Cleaning In Place Of RO System Work

Instructions

Developer Omar Ibrahim Alkhaligy SCE 26July 2011

Reviewer M Rafi OM 26 July 2011

Approver Sunil K. Vellat PM 26 July 2011

Name Title Date Signature

Revision Date Description

01 26 July 2011 Cleaning In Place Of RO System Work Instruction NE/OPR/SP-001/WI-017
00 25 May 2010 Cleaning In Place Of RO System Work Instruction NE/OPR/SP-001/WI-017
Document Revision and Approval
WI No: NE/OPR/SP-001/WI-017
WI Title: Cleaning In Place Of RO System Work Instruction

Uncontrolled, if printed *Refer latest version in the server / SAP *If required, print both the sides*
 Cleaning in Place of RO System Work
Instructions

Table of Contents

1. Purpose....................................................................................................................................................3
2. Scope........................................................................................................................................................3
3. Safety and Health Precautions.................................................................................................................3
4. Environmental Precautions......................................................................................................................3
5. Quality Requirements..............................................................................................................................3
6. Roles and Responsibilities........................................................................................................................3
7. Equipment/Software................................................................................................................................4
8. Terminology.............................................................................................................................................4
9. Procedure/Work Instructions...................................................................................................................4
10. Records.....................................................................................................................................................4
11. Legal Requirements and References........................................................................................................7

Uncontrolled, if printed * Refer latest version in the server / SAP * If required, print both the sides *
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 Cleaning in Place of RO System Work
Instructions
1. Purpose

The purpose of the Cleaning in Place (CIP) is to flow membrane cleaning solutions through an RO
unit on occasion to clean the membranes (in place) to restore their permeability.

2. Scope

Membrane cleaning is always a manual operation as the operator must set the manual
valves to their correct position and press the “STOP/START” pushbuttons on the DCS to
operate the CIP pump. Chemist to check cleaning solution pH.

3. Safety and Health Precautions

a) Wear Eye glasses, helmet and safety shoes and chemicals protection clothes
when filling CIP tanks with chemicals.
b) Chemicals handling procedure should be followed.
c) Maintain housekeeping of the area.

4. Environmental Precautions

a) Neutralization pH should be maintained before discharge to DWT.

b) Don't dispose any chemicals in waste bags or on the floors.

5. Quality Requirements

1. Structural and other details for the CIP can be taken from W07005-XG02-GDK-
464001 P&ID, W07005-XG02-GDK-464002 and W07005-XG02-GDM-464003 for CIP
system.
2. Operating limitation, precautions and further details for the CIP can be taken from
vendor operation manual gd1.tp8.02.

6. Roles and Responsibilities

6.1 SCE : Responsible for overall execution of the work instruction

6.2 CCRO : Responsible for checking smooth execution of the work on DCS
6.3 Auxiliary Operator : Responsible for execution of the work instruction in
field
6.4 Shift Chemist : Responsible for keeping cleaning solution pH in
range and its records.

Uncontrolled, if printed * Refer latest version in the server / SAP * If required, print both the sides *
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 Cleaning in Place of RO System Work
Instructions
7. Equipment/Software
7.1 CIP Cleaning Tanks
7.2 Each tank has a mixer and two electric heaters.
7.3 Reagent Loading Pumps: These pumps.
7.4 CIP Cartridge Filter
7.5 Cleaning/Flushing Pumps

8. Terminology

Record : Performed and signed copy of work instruction

SCE : Shift Charge Engineer
CCRO : Central control room operator
DC : Document Controller
DCS : Distributed control system
PTW : Permit to work
SW : Sea water

9 Work Instructions/Procedure
9.1 Pre start up checks

a. Check the components on DCS are in normal condition.

b. Check the components in local are in normal condition.

9.2 Operation procedure

Membrane cleaning is always a manual operation as the operator must

1. set the manual valves to their correct position and press the
“STOP/START” pushbuttons on the DCS to operate the CIP pump

2. To perform the membrane cleaning, the operator will use the following
procedure

3. Select the pump for cleaning ( Selector 3)

NOTE: In a normal position, the pump (04GDK00 AP001) will be selected
for cleaning stage and the pump (04GDK00 AP002) will be selected in
flushing stage

4. When selecting any pump for cleaning the operator must check manual
valves status as per P&ID.

5. When AP 001 and Flushing pump AP002 are selected, following valve
positions should be maintained.
5.1 Valves 04GDU14 AA001, 04GDK00 AA004, 04GDK00 AA005, 04GDK00
AA006, 04GDK01 AA002, 04GDK01 AA003, 04GDK10 AA001 should be
open

5.2 Valves 04GDK00 AA003, 04GDK10 AA002 should be closed.

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 Cleaning in Place of RO System Work
Instructions

6. When selecting CIP pump AP 002 to be in service, the following valve

positions should be maintained:

6.1 Valves 04GDU14 AA001, 04GDK00 AA003, , 04GDK00 AA006, 04GDK01

AA002, , 04GDK10 AA002 should be open

Valves 04GDK00 AA004, 04GDK00 AA005, 04GDK00 AA003, 04GDK10

6.2
AA001 should be closed.

7. Select the CIP tank to be used for cleaning.

Fill the selected cleaning tank with the prescribed amount (75%) of
7.1 service water through the manual valve 04GKU06 AA005 (for tank #1) or
04GKU06 AA004 (for tank #2).

After the cleaning tank level has filled above at least it’s low alarm level
(LA- 04GDK70 CL001 or LA- 04GDK80 CL001), turn the heaters on for the
7.2 selected tank (04GDK70 AH001 & 04GDK70 AH002 or 04GDK80 AH001 &
04GDK80 AH002) and turn the mixer on for the selected tank (04GDK70
AM001 or 04GDK80 AM001).

Set the manual valves at the CIP tank & CIP pump for recycle (from the
7.3
tank, to the pump, and back to the tank for chemical mixing) as follows

When CIP TANK #1 SELECTED, following valve positions are to be

8.
maintained.

8.1 OPEN tank #1 outlet valve 04GDK00 AA001

8.2 OPEN CIP recycle valve 04GDK10 AA001

8.3 OPEN the CIP return to tank #1 valve 04GDK41AA002

When CIP TANK #2 SELECTED, following valve positions are to be

9
maintained.

9.1 OPEN tank #2 outlet valve 04GDK00 AA002

9.2 OPEN CIP recycle valve 04GDK10 AA004

9.3 OPEN the CIP return to tank #2 valve 4GDK41AA003

9.4 Prepare the cleaning solution as recommended by the supplier for

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 Cleaning in Place of RO System Work
Instructions
specific cleaning purpose.

Start the selected CIP pump. If necessary partially close some of the
9.5 valves between the pump discharge and the CIP tank to provide
backpressure for suitable pump operation

While the CIP fluid is recycling, add the specified amount of liquid
9.6 reagent (ref. table 2) to the CIP tank using the liquid reagent loading
pump

Select the RO train to be cleaned. One bank of SWRO can be cleaned at a

10
time or one train of BWRO can be cleaned at a time.

If SWRO X and bank 1 is selected, close the valves 04GDJX5AA101,

10.1 04GDJX6 AA101, 04GDJX6 AA403, 04GDJX7 AA105 and open 04GDJX7
AA101 & 04GDJX7 AA102
If SWRO X and bank 2 is selected, close the valves 04GDJX5 AA102,
10.2 04GDJX6 AA102, 04GDJX6 AA404, 04GDJX7 AA105, and open 04GDJX7
AA103 & 04GDJX7 AA104
10.3 If BWRO X is selected, close the valves 04GDLX1 AA151, 04GDLX3 AA101,
04GDLX2 AA101, 04GDLX4 AA101, 04GDLX2 AA102, 04GDLX4 AA102
11.0 The operator will then set the following manual CIP valves to the
selected RO bank.
12.0 If 1st PASS RO #1 Bank 1, #2 Bank 1 … or #10 Bank 1 is selected, Open
valves 04GDKX6 AA002, 04GDKX7 AA001, 04GDKX9 AA001
13.0 If 1st PASS RO #1 Bank 2, #2 Bank 2 … or #10 Bank 2 is selected, open the
valves 04GDKX6 AA001, 04GDKX7 AA002, 04GDKX9 AA001.
If a 2nd Pass RO #1, #2 … or #10 is selected, open the valves 04GDKX2
14.0 AA001, 04GDKX2 AA002, 04GDKX5 AA001, 04GDKX5 AA002, 04GDKX3
AA001, and 04GDKX3 AA002
When the manual valves correct positions are confirmed through their
limit switches, the operator should: OPEN the CIP return to drain valve
15.0 04GDK41 AA001, START the CIP pump (04GDK00 AP001 or 04GDK00
AP002), Allow the cleaning solution to recirculate through the
membranes to drain for 1 minute to displace water from the membranes
with the cleaning solution.
After the 1 minute displacement the operator must open the CIP return
to CIP tank valve (04GDK41 AA002 or 04GDK41 AA003, CLOSE the CIP
16.0 return to drain valve 04GDK41 AA001. Wait for the CIP tank to
completely drain the spent cleaning solution from the CIP tank to the
neutralization tank
The cleaning regimen may also require the CIP pump to be stopped to
allow the membranes to soak in the cleaning solution and then be re-
17.0 started for another recirculation period. Soak period is typically 30 to 60
minutes but refer to cleaning chemical suppliers data for specific
cleaning procedures
18.0 Drain The Spent Cleaning Solution. To drain the spent cleaning solution,

Uncontrolled, if printed * Refer latest version in the server / SAP * If required, print both the sides *
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 Cleaning in Place of RO System Work
Instructions
first confirm there is sufficient free volume in the neutralization tank to
accept the cleaning solution plus an approximately equal volume of
flushing water.
OPEN the CIP return to neutralization system valve 04GDK41 AA001,
19.0 CLOSE the CIP return to tank #1 valve 04GDK41AA002 or the CIP return
to tank #2 valve 04GDK41AA003
STOP the mixer (04GDK70 AM001 or 04GDK80 AM001 and turn off the
20.0 heaters (04GDK70 AH001 & 04GDK70 AH002 or 04GDK80 AH001 &
04GDK80 AH002
21.0 Once cleaning procedure has been completed, return the CIP and RO to
the pre cleaning state.
22.0 The operator will close all the manual valves of the respective trains and
also the CIP system all valves to closed position.
CIP TANK #1 SELECTED. CLOSE tank #1 outlet valve 04GDK00 AA001.
23.0 CLOSE CIP recycle valve 04GDK10 AA001. CLOSE the CIP return to tank #1
valve 04GDK41AA002
CIP TANK #2 SELECTED. CLOSE tank #2 outlet valve 04GDK00 AA002.
24.0 CLOSE CIP recycle valve 04GDK10 AA004. CLOSE the CIP return to tank #2
valve 04GDK41AA003
25.0 CIP PUMP AP001 SELECTED. CLOSE AP001 inlet valve 04GDK00 AA005.
CLOSE AP001 discharge valve 04GDK01 AA003
FLUSHING PUMP AP002 SELECTED. CLOSE the spare pump inlet crossover
26.0 valve 04GDK00AA003. CLOSE AP002 inlet valve 04GDK00 AA006. CLOSE
AP002 discharge valve 04GDK01 AA002. CLOSE the spare pump discharge
crossover valve 04GDK10 AA002

10 Records
Retention
Record Number Record Title Responsibility
Period
Cleaning In Place Of
NE/OPR/SP-001/WI-17 Ro System Work Document Controller
Instruction

11 Legal Requirements and References

For further details refer to
1. (Doosan Operation Manual gd2.tp8.02 - RO & Pretreatment System Sec 02
2. RO_024 W07005-XG02-GDK-464001 P&ID FOR RO PLANT CIP TANKS
3. RO_025 W07005-XG02-GDK-464002 P&ID FOR RO PLANT CIP & FLUSHING

Uncontrolled, if printed * Refer latest version in the server / SAP * If required, print both the sides *
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