIST
 ANNEXURE-VII_DAF_O&M MANUAL
 ANNEXURE-VIII_SCF MANUAL
 ANNEXURE-IX_UF MANUAL
 ANNEXURE-X_PRESSURE EXCHANGER MANUAL
 ANNEXURE-XI_PROGRESSIVE CAVITY O&M MANUAL

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1.0 USE OF THE O & M MANUAL
1.1. General
This Manual contains essential information required by trained Operator to efficiently operate this
Water Treatment Plant.
Emphasis has been placed on specific instructions on "how to" Operate the Plant. The Sections
"Operation Guidelines" together with Section "O & M Job-Descriptions" are therefore key Sections in
this respect and should be read carefully. The latter Section contains Job-descriptions in table
format. These short-versions of texts (for the most important O & M tasks) gives the Operator a
quick reference to all main jobs to be carried out to meet the requirements for proper operation and
maintenance of the Plant.
Section 4, "Operating Philosophy & Alarm Summary" describes what controls and instrumentation
the Plant consists of and where these controls are located.

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1.2. Glossaries of Terms

Alkali A soluble salt largely consisting of potassium or sodium carbonate
The quantitative capacity of aqueous media to react with hydrogen ions. "M"
alkalinity is that which will react with acid as the pH of the sample is reduced to
Alkalinity
the methyl orange endpoint about 4.2. "P" alkalinity is that which reacts with
acid as the pH of the sample is reduced to 8.2
Anhydrous Free from water
Anthracite A granular hard coal used as a filtration medium
Backwash To reverse the flow of water through filtration media to clean filters
Brackish Water Saline waters, less than 20,000 mg/l TDS
The reject stream from an R.O Unit. Portion of the feed stream which does not
REJECT Stream
pass through the membrane
Sea Water reverse Osmosis; reverse osmosis applied to brackish water, usually
SWRO
with TDS of higher than 20,000 mg/l

Brackish Water reverse Osmosis; reverse osmosis applied to brackish water,
BWRO
usually with TDS of less than 20,000 mg/l
A method for expressing mg/L as ion as a ratio of Calcium Carbonate.
Calcium Carbonate
Concentration in Calcium carbonate equivalent is calculated by multiplying
Equivalents mg/l
concentration in mg/L of the ion by the equivalent weight of Calcium Carbonate
(CaCO3)
(50) and dividing by the equivalent weight of the ion
Small pressure filters containing replaceable cartridges for filtration of particles
Cartridge Filters
in the micromilli‐meter (m) range
A control scheme where one controller (primary or master) is actuated by the
process variable which is to be regulated, and a secondary controller is actuated
Cascade Control by a variable that can be used to cause changes in the primary variable. The
primary controller output adjusts the set point of the secondary controller
which, in turn, operates the final control element
CCP Central Control Panel

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Cleaning Cartridge Cartridge filters installed in inlet pipe to Cleaning Tank to filter out smaller
Filter particles (usually down to 10 Micron (µm)
The reciprocal of the resistance in ohms measured between opposite faces of
Conductivity
centimeter cube of aqueous solution at a specified temperature
A group of Pressure Vessel or Permeators having a common piping and control
Control Block
system
Conversion Product water (permeate) flow rate divided by feed water flow rate
De‐chlorination To remove chlorine from the water
Desalinate To remove salt from the water
Difference in static pressure as measured across a process equipment or
Differential Pressure
between two points in a process
The water entering a membrane at high pressure to be either passed or rejected
Feed Water
by the membrane
Pump used to transfer the final product from the Product Tank. If the final
Product Pump
product is potable water, pump is renamed "Potable Water Pump"
Tank used to temporary store the final product water from a Plant. The final
Product Tank
product may contain a mixture of permeate
The set of membranes which use filtered and chemically pretreated water to the
First Stage
pass as feed water to first R.O Unit
Valve installed on REJECT side of Pressure Vessel to control flow of REJECT
Flow Control Valve
(reject)
GPD Gallons per day
High Pressure Pump Pump supplying feed water to R.O Unit at required pressure
A coagulation process performed by continually adding a coagulant to the raw
In‐Line Coagulation feed water and then immediately passing the water through a pressure media
filter to remove the microfloc which has been formed
Langelier Saturation Index. A parameter used to define the scaling potential of
LSI REJECT. When the parameter is negative it means the pH of the REJECT is less
than the pH at which saturation of calcium carbonate occur, thereby preventing
precipitation. LSI is measured in brackish water application where the TDS

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content of the REJECT less than 10,000 mg/L, see also S & DSI
A combination of two or more interconnected instruments arranged to measure
Loop
and / or control a process variable
Pressure filters, containing one, two or three different media, for instance Sand,
Media Filters
Activated Carbon, Anthracite, and BIRM etc.
The semi permeable materials, with the necessary apparatus for support and
distribution, which is capable of rejecting dissolved solids in the feed water and
Membrane
passing product water (permeate) having a lower concentration of dissolved
solids
Membrane Cleaning Process employed to clean the membrane after fouling has occurred
Process employed prior to and after membrane cleaning using chlorine‐free
Membrane Flushing
water for flushing out regular feed water
Precipitation of foreign matter on a membrane, thereby reducing its flow
Membrane Fouling
capacity and ability to reject salt‐passage
A weight‐volume measurement, which expresses the concentration of a solute
in milligrams in a liter of solution. When specific gravity gravity is unity, [mg/l =
Milligram Per Liter ppm]. When specific gravity is not unity, [mg/l] divided by specific gravity of
(mg/l) solution equals [ppm]
Relating to or derived from natural living organisms, not produced chemically.
Organic Matter Relating to or containing carbon compounds of living beings and most other
carbon compounds
Diffusion through a semi permeable membrane, typically separating a solvent
Osmosis
and a solution that tends to equalize their concentration
Parts per million A measure of proportion by weight, equivalent to a unit weight of solute per
(ppm) million unit weights of solution
The influent water which passes through the membranes and thereby contains a
Permeate
lower concentration of dissolved solids than the feed water

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A measurement of the acidity or alkalinity of a liquid. Values run from 0‐14 with
7 representing neutrality and numbers less than 7 represent increasing acidity
pH and numbers more than 7 represent increasing alkalinity. Technically, pH is the
negative logarithm of the effective hydrogen ion concentration or hydrogen ion
activity in gram equivalents per liter
Programmable Logic Controller. Device used to monitor process parameters via
PLC instrumentation and to activate control functions on equipment, valves etc and
to generate alarms
Process applied downstream an R.O Unit to render it suitable for its design
Post‐treatment
application, for instance degassing, pH adjustment or post‐chlorination
Potable Water Water suitable for drinking
Precipitate The process of separating an element or compounds from a solution
Pressure Control Valve used to control operating (inlet) pressure to an R.O Unit. Installed in feed
Valve line after the High Pressure Pump
Pressure Filtration Filtration aided by imposing a pressure drop across an enclosed filter vessel
Processes applied for treatment of water prior to feeding the water to an R. O
Pre‐Treatment
Unit
Raw Water Water which has not been treated for R.O application
A parameter usually given in percent the amount of permeate from an R.O Unit
Recovery
in relation to total feed water volume (product flow rate divided by feed flow
(Conversion)
rate)
Reject Stream REJECT stream from Permeator
A tank for temporary storage of all rejects water from an R.O Plant. May receive
Reject Water Tank
REJECT as well as backwash water from filters
Residual Something that remains after a part is removed or separated
To rearrange or restore in layers usually alternating with moisture holding
Restratify
material
Removal of salt and other dissolved solids from a solution by applying external
Reverse Osmosis pressure greater than the osmotic pressure of the solution and where the water
flows across a membrane

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A group of Pressure Vessels with membranes cartridges mounted on a rigid
Reverse Osmosis Unit frame and designed so as to be a completely self sufficient unit of a reverse
osmosis pass
Concentration of dissolved salts in the product divided by the dissolved salt in
Salt Passage (in %)
the feed
Salt Rejection 100 % ‐ (salt passage)
Silt Density Index. A test to check the amount of particles in the water prior to
SDI
feeding this water to an R.O Unit
Stiff & Davis Saturation Index. Defined similar to LSI but applied in seawater RO's
S & DSI
where TDS of REJECT is larger than 10,000 mg/l
Treatment stage where usually REJECT from first stage is further treated by a
Second Stage
second R.O Unit.
Process applied if membranes have become biologically fouled, if storage of
membranes is required for more than one (1) day after being cleaned with an
Sterilization
organic solution or prior to biological cleaning to improve the effect of the
cleaning process
Sulphite A salt of sulphurous acid
Total Bacteria Count; the total number of viable microorganisms present in the
TBC
sample, excluding anaerobic organisms
TDS Total Dissolved Solids
Turbidity A suspension of particles that obscures light rays

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2.0 INTRODUCTION

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2.1 Scope
The purpose of this document is to describe about the Water Treatment System units and its
operational philosophy.
2.2 Water Treatment System
The Water Treatment Plant at PT Smart Indonesia is designed to reduce dissolved solids in
water received from the sea. A DAF (Diffused Air Floatation), SCF (Self Cleaning Filter) and UF
(Ultra-Filtration) units are provided before RO System to remove suspended particles and oil
from the feed water. Further removals of suspended particle are carried out in Cartridge filter.
The coagulant aid, Sodium Hypochlorite (NaOCl) and Ferric chloride (FeCl3) dosing is provided
before the DAF. Anti-scalant dosing is provided before cartridge filter as scale inhibitor in feed
water. Sodium Bisulphite is dosed before cartridge filter to remove the residual chlorine.
Caustic soda (NaOH) dosing is provided at BWRO feed for pH correction.
Sodium Bisulphite
Ferric Chloride Dosing Antiscalant Dosing
DAF SCF UF SWRO

CARTRIDGE
FILTER

BWRO SWRO SWRO
Sea Water CARTRIDGE Permeate
Intake Pump FILTER tank (by
. others)
NaOCl Dosing NaOH Dosing SWRO High Pressure Pump

BWRO BWRO
Permeate
Ferric Chloride tank (by
Dosing others)
Coagulant Aid Dosing
(Polymer)

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 RO Cleaning System is provided for cleaning purpose. It consists of Cleaning Tank equipped
with agitator, Cleaning Pump and Cartridge Filter.
BWRO Permeate
RO Cleaning RO Cleaning
Tank Cartridge Filter To RO System
2.3 Reference Document
 Piping & Instrumentation Diagram, 320PRJ1201007-01-001.

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3. DESIGN BASIS AND WATER QUALITY

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3.1 Feed Water Analysis
The plant is designed on the following parameters of feed sea water
Parameter Maximum Level

pH - 6.5 - 8.5
Temperature  C 28 – 35o C
TDS mg/l 40000
TSS mg/l <1
Turbidity NTU <1
Organic as KMnO4 mg/l 5
Ammonium (NH4) mg/l 0.83
Oil & Grease mg/l NIL
Potassium as K mg/l 280
Sodium as Na mg/l 12018
Calcium as Ca mg/l 1120
Magnesium as Mg mg/l 1400
Bicarbonate as HCO3 mg/l 137
Chloride as Cl mg/l 24053
Sulphate as SO4 mg/l 964
Silica as SiO2 mg/l 20
3.2 DAF Product Water Quality
Parameter Unit Maximum Level
Turbidity NTU < 10.
Oil & Grease mg/l 5
TSS mg/l < 10

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3.3 UF Product Water Quality
Turbidity NTU < 0.2
Organics as KMnO4 mg/l <1
TSS mg/l < 0.5
SDI <3
3.4 Design Product Water Quality
SWRO permeate TDS mg/l < 300
BWRO permeate TDS mg/l < 15

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4. EQUIPMENT AND PROCESS DESCRIPTION

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4.1 Sea Water Intake Pumps (1007-P101A/B)
One duty and one standby Sea Water Intake Pumps are installed on jetty. The capacity of each
pump is 250 m3/h @ 2.8 bar (differential) pressure.
Sea Water Intake Pumps receive water from the sea and deliver to Diffused Air Floatation (1007-
DAF101) system through Static Mixer (1007-SM101).Each pump is provided with isolation valves
and Pressure Indicator.
Sea water intake pumps can be started from field as well as from PLC.
Field Operation:
Local / Remote selector switch is provided in the field for each pump. In local condition each pump
can be started & stopped from the field.
PLC Operation:
Each pump operated through PLC in Auto / Manual mode operation.

Manual Operation
In manual operation mode, each pump can be started and stopped manually from the PLC.
Auto Operation
In auto operation mode, pump starts and stops automatically based on the Level in Clarified Water
Tank (1007-T102) as per below;
 Start pump on High Level (LT-301)

 Stop pump on HH level (LT-301)
4.2 Dissolved Air Floatation system (1007-DAF101)
One Dissolved Air Flotation (DAF) is provided to remove the suspended solids, fats, oils and
greases, and other insoluble materials.
The Dissolved Air Flotation (DAF) is process whereby micro-air-bubbles cause suspended materials
to float to the surface of a vessel to achieve liquid/solids separation. The wastewater first
enters the influent box where coagulants and flocculants may be introduced to increase the particle
size along with “whitewater.” Whitewater is a mixture of a portion of the DAF effluent, which has
been saturated with compressed air via the DAG air dissolving technology. The wastewater then
enters the vessel across the length of the system. The velocity of the water is significantly
reduced to maximize separation potential. Inside the vessel, the microbubbles, which have
attached to the particle surface affect the particle density, cause the suspended solids to float to
the surface where a chain and flight skim them from the surface into a top cone. The “clean” liquid is

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continuously removed at several points inside the vessel and passes over pipe weirs into an effluent
box. From the effluent box, the wastewater gravity feeds out of the system.
It is constructed in polypropylene frame which provides superior qualities compared to stainless

steel such as: lighter weight, higher chemical resistance (corrosion resistance), longer life
span and lower maintenance.
The Dissolved Air Flotation (DAF) is equipped with the Dissolved Air Pump, Sludge Pump, Rake
Drive, Air compressor, Manual Cone Valves and associated piping.
Dissolved Air Flotation (DAF) system is operates automatically through it dedicated control panel.
For operational philosophy, refer the ANNEXURE-VII_OPERATION & MAINTENANCE MANUAL”
4.3 Static Mixer (1007-SM101)
One static mixer of 250 m3/h capacity is provided at upstream of DAF unit to ensure proper mixing of
Ferric chloride and sodium hypochlorite dosed. Material of construction of static mixer is PVC.
4.4

Clarified Water Tank (1007-T102)
One Clarified Water Tank is provided as break tank for ultrafiltration system. The treated sea water
from DAF system is collected by gravity in clarified water tank. The capacity of provided tank is 70
m3.
The tank is constructed from FRP panels with dimension 6 m L x 5 m W x 3 m H. Sea water from
tank is pumped by UF feed pumps (1007-P103 A/B) to UF system.
One level transmitter (LT-301) is provided at top of tank for tank level monitoring and process control.
4.5

Oily Sludge Tank (1007-T102)
One Oily Sludge Tank is provided to collect the oily scum and sludge generated from DAF unit. The
capacity of provided tank is 5 m3.
The tank is constructed from FRP panels with dimension 2 m L x 2 m W x 2 m H.
The waste water from tank is transferred to others treatment facility for proper disposal.
One level switch (LS-301) is provided at top of tank for level monitoring and process control.

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4.6 UF Feed Pumps (1007-P103A/B)
Two UF Feed Pumps, one working and one standby are provided to feed UF system. UF Feed
Pumps receives water from clarified water tank (1007-T102) and feeds to Self Cleaning Filter (1007-
SCF101).
The capacity of each pump is 252 m3/h @ 4.25 barg (differential) pressure. The material of
construction of pump is Duplex Stainless Steel.
Each pump is equipped with suction / discharge piping, isolation valves and pressure indicator. At
pump discharge one Flow Transmitter (FT-401) is provided to monitor and control the flow by control
valve (1007-FCV-401).
PLC Operation:

Manual Operation
Auto Operation
In auto operation mode, pump starts and stops automatically based on UF operation sequence.
(Refer ANNEXURE- II)
4.7 Self Cleaning Filter (1007-SCF 101)
One Self Cleaning Filter is provided at upstream of UF system to trap the particle more size than 100
micron. The material of provided filter is GRP with wetted parts in Duplex SS.
The particle / suspended matter deposited on screen surface are removed in backwash operation
without disturbing the normal service operation. Provided filters are pressure filter with an automatic
flushing arrangement. It has a filter casing and filter basket. It has the inlet directly in line and the
outlet at a 90o angle. This permits access to dismantle the filter basket for maintenance without
removing the connections. Automatic flushing is carried out at regular set intervals without
interrupting the filtering process. The flushing arrangement contains a flushing valve. Flushing
operation is initiated by the differential pressure 1.0 bar or the timer based through PLC. For this
purpose the Differential Pressure Switch (DPS-401) is installed on filter. Water enters the filter basket
A flushing valve for draining the dirt is located at the outlet of the dirt collection section.
Self Cleaning Filter is provided with the inlet and outlet Pressure Indicators (PI-401 & PI-402) for
monitoring purpose.
Following are the operational modes involved in self cleaning filtration.

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Normal Operation:
The filter is in the normal filtration phase. The flushing valve
is closed. The piston mounted in the cover is outside the
filter basket in its starting position. The flow characteristics in
the strainer cause the particles to deposit from the outlet to
the inlet flange. The duration of the filtration phase depends
upon the degree of contamination of the medium. There are two
reasons why particles are not deposited in the filter inlet
during his phase: one is because of the design, and the
other is because of the flow characteristics.
Filtration and first

flushing phase Operation:
The flushing valve opens in this phase. This creates a
pressure gradient with respect to the system pressure in
the piping. This pressure gradient causes the coarser and
easily removable particles to be flushed out of the strainer
insert. The filtration continues during this phase and the
flushing volume is defined and limited by a restrictor in the
flushing is initiated by the differential monitor or by the time
internal control system.
Second flushing Operation:

The flushing interval is open. The pneumatically-actuated
piston with the flushing disc moves into the strainer and
creates a large local increase in speed within the gap between
the flushing disc and the strainer insert. The causes a static
pressure drop – this is known as the Bernoulli Effect. The
external pressure on the clean side of the filter then is
higher in the area of the flushing disc than in the area of
the flushing disc and the strainer. Together with the greatly
increased flow speed, this causes “suction” on the filter
element. The contaminants are flushed out of the filter as
a result of the flushing valve being open creating a pressure
gradient.

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Final flushing Operation:

The flushing disc returns to the starting position but the flushing
valve remains open. This allows the remaining particles to exit
the filter. In addition, the lower section of the filter insert is
cleaned during the up wards movement of the flushing disc.
The flow characteristics returning to what they were has a
self-cleaning effect, according to Bernoulli.
Self cleaning filter is having its own control panel through which all operations will be controlled.
4.8 Ultra Filtration System (1007-UF 101)
Capacity: 225 m3/h (Permeate).

Number of Membranes: 54 nos.
Membrane type: Hollow Fiber
Clarified water is pumped from the Clarified Water Tank (1007-T102) to the UF system via Self
Cleaning Filter (1007-SCF101), to prevent the entry of particulate/harmful matter.
Membrane filtration is executed inside-out, which means that the substances are retained on the
inner surface of the UF membranes. UF permeate is collected in the RO feed/UF Backwash tank
(1007-T103).
The UF membranes are cleaned on a regular basis by means of HC and CEB. The HC consists of a
combination of Forward Flush (FF), and Backwash (BW). During FF, the substances retained by the
membranes are removed by flushing UF feed water along the inner UF membrane feed surface to
concentrate. During BW the UF membranes are cleaned outside-in with part of the permeate
produced.

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During CEB, chemicals are introduced into the BW flow and any substances adsorbed to the UF
membrane surface are removed during a limited chemical soak period. For this purpose three
chemical dosing sets are installed for acid (H2SO4), caustic soda (NaOH) and hypochlorite (NaOCl).
Apart from the automatic Backwash and CEB facilities, which will be sufficient to maintain UF
performance under normal circumstances, availability of a CIP system is required to increase
operation flexibility. This will allow execution of a semi-automatic dynamic cleaning to remove
residual fouling and to restore minimum operational TMP (i.e. minimum operational energy
consumption), in case of incidents such as out-of-spec feed water conditions and excessive
overdosing or carry-over of coagulant. During a CIP, the applicable UF is taken off-line a (optionally
heated) chemical solution is circulated over the applicable UF unit. For this purpose the individual UF
units will be provided with CIP-connections on the feed, permeate and concentrate manifolds.
The UF plant can perform the following programs in auto or manual control mode.
1. Filtration
2. Hydraulic cleaning (HC)
3. Chemically Enhanced Backwash 1
4. Shut-Down
5. Backwash
6. Filling
Filtration:
During filtration the UF unit receives feed water and produces permeate. The feed flow will be
controlled by Flow control Valve (1007-FCV-401). The operation sequences for filtration is carried out
as per described in valve sequence chart- ANNEXURE- II.
Filtration Operation shall be terminated immediately for following condition
 High Trans Membrane Pressure (TMP), the trans membrane pressure is calculated by
subtracting the permeate pressure (PT401) from the feed pressure (PT402), value shall be
required below 1 bar, if exceeds then it is indication of membrane fouling.

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Hydraulic Cleaning (HC):
During the hydraulic cleaning (HC) operation, the foulants that have accumulated during filtration are
removed from the membrane surface and washed out of the system by a combination of several
cleaning methods with feed water and clean permeate. The following cleaning methods are followed.
 Forward flush (FF): Feed water is pumped from the feed to the concentrate side along the
membrane surface.
 Backwash (BW): Permeate is pumped from the outside to the inside of the membranes.
The HC program is executed after elapse of a Filtration program. The operation sequence for HC is
described in valve sequence chart ANNEXURE- II.
Chemical Enhanced Backwash (CEB):
The CEB program starts with a hydraulic cleaning after which the cleaning is enhanced by the
addition of chemicals to the backwash flow. Once the UF unit is filled with the chemical solution a
chemical soak period starts during which the chemicals are left in the membranes. After the soak
time the chemicals (and dislodged foulants) are flushed out by means of a backwash.
The CEB1 program is initiated with a counter on the total number of HC performed on UF unit . After
elapse of this counter, UF unit will perform a CEB1 instead of a normal HC.
The operation sequence for CEB is described in valve sequence chart ANNEXURE- II.
Shut-Down
The plant can be shutdown from the PLC. During shutdown if CEB operation is running, then all
sequences are finished first. Then plant shutdown will be executing as per below:
1. Initiate the Hydraulic cleaning (HC) operation.

2. After completion of Hydraulic cleaning (HC) steps, all pumps are stopped followed by
closing the auto valves.

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Backwash
Normally the hydraulic cleaning is used, but in those cases only clean UF permeate water and no
feed water must be used a backwash can be started. For instance in the case the UF unit has not
been used for more than 24 hours it is recommended to flush clean water in the UF unit by
Performing a backwash.
The operation sequence for the backwash is described in valve sequence chart ANNEXURE- II.
Filling
During start-up of the UF unit or whenever UF unit has been opened, drained or integrity tested, a
filling program must be executed to expel the air from the UF unit and fill it with water. Then filling
program is carried out. The filling program must be Manually initiated at start-up, after the UF unit
has been drained, and after maintenance work on the UF unit has been completed.
The operation sequence for the filling program is described in valve sequence chart ANNEXURE- II.
UF system (1007-UF101) is operated through the PLC in following mode

 Auto Mode
 Semi-Auto Mode
 Manual Mode

Auto Mode:
Following operations are performed automatically from PLC when selected in Auto mode.
1. Filtration
2. Hydraulic cleaning (HC)
3. Chemically Enhanced Backwash 1 (CEB1)
The above operation sequence is determined by HC counter (Number of HC performed). The HC

counter triggers execution of the CEB1. All operations & sequences are time based.
Operation sequences are executed as below,
1. The UF unit starts with the filtration program. When the filtration program is finished, the HC
total counter is checked.

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2. As long as the HC counter is below the set point, a HC program is started. When the HC is
finished, the HC counter is incremented and a new filtration program is started.
3. If the HC counter reaches the HC counter set-point, a CEB1 program is started instead of a
HC program.
4. When the CEB1 program is finished, the HC counter is reset and a new filtration program is
started.
5. HC counter shall be set for 46 no. It shall be settable from PLC with supervisory password
protection.
Auto operation can be terminated by operators intervention by selecting the shut down sequence
incase required.
For detailed operation sequence, refer the valve sequence chart ANNEXURE- II.
Semi-Auto Mode
In Semi-auto mode, operator can select following operation from PLC.
 Filtration
 HC (Hydraulic cleaning)
 CEB (Chemically Enhanced Backwash 1)
 Shut-Down
 Backwash
 Filling
With selection of above operation, the UF system will perform the specific selected operation
automatically as per the valve sequence chart (ANNEXURE-II) & after completion of sequences the
UF system will stopped & wait for operator intervention.
Manual Mode
In manual mode each valve is open and close from PLC. Also all drives can be started and stopped
from PLC. This mode is useful in start up and for testing purpose.
Operation of UF System:
UF system will start and stop based on the level in RO Feed/UF Backwash Tank, at HH Level (LT-
501) UF system will stop & at H2 Level (LT-501) UF system will Stop.
In all mode process and safety interlocks shall be applicable.

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If UF system is idle due to the HH Level (LT-501) in RO Feed /UF Backwash Tank for more than 24
hours then operator to perform the backwash operation through Semi-Auto Mode.
4.9

RO Feed / UF Backwash Tank (1007-T103)
One RO Feed / UF Backwash Tank is provided to store the UF permeate water. UF permeate water
further utilized for UF backwashing & feed to SWRO system. The capacity of supplied tank is 70 m3.
The material of RO Feed / UF Backwash tank is FRP and dimension is 5 m L X 4 m W X 4 m H.
The tank is equipped with one level transmitter (LT-501) for eve monitoring purpose.
4.10 UF Backwash Pumps (1007-P105 A/B)
Two (One duty and one standby) Backwash Pumps are provided to carry out the backwash &
Chemical Enhanced Backwash (CEB) operation of UF system. The capacity of each pump is 825
m3/h @ 3 bar (differential) pressure.
UF Backwash Pumps receive water from the RO feed/UF back flush tank (1007-T103) and deliver to
UF system through Static Mixer (1007-SM102).
Flow Transmitter (FT-501) is provided at common discharge of pumps to monitor the backwash flow
rate to UF System. Pumps are operated through VFD One to maintain the backwash flow rate.
12% sodium hypochlorite, 25 % NaOH & 98 % H2SO4 injection points are provided at backwash
pump discharge. Chemical injection is required during the Chemical Enhanced Backwash (CEB)
operation.
Each pump is equipped with discharge piping, isolation valves, Pressure Indicator and common flow
transmitter (1007-FT501)
PLC Operation:

Manual Operation
Auto Operation
In auto operation mode, pump starts and stops automatically based on UF operation sequence,
ANNEXURE- II.

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One static mixer is provided at UF backwash pump discharge for proper mixing of dosed chemicals,
capacity of provided static mixer is 890 m3/h. Material of construction of static mixer is PVC.
4.12 SWRO Feed Pumps (1007-P104 A/B)
One duty and one standby SWRO feed Pumps are provided. The capacity of each pump is 225 m3/h
@ 4.5 bar (differential) pressure.
SWRO feed Pumps receives water from the RO feed/UF back flush tank (1007-T103) and deliver to
SWRO cartridge filter (1007-CF101) through static Mixer (1007-SM102) to ensure proper mixing of
dosing chemicals (SBS and Antiscalant are provided before static mixer). Each pump is equipped with
discharge piping, isolation valves, Pressure Indicator.
PLC Operation:

Manual Operation
Auto Operation
In auto operation mode, pump starts and stops automatically based on SWRO operation sequence.
One static mixer of 225 m3/h capacity is provided after Antiscalant and sodium bisulfate dosing point to
ensure proper mixing. Material of construction is PVC.
4.14 SWRO Cartridge Filter (1007-CF101)
There is one Cartridge Filter supplied with capacity of 225 m³/h. UF permeate water from RO Feed
Tank is pass through cartridge filters for removal of fine suspended solids above 5-micron size if
any. It will also provide safeguard the SWRO membranes against any traces of fine solids escaping
from pre treatment.
The filter is provided with air release valve on the top of the vessel and drain valve to drain the filter.
Inlet pressure indicator is provided on each cartridge filter for pressure monitoring.

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Differential Pressure Switch (DPS-601) is provided across cartridge filter for continuous monitoring of
pressure drop. if it increases beyond acceptable level (1.0 bar), cartridge elements are required to be
replaced.
4.15 SWRO High Pressure Pump (1007-P-106 A/B)
Two high pressure pumps one working and one standby are provided. The filtered and de-
chlorinated water is pumped to the Reverse Osmosis system by SWRO High Pressure Pump with
combination of Pressure exchanger (1007-PX101A/B) and ERD Booster Pumps (1007-P107 A/B)
receives the filtered water from 5 micron Cartridge Filter and deliver to SWRO System (1007-RO-
101). The two pumps are of capacity 101 m³/h & differential pressure of 64 barg is supplied. Both
pumps are operated through VFD.
The pump is provided with suction and discharge Pressure Switch.
PLC Operation:

Manual Operation
Auto Operation
In auto operation mode, pump starts and stops automatically based on SWRO operation sequence.
Start Permissive Condition
1. SWRO HPP suction pressure not less than 1 barg
2. ERD Booster Pump (1007-P-107A/B) is running.

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Alarm and Trip
Alarm & Trip SWRO High Pressure Pump at following conditions:
SR. NO. CONDITION SET POINT
1 Low suction Pressure < 1barg
2 High discharge Pressure 62 barg
3 High SWRO permeate flow– delay 5 sec 105 m3/h
5 High & Low Feed pH– delay 300 sec 8.5 – 6.5
6 High ORP 350mv
8 SWRO Recovery (FT-701/(FT-601+FT-701)) 48%
9 Low Level in Sodium Bisulfite Tank - delay 60 sec 100 mm
10 Low Level in Antiscalant Dosing Tank - delay 60 sec 100 mm
12 High Differential Pressure High - delay 300sec. 1 barg
13 SWRO Permeate Conductivity High High - 300 sec delay 800 µS/cm
14 ERD Booster Pump (1007-P-107A/B) Not running OR in

Fault
4.16 Pressure Exchanger (1007-PX-101A/B)
The PX Pressure Exchanger energy recovery device recovers hydraulic energy from the high-
pressure reject stream from a reverse osmosis (RO) system and transfers it to low-pressure feed
water. This pressurized feed water from the PX device is pumped to the SWRO High Pressure Pump
discharge by a ERD Booster Pump (1007-P-107A/B).
The PX device contains a single moving part the rotor. Inside the rotor are chambers in which
pressure exchange occurs. Concentrate from the membrane and feed water coming from cartridge
filter comes into direct, momentary contact in the rotor chambers. Pressure energy transfer directly

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from the high pressure concentrate/reject stream to low pressure feed stream. The self adjusting
rotor limits mixing by keeping the concentrate-feed water interface inside the exchange chambers.
4.17 ERD Booster Pump (1007-P-107A/B)
It is a vertical inline pump with a high pressure design. The PX Circulation Pump boosts the pressure
in the high pressure flow of a SWRO energy recovery system to make up for the small pressure
losses that occur through the membranes, the PX units and the associated piping. The capacity of
ERD booster pump is provided as 122 m3/hr @ 2.7 barg.
Note:
ERD Booster Pumps (1007-P-107A/B) are required to start and flow conditions to be established first
then start SWRO High Pressure pump. Do not start the SWRO High Pressure pump without Booster
pump.
4.18 SWRO System (1007-RO101)
The filtered water from Cartridge Filter is pumped by SWRO High Pressure pumping system to
SWRO system at required pressure of 60 bar. The arrangement of SWRO system is single array with
7 elements in each pressure vessel, total 24 nos of pressure vessels are provided. The RO system
reduces the permeate water of 400 mg/l TDS. The recovery of SWRO system is 45%.
There are two streams coming out from the RO system. The permeate (product) water stream comes
out at 100 m3/h normal flow and reject (brine) at 122.5 m3/h.
Permeate water from SWRO system is collected in SWRO Permeate Water Tank (by others) and
reject water from system is send to the sea through Pressure Exchangers.
The ORP meter (AT-602), pH Indicator (AT-601) are provided at SWRO high pressure pumps (1007-
P106A/B) common suction for monitoring the ORP, pH of sea water before entering the SWRO
System.
The ORP meter is provided to monitor the ORP value of the RO feed water to ensure absence of
free chlorine in feed water. Dump valve (1007-XV601) is provided at the common suction header of
SWRO high pressure pump. If the ORP meter detects high ORP value (350 mv) in the RO feed
water then feed dump valve will open to drain the feed water. The water will drain out until the ORP
meter shows value within range.

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The SWRO System is provided with Flow Transmitter and Conductivity Transmitter on the permeate
line to monitor the flow and conductivity of product water.
Permeate dump valve (1007-XV701) is provided at permeate line to drain permeate line whenever
SWRO plant stops. The differential pressure transmitter (PDS-701) is provided across the feed and
reject of the SWRO system to monitor the differential pressure. High differential pressure across feed
and reject indicates the deposition of solid or scaling on membrane surface. The pressure differential
across the membrane increases as deposition progresses. If this occurs, the cleaning operation is
required to carry out to prevent scaling and reduce differential pressure.
Start Permissive condition:
1. The SWRO system will not start in at High-High Water Level (LT-801) in SWRO Permeate
Water Tank.
2. Sodium Bisulphite Dosing Tank (DT-108) and Antiscalant Dosing Tank (DT-107) are
sufficiently filled.
3. All normally open valves (manual) are open.
SWRO unit is provided with selector switch on PLC to operate the system in Auto or Semi-Auto
mode.
Auto Mode Operation
SWRO system can be operated in Auto by putting the selector switch on “Auto”. Upon Auto mode
selection, RO system will perform following operational sequence.
Auto start-up
 At the start up, feed dump valve (1007-XV601) will open. High pressure Pump suction Valve
XV-602A/B & ERD Booster pump Suction Valve XV-603A/B will close.
 SWRO Feed Pump (P-104A/B) will start to feed the water to Cartridge Filters (CF-101).
 Sodium Bisulphite Dosing Pumps (DP-108A/B) and Antiscalant Dosing Pump (DP-107A/B)
will start.
 Three minutes timer will start from this stage. The feed parameters like ORP, pH are checked
and, if all these parameters are within the limits for 30 seconds, then cycle will proceed to
next step.

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 If the parameters are not within the limits then the time will be extended for another 5
minutes. If during this time the feed parameters are still not within the limits then the system
will stop with an alarm.
 If ORP and pH are within the limits the feed dump valve (1007-XV601) will close. High
pressure Pump suction Valve XV-602A/B & ERD Booster pump Suction Valve XV-603A/B will
open.
 After 1 min, ERD Booster pump (P-107A/B) will start through VFD at a low flow rate to
achieve the flow 122 m3/h.
 After 2 min, check is made for low- pressure (PS-601A/B) reading; if it is within the range then
the SWRO High Pressure Pump will start. If there is a low pressure then the system will stop
with an alarm.
 RO system will run continuously till the High-High Level in the SWRO Permeate Water Tank.
At High-High level, SWRO system will shut down.
Auto shutdown
 RO plant will shutdown in auto mode for all the trip conditions described for SWRO High
Pressure Pump.
 After 30 sec, ERD Booster pump (P-107A/B) will stop.
 After completion of 3 minutes, SWRO Feed Pump (P-104A/B) will stop along with Sodium
Bisulphite Dosing Pumps (DP-108A/B) and Antiscalant Dosing Pump (DP-107A/B).
Auto Flushing:
SWRO flushing occurs once in 12 hours of continuous operation of SWRO plant. Following
steps are preformed for Flushing operation.
 At the start up, feed dump valve (1007-XV-601) will open and the SWRO Feed Pump (P-
104A/B), Sodium Bisulphite Dosing Pumps (DP-108A/B) and Antiscalant Dosing Pump (DP-
107A/B) will start.
 The feed parameters like ORP and pH are checked and, if all these parameters are within
the limits for 30 seconds, then cycle will proceed to next step.

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 If the parameters are not within the limits then the time will be extended for another 5
minutes. If during this time the feed parameters are still not within the limits then the system
will stop with an alarm.
 If ORP and pH are within the limits the SWRO permeate dump valve (1007-XV-701) will
open and at the same time the feed dump valve (1007-XV-601) will close. This step is
flushing of the SWRO system. The flushing is performed for 3 minutes.
 After completing 3 minute flushing, auto start-up sequence as described above in Auto mode
operation will be performed to put the system back in operation.
Semi-Auto Mode Operation
SWRO system can be operated in semi auto mode by putting selecting the Semi- Auto switch.
In semi auto mode, following operations can be performed.
 Dumping start
 Service start
 Flushing start
Start push button is provided on the panel front for above operations.
Dumping start
Pressing “DUMPING START” button will let the system to go in to automatic mode to perform
following sequence. Select the stop button form PLC to stop the dumping sequence.
 At the start up, feed dump valve (1007-XV-601) will open. High pressure Pump suction Valve
XV-602A/B & ERD Booster pump Suction Valve XV-603A/B will close.
 SWRO Feed Pump (P-104A/B) will start to feed the water to Cartridge Filters (CF-101).
 Sodium Bisulphite Dosing Pumps (DP-108A/B) and Antiscalant Dosing Pump (DP-107A/B)
will start.
Service start
When “SERVICE START” is pressed, auto start-up sequence of SWRO system are performed as
described earlier.

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Flushing start
Pressing “FLUSHING START” button, auto flushing sequence of SWRO system are performed as
described earlier.
Permeate Dump Valve Operation
The Permeate Dump Valve (1007-XV-701) is provided to protect SWRO membrane against high back
pressure. Permeate dump valve shall operate under following condition.
 Open permeate dump valve at every stoppage of SWRO High Pressure Pump.
 Permeate dump valve will close 20 sec after SWRO feed pump is put in operation.
 Dump valve opening-closing is also based on outlet conductivity, If outlet conductivity is
within permissible range then only dump valve will get Closed.
4.19 SWRO Permeate Tank (1007-T104) (By others)

One SWRO permeate Tank is provided with 400 m3 capacity. The provided size of tank is 20 m Dia X
20 mH. The tank receives the SWRO permeate from top of the tank through SWRO system (1007-
RO101).
SWRO permeate from this tank is pumped by BWRO feed pumps (1007-P108 A/B) to BWRO
cartridge filter (1007-CF102).
The tank is equipped with one level transmitter (LT-801).
4.20 BWRO Feed Pumps (1007-P108 A/B)
One duty and one standby SWRO feed Pumps are provided. The capacity of each pump is 100 m3/h
@ 3.5 bar (differential) pressure.
BWRO feed Pumps receives water from the SWRO permeate tank (1007-T104) and deliver to
BWRO cartridge filter (1007-CF102). Each pump is equipped with discharge piping, isolation valves,
Pressure Indicator.
PLC Operation:

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Manual Operation
Auto Operation
In auto operation mode, pump starts and stops automatically based on BWRO operation sequence.
4.21 BWRO Cartridge Filter (1007-CF-102)
The capacity of Cartridge filter is 100m³/h with 5 micron size. The suspended solids above 5-micron
size are removed. These filters also prevent large solid particle going into high-pressure pump.
Cartridge filter is provided with differential pressure switch (DPS-801) to monitor the pressure drop, if
it increases beyond acceptable level (1.0 bar), cartridge elements are required to be replaced.
The filter is provided with air release valve on the top of the vessel and drain valve to drain the filter.
Inlet pressure indicator is provided on each cartridge filter for pressure monitoring.
4.22 BWRO High Pressure Pumps (1007-P106 A/B)
The SWRO permeate water is pumped to the RO system by BWRO High Pressure Pumps. The two
vertical pumps of capacity 100 m³/h @ 15 barg are supplied.
The pump is provided with suction and discharge Pressure Switch.
PLC Operation:

Manual Operation
Auto Operation
In auto operation mode, pump starts and stops automatically based on BWRO operation sequence.

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Alarm and Trip
Alarm & Trip BWRO High Pressure Pump at following conditions:
SR. NO. CONDITION SET POINT
1 Low-Low Level in SWRO Permeate Tank (LT-801) 1000 mm
3 Low Suction pressure (PS-801A/B) < 1 barg
4 High discharge pressure (PS-802A/B) 15 barg
5 High BWRO inlet pressure (PS-901) 13.5 barg
6 RO Recovery (FT-901/(FT-901+FT-902) x 100 – 85%

delay 5 sec
4.23 BWRO System (1007-RO-102)
The SWRO permeate water is pumped by BWRO High Pressure Pump to BWRO system at required
pressure of 11.3. The arrangement of BWRO system is array configurations with 7 elements in each
pressure vessel of number 8. The RO system reduces the TDS to 10 mg/l in permeate. The
recovery of BWRO system is 80%.
BWRO Permeate water from BWRO system is collected in BWRO Permeate Water Tank (1007-T-
106) by others and BWRO reject water from system is collected in the BWRO reject water tank
(1007-T-105) by others.
The BWRO System is provided with Flow Transmitter (FT-901) and Conductivity Transmitter (AT-
901) on the permeate line to monitor the flow and conductivity of permeate water.
Flow Transmitter (FT-902) is provided on reject line. Permeate dump valve (1007-XV-901) is
provided at permeate line to drain permeate line whenever BWRO plant stops.
Permissive condition:
1. The BWRO system will not start if High-High Water Level (LT-1001) in BWRO Permeate
Water Tank (1007-T-106).
2. The BWRO system will not start if High Level (LT-901) or above High Level in BWRO Reject
Water Tank (1007-T105).

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Feed Control Valve (FCV-801)
One flow control valve (FCV-801) is provided at BWRO inlet to maintain flow of 100 m3/h. Flow
control valve modulates based on the summation flow rates of permeate line (FT-901) & reject line
(FT-902).
Auto Mode Operation
Selecting Auto mode, BWRO system will perform following operational sequence. Ensure required
SWRO permeated Water is available in the tank and the respective valves to the BWRO High
Pressure Pump Suction and Discharge are open and the cartridge filter is in service.
Start-up
 At start up, reject bypass valve (1007-XV-902) and permeate dump valve (1007-XV-901)
will open.
 After 5 sec delay BWRO Feed Pump (1007-P108A/B) will start.
 NaOH Dosing Pump (1007-DP109A/B) will start as per feed water pH value (AT-801).
 After two minutes, check is made for low- pressure (PS-801A/B) reading; if it is within the
range then the BWRO High Pressure Pump (P-109A/B) will start. If at the end of the 30
seconds, there is a low pressure then the system will stop with an alarm.
 After 30 sec reject bypass valve (1007-XV-902) and permeate dump valve (1007-XV-901)
will closed.
 BWRO system will run continuously till the High-High Level (LT-1001) in BWRO
Permeate Water Tank. At High-High level (PT-1001), BWRO plant will shut down as per
the sequence described below for “Shutdown”.
Auto Shutdown
 BWRO plant will shutdown in auto mode for all the trip conditions described for BWRO
High Pressure Pump.
 Reject bypass valve (1007-XV-902) and permeate dump valve (1007-XV-901) will open.
 After completion of 3 minutes, BWRO Feed Pump (P-108A/B) will stop along with NaOH
Dosing Pumps (1007-DP-109A/B).
 After 5 sec delay, reject bypass valve (1007-XV-902) and permeate dump valve (1007-
XV-901) will closed.

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BWRO Flushing
BWRO flushing occurs once in 12 hours of continuous operation of BWRO plant. Following
steps are preformed for BWRO Flushing operation.
 For the flushing operation, reject bypass valve (1007-XV-902) will open and the BWRO Feed
Pump (1007-P108A/B) will start.
 On completion of 3 min. flushing operation, reject bypass valve (1007-XV-902) will close and
BWRO feed pump will stop.
 After completing 3 minute flushing, auto start-up sequence as described above in Auto mode
operation will be performed to put the system back in operation.
Semi-Auto Mode Operation
BWRO system can be operated in semi auto mode by selecting the Semi- Auto switch.
In Semi-Auto mode, following operations can be performed.
 Service start
 Flushing start
Start push button is provided on the panel front for above operations.
Service start
When “SERVICE START” is pressed, auto start-up sequence of BWRO system is performed as
described earlier.
Flushing start
When “FLUSHING START” is pressed, the sequences are performed for flushing operation as
described earlier.
Permeate Dump Valve Operation
The Permeate Dump Valve (1007-XV-901) is provided to protect BWRO membrane against high back
pressure. Permeate dump valve shall operate under following condition.
 Open permeate dump valve at every stoppage of BWRO High Pressure Pump.
 Permeate dump valve will close 20 sec after BWRO feed pump is put in operation.

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 Dump valve opening-closing is also based on outlet conductivity, if outlet conductivity is

within permissible range then only dump valve will get closed.
4.24 BWRO Permeate Tank (1007-T106) (By others)

One BWRO permeate Tank is provided with 270 m3 capacity. The provided size of tank is 13.5 m Dia
X 20 mH. The tank receives the BWRO permeate from top of the tank through BWRO system (1007-
RO102).
The tank is equipped with one level transmitter (LT-1001) (by others).
4.25 BWRO Reject Water Tank (1007-T105) (By others)

One BWRO reject water Tank is provided with 169.6 m3 capacity. The provided size of tank is 10.6 m
Dia X 16 mH. The tank receives the BWRO reject from top of the tank through BWRO system (1007-
RO102).
The tank is equipped with one level transmitter (LT-901) (by others)
4.26 Coagulant Aid Tank (1007-DT101 A/B)
Two Coagulant Aid Tank of 3000 lit capacity each is provided. It is designed for preparation of
coagulant (polymer) solution. Coagulant is added in the tank through the filling cap at the top of the
tank. Start mixer for mixing. Fill the tank with dilution water up the marked height. Switch over of
coagulant tank is to be done manually.
Coagulant (Polymer) solution from the tank is pumped by Coagulant Aid Dosing Pump (1007-DP101
A/B) to DAF feed (1007-DAF101) inlet before the Static Mixer (1007-SM101). The material of dosing
tank is FRP. Each tank is equipped with one Level Switch (LS-1001/1002) and tank mixer (MX-101
A/B).
Coagulant Aid Dosing Tank Mixer (MX-101A/B)
Coagulant aid dosing tank Agitator can be started & stopped manually form the control panel.
4.27 Coagulant Aid Dosing Pumps (1007-DP101 A/B)
There are two pumps provided one working and one standby. The design flow of the pump is 350
LPH at discharge pressure of 4 barg.

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Dosing Pump receives coagulant from coagulant aid tank (1007-DT101A/B) and delivers to the DAF
system (1007-DAF101).
PLC Operation:

Manual Operation
Auto Operation
In auto operation mode, pump starts and stops automatically based on Sea Water Intake Pump
(1007-P-101 A/B) start / stop.
4.28 Sodium Hypochlorite Dosing Tank (1007-DT102)
One Sodium Hypochlorite Dosing Tank is provided with 200 lit capacity. The tank receives the liquid
Sodium Hypochlorite from top of the tank. Sodium Hypochlorite loading operation to dosing tank is
manual.
The material of dosing tank is Poly Ethylene (High Density). Sodium Hypochlorite from the tank is
pumped by Sodium Hypochlorite Dosing Pump (1007-DP102A/B).
The tank is equipped with one level switch (LS-1003)
4.29 Sodium Hypochlorite Dosing Pump (1007-DP102 A/B)
Dosing Pump receives Sodium Hypochlorite from Dosing Tank (1007-DT102) and delivers at the
Static Mixer (1007-SM102) Inlet at the UF backwash pumps discharge (1007-P105A/B).
PLC Operation:

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Manual Operation
Auto Operation
4.30 Caustic Soda Dosing Tank (1007-DT103)
One Caustic Soda (NaOH) Dosing Tank is provided with 500 lit capacity. The tank receives the 25 %
Caustic soda from top of the tank. Caustic Soda loading to dosing tank is manual operation.
The material of dosing tank is Polypropylene. Caustic soda from the tank is pumped by NaOH dosing
pump (1007-DP103A/B) to perform CEB of UF system.
The tank is equipped with one level switch (LS-1101).
4.31 Caustic Soda Dosing Pump (1007-DP103A/B)
LPH at 4 barg.
Dosing pumps receive caustic from dosing tank (1007-DT103) and deliver in the UF backwash
discharge line. Caustic dosing is provided to perform CEB of UF system.
PLC Operation:

Manual Operation
Auto Operation

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4.32 Sulphuric Acid Dosing Tank (1007-DT104)
One Sulphuric Acid (H2SO4) Dosing Tank is provided with 200 lit capacity. The tank receives the 98
% Sulphuric acid from top of the tank. Sulphuric acid loading to dosing tank is manual operation.
The material of dosing tank is CS. Sulphuric Acid from the tank is pumped by H2SO4 dosing pump
(1007-DP104A/B) to perform CEB of UF system.
4.33 Sulphuric Acid Dosing Pump (1007-DP104A/B)
LPH at 4 barg.
Dosing pumps receive sulphuric acid from dosing tank (1007-DT104) and deliver in the UF backwash
discharge line. Sulphuric acid dosing is provided to perform CEB of UF system.
PLC Operation:

Manual Operation
Auto Operation
4.34 Sodium Hypochlorite Dosing Tank (1007-DT105)
One Sodium Hypochlorite Dosing Tank is provided with 500 lit capacity. The tank receives the liquid
Sodium Hypochlorite from top of the tank. Sodium Hypochlorite loading operation to dosing tank is
manual.
The material of dosing tank is Poly Ethylene (High Density). Sodium Hypochlorite from the tank is
pumped by Sodium Hypochlorite Dosing Pump.
The tank is equipped with one level switch (LS-1201)

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4.35 Sodium Hypochlorite Dosing Pump (1007-DP105A/B)
There are two pumps provided one working and one standby. The design flow of the pump is 32.5
Dosing Pump receives Sodium Hypochlorite from Dosing Tank and delivers at the Static Mixer
(1007-SM101) Inlet at the DAF inlet.
PLC Operation:

Manual Operation
Auto Operation
In auto operation mode, pump starts and stops automatically through PLC based on Sea Water
Intake Pump (1007-P-101 A/B) start / stop.
4.36 Ferric Chloride Dosing Tank (1007-DT106)

One Ferric Chloride Dosing Tank is provided with 1000 lit capacity. The tank receives the liquid
Ferric Chloride from top of the tank. Ferric Chloride loading operation to dosing tank is manual.
The material of dosing tank is Fiber Reinforced Plastic (FRP). Ferric Chloride from the tank is
pumped by Ferric Chloride Dosing Pump (1007-DP106 A/B/C/D).
4.37 Ferric Chloride Dosing Pump (1007-DP106 A/B/C/D)
There are four dosing pumps supplied. Two dosing pumps (DP-106 A/B) one working one standby
are for DAF feed and the other two dosing pumps (DP-106 C/D) one working one standby are for UF
feed. The design flow of each pump (1007-DP-106 A/B) is 30 LPH at discharge pressure of 4 barg
and flow of pump (DP-106 C/D) is 3.2 LPH at 4 barg discharge pressure.

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Dosing Pump receives Ferric Chloride from Dosing Tank and delivers at the flocculation tank and UF
inlet.
Ferric Chloride dosing rate shall be selected based on the turbidity available in feed water.
Accordingly the dosing rate is required to establish for expected low to high range of turbidity by
conducting the various jar tests. Once the dosing rates are set based on feed turbidity then operator
to adjust the pump dosing rates accordingly by changing the pump stroke rate.
PLC Operation:
Manual Operation
Auto Operation
a. 1007-DP106 A/B
In auto operation mode, pump starts and stops automatically through PLC based on Sea Water
Intake Pump (1007-P-101 A/B) start / stop.
b. 1007-DP106 C/D
In A (Auto) operation mode, duty pump starts and stops automatically through PLC based on UF
operational sequence. Refer Annexure-II “VALVE SEQUENCE CHART - UF SYSTEM (1007-UF-
101)”
Alarm and Trip
1. Alarm & Trip Ferric Chloride Dosing Pump at Low Level (LS-1402).
4.38 Antiscalant Dosing Tank (1007-DT107)

One Antiscalant Dosing Tank is provided with 100 lit capacity. The tank receives the liquid
Antiscalant from top of the tank. Antiscalant Loading operation to dosing tank is manual.
The material of dosing tank is Polypropylene. Antiscalant from the tank is pumped by Antiscalant
Dosing Pumps.

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4.39 Antiscalant Dosing Pump (1007-DP107A/B)
There are two pumps supplied one working and one standby. The design flow of the pump is 2 LPH
at discharge pressure of 4 barg.
Antiscalant from the tank is pumped by Antiscalant Dosing Pump (1007-DP107A/B) to Cartridge filter
(1007-CF-101) inlet of SWRO System (1007-RO-101) before the Static Mixer.
An Antiscalant chemical is added to the SWRO feed water to prevent scale build-up on membranes
resulting from chemicals having scaling potential such as Calcium Carbonate and Calcium Sulfate.
Deposition of scale material on membranes will reduce membranes permeability by clogging the
pores and thereby causing fouling. Hence it is important to maintain Antiscalant dosing.
A-O-M selector switch is provided for Manual and Auto operation.
Manual Operation
One common A-O-M selector switch is provided on control panel for entire plant. In ‘M’ (Manual)
mode of selector switch, pump can be started and stopped from control panel.
Auto Operation
In A (Auto) operation mode, duty pump starts and stops automatically through PLC based on SWRO
mode sequence.
Alarm and Trip
1. Alarm & Trip Antiscalant Dosing Pump at Low Level (LS-1403).
4.40 Sodium Bisulfite Dosing Tank (1007-DT108)
One Sodium Bisulfite Dosing Tank of 500 lit capacity is provided. It is designed for preparation of
Sodium Bisulfite solution.
SBS is added in the tank through the filling cap at the top of the tank keeping the mixer ON. After 5
minutes of mixing the level of the tank is made to the maximum height by adding water for dilution
and the mixer will be put OFF.

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Sodium Bisulfite solution from the tank is pumped by Sodium Bisulfite Dosing Pump (1007-
DP108A/B) to Cartridge filter (1007-CF101) inlet before the Static Mixer. The material of dosing tank
is Polyethylene. Tank is equipped with one Level Switch (LS-1204) and tank mixer (MX-108).
SBS Tank Mixer (MX-102)
SBS Tank Agitator can be started & stopped manually form the control panel.
4.41 Sodium Bisulfite Dosing Pump A/B (1007-DP108 A/B)
There are two pumps supplied one working one standby. The design flow of each pump is 16 LPH at
discharge pressure of 4 barg. Dosing Pumps receive Sodium Bisulfite solution from Dosing Tank and
deliver at the common inlet header to SWRO system.
The Sodium Bisulfite solution is dosed in SWRO feed water for de-chlorination purpose. Feed water
entering to RO plant should be free of residual chlorine. Adequate Sodium Bisulfite dosing ensures
complete de-chlorination.
A-O-M selector switch is provided for Manual and Auto operation.
Manual Operation
One common A-O-M selector switch is provided on control panel for entire plant. In ‘M’ (Manual)
mode of selector switch, pump can be started and stopped from control panel.
Auto Operation
mode sequence.
Alarm and Trip
Alarm & Trip Sodium Bisulfite Dosing Pump at Low Level (LS-1404).
4.42 Caustic Soda Dosing Tank (1007-DT109)
One Caustic Soda (NaOH) Dosing Tank is provided with 100 lit capacity. The tank receives the 45 %
Caustic soda from top of the tank. Caustic Soda loading to dosing tank is manual operation.

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The material of dosing tank is Polypropylene. Caustic soda from the tank is pumped by dosing pump
to correct the pH of permeate water from SWRO unit.
4.43 Caustic Soda Dosing Pump (1007-DP109A/B)
There are two pumps provided one working and one standby. The design flow of the pump is 3.2
LPH at 4 barg.
Dosing pumps receive caustic from dosing tank and deliver in the common permeate line of SWRO
system. Caustic dosing is provided to adjust the product water pH to 7-8.5. The dosing rate is
controlled automatically by the pH Transmitter (AE 801A) to achieve the required pH in the SWRO
common permeate outlet.
A-O-M selector switch is provided for manual and auto operation.
Manual Operation
One common A-O-M selector switch is provided on control panel for entire plant. In ‘H’ (Hand) mode
of selector switch, pump can be started from the control panel.
AUTO Operation
mode sequence.
Alarm and Trip
1. Alarm and Trip NaOH Dosing Pump at Low level (LS 1405) in Caustic Soda Dosing Tank.
2. Alarm when the pH is not in set pH range.
4.44 CIP Tank (1007-T-112)
One Cleaning Tank is provided with 10 m3 capacity. The tank is designed to carry out preparation of
cleaning solution from solid (powder form) or liquid cleaning chemical.
The tank receives the cleaning chemical from top of cleaning tank and BWRO permeate water to
prepare the solution of required concentration. An agitator (1007-MX-103) is provided to make
homogeneous cleaning solution. Loading operation of cleaning chemical to cleaning tank is manual.

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Cleaning solution from the cleaning tank is pumped to RO System by CIP Pump. The circulated
cleaning solution from RO System is again collected in the CIP tank.
The construction material of cleaning tank is Fiber Reinforced Plastic (FRP). The tank is equipped
with one Level transmitter (LT-1301) for dry run protection of cleaning pump.
CIP Tank Mixer (MX-103)
CIP Tank Agitator can be started & stopped manually form the control panel.
4.45 CIP Pumps (1007-P-112A/B)
Vertical Pump of capacity 144 m³/h @ 4.5 barg is supplied to carry out the cleaning operation for the
RO system. The Cleaning Pump receives the cleaning solution from the CIP Tank (1007-T112) and
delivers to RO cleaning Cartridge Filter (1007-CF-103). The discharge line of cleaning pump is
provided with bypass line arrangement back to the cleaning tank to control the cleaning solution flow
rate to SWRO and BWRO system.
Before starting cleaning operation, ensure the cleaning connection to SWRO/BWRO unit and from
SWRO/BWRO unit connected back to cleaning system. Cleaning solution is prepared in cleaning
tank.
One Flow Indicator Transmitter (FT-1301) is provided at pump discharge line to monitor the flow of
cleaning solution.
Manual Operation
Pump can be started & stopped manually from the control panel.
Alarm and Trip
1. Alarm and Trip RO Cleaning Pump at Low Level (LT-1301).
2. Alarm and Trip Agitator for Cleaning Tank at Low Level (LT-1301).
4.46 CIP Cartridge Filter (1007-CF-103)
The cleaning solution from Cleaning Pump is filtered in Cartridge Filter of 5 micron size before it
enters into the RO System. Cartridge elements are provided in the cartridge vessel to entrap

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suspended solid on the surface of cartridge element & filtered cleaning solution is fed to the RO
System for cleaning the membrane.
Cartridge filter supplied for capacity of 144 m³/h. Air release valve is provided on the top of the
vessel. Drain is provided with isolation valve to drain out the accumulated suspended solids.
It is recommended to use new cartridge filters for every cleaning after 2-3 months or 6 months.

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5.0 ALARM LIST

(Refer Annexure - I)

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6.0 PRECOMMISSIONING CHECKS

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6.1 General.
Check that plant has been installed in accordance with the piping and instrumentation diagram. Also
refer to an equipment supplier’s O&M catalogues.
6.2 Preparation for Initial Start-Up
Ensure that all the equipments are erected, aligned, piping assembled, instruments calibrated and
loops are checked before start up. This section gives details for the preparations for start up when
the plant is being started for the first time in its service. A normal start up is restarting the plant after
shut down.
6.3 General Check-Up.
First of all ensure that all the equipments are properly erected and the bolting / fastening is done
properly. All the tanks must be manually cleaned to remove dust, debris and any other construction
material that might be left inside the tanks. Ensure required lubrication level in pumps.
Decouple all the motors from their respective driven equipments; check insulation resistance,
earthing greasing and free rotation of the motor. Conduct the no-load trials of motors; check
calibration of electronic instruments to ensure accuracy.
6.4 Line Flushing
All the installed pipelines always have some dust, bits of metals, welding burs etc. that should be
cleaned by flushing.
Flush the pipeline before each vessel before it is hooked up with the vessel, starting the feed pumps.
Vessel pipeline should be flushed by starting feed pumps. Pipeline should be flushed by taking feed
water in the respective tanks.
Filtered water can be used for flushing the acid, caustic injection lines as well as for checking
leakages.
Connect the vessels with piping after flushing and fill and drain them.
Fill all the acid and caustic tanks with fresh water check leakages and drain off before filling the
chemicals.
6.5 Leak Testing
During the above operation of line flushing, leak testing of all the lines can be carried out to check if
there is any leaking joint. This is not a pressure test like hydro test and is only a check to make sure
proper tightness of joints.

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6.6 Electrical Checks
The control panel and local junction boxes were electrically checked and tested before leaving the
factory. However, it is still recommended that the following checks to be made by qualified
electricians before electrical power is provided to the system.
 Check for shorts between grounds and again between bus and enclosure.
 Check motors leads to ground. There should be no continuity.
 Perform meager test on motors for conformity.
6.7 Instrumentation Check
Instruments must be carefully checked for correct installation and calibration by a qualified
instrument services man.
The entire test that can be performed to similar operating conditions should be carried over to ensure
that the instruments might operate properly.
Check the alarms, blocks, gauges, automatic starting and / or stopping devices, automatic sequence
as well as the operations of the control valves.
Carry out the calibration of the pH meters included in the plant using buffer solutions.
Calibrate the alarm points of all the instruments.
See the relevant operating instructions of sub-suppliers.
6.8 Pump Pre-Start Check
The following checks must be carried out
 Carefully check direction of motor rotation, normally shown by arrow.

 Check the alignment of all piping connections with the pump.
 Oil level should be at marked level.
 The pump discharge & suction header must be completely filled with water before starting.
Operating the pump dry shall cause severe damage to pump internal parts. The pump
impeller should be turned by hand in order to ensure their free rotation.
 Open all the shut off components in the suction and delivery lines.
In any case follow all the information and instructions provided in the operating manuals of the
pumps.
6.9 Availability of Utilities
Ensure following utilities are available at the package Limit at design conditions:
 Service air
 Instrument air

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 BWRO Permeate Water.

 Service Water
 Power supply
6.10 Availability of Chemicals
Ensure following chemicals are available at the package

Limit of desired quality and concentration:
 Ferric Chloride
 Coagulant Aid
 Antiscalant
 Sodium Hypochlorite
 Sodium Bisulfite
 Sulphuric acid
 Caustic soda
 Availability Of Other Facility :
 Safety wears for chemical handling.

 Safety showers / Eye wash fountain
6.11 Chemical Injection System
Check and ensure sufficient stocks of regenerants are available. Whenever new regenerant is
charged, take a sample and have it analyzed and ensure that regenerant meets relevant
specifications. Check the concentration of chemicals and set dosage accordingly.
Dosing pumps are checked for sufficient oil level and required % stroke setting. Always ensure
suction, discharge is fully open prior to running of the pump.
While injection measure the concentration of diluted acid and caustic. If required make fine setting for
dilution water flow rate. Minor variation in concentration value (+/- 0.25) should be ok. Cross check
the value with concentration meter.
6.12 Valve Check & Dry Test
Please check instrument air tubings are secured and adequate supply air is available for pneumatic
valves. Check all the auto valves for proper functioning. Check it by manually open and closing the
valve. If hand wheel is not provided, check operation by operating manual over ride of the solenoid
valve. Ensure valve is physically open when open indication appears on position indicator. Wherever
flow rate setting is required leave the pneumatic valve fully open and the flow setting is done with
manual valve installed in same pipeline network. Check if NRV’s are installed as per flow direction
marked. Check all the blinds are removed from the pipe works which are installed to perform hydro
test of the package.
Carry out dry run sequence test (without water, chemicals, motor power) and ensure all drives and
valves are operating as per valve sequence test.

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6.13 Dissolved Air Floatation system (1007-DAF101)
Refer Annexure VII.
6.14 Self Cleaning Filter (1007-SCF101)
Refer Annexure VIII
6.15 UF System (1007-UF 101)
Refer Annexure IX.
6.16 Pressure Exchanger (1007-PX 105 A/B)
Refer Annexure X.
6.17 Progressive Cavity Pump (1007-P101A/B)
Refer Annexure XI.

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7.0 INITIAL START UP

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7.1 Preparation for Initial Start-up
7.1.1 General
Operators should be thoroughly familiar with the plant layout so that they will have easy
access to all instrumentation. The piping and instrumentation diagram (P&ID) should be
checked to confirm the location of all vents, drains, valves, gauges and controls.
All mechanical/ electrical equipment, including all instrumentation shall be checked and
prepared before start-up of the plant.
After installation of equipment and finishing of piping and wiring work, the following shall be
executed in the preparation for the plant initial start-up:
 Execute a careful visual inspection for loose, broken or damage components, controls,
gauges and so on. Defective parts should be repaired and recalibrate correctly.
 Confirm that all laboratory equipment is available since water analysis must be conducted
on starting the RO units.
The below instructions are intended to guide qualified operating personnel in the operation
of reverse osmosis unit. This manual may not cover all possible contingencies. Careful
attention to the values of temperature, pressure, flows and alarm systems should be paid
in order to maintain stable operation.
 Control Mode
All motor driven equipment shall be started from central control panel (CCP). Continuous
operation shall be performed from the CCP.
 Raw Water Quality
The raw water quality shall be analysed at regular intervals.
 Utilities
Check that the following utilities are available with their design values:
- Electric power
- Chemicals
- Plant service water
7.1.2 Flushing
In order to prevent the equipment from damage by foreign matters, the following flushing
procedure should be conducted:

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7.1.3 Piping
Before flushing the piping line, all block valves and control valves shall be fully opened, and
isolation valves for instruments closed. Nozzles of equipment will be blinded to prevent
equipment from ingress of foreign matter. Insert temporary strainers to the suction line of all
pumps. Flushing shall be done with clear water and continued until foreign matter is no longer
present. Flushed water will be drained through the piping drain valve or the gap of flanges.
7.1.4 Dissolved Air Floatation system (1007-DAF101)
Refer Annexure VIII.
7.1.5 Self Cleaning Filter (1007-SCF101)
Refer Annexure IX.
7.1.6 UF System (1007-UF 101)
Refer Annexure X.
7.1.7 Pressure Exchanger (1007-PX 105 A/B)
Refer Annexure XI.
7.1.8 Cartridge Filters
Before flushing, cartridge filter elements shall be removed. After flushing, cartridge filter
vessel and shell flanges should be properly bolted. During replacement of filter elements,
take care to avoid damaging the elements.
7.1.9 R.O. Membrane
Permeators are shipped with preservative coatings to provide protection against freeze
damage and to maintain sterile conditions. The solution must be flushed from the units on a
once-through basis before being put in service.
7.2 RO PLANT OPERATION
7.2.1 General
The RO system has been designed to run with a minimum amount of attention. No adjustments are
therefore required under normal circumstances.
Exactly how the system is operated depends on the water demand cycle. It is recommended that the
Auto-mode be used as soon as the system is started up. Initially, the operation of the Plant should be
monitored rather closely with the Operator checking the system every hour, later increasing the

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inspection period to two to four hours depending on Plant running condition, parameter to be
checked, etc.
All new machinery needs a "shakedown" period, and a Reverse Osmosis Plant is no exception. After
the initial start-up, the system needs to be checked out at least every second hour. If water demand
or supply is extremely variable, close supervision may be necessary. Each time the system is
checked an entry should be made in the Operation Log.
7.2.2 Routine Checks
Fill the data in the various Operation Logs. The daily check should consist of the following:
a) Carry out daily routine jobs and checklist, see Table No. 1 – Section 10.2
b) Check and record all R.O instrumentation including flow meters and pressure gauges and carry
out SDI test of R.O feed water. Be aware of any drastic changes from previous readings!
c) Record filter inlet and outlet pressures. Oversee that filter is backwashed if pressure drop is more
than what is set. Record the Cartridge Filter pressure, read from the gauge on the filter. Change
cartridges if pressure changes by as much as 70 kPa (10 psi) by opening the housing and
replacing the cartridges
d) Check and record raw water and filtered water tests
e) Check and record the product quality. Be aware of any significant changes from previous
readings.
Periodic check should consist of the following:
a) Check suction strainers provided for all dosing pumps once in a week, to drain the dirt
accumulated, if any.
Note: A change in product quality accompanied by a change in quantity could indicate problems
developing - Refer to the troubleshooting guide
After the above log entries are made, check the following:
- Antiscalant Dosing Tank level (Refill tank if required)
- Levels in other Chemical Dosing Tanks
7.2.3 R.O Plant Shutdown
If there is a need for stopping an R.O Unit this can be done manually by switching the selector switch
from panel to Off-position.
If the R.O Unit is in Auto, the Unit will automatically shut down depending on the various instrument
control logic.

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Shutting down the system for one or two days will not damage the R.O Unit if it contains water above
freezing. Any stagnant water will in time, breed bacteria and algae, and if these are allowed to grow
within the membranes, the product flow rate and quality will both be changed when the system is
restarted.
7.2.4 Duties of Plant Operator
In general terms, the duties of a Plant Operator may be described as listed below:
 TO ENSURE THAT THE PLANT CONSISTENTLY PRODUCES A WATER OF NO

LOWER QUALITY THAN IT WAS DESIGNED TO PRODUCE
 TO SEE THAT ALL OPERATING DETAILS ARE PERFORMED PROMPTLY AND

EFFICIENTLY. THIS IS BEST ACCOMPLISHED BY ESTABLISHING A ROUTINE
SCHEDULE OF OPERATION
 TO SYSTEMATICALLY MONITOR AND RECORD DIFFERENT PROCESS

PARAMETERS INCLUDING CHEMICAL CONSUMPTION
 TO CARRY OUT OR ARRANGE FOR ALL REQUIRED LABORATORY ANALYSIS

AND TESTS OF THE WATER PASSING THROUGH THE PLANT AS TO MAINTAIN
PROPER EFFICIENCY IN OPERATION
 TO MAINTAIN ALL EQUIPMENT AND STRUCTURES OF THE PLANT IN GOOD

ORDER AND CONDITION
 MAINTAIN SEGREGATION OF CHEMICALS BASED ON USAGE LIKE CLEANING

CHEMICALS AND ROUTINE DOSING CHEMICALS.
 ENSURE THAT ALKALI DOSING TANK SHOULD NOT GET OVERFLOW WHILE
FILLING THE PRODUCT WATER THOUGH UTILITY PUMP.
 TO ENSURE THAT ALL PRECAUTIONS NECESSARY FOR THE SAFETY OF

PERSONNEL AND PROPERTY ARE OBSERVED
 TO BRING THE NOTICE OF THE ENGINEER ANY ALTERATION WORK, OR

FACILITIES WHICH MAY BE NECESSARY TO PLACE OR MAINTAIN THE PLANT IN
EFFICIENT OPERATION

 TO PLACE AND MAINTAIN THE SURROUNDINGS OF THE PLANT IN A CONDITION
AS ATTRACTIVE AS POSSIBLE
7.2.5 General Operating Requirements
Feed water temperature must be in the range 28 Deg.C and 35 Deg.C.
Pre-filtration equipment is included with the system. The Cartridge Filters will retain particles down to
5 micron in the feed water and protect the RO feed pump and RO system.

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The SDI at the membranes must be held to less than 3.0 at all times.
The pH level is governed by the incoming water flow quality. The pH is displayed on the panel-
mounted indicator.

Antiscalant is automatically injected when the Cartridge Filter Feed Pump is running. Ensure that
there is an adequate quantity of scale-inhibitor in the storage tank.
Product backpressure must be below 1 bar g otherwise performance is impeded.
7.3 Data logging
7.3.1 General
The R.O. system has been designed to run with a minimum amount of attention. No adjustments are
therefore required under normal circumstances.
Exactly how the system is operated depends on the water demand cycle. It is recommended that the
auto-mode be used as soon as the system is started up. Initially, the operation of the plant should be
monitored rather closely with the operator checking the system every hour, later increasing the
inspection period to two to four hours depending on plant running condition, parameter to be
checked etc.
All new machinery needs a "shakedown" period, and a reverse osmosis plant is no exception. After
the initial start-up, the system needs to be checked out at least every second hour. If water demand
or supply is extremely variable, close supervision may be necessary. Each time the system is
checked an entry should be made in the operation log.
7.3.2 Daily Routine Checks
Fill the data in the various operation logs. The daily check should consist of the following:
a) Carry out daily routine jobs and checklist.
b) Check and record all RO instrumentation including flow meters and pressure gauges and carry
out SDI test of RO feed water. Be aware of any drastic changes from previously readings!
c) Record cartridge filter inlet and outlet pressures. read from the gauge on the filter. Change
cartridge if pressure changes by as much as 100 kPa (14.5 psi) by opening the housing and
replacing the cartridges.
d) Check and record raw water and filtered water tests.
e) Check and record the product quality. Be aware of any significant changes from previous
readings.
Note: A change in product quality accompanied by a change in quantity could indicate problems
developing - Refer to the troubleshooting guide.

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After the above log entries are made, check the levels in the chemical dosing tanks. If there is not
sufficient chemical to last until the next check, the system may shut down.
7.3.3 R.O. Plant Shutdown
If there is a need for stopping an RO unit this can be done manually by switching the selector
switch to off-position.
If the RO Unit is in auto, the unit will automatically shutdown depending on the level in the
final product tank.
Shutting down the system for one or two days will not damage the RO unit if it contains water
above freezing. Any stagnant water will in time, breed bacteria and algae, and if these are
allowed to grow within the membranes, the product flow rate and quality will both be changed
when the system is restarted. Bacteria will eat the membranes and therefore it is necessary
to sanitize the elements in line with required recommendations.
7.3.4 General Operating Requirements
Feed water temperature must be in the range 28°C to 35°C (max) while the system is
operating.
Feed water pressure at inlet to high pressure pump should be at least 200 kPa (3 bar) when
the high pressure pump is operating. This low limit is required in order to overcome the
pressure drop of the filters and to prevent activation of the low feed pressure switch and still
not starve the high pressure pump.
Pre-filtration equipment is included with the system. The cartridge filters will retain particles
down to 5 micron in the feed water and protect the high pressure pump.
The SDI at the membranes must be held to less than 3.0 at all times.
The concentrate line (REJECT) must be free-flowing (vented to atmosphere). This is to

prevent backpressure. Under no circumstances should valves or other isolating devices be
installed in the permeate (product) line without consulting Metito. The discharge into the final
product tank must be opening ended (vented to atmosphere).
7.3.5 Summary Preliminary Checks
Before starting make the following checks.
a) Raw water is available and it meets the quality.
b) The feed pump system is operational.
c) All necessary valves on the raw water line are opened.

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d) 5 micron rated cartridges are correctly fitted in the pre-treatment cartridge filter housing.
e) SBS pumps are primed.
f) SBS tanks contain solution.
g) Antiscalant pumps are primed.
h) Antiscalant tanks contain solution.
i) Ferric Chloride pumps are primed.
j) Ferric Chloride tanks contain solution.
k) Coagulant aid pumps are primed.
l) Coagulant aid tanks contain solution.
m) Sodium hypochlorite pumps are primed.
n) Sodium hypochlorite tank contains solution.
o) Sulphuric acid pumps are primed.
p) Sulphuric acid tanks contain solution.
q) Sodium hydroxide dosing pumps are primed.
r) Sodium hydroxide tanks (pH adjustment), contains solution.
s) Check/adjust strokes and speeds of all chemical pumps.
7.4 Start-Up Procedure
When starting the RO unit for the first time, following checks should be performed to ensure
safety of equipment and personnel and to exclude any possibility of malfunction:
1. Insulation test should be done using a mega-ohm tester when power cables are
disconnected from motors, panel de-energized. Insulation resistance should not be
less than 5 Mega Ohm.
2. Dry run test should be performed when power circuit breakers for motors are off,
control circuit energized. This test consists of a simulation. That's to make sure that the
process will be controlled properly.
Having performed the preliminary checks, the plant can be started in the following manner:

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1. Put all selector switches in "OFF" position.
2. Put all breakers inside the panel in "ON' position.
3. With doors closed, main isolator and circuit breaker should be switched ON using the
handles.
4. Put selector switch for feed pump selected to work in AUTO position.
5. Select duty feed by corresponding selector switch.
The RO unit is now ready for start-up by putting RO selector switch in "MANUAL" or "AUTO"
position. Unit will start according to the sequence.
7.5 Normal Maintenance
1. Change filter cartridges every 30 days or when pressure drop exceeds 14.5 psi (1 bar)
whichever occurs first
2. Replace chemical supplies as needed.
3. The pH monitor should be calibrated once every 7 days using standard buffer
solutions.
4. The permeators require no maintenance other than cleaning, which should not be
necessary more than 4 times per year. Failure to recognize that some form of fouling is
taking place and to initiate a cleaning procedure is the most common reason
permeators are destroyed.
Fouling, if recognized in time, can be stopped and system performance restored.
If a permeator appears to have failed-e.g, the TDS of the product water has increased
by 15%, or, perhaps, there is much less product flow than usual- the permeator should
be returned to METITO for analysis.
7.6 SBS Dosing System
7.6.1 General
Sodium bisulfite (SBS) is normally used as the de-chlorination agent. Operation of the SBS
feed system must be coordinated with the operation of the RO units. Whenever water is to be
treated by the RO units, SBS must be fed to de-chlorinate the flow to protect the RO
membranes.

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7.6.2 Start-up
1. Determine that the SBS solution in the dosing tank is full of chemical.
2. Determine the SBS dosage based on chlorine residual. Approximately 1.5 parts of
bisulfite are required per part chlorine. Provide an additional two parts of bisulfite for
safety. For example, if lab-results show 1.2 mg/L chlorine residual in the feed water,
then the SBS dosage is:
(1.2 x 1.5) + 2 = 3.8 mg/L
7.6.3 Shutdown
SBS feed will stop automatically when the filter feed pump stops.
7.6.4 Normal Operation
Normal operation of the SBS feed system involves supplying the proper dosage of SBS to the
feed water for the RO units. Operation of the de-chlorination dosing pumps is automatic. The
Operator's attention is required to monitor system operation and coordinate with the operation
of the RO units. The Operator's assistance is required for making up SBS solution batches
and maintaining SBS inventory in the dosing tank.
7.6.4.1 Operating Procedures
1. Ensure that there is adequate SBS solution in the dosing tank by checking the tank
liquid level. Record the level once per shift.
2. Periodically (at least once per week) open the strainer drain valves for the dosing
pump to blow down any accumulated solids to drain.
3. Inspect for signs of chemical leaks or spills. Contact maintenance for repairs. Flush
spills to drain.
7.7 Cartridge Filter
7.7.1 General
Operation of the cartridge filter must be coordinated with the operation of the RO units.
7.7.2 Start-up
1. Before the cartridge filter (CF) brought on line, the RO feed water must meet
specifications for feeding to the RO membranes.

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2. Cartridge filter shall be brought on line. The valves on the cartridge filter should all be
closed initially.
3. Open the vent valve on the filter lid. Slightly open the inlet valve to allow R.O. feed
water to pressurize the filter. When the air has vented from the filter, close the vent
valve and fully open the inlet valve.
4. When the RO units are ready to start, slowly open the CF outlet valves. Then proceed
with start up procedures for the RO units.
7.7.3 Shutdown
1. Coordinate the shutdown of the cartridge filter with the RO units.
2. Take the cartridge filter off line by first closing the outlet valve. Then close the inlet
valve.
3. If the CF's are to be off line for longer than one (1) day, they should be drained to
prevent biological growth in the de-chlorinated water. Open the vent valve on the filter
lid. Open the drain valve on the CF side. After the filter has drained, close the vent and
drain valves. Closing the valves will prevent the cartridges from drying out due to
evaporation.
Cartridge filter is operating manually. Operator's attention is required to coordinate with the
operation of the RO units. The Operator shall monitor system differential pressure to
determine when cartridges should be replaced.
Operating Procedures
1. Read cartridge filtration system differential pressure. When all cartridges are new, the
differential pressure will be less than 35 kPa (5 psi). When all cartridges are dirty and
should be replaced, the differential pressure will be approximately 1 bar. Record
pressure once per shift.
2. Read the cartridge filter effluent pressure. Record the pressure once per shift.
7.7.5 Cartridge Filter Changing
One operator is required for changing the cartridge filter and the RO unit must be Off.
1. Shut the cartridge filters housing inlet and outlet valves and open drain valve.
2. Unscrew the housing of cartridge filter.
3. Remove the old filter elements.

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4. Fit the necessary amount of filter elements, and make sure they fit in the bottom slots
of the housing.
5. Fit the housing cover back to original position.
6. Close drain valves.
7. Open the filter housing unit inlet and outlet valves to put it back to service.
7.8 SWRO Unit
7.8.1 General
Put the RO units into operation only if the product water tank is ready to receive the water.
7.8.2 Start-up
1. Verify that the feed control valves are open.
2. Turn on high pressure pump by pressing the start push button.
3. After start-up, monitor the inlet pressure, permeate and the REJECT flow rate.
4. Adjust the VFD to get the required feed pressure and recovery.
7.8.3 Shutdown
1. To accomplish a normal shutdown, stop the high pressure pump by selector switch (off
position) on the Panel.
2. High pressure pump is electrically-interlocked to shutdown if one or more of the

following occurs:
 Low suction pressure is detected by the low pressure switch. In addition to shutting
down the pump, this will also sound an alarm on the CCP.
 High ORP in feed water.
 High & Low pH.
 High discharge pressure is detected by the high pressure switch.
Normal operation of the RO unit involves the on-line operation of RO units. Operator's
attention is required to monitor system operation and changing feed water conditions.

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The membranes must be protected against chlorine, high pressure and high temperature
exposure. The manufacturer's guidelines for operating temperature and pressure are as
follows:
 For continuous operation at 28°C, feed pressure must not exceed (62 bar).
 Membranes must not be operated above 40°C (In our case max. operating temperature is
35°C).
The membranes must never be exposed to feed water containing chlorine to avoid rapid
deterioration.
The operator shall regularly check all of above parameters.
7.8.5 Operating Procedures
1. The RO unit is not completely automated.
2. Operator shall periodically check for signs of water or air leaks in the system. If found,
Maintenance personnel should be notified.
3. Record keeping is an extremely important function of operations. The frequency,

accuracy and completeness of the operating log is vital for the successful
troubleshooting of the RO units. The testing and record keeping procedures contained
in this manual are also required by the manufacturer's guarantee for the membranes.
4. Keeping a log of maintenance activities is also important and a requirement of

manufacturer's guarantee for the membranes. As a minimum, the maintenance log
must include the following:
 Routine maintenance
 Mechanical failures / replacements
 Membrane replacements
 Cleanings (cleaning agents, temperature, pressure and other conditions used)
 Chemical post-treatments (type and conditions used)
 Sterilization
 Frequency of changing 5-micron Cartridge Filters
 Calibration of all instruments
7.9 MEMBRANE CLEANING PROCEDURE
It must be realized that all Reverse Osmosis systems are sensitive to the build-up of fouling materials
on the membrane over a period of time. This build-up can cause premature failure of the whole
system, which will then not be covered by the warranty. Thus, the system operator should become
alert to the symptoms that indicate the presence of fouling and take prompt correctly action.

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It is extremely important that the operator understands the answers to these questions: The reasons
to clean? When to clean? How to clean? The long term success or failure of the R.O. system may
depend on it.
The Reason to Clean
It is important that the membranes to maintained in a clean state because, first, the flow output and
TDS passage depend on cleanliness, and second, that fouling, if not stopped early, can destroy all
the membranes in a relatively short time.
Fouling is progressive. Once build-ups start to occur inside the permeators, these build-ups tend to
stop the flow in spots, causing additional build-ups of substances, which would not otherwise have
given problems. As time progresses, many of the internal flow channels can become plugged. These
causes TDS passage to increase and product flow to decrease, and it becomes more and more
difficult to push water through the permeators. More substances then start accumulating, and the
membrane bundles can become so clogged that it is impossible to clean them.
This can all be avoided though, if the simple instructions in this SECTION are followed. Make sure
that all the pretreatment is well maintained, and problem will be minimized.
When to Clean
The daily log sheets should provide plenty of warning. The key thing to look for is that the TDS
passage has increased by 50 percent from the previous cleaning (or from initial start-up). The TDS
passage can be found (in percent) by dividing the product TDS by the feed TDS and multiplying by
100.
Example:
On a given day of feed TDS is 2400 mg/l and the product TDS is 80 mg/l (both written in the daily log
sheets); gives 3%. If this is the value just after the pervious cleaning, the system should be cleaned
again before the passage reaches 4.5% (one and half times 3%).
How to Clean
This is the most difficult question, since without a chemical analysis of the fouling material, it is
difficult to say exactly what substance is causing the membrane to degrade. However, METITO has
gained considerable experience from installing R.O. systems and can give some good clues as to
how to clean at first. Once it is discovered how to dissolve and flush away the fouling materials,
subsequent cleanings will be easy.
Important Notice - Please Read
Please be advised that the preparation of cleaning solutions will involve the use of corrosive
chemicals. Each individual who handles such chemicals must familiarize him with the recommended,
safe handling practices. Some of the more important are highlighted below:

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1. Do not breathe fumes.
2. Wear protective clothing, including eye/face protection.
3. Dilute the chemicals. Do not mix acid or caustic full-strength into solution tanks.
4. Always add acid or caustic to the water slowly.
5. Use common sense-avoid accidents.
6. Before and after each cleaning, the permeators must be thoroughly flushed with high quality
water, preferably permeate. If flushing is not done, possible damage can occur to the permeators
and piping, as well as possible injury to the operators by the interaction of different cleaning
formulations, or by heavy accumulations.
7. For the same reason as in 6, all chemicals in a given solution should be completely dissolved
and well mixed before injection into the permeators.
8. After any cleaning procedure, the system should be rinsed thoroughly before permeate water is
collected. This is particularly important for potable applications.
9. It is recommended that a safety shower and eye shower be readily available near the R.O.
cleaning system to allow rapid irrigation upon exposure to any cleaning chemical.
RO Membrane Element Foulants
During normal operation over a period of time, RO membrane elements are subject to fouling by
suspended or sparingly soluble materials that may be present in the feedwater. Common examples
of such foulants are calcium carbonate scale, calcium sulfate scale, metal oxides scale, silica
coating, and organic or biological deposits.
The nature and rapidity of fouling depends on the condition of the feedwater. Fouling is progressive,
and, if not controlled early, will impair the RO membrane element performance in a relatively short
time.
Foulant Removal
Foulant removal is controlled by cleaning and flushing or by changing the operating conditions. As a
general guide, foulant removal is required when any of the following conditions occur:
Permeate flow has dropped to 10-15 percent below rated flow at normal pressure.
Temperature-corrected feed water pressure has increased 10-15 percent to maintain rated product
water flow.
Product water quality has decreased 10-15 percent; salt passage has increased 10-15 percent.
Applied pressure has increased about 10-15 percent.
The differential pressure across an RO stage has increased noticeably (instrumentation may not be
available to monitor this indicator).

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The following paragraphs provide a discussion of the common foulants and their removal. The details
of suggested cleaning solutions would be illustrated below:
RO Membrane Element Cleaning
A general procedure for cleaning the RO membrane elements is as follows:
Before starting the cleaning operation, operator to ensure the following position of valves.
 Ensure that cleaning tank isolation valve V-1302 A/B is open, otherwise dry run of CIP
pump may happen.
 V-1305 A/B or V-1307 are opened prior to cleaning
Flush the pressure tubes by pumping clean, chlorine-free product water from the cleaning tank (or
equivalent source) through the pressure tubes to drain for several minutes.
Mix a fresh batch of the selected cleaning solution in the cleaning tank, using clean product water.
Cleaning tank is provided with ladder to go on the top to add cleaning chemical inside the tank.
Circulate the cleaning solution through the pressure tubes for approximately one hour or the desired
period of time, at a flow rate of 35 to 40 gpm (133 to 151 l/min.) per pressure tube
After completion of cleaning, drain and flush the cleaning tank; then fill the cleaning tank with clean
product water for rinsing.
Rinse the pressure tubes by pumping clean, chlorine-free product water from the cleaning tank (or
equivalent source) through the pressure tubes to drain for several minutes.
After the RO system is rinsed, operate it with the product dump valves open until the product water
flows clean and is free of any foam or residues of cleaning agents (usually 15 to 30 minutes).
Table 1. RO Membrane Element - Foulant & Symptoms
FOULANT GENERAL SYMPTOMS
1. Calcium Precipitates (carbonates A marked decrease in rejection & a moderate

and phosphates, generally found at increase in (between feed & concentrate. Also,
the concentrate end of the system) slight decrease in system production.
A rapid decreases in salt rejection and a rapid
2. Hydrated Oxides (iron, nickel,
increase in (P between feed and concentrate.
copper, etc.)
Also, a rapid decreases in system production.

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A slight decreases in salt rejection and a

gradual increase
3. Mixed Colloids (iron, organics, and
in (between feed and concentrate.
silicates)
Also, gradual decreases over several weeks in
system production.
A significant decrease in salt rejection and a

4. Calcium Sulfate slight to moderate increase in (between feed
(generally found at the concentrate and concentrate.
end of the system) Also, a gradual decreases in system
production.
Possible decrease in salt rejection and gradual
increase in (P between feed and concentrate.
5. Organic Deposits
Also, a gradual decreases in system
production.

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7.9.1 Cleaning
It must be realized that all reverse osmosis systems are sensitive to the build-up of fouling
materials on the membrane over a period of time. This build-up can cause premature failure
of the whole system, which will then not be covered by the warranty. Thus, the system
operator should become alert to the symptoms that indicate the presence of fouling and take
prompt correctly action.
It is extremely important that the operator understands the answers to these questions: The
reasons to clean? When to clean? How to clean? The long term success or failure of the R.O.
system may depend on it.
The Reason to Clean
It is important that the membranes to maintained in a clean state because, first, the flow
output and TDS passage depend on cleanliness, and second, that fouling, if not stopped
early, can destroy all the membranes in a relatively short time.
Fouling is progressive. Once build-ups start to occur inside the membrane, these build-ups
tend to stop the flow in spots, causing additional build-ups of substances which would not
otherwise have given problems. As time progresses, many of the internal flow channels can
become plugged. This causes TDS passage to increase and product flow to decrease and it
becomes more and more difficult to push water through the membrane. More substances
then start accumulating, and the membrane bundles can become so clogged that it is
impossible to clean them.
This can all be avoided though, if the simple instructions in this SECTION are followed. Make
sure that all the membranes is well-maintained, and problem will be minimized.
When to Clean
The daily log sheets should provide plenty of warning. The key thing to look for is that the
TDS passage has increased by 50 percent from the previous cleaning (or from initial start-
up). The TDS passage can be found (in percent) by dividing the product TDS by the feed
TDS and multiplying by 100.
Example:
On a given day of feed TDS is 2400 mg/l and the product TDS is 80 mg/l (both written in the
daily log sheets); gives 3%. If this is the value just after the pervious cleaning, the system
should be cleaned again before the passage reaches 4.5% (one and a half times 3%).
How to Clean
This is the most difficult question, since without a chemical analysis of the fouling material; it
is difficult to say exactly what substance is causing the membrane to degrade. However,
METITO has gained considerable experience from installing RO systems and can give some
good clues as to how to clean at first. Once it is discovered how to dissolve and flush away
the fouling materials, subsequent cleanings will be easy.

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Important Notice - Please Read
Please be advised that the preparation of cleaning solutions will involve the use of corrosive
chemicals. Each individual who handles such chemicals must familiarize himself with the
recommended, safe handling practices. Some of the more important are highlighted below:
1. Do not breathe fumes.
2. Wear protective clothing, including eye/ face protection.
3. Dilute the chemicals. Do not mix acid or caustic full-strength into solution tanks.
4. Always add acid or caustic to the water slowly.
5. Use common sense-avoid accidents.
6. Before and after each cleaning, the permeators must be thoroughly flushed with high
quality water, preferably permeate. If flushing is not done, possible damage can occur
to the permeators and piping, as well as possible injury to the operators by the
interaction of different cleaning formulations, or by heavy accumulations.
7. For the same reason as in 6, all chemicals in a given solution should be completely
dissolved and well mixed before injection into the permeators.
8. After any cleaning procedure, the system should be rinsed thoroughly before permeate
water is collected. This is particularly important for potable applications.
9. It is recommended that a safety shower and eye shower be readily available near the
RO cleaning system to allow rapid irrigation upon exposure to any cleaning chemical.

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7.9.2 RO Membrane Element Foulants
During normal operation over a period of time, RO membrane elements are subject to fouling
by suspended or sparingly soluble materials that may be present in the feed water. Common
examples of such foulants are calcium carbonate scale, calcium sulphate scale, metal oxides
scale, silica coating, and organic or biological deposits.
The nature and rapidity of fouling depends on the condition of the feed water. Fouling is
progressive, and, if not controlled early, will impair the RO membrane element performance in
a relatively short time.
Foulant Removal
Foulant removal is controlled by cleaning and flushing or by changing the operating

conditions. As a general guide, foulant removal is required when any of the following
conditions occur:
- Permeate flow has dropped to 10-15 percent below rated flow at normal pressure.
- Temperature-corrected, feed water pressure has increased 10-15 percent to maintain
rated product water flow.
- Product water quality has decreased 10-15 percent; salt passage has increased 10-15
percent.
- Applied pressure has increased about 10-15 percent.
- The differential pressure across an RO stage has increased noticeably (instrumentation
may not be available to monitor this indicator).
The following paragraphs provide a discussion of the common foulants and their removal.
The details of suggested cleaning solutions will be illustrated below:
Calcium Carbonate Scale
Calcium carbonate may be deposited from almost any feed water if there is a failure in the
inhibitor addition system or in the acid injection or pH control system that results in a high
feed water pH. An early detection of the resulting calcium carbonate scaling is absolutely
essential to prevent the damage that crystals can cause on the active membrane layers.
Calcium carbonate scale that has been detected early can be removed by lowering the feed
water pH to between 3.0 and 5.0 for one or two hours. Longer resident accumulations of
calcium carbonate scale can be removed by recalculating a citric acid solution of 2-percent
strength and a pH of no less than 4.0 through the RO membrane elements.
Note: Ensure that the pH in any cleaning solution does not fall below 4.0. Otherwise, damage
to the RO membrane elements may occur, particularly at elevated temperatures. The
maximum pH should be less than 10.0. Use ammonium hydroxide to raise the pH, and
sulphuric or hydrochloric acid to lower it.
Calcium Sulphate Scale

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Solution 2 is the best known method for removing calcium sulphate scale from the RO
membrane.
Metal Oxides Scale
Precipitated hydroxides (e.g., ferric hydroxide) can usually be removed by using the
techniques described above for calcium carbonate scale.
Silica Coating
A silica coating not associated with either metal hydroxides or organic matter will usually
respond only to very specialize cleaning methods. Contact METITO for instructions related to
a specific problem.
Organic Deposits
Organic deposits (e.g., microbiological slimes and molds) are best removed by using Solution
3. To inhibit additional growth, recirculate and soak the membranes with approved biocide
solution. This requires extended exposure to be effective; a biocide solution is best employed
when an RO block or train is to be left in a standby condition for more than three days.
Contact METITO for the biocide best suited for specific conditions.
Cleaning Solutions
The following chemical solutions are recommended for cleaning the RO membrane elements.
The appropriate solution to use can be determined by chemical analysis of the fouling
material. A detailed examination of the results of the analysis will provide additional clues as
to the best method of cleaning. Keeping records of the methods used and results obtained
will provide data useful in developing the methods and solutions that work best under the
feed water conditions at hand.
Solution 1 is recommended for inorganic fouling
Ingredient Quantity 1000 liters pH adjustment
Citric Acid 20.3kg Adjust to pH =4.0

using
ammonium hydroxi
Liquid Non- 1.0568 liters de (NH4OH).
ionic Detergent
Concentrate (Triton X-
100, Tergitol 8, etc.)
R.O permeate 1000 liters
Solution 2 is specifically recommended for calcium sulphate and organics

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Ingredient 1000 lit pH adjustment
Sodium 20.3 kg Adjust to pH = 7.5

Tipolyphosphate with sulphuric acid
H2SO4
Sodium EDTA 8.4 kg
( Versene or equal)
Liquid Non – Ionic 1.0568 lit

Detergent
Concentrate (X-100,
Tergitol 8, etc.)
RO Permeate 1000 lit
Solution 3 is recommended for high organic fouling
Ingredient Quantity per 1000 lit pH adjustment
Liquid Non – Ionic 1.056 lit Adjust to pH = 7.5

Detergent Concentrate with sulphuric acid
(X-100, Tergitol 8, H2SO4
etc.)
Sodium Perborate 5.019 kg
RO Permeate 1000 lit
All solutions are to be used at the highest available temperature up to 104°F (40°C) for up to
60 minutes of cleaning. The quantities given are per (1000 lit) of water. Prepare the solutions
by proportioning the amount of chemicals to the amount of cleaning water to be used. Uses
chlorine-free permeate to mix the solutions. Mix thoroughly. If additional information is
needed, please contact METITO.
RO Membrane Element Cleaning
A general procedure for cleaning the RO membrane elements is as follows:
1. Flush the pressure tubes by pumping clean, chlorine-free product water from the
cleaning tank (or equivalent source) through the pressure tubes to drain for several
minutes.

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2. Mix a fresh batch of the selected cleaning solution in the cleaning tank, using clean
product water.
3. Circulate the cleaning solution through the pressure tubes for approximately one hour
or the desired period of time, at a flow rate of 35 to 40 gpm (133 to 151 l/min.) per
pressure tube.
4. After completion of cleaning, drain and flush the cleaning tank then fill the cleaning
tank with clean product water for rinsing.
5. Rinse the pressure tubes by pumping clean, chlorine-free product water from the
cleaning tank (or equivalent source) through the pressure tubes to drain for several
minutes.
6. After the RO system is rinsed, operate it with the product dump valves open until the
product water flows clean and is free of any foam or residues of cleaning agents
(usually 15 to 30 minutes).

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Table 1. RO Membrane Element Foulant Symptoms
FOULANT GENERAL SYMPTOMS RESPONSE
1. Calcium Precipitates A marked decrease in rejection & a Chemically

(carbonates moderate increase in (between feed clean the
and phosphates, & concentrate. Also, slight decrease system with
generally found at in system production. Solution 1
the concentrate end of
the system)
2. Hydrated Oxides A rapid decrease in salt rejection and Chemically

(iron, nickel, copper, a rapid increase in (P between feed clean the
etc.) and concentrate. Also, a rapid system with
decrease in system production. Solution 1.
3. Mixed Colloids (iron, A slight decrease in salt rejection and Chemically

organics, and silicates) a gradual increase clean the syst
in (between feed and concentrate. em with
Also, gradual decrease over several Solution 2.
weeks in system production.
4. Calcium Sulfate A significant decrease in salt Chemically

(generally found at the rejection and a slight to moderate clean the
concentrate end of the increase in (between feed and system with
system) concentrate. Also, a gradual solution 2.
decreases in system production.
5. Organic Deposits Possible decrease in salt rejection Chemically

and gradual increase in (P between clean the
feed and concentrate. Also, a system with
gradual decrease in system solution 2. For
production. heavy fouling
solution 3.
6. Bacterial Fouling Possible decrease in salt rejection Chemically

and a marked increase in (P between clean the
feed and concentrate. Also, a system with
marked decrease in system either solution
production. dependent on
possible
compound
fouling.
Shutdown Procedures

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Extended Shutdown provided a minimum of 48 hours of operation has occurred.
1. Shutdown R.O. system in accordance with instructions.
2. Flush the system with an oxidant free solution of 0.5 to 1.0 weight percent
formaldehyde or 0.5 to 1% sodium metabisulfite continue flushing until the REJECT
discharge stream contains minimum 0.5 W % formaldehyde. Approx. time required is
30 minutes.
3. With the system full of this solution close all inlet and outlet of pressure tubes.
4. Repeat procedure every 30 days.
Note:
a) Water used must be oxidant free.
b) On system restart, drain product for at least one hour.
c) If system has not operated for 48 hrs, formaldehyde should not be used. Use sodium
metabisulfite.
Short Term Shutdown
Use this procedure for system shutdown less than 5 days.
1. Shutdown RO system.
2. Flush with oxidant free water 30 minutes.
3. Close inlet and outlet valves.
4. Repeat every 2 days.

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7.10 Instructions for SDI Kit
The silt density index (SDI) of the feed water is measured using an SDI Kit.
The kit consists of a pressure regulator, a filter holder containing a 0.45 micron special filter
element called a 'Millipore Disc', and a 500 ml measuring cylinder.
A stop-watch and 500 ml measuring cylinder is also required for the test.
A minimum feed pressure of 35 psi is necessary for this test. The pressure regulator is set at
30 psi by adjustment of the set screw on the top of the body.
The procedure for measuring SDI is as follows:
1. Connect the hose connector end of the kit to the sample valve on the RO unit high
pressure pump suction line. Remove the outlet half of the filter holder by undoing the
three retaining screws. Put the o-ring in a safe place and discard the remaining
millipore disc if present.
2. Open the sample valve and the valve attached to the regulator to flush the kit. Pour the
outlet water over the inverted outlet half of the filter holder to flush this part as well.
3. Hold a finger over the spout of the outlet filter holder and 'fill' it with water. Remove it
from the stream of water keeping it vertical and with the finger still in place. 'Float' a
millipore disc onto the holder. (Preferably use tweezers in handling the disc millipore
disc or carefully hold it at the edge between finger and thumb. NEVER TOUCH THE
FILTERING SURFACE WITH YOUR FINGERS). When it is fully wetted and centred,
remove the finger and the disc will seal. If it slightly off centre, tap the holder in the
direction the disc is to move, close the inlet valve.
4. Replace the o-ring and screw the holder together. Now loosen the three retaining
screws to provide an even 'crack' that can just be seen above the o-ring.
5. Hold the filter at eye level and slightly open the inlet valve to allow enough water to fill
the cavity, this will displace any air which would otherwise invalidate the test. Tighten
up the three screws evenly (it is extremely important that all air is displaced, if air is
present the disc will exhibit uneven loading or even patches of no loading).
6. Briefly open the inlet valve fully to make sure the regulator is set at 30 psig. If
necessary during the test adjust the regulator to maintain 30 psig.
The idea of the test is to see how long it takes to fill a 500 ml measuring cylinder. So, pointing
the spout of the filter holder of the measuring cylinder, open the inlet valve fully and record
how many seconds it takes to fill to 500 ml. Allow the water flow and the clock to continue.
After 15 minutes put the measuring cylinder under the water flow again and record the time to
fill to 500 ml again.
The SDI is a ratio obtained form the two times measured to collect 500 ml of water.

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The following example show how the SDI is obtained:
1. For instance: Initially it took 28 seconds to collect 500 ml. The final sample at 15
minutes took 43 seconds.
Divide the first time by the second time: 28 = 0.65

43
2. Move the decimal over two places to the right: 65
3. Subtracts from 100:

100
- 65
35
4. Divide the answer by the number of minutes the test ran, in this case 15 minutes.
35 = 2.3
15
5. Therefore, the SDI is 2.3
Or, if you prefer to remember the formula:
(1-T1/T2) x 100 Where T1 = First time for 500 ml

15 T2 = Second time for 500 ml

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Helpful Information
 Some tests don't go the full 15 minutes. Record the initial time the flow reduced to
drops. The test is over when the flow becomes to drops.
 Keep the equipment clean. Bacteria in the water being sampled will breed, and the
next time the equipment is used, the bugs will come out on the filter disc and invalidate
the times. Soaking in a Clorox (liquid bleach) solution for 30 minutes will help.
 The method described for purging air is the best to date. If air is trapped, it will be
apparent as uneven loading on the filter disc or even areas of no loading. Ignore the
test if air is considered to have been present and repeat.
 It is recommended that 500 ml timed samples at the 5 and 10 minute marks be taken.
This information describes the "trend" of pluggage. Also, if the test doesn't go the full
15 minutes, it is an indication of the rate of pluggage. Keep all the water passed during
the test and record its volume.
 The SDI provides an indication of the presence or absence of suspended material in

the water and some insight to the particle size distribution.
 The highest possible index is 6.66 i.e. if the initial time was 20 seconds and the final
time was an absurd at 2000 seconds, the formula will give an SDI of 6.6.
 A filter disc exhibiting areas of pale green and/or faint green lines indicates the
presence of algae.
 A filter disc exhibiting areas of brown indicates the presence of iron.

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8 GUIDELINES FOR DATA RECORDING
8.1 General
From the previous sections it is obvious that there are a number of physical observations, test
procedures, and regular services, which will assist the Operator, maintain his Plant performing
efficiently. By keeping records of these observations, tests results and services/ repairs jobs, an
Operator can often readily recognize imminent problems which are developing and affect remedial
operating measures to ensure that treatment process is maintained and equipment restored in good
working condition.
Reference to old records of Plant conditions and performance can be of great assistance when deciding
a course of action to be taken with a particular plant-operating problem.
8.2 Purpose of Record Keeping
The regular recording of operating parameters and other information serves many purposes.
Records are needed for the following reasons:
 Plant Operation
Review of operating records can indicate:
- Efficiency of the Plant and its treatment units
- Process malfunctions
- The success of plant process adjustments
- Necessary adjustments to the treatment processes required because of raw water changes due to
seasonal or environmental conditions, and past problems
 Plant Maintenance
Records are needed to show type and frequency of maintenance of operating units and evaluation
of effectiveness of maintenance programs.
 Evaluations & Process Adjustments
Records of past performance and operational procedures are invaluable tools for the engineers in
the evaluation of present performance and serve as a basis for the design of future treatment units
 Budgets
Records are used to support budget requests for personnel, additional facilities, or equipment
 Reporting
Records provide the actual data for the preparation of monthly or annual reports

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 Accidents
Records may be needed in damage suits. They can be especially helpful to the Operator if an
accident occurs. As soon as possible after an accident someone should record the chain of events
leading to the accident, exactly what happened, and any preventive or corrective action
 Warranty Claims
Guarantee requirement records provide backup information to substantiate any warranty claims to
substantiate any warranty claims on equipment, especially the system performance guarantee for
the R.O membranes
The following record keeping procedures are a requirement of membrane manufacturers:
Changes in the treatment method or operational routine should always be recorded as well as
unusual weather or operating conditions.
Examples of items to be noted include bringing equipment on line, taking equipment off line,
replacing Cartridge Filters or Pressure Vessel bundles, changing treatment chemicals or modifying
their dose, changing the method or frequency of sample collection, and changing laboratory
procedures or equipment
Changes in the operational routine could have an impact on the interpretation of R.O Plant and
operating data
Records must be permanent, complete, and accurate. Write entries on data sheets in ink or with an
indelible pencil. A lead pencil should never be used because notations can smudge and be altered
or erased.
- FALSE AND MISLEADING RECORDS MAY ACTUALLY DO MORE HARM THAN LACK OF
RECORDS!
8.3 Operation Logs
The method employed of recording operation data will vary according to the size and type of Plant
and the ability of the Operator to carry out certain tasks. However, there are commonly two main
classifications:
1) RECORD LOGS/SHEETS
2) MONTHLY REPORT
These two categories are described in more detail below:
1) RECORD LOGS/SHEETS:
These are normally divided in the following groups:
A) DIARY LOG

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B) DAILY ROUTINE JOBS & CHECKLIST
C) DAILY, WEEKLY OR MONTHLY DATA RECORD SHEETS
Note: Daily record sheets will also include record sheets for each shift where frequent monitoring is
required
D) HYDROLOGICAL LOG
E) PLANT DATA INFORMATION
This O & M Manual includes record sheets in-group B) and C). These are pre-prepared in size A4
suitable to be kept on a "clipboard" so that an Operator is able to keep them neat and tidy.
The content of the above categories are shortly described below:
A) A DIARY LOG shall be a wide variety of factual information on matters such as progress of
construction or maintenance work equipment failures, accidents, time spent on the Plant, bypassing
of a unit, complaints and visitors. This information is valuable for later references
B) The DAILY ROUTINE JOBS & CHECKLIST shall verify that the Operator has carried out necessary
inspection and observations
C) DATA RECORD SHEETS shall be used for recording of process parameters, such as flows,
pressures, and pH readings etc, as well as other instrument readings such as running hours and
tank levels, etc. Daily, weekly or monthly analysis (both from field tests and laboratory tests) shall be
recorded
Readings of instrument data (both panel and field mounted) is in general recorded on different sheets
than data from laboratory analysis (tests)
D) The HYDROLOGICAL LOG shall contain daily notations of weather such as temperature, wind and
rainfalls. Special occurrences shall be noted such as floods or unusual storms. This log may be
combined with the "DIARY LOG"
E) PLANT DATA INFORMATION
At the R.O Treatment Plant information should also be kept on:
a) Date on which the Plant commenced operation
b) Point(s) of raw water sources(s)
c) Plans showing the complete details of the construction of distribution network and Pumping Stations,
which deliver raw water to the Plant
d) Details of number and types of connections to the water distribution system e.g. number of
population connected.

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9.0 O&M JOB DESCRIPTIONS
9.1 General
In order to ensure that procedures necessary for process control are carried out, operating conditions
shall be recorded for later reference. Likewise, it is important that maintenance of equipment is
performed as specified in suppliers service manuals and it is essential that Operators maintain suitable
maintenance servicing records for all major equipment.
9.2 Operation Schedules
TABLE No. 1 Page: 1(2)

OPERATOR DAILY ROUTINE JOBS & CHECKLIST
JOB DESCRIPTION REMARKS/REFERENCES
CENTRIFUGAL PUMPS
Check the following:

1. Motor current and voltage Daily
2. Noise
3. Vibration
4. Discharge and suction pressure
Once pr. shift
5. Seal leakage
6. Bearing temperature
7. Lubricant oil level
AIR BLOWER
1. Open drain valve to empty Daily
discharge pipe, in case filled with
water.
CHEMICAL DOSING PUMPS
Check for:
1. Noise
2. Vibration Once pr. shift
3. Leakage from pipe connections
CHEMICAL DOSING TANKS AND
MIXERS
Check for:
1. Leakage Once pr. shift
2. Noise
When mixer is operated
3. Vibration
(Continue next page)

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OPERATOR DAILY ROUTINE JOBS & CHECKLIST
(Cont'd)
INSPECTION ROUND AT EACH SHIFT
Check for:
1. Leakage pipe points
2. Leaking valves
3. Loose cable connections
4. Fraying, wear or damage to
Electrical cables and instrument
lead

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TABLE No.2 Page: 1(3)

INSTRUMENT READINGS
FLOWS
RAW WATER INLET. Every 2nd hour.
R.O FEED Twice pr. Shift

PERMEATE (= Every 4 hours).
REJECT/REJECT Every 2nd hour
During Plant startup
FILTER PRESSURES
MEDIA FILTER INLET

MEDIA FILTER OUTLET Once pr. Shift
PRESSURE DIFF., MEDIA FILTERS
CARTR. FILTERS INLET & OUTLET Twice pr. shift,

(=Every 4 hours)
PRESSURES, R.O UNITS
SWRO / BWRO HIGH PR. PUMP

DISCHARGE
SWRO / BWRO FEED HEADER Twice pr. Shift
PRESSURE (= Every 4 hours)
SWRO / BWRO REJECT HEADER Every 2nd hour
BWRO 1ST STAGE REJECT HEADER During Plant startup
SWRO / BWRO DIFFERENTIAL
PRESSURE
OTHER PRESSURE READINGS
FILTER FEED PUMPS

BACKWASH PUMPS Once per day
AIR BLOWERS

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INSTRUMENT READINGS
(Cont’d)
TEMPERATURE
SWRO FEED Once pr. shift and
(after cartridge filter) Every 2nd hour during Plant startup,
ORP & pH
SWRO FEED Twice per shift

(= Every 4 hours).
Every 2nd hour
CONDUCTIVITY
SWRO FEED Twice per shift

PERMEATE (=Every 4 hours).
BWRO PERMEATE Every 2nd hour
RUNNING HOURS
FILTER FEED PIMP

FILTER BACKWASH PUMP Weekly
SWRO / BWRO HIGH PR. PUMP

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INSTRUMENT READINGS
(Cont'd)
TANK LEVELS
SWRO PERMEATE TANK

DOSING TANKS Once to twice
BWRO PERMEATE TANK per shift

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LABORATORY & INSTRUMENT TESTS
TURBIDITY
RAW WATER Once pr. Week
SDI
MEDIA FILTER OUTLET Once pr. Shift
SWRO FEED (after Cartridge Filter) Once pr. Shift.

Every 2nd hour
LSI
REJECT FLOW Monthly

TOTAL IRON Once pr. shift during
Plant startup
MEDIA FILTER OUTLET
TDS
RAW WATER Once pr. shift
SWRO / BWRO FEED

PERMEATE of each stage Once pr. month
REJECT
EACH PRESSURE VESSEL Once pr. week
FINAL PRODUCT WATER Once pr. shift
pH
FINAL PRODUCT WATER Once pr. shift

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LABORATORY & INSTRUMENT TESTS
FREE RESIDUAL CHLORINE
FINAL PRODUCT Once pr. shift
SULPHATE
CARTRIDGE FILTER OUTLET Once pr. shift
ALKALINITY
CARTRIDGE FILTER OUTLET Once pr. shift
CHLORIDE & CONDUCTIVITY
R.O FEED Eight (8) times

PERMEATE per month
REJECT ( Twice a week)
TEMPERATURE
TOTAL BACTERIAL COUNT (TBC)
R.O FEED
PERMEATE Once pr. month
REJECT
COMPLETE WATER ANALYSIS
RAW WATER
R.O FEED Quarterly
PERMEATE (Every 3 months)
REJECT

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9.3 Pre Start-up Checks (For detailed procedure refer Mechanical completion and pre
commissioning checks)
TABLE No. 4.0

R.O PRE-STARTUP CHECK LIST
Rotating Equipment
1. Before inspection of rotating parts, Before starting up this Plant each unit shall
power supply should be shut off at the be checked in accordance with the
Control Panels. Manual isolation valves procedures as described
are closed
2. Confirm that lubricant oil level is normal

and oil is clean. Changing of oil shall be
done at regular intervals in accordance
with the Lubrication Schedule
3. Confirm that the rotating friction element

is correctly greased. Makeup or
replacement of grease is carried out in
accordance with Lubrication Schedule
4. Confirm that the rotating equipment is

correctly coupled with its drive and
securely bolted to the base
5. Make sure that coupling alignment is

accurate
6. Confirm that external cooling/ flushing

water is supplied as required
7. Confirm by hand that the rotating

element is free and check direction of
rotation
8. Verify that the isolation valves are

operational

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TABLE No. 4.0

(Cont'd)
9. Grease up all points
10. All water pumps must be fully primed

and air vented
11. Action a short test run to ensure that NEVER START PUMP UNDER DRY
there is no abnormal sound or vibration CONDITION
R.O Units
1. Open all manual isolation valves on

feed, REJECT and product (permeate)
lines
MEDIA FILTERS
1. Open all Filter Inlet/Outlet Valves
2. Close other valves (including drain

valve)
3. Check that manholes are closed
4. Check that Pressure Indicators,

analysis element sample valves, Flow
Control Valve(s) etc., all are installed in
correct positions

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TABLE No. 4.0

(Cont'd)
Cartridge Filters
1. Open air vent valve until all air is

expelled and close valve
2. Open isolation valves of filter vessel
3. Open drain valve after cartridge filter and

check for SDI
4. Close drain valve when SDI is as

required

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TABLE No. 4.0

(Cont'd)
Chemical Dosing Tanks
1. Check that new chemical solutions for all

chemical feed systems have been filled
2. Adjust stroke frequency and/or stroke

length knobs as required
3. Open all manual isolation valves
4. Check that the tubing and valves are

correctly connected
Water Tanks
1. Check that isolation valves are installed

in correct position
2. Check that the float or level switches

are installed in the correct position (if
present)
3. Close all manholes

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TABLE No. 4.0

(Cont'd)
Cleaning System
1. Check Cleaning Pump with same

procedure as "Rotating Equipment"
2. Check "Cleaning Cartridge Filter" with

same procedure as "Cartridge Filters"
3. Purge all air from the piping line if vent

valves are available
4. Check that level in Cleaning Tank is

enough
Pipelines & Valves
1. Vent all air from water pipe lines
2. Open/close the block valves as

required

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TABLE No. 4.0 Page: 6(7)

(Cont'd)
3. Close air vent and drain valves after
flushing
4. Drain all water from air pipeline
5. Check pipe supports
6. Check pipe and fittings
Electric Equipment & Instruments
1. Check that control and power cabling is Following description shows an outline of
correct check items for electrical equipment and
instruments. Details are given at individual
sections of this O & M Manual
2. Make sure sequence check and
interlock check
3. Check that power supply is available
4. Check that selector switches of

electrical eqipment are in correct
position
5. Check the insulation resistance of

transmitter coils
6. Confirm that analyzers are ready for

operation
7. Confirm that all instruments are

correctly indicated and calibrated
8. Make sure that all ORP equipment are

calibrated on site during operation

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TABLE No. 4.1

(Cont'd)
Control Panels:
1. Check the voltage and frequency of

electric power supply
2. Check all panel mounted equipment

and calibrate
3. Lamp test
4. Interlock and sequence check

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9 .4 RO Plant start-up (for detailed procedure refer commissioning procedure documents)
TABLE No. 4.2

R.O PLANT STARTUP
Preliminary checks
Before starting make sure that : The Plant is assumed to be off line and all
selector switches are set to "Off ".
1. Raw water is available and it meets If the Plant is in long term storage condition,
the required quality i.e. filled with sanitizing fluid then it will be
necessary to initially flush the product to
2. The feed pump systems are opera- drain by disconnecting the product discharge
tional piping and connecting a hose
3. The filter(s) have been back-washed

and the valves are set to service
position
4. All necessary valves on the raw

water line are open
5. 5 micron (5µ) rated cartridges are

correctly fitted in the housing for pre-
treatment Cartridge Filters
6. All Chemical Dosing Tank contains

solution
7. All Chemical Dosing Pumps are

primed
8. Strokes and speeds of all Dosing

Pumps are correctly set

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TABLE No. 4.2

R.O PLANT STARTUP
(Cont'd)
Filling of filters
The filters must be filled with water before

they are put in service. Each filter is filled by
manually operating the backwash system
and filter valves as follows:
1. Select the filter to be filled. Open The other filter valves should be closed
Backwash Inlet and Backwash Outlet
Valves for that filter
2. Open the suction valve for the

Backwash Pump to be used for filter
filling and keep discharge valve closed
3. Start the pump by placing its selector

switch in Manual-position. As soon as
the pump starts, manually open the
backwash pump discharge Valve and
control the backwash flow.
4. When the filter is full, close the

discharge valve and switch the
Backwash Pump to "Off "
5. Repeat above steps for each filter

until all filters are filled

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TABLE No. 4.2

R.O PLANT STARTUP
(Cont'd)
Startup Procedure
1. Startup preparation (Plant line up) When starting the R.O Unit for the first time,
the following checks should be per-formed to
ensure safety of equipment and personnel
and to exclude possible malfunction:
a. Insulation test should be done using a

mega ohm tester when power cables
are disconnected from motors, panel
de-energized. Insulation resistance
should not be less than 5 mega ohms
b. Dry run test should be performed when

power circuit breaker for motors are
"Off” and control circuit energized. This
test consists of a simulation to make
sure that the process will be controlled
properly
2. Fill media filters with water
3. Prepare chemical solutions
4. Startup of filtration systems)
5. Startup of Chemical Dosing Pumps
6. Open Cartridge Filters valve
7. Check pH, Temp., SDI, Cl2, Biological
matter, F, Ba++, Sr++, Iron... etc.
8. Start R.O High Pressure Pump

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TABLE No. 4.3

R.O PLANT SHUTDOWN
1. Stop R.O Feed Pumps Note: Only stop R.O Unit by switching the
main power switch to "Off " in
2. Flush R.O Units using feed water Event of an emergency; never
Else 
3. Stop all Chemical Dosing Pumps Note: When stopping for more than two (2)
days, membranes must be prepared
for "long term storage" by filling with
sterilizing solution, see step 8
4. Backwash the filter(s),
5. Stop filtration system by shutting If shutdown period is greater than two

down Feed Pumps. Close filters and (2) days: Go to step 7. If not Go to
Cartridge Filters step 8
If it is more than 7 days go to step 10
7. Fill R.O membranes with 1.0 wt % To prevent growth within membranes

Formaldehyde
8. Daily operation of pretreatment Replacement with filtered raw water (fresh

system, filters, Cartridge Filters and water)
pumps to replace the stagnant water
inside filter(s)
9. Wait for startup
10. Re-sanitize membranes with 0.5 wt %

Formaldehyde, 250 mg/L Mg++ from
MgCl2

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TABLE No. 5
EMERGENCIES
The specific emergency conditions described This Table describes how to deal with
in this Table are : operating emergencies - the unexpected
events that occur suddenly, without warning,
 Power Failure and create unfavorable conditions that affect
 Instrument Air Failure the safe, continuous operation of the R.O
 Fire Plant
 Large Water Spills
The emergency operations procedures
described are designed to prevent
equipment damage, to safeguard against
electrical hazards and chemical spills, and to
prevent serious water spills.
Emergency operations will not be needed as

a direct result of sandstorm's, rainstorms, or
excessive heat. Lightning may result in
power outages that should be handled as
described below
In the event of a power failure, all electrically-

driven equipment (for example, all motors)
will stop

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TABLE No. 5
EMERGENCIES
(Cont’d)
Power Failure
UPON LOSS OF POWER, NOTIFY

MAINTENANCE IMMEDIATELY AND
BEGIN CORRECTIVE ACTION AS
FOLLOWS:

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TABLE No. 5
EMERGENCIES
(Cont’d)
Instrument Air Failure
If pressure in the instrument air supply

header falls below required, entire Plant will
shut down automatically
UPON LOSS OF INSTRUMENT AIR

PRESSURE, THE OPERATOR NEEDS TO
NOTIFY MAINTENANCE IMMEDI-ATELY
AND BEGIN CORRECTIVE ACTION, AS
FOLLOWS :
 Check the pumps and valves and make The immediate consequences of shut-down
sure that their status/position is correct. will be similar to shutdown from automatic
If not, turn Off the pumps and/or pump trips (resulting from reasons such as
manually position the appropriate valves high discharge pressure). One way in which
it is not similar to an automatic trip shutdown,
however, is that the automatic R.O flush
sequence will not be operative
Refer to "Plant Startup" for instructions

regarding restart

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TABLE No. 5
EMERGENCIES
(Cont’d)
Fire
IN CASE OF FIRE AND YOU NEED TO Fire hazards in the R.O plant area are
SHUTDOWN THE PLANT, THE ENTIRE relatively minor. Lubricating oils and
R.O PLANT CAN BE SHUT-DOWN greases, flammable building materials, and
QUICKLY AS FOLLOWS: electrical equipment & however present low-
level fire risks. Fires could be caused from
 Push the Filter Feed Pump EMER- electrical shorts by a spreading of fires
GENCY STOP push buttons started in adjacent or by lightning
 Push the R.O High Pressure Pumps

push buttons

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TABLE No. 6
REGULAR SERVICING & MAINTENANCE JOBS
INTERVAL OR
CRITERIA
CARTRIDGE FILTER
1. Change Cartridge element at Open vent and drain valve to 30 Days or

regular interval depressurize the cartridge filter at p>70 kPa
pH MONITOR
1. Calibrate using standard buffer 7 Days

solution
MEMBRANE CLEANING Failure to recognize that some form 3 Months

of failure is taking place and to
initiate cleaning is the most
common reason membranes are
destroyed. Fouling if recognized in
time, can be stopped and system
performance restored
LUBRICATE BEARINGS ON 3 Months

CENTRIFUGAL PUMP
1. Check gland packing, shift 1 Year

sleeves, Gaskets etc. for any
sign of deterioration
CALIBRATION OF GAUGES 3 Months
AIR COMPRESSOR / BLOWER
1. Clean Air Filter 1 Week
2. Replace Air Filter 1 Year

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TABLE No. 6
REGULAR SERVICING & MAINTENANCE JOBS
INTERVAL OR
CRITERIA
(Cont’d)
ELECTRICAL EQUIPMENT
1. Check adjustment and the 1 Month

operation of the protection
devices (thermal, magnetic)
2. Check time delay adjustments 1 Year
3. Tighten the connection 1 Year

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10. PLANT SERVICE LOG SHEET

(PLEASE REFER ANNEXURE- V)

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11. CHEMICAL REQUIREMENT

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11.1 Chemical Consumption:

Daily Consumption 40%
Description
(kg/day)
FeCl3 Consumption - DAF Inlet 600
FeCl3
FeCl3 Consumption - UF INLET 75
Total Daily Consumption of FeCl3 675
Description
(kg/day)
Polymer Polymer Consumption- DAF feed 6
Total Daily Consumption of Polymer 6
Description
(kg/day)
Sodium Sodium Hypochlorite Consumption- DAF Inlet

500
Hypochlorite
Sodium Hypochlorite Consumption-UF CEB 10
Total Daily Consumption of Sodium Hypochlorite 510

Description
(kg/day)
Sodium Bi Sulphite Sodium Bi Sulphite Consumption SWRO Inlet 324
Total Daily Consumption of Sodium Bisulphite 324

Description
(kg/day)
Antiscalant Antiscalant Consumption - SWRO Inlet 27
Total Daily Consumption of Antiscalant 27

Description
(kg/day)
Sulphuric Acid Sulphuric Acid Consumption for UF CEB 5.5
Total Daily Consumption of H2SO4 5.5
Description
(kg/day)
NaOH Consumption UF CEB 3
NaOH
NaOH Consumption - (BWRO) 80
Total Daily Consumption of NaOH 83
11.2 Chemical Loading Procedure
1. Ferric Chloride Dosing
A) Fill the Ferric Chloride (40 % of FeCl3) in Ferric Chloride (FeCl3) Dosing Tank of capacity
1000 liters, which will be sufficient for at an injection rate of 30 LPH through FeCl3 Dosing
Pump (1007-DP106A/B) for Coagulation (Charge neutralization).

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B) Fill the Ferric Chloride (40 % of FeCl3) in Ferric Chloride (FeCl3) Dosing Tank of capacity
1000 liters, which will be sufficient for 1 days operation at an injection rate of 3.2 LPH through
FeCl3 Dosing Pump (1007-DP106C/D) for UF feed
2. Coagulant Aid Dosing
Fill the Coagulant Aid (Polymer) (50 %) in Coagulant Aid Dosing Tank of capacity 3000 liters of two
tanks, which will be sufficient for 1 days operation at an injection rate of 350 LPH through Coagulant
Aid Dosing Pump (1007-DP101A/B).
3. Sodium Hypo Chlorite Dosing
A) Fill the Sodium Hypochlorite (12 % of Sodium Hypochlorite) in Hypochlorite Dosing Tank of
capacity 200 liters, which will be sufficient for at an injection rate of 743 LPH through Sodium
Hypochlorite Dosing Pump (1007-DP102A/B) for Disinfection.
B) Fill the Sodium Hypochlorite (12 % of Sodium Hypochlorite) in Hypochlorite Dosing Tank of
capacity 500 liters, which will be sufficient for 1 days operation at an injection rate of 21.74
LPH through Sodium Hypochlorite Dosing Pump (1007-DP105 A/B) for Disinfection
4. Antiscalant Dosing
Fill the Antiscalant in Antiscalant Dosing Tanks of capacity 100 liters solution, which will be sufficient
for 1 days operation An Antiscalant chemical is added to the SWRO feed water at an injection rate of
2 LPH through Antiscalant Dosing Pump For SWRO (1007-DP107A/B) to prevent scale build-up on
membranes resulting from chemicals having scaling potential such as Calcium Carbonate and
Calcium Sulfate.
5. SBS Dosing
Fill the SBS in Sodium Bisulphite (SBS) Dosing Tanks of capacity 500 liters solution, which will be
sufficient for 1 days operation at an injection rate of 16 LPH through Sodium Bisulphite Dosing Pump
(1007-DP108A/B) in SWRO feed water for dechlorination. Feed water entering to SWRO plant
should be free of residual chlorine. Adequate SBS dosing ensures complete dechlorination.
6. H2SO4 Dosing
Fill the Acid (98 % of Sulfuric Acid) in Sulfuric Acid (H2SO4) Dosing Tank of capacity 200 liters, which
will be sufficient for at an injection rate of 350 LPH through Acid Dosing Pump (1007-DP104A/B) to
adjust the SWRO feed pH to around 6.8- 7.8.
7. Caustic Soda (NaOH) Dosing

Fill the Caustic Soda (45 % NaOH) in Caustic Soda (NaOH) Dosing Tanks of capacity 100 liters
solution, which will be sufficient for 1 days operation at an injection rate of 3.2 LPH through Alkali
(NaOH) Dosing Pump (1007-DP109A/B) and deliver it to permeate header of BWRO to adjust the pH
7 - 8.5.

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12 QUALITY OF CHEMICAL REQUIRED

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12.1 Ferric Chloride
PARAMETER VALUE
CONCENTRATION 40 %
GRADE Technical Grade
12.2 Sodium Hypochlorite
PARAMETER VALUE
CONCENTRATION 12 %
12.3 Sodium Bisulphite Powder
PARAMETER VALUE
COCENTRATION 100 %
12.4 Coagulant Aid
PARAMETER VALUE
COCENTRATION 50 % liquid
12.5 Sulphuric Acid
PARAMETER VALUE
CONCENTRATION 98 %
OTHER INPURITIES Technical Grade

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12.6 Caustic Soda
PARAMETER VALUE
PURITY 50 %
COLOUR COLOURLESS
ODOUR ODOURLESS
APPERERANCE CLEAR VISCOUS LIQUID, FREE OF
COLOUR & SUSPENDED SOLID
TOTAL ALKALINITY (as N2OH) 49.00 - 51.00 Wt %
TOTAL ALKALINITY (as N2O) 35.00 - 39.50 Wt %
N2CO3 0.20 max Wt %
NaCl 100 max mg/kg
Fe 5 max mg/kg
Na2SO4 100 max mg/kg
NaCLO3 65 max mg/kg
ALLUMINIUM <10 ma/kg as Al
SILICA <100 as mg/kg as SiO2
MERCURY <1.5 mg/kg as Hg
HARDNESS <100 as mg/kg as Ca

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13URGENCY PLAN FOR PREVENTATIVE MEASURES

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13.1 Emergency Shutdown Procedure and Probable Causes
Emergencies, which occur in the unit, must be recognized and acted upon immediately. Operators
and supervisors personnel should become thoroughly familiar with the actions to be done in such
situations. Some emergencies cannot result in unit shutdown only, but if not handled properly can
cause injury to personnel and serious damage to equipment. In some circumstances, emergency
conditions can be tolerated for a short time, if proper measures are taken. It is something possible to
maintain the unit in operating during a localized emergency, (e.g. during out of service of a control
valve, by operating in manual control through its by-pass until repair is completed.
In emergencies, the following guidelines must be observed by operating personnel:
 Determine the extent of emergency conditions

 Arrange to notify the emergency to other units if required.
 Decide how to face with the emergency:
 Deal with the localized condition without shutting down whole unit.
 Shutdown the whole unit according to normal shutdown procedure.
 Shutdown the whole unit order emergency procedure
 Perform all operations to prevent immediate or future danger, which may damage equipment
(e.g. pump running dry, vacuum or overpressure situations etc.) During shut-down try to keep
unit conditions suitable for rapid start-up
Emergency conditions are usually caused by:
 Loss of utilities electric power, instrument air

 Mechanical failure of equipment (pump, mixers etc)
 Loss of fluid (water, chemicals) due to leakages, malfunctioning of valves etc.
 Not all possible specifications and rules can be made to cover all situations, which might
arise.
Therefore, the following procedures will cover only those emergencies, which are the most common.
Total Air Failure
In the event of total air failure, operator should perform the following:
 Stop all the running drives from the panel.

 Isolate the vessel by closing the inlet and outlet manual valves.
Total Power Failure
 In the event of total power failure the running drive will stop, and the auto valves will go to
their fail position.
 The operator should put the switches from normal service to off position and the plant can be
restored as per the normal start up on restoration of power.
Local Electric Failure

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 These may be traced back to fuses generally; however there are other sources of local
problems, which may include overload relays for drive motors low voltage trips if they are
employed. In all cases of failure, it is advisable to consult the electrical maintenance
department to determine the reasons for the failure. Where fuses have ruptured or failed they
may be replaced, but if trouble persists, then the electrical maintenance department should
be called into determine the reasons.
13.2 Conservation Instructions for Long Shut-Down
 Co-ordinate with all concerned agencies for the time and manner in which the unit can be
shut down. It is important to check and ensure that enough water is stored for any likely use
during this period.
 It is recommended that the shutdown should be planned when the service cycle is completed.
 Stop the plant operation normally from the control panel. Ensure water supply is stopped and
there is no running equipment.
 Visually inspect the plant for any abnormality.
 Depressurize the pressure vessels by opening vent valves.
 If required, drain out the chemicals from the chemical tanks and flush all the chemical lines
and tanks (if applicable) with clean water.
13.3 Trouble Shooting
Process
Despite efforts to ensure that, the water treatment plant runs smoothly, problems may still be
encountered in the operation of the plant. It is necessary to be equipped with certain tools to combat
these problems. A trouble-shooting guide provides one such tool to tackle problems.
1. Trouble-shooting involves the process of elimination of problems and plant personnel must
investigate the possible problems before arriving at a logical conclusion.
2. The problems that can occur are many and varied.
3. One must not jump to conclusions when a problem is encountered.
4. Eliminate first CAUSES attributable to engineering factors.
5. When a problem is being analyzed, check for deviations from the design. The majority of
problems fall into this category. The result found will be a changed influent in terms of both
total ionic content and specific ionic ratios.
6. It is advisable to analyze and log influent water for every week to ensure that design influent
conditions are not exceeded. Normally leakage from trim cooler is a major cause of high
salinity
7. The logbooks (that plant personnel should continuously update) will help guide personnel to
locate problems; the logbooks register events taking place in the plant from day to day.
Changes become evident and corrective action can be taken accordingly.

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8. Periodic detailed ( once in fortnight ) analysis of outlet water shall be carried out, in addition
to regular logging of outlet conductivity & pH
9. In case of high inlet water temperature the plant will be automatically shutdown.

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14.0 EQUIPMENT SHUTDOWN & PREPARATION FOR

SHUTDOWN

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14.1 Normal Shut Down Procedure
Generally, the term “Unit Shut Down” means a planned shut down which is carried out when the
plant is under normal operating conditions. On the other hand, the shut down can be due to the
failure of utilities, machinery or equipment. In case of utilities failure, general instructions are given
under the following paragraph. They should be followed more or less closely accordingly to the
expected duration of failure.
The following procedure provides instructions for a planned shutdown; the plant personnel must
consider three main activities:
 Co-ordinate with all departments of the plant in order to plan integrated actions.
 Observe all precautions and special instructions for safety to personnel and plant facilities.
 Carry out in the proper sequence of steps for shutting down the plant.
The unit’s supervisor will co-ordinate with:
 Other units directly correlated with his units, of shutdown schedule and date in order to
comply with plant requirements and planning.
 Maintenance department in order to provide inspection and proper maintenance of unit
facilities according to a program already prepared and discussed with plant management.
 Safety department in order to mutually agree on safety requirements, instructions and
assistance to apply during unit shut down.
Normal shut down will be carried out by the operator from the control board operating on push-button
and selector switches. Before the shutdown of a line, the operator will check that the stand-by stream
is available for services.
14.2 Preservation Measures for long plant shut down.
The preservation measures to be taken during prolonged shut down or outages are all straight
forward and simple in nature.
 Intermediate pumps should have casing drains opened, suction and delivery line valves
closed and lines drained.
 The neutralization basin must be filled with water, rinsed and then completely empty, in this
case tank may be dried.
 Not special measures are needed for the trap draining and venting.
 Caustic soda dosing pumps should be flushed with demineralized water and drained.
14.3 Plant Maintenance
14.3.1 Safeguards
There are safeguards specific for maintenance works that will be required before the dismantling
operations take place, to remove other items of the plant, in a strictly sequential order: before any
major lifts, jacking operations or removal of rotors from rotating machinery.

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Other “non built” safeguards, must be considered when removing pipe sections. Like the removal of
valves for maintenance purposes, and work on lines which have contained or continue to contain
liquids of a dangerous or corrosive nature. The permit to work system should be identified and
nominated steps to be carried out prior to the commencement of work on any part of the plant.
Protective clothing to be worn must be itemized; but the maintenance department should produce a
procedure for carrying out the work before a permit to work is issued. The isolation, lock off and
make safe of various items of equipment is an operational function to be performed by a senior
authorized person.
14.3.2 General Prevention
Operating and maintenance procedure will be useless if personnel are not adequately trained in their
correct implementation. Supervisory personnel in charge of such training should themselves be
adequately experienced; preferably in plants of similar type and handling similar materials. The best
protection of the safety of personnel is to prevent the occurrence of any hazardous situation. The
normal condition is that no gases, vapours or chemicals are present in the atmosphere or on the floor
of the process area. If this should not be possible, other means must be applied to prevent accidents
to personnel and to avoid damages to the equipment.
14.3.3 Personnel Protective Equipment
Protective equipment is not a substitute for good safe working conditions: adequate ventilation and
intelligent conduct of the operators are fundamental for accident prevention. When protective
equipment is necessary, it must be properly selected and must be suitable for the purpose; the
person using the protective equipment must be familiar with it.
14.3.4 Protective Apparatus
Substances that are absorbed through or irritate the skin require some type of clothing as a
protective barrier. Such clothing must be suited to the nature of this substance, the exposure
involved and the kind of work that is to be done. It must permit adequate movement and be resistive
to reactions by the substance in question. The clothing should not absorb the substance or be easily
penetrated by it. Particular attention must be paid while filling the storage tanks of the chemicals
involved in this plant. Employed staff must be equipped with gloves, boots, rubber aprons, glasses
and a mask for the protection of the respiratory organs.
14.3.5 Regular and Preventative Maintenance
Regular and preventative maintenance includes the periodic check of equipment working conditions
during normal operation, as well as the removal of defects and inconsistencies that are observed
during equipment operation.
Examples of routine and normal maintenance are:
 Checking vibrations of machinery

 Equipment power absorption, etc.
 Providing maintenance recommended by machine manufacturer supplier
 Replacing or cleaning filters and similar equipment

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 Lubricating machinery
 Checking correct operation and readings of instruments
 Changing bearings
 Replacing Gaskets
 Eliminating Leaks
 Rewinding electric motors
 Overhauling pumps
 Installing new level gauges, pressure indicators, etc.
 Checking/ replacing desiccant breather and oil seal in acid tank overflow line
14.3.6 Inspection and Regular Maintenance
Scope of the periodic inspection is the verification of actual plant conditions against design
specifications, and the check of actual performance.
Examples of periodic inspection are:
 Measuring thickness
 Testing at no load or under full load
 Checking of Set Points of safety valves
 Checking hydrostatic pressure
In particular, pressure gauges should undergo tests by dead weight and manometer procedures
once a year or when they are suspected of being faulty. The schedule maintenance of the
demineralization plant is based and devised on the history of operating times, failures and other
allied problems. They are based on operating experience and maintenance reports.
The importance of correct reporting of maintenance functions, conditions of the plant, and
extrapolated extensions of operating times, is reflected in the decrease of outage time, higher
availability and the shortening of amortization times. A correct scheduled maintenance procedure is
based principally on the correct recording of the plant equipment history. This information should be
recorded as time passes. History sheets can then be devised and most probable dates of overhaul,
parts replacement, and down rating where the need appears, can then be reasonably predicted with
an 85 – 90 % probability of getting maximum use of any particular item of the plant.
However, it must be borne in the mind that where items of the plant deal with particularly aggressive
or corrosive medium, that predicted wear and outage times of these items will be subject to a fairly
wide variation. This is generally accepted as a random factor that defies isolation.
The requirements for electrical maintenance in the demineralization plant have no statutory pattern
and will be confined to emergencies and scheduled needs.

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15 SAFETY

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15.1 General
The primary objective of safety measures is to reduce the chance of injury to plant personnel or
visitors. The design of this plant incorporates a number of safety features for providing a safe place
to work.
The Operator has the responsibility for the Plant and must see to it that it is maintained in such a
manner that a safe place to work is continuously provided. This can only be done by constantly
acting and thinking safety.
The Operator has the responsibility of protecting himself, other plant personnel and visitors by
making sure that proper safety procedures are followed.
All operation personnel should train themselves to analyze jobs, work areas and procedures from a
safety standpoint. Potentially hazardous actions or conditions shall be recognized.
If a hazard is recognized, take immediate steps to eliminate it by corrective action. If corrective

action is not possible, guard against the hazard by proper use of warning signs and devices.
Accidents can be prevented by using good common sense, following established safety procedures,
and particularly by acquiring a good knowledge of the hazards peculiar to specific jobs.
REMEMBER: ACCIDENTS DON'T JUST HAPPEN - - -

THEY ARE CAUSED!
Behind every accident, there was a chain of events, which led to an unsafe act, unsafe condition, or
a combination of both.
THERE IS NO JOB SO IMPORTANT, NO EMERGENCY SO GREAT THAT YOU CANNOT TAKE

THE TIME TO DO YOUR WORK SAFELY. THINK SAFETY!
15.2 Kinds of Hazards
The type of equipment and structures required by a Demineralization Plant can be hazardous. The
plant has all the necessary safety signs display warning the personnel about any potential Hazard.
But even the best of safety measures are of no value if established safety procedures are not
followed. If an accident occurs, it is equally necessary to know what steps to take to minimize further
injury and damage.
This section describes potential safety hazards of the Plant and recommends ways to avoid or
minimize these hazards. However, you should not rely upon the information presented here
exclusively, because work habits and method of operation and maintenance that develop over the
life of the plant may introduce additional hazards. As conditions will change continually, it is
extremely important that all personnel always be on the lookout for potentially hazardous actions or
conditions.
Plant personnel may be exposed to the following hazardous conditions:

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 Physical Injuries
 Chemical Burns
 Fire
 Electrical Shock
 Noise
15.2.1 Physical Injuries
The most common physical injuries to which plant personnel are exposed to are cuts, bruises, burns
and crushed or broken bones. Injuries can be caused by rotating equipment such as pumps, blowers
and fans. Falling from or into tanks and elevated platforms can be extremely hazardous. Most of
these hazards can be avoided by the proper use and maintenance of ladders, handrails, hand tools,
and safety equipment and by following established safety procedures.
15.2.2 Chemical Burns
Plant operators handle potentially hazardous chemicals on a daily basis. Chemicals to which the
Operator will be exposed include acids and bases. Chemical safety data for most chemicals
anticipated to being used on the plant site including first aid measure and recommended methods of
cleaning up spills are presented.
As contact with or ingestion of all of these chemicals can be extremely hazardous or lethal, it is very
important for all plant personnel to be familiar with the recommended first aid procedures to be
administered in case of accident.
BECOME FAMILIAR WITH FIRST AID PROCEDURES BEFORE AN ACCIDENT OCCURS!
Most often, speed in rinsing a chemical out of your eyes or off your skin is extremely important, if
permanent injury is to be avoided. Therefore, waiting until an accident occurs to learn the proper first
aid procedures will often worsen the injury and mean the difference between a minor injury and
permanent damage to the persons involved.
Planning ahead is also essential for handling chemical spills. Personnel working on cleaning up
spilled chemicals must use proper protective clothing and equipment to prevent body contact with the
chemical.
An emergency shower and eyewash is located in the Plant for washing hazardous chemicals off the
skin and out of the eyes. All plant personnel should know where the emergency shower and eye
wash is located.
15.2.3 Exposure to chemicals and toxic vapours
Toxic or suffocating gases or vapours may come from any of the chemicals used in the treatment
process. You are especially subject to this hazard when chemicals are in contact with water or when
working with chemicals in enclosed and unventilated areas.

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Because toxic gases and vapours can rapidly disable a person, it is important to constantly be alert
to conditions of unusually strong vapours and fumes or situations where you might be subject to
hazardous concentrations of toxic vapours or fumes. Take immediate actions to correct any unusual
situation.
15.2.4 Fire
Burns from fire can cause very serious injury. Avoid the accumulation of flammable material and
store any material of this type in approved containers at proper locations. Note the location of fire
fighting equipment.
15.2.5 Electrical Shock
Electrical shock frequently causes serious injury. Take precautions to disconnect the mains supply
when working on any equipment that is connected to an electric power supply. Do not leave the
terminal boxes / MCC or control panel doors / covers open when leaving the work site.
15.2.6 Noise
Loud noise from Air Blowers can cause permanent ear damage. Personnel need to wear proper ear
protecting devices whenever working in noisy areas.
15.2.7 Specific Hazards
Potential safety hazards specific to the plant systems and equipment are described below. The
hazards described below may not comprise all the potential hazards since changes in operation of
the Plant over a period of time may introduce additional hazards.
15.2.8 Pressure Tanks and Piping
On a day-to-day basis, the most common hazards associated with the pressure tanks and
piping will be bumps and bruises resulting from running into and tripping over valves and
piping. To minimize such injuries, always watch your steps. Watch out for low overhead
piping. Always wear a hard-hat when working in areas with low overhead piping.
Inspecting or doing repair work inside a filter presents the hazard of insufficient oxygen. Before
entering a pressure tank or filter for inspection or maintenance work, set up a ventilating fan to
adequately “air out” the filter before entering. Ventilate the filter with air before going into work and
continue ventilating the filter until you have left it. Never enter an enclosed, unventilated structure,
such as a filter, without first checking for oxygen level and providing ventilation.
When working with the filter, you must be particularly careful not to bump, scrape, or cut yourself on
the internal water distribution and collection piping and piping supports.
15.2.9 Chemical Addition Systems
As an Operator, you will be handling a variety of chemicals in conjunction with batch mixing and will
be performing maintenance on pumps, valves, and piping. You will also be exposed to various types
of toxic chemicals. All these chemicals can cause serious injuries, if they are exposed to your skin, if
they are ingested, or if their vapours are inhaled.

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It is extremely important that whoever is in charge of each specific chemical addition system be
thoroughly familiar with the hazards, first aid, and clean-up procedures to be followed for each
chemical. This information must be known before an accident occurs. Speed in taking first aid
measures is extremely important. Having to stop to determine the appropriate first aid procedures will
most likely increase the seriousness of the injury and may prove fatal.
Other hazards associated with the chemical addition systems include cuts, bruises, broken bones
and head injuries due to tripping over or bumping into piping systems. Always be careful of where
you walk and be aware of the location of overhead piping. Always wear a hard-hat when working
around overhead piping.
Whenever working on chemical tank platforms, you are at risk of falling to the ground or into a tank.
Such falls may cause serious injuries or drowning. Whenever working on raised platforms, stairways
or ladders make sure that you have a clean, firm surface to stand on. Remove all slimes, rags,
greases, or other material that may cause you to slip. Good housekeeping in these areas is
mandatory.
15.2.10 Atmospheric Tanks
The greatest hazard involved in working on or in an atmospheric tank is the danger of slipping.
Maintain a good non-skid surface on all stairs, ladders, and platforms. Railing should be installed
along the tank side of all stairways and platforms. Maintain these handrails in good condition. Always
work from behind the handrails. When it is necessary to work between the handrails and tank,
always wear a harness with a safety line and have someone with you. A fall may result in a very
serious injury.
Be cautious when working on the bottom of a tank. When hosing down, always hose a clean path to
walk on. Avoid walking on areas that have chemical deposits whenever possible. Always turn off,
lock out and tag tank feed valves and pumps before working in tanks.
15.2.11 Pumps and Blowers
Always turn off, lock out, and tag pumps and blowers before working on them. Stay clear of any
situation where your body or the tools you are using may become caught in the machinery. Keep the
guards in place whenever the unit is in operation.

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15.2.12 Laboratory
Because you may be required to collect water samples and conduct certain laboratory tests, you
must be aware of the specific hazards involved in this type of work.
Laboratory Procedures
Some basic procedures to follow when working in the laboratory are as follows: -
1. Use proper safety goggles or face shield in all tests where there is a danger to your eyes.
NEVER LOOK INTO THE OPEN END OF A CONTAINER DURING A REACTION
2. Use care in making rubber-to-glass connections. Lengths of glass tubing should be supported
while they are being inserted into rubber. The ends of the glass should be flame-polished to
smooth them out and a lubricant such as water should be used. Never use grease or oil.
Gloves or some other form of protection for the hands should be used when making such
connections. The tubing should be held as close to the end being inserted as possible to prevent
bending or breaking. Never try to force rubber tubing or stoppers from glassware. Cut the
rubber as needed to remove it
3. Always check labels on bottles to make sure that the proper chemical is selected. Never permit
unlabeled or undated containers to accumulate in the Laboratory. Keep storage areas organized
so that chemical selection is easier. Clean out old or excess chemicals. Separate flammable,
explosive or special hazard items for storage in an approved manner
4. Never handle chemicals with bare hands. Use a spoon or spatula for this purpose
5. Be sure that your Laboratory is adequately ventilated. Even mild concentrations of fumes or
gases can be dangerous
6. Never use Laboratory glassware for a coffee cup or food dish
7. When working in the Laboratory, smoking or eating shall not take place
8. Do not pipette chemicals by mouth. Always use a suction bulb or an automatic burette
9. Handle all chemicals and agents with care. Read and become familiar with all precautions or
warnings on labels. Know and have available the antidote for all poisonous chemicals in your
Laboratory
10. Dispose of all broken or cracked glassware immediately
11. ADD ACID TO WATER --- NEVER WATER TO ACID!
12. Wear a protective smock or apron when working around chemical

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15.3 Fire Prevention
Fires are a serious threat to the health and safety of the Operator and to the buildings and
equipment in the Treatment Plant. Fires may injure or cause the death of a person. Equipment
damaged by fire may no longer work properly and the Plant may have difficulty to function.
Know where fire extinguishers are kept and know where the fire hydrants are located. Find out
what each is for and how to use them. You can prevent fires by:
 Maintaining a neat and clean work area and preventing accumulation of rubbish
 Putting oil and paint-soaked rags in covered metal containers
 Observing all "No Smoking" signs
 Keeping exits, stairs, and fire fighting equipment clear of obstruction
 Reporting any fire hazards you see that are beyond your control, especially
electrical hazards, which are the source of many fires
15.4 Safety Equipment
It is the responsibility of the operating personnel to know the location and types of safety equipment
available at the Plant (breathing apparatus etc).
They should inspect these periodically to be certain that they can safely use the piece of equipment
as well as to be sure that it is in operating condition.
15.5 Housekeeping
Good housekeeping can and has prevented many accidents. When tools and equipment are not
being used, see that they are kept in their proper place.
Clean up all spills of oil, grease, and other substances. Keep walkways and work areas clean.
Provide proper containers for waste, oily rags, papers, etc. and empty these frequently.
A CLEAN PLANT WILL REDUCE THE POSSIBILITY OF PHYSICAL INJURIES!

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15.6 First Aid Kit
At times, no matter how careful you try to be, an accident may occur. A well-stocked first aid kit
should always be maintained. Whenever any material in the kit begins to run low, a fresh supply
should be purchased and placed in the kit.
Become familiar with the location of the first aid supplies at your Plant and learn how to properly treat
burns, cuts, and other injuries so you will be prepared if an accident does occur.
15.7 Emergency Notification
An emergency notification schedule such as the one presented below should be developed and posted
at the Operators office and at the office of the Engineer.
INJURY TEL. NO.

Fire Department ______________________
Ambulance ______________________
Hospital Emergency Room ______________________
Poison Center ______________________
FIRE-EXPLOSION-CHLORINE
Fire Department ______________________
Local Police ______________________
Local Chlorine Supplier ______________________
RESPONSIBLE PLANT PERSONNEL

Operator ______________________
Assistant Operator ______________________
Person in Charge of ______________________
Collection System
15.8 Chemical Handling & Safety
Product: Membranes
15.8.1 Hazards Identification
Some of the actions that must be taken in case of certain accidents
 When ever in contact with chemical, immediately take off all contaminated clothing.

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 Following skin contact, remove the product mechanically. Wash skin immediately with plenty
of water and soap. If skin reactions occur, contact a physician.
 Following eye contact, open the eyelids and rinse for an adequate length of time with water.
Consult an eye specialist immediately.
 Upon inhalation, take the person into the fresh air; if there is difficulty in breathing, medical
advice is required.
 Upon swallowing, rinse the mouth with plenty of water. If you feel unwell, seek medical
advice,
 Information for Physician: Basic Aid, decontamination and symptomatic treatment.
15.8.2 Fire Fighting Measures
 Extinguishing Media: CO2, foam, and dry powder.

 In cases of larger fires, water spray should be used.
 Fire men have to wear self-contained breathing apparatus.
15.8.3 Accidental Release Measures
Take up mechanically and fill into labelled closable containers. Spilled product causes a risk of
slipping.
15.8.4 Handling & Storage
Storage between -10ºC and +40ºC.

Prevent losing any of its moisture.
Precautions should generally be taken against electrostatic charges according to the equipment used
and the way the product is handled and packaged. Static charges lead to agglomeration of dry
beads.
15.8.5 Exposure Controls / Personal Protection
Eye Protection : Goggles

Hand Protection : Gloves
When handling the usual precautionary measures for chemicals. Avoid contact with eyes and skin.
Wash hands before breaks and at end of work.
15.8.6 Stability & Reactivity
Hazardous and decomposition products must be stored correctly. The formation of carbon monoxide,
carbon dioxide, sulphur dioxide and other toxic gases in case of fire during thermal decomposition is
possible.
Hazardous reaction: Contact with strong oxidizing agents may cause hazardous reactions. No
hazardous reactions, when used as directed.
15.8.7 Ecological information
Do not allow chemical to escape into water, wastewater or soil.

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15.8.8 Disposal Considerations
Examine possibilities for re-utilization. Constantly observe local regulations, for example by
controlled incineration. Contaminated, empty containers are to be treated in the same way as the
contents. Where large quantities are concerned, consult the supplier. When unclean empty
containers are passed on, the recipient must be warned of any possible hazards that may be caused
by residues.
15.8.9 Transport Information
Avoid temperatures below -10ºC and above +40ºC. Keep separated from foodstuffs.
Proper labeling like hazard descriptions, hazard symbols, risks, etc. should be properly mentioned.
General Work Safety Measures should be followed for handling dangerous materials.
15.8.10 Other Information
The purpose of this data sheet is to describe the products in terms of their safety requirements. The
data does not signify any warranty with regard to the product properties.
15.9 Ferric Chloride
PRODUCT : Ferric Chloride

Formula : FeCl3
Form : Liquid
Colour : Yellowish Brown (Dark)
Specific Gravity : 1.4
Concentration : 40 %
Extremely hazardous in case of skin contact (irritant), of eye contact (irritant), of ingestion, of
inhalation. Very hazardous in case of skin contact (corrosive). Liquid or spray mist may produce
tissue damage particularly on mucous membranes of eyes, mouth and respiratory tract. Skin contact
may produce burns. Inhalation of the spray mist may produce sever irritation of respiratory tract,
characterized by coughing, choking, or shortness of breath. Inflammation of the ye is characterized
by redness, watering and itching. Skin inflammation is characterized by itching, scaling, reddening or
occasionally blistering.
Handling
Because of its corrosive nature, care must be taken during the handling of FeCl3. Eye goggles, face
shield, mask, rubber gloves and rubber boots must be worn while handling FeCl3.
It is also advisable to wear a plastic or rubber apron, which is long enough so that is also covers part
of the legs.
Storage
Store in a well-ventilated dry and cool place when supplied as flakes. According to safety rules,
corrosive substances such as FeCl3 must be stored in suitable vessels only.

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Refer Material Safety Data Sheet for Ferric Chloride (Attachment 1) for more information.
15.10 Sodium Hypochlorite
PRODUCT : Sodium Hypochlorite

Formula : NaOCl
Form : Liquid
Colour : Pale Yellow Colour
pH : 11.2 – 11.4
Viscosity : 1.75 – 2.5 Centi poise.
It is a very active chemical that reacts readily with most forms of living tissue as other organic and
inorganic materials, metals and non-metals. This reactivity also allows its use in oxidizing objectionable
chemicals in waste. However, because of its reactivity, chlorine is difficult to handle, while its toxicity
makes it hazardous if it is not properly handled and controlled.
If exposed to this chemical in a hazardous way, the patient shall in all cases be removed immediately
from the contaminated area, a physician called and appropriate first aid must begin immediately.
A brief outline of first aid measures for exposure to chlorine is as follows:
Eyes
In case chemical is splashed into the eye (no matter the quantity), quick action is vital. The patient
should be laid down, using force if necessary, the eyelids should be held apart and the eyes flushed
copiously with running water (a boric saline solution may also be used).
The flushing should be continued for about 15 minutes and repeated if necessary. The patient should be
encouraged to roll his eyes during the operation. No medication should be attempted except under
specific instruction from a physician.
Skin
The patient should be placed under a shower immediately, clothes and all. Clothing should be removed
while the shower is running and the skin washed with larger quantities of soap and water.
Neutralization of chlorine with chemicals should not be attempted. Salves or ointments should not be
applied, except as directed by a physician.
Inhalation
If the patient is breathing he should be placed in a comfortable position, and kept warm and rest until a
physician arrives. If breathing seems to have stopped, artificial respiration should begin immediately.
Mouth to mouth resuscitation or any approved method may be used.
Oxygen should be administered if equipment and trained personnel are available. Automatic artificial
respiration is considered preferable to manual, but only when administered by an experienced Operator.
Some rest is recommended after severe chlorine exposure.

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Refer Material Safety Data Sheet for Sodium Hypochlorite (Attachment 1) for more information.
15.11 Sodium Bisulphite
PRODUCT : SODIUM Bisulphite

Formula : NaHSO3
Form : Liquid
Colour : Clear Colourless
Odour : Slight Pungent
Specific Gravity : 1.05 – 1.15
pH : Acidic
Contact may cause eye irritation or allergic skin reaction. Wash areas of contact with plenty of water
and induce vomiting. Reacts with acids to liberate Sulfur Dioxide fumes.
Eye contacts may cause irritation, redness, pain and tearing. Inhalation may cause irritation to the
nose, throat and respiratory tract. May cause allergic reaction
Handling
First Aid
If Sodium Bisulfite comes into contact with part of the human body, rinse immediately with plenty of
water.
Refer Material Safety Data Sheet for Sodium Bisulfite (Attachment 1) for more information.

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15.12 Caustic Soda
PRODUCT : SODIUM HYDROXIDE

Formula : NaOH
Form : Liquid
Colour : Water white
Iron : 10 ppm
NaCl : 0.50 %
Silica : 10 ppm
Sodium Carbonate : 0.50 %
Viscosity @ 28ºC : 23 centi poise
This product can destroy living tissue. It is highly toxic by ingestion and is a strong irritant to eyes,
skin & mucous membrane. Tolerance is 2 mg per cubic meter of air. The higher the concentration
and the temperature of Caustic Soda, and the longer it is allowed to react, the more serious is the
damage to the cellular tissue.
Handling
Because of its corrosive nature, care must be taken during the handling of NaOH. Eye goggles, face
shield, mask, rubber gloves and rubber boots must be worn while handling NaOH.
It is also advisable to wear a plastic or rubber apron, which is long enough so that is also covers part
of the legs.
Storage
Store in a well-ventilated dry and cool place when supplied as flakes. According to safety rules,
corrosive substances such as NaOH must be stored in suitable vessels only. For SMC Project,
Caustic is stored in Caustic storage tank. Caustic is brought by tanker and unloaded by Caustic
unloading pumps.
First Aid
If NaOH comes into contact with part of the human body, rinse immediately with plenty of water. DO
NOT attempt to neutralize on the skin. Clothing which is splashed with NaOH must be removed
immediately.
In case of serious chemical burns caused by Caustic Soda, a doctor must be consulted immediately.
Refer Material Safety Data Sheet for Sodium Hydroxide (Attachment 1) for more information.

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15.13 Sulphuric Acid
PRODUCT : Sulphuric Acid
Formula : H2SO4
Form : Liquid
Colour : Clear colorless or slightly yellow liquid with pungent
odour. Concentrated acid is fuming.
Safety
This product is acidic and corrosive to body tissue and must be handled with great care. Skin and
eye contact must be avoided and gloves and goggles should be worn, along with protective overalls
and an apron, when handling the product or a solution containing the product.
Ensure that the operator is fully informed and familiar with the use of the product. Avoid investigation
of the product by mouth and nose. To eliminate the possibility of accidental ingestion, operator
should never eat, drink or smoke when using chemicals. In addition, protective clothing should be
removed, and the hands washed prior to eating, drinking or smoking.
DO NOT ADD WATER TO ACID

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16 DUTIES OF PLANT OPERATOR

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In general terms, the duties of a Plant Operator may be described as listed below:
 TO ENSURE THAT THE PLANT CONSISTENTLY PRODUCES A WATER OF NO LOWER

QUALITY THAN IT WAS DESIGNED TO PRODUCE.
 TO SEE THAT ALL OPERATING DETAILS ARE PERFORMED PROMPTLY AND

EFFICIENTLY. THIS IS BEST ACCOMPLISHED BY ESTABLISHING A ROUTINE SCHEDULE
OF OPERATION.
 TO SYSTEMATICALLY MONITOR AND RECORD DIFFERENT PROCESS PARAMETERS

INCLUDING CHEMICAL CONSUMPTION.
 TO CARRY OUT OR ARRANGE FOR ALL REQUIRED LABORATORY ANALYSIS AND

TESTS OF THE WATER PASSING THROUGH THE PLANT AS TO MAINTAIN PROPER
EFFICIENCY IN OPERATION.
 TO MAINTAIN ALL EQUIPMENT AND STRUCTURES OF THE PLANT IN GOOD ORDER

AND CONDITION.
 TO KEEP PROPER RECODS OF OPERATION & MAINTENANCE JOBS INCLUDING

SPARE PART COSTS AND CONSUMED MAN HOURS.
 TO ENSURE THAT ALL PRECAUTIONS NECESSARY FOR THE SAFETY OF

PERSONNEL AND PROPERTY ARE OBSERVED.
 T BRING THE NOTICE OF THE ENGINEER ANY ALTERATION WORK, OR FACILITIES

WHICH MAY BE NECESSARY TO PLACE OR MAINTAIN THE PLANT IN EFFICIENT
OPERATION.
 TO PLACE AND MAINTAIN THE SURROUNDINGS OF THE PLANT IN A CONDITION AS

ATTRACTIVE AS POSSIBLE.

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17 TROUBLE SHOOTING GUIDELINES

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17.1 TROUBLESHOOTING GUIDE
17.2 Overview
A number of operation problems might be encountered in all Reverse Osmosis Plants. The most
common problems are outlined in the ten (10) Tables enclosed in this Section.
Each Process Unit is exposed to various problems. The suggested remedy for each problem is listed in
separate Tables for each main unit. Some operating conditions activates an alarm.
In the previous Sections various operation parameters are discussed in more general terms. Possible
"counteractions" (or remedies) will therefore also be found there.
An overview of the Tables is listed below:
TABLE No. 1 - ELECTRIC MOTORS
TABLE No. 2 - CENTRIFUGAL PUMPS
TABLE No. 3 - MEDIA FILTER& CARTRIDGE FILTERS
TABLE No. 4 - FILTER BACKWASH SYSTEM
TABLE No. 5 - AIR BLOWERS
TABLE No. 6 - REVERSE OSMOSIS UNITS
TABLE No. 7 - MEMBRANE CLEANING SYSTEM
TABLE No. 8 - CHEMICAL DOSING SYSTEMS

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TABLE No. 1: ELECTRIC MOTORS
Necessary Check &

Trouble Possible Cause
possible Corrective Actions
1. Motor does not a. Incorrectly - Connect correctly per diagram on

start. (Switch is connected motor
on and not
defective). May b. Incorrect power - Use only with correct rated power
result in burnout supply supply
c. Fuse out, loose or - correct open circuit condition

open connection
d. Rotating parts of - Check and correct

motor may be
jammed 1. Bent shaft
mechanically 2. Broken housing
3. Damaged bearing
4. Foreign material in motor
e. Driven machine - Correct jammed condition

may be jammed
f. No power supply - Check for voltage at motor and work

back to power supply
g. Internal circuitry - Correct open circuit condition

open
2. Motor starts but a. Same as 1-a, b, c - Same as 1-a, b, c above

does not come above
up to speed.
May result in b. Overload - Reduce load to bring current to rated
burnout limit. Use proper fuses and overload
protection
c. One or more - Look for open circuits.

phases out on a 3-
phase motor

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TABLE No. 1: ELECTRICAL MOTORS (Cont'd).
Necessary Check &

3. Motor noisy a. Same as 1-a, b, c - Same as 1-a, b, c above

electrically above
4. Motor runs hot a. Same as 1-a, b, c - Same as 1-a, b, c above

(exceeds rating) above
b. Overload - Reduce load
c. Impaired - Remove obstruction

ventilation
d. Frequent start or - 1. Reduce number of starts or

stop reversals
2. Secure proper motor for this duty
e. Misalignment - Realign
between rotor and
stator laminations
5. Noisy (mecha- a. Misalignment of - Correct misalignment

nically) coupling or
sprocket
b. Mechanical - Find unbalanced part, then balance

unbalance of
rotating parts
c. Lack of or - Use correct lubricant, replace parts as

improper lubricant necessary
d. Foreign material in - Clean out and replace bearings

lubricant

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TABLE No. 1: ELECTRICAL MOTORS (Cont'd).
Necessary Check &

e. Overload - Remove overload condition. Replace

damaged parts
f. Shock loading - Correct causes and replace damaged

parts
g. Mounting acts as - Isolate motor from base

amplifier of normal
noise
h. Rotor dragging - Replace bearings, shaft or bracket as

due to worn needed
bearings, shaft or
bracket
6. Bearing failure a. Same as 5-a, b, c, - Replace bearings and follow 5-a, b, c,

d, e, f d, e, f
b. Entry of water or - Replace bearing and seals and shield

foreign material against entry of foreign material (water,
into bearing dust, etc.). Use proper motor
housing

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TABLE No. 2: CENTRIFUGAL PUMPS
Necessary Check &

1. Pumping failure a. Insufficient venting - Air venting

of air
b. Gas accumulation - Air venting

in suction piping
c. Low rotating speed - Check the motor specification
d. Wrong rotating - Correct the motor cabling

direction
2. Insufficient a. Low rotating speed - Check the motor specification

pressure
b. Gases mixed in - Gas evacuation
large quantity
c. Wrong rotating - Correct the motor cabling

direction
d. Damaged impeller - Replace the damaged impeller
3. Excessive a. High rotating - Check the motor specification

power of prime speed
mover
b. Wrong rotating - Correct the motor cabling
direction
c. Specific gravity - Check and recalculate

and viscosity of
pumping liquid
differ from the
design value

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TABLE No. 2: CENTRIFUGAL PUMPS (Cont'd).
Necessary Check &

d. Foreign sub- - Overall and remove foreign subs-

stances are caught tances
by impeller
e. Rotary part makes - Reassemble the parts

contact with fixed
part during
operation
f. Poor assembly of - Reassemble the mechanical seal

mechanical seal
4. Excessive a. Pump or suction - Water filling

vibration or pipe is not filled
noise from with pumping liquid
pump
b. Excessive suction - Check design value

head
c. Cavitation - Check suction pressure and increase

suction pressure above NPSH value
d. Low flow operation - Increase flow above minimum flow
e. Poor alignment - Realignment
f. Foundation is not - Remake foundation

durable or solid
g. Bent shaft - Replace bent shaft

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Necessary Check &

h. Rotary part makes - Reassemble the contact parts

contact with fixed
part during
operation
i. Worn out bearing - Replace the worn out bearing
j. Damaged impeller - Replace the damaged impeller
k. Unbalanced rotary - Replace the rotary part

part
l. Ingress of dust into - Replace the bearings

bearings
m. Rusty bearing - Replace the bearing
5. Overheating a. Poor centering - Reassemble

of
bearing b. Bent shaft - Replace bent shaft
c. Vibrations due to - Rebalance the rotary part

unbalanced rotary
part
d. Generation of - Replace or reassemble

abnormal trust due
to mecha-nical
defects of pump.
Inferior or defective
balancing
mechanism

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Necessary Check &

Possible Corrective Actions
e. Overheating of - Drain out lubrication oil to normal level

bearing due to
excessive
lubrication oil
f. Poor lubrication - Modify the lubrication system
g. Mounting failure or - Reassemble

combination defect
bearing
h. Ingress of dust into - Replace the bearing

bearing
i. Rusty bearing - Replace the rusty bearing
6. Overheating of a. Insufficient venting - Air venting

pump of air
b. Insufficient Net - Increase suction pressure

Positive Suction
Head (NPSH)
c. Excessive low flow - Increase flow rate minimum flow

operation
d. Poor alignment - Realignment
e. Rotary part makes - Reassembling

contact with fixed
part during normal
operation

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Necessary Check &

f. Eccentric rotation - Replace bearing or realignment

of shaft due to
worn out bearings
or poor alignment
g. Vibration due to - Replace the rotary part

unbalanced rotary
part
h. Ingress of foreign - Overhaul and remove foreign

substances substance
7. Short service life a. Clogged - Clean out mechanical seal

of mechanical mechanical seal
seal
b. Poor alignment - Realignment
c. Bent shaft - Replace bent shaft
d. Worn out bearings - Replace worn out bearings
e. Improper assem- - Reassemble the mechanical seal

bly of mechanical
seal
f. Mechanical seal - Replace the mechanical seal

insuitable for
operating condition

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Necessary Check &

g. Vibration due to - Replace the rotary part

unbalanced rotary
part
h. Mechanical seal - Replace the damaged part

sliding surface is
scratched due to
foreign substances
or dust
i. Main shaft is not - Readjust the sliding surface

perpendicular to
sliding surface of
mechanical seal

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TABLE No. 3: MEDIA FILTERS & CARTRIDGE FILTERS
Necessary Check &

Media Filters
1. No flow through a. Valves in wrong - Put the valves to correct position

filter position
2. High differential a. Accumulated - Backwash the filter

pressure solids
b. Instrument failure - Calibrate the differential pressure
gauge
3. Backwash fail a. Valves in wrong - Put valves to correct position

position
b. Backwash Pump - Release the start interlocks of

failure Backwash Pump
4. High differential a. Accumulated - Backwash filter

pressure solids
5. High SDI value a. Coagulant (Ferric - Check chemical dosing quantity and
Chloride) failure increase if necessary
b. Backwash failure - Check the backwash sequence and

take proper countermeasure if
necessary
Cartridge Filters
1. High pressure a. Valves in wrong - Put the valves to correct position

loss through position
micron filter
b. Filter element dirty - Replace the fouled elements by the
new ones

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TABLE No. 4: FILTER BACKWASH SYSTEM
Necessary Check &

Backwash
Tank
1. Low level a. Insufficient sea - Check visually for tank level or for
(initiates alarm) water flow to meet broken pipe
backwash
requirements
b. Instrument failure - Request Maintenance to check
2. Low-Low level - Same as Low level

(trips Backwash
Pumps)
Backwash
Pumps
3. No flow when a. Valves in wrong - Open suction and discharge valves

required position
4. Pump shutdown a. Valves in wrong - Open suction valves

due to low position
suction
pressure
b. Low-Low level in - Same as tank Low level, see 1.
tank
5. Pump shut- a. Pump discharge - Open discharge valve

down due to valve closed
high discharge
pressure

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TABLE No. 5: AIR BLOWERS
Necessary Check &

1. High discharge a. Valves in wrong - Open Air Blower discharge valve.

pressure alarm. position Place Air Scour Valve selector switch
Air Blower in Automatic. The pressure switch
shutdown must be reset manually before the Air
Blower can be restarted
b. Air Blower / - Switch to standby Air Blower.

control failure Request Maintenance to check
Blower and controls

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TABLE No. 6: REVERSE OSMOSIS UNITS
Necessary Check &

1. Product rate a. Feed water - None

down temperature down
b. Feed solids have - Check feed quality, if OK check filter

increased internals - no remedy
c. Elements fouling - Clean elements
d. High permeate - Check for cause of back pressure and

back pressure restore to original level
2. Product rate up a. Feed water - None

temperature up
b. Leak either in a - Detect and repair leak

Pressure Vessel or
piping
c. High system - Adjust flow controller

pressure
3. Product quality a. Feed quality down - None

down
b. Leak either in a - Detect and repair leak
Pressure Vessel or
piping
c. Change in pH - Adjust pH to proper level
d. Elements fouling - Monitoring, clean when necessary

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TABLE No. 6: REVERSE OSMOSIS UNITS (Cont'd).
Necessary Check &

4. Unexpected a. pH out-of-range - Adjust setting on acid pump for proper

pump shutdown pH range
b. Low feed pressure - Check fault, light-raise feed pressure
c. Electrical - Restart system if it will restart in

malfunction Manual, check electrical circuits
5. Low system a. Filters plugged - Check filters

pressure
b. Air in feed line - Check feed line for air leaks (at the
pumps)
c. Gauge reading - Recalibrate or replace gauge

improper
d. Leak - Detect and repair leak
e. Flow Control Valve - Examine and check in line with

malfunctioning manufacturers maintenance manual
6. High a. Membrane Fouling - Clean Membranes

conductivity of
product water

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TABLE No. 7: CHEMICAL DOSING SYSTEMS
Necessary Check &

1. High Conducti- a. Sensor Failure - Change sensor

vity alarm of
permeate b. More salinity in - Stop the system and contact METITO
(product) feed water
c. Brine valve closed - Re-adjust Flow Control Valve for brine

too much
2. High Chlorine a. Insufficient - Field check Chlorine residual. Check

alarm Bisulphite flow operation of Bisulphite system
- Monitor temperature rise as R.O Units

will trip at too high temperature
- Check Dechlornation Feed System for

proper operation
- Check Chlorine and sulphite indicators.

Switch to other ORP analyser.
Request Maintenance to check
instruments
3. High ORP alarm a. Insufficient

Bisulphite
b. Instrument failure
4. High Tempera- - Monitor temperature closely. Stop R.O

ture alarm if required

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TABLE No. 8: CHEMICAL DOSING SYSTEMS (Cont'd).
Necessary Check &

Mixing Tanks
5. Low level alarm a. No solution, - Refill solution, check suction valve

suction valve
closed
Dosing Tanks
Dosing Pumps
6. No flow when - Same as transfer pump. Request

required Maintenance to make sure selector
switch is in Automatic position
7. Insufficient or a. Pump calibration - With Maintenance assistance, check

excessive flow actual pump flow using calibration tube
and stop watch

320PRJ1201007-10-201 - O&M MANUAL - Rev 0

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DOC. No.

MAINTENANCE MANUAL SHEET Page 1of 164

0 02/10/2013 Issued For Information CT PA TM

Rev. Date DESCRIPTION PREPARED CHECKED APPROVED

1. USE OF THE O & M MANUALL ............................................................................................ 9

4.18 SWRO System (1007-RO101) .............................................................................................. 36

6.4 Line Flushing ....................................................................................................................... 58

7.3.1 General ........................................................................................................................ 64

7.7.3 Shutdown .................................................................................................................... 72

14.3.3 Personnel Protective Equipment ............................................................................ 130

17.1 TROUBLESHOOTING GUIDE ..................................................................................... 149

1.0 USE OF THE O & M MANUAL

2.2 Water Treatment System

DAF SCF UF SWRO

2.3 Reference Document

 Piping & Instrumentation Diagram, 320PRJ1201007-01-001.

3. DESIGN BASIS AND WATER QUALITY

3.1 Feed Water Analysis

The plant is designed on the following parameters of feed sea water

Parameter Maximum Level

3.2 DAF Product Water Quality

Parameter Unit Maximum Level

Turbidity NTU < 10.

Oil & Grease mg/l 5

TSS mg/l < 10

3.3 UF Product Water Quality

Parameter Unit Maximum Level

Turbidity NTU < 0.2

Organics as KMnO4 mg/l <1

TSS mg/l < 0.5

3.4 Design Product Water Quality

Parameter Unit Maximum Level

SWRO permeate TDS mg/l < 300

BWRO permeate TDS mg/l < 15

4. EQUIPMENT AND PROCESS DESCRIPTION

4.1 Sea Water Intake Pumps (1007-P101A/B)

Each pump operated through PLC in Auto / Manual mode operation.

 Start pump on High Level (LT-301)

4.2 Dissolved Air Floatation system (1007-DAF101)

It is constructed in polypropylene frame which provides superior qualities compared to stainless

4.3 Static Mixer (1007-SM101)

The tank is constructed from FRP panels with dimension 2 m L x 2 m W x 2 m H.

4.6 UF Feed Pumps (1007-P103A/B)

Each pump operated through PLC in Auto / Manual mode operation.

4.7 Self Cleaning Filter (1007-SCF 101)

Following are the operational modes involved in self cleaning filtration.

Filtration and first

Second flushing Operation:

Final flushing Operation:

4.8 Ultra Filtration System (1007-UF 101)

Capacity: 225 m3/h (Permeate).

Filtration Operation shall be terminated immediately for following condition

Hydraulic Cleaning (HC):

Chemical Enhanced Backwash (CEB):

1. Initiate the Hydraulic cleaning (HC) operation.

UF system (1007-UF101) is operated through the PLC in following mode

The above operation sequence is determined by HC counter (Number of HC performed). The HC

Operation sequences are executed as below,

In Semi-auto mode, operator can select following operation from PLC.

In all mode process and safety interlocks shall be applicable.

The material of RO Feed / UF Backwash tank is FRP and dimension is 5 m L X 4 m W X 4 m H.

4.10 UF Backwash Pumps (1007-P105 A/B)

Each pump operated through PLC in Auto / Manual mode operation.