Plant

SSS
Salt Separation Services
OPERATION AND MAINTENANCE MANUAL
FOR
S846-40 400 m3/d SWRO PLANT
CLIENT : Crystal Cruises
CLIENTS ORDER NO : M-2-09-0884
SALT SEPARATION SERVICES CONTRACT NO : S09247
DATE OF ISSUE : April 2010
PLANT INSTALLED ON : Crystal Symphony
COPYRIGHT
This document is the property of

Salt Separation Services. It is
supplied on the express conditions
that it must not be copied or the
contents communicated to a third
party without prior written consent
from Salt Separation Services.
SSS
OPERATION AND MAINTENANCE MANUAL
FOR
S846-40 400 m3/d SWRO PLANT
SECTION CONTENTS REV
1.0 Process Description 01
2.0 Electrical Control 01
3.0 Installation 01
4.0 Plant Data Sheets 01
5.0 Health and Safety Information 01
6.0 Operation 01
7.0 Routine Maintenance/Data Normalisation/ 01

Potable Water Testing/Lubrication/Spares
8.0 Fault Finding 01
9.0 Equipment Literature 01
10.0 Drawings 01
Rev Comments on Revision

01 Issued to Customer
Rev 1 Rev 2 Rev 3 Rev 4

Prepared By
Checked By
Approved By
Issued Date 07.04.10
S846-40 400 m3/d SWRO PLANT CONTENTS DATE : 19.02.10

O & M MANUAL (S09247) REV : 01
SSS
S alt S eparation S ervices
OPERATION AND MAINTENANCE MANUALS
Controlled copies of this manual are subject to updating.
Copies printed on Salt Separation Services logo embossed paper or issued on company embossed
CD’s are denoted as being controlled.
In the event of an update, a new revised contents page will be issued along with the revised
section/sections or (in case of CD’s a new CD will be issued). These will be issued with a
Document Submission Sheet which should be signed and returned to Salt Separation Services to
confirm receipt of the revisions
Please complete the Revision status box below upon receipt of any revisions.
REVISIONS
Rev Sections Issued Inserted By Date
FURTHER COPIES OF THIS MANUAL MAY BE OBTAINED FROM
SALT SEPARATION SERVICES LTD

GROSVENOR HOUSE
GORRELL STREET
ROCHDALE
LANCASHIRE
OL11 1AP
U.K.
Tel : + 44 (0) 1706 655522
Fax : + 44 (0) 1706 654475
E-mail : sss@saltsep.co.uk
S846-40 400 m³/d SWRO PLANT REVISIONS DATE : 19.02.10

SSS
1.0 PROCESS DESCRIPTION
1.1 INTRODUCTION
1.2 REVERSE OSMOSIS
1.3 GENERAL
1.4 RAW WATER
1.5 FEED/BACKWASH PUMP
1.6 SAND FILTRATION
1.7 ANTISCALANT DOSING
1.8 CARTRIDGE FILTRATION
1.9 HP FEED PUMP AND ASSOCIATED EQUIPMENT
1.10 MEMBRANE ARRAY
1.11 PERMEATE OUTPUT/QUALITY
1.12 MEMBRANE ELEMENT FOULING
1.13 MEMBRANE ELEMENT PRESERVATION
1.14 POTABLE WATER HARDNESS
1.15 POTABLE WATER CHLORINATION
1.16 ENERGY RECOVERY
S846-40 400 M³/DAY SWRO PLANT 1/1 DATE : 19.02.10

SSS
1.0 PROCESS DESCRIPTION
Refer to the following drawings in Section 10.0 of this manual:
Drawing No. Title
09247-01-01 Sht 01 P & I Diagram of Pre-Treatment

09247-01-01 Sht 02 P & I Diagram of RO Plant
1.1 INTRODUCTION
Filtration of relatively large suspended solids (macro or particle filtration) is

accomplished by passing a feed solution through the filter media in a perpendicular
direction. The entire solution passes through the media, creating only one exit stream.
Examples of such filtration devices include cartridge filters, bag filters, sand filters and
multimedia filters. Macrofiltration separation capabilities are generally limited to
undissolved particles greater than 1 micron, or one thousandth of a millimetre.
For the removal of sub micron particles and dissolved salts, membrane separation systems
are utilised which involve a different methodology than conventional particle filtration.
Termed crossflow membrane filtration, this method involves pressurising the feed stream
which is then forced to flow parallel to the membrane surface (see figure 1). A portion of
this stream passes through the membrane leaving behind the rejected particles and salts in
the concentrated, remainder of the stream. Since there is a continuous flow across the
membrane surface, the rejected particles do not accumulate but instead are swept away by
the concentrate stream. Thus, one feed stream is separated into two exit streams: the
solution passing through the membrane surface (permeate) and the solution passing
across and subsequently off the membrane (reject).

SSS
There are four general categories of crossflow membrane filtration : Microfiltration (MF),
Ultrafiltration (UF), Nanofiltration (NF) and Reverse Osmosis (RO).
Microfiltration removes particles in the range of approximately 1000 to 10000 Angstroms

(0.1 to 1.0 micron).
Ultrafiltration provides macro-molecular and molecular separation for particles in the 20

to 1000 Angstrom range (upto 0.1 micron).
Nanofiltration provides molecular separation and operates in the Ionic/molecular size

range of around 10 Angstroms (1 Nanometre).
Reverse Osmosis provides ionic separation and operates in the ionic/molecular size range
of 1 to 10 angstroms.
Note
10 Angstroms is one thousandth of a micron or one millionth of a millimetre.
Reverse Osmosis is by far the finest level of 'filtration' available, the RO membrane acts
as a barrier to almost all dissolved salts and inorganic molecules, as well as the larger
organic molecules.
1.2 REVERSE OSMOSIS
Reverse Osmosis is a membrane separation process from which the feed water emerges in
two streams : one of high-purity water from which all colloids, viruses etc.. and 90% to
99% of the dissolved salts have been rejected in passing through the membrane, and a
second stream consisting of the remainder of the feed water plus the rejected salts etc.
RO theory is based on two physical processes: Osmosis and Ionic repulsion, the basic
principle is readily appreciated by considering first the phenomenon of osmosis.
Osmosis is a natural process involving fluid flow across a membrane which is said to be
semi permeable (see figure 2). The direction and relative quantities of fluid flow is
determined by the chemical potential which is a function of pressure, temperature and
concentration of dissolved solids.
When two solutions of different concentrations are separated by a semi pemeable

membrane, water from the less concentrated solution will, due to the natural phenomenon
of osmosis, pass through the membrane to dilute the more concentrated solution to make
it an equivalent concentration to itself.

SSS
However, if the hydraulics of this process are taken into account, as the water passes from
the less concentrated solutions into the more concentrated solution to dilute it, the static
head of the more concentrated solution increases and the one of the less concentrated
solution decreases thus giving a net pressure.
Equilibrium of the two solutions occurs when the pressure differential is sufficiently high
to arrest the fluid flow across the membrane - this is termed the osmotic pressure.
Reverse Osmosis is the use of this natural process in the reverse direction. Pressure is
exerted on the more concentrated side of the membrane to overcome the natural osmotic
pressure and force water ‘out of’ the concentrated solution and through the membrane.
Particles, bacteria and the larger organics are blocked by molecular sieving, however RO
also involves an Ionic repulsion process, where by only water is allowed to pass through
the semi-permeable membrane, whilst virtually all dissolved molecules are rejected. The
semi-permeable membrane rejects multi charged ions such as calcium and sulphate at
rates exceeding 99% while single charged ions such as sodium are rejected at rates from
90-96%
The semi-permeable membranes employed in Salt Separation Services Plants are spiral
wound Thin Film Composites (see figure 3) where the membrane consists of three layers:
a polyester support web, a microporous polysulphone interlayer and a polyamide ultra
thin barrier layer .

SSS
The membrane element consists of a central permeate (product water) tube, around
which the membrane is wound. The feed, under pressure is introduced from one end via
mesh spacers which promote turbulent conditions and allow the feed to contact the entire
membrane surface. A portion of the feed passes through the membrane as high quality
water and collects in the central permeate outlet tube. The water, which fails to pass
through the membrane leaves the element as a concentrated solution (reject). Where
several elements are arranged in series the concentrate from the first element becomes the
feed supply to the second and so on until , after passing through the last element of the
series, it is discharged to waste.
1.3 GENERAL
The plant has been designed to produce potable water at the rate of 16.7 m3/h with a
quality of less than 500 mg/l total dissolved solids (1000 μS/cm) from a feed water with a
total dissolved solids of 35,011 mg/l (53,250 μS/cm) to 42,000 mg/l (63,8800 μS/cm) at
temperatures between 5°C and 35 °C.
It is a self contained unit, with its own integral instrumentation and control.
1.4 RAW WATER
During normal operation a raw water supply of 40 m³/h is required at the feed pump inlet.
The raw water to the Reverse Osmosis plant is likely to be contaminated with suspended
solids, colloidal matter and ions with scaling potential. To increase the efficiency and life
of a Reverse Osmosis system it is essential that effective pretreatment is carried out to the
raw water prior to the Reverse Osmosis plant.

SSS
For the S846-40 400 m³/d SWRO plant this conditioning is achieved by straining, sand
filtration, antiscalant dosing and cartridge filtration.
1.5 FEED/BACKWASH PUMP
A vertical, in-line single stage centrifugal pump (P1) is installed to provide both feed
water to the RO plant and backwash water for the sand filters. The suction of this pump
is protected by a simplex basket strainer installed with a 1/16" stainless steel mesh basket.
1.6 SAND FILTRATION
The two sand filter vessels are required for the removal of relatively large suspended
solids that may be present in the raw water.
Each filter comprises of a 1200mm ID vertical mild steel pressure vessel.
Each vessel is coated internally and externally with fusion bonded epoxy.
A header is fitted to the top of each vessel which distributes the feed water under normal
operation and allows backwash water out of the vessel during washing. At the bottom of
each vessel is a lateral system, which enables collection of filtered water and retains the
media, the laterals also allow backwash water to enter the vessel during backwashing.
Each vessel is partially filled with a combination of 3-6mm gravel, 2-3mm gravel and
16/30 sand. A void is left above the media to allow for bed expansion during filter
backwashing.
The design throughput of the filter is such that they will provide sufficient filtered water
for correct operation of the Reverse Osmosis Plant.
The total design flowrate of both filters in parallel is 40 m³/h, this flow should not be
exceeded as the filtration rate for optimum performance will be exceeded which in turn
could mean a vastly reduced quality filtrate.
During operation of the sand filters they will become fouled, this can be seen by
differential pressure increase using the inlet (PI2) and outlet (PI3) pressure gauges.
Backwashing of the filters is carried out to remove the accumulated solid particulates
from the media beds, it involves reversing the normal flow and discharging it to waste.
Backwashing is carried out semi-automatically using controls provided on the plant

control panel, each of the vessels are washed in sequence.
The filters should be washed when the differential pressure increases by 1.0 barg from the
clean condition or every 24 hours whichever is the sooner. An alarm is incorporated in
the plant to inform operators when the filter requires washing.
The backwash flowrate will vary depending upon the feedwater temperature.

SSS
It is critical that the correct flowrate is used, a satisfactory wash may not be achieved if it
is too low or, on the other hand, media may be washed away if the wash water flow rate is
to high.
The varying backwash flowrates are as follows:
Raw Water Temperature Flowrate Required
5 °C 23.2 m³/h
10 °C 26.4 m³/h
15 °C 29.3 m³/h
20 °C 32.9 m³/h
25 °C 35.8 m³/h
30 °C 39.5 m³/h
35 °C 42.7 m³/h
1.7 ANTISCALANT DOSING
Seawater contains sparingly soluble salts of Calcium, Barium, etc... These salts naturally
have no tendency to precipitate, however, as the seawater passes through the plant and
permeate is removed, the concentration of salts increases to such a degree that
precipitation on the membrane surface can occur and thereby reduce their performance.
To suppress the precipitation of these salts a solution of a proprietary antiscalant

compound is dosed into the feed water which acts as a scaling inhibitor, thus allowing
more efficient operation.
The antiscalant solution is made and stored in a 100 litre tank (T100) which has sufficient
capacity for approximately 7 days, and is dosed into the feed flow via a solenoid driven
dosing pump (P105).
1.8 CARTRIDGE FILTRATION
The feed water free from large suspended solids and dosed with antiscalant is passed
through a 10 micron absolute rated cartridge filter, this ensures that the feed water to the
RO membrane elements is free from any fine particulate matter ensuring maximum
performance from the RO membrane elements, the filter also protects the HP pump in the
event of a sand filter lateral failure.
The cartridge filter housing (PV100) comprises of a horizontal FRP vessel with a quick
release end plug for cartridge changeouts.
The cartridges are a disposable type, which should be changed when the differential
pressure increases by 1.0 barg from the clean condition or every 6 to 8 weeks, whichever
is the sooner.
It is also good practice to replace the filter cartridges after the membranes have been
chemically cleaned.

SSS
1.9 HP FEED PUMPS AND ASSOCIATED EQUIPMENT
The seawater feed to the RO membrane must be pressurised to between 50 and 79 barg,
this is achieved by four HP pumps (P100, P101, P102 & P103) running in parallel.
Each pump is an axial piston pump with a capacity of 10 m3/h at a maximum discharge
pressure of 80 barg. Each pump is driven by a direct coupled 32.5kW electric motor.
The pump suction is protected by a low pressure switch (PS100), which trips the HP
pumps if the inlet pressure to the pumps falls below 1.0 barg.
Vibration transmission into the system is reduced by suction and discharge flexible hoses
which are installed between each HP pump and the system pipework.
A pressure gauge is mounted on the discharge of the pumps to enable monitoring of pump
discharge pressure.
The pipework, vessels, etc… downstream of the HP pumps are protected from over
pressurisation by three devices:
1) Two high pressure switches (PS101 & PS102) which trip the pump if their
discharge pressure exceeds 80 barg.
2) A pressure relief valve (PSV100) set at 83 barg which will relieve pressure in the
event that the high pressure transmitter fails.
1.10 MEMBRANE ARRAY
Filtered, pressurised water is passed to the RO membrane elements and is desalinated.

The membrane elements are housed in GRP pressure vessels which are arranged in four
streams each containing two vessels.
Each vessel contains three 8 inch diameter 40 inch long thin film composite spiral wound
membrane elements.
Within each stream feed water enters the first vessel and is split into two flows, permeate
(high quality, potable water) and reject (concentrated feed water). The reject from the
first vessel then feeds the second vessel where again it is split into two flows, permeate
and reject. This process is the same in each of the remaining three streams.
Reject from the last vessel in each of the four streams is manifolded together then flows
through the reject control valve (V101) and to waste. The reject control valve is used to
regulate the pressure within the membrane stack, which in turn regulates the permeate
flow rate and quality.
Permeate is collected in a manifold, passed over a conductivity cell (QT101) through a

flow sensor (FT101) and discharged to the rehardener or dumped to waste, depending
upon the quality of the water.

SSS
A permeate relief valve (PSV101) is provided to protect the permeate pipework in the
event of over pressurisation.
Membrane stack inlet and membrane stack outlet pressure gauges (PI102, PI103) are
provided so operating and differential pressures can be determined across the membrane
stack.
1.11 PERMEATE OUTPUT/QUALITY
The plant has been designed to normally produce 16.7 m³/h (400 m³/d) of permeate with a
total dissolved solids content less than 500 mg/l (1,000μS/cm) from raw water with a
total dissolved solids content of upto 42,000 mg/l (63,880 μS/cm) at a feed water
temperature of between 5°C and 35°C.
The permeate output is dependent upon several factors :
a) Feed Water Temperature - As the temperature increases the driving pressure

required to produce the design permeate output decreases, at the same time the
salt passage across the membrane increases, effectively giving a poorer quality
permeate.
b) Feed Water Concentration - As the concentration of the feed water increases

then the driving pressure required to produce the design permeate output
increases, at the same time salt passage also increases due to the concentration
differential across the membrane being higher.
c) Feed Water Pressure - As the driving pressure decreases the quality of the
permeate tends to decrease, this is due to the fact that the water flowrate through a
membrane is proportional to the pressure differential across the membrane, while
the salt passage is proportional to the concentration differential. Thus a decrease
in operating pressure will decrease the water flow without changing the salt
passage, effectively giving a poorer quality permeate.
If the driving pressure is increased, then permeate flow increases whilst the salt
passage remains the same, thus the increased permeate flow dilutes the salt flow
effectively giving a better quality permeate.
The maximum recovery for the RO plant is 45%, this is to ensure that the retentate is
flushed from the system, therefore helping to prevent scaling and fouling.
The maximum operating pressure of this plant is 79 barg, measured on the stack inlet
pressure gauge (PI102).
The design potable water output of this plant is 16.7 m³/h (400 m³/d), measured on the
permeate flowmeter (FI101). However, the maximum potable water output of this plant
can be increased to 18 m3/h (430 m3/d), under certain conditions.

SSS
If, due to temperature increase, maximum permeate flow is achieved and a poor quality
permeate is produced, the facility exists on the plant to isolate permeate production from
various membrane element vessels with the use of permeate diversion [recycle] valves
(V250 to V257 inclusive).
The use of these valves enables the permeate from the diverted vessel to be recycled back
into the feed water, consequently diluting the feed water thereby reducing the feed TDS
and, consequently, the permeate TDS.
This also enables plant operation if one (or more) vessel(s) has failed RO membrane
elements.
Plant output has been based on the following:
5°C Feedwater Temperature
Feed Flow = 40 m³/h

Feed Quality = 35,011 mg/1 ≡ 53,250 μS/cm
Feed Pressure = 78 barg
Recovery = 41.7%
Permeate Flow = 16.7 m3/h = 400 m3/d
Design Permeate Quality = 52 mg/l (TDS)
Produced from 24 off SW30HRLE-400 membrane elements in 4 streams of 6.
Feed Flow = 40 m3/h

Feed Quality = 37,592 mg/l ≡ 57,175 μS/cm
Recovery = 41.7%
Design Permeate Quality = 236 mg/l (TDS)
Feed Flow = 40 m³/h

Feed Quality = 42,000 mg/l ≡ 63,880 μS/cm
Recovery = 41.7%
Design Permeate Quality = 500mg/l (TDS)

SSS
1.12 MEMBRANE ELEMENT FOULING
During operation of the plant the membranes will become fouled. Deposits build up on
the membrane surface until they cause loss of permeate output, loss of salt rejection, or
both.
Membranes should be cleaned whenever the normalised permeate flow drops by 10%, the
normalised salt content of the permeate increases by 10% or the differential pressure
across the membranes increases by 15% (refer to section 7.0 of this manual).
It should be noted that the water output will quite naturally drop if the feed water
temperature decreases and vice versa.
When the membranes become fouled they can be cleaned by recirculating chemical
cleaning solutions through them.
The solutions are made up in the flushing tank (T101) and recirculated using the flushing
pump (P104).
Permeate should be dumped for at least 30 minutes immediately after cleaning due to the
possibility of it being contaminated with cleaning chemicals.
1.13 MEMBRANE ELEMENT PRESERVATION
If the plant is not to be used for more than 24 hours it should be either flushed daily
(where operational conditions allow) or preserved with a 1% (by weight) solution of
Sodium Metabisulphite or other approved preservative to prevent biological growth.
It is recommended that the membrane elements are chemically cleaned prior to

preservation.
On start-up, after the plant has been preserved, permeate should be dumped for at least 1
hour, to ensure preserving chemicals are flushed from the system.
1.14 POTABLE WATER HARDNESS
RO permeate has an extremely aggressive nature due to the absence of natural inhibitors
such as calcium or magnesium hardness. The pH also tends to fluctuate unstably due to
the absorption of trace amounts of carbon dioxide picked up by coming into contact with
air and the fact that the permeate has little buffering capacity.
As well as having a rather ‘flat’ taste to most palates, untreated RO permeate is very
aggressive to many of the materials commonly used in water distribution and storage
systems. Its introduction into old established distribution systems often cause rapid
stripping of natural pipe deposits which leads to the alarming ‘Red Water’ effect.
The permeate can be treated to reduce its aggressive nature, the hardness of the water
should be raised, typically to be in the range of 40 to 80 mg/l as CaCO3 the pH between
6.5 and 8.5 and the Langellier Saturation Index (LSI), which expresses the tendency of

SSS
the water to precipitate calcium carbonate instead of dissolve it, should be slightly
negative. Seawater RO permeate typically has a hardness of 10 mg/l as CaCO3.
Rehardening of the RO permeate is achieved by first slightly acidifying (by injecting

carbon dioxide) and then passing a portion of water through a vessel filled with granules
of a calcium rich media, this increases the alkalinity and hardness of the water.
The portion of water passing through the vessel can be adjusted until the resulting water
has a slightly positive LSI of the order of +0.5.
Carbon Dioxide (CO2) from a gas bottle is regulated to a low pressure via a regulator
assembly (V206) fitted with integral pressure relief. It then passes through a solenoid
valve (V209) switched from the control panel to only open whilst permeate is flowing,
this stops any build up of CO2 when the plant is shutdown.
The flow of CO2 into the water is controlled by a needle valve and monitored through a
flowmeter before injection into the water flow, a diffuser ensures that the CO2 is
adequately mixed with the water stream.
An excess amount of CO2 may be present which will be released from the water, usually
at the point of the lowest flow which is in the media vessel, this could build up at the top
of the vessel and can cause streaming of the flow through to media. To eliminate this an
automatic air release valve (V208) is fitted in the top of the vessel (PV200).
A sight glass is installed on the front of the vessel to indicate media level and a filling
port is provided for topping up the media.
The proportion of permeate flowing through the media bed is adjusted with the inlet
(V200) and bypass valves (V202) with the bypassed flow being indicated on the bypass
flowmeter (FI200).
1.15 POTABLE WATER CHLORINATION
RO permeate is free from bacteria, viruses and pyrogens, however as there is no chlorine
residual present the potable water may become contaminated during storage.
The potable water is dosed with a dilute solution of Hypochlorite to maintain a small
residual of chlorine. Current WHO guidelines state that a 0.2 to 0.5 mg/l free chlorine
residual should be in all portions of the distribution system.
To achieve this we recommend a dose rate of 1.0 to 1.5 mg/l measured as a Total
Residual Chlorine be added to the water as it is put into the storage tank, this will then
make allowance for 'gassing off' and usage. However, USPH recommend a dose rate of
up to 5 mg/l.
1.16 ENERGY RECOVERY
Desalination, the product of potable water for seawater, has been done for centuries. Until
now, however, desalination has been considered a costly alternative because of the high
energy consumption in the process.
SSS
Early desalination plants relied on evaporation technology. The most advanced seawater
evaporation desalination plants using multiple stages have an energy consumption of over
9 kW/m³ of potable water produced. For this reason large plants were initially constructed
in places with cheap abundant energy such as the Middle East.
During the 1970’s a new process called seawater reverse osmosis (SWRO) was
developed (commercially) which made potable water from seawater by forcing it under
high pressure through semi-permeable membrane thus separating out salts and impurities.
The membrane produces a (purified) water stream (permeate) and a concentrated brine
(reject) stream. It is this concentrated brine stream that contains a large amount of
pressure energy that is usually ‘throttled’ down using a control valve.
SWRO plants without energy recovery typically have an energy consumption of over 7
kW/m³ of potable water produced.
Fitting an energy recovery device to utilise the ‘wasted’ energy in the reject stream can
reduce energy consumption by upto 40%, resulting in an energy consumption in the
region of 3 kW/m³ of potable water produced.
The device recovers hydraulic energy from the high pressure reject stream and transfers
that energy to the feed stream. In real terms, for example, the high pressure pumps would
only need to delivery 16.5 m³/h at 45.7 barg instead of 16.5 m³/h at 71 barg.
In order to maintain plant reliability, the high pressure pumps and motors are sized for
full duty (i.e. without the energy recovery device on-line), therefore the RO plant could
still be utilised even if the energy recovery device was out of service.

SSS
2.0 ELECTRICAL CONTROLS
2.1 CONTROL PANEL OVERVIEW
2.1.1 Incoming Supply
2.1.2 Emergency Stop
2.1.3 Three Phase Equipment (440V)
2.1.4 Single Phase Equipment (110V)
2.1.5 Instrumentation/Control/Indication
2.2 ALARMS
2.2.1 Emergency Stop Activated Alarm (E STOP)
2.2.2 Low Air Pressure Alarm (PAL1)
2.2.3 Feed/Backwash Pump Motor Tripped Alarm (M1-TRIP)
2.2.4 Low Suction Pressure Alarm (PAL100)
2.2.5 High Pressure Pump Motor Trip Alarm (M100-TRIP)
2.2.9 Flushing Pump Motor Trip Alarm (M104-TRIP)
2.2.10 High HP Pump Discharge Pressure Alarm (PAH101)
2.2.11 High Feed/Cleaning Temperature Alarm (TAH100)
2.2.12 Flushing/Cleaning Tank Low Level Alarm (LAL100)
2.2.13 Antiscalant Dosing Pump Fault Alarm (P105-F)
2.2.14 High Permeate Flow Alarm (FAH101)
2.2.15 High Permeate Conductivity Alarm (QAH100)
2.2.16 Membrane Clean Overdue Alarm

SSS
2.2.17 High Panel Temperature Alarm (TAH1)
2.2.18 Emergency Shut Down Alarms (ESD)
2.2.19 Attend Alarms (ATTEND)
2.2.20 Remote Alarms
2.3 CONTROL FUNCTIONS
2.3.1 Feed/Backwash Pump Motor (M1) Control
2.3.2 High Pressure Pump Motors (M100, M101, M102 & M103) Control
2.3.3 Flushing Pump Motor (M104) Control
2.3.4 Antiscalant Dosing Pump (P105) Control
2.3.5 High Permeate Conductivity Dump System
2.3.6 Plant Inlet/Outlet Valves (V60 & V61)
2.3.7 CO₂ Injection Valve (V209)
2.3.8 RO Running Remote Output
2.3.9 RO Attendance Alarm Remote Output
2.3.10 RO Emergency Shutdown Remote Alarm Output
2.3.11 RO Stopped Remote Output
2.3.12 Sand Filter Control Selector
2.4 PLC CONTROL SEQUENCE
2.4.1 Sand Filter
2.4.2 Backwash Sequence
2.4.3 Plant Startup & Shutdown Sequence

SSS
2.0 ELECTRICAL CONTROLS
Refer to the following drawings:
Drawing Number Title
09247-13-01 Shts 1 to 27 Electrical Schematics

09247-13-02 Panel Arrangement
09247-13-04 Shts 1 to 3 Electrical Connection Diagram
2.1 Control Panel Overview
2.1.1 Incoming Supply
The incoming power supply will be 440V, 3 Phase, 60Hz, **kW fed via a **mm2, * core un-
armoured cable.
2.1.2 Emergency Stop Capability
A mushroom stayput twist release type emergency stop pushbutton is provided in the panel
facia. On operation all pumps stop, all valves return to their fail-safe position and any
sequencing resets.
The emergency stop is fail-safe, with a red ‘EMERGENCY STOP ACTIVATED’ indicator
and separate reset pushbutton.
Two additional remote emergency stop facilities are provided for, this enables the end user to
install remote mounted pushbuttons/integration as necessary.
2.1.3 Three Phase Equipment (440V, 3 Phase, 60Hz)
Three phase items of equipment controlled from the panel are as follows:
a) 1 off Feed/Backwash Pump Motor (M1)

13kW Direct-On-Line starting. FLC – 21.5A
b) 4 off High Pressure Pump Motor (M100, M101, M102 & M103)
32.5kW Direct-On-Line starting. FLC – 55A
c) 1 off Flushing Pump Motor (M104)

7.5kW Direct-On-Line starting. FLC – 15.4A
2.1.4 Single Phase Equipment (110V, 1 Phase, 60Hz)
Single phase items of equipment controlled from the panel are as follows:
a) 1 off Antiscalant Dosing Pump (P105) 110V Solenoid driven diaphragm type.
Average current draw 2.0 amps. Peak input power 120 Watts.

SSS
b) 1 off CO2 solenoid valve (V209) 110V.

Power consumption 12 Watts (normally closed, energise open).
c) 1 off Cooling Fan & Filter is installed in the panel to dispense temperature build-up
due to the possible high ambient temperature of the ships compartment. The
fan runs intermittently, controlled by an internally mounted adjustable
thermostat.
2.1.5 Instrumentation/Control/Indication
Instrumentation housed within the panel:
a) 1 off Feed/Permeate Conductivity Analyser (DIC100) 24V DC, 0-200 mS/cm

and 0-1000 µS/cm. Dual channel (i.e. two sensors).
b) 5 off Ammeters for monitoring the current drawn by M1, M100, M101, M102,
M103 and M104, each with a fixed red line on the ammeter facia indicated the
motor full load current.
c) 1 off Feed/Permeate flow transmitter (FI100) 24V DC. Dual channel (i.e. two
sensors).
d) 1 off RO Plant Hours Run Meter – for total RO Plant Running Hours.
e) 4 off Resettable Hours Run Meter – one for each HP pump.
Control system housed within the panel:
a) 1 off Mitsubishi FX3u Programmable Logic Controller (PLC).
The following plant functions are monitored by the panel:
a) Sand Filter Differential Pressure – Digital Input - Switch (DPS1).
b) Low Air Pressure (PAL1) – Digital Input - Switch (PS1) panel mounted.
c) Low Level Flushing/Cleaning Tank (LAL100) – Digital Input - Switch (LS100).
d) Low HP Pump Suction Pressure (PAL100) – Digital Input - Switch (PS100).
e) High Permeate Flow (FAH101) – Digital Input – Relay from FI100 R1.
f) High Feed Temperature (TAH100) – Digital Input - Relay From DIC100 R2.
g) High HP Pump Discharge Pressure (PAH101) – Digital Input - Switch (PS102).
h) High Permeate Conductivity (QAH100) – Digital Input - Relay From DIC100 R1.
i) Antiscalant Dosing Pump Fault (P105-F) – Digital Input - Pulse From (P105-P).
j) High Membrane Inlet Pressure (PAH101) – Digital Input – Switch (PS101)

SSS
The following indication is provided in the panel facia (titles for the nameplates is shown
thus ‘description’):
a) ‘Low Air Pressure (PAL1)’ – Alarm (Amber)

b) ‘Feed/Backwash Pump Motor (M1/P1)’ ‘Run’ – Status (Green)
c) ‘Feed/Backwash Pump Motor (M1/P1)’ ‘Stop’ – Status (Red)
d) ‘Feed/Backwash Pump Motor (M1/P1)’ ‘Trip’ – Status (Amber)
e) ‘Flushing Pump Motor (M104/P104)’ ‘Run’ – Status (Green)
f) ‘Flushing Pump Motor (M104/P104)’ ‘Stop’ – Status (Red)
g) ‘Flushing Pump Motor (M104/P104)’ ‘Trip’ – Status (Amber)
h) ‘Sand Filters ‘Backwash Required’ – Status (Amber)
i) ‘Sand Filters ‘Standby’ – Status (Blue)
j) ‘Sand Filters ‘Filtering’ – Status (Blue)
k) ‘Sand Filters ‘Flushing’ – Status (Blue)
l) ‘Sand Filters (PV2A)’ ‘Backwash’ – Status (Blue)
m) ‘Sand Filters (PV2B)’ ‘Backwash’ – Status (Blue)
n) ‘Antiscalant Dosing Pump (P105)’ ‘Stop’ – Status (Red)
o) ‘Antiscalant Dosing Pump (P105)’ ‘Run’ – Status (Green)
p) ‘Antiscalant Dosing Pump (P105)’ ‘Fault’ - Alarm (Amber)
q) ‘Low Level Flushing/Cleaning Tank (LAL100)’ – Alarm (Amber)
r) ‘Low Suction Pressure (PAL100)’ – Alarm (Amber)
s) ‘HP Pump (P100)’ ‘Run’ – Status (Green)
t) ‘HP Pump (P100)’ ‘Stop’ – Status (Red)
u) ‘HP Pump (P100)’ ‘Trip’ – Alarm (Amber)
v) ‘HP Pump (P101)’ ‘Run’ – Status (Green)
w) ‘HP Pump (P101)’ ‘Stop’ – Status (Red)
x) ‘HP Pump (P101)’ ‘Trip’ – Alarm (Amber)
y) ‘HP Pump (P102)’ ‘Run’ – Status (Green)
z) ‘HP Pump (P102)’ ‘Run’ – Status (Red)
ab) ‘HP Pump (P102)’ ‘Run’ – Status (Amber)
ac) ‘HP Pump (P103)’ ‘Run’ – Status (Green)
ad) ‘HP Pump (P103)’ ‘Run’ – Status (Red)
ae) ‘HP Pump (P101)’ ‘Run’ – Status (Amber)
af) ‘High HP Pump Discharge Pressure (PAH101)’ – Alarm (Amber)
ag) ‘High Permeate Flow (FAH101)’ – Alarm (Amber)
ah) ‘High Permeate Conductivity (QAH100)’ – Alarm (Amber)
ai) ‘Supply Valve (V116)’ ‘Open’ – Status (Green)
aj) ‘High Panel Temperature (TAH1)’ – Alarm (Amber)
ak) ‘Membrane Clean Overdue’ – Alarm (Amber)
al) ‘CO2 Injection Valve (V209) Open’ – Status (Green)
am) ‘Plant Inlet Valve (V60) Open’ – Status (Green)
an) ‘Plant Inlet Valve (V60) Closed’ - Status (Red)
ao) ‘Plant Discharge Valve (V61) Open’ – Status (Green)
ap) ‘Plant Discharge Valve (V61) Closed’ – Status (Red)
aq) ‘High Feed/Cleaning Temperature (TAH100)’ Alarm (Amber)
ar) ‘Dump Valve (V115)’ ‘Open’ – Status (Red)
The following pneumatic pilot solenoid valves are housed, piped and wired within the panel,
each solenoid valve has its own PLC output:
a) 2 off Media Filter Control Pilot (normally closed/energise to open) Solenoid

Valve SV3 A/B ‘Filter Inlet’.
SSS
b) 2 off Media Filter Control Pilot (normally closed/energise to open) Solenoid

Valve SV4 A/B ‘Filter Outlet’.
c) 2 off Media Filter Control Pilot (normally closed/energise to open) Solenoid

Valve SV5 A/B ‘Backwash Inlet’.
d) 2 off Media Filter Control Pilot (normally closed/energise to open) Solenoid

Valve SV6 A/B ‘Backwash Outlet’.
e) 2 off Media Filter Control Pilot (normally closed/energise to open) Solenoid

Valve SV7 A/B ‘Flushing Outlet’.
f) 1 off ‘Plant Inlet’ Pilot (normally closed/energised to open) Solenoid Valve SV60.
g) 1 off ‘Plant Discharge’ Pilot (normally closed/energised to open) Solenoid Valve

SV61.
h) 1 off ‘Permeate Dump’ Pilot (normally closed/energise to open) Solenoid Valve

SV115.
i) 1 off ‘Permeate Supply’ Pilot (normally closed/energise to open) Solenoid Valve

SV116 .
A siren and a flashing beacon are mounted on top of the panel for alarm purposes.
A lamp test facility is provided, when depressed all indicators illuminate (hard wire and PLC
initiated), the flashing beacon operates (PLC initiated), the siren sounds (PLC initiated) and
the remote alarm contacts energise (PLC initiated).
The following client interfaces are supplied in the panel for connection to the ships
monitoring system.
a) RO Running – Digital Output – Tag Number TBC.
b) RO Attendance Alarm – Digital Output – Tag Number TBC.
c) RO Emergency Shutdown Alarm – Digital Output – Tag Number TBC.
d) RO Stopped – Digital Output – Tag Number TBC.
e) RO Permeate Flow – Analogue Output (4-20 mA)– Digital Input – Tag Number
TBC.
f) RO Permeate Conductivity – Analogue Output (4-20 mA) - Tag Number TBC.
The digital outputs are consist of 4 pairs of volt-free change-over contacts.

SSS
2.2 ALARMS
2.2.1 Emergency Stop Activated Alarm (ESTOP)
If any emergency stop pushbutton, an audible alarm is initiated and the ‘EMERGENCY
STOP ACTIVATED’ indicator illuminates.
On depressing the ‘ALARM ACCEPT/RESET’ pushbutton the audible alarm ceases.
The indicator remains illuminated until it is reset by removing the emergency stop input
condition and depressing the ‘EMERGECNY STOP RESET’ pushbutton.
There is a 0.5 second delay incorporated in the PLC software to reduce nuisance alarms.
* Emergency Shut Down Alarm
2.2.2 Low Air Pressure Alarm (PAL1)
If a low air pressure (less than 4 barg) is detected from pressure switch PS1, an audible alarm
is initiated and the ‘LOW AIR PRESSURE (PAL1)’ indicator flashes.
On depressing the ‘ALARM ACCEPT/RESET’ pushbutton the audible alarm ceases and the
indicator becomes steady.
The indicator remains illuminated until it is reset by depressing the panel “ALARM
ACCEPT/RESET” pushbutton for 2 seconds.
There is a 2 second delay incorporated in the PLC software to reduce nuisance alarms.
* Emergency Shut Down Alarm
2.2.3 Feed/Backwash Pump Motor Tripped Alarm (M1-TRIP)
In the event of a motor protection device (2MCB3) trip, an audible alarm is initiated and the
‘FEED/BACKWASH PUMP/MOTOR TRIP’ indicator flashes.
The indicator remains illuminated until the MCB is manually reset inside the control panel.
This requires the panel to be isolated and therefore the alarm will be reset upon re-
energising the panel.
* Emergency Shutdown Alarm.

SSS
2.2.4 Low Suction Pressure Alarm (PAL100)
If a low inlet pressure to the HP pump (less than 2 barg) is detected from pressure switch
PS100 when the HP pump is running, an audible alarm is initiated and the ‘LOW SUCTION
PRESSURE (PAL100)’ indicator flashes.
On depressing the “ALARM ACCEPT/RESET” pushbutton the audible alarm ceases and the
The indicator remains illuminated until it is reset by depressing the panel “ALARM
The HP pump motors are inhibited from running
‘HP PUMP/MOTOR M100 TRIP’ indicator flashes.

SSS
2.2.7 High Pressure Pump Motor Trip Alarm (M102 – TRIP)
2.2.8 High Pressure Pump Motor Trip Alarm (M103 – TRIP)
2.2.9 Flushing Pump Motor Trip Alarm (M104-TRIP)
‘FLUSHING PUMP/MOTOR TRIP’ indicator flashes.

SSS
2.2.10 High HP Pump Discharge/High Membrane Inlet Pressure Alarm (PAH101)
If a high pressure (greater than 80 barg) is detected from either pressure switch PS101 or
PS102 an audible alarm is initiated and the ‘HIGH HP PUMP DISCHARGE PRESSURE
(PAH101)’ indicator flashes.
On depressing the “ALARM ACCEPT/RESET” pushbutton the audible alarm ceases and the
The indicator remains illuminated until it is rest be depressing the ‘ALARM

ACCEPT/RESET’ pushbutton for 2 seconds.
* Emergency Shutdown Alarm
2.2.11 High Feed/Cleaning Temperature Alarm (TAH100)
If a high cleaning solution temperature (greater than 45 deg C) is detected from DIC100 and
the feed pump motor (P1/M1) is running or the flushing pump motor (P102/M102) is
running, an audible alarm is initiated and the ‘HIGH FEED/CLEANING TEMPERATURE’
indicator flashes.
The indicator remains illuminated until it is reset by depressing the “ALARM

* RO Attend Alarm
2.2.12 Flushing/Cleaning Tank Low Level Alarm (LAL100)
If a low level in the flushing/cleaning tank (T101) is detected from level switch LS100 and
the flushing pump is running, an audible alarm is initiated and the ‘FLUSHING/CLEANING
TANK LOW LEVEL’ indicator flashes.

* RO Attend Alarm

SSS
2.2.13 Antiscalant Dosing Pump Fault Alarm (P105-F)
The pump gives a pulsed output (P105-P) to the PLC, if no pulse is detected for more than 15
minutes and the pump is being enabled to run, an audible alarm is initiated and the
“ANTISCALANT DOSING PUMP FAULT’ indicator flashes.

* RO Attend Alarm
2.2.14 High Permeate Flow Alarm (FAH101)
If a high permeate flow (greater than 18 m3/h) is detected, an audible alarm is initiated and
the ‘HIGH PERMEATE FLOW (FAH101)’ indicator flashes.
On depressing the "ALARM ACCEPT/RESET" pushbutton the audible alarm ceases and the
The indicator remains illuminated until it is reset by depressing the ‘ALARM

* RO Attend Alarm.
2.2.15 High Permeate Conductivity Alarm (QAH100)
If a high conductivity is detected, the HP pumps are running, and the local dump valve
selector is in "AUTO", an audible alarm is initiated and the ‘HIGH PERMEATE
CONDUCTIVITY (QAH100)’ indicator flashes.
On depressing the "ALARM ACCEPT/RESET" pushbutton the audible alarm ceases and
the indicator becomes steady.

ACCEPT/RESET’ for 2 seconds.
If the local "TO DUMP" mode is selected the alarm is inhibited.

The alarm is also inhibited for 3 minutes after plant start-up.
* RO Attend Alarm.

SSS
2.2.16 Membrane Clean Overdue Alarm
Every 1,000 hours of running, an audible alarm is initiated and the "MEMBRANE CLEAN
OVERDUE" indicator flashes.
On depressing the "ALARM ACCEPT/RESET" pushbutton, the audible alarm ceases and the
The indicator will remain illuminated until it is reset by carrying out a clean sequence.
In the event that the membrane elements are cleaned prior to the alarm, the timer will be reset
during a clean sequence.
* RO Attend Alarm.
2.2.17 High Panel Temperature Alarm (TAH1)
A high temperature stat (factory pre-set with the required temperature) is installed in the
panel, in the event of an unacceptable temperature being achieved, i.e. in excess of
manufacturers temperature limits for PLC, contactors, etc.., an audible alarm is initiated and
the ‘HIGH PANEL TEMPERATURE’ indicator flashes.

2.2.18 Emergency Shut Down Alarms (ESD)
An emergency shutdown alarm will stop all pumps, reset any current sequencing and return
all valves to their fail safe positions.
Any one of the following alarms will initiate an ESD:
a) Emergency Stop
b) Low Air Pressure
c) Feed Pump Trip
d) Low HP Pump Suction Discharge
e) Any HP Pump Trip (4 in total)
f) Flushing Pump Trip
g) High HP Pump Discharge Pressure
h) Sequence Failure
2.2.19 Attend Alarms (ATTEND)
An attend alarm alerts operators to non-critical alarms and will not stop the system from
operating.
Any one of the following alarms will initiate an ATTEND:

SSS
a) High Feed/Cleaning Temperature

b) Flushing/Cleaning Tank Low Level
c) Antiscalant Dosing Pump Fault
d) High Permeate Flow
e) High Permeate Conductivity
f) Membrane Clean Required
g) High Panel Temperature
h) Sand Filter Backwash Required
2.2.20 Remote Alarms
If any of the following plant alarms occur an "RO EMERGENCY SHUTDOWN" remote
alarm is initiated:
a) Emergency Stop
b) Low Air Pressure
c) Feed Pump Trip
e) Any HP Pump Trip
h) Sequence Failure
If any of the following plant alarms occur an "RO ATTENDANCE REQUIRED" remote
alarm is initiated:

h) Sand Filter Backwash Required
If any alarm condition occurs an audible alarm and flashing beacon are initiated.
On depressing the ‘ALARM ACCEPT/RESET’ pushbutton the audible and flashing beacon
cease.
Note
Remote alarms [volt-free] latch even when indicator on panel is flashing.

SSS
2.3 CONTROL FUNCTIONS
2.3.1 Feed/Backwash Pump Motor (M1) Control
The pump is started and stopped by start and stop pushbuttons in normal operation. During
backwashing sequences the pump is started and stopped by the PLC. Refer to PLC sequences
for details.
Running, stopped and tripped indication is provided in the panel facia.
An ammeter is provided for the motor, to enable current to be monitored.
Protection for the motor is provided by a triple pole motor MCB incorporating a thermal and
magnetic trip. (Type 2 co-ordination).
Any emergency shutdown alarm instantly stops the motor.
2.3.2 High Pressure Pump Motors (M100, M101, M102 & M103) Control
The pumps are started and stopped manually by start and stop pushbuttons, which then
initialise sequenced starting/stopping by the PLC in normal operation. Refer to PLC
sequences for details.
Running, stopped and tripped indication is to be provided in the panel facia.
An hours run meter is provided for each pump/motor. These are mounted on the control
panel facia and display resettable running hours.
An ammeter is to be provided for the motor, to enable current to be monitored.
Protection for the motor is provided by a triple pole motor MCB incorporating a thermal and
magnetic trip. (Type 1 co-ordination).
Any emergency shutdown alarm instantly stops the motors.
2.3.3 Flushing Pump Motor (M104) Control
The pump is started and stopped by start and stop pushbuttons.
Running, stopped and tripped indication is provided in the panel facia.
An ammeter is provided for the motor, to enable current to be monitored.
Protection for the motor is a triple pole motor MCB incorporating a thermal and magnetic
trip. (Type 2 co-ordination).
Any emergency shutdown alarm instantly stops the motor.
The pump is inhibited from running in the event of a low level in the flushing tank

SSS
2.3.4 Antiscalant Dosing Pump (P105) Control
The pump is started and stopped by the PLC in normal operation. Refer to PLC sequences for
details.
Running, stopped and fault indication is provided in the panel facia.
The pump solenoid is protected via a miniature circuit breaker in the live supply.
Any emergency shutdown alarm instantly stops the pump.
2.3.5 High Permeate Conductivity Dump System
A normally open solenoid permeate dump valve (V115) and a normally closed solenoid
supply valve (V116) the valves are controlled via the conductivity controller (DIC100) and
PLC, via pilot solenoid valves.
The pilot valves (SV115 & SV116) are only controlled when the plant is fully running and
the dump system control is in ‘AUTO’ mode. A timer is incorporated in the software which
delays operation of the valves once conductivity is in range for 10 seconds, this is to prevent
valve hunting at the conductivity set point.
A dump system control switch "AUTO/TO DUMP" is incorporated to bypass control of the
valves, irrelevant of signals from the conductivity controller.
a) When ‘Auto’ is selected and
The conductivity controller senses a high conductivity the valves are de-energised
(i.e. dump valve open/supply valve closed).
Or
The conductivity controller senses an acceptable conductivity for more than

10 seconds the valves are energised (dump valve closed/supply valve open).
b) When ‘TO DUMP’ is selected the valves are de-energised (dump valve open/supply
valve closed).
Timers are to be incorporated in the software to ensure that when the valves
changeover from closed to open or vice versa that both valves are never closed
together. This being possible if the reaction time of one of the valves being
controlled is lower than the other.
(N.B. Each valve and lamp has a separate PLC output).
Both valves remain closed when the flushing pump (P104) is started manually.

SSS
2.3.6 Plant Inlet/Outlet Valves (V60 & V61)
The valves are controlled by the PLC via an ‘OPEN/CLOSE’ switch mounted on the panel
facia.
Open and closed indication is provided on the panel for both valves.
Limit switches are provided on each valve to enable valve position to be monitored by the
panel.
In addition, for the overboard valve (V61) only, digital inputs and outputs are required
to enable remote operation and indication of this valve via the ships control system (i.e.
2 x I/P and 2 x O/P).
2.3.7 CO2 Injection Valve (V209)
The valve is controlled via an ‘AUTO/OFF’ switch.
When ‘OFF’ is selected, the valve remains closed.
When ‘AUTO’ is selected, the valve opens when the permeate supply valve (VI16) is open
and permeate conductivity is in range.
A lamp is provided on the panel to indicate when the valve is open.
2.3.8 RO Running Remote Output
When the RO plant is running normally (i.e. HP pumps running, conductivity in range and
supply valve open) "RO RUNNING" remote signal will be active (i.e. relay state on –
running, relay state off – not running).
2.3.9 RO Attendance Alarm Remote Output
If any of the following plant alarms occur an ‘RO ATTENDANCE’ remote signal will be not
active (i.e. relay state on – healthy, relay state off – alarm):

2.3.10 RO Emergency Shutdown Remote Alarm Output
If any of the following plant alarms occur an ‘RO EMERGENCY SHUTDOWN’ remote
signal will be not active (i.e. relay state on – healthy, relay state off – alarm):
a) Emergency Stop
b) Low Air Pressure

SSS
c) Feed Pump Trip

e) Any HP Pump Trip
h) Sequence Failure
i) Sand Filter Backwash Required
2.3.11 RO Stopped Remote Output
When the RO plant is stopped the remote signal will be active (i.e. relay state on).
2.3.12 Sand Filter Control Selector
A backwash selector switch 'FILTER/MANUAL/AUTOMATIC' is to be provided in the

panel facia to enable control of the sand filter backwash.
In 'AUTOMATIC 'the backwash sequence is to be controlled via the PLC.
In 'MANUAL' the backwash sequence is to be controlled via a "stepping" pushbutton

mounted on the panel facia.
In 'FILTER' the filter will not backwash, the feed/backwash pump can be stopped and
started via the pushbuttons and the HP pumps are not inhibited from running, the filter inlet
and outlet valves (V3A,B/V4A,B) are open.
2.4 PLC CONTROL SEQUENCE
2.4.1 Sand Filter
Either ‘FILTER’, ‘MANUAL’ or ‘AUTO’ control can be selected using the sand filter
control selector switch.
When the switch is in 'FILTER', the sand filter inlet and outlet valves (V3A/B,V4A, B) are
to be opened, when the feed/backwash pump is started the filtering lamp is to illuminate.
In 'MANUAL' the filter backwash sequence is to be carried out by an operator stepping

through the sequence via a pushbutton on the panel facia.
In the event of a low air pressure alarm the backwash sequence halts until the alarm is reset
A backwash sequence is to be initiated by depressing the ‘BACKWASH INITATE’
pushbutton on the panel facia.
A backwash required lamp is to flash and an audible alarm initiated when:
a) A high differential pressure is indicated from DPS1.
b) On time – if the filter has been filtering for 24 hours as determined by the length of
time the feed/backwash pump has run.

SSS
On depressing a common alarm mute pushbutton the audible alarm is to cease and the lamp
become steady.
In either 'AUTO' or 'MANUAL' a backwash must be prohibited if the HP pump motors

(P100/P101/P102/P103) are running.
Lamps are to be provided in the panel facia to indicate where in the sequence the filter
operation is:
a) Backwash Required
b) Filtering
c) Flushing
d) Backwashing PV2A
e) Backwashing PV2B
2.4.2 Backwash Sequence
At any stage the switch is able to be switched from 'MANUAL' to 'AUTO' and the PLC
will continue from that point.
1) Filter selector switch in 'MANUAL' or 'AUTO'

Backwash initiation by manual initiate
2) 'BACKWASH REQUIRED' indicator off
Close filter outlet valves (V4A & B)
‘FILTERING’ indicator off
‘Backwash A’ indicator flashing
Close filter inlet valve (V3A & B)
Wait 5 seconds
3) Open filter backwash outlet valve (V6A)
Open filter backwash inlet valve (V5A)
Sand Filter A 'BACKWASH' indicator flash
Wait 5 seconds
4) Start feed/backwash pump (P1)
Sand Filter A 'BACKWASH' indicator on

Wait 10 minutes
5) Stop feed/backwash pump (P1)
Sand Filter A 'BACKWASH' indicator flash
Wait 10 seconds
6) Close filter backwash inlet valve (V5A)

Close filter backwash outlet valve (V6A)
Sand Filter A 'BACKWASH' indicator off

Wait 5 seconds
7) Sand Filter B 'BACKWASH' indicator flash
Open filter backwash outlet valve (V6B)

SSS
Open filter backwash inlet valve (V5B)

Wait 5 seconds

Sand Filter B 'BACKWASH' indicator on
Wait 10 minutes

Sand Filter B 'BACKWASH' indicator flash
Wait 10 seconds
10) Close filter backwash inlet valve (V5B)

Close filter backwash outlet valve (V6B)
Sand filter B ‘BACKWASH’ indicator off
Wait 5 seconds
11) Open filter drain valve (V7A/B)

Open filter inlet valves (V3A/B)
'FLUSHING' indicator flash
Wait 5 seconds

'FLUSHING' indicator on
Wait 5 minutes

'FLUSHING' indicator flash
Wait 5 seconds
14) 'FLUSHING' indicator off

Close filter inlet valve (V3A/B)
Close filter drain valve (V7A/B)
Wait 5 seconds
15) Standby indicator flash

Reset filter wash timer
Once the filter selector switch is switched to 'FILTER' for more than 3 seconds the
'STANDBY’ indicator is to go out and filter inlet valves (V3A/B) and outlet valves (V4
A/B) open.
2.4.3 Plant Startup & Shutdown Sequence
1) Reset 'EMERGENCY STOP' pushbutton

2) Open ships side valves (V60/V61) wait for open signals
3) Feed Pump (P1) able to start
4) Feed Pump (P1) start initiated by 'START' pushbutton

SSS
5) HP Pumps (P100/P101/P102/P103) able to start (when suction pressure greater than

2 barg)
6) HP Pump start sequence initiated by 'START' pushbutton
7) HP Pump (P100) start
8) Wait 5 seconds
10) Wait 5 seconds
12) Start Antiscalant Dosing Pump (P105)
13) Wait 5 seconds
15) Wait 5 seconds
16) Enable permeate dump system
17) HP Pump stop sequence initiated by 'STOP' pushbutton.
18) HP Pump (P100) stop
19) Wait 5 seconds
20) HP pump (P101) stop
21) Wait 5 seconds
23) Stop Antiscalant Pump (P105)
24) Wait 5 seconds
26) Feed Pump stopped by 'STOP' pushbutton
Note
If any instant shutdown alarms occur all pumps stop and valves return to fail safe positions.
The start up and shutdown sequences reset.

SSS
3.0 INSTALLATION
3.1 GENERAL
3.2 PROCESS REQUIREMENTS
3.3 ELECTRICAL REQUIREMENTS
3.4 SITE REQUIREMENTS
3.5 INSTALLATION OF PLANT
3.6 INSTALLATION OF SAND FILTER MEDIA
3.7 INSTALLATION OF CARTRIDGE FILTER ELEMENTS
3.8 INSTALLATION OF REHARDENER MEDIA
3.9 INSTALLATION OF RO MEMBRANE ELEMENTS
S846-40 400 m3/d SWRO PLANT 3/1 DATE : 22.02.10

SSS
3.0 INSTALLATION
Refer to the following drawings in section 10.0 of this manual:
Drawing No Title
09247-01-01 Sht 1 P & I Diagram Pre-Treatment

09247-01-01 Sht 2 P & I Diagram RO Plant
09247-01-10 Shts 1 to 6 General Arrangement of RO Plant
09247-13-01 Shts 1 to 27 RO Control Panel Electrical Schematics
09247-13-04 Shts 1 to 3 Electrical Connection Diagram
3.1 GENERAL
The Reverse Osmosis plant is made up of various pre-wired, pre-piped skids and pieces
of equipment. Additional pipework required will be the interconnecting pipework
between the skids and to the ships services, i.e. suction/overboard discharges, gravity
drains and potable water storage tanks.
The plant comprises of the following main items of equipment:
a) One feed/backwash pump and suction strainer (P1/PV1): Single stage centrifugal
pump and 4" NB bronze strainer fitted with 1.6mm mesh basket.
b) Two sand filters (PV2A/PV2B): Vertical carbon steel pressure vessels 1200mm
diameter, 1800mm high, fusion bonded epoxy coated.
c) Flushing/cleaning system (P104/T101): multistage centrifugal pump and flushing

tank.
d) Antiscalant dosing equipment (P105/T100): Solenoid type dosing pump and 100L
dosing tank complete with agitator.
e) Cartridge filter (PV100): Horizontal FRP vessel.
f) Four HP pump sets (P100/P101/P102/P103): Axial piston pump each driven via a
32.5 kW electric motor.
g) Eight RO membrane element pressure vessels (PV101 to PV108): 8" diameter

internal dia GRP pressure vessels.
h) Twenty Four RO membrane elements: 8" diameter SW30HRLE-400 thin film

composite spiral wound membrane elements.
i) Rehardening equipment: Vertical carbon steel fusion bonded epoxy coated

pressure vessel with ABS frontal pipework.

SSS
k) Instrumentation.
l) Pipework.
m) Valves.
n) Control Panel.
o) Energy Recovery Device.
All items of equipment fitted to the plant are identified with a stainless steel tag or
nameplate.
In addition each item is also marked with an SSS Ref No this will be either engraved,
marked with indelible ink or by adhesive label.
The SSS Ref No should be used to purchase replacement items.
3.2 PROCESS REQUIREMENTS
Plant design has been based on the following:
Feed Pressure: Sustained Positive Flooded Suction

Feed Flow (Normal): 40 m3/h
Feed Flow (Backwashing): upto 42.7 m3/h at 35°C
Maximum Permeate Flow: 18 m3/h
Maximum Allowable Permeate Backpressure: 2 barg
Maximum Reject Flow: 40 m3/h
Maximum Backwash Outlet Flow: 42.7 m3/h
Membrane designs are based on seawater as follows:
At 5°C
TDS = 35,011 mg/l ≡ 53,250 μS/cm
pH = 7.9
At 20°C
TDS = 37,592 mg/l ≡ 57,175 μS/cm
pH = 7.9
At 35°C
TDS = 42,000 mg/l ≡ 63,880 μS/cm
pH = 7.9
Air Supply:
Quality: Dry, oil free

Pressure: 7 barg minimum (10 barg maximum)
Volume: 1.8 NL every 24 hours

SSS
3.3 ELECTRICAL REQUIREMENTS
The plant has been designed to operate on a 440V AC, 3 Phase, 3 Wire 60 Hz supply.
The motors installed on the plant have been oversized to compensate for the high ambient
temperature (approximately 45°C).
1. Electrical Power Installed:
Flushing/Cleaning Pump (P104): 7.5 kW (FLC 15.4 Amps)

Feed/Backwash Pump (P1): 13 kW (FLC 21.5 Amps)
4 off High Pressure Pumps (P100, P101, P102): 32.5 kW (FLC 55 Amps) x 4
Chemical Dosing Pumps (P105): 0.24 kW
Electrical Controls: 0.10 kW
Total 103.10 kW
2. Electrical Power Normal Running:
Feed/Backwash Pump (P1): 9.5 kW

4 off High Pressure Pumps (P100, P101, P102, P103): 14.8 kW x 4
Chemical Dosing Pumps (P105): 0.20 kW
Electrical Controls: 0.10 kW
Total 69.0 kW
3. Volt free contacts are provided in the electrical control panel for remote attendance
required, shutdown, running and stopped annunciation.
4. Terminals are provided in the main electrical control panel for three remote emergency
stop buttons to be fitted.
5. Terminals are provided in the electrical control panel for interface with the ships control
system (2 x 4-20mA outputs and 4 x digital outputs).
3.4 SITE REQUIREMENTS
The plant is supplied in a number of distinct pieces; the RO plant, four single HP pump
sets, two sand filters, flushing tank, antiscalant dosing set, rehardener, cartridge filter,
suction strainer and feed/backwash pump. These will require suitably mounting, piping
and wiring to ships services.
A clearance of 1m from both ends of the RO membrane element vessels must be allowed
for the removal and installation of the RO membrane elements, also sufficient provision
from the end of the cartridge filter housing should be left for cartridge removal.
All equipment has been designed to be installed as per the General Arrangement drawing.

SSS
Due to the location and inaccessibility of the area for the plant, it has been designed so
that it can be transported to the ship piecemeal, and installed by engineers on the ship.
Inlet and outlet plant termination point specifications are as follows:
Raw Water Inlet (TP1) - 6" NB NP10/16 Flange

Overboard Discharge (TP2) - 4" NB NP10/16 Flange
Potable Water Outlet (TP200) - 2" NB NP10/16 Flange
Cold Potable Water Inlet (TP4) - 1" BSP Female Brass
Hot Potable Water Inlet (TP5) - 1" BSP Female Brass
3.5 INSTALLATION OF PLANT
Installation will be carried out by engineers under the supervision of Salt Separation
Services engineers, generally as follows:
1. Ensure structural steelwork is in place to support main items of equipment.
2. Equipment will be assembled and positioned in its correct position then its deck pads
welded down.
3. All pipework will be connected/run following good engineering practice such as pipe
runs of minimal length, working from pumps, avoiding dead areas in suction lines, paying
attention to mixed metals, adequate bracketing, adequate isolation, attention to noise
shorts, expansion allowance, access, drain down provision, etc...
4. Electrically connect the plant.
Note
All keys for the control panel will be tied to the frame adjacent to the panel.
3.6 INSTALLATION OF SAND FILTER MEDIA
WARNING
Ensure vessels are not under pressure before opening.
1. Remove the filter top inspection flange, then using caution due to its weight,
approximately 40 Kg, remove the flange.
2. Remove any commissioning debris.
3. Quarter fill the vessels with water - this ensures that when the underbed of gravel is
installed, the ABS nozzles are not shattered by the falling media.
4. Install the filter media by pouring slowly into the top of the vessels, if the media is dry a
dust mask should be worn, the media should be levelled to ensure correct depths.

SSS
Quantities are as follows per filter vessel:
100mm 3-6mm Gravel Approximately 19 x 25 Kg Bags (467 Kg)2
150mm 2-3mm Gravel Approximately 10 x 25 Kg Bags (236 Kg)2

600mm 16/30 Sand Approximately 40 x 25 Kg (976 Kg)2
1
Above highest point of laterals.
2
Actual weight required.
Ensure that the flange faces are free from media, replace the gasket and flange. Bolts should
be fitted with washers both sides, treated with a suitable anti-seize compound and torqued
following good engineering practice (see table below):
SAND FILTER VESSEL BOLT TORQUES
FLANGE DESCRIPTION TORQUE (Nm) TORQUE (lbf ft)

Inspection Flanges 19 14
Inlet/Outlet Flange 10 8
Main Body Flange 167 123
6. Repeat for the second vessel.
Note
The sand filters must be given an extended backwash before use, refer to operation, section
6.0 of this manual.
Do not use petroleum jelly or lubricants other than those specified as these can irreversibly
damage RO membrane elements.
3.7 INSTALLATION OF CARTRIDGE FILTER ELEMENTS
WARNING
Ensure vessel is not under pressure AND is securely isolated before opening.
1. With the RO plant shutdown and electrically and mechanically isolated, close RO plant inlet
valve (V100).
2. Open filter drain valve (V133) to de-pressurise and drain vessel.
3. Remove the end plug retaining ring (Stainless Steel ring with ring-pull).
4. Extract the end plug using the built-in handle.
5. Remove and dispose of the old cartridge filter element.
6. Clean the pressure vessel on the inside and check visually.

SSS
7. Lubricate ‘O’ rings (use only glycerine or silicone grease) at bottom of the new cartridge
and install cartridge into housing ensuring both ‘O’ rings are pushed firmly home to seal.
8. Lubricate the end plug ‘O’ ring with silicone grease and refit into the vessel.
9. Refit the retaining ring into the groove ensuring that it is installed fully.
10. After starting the feed pump but before starting the high pressure pumps, open the filter
drain valve (V133) to flush out any debris. Ensure the high pressure pumps are correctly
primed before starting.
3.8 INSTALLATION OF REHARDENER MEDIA
WARNING
Ensure vessel is not under pressure before opening.
1. Drain vessel via the drain cock (V217) located underneath the vessel.
2. Open the top filling port cap (100 NB blind flange). For the initial fill, it will be easier to
remove the top manway flange (450 NB flange), however, use caution due to its weight
(approximately 40Kg).
3. Quarter fill the vessel with water – this ensures that when the underbed of gravel is
installed, the ABS nozzles are not shattered by the falling media.
4. Carefully install the 3-6mm gravel by pouring into the vessel using a suitable container.
The media should be levelled to ensure the correct depth (50mm above the highest point
of the laterals – approximately 10 x 25 Kg bags).
5. Using a suitable container pour rehardening media into the vessel until the level is at the
top of the sightglass (approximately 54 x 25Kg bags).
Note
a) If the media is dry a dust mask should be worn.
b) Care should be taken as there are plastic nozzles inside the vessel.

SSS
6. Replace filling port flange and, ensuring the gasket and flange faces are free from media,
tighten following good engineering practice (see the following table):
REHARDENER VESSEL BOLT TORQUES
FLANGE DESCRIPTION TORQUE (Nm) TORQUE (lbf ft)

Inspection Flanges 19 14
Relief Valve Flange 5 4
Outlet Flange 6 4
Inlet/Drain Flange 10 18
Main Body Flange 171 127
7. The rehardener must be given an extended flush before use, refer to 'Operation', section
6.0 of this manual.
3.9 INSTALLATION OF RO MEMBRANE ELEMENTS
WARNING
Ensure vessels are not under pressure AND are securely isolated before opening.
Do not use petroleum jelly or lubricants other than those specified as these can
irreversibly damage RO membrane elements.
Refer to Section 5.0 for Health and Safety Information
Note
Also refer to RO vessel manufacturers instructions, 'Equipment Literature' Section 9.0.
1. Remove the couplings connecting the ‘U’ bends to the vessel(s) and manifold(s), and
store safely. Remove the permeate pipework from the centre of the vessel(s) and remove
the permeate sample valve(s) from the opposing ends to avoid breakages.
2. Only remove the feed end head from each vessel.
3. Examine the end closure for any corrosion or damage. Remove any corrosion with a wire
brush and flush away the deposits with clean water. Order replacement component as
required.
4. Pull the retaining ring out of the groove in the shell. After the ring is removed from the
groove for ¼ turn, stop pulling. Finish removing the ring by running your fingers behind
the ring and carefully pulling the ring from groove. It is best to follow the ring in a clock-
wise direction while removing to avoid stretching the ring.
5. While holding the permeate port with your hand, simply pull the head from the shell. In
some instances it may be required to gently rock the head up and down to release the head
from the shell. Alternatively, a head removal tool is available to aid removal.
6. When pressure vessels are re-assembled, make sure that the parts of one vessel are not
mixed with parts of other vessels.
SSS
7. Clean the pressure vessel on the inside and check visually.
8. Insert one thrust ring at the reject end (opposite the feed end) of each vessel.
9. Carefully unpack a membrane noting the warnings on the packaging.
10. Lubricate the ‘U’ cup brine seal with glycerine. Install the ‘U’ cup brine seal with the
open end of the seal facing the feed end of the vessel.
11. Lubricate the two ‘O’ rings on the permeate adaptor with M494 silicone grease and install
the adaptor onto the reject end of the membrane.
12. Note the serial number of the membrane for record purposes. This can be found on a
white label half way along the length of the membrane.
13. With the vessel securely fixed in position, slide the membrane into the vessel with a slight
twisting motion, keeping the open side of the ‘U’ cup brine seal facing the feed end of the
vessel. The permeate adaptor will seat into the permeate port of the end cap (first element
only).
14. Lubricate the two ‘O’ rings on the interconnector supplied with the membrane with M494
silicone grease.
15. With a slight twisting motion, gently insert one end of the interconnector into the
permeate tube (centre) of the membrane. The membrane will accept approximately one
half of the interconnector.
16. Repeat steps 9 to 12 for the next two membranes. Ensure the membrane serial number is
noted.
17. Slide the second (third) membrane with a slight twisting motion into the vessel, ensuring
the open side of the ‘U’ cup brine seal is kept facing the feed end of the vessel. The
exposed portion of the interconnector should enter the membranes product tube. The
membranes will touch each other. Maintain element alignment carefully during the
assembly process.
Do not allow the membranes weight to be supported by the interconnector. Misalignment

can result in damage to the permeate tube.
18. Lubricate the two ‘O’ rings on the permeate adaptor with M494 silicone grease and install
the adaptor onto the feed end of the membrane.
19. Lubricate each individual ‘O’ ring on the feed end cap with M494 silicone grease and
refit into the vessel. Insert the end cap squarely, sufficiently enough to allow the retaining
ring to be inserted fully into the groove in the end of the vessel.
20. Ensure parts are lined up and refit ‘U’ bends to the vessel/(s) and manifold/(s) ensuring
that the victaulic gasket is lubricated with M494 silicone grease and the bolts are treated
with a suitable anti-seize compound (molyslip).

SSS
Notes
1. When ‘O’ rings are installed, expand them slightly – do not roll them into position.
2. When pressure vessels are reassembled, ensure that the parts of one vessel are not mixed
with parts of another vessel.
3. Check that each vessel is solidly secured to its rack.
4. The membranes should be kept moist at all times.
5. Permeate obtained from the first hour of operation should be discarded. This ensures all
traces of the preservation solution are flushed from the system.
6. After initial pressurisation of the membrane stack, end caps should be checked for
tightness.

SSS
4.0 PLANT DATA SHEETS
Page No Description Rev
4.4 FEED/BACKWASH PUMP 01
4.5 FEED/BACKWASH PUMP MOTOR 01
4.6 SAND FILTER VESSEL 01
4.7 STRAINER 01
4.8 SAND FILTER BACKWASH INLET VALVES 01
4.9 SAND FILTER BACKWASH INLET VALVE ACTUATORS 01
4.10 SAND FILTER DRAIN VALVES 01
4.11 SAND FILTER DRAIN VALVE ACTUATORS 01
4.12 PERMEATE RECYCLE FLOWMETER 01
4.13 FEED/BACKWASH FLOWMETER 01
4.14 PRE-TREATMENT PRESSURE GAUGES 01
4.15 FLUSING TANK 01
4.16 DP PRESSURE SWITCH 01
4.17 ANTISCALANT DOSING PUMP 01
4.18 ANTISCALANT DOSING TANK 01
4.19 CARTRIDGE FILTER VESSEL 01
4.20 CARTRIDGE FILTER PRESSURE GAUGES 01
4.21 LP PRESSURE SWITCH 01
4.22 HP PUMP 01
4.23 HP PUMP MOTOR 01
4.24 HP BALL VALVES 01
4.25 HP PRESSURE SWITCH 01
4.26 RO PRESSURE VESSELS 01
S846-40 400 m3/d SWRO PLANT 4/1 DATE: 22.02.10

O & M MANUAL (S09247) REV: 01
SSS
4.27 RO MEMBRANES 01
4.28 HP PRESSURE GAUGES 01
4.29 REJECT CONTROL VALVE 01
4.30 HP RELIEF VALVE 01
4.31 FEED/PERMEATE FLOW TRANSMITTER 01
4.32 PERMEATE PRESSURE GAUGE 01
4.33 CONDUCTIVITY ANALYSER 01
4.34 PERMEATE SUPPLY VALVE 01
4.35 PERMEATE SUPPLY VALVE ACTUATOR 01
4.36 PERMEATE DUMP VALVE 01
4.37 PERMEATE DUMP VALVE ACTUATOR 01
4.38 PERMEATE & REHARDENER RELIEF VALVES 01
4.39 REHARDENER VESSEL 01
4.40 REHARDENER CONTROL VALVES 01
4.41 REHARDENER FLOWMETER 01
4.42 CO2 SOLENOID VALVE 01
4.43 CO2 FLOWMETER 01
4.44 FLUSHING PUMP 01
4.45 FLUSHING PUMP MOTOR 01
4.46 FEED RELIEF VALVE 01
4.47 INLET VALVE 01
4.48 INLET VALVE ACTUATOR 01
4.49 DISCHARGE VALVE 01
4.50 DISCHARGE VALVE ACTUATOR 01
4.51 REJECT RELIEF VALVE 01
4.52 FEED/BACKWASH PUMP SUCTION PRESSURE GAUGE 01

SSS
4.53 ENERGY RECOVERY DEVICE 01
4.54 BACKWASH CONTROL VALVE 01
4.55 RO PLANT INLET VALVE 01

SS
S
EQUIPMENT DATA SHEET
DATA SHEET FOR: Feed/Backwash Pump
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: P1 SSS REF: AQ934/2.1
LOCATION: Indoor AMBIENT TEMP: 5 to 50 ºC
ENVIRONMENT: Saliferous AREA: Safe
OPERATING DATA
FLUID: Seawater FLUID NATURE: Corrosive

FLUID TEMP: 5 to 35 ºC FLUID pH: 7.9 FLUID SG: 1.025
DUTY: Continuous SUCTION CONDITIONS: Flooded

MAIN DUTY FLOW: 40m³/h @ 4.7 barg
ANCILLARY DUTY FLOW: 42.7m³/h @ 44 barg (filter backwashing)
MECHANICAL DATA
PUMP TYPE: Single Stage MODEL: NISM40-200/01 U3.1DW3

MAX DISCHARGE PRESSURE: 5.2 barg PUMP SPEED: 3540 rpm
DRIVE: Direct ROTATION (SHAFT END): Anti-Clockwise
INSTALLED POWER: 12 kW MAIN DUTY ABSORBED POWER: 9.53 kW
MOTOR DATA
SUPPLY: 440V 3pH 60Hz FRAME: 200 COOLING: Fan

IP RATING: 55 INSULATION CLASS: F POLES: 2 SPEED: 3500 rpm
MATERIAL SPECIFICATION CONNECTIONS
CASING & COVER: Bronze G-CuAl10Ni INLET: 50mm PN16 Flange

IMPELLOR: Bronze G-CuAl10Ni OUTLET: 50mm PN16 Flange
SHAFT: Stainless Steel 1.4571 COATING
WEIGHT EXTERNAL: Top PM1030G, Colour RAL5017 (Blue)

WEIGHT: 80 kg
DESIGN AND TEST REQUIREMENTS
DESIGN STANDARDS: ISO 2858

MATERIAL CERTIFICATES: Required HYDRO TEST CERTIFICATE Not Required
PERFORMANCE CERTIFICATES: Type Performance Curves Only
DATA SHEET NO: S09247-DS01 R01/kas

REV DATE COMMENTS/DETAILS PREPARED BY REVIEWED BY APPROVED BY
1 05.08.09 Issued for Purchase/Manufacture Phill Eccles DWS D W Shackleton

Invalid signature
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
Ltd It mustt nott be
b copied,
i d nor the
th contents
t t communicated
i t d X
to a third party without prior written consent from the company.
EDS‐PUMP‐CENTRIF REV08 14.10.08

SS
S
DATA SHEET FOR: Feed/Backwash Pump Motor
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: P1 (M1) SSS REF: AQ934/2.1
OPERATING DATA
STARTING METHOD: D-O-L STARTS PER HOUR: Continuous

SPEED: Fixed POWER REQUIRED: 9.5 & 10 kW
ROTATION FROM FAN END: Clockwise
MECHANICAL DATA
FRAME SIZE: 160M RATED OUTPUT: 12 kW EFFICIENCY: 86.9%

SYNCHRONOUS SPEED: 3500 rpm FULL LOAD SPEED: 3540 rpm
MOUNTING: Flanged Vertical (V1) COOLING: TEFC
HEATERS: Not Required THERMISTORS: Not Required
BEARINGS: TBC LUBRICATION: Sealed for Life
NO OF POLES:
NO. POLES 2 CONNECTION Star
TERMINAL BOX CONNECTION: St
TERMINAL BOX POSITION (FROM SHAFT END): Top WEIGHT: TBC
ELECTRICAL DATA
SUPPLY: 440V 3 Phase 60 Hz RATED CURRENT: 21.5 A

ENCLOSURE: Standard INSULATION CLASS: F
IP RATING: 55 ZONE: N/A GAS GROUP: N/A TEMP CLASS: B
POWER FACTOR: 0.92 COSØ
MATERIAL SPECIFICATION
FRAME: Aluminium FAN: Polypropylene c/w 20% Glass Fibre

FAN COWL: Polypropylene TERMINAL BOX: Die Cast Aluminium
PROTECTIVE COATING
Single Coat Primer Type PM1619M, Single Coat Top PM1030G, Colour RAL5017 (Blue)
DESIGN AND TEST EQUIPMENT
PERFORMANCE CURVES: Type Test Not Required ATEX CERTIFICATE: Not Required

1 05.08.09 Issued for Purchase/Manufacture Phil Eccles DWS D W Shackleton

Invalid signature
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
EDS‐MOTORS‐ELECTRIC REV0826.09.08
SS
S
DATA SHEET FOR: Sand Filter
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: PV2A & PV2B SSS REF: AR912/11.08
OPERATING DATA

INLET PRESSURE: Max. 5 barg MAX DIFFERENTIAL PRESSURE: 1.0 barg
FLOWRATE: 20 m³/hr FILTERING RATE: 17 m²/m³/hr
BACKWASH RATE: 23.2 m³/h @ 5ºC to 42.7 m³/h @ 35ºC
MECHANICAL DATA MATERIAL SPECIFICATION
TYPE: Vertical SHELL: S275JR-430B

HEIGHT OVERALL: 1672 mm DISHED ENDS S275JR-430B
INSIDE DIAMETER: 1188 mm MAIN VESSEL FLANGES: BS1501-151-430A
DESIGN PRESSURE: 6 barg NON PRESSURE PARTS BS4360 43A
TEST PRESSURE 9 barg
b BOLTING
BOLTING: Q lit Stainless
A2 Quality St i l Steel
St l
DESIGN TEMP: 0 to 50ºC GASKETS: 6mm Thk Neoprene
CORROSION ALLOWANCE: 1 mm COATING
DISTRIBUTION: Laterals INTERNAL: Scotchkote 206N FBE

NOZZLE SIZE EXTERNAL: Scotchkote 206N FBE
INLET: 125 NB EN1092-1:2001 PN16 MEDIA
OUTLET: 125 NB EN1092-1:2001 PN16 UNDERBED: 3-6mm Gravel (100mm above laterals)
DRAIN FLANGE: 125 NB EN1092-1:2001 PN16 UNDERBED: 2-3mm Gravel (150mm)
MANWAYS MEDIA: 16/30 Sand (600mm)
INSP HOLE: 200 NB EN1092-1:2001 PN6 VESSEL WEIGHT: WET: TBC kg DRY: TBC kg
DESIGN CODE: Generally to PD5500:2009 Cat III

MATERIAL CERTIFICATE: Required HYDRO TEST CERTIFICATE Required
NDT: None RADIOGRAPHY: None

1 07.12.09 Issued for Purchase/Manufacture Phil Eccles Phil Eccles G Haworth

11/12/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
EDS‐VESSEL‐SAND REV08 16.10.08

SS
S
DATA SHEET FOR: Suction Basket Strainer
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: PV1 SSS REF: AQ935/2.3
OPERATING DATA

INLET PRESSURE: Positive Head PRESSURE DROP (50% BLOCKED) 0.03 barg
FLOWRATE: 40 upto 42.7 m³/hr MAX RATED FLOWRATE: 50 m³/hr
TYPE: In-line Simplex Basket Strainer COVER: Bronze

HEIGHT OVERALL: 505 mm HOUSING: Bronze
INSIDE DIAMETER: Approx. 240 'O' RINGS: Buna-N
DESIGN PRESSURE: 13.8 PLUG: Bronze
TEST PRESSURE:
PRESSURE 20 7
20.7 FILTER/STRAINER
DESIGN TEMP: 37.8ºC TYPE: 1/16" Perforated Basket

CORROSION ALLOWANCE: 0 mm DIAMETER: 150 mm LENGTH: 250 mm
CONNECTIONS MATERIAL:
INLET: 4" NB ANSI B16.24 125 lb Flange RATING: 1588 Micron Nominal
OUTLET: 4" NB ANSI B16.24 125 lb Flange
DRAIN: ½" NPT-F VESSEL WEIGHT
AIR RELEASE: N/A DRY: 64 kg WET: 100 kg
DESIGN CODE: None - Manufacturers Standard

MATERIAL CERTIFICATES: Not Required
NDT: Not Required RADIOGRAPHY: Not Required
HYDROSTATIC TEST: Not Required


Invalid signature
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
EDS‐STRAINER REV08 14.10.08

SS
S
DATA SHEET FOR: Sand Filter Backwash & Inlet/Outlet Valve
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: V5A, V6A, V5B & V6B SSS REF: AR419-09247/1.9
OPERATING DATA

FLUID TEMP: 5 to 35ºC FLUID pH: 7.9 FLUID SG: 1.025
MAXIMUM WORKING PRESSURE: 5.5 barg
MECHANICAL DATA
SIZE: 3" NB FLANGE TYPE: BS4504 NP10/16

DESIGN PRESSURE: 10 barg DESIGN TEMP: -10 to 80 ºC
ACTUATION: Pneumatic Actuator SEE EDS NO: S09247-DS06
VALVE Kv (L/min @ 1 barg): 8183 WEIGHT: 6.6 kg
BODY: Cast Iron DISC: UNS S31803 Duplex Stainless Steel

SHAFT
SHAFT: UNS S31803 Duplex
D l Stainless
St i l Steel
St l PINS
PINS: UNS S31803 Duplex
D l Stainless
St i l Steel
St l
SEAT: Nitrile

HYDROSTATIC TEST: Not Required SEAT LEAKAGE TEST: Not Required


30/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
EDS‐VALVE‐BUTTERFLY REV08 15.10.08

SS
S
DATA SHEET FOR: Sand Filter Backwash & Inlet/Outlet Valve Actuator
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: V3A/B, V4A/B, V5A/B, V6A/B SSS REF:AR419-09247/1.8
OPERATING DATA
Refer to Valve Data Sheet S09247-DS05 for Valve Details

ACTION: Single Acting
AIR CONNECTION: ¼" BSP Female
FAIL SAFE POSITION: Normally Closed
POSITIONAL INDICATOR: Optical
STROKE ADJUSTER: No
MANUAL OVERRIDE: No
3/2 WAY PILOT SOLENOID VALVE
GENERAL
LOCATION: Panel Mounted TAG NO: V5A, V6A, V5B & V6B
ENVIRONMENT
ENVIRONMENT: S lif
Saliferous AMBIENT TEMP:
TEMP 5 to
t 50 ºC
MECHANICAL DATA
FLOW: 200Nl/min @ 6 barg DESIGN PRESSURE: 8 barg DESIGN TEMP: -10 to 50 ºC

kv: 2.21 FAILSAFE POSITION: Normally Closed
CONNECTIONS: 6mm Push-In ORIFICE DIAMETER: 3 mm
7
MANUAL OVERRIDE: Maintained MECHANICAL LIFE: 1.5 x 10 Operations
BODY: Zamack SEALS: Nitrile ENDS: Zamack

ELECTRICAL DATA
SUPPLY: 24V ENCLOSURE: Standard

IP RATING: 20 ZONE: N/A GAS GROUP: N/A INSULATION CLASS: F
POWER CONSUMPTION: 1 W
SIZE OF COIL: 24V DC 1W
ELECTRICAL CONNECTIONS: Plug-Ins


30/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
EDS‐VALVE‐PNEUMATIC REV08 15.10.08

SS
S
DATA SHEET FOR: Sand Filter Drain [Rinse] Valve - Diaphragm Valves
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1& 2 TAG NO: V7A & V7B SSS REF: AR418-09247/1.17
OPERATING DATA

MECHANICAL DATA
SIZE: 1½" NB DESIGN PRESSURE: 10 barg DESIGN TEMP: 80 ºC

ACTUATION: Pneumatic SEE EDS NO: S09247-DS08
END CONNECTIONS: 1½" Spigot
VALVE kV (L/min @ 1 barg): 416 WEIGHT: 2.5 kg
BODY: ABS BOLTS: Steel Cad. Plated

BONNET: PP/Glass HANDWHEEL N/A
DIAPHRAGM: EPDM
MATERIAL CERTIFICATE: Not Required

HYDROSTATIC TEST CERTIFICATE: Not Required SEAT LEAKAGE TEST CERTIFICATE: Not Required


30/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
EDS‐VALVE‐DIA REV08 15.10.08

SS
S
DATA SHEET FOR: Sand Filter Drain [Rinse] Valve - Pneumatic Actuator
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: V7A & V7B SSS REF: AR418-09247/1.17
OPERATING DATA

AIR CONNECTION: ¼" Female
STROKE ADJUSTER: Yes
MANUAL OVERRIDE: No
GENERAL
LOCATION: Panel Mounted TAG NO: V7A & V7B

ENVIRONMENT
ENVIRONMENT: S lif
TEMP 5 t
to 50 ºC
MECHANICAL DATA
FLOW: 200N l/min @ 6 barg DESIGN PRESSURE: 8 barg DESIGN TEMP: -10 to 50 ºC
7

ELECTRICAL DATA
SUPPLY: 24V DC ENCLOSURE: Standard

POWER CONSUMPTION: 1W
ELECTRICAL CONNECTIONS: Plug-In


30/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X

SS
S
INSTRUMENT DATA SHEET
DATA SHEET FOR: Permeate Recycle Flowmeter
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: FI102 SSS REF: AR420-09247/6.12
OPERATING DATA
FLUID: Reverse Osmosis Permeate FLUID NATURE: Non Corrosive

FLUID TEMP: 5 to 35ºC FLUID pH: 5.5 to 8.0 FLUID SG: 1.0
NORMAL FLOW: 0 m³/hr MAX FLOW: 18 m³/hr
WORKING PRESSURE: 4 barg LINE SIZE: 1½" NB
MECHANICAL DATA
SCALE LENGTH: 376 mm (Tube) UNITS: m³/h

MOUNTING: Line SCALE RANGE: 1 to 9
ACCURACY: 2.5 %FSD DESIGN PRESSURE: 10 barg DESIGN TEMP: 60 ºC
CONNECTIONS: 1½" NB Solvent Weld Union WEIGHT: 2.2 kg
TUBE:
TUBE Trogamid
T id END CONNECTIONS:
CONNECTIONS ABS
FLOAT: 316 Stainless Steel END SEALS: EPDM
MATERIAL CERTIFICATES: Not Required HYDRO TEST CERTIFICATE: Not Required

CALIBRATION CERTIFICATE: Not Required ATEX CERTIFICATE: Not Required


24/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
IDS‐FLOW‐ROTO REV08 17.10.08

SS
S
DATA SHEET FOR: Feed/Backwash Flowmeter
GENERAL
OPERATING DATA

NORMAL FLOW: 40 m³/hr (667 lpm) MAX FLOW: 42.7 m³/hr

WORKING PRESSURE: 4.7 barg LINE SIZE: 3" NB
MECHANICAL DATA
SCALE LENGTH: 430 mm (Overall Length) UNITS: lpm

MOUNTING: Line SCALE RANGE: 200 to 1000
ACCURACY: +1- %FSD DESIGN PRESSURE: 6 barg DESIGN TEMP: 60 ºC
TUBE:
TUBE Trogamid
CONNECTIONS ABS (by
(b SSS)
FLOAT: Stainless Steel END SEALS: Silicone Rubber



24/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X

SS
S
DATA SHEET FOR: Sand Filter Inlet/Outlet Pressure Gauge
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: PI2 & PI3 SSS REF: AR441-09247/6.9
OPERATING DATA

MIN PRESSURE: 0 barg MAX PRESSURE: 4.5 barg NORM PRESSURE: 4.0 barg
MECHANICAL DATA
SCALE RANGE: 0 to 6 UNITS: barg

DIAL SIZE: 100 mm ACCURACY: 1% FSD MAX OVERPRESSURE: 7.8 barg
ELEMENT: Bourdon Tube
SAFETY GLASS: Yes BLOW OUT PLUG: Top
GLYCERINE FILLED: Yes MOUNTING: Panel Clamp Fixing
CONNECTION: ¼" BSPP Male Rear PANEL MOUNT CUT OUT: 106 mm
CASE: 304 Stainless Steel MOVEMENT: 304 Stainless Steel

WETTED PARTS: 316 Stainless Steel WEIGHT: 0.95 kg
DESIGN CODE: BS EN 837-1:1998

CALIBRATION CERTIFICATE: Not Required (to be verified on receipt at SSS)


28/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
IDS‐PRESSURE‐GAUGE REV08 18.10.08

SS
S
DATA SHEET FOR: Flushing/Cleaning Tank
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: T101 SSS REF: AR471/3.2
OPERATING DATA
FLUID: Acidic and Alkali RO Membrane Cleaners

FLUID NATURE: Corrosive CAPACITY: 1,000 litres
FLUID TEMP: 5 to 40 FLUID pH: 2 to 12 FLUID SG: 1.1
TANK HEIGHT: 1470 mm BODY: LMDPE

TANK DIAMETER: 990 mm LID: LMDPE
TANK LENGTH X WIDTH: N/A STAND: Mild Steel
DESIGN PRESSURE: Atmospheric COATING
TEST PRESSURE Atmospheric STAND: SSS Standard Finish (Light Grey)

CORROSION ALLOWANCE: N/A TANK INTERNAL: N/A
MANHOLE/LID TANK EXTERNAL
EXTERNAL: N/A
SIZE: 285 mm Dia (Screw-On) WEIGHT
EMPTY: 25 kg FULL: 1025 kg

ACCESSORIES
Level Switches, Overflow and Drain

CONNECTIONS
TP No. SERVICE FLANGED/SCREWED SIZE RATING
N/A Flushing Outlet SSS Special 4" NB +ve Head

N/A Flushing Return Victaulic 3" NB +ve Head
N/A Permeate Return Victaulic 2" NB +ve Head
N/A Drain/Overflow Tank Connector 3" NB +ve Head
N/A Hot/Cold Water 2 x 1" BSP Female 28mm +ve Head
DESIGN CODE: Manufacturers Standard HYDROSTATIC TEST CERTIFICATE: Not Required



07/01/2010
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
EDS‐TANK REV08 14.10.08

SS
S
DATA SHEET FOR: Sand Filter Differential Pressure Switch
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: DPS1 SSS REF: AR455/6.17
OPERATING DATA
FLUID: Seawater FLUID NATURE:Corrosive

MIN PRESSURE: 0 barg MAX PRESSURE: 5 barg NORM PRESSURE: 4.5 barg
MECHANICAL DATA
SWITCH RANGE: 0.4 to 4 barg MAX OVERPRESSURE: 30 barg

ELEMENT: Diaphragm
CONNECTION: Side SIZE: ¼" BSPP Female
WEIGHT: 2.3 kg
MATERIAL SPECIFICATION ENCLOSURE
ENCLOSURE: Aluminium Alloy Casting ENCLOSURE: Aluminium Alloy Casting

PARTS:
CONNECTIONS/WETTED PARTS 316 Stainless
St i l Steel
St l
DIAPHRAGM/TUBE/BELLOWS: Hastelloy C
ELECTRICAL SPECIFICATION
SWITCH TYPE: SPDT 1

NO OF SWITCHES:
CONTACT RATING: 250V AC 4A, 28V DC 2A

HOUSING RATING: Weatherproof (Epoxy Hardened Stove Enamel Finish)
IP RATING: IP66 ZONE: N/A GAS GROUP: N/A TEMP CLASS: N/A
DIFFERENTIAL: Fixed: 3%
SET PRESSURE: S1: 1.0 Barg Rising

CALIBRATION CERTIFICATE: Required (by SSS) ATEX CERTIFICATE: Not Required

1 05.08.09 Issued for Purchase/Manufacture Phil Eccles Phil Eccles G.Haworth

22/10/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
IDS‐PRESSUE‐OPS REV08 17.10.08

SS
S
DATA SHEET FOR: Antiscalant Chemical Dosing Pump
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: P104 SSS REF: AR534/9.5
OPERATING DATA
FLUID: Genesys SW Antiscalant Solution FLUID NATURE: Non Corrosive

FLUID TEMP: 5 to 45ºC FLUID pH: 3 to 4 FLUID SG: 1.1
DESIGN FLOW: 0.57 l/hr DESIGN PRESSURE: 4.0 barg
DUTY: Continuous barg
MECHANICAL DATA
MODEL: BT4A1601 DRIVE METHOD: Solenoid

PUMP TYPE: Diaphram STROKES PER MIN: 0 to 180
STROKE LENGTH: 1.25 mm PLUNGER/DIAPHRAGM: 48 mm
MIN FLOW: 0 l/hr MAX FLOW: 0.7 l/hr MAX PRESSURE: 10 barg
ACCESSORIES
PP Foot
F t Valve,
V l ½" BSP Injection
I j ti Valve
V l & Suction/Dosing
S ti /D i Tube,T b Semi-Conductor
S i C d t Switched
S it h d Paced
P dO Output.
t t
ELECTRICAL DATA
SUPPLY: 110V 1 Phase 60 Hz POWER: 0.02 kW IP RATING: IP65

SPEED: N/A INSULATION CLASS: F RATED CURRENT: 2.0 amps
PUMP HEAD: Polypropylene INLET: 6 x 4 Hose Connection

PLUNGER/DIAPHRAGM: Developan OUTLET: 6 x 4 Hose Connection
VALVES COATING
VALVE SEATS: EPDM EXTERNAL: Luranyl

INLET/OUTLET CONNECTIONS: PP WEIGHT
SEALS: EPDM WEIGHT: 2.9 kg

DESIGN CODE: Manufacturers Standard PERFORMANCE CERTIFICATES: Not Required



15/10/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
EDS‐PUMP‐DOSING REV08 14.10.08

SS
S
DATA SHEET FOR: Antiscalant Dosing Tanks
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: T100 SSS REF: AR471/9.1
OPERATING DATA
FLUID: Genesys SW
FLUID NATURE: Corrosive CAPACITY: 108 litres
TANK HEIGHT: 680 mm BODY: LMPDE

TANK DIAMETER: 470 mm LID: LMPDE
TANK LENGTH X WIDTH: N/A STAND: Mild Steel
DESIGN PRESSURE: Atmospheric COATING
TEST PRESSURE Atmospheric STAND: SSS Standard Finish (Light Grey)

CORROSION ALLOWANCE: N/A TANK INTERNAL: N/A
MANHOLE/LID TANK EXTERNAL
EXTERNAL: N/A
SIZE: 155mm Dia (Screw On) WEIGHT
EMPTY: 5 kg FULL: 113 kg

ACCESSORIES
Manual Agitator, Drain Valve & Filling Valve

CONNECTIONS
TP No. SERVICE FLANGED/SCREWED SIZE RATING
N/A Dosing Pump Suction Tube 6x4 +ve Head

N/A Drain Tank Connector 1" NB +ve Head
N/A Filling Tank Connector ½" NB +ve Head
DESIGN CODE: Manufacturers Standard HYDROSTATIC TEST CERTIFICATE: Not Required



15/10/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
EDS‐TANK REV08 14.10.08

SS
S
DATA SHEET FOR: Cartridge Filter
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: PV100 SSS REF: AR505-09247/7.1
OPERATING DATA
FLUID: Seawater/Mild Detergents Corrosive

FLUID NATURE:

INLET PRESSURE: 4 barg MAXIMUM DIFFERENTIAL PRESSURE: 2.07 barg
FLOWRATE: 40 m³/hr MAXIMUM RATED FLOWRATE: 57 m³/hr
INLET QUALITY: Micron Nominal OUTLET QUALITY: 10 Micron Absolute
TYPE: Horizontal 8" Single HOUSING/SHELL: Glass Fibre Epoxy Resin

HEIGHT OVERALL: 1890 mm LID/FLANGES: Epoxy Glass Bearing Plate
INSIDE DIAMETER: 201.9 mm INTERNALS: Glass Fibre Epoxy Resin
DESIGN PRESSURE: 10.3 Barg GASKETS/SEALS: EPDM
TEST PRESSURE 15 5 barg
15.5 b BOLTING
BOLTING: 316 Stainless
St i l Steel
St l QR Spiral
S i l Ring
Ri
DESIGN TEMP: 49 ºC CARTRIDGES
CORROSION ALLOWANCE: 0 mm NO: 1 TYPE: Aqualine

CONNECTIONS DIAMETER: 171.5 mm LENGTH: 1020 mm
INLET: 3" NB Victaulic (Epoxy Glass) MATERIAL: Polypropylene
OUTLET: 3" NB Victaulic (Epoxy Glass) CORE MATERIAL: Polypropylene
DRAIN: 1" NPT RATING: 10 Micron Absolute
AIR RELEASE: 1" NPT
COATING VESSEL WEIGHT
INTERNAL/EXTERNAL: White High Glass Polymaethane Paint DRY: TBC kg WET: TBC kg
DESIGN CODE: Manufacturers Standard MATERIAL CERTIFICATE: Not Required

NDT: None HYDRO TEST CERTIFICATE Not Required
RADIOGRAPHY: None


23/10/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
EDS‐VESSEL‐CF REV08 16.10.08

SS
S
DATA SHEET FOR: Cartridge Filter Inlet/Outlet Pressure Gauge
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: PI100/PI101 SSS REF: AR441-09247/6.9
OPERATING DATA
FLUID: Seawater/Mild Detergents FLUID NATURE: Corrosive

MECHANICAL DATA

CONNECTION: ¼" BSPP Male Rear PANEL MOUNT CUT OUT: 106 mm




28/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X

SS
S
DATA SHEET FOR: HP Pump Suction Pressure Switch
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: PS100 SSS REF: AR455/6.18
OPERATING DATA

FLUID TEMP: 5 to 35 ºC FLUID pH: 2 to 12 FLUID SG: 1.025
MIN PRESSURE: 2 MAX PRESSURE: 4.3 Barg NORM PRESSURE: 2 to 3 barg
MECHANICAL DATA
SWITCH RANGE: 0.2 to 3.0 barg MAXIMUM OVERPRESSURE: 30 barg

ELEMENT: Diaphragm
PROCESS CONNECTION: Bottom SIZE: ¼" BSPP Female
MATERIAL SPECIFICATION PROTECTIVE CLOTHING
ENCLOSURE: Aluminium Alloy Casting Epoxy Hardened Stove Enamel Finish

CONNECTIONS: 316 Stainless Steel
DIAPHRAGM/TUBE/BELLOWS
DIAPHRAGM/TUBE/BELLOWS: H t ll C
Hastelloy WEIGHT
WEIGHT: 1 3 kg
1.3 k
ELECTRICAL DATA
SWITCH TYPE: SPDT NO OF SWITCHES: 1

CONTACT RATING: 250 V AC 4A, 28V DC 2A
HOUSING RATING: Weatherproof
SET PRESSURE: S1: 1.3 Barg Falling

CALIBRATION CERTIFICATE: Required (by SSS) ATEX CERTIFICATE: Not Required


22/10/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
IDS‐PRESSURE‐SWITCH REV08 18.10.08

SS
S
DATA SHEET FOR: HP Pump
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: P100, P101, P102 & P103 SSS REF: AR422-09247/4.1
OPERATING DATA

DESIGN FLOW: 10 m³/hr DESIGN PRESSURE:80 barg
DUTY: Continuous SUCTION PRESSURE: 2 to 3 barg
RELIEF VALVE SET PRESSURE 83 barg
MECHANICAL DATA
MODEL: APP 10.2 DRIVE METHOD: Direct
SPEED: 1783 rpm RATED MAX SPEED: 1800 rpm NO. OF CYLINDERS: 9
DISPLACEMENT: 100cm³/rev LUBRICATION: Pumped Fluid
MIN SUCTION PRESSURE: 1 barg (Absolute) MAX SUCTION PRESSURE: 5 barg
POWER 24.7
DESIGH ABSORBED POWER: 24 7 kW POWER 30 kW
MAX ABSORBED POWER:
MOTOR DATA
SEE EQUIPMENT DATA SHEET EDS NO: S09247-DS20

HEAD: UNS S32750 Super Duplex St/St INLET: 1½" NB Victaulic OUTLET: 1½" NB Victaulic
PLUNGERS: UNS S32750 Super Duplex St/St COATING
PORT PLATE: UNS S32750 Super Duplex St/St EXTERNAL: N/A

WEIGHT
WEIGHT:
DESIGN CODE: Manufacturers Standard



25/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
EDS‐PUMP‐AXIAL PISTON REV 05 14.10.08

SS
S
DATA SHEET FOR: High Pressure Pump Motor
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: M100, M101, M102 & M1 SSS REF: AR421-09247/4.7
OPERATING DATA
STARTING METHOD: D-O-L STARTS PER HOUR: Max. 6

SPEED: Fixed POWER REQUIRED: 24.7 kW
MECHANICAL DATA
FRAME SIZE: 180 lb RATED OUTPUT: 32.5 kW EFFICIENCY: 93.2 to 93.9 %

SYNCHRONOUS SPEED: 1800 rpm FULL LOAD SPEED:1765 rpm
MOUNTING: Vertical Flange (V1) COOLING: TEFC
BEARINGS: 6310-2Z/C3-6209-2Z/C3 LUBRICATION: Grease
POLES 4
NO OF POLES:
NO. CONNECTION 2 x M40
TERMINAL BOX CONNECTION:
TERMINAL BOX POSITION (FROM SHAFT END): Top WEIGHT: 161 kg
ELECTRICAL DATA
SUPPLY: 440V 3 Ph 60 Hz RATED CURRENT:54 amps

ENCLOSURE: Tropicalised INSULATION CLASS: F
IP RATING: 55 ZONE: N/A GAS GROUP: N/A TEMP CLASS: B
POWER FACTOR: 0.79 COSØ
FRAME: Cast Aluminium FAN: Polypropylene

FAN COWL: Mild Steel TERMINAL BOX: Cast Aluminium
PROTECTIVE COATING
Polyester Powder Paint > 60µm Munsell Blue

PERFORMANCE CURVES: Not Required ATEX CERTIFICATE: Not Required


25/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
SS
S
DATA SHEET FOR: HP Flushing Return Ball Valve
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: V102 SSS REF: AL603/C
OPERATING DATA
FLUID: Seawater & RO Membrane Cleaning Solutions FLUID NATURE: Corrosive

MAXIMUM WORKING PRESSURE: 83 barg
MECHANICAL DATA
TYPE: 2-Way
SIZE: 2" NB DESIGN: (Class 800) 138 barg DESIGN TEMP: 200 to +260ºC
BORE: Full END CONNECTIONS: Butt Weld x BSPP
ACTUATION: Lever Handle SEE EDS NO: N/A
VALVE Kv (L/min @ 1 barg): 3783 WEIGHT: 10 kg
BODY
BODY: F53 (UNS S32750 Super
S D l St/St)
Duplex ENDS
ENDS: F53 (UNS S32750 Super
S Duplex
D l St/St)
BALL: F53 (UNS S32750 Super Duplex St/St) STEM: F53 (UNS S32750 Super Duplex St/St)
END SEALS: TSVG & Graphite SEAT: TRSBU
HANDLE: Stainless Steel FASTENERS: Stainless Steel

HYDROSTATIC TEST: Not Required SEAT LEAKAGE TEST CERTIFICATE: Not Required


30/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
EDS‐VALVE‐BALL REV08 14.10.08

SS
S
DATA SHEET FOR: HP Pump Discharge Pressure Switch
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: PS101 SSS REF: AR455/6.19
OPERATING DATA

MIN PRESSURE: 0 barg MAX PRESSURE: 81 barg NORM PRESSURE: 55 to 75 barg
MECHANICAL DATA
SWITCH RANGE: 20 to 210 barg MAXIMUM OVERPRESSURE: 350 barg

ELEMENT: Diaphragm
PROCESS CONNECTION: Bottom SIZE: ¼" NPT
MATERIAL SPECIFICATION PROTECTIVE CLOTHING
ENCLOSURE: Aluminium Alloy Casting Epoxy Hardened Stove Enamel Finish

CONNECTIONS: 316 Stainless Steel
DIAPHRAGM/TUBE/BELLOWS
DIAPHRAGM/TUBE/BELLOWS: H t ll C
Hastelloy WEIGHT
WEIGHT: 1 3 kg
1.3 k
ELECTRICAL DATA
SWITCH TYPE: SPDT NO OF SWITCHES: 1

CONTACT RATING: 250V AC 4A, 28V DC 2A
SET PRESSURE: S1: 81 Barg Rising

CALIBRATION CERTIFICATE: Not Required (by SSS) ATEX CERTIFICATE: Not Required


22/10/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
IDS‐PRESSURE‐SWITCH REV08 18.10.08

SS
S
DATA SHEET FOR: RO Membrane Pressure Vessels
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: PV101 to PV109 incSSS REF: AQ937/5.2
OPERATING DATA
FLUID: Seawater/Mild Detergents

FLUID NATURE: Corrosive FLUID pH: 2 to 12 FLUID SG: 1.025
OPERATING PRESSURE 4 to 75 barg FLUID TEMP: 5 to 40 ºC
NO OF VESSELS: 8 MEMBRANE SIZE: 8" MEMBRANE TYPE: SW30HRLE-400
MEMBRANE MANUFACTURER: FilmTec NO MEMBRANES PER VESSEL: 3
DESIGN PRESSURE: 83 Barg VESSEL: Glass Fibre Epoxy Resin

DESIGN TEMPERATURE -7 to 49ºC FEED PORT: SAF2507 Super Duplex Stainless Steel
TEST PRESSURE 124.5 barg REJECT PORT: SAF2507 Super Duplex Stainless Steel
OVERALL LENGTH: 3683 mm PERMEATE PORT: PVC Thermoplastic
VESSEL END LENGTH:
LENGTH 305 mm 'O' RING SEALS:
SEALS EPDM
SUPPORT CENTRES: 2032 mm END CAP: PVC Thermoplastic
VESSEL BODY OD: 241 mm END PLUG: Engineer Thermoplastic
VESSEL ENDS OD: 277 mm BEARING PLATE: 6061-T6 Aluminium Hard Anodised
VESSEL ID: 202.1 mm SEGMENTED RING: 316 Stainless Steel QR Retaining Ring
CONNECTIONS COATING
FEED: 1½" NB Victaulic EXTERIOR ONLY: High Gloss Polyurethane Paint

CONCENTRATE: 1½" NB Victaulic COLOUR: White
PERMEATE PORT FEED END: 1¼" NPT Male VESSEL WEIGHT
PERMEATE PORT OPPOSITE END: ½" NPT Female DRY: 113 kg WET: 262 kg
DESIGN CODE: Generally to AMSE X

MATERIAL CERTIFICATE: Required HYDRO TEST CERTIFICATE Required

Invalid signature
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
EDS‐VESSEL‐RO REV08 16.10.08

SS
S
DATA SHEET FOR: RO Membrane Elements
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: N/A SSS REF: AR422-09247/5.1
MEMBRANE MODEL NOS: SW30HRLE-400 NUMBER REQ: 24
PLANT DESIGN DATA
FEED WATER Seawater & Mild Detergents Occasionally

FEED TEMPERATURE: 5 to 40ºC FEED FLOW: 40 m³/hr
FEED TDS: 35,011 to 42,000 MEMBRANE ARRAY: 4:6
PLANT OUTPUT FLOW: 16.7 to 18 m³/hr PLANT OUTPUT TDS: <500 mg/l
OVERALL PLANT RECOVERY: 41 to 45 %
MEMBRANE DATA
MEMBRANE TYPE: Spiral Wound Thin Film Composite
MEMBRANE MATERIAL: Polyamide MANUFACTURER: FilmTec
MAX OPERATING PRESSRUE: 83 barg MAX OPERATING TEMP: 45 ºC
MAX FEED TURBIDITY: 1 NTU MAX FEED SDI: 5 MAX CHLORINE: 0 ppm
PH INTERMITTANT: 1 - 12 PH CONT: 2 -11 MAX RECOVERY: 8%
MAX FEED FLOW: 16.8 m³/hr RATED PRODUCT FLOW: 28 m³/day
MIN CHLORIDE REJECTION 99 60%

99.60% TYPICAL CHLORIDE REJECTION:
REJECTION 99 75%
99.75%
SIZE: 8 Dia x 40" Length WEIGHT: 17 kg
CLEANING CHEMICALS
3 to 4% Low pH Genesol 38 Cleaner

2 to 3% High pH Genesol 40 Cleaner
PRESERVING CHEMICALS
Solution of 1% Sodium Metabisulphite


25/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
EDS‐MEMBRANE REV08 26.09.08

SS
S
DATA SHEET FOR: Membrane Stack Inlet/Outlet Pressure Gauge
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: PI102/PI103 SSS REF: AR441-09247/6.10
OPERATING DATA

MIN PRESSURE: 0 barg MAX PRESSURE: 69 barg NORM PRESSURE: 60 to 68 barg
MECHANICAL DATA

DIAL SIZE: 100 mm ACCURACY: 1% FSD MAX OVERPRESSURE: 130 barg
CONNECTION: ¼" NPT Male Rear PANEL MOUNT CUT OUT: 106 mm

DESIGN CODE: Manufacturers Standard BS EN 837-1:1998



28/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X

SS
S
DATA SHEET FOR: Reject Control Valve
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: V101 SSS REF: AP500-STK-R02
OPERATING DATA
FLUID: RO Reject (Brine) Corrosive

FLUID NATURE:

LINE SIZE: 3" NB FLOWRATE NORMAL: 23.3 FLOWRATE MAXIMUM: 40 m³/hr
CONTROL INLET PRESSURE: upto 72 barg CONTROL DISCHARGE PRESSURE 2 barg
CLOSED VALVE DP: 83 barg FULLY OPEN DP: <10 CONTROL DP: upto 75 barg
MECHANICAL DATA
TYPE: Globe (RCVMK1-40) TRIM TYPE: Equal Percent (Flow Under)

VALVE SIZE: 1 1/2" NB DESIGN PRESSURE: 83 barg DESIGN TEMP: 50ºC
END CONNECTIONS: 1 1/2" NB Victaulic
ACTUATION: Handwheel/Manual (9" Diameter) SEE EDS NO: N/A
BODY BONNET: Super Duplex St/St 25% Cr NEEDLE/PLUG: Super Duplex St/St
STEM: Super Duplex St/St 25% Cr GLAND PACKING: PTFE
SEAT: Super Duplex St/St 25% Cr FASTENERS: 304 Stainless Steel
OTHER
VALVE kV (L/min @ 1 barg): TBC WEIGHT: 25 kg
MATERIAL CERTS: Required DIN 50049/3.1B SEAT LEAKAGE: BS6755:1986

HYDROSTATIC TEST: Required SEAT LEAKAGE TEST: Not Required


24/02/2010
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
EDS‐VALVE‐CONTROL REV08 15.10.08

SS
S
DATA SHEET FOR: HP Pump Discharge Pressure Relief Valve
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: PSV100 SSS REF: AQ936/1.2
OPERATING DATA

RELIEVING FLOW: 40 m³/hr NORMAL LINE PRESSURE: 69 barg
VALVE DISCHARGE BACKPRESSURE: 0 barg LINE SIZE: 3" NB barg
MECHANICAL DATA
SET PRESSURE: 83
SET PRESSURE TOLERANCE: ± 2% barg
OVERPRESSURE 10% BLOWDOWN: 20%
RATED CAPACITY: 47.3 m³/hr EASING LEVER: Not Required
VALVE ORIENTATION: Vertical
WEIGHT
WEIGHT: 7 3 kg
7.3 k
INLET CONNECTION: 1" NPT Male
OUTLET CONNECTION: 1½" NPT Female
BODY: UNS S31803 Duplex Stainless Steel SPRING: 316 Stainless Steel (Non-Wetted)
SEAT: UNS S31803 Duplex Stainless Steel SEALS: 316 Stainless Steel (Non-Wetted)
DISC: 316 Stainless Steel (Non-Wetted) NOZZLE: 316 Stainless Steel (Non-Wetted)
NOTE: All Wetted Parts are Duplex Stainless Steel
DESIGN CODE: ASME Sec VIII

MATERIAL CERTIFICATE: Required DIN 50049/3.1B HYDRO TEST CERTIFICATE Required
SIZING CALCULATIONS: Required SET PRESSURE TEST CERTIFICAT Required (by SSS)
SEAT LEAKAGE TEST CERTIFICATE: Not Required


Invalid signature
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
EDS‐VALVE‐PSV REV09 16.10.08

SS
S
DATA SHEET FOR: Feed/Permeate Flow Transmitter
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: FT100 & FT101 SSS REF: AR422-09247/6.4
ENVIRONMENT: Non Corrosive AREA: Safe
OPERATING DATA
FLUID: Seawater, Mild Detergents & RO Permeate FLUID NATURE: Non Corrosive
FLOW MIN: 0 m³/hr FLOW MAX: 40 m³/hr FLOW NORMAL: 40 m³/hr & 16.7 m³/hr
MAX PRESSURE: 4 barg LINE SIZE: 3" NB (Feed) & 2" NB (Permeate)
WEIGHT: 0.325 kg (Meter)
MECHANICAL DATA
UNITS: m³/hr
TYPE: Paddlewheel MOUNTING: Panel
INDICATION: Digital FLOW SWITCHES FITTED: Yes (Open Collector)
DIAL SIZE: 2 x 16 LCD SCALE RANGE: 0 to 60 m³/hr ACCURACY: +/- 0.5% of reading
CONNECTION
CONNECTION: 3" NB PN16 Flanged
Fl d (Feed)
(F d) 2" NB Union
U i TeeT (Permeate)
(P t )
BODY: Polypropylene TURBINE/PADDLEWHEEL: PVDF CASE: PBT

TEE: Polypropylene (Feed) & uPVC (Permeate)
ELECTRICAL DATA

ELECTRICAL SUPPLY: EXTERNAL: 24 Volt DC
OUTPUT SIGNAL: 2 x 4-20mA & 2 x Open Collectors (30V DC, 50mA)

CALIBRATION CERTIFICATE: Yes (by SSS) ATEX CERTIFICATE: No


25/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
IDS‐FLOW‐TURBINE REV08 17.10.08

SS
S
DATA SHEET FOR: RO Permeate Pressure Gauge
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: PI104 SSS REF: AR441-09247/6.9
OPERATING DATA
FLUID: Reverse Osmosis Permeate FLUID NATURE: Aggressive

FLUID TEMP: 5 to 35ºC FLUID pH: 6 FLUID SG: 1.0
MECHANICAL DATA

CONNECTION: ¼" BSPP Male Rear PANEL MOUNT CUT OUT: mm
CASE: 304 St/St MOVEMENT: 304 St/St

WETTED PARTS: 316 St/St WEIGHT: 0.95 kg



28/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X

SS
S
DATA SHEET FOR: Feed/Permeate Conductivity Analyser
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: DIC100 SSS REF: AR422-09247/6.1
OPERATING DATA
FLUID: Seawater & RO Permeate FLUID NATURE: Corrosive

MECHANICAL DATA
SCALE RANGE: 0.055 to 400,000 UNITS: µS/cm MOUNTING: Panel

INDICATION: Digital DISPLAY SIZE: 2 x 16 LCD ACCURACY: ± 2% of reading
TEMP COMPENSATION: Automatic @ 2% per ºC ENCLOSURE MATERIAL: PBT
CONDUCTIVITY/CELL INFORMATION
CELL DESCRIPTION FEED CONDUCTIVITY PERMEATE CONDUCTIVITY
CELL TYPE Contacting Inductive Contacting Inductive

CELL CONSTANT K= 10.0 K= 0.1
CELL DESIGN PRESSURE 6 9 barg
6.9 b 66.9
9 bbarg
CELL DESIGN TEMPERATURE 100 ºC 100 ºC
CELL CABLE LENGTH 4.6 m 4.6 m
PROCESS CONNECTIONS ¾" NPT-M ¾" NPT-M
CELL BODY MATERIAL CPVC & 316 Stainless Steel 316 Stainless Steel
CELL ELECTRODE MATERIAL 316 Stainless Steel 316 Stainless Steel
PROCESS FLUID Seawater RO Permeate
ELECTRICAL DATA

CABLE ENTRY: N/A SWITCHES: Two ALARM SET POINT: 1000 µS/cm Rising (Break Make on Alarm)
SWITCH CONTACT RATING: 5A 30V DC SIGNAL OUTPUT: 3 x 4-20mA
CALIBRATION CERTIFICATE: by SSS ATEX CERTIFICATE: Not Required


25/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
IDS‐ANALYSER‐COND REV09 16.10.08

SS
S
DATA SHEET FOR: Permeate Supply Valve - Diaphragm Valves
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: V116 SSS REF: AR418-09247/1.18
OPERATING DATA
FLUID: Fluid Osmosis Permeate FLUID NATURE: Aggressive

MECHANICAL DATA
SIZE: 2" NB DESIGN PRESSURE: 10 barg DESIGN TEMP: 80 ºC

ACTUATION: Pneumatic SEE EDS NO: S09247-DS32
END CONNECTIONS: 2" NB Solvent Weld Union

DIAPHRAGM: EPDM



22/10/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X

SS
S
DATA SHEET FOR: Permeate Supply & Return Valve - Pneumatic Actuator
GENERAL
OPERATING DATA

STROKE ADJUSTER: No
MANUAL OVERRIDE: No
GENERAL
LOCATION: Panel Mounted TAG NO: SV116 & SV

ENVIRONMENT
ENVIRONMENT: S lif
TEMP 5 to
t 50
MECHANICAL DATA
FLOW: 200N l/min @ 6 barg DESIGN PRESSURE: 8 barg DESIGN TEMP: -10 to +50 ºC
CONNECTIONS: 6mm Push-In ORIFICE DIAMETER: 3mm
7

ELECTRICAL DATA
SUPPLY: 24 V DC ENCLOSURE: Standard



22/10/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X

SS
S
DATA SHEET FOR: Permeate Dump Valve - Diaphragm Valves
GENERAL
OPERATING DATA

MECHANICAL DATA


DIAPHRAGM: EPDM



30/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X

SS
S
DATA SHEET FOR: Permeate Dump Valve - Pneumatic Actuator
GENERAL
OPERATING DATA

FAIL SAFE POSITION: Normally Open
STROKE ADJUSTER: No
MANUAL OVERRIDE: No
GENERAL
LOCATION: Panel Mounted TAG NO: SV115

ENVIRONMENT
ENVIRONMENT: S lif
TEMP 5 to
t 50 ºC
MECHANICAL DATA
7

ELECTRICAL DATA

SIZE OF COIL: Plug-In
ELECTRICAL CONNECTIONS:

1 05.08.09 Issued for Purchase/Manufacure Phil Eccles Phil Eccles G Haworth

30/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X

SS
S
DATA SHEET FOR: Permeate & Rehardener Relief Valves
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: PSV101/PSV200 SSS REF: AR419-09247/1.4
OPERATING DATA

RELIEVING FLOW: 16.7 m³/hr NORMAL LINE PRESSURE: 2.0 barg
VALVE DISCHARGE BACKPRESSURE: 0 barg LINE SIZE: 2" NB
MECHANICAL DATA
SET PRESSURE: 4.0 barg

SET PRESSURE TOLERANCE: ± 3%
VALVE ORIENTATION: Vertical Upright
WEIGHT
WEIGHT: 2 6 kg
2.6 k
INLET CONNECTION: 1" BSP Female
OUTLET CONNECTION: 1½" BSP Female
BODY: Gunmetal BS1400 LG2 SPRING: St/St BS 2056-302-S26

SEAT: Viton SEALS: Viton
DISC: 316 Quality St/St
DESIGN CODE: BS6759 Parts 1, 2 & 3

MATERIAL CERTIFICATE: Not Required HYDRO TEST CERTIFICATE Not Required
SIZING CALCULATIONS: Not Required SET PRESSURE TEST CERTIFICAT Required by SSS


24/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X

SS
S
DATA SHEET FOR: Rehardener
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1&2 TAG NO: PV200 SSS REF: AR913/8.08
OPERATING DATA
FLUID: Reverse Osmosis Permeate

FLOW RATE: 16.7 m³/hr INLET PRESSURE: 1.5 barg
FLUID TEMP: 5 to 35 ºC FLUID pH: 6 to 7 OUTLET pH: 8 to 9
DOLOMITIC MEDIA USEAGE: 1.3 kg/day TOP UP FREQUENCY: Monthly
BACKFLUSH FREQUENCY: N/A BACKFLUSH RATE: N/A
TYPE: Vertical SHELL: S275JR-430B

HEIGHT OVERALL: 1800 mm DISHED ENDS: S275JR-430B
INSIDE DIAMETER: 1100 mm MAIN VESSEL FLANGES: BS1501-151-430A
DESIGN PRESSURE: 4 barg NOZZLES: Polypropylene
TEST PRESSURE:
PRESSURE 6 barg
b NON PRESSURE PARTS BS 4360 43A
DESIGN TEMP: 0 to 45 ºC GASKETS: 6 mm Thk Neoprene
CORROSION ALLOWANCE: 1 mm BOLTING: A2 Grade Stainless Steel
CONNECTIONS MEDIA
INLET: 125 NB EN1092-1:2001 PN16 DOLOMITIC MEDIA: Juraperle

OUTLET: 80 NB EN1092-1:2001 PN16 COATING
VENT: INTERNAL: ScotchKote 206N FBE

RELIEF: 40 NB EN1092-1:2001 PN16 EXTERNAL: ScotchKote 206N FBE
FILLING: 200 NB EN1092-1:2001 PN16 VESSEL WEIGHT
INSP HOLE200 NB EN1092-1:2001 PN16 DRY: TBC kg WET: TBC kg

DESIGN CODE: Generally to PD5500:2009 Cat III

MATERIAL CERTIFICATES: Required RADIOGRAPHY: None
NDT: None HYDROSTATIC TEST: Required


11/12/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
EDS‐VESSEL‐REHARD REV08 23.10.08

SS
S
DATA SHEET FOR: Rehardener Control Valves, Reject Backpressure Valve - Diaphragm Valves
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: V200, V202, V114 SSS REF: AR418-09247/1.16
OPERATING DATA

FLUID TEMP: 5 to 35 ºC FLUID pH: 6.0 to 8.0 FLUID SG: 1.0
MECHANICAL DATA

ACTUATION: Handwheel Actuator SEE EDS NO: N/A

DIAPHRAGM: EPDM



30/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X

SS
S
DATA SHEET FOR: Rehardener By-Pass Flowmeter
GENERAL
OPERATING DATA
FLUID: Reverse Osmosis Permeate FLUID NATURE: Non Corrosive

FLUID TEMP: 5 to 35 ºC FLUID pH: 5.5 to 8.0 FLUID SG: 1.0
NORMAL FLOW: 0 m³/hr MAX FLOW: 18 m³/hr
WORKING PRESSURE: 1.5 barg LINE SIZE: 2" NB
MECHANICAL DATA
SCALE LENGTH: 376 mm (Tube) UNITS: m³/hr

MOUNTING: Line SCALE RANGE: kg
ACCURACY: 2.5 %FSD DESIGN PRESSURE: 10 barg DESIGN TEMP: 60 ºC
TUBE:
TUBE Trogamid
CONNECTIONS ABS
FLOAT: 316 Stainless Steel END SEALS: EPDM



24/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X

SS
S
DATA SHEET FOR: CO2 Solenoid Dosing Valve
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: V209 SSS REF: AR455/6.20
OPERATING DATA
FLUID: CO2 Gas FLUID NATURE: Aggressive

FLUID TEMP: Ambient FLUID pH: 6 FLUID SG: 1.0
MAXIMUM WORKING PRESSURE: barg
MECHANICAL DATA
SIZE: ⅛" NB DESIGN PRESSURE: 70 barg DESIGN TEMP: TBC

Kv (L/min @ 1 barg): ⅛" FAILSAFE POSITION: Closed
CONNECTIONS: ⅛" NPT Female
BODY: Stainless Steel SEALS: Cast Urethane Disc

ENDS: Stainless Steel
ELECTRICAL DATA
SUPPLY: 110V 60Hz AC ENCLOSURE: Standard

IP RATING: IP65 ZONE: N/A GAS GROUP: N/A TEMP CLASS: F
POWER CONSUMPTION: (In Rush) AC 110VA (Hold) AC 23.6 VA W
SIZE OF COIL: CM12-FT
ELECTRICAL CONNECTIONS: LED DIN Plug
OTHER

HYDROTEST: Not Required SEAT LEAKAGE TEST: Not Required


11/12/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
EDS‐VALVE‐2WSOL REV08 14.10.08

SS
S
DATA SHEET FOR: CO2 Flowmeter
GENERAL
OPERATING DATA
FLUID: CO2 FLUID NATURE: Aggressive

FLUID TEMP: Ambient FLUID pH: 6.0 FLUID SG: 1.0
NORMAL FLOW: 85g/hr CO2 MAX FLOW: 100g/hr CO2
WORKING PRESSURE: 2 barg LINE SIZE: 6mm OD
MECHANICAL DATA
SCALE LENGTH: 116 mm UNITS: lpm

MOUNTING: Line SCALE RANGE: 0.2 to 2.0
ACCURACY: ±/-10% FSD DESIGN PRESSURE: 30 barg DESIGN TEMP: 75 ºC
CONNECTIONS: ¼" BSP-F WEIGHT: 0.3 kg
TUBE
TUBE: Acrylic
A li END CONNECTIONS:
CONNECTIONS AISI 316 Stainless
St i l Steel
St l
FLOAT: Plastic END SEALS: EPDM
NOTE: Screwdriver adjustable needle valve. Flowmeter ranged for CO2 @ ATP 2 Bar A, 20ºC.



24/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X

SS
S
DATA SHEET FOR: Flushing Pump
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: P104 SSS REF: AR472/3.1
OPERATING DATA
FLUID: Mild Detergent (Membrane Cleaning) Solutions FLUID NATURE: Non Corrosive

DUTY: Continuous Intermittant SUCTION CONDITIONS: Flooded
MAIN DUTY FLOW: 36 m³/h @ 4.3 barg
ANCILLARY DUTY FLOW: N/A
MECHANICAL DATA
PUMP TYPE: Multistage Centrifugal MODEL: CRN32-2

MAX DISCHARGE PRESSURE: 5.7 barg PUMP SPEED: 3500 rpm
DRIVE: Vee Belt Coupling Direct ROTATION (SHAFT END): Anti-Clockwise
INSTALLED POWER: 7.5 kW @ 60 Hz MAIN DUTY ABSORBED POWER: 6.3 kW
MOTOR DATA
SUPPLY: 440V 3 pH 60 Hz FRAME: 132SD (FF265) COOLING: TFC

IP RATING: 55 INSULATION CLASS: F POLES: 2 SPEED: 3500 rpm
CASING & COVER: 316 Quality Stainless Steel INLET: 2½" NB BS4504 PN16 Flange
IMPELLOR: 316 Quality Stainless Steel OUTLET: 2½" NB BS4504 PN16 Flange
SHAFT: 316 Quality Stainless Steel COATING
WEIGHT EXTERNAL: Std Manufacturers Finish

WEIGHT: 97 kg
DESIGN STANDARDS: Manufacturers Standard

MATERIAL CERTIFICATES: Not Required HYDRO TEST CERTIFICATE Not Required
PERFORMANCE CERTIFICATES: Not Required Type Performance Curves Only


22/10/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
EDS‐PUMP‐CENTRIF REV08 14.10.08

SS
S
DATA SHEET FOR: Flushing Pump Motor
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: M104 SSS REF: AR472/3.1
OPERATING DATA
STARTING METHOD: D-O-L STARTS PER HOUR: Max. 6

SPEED: Fixed POWER REQUIRED: 6.3 kW
MECHANICAL DATA
FRAME SIZE: 132SD RATED OUTPUT: 7.5 kW EFFICIENCY: 89.50%

SYNCHRONOUS SPEED: 350 rpm FULL LOAD SPEED:3490-3530 rpm
MOUNTING: Vertical Flanged COOLING: TEFC
BEARINGS: LUBRICATION: Sealed for Life
NO OF POLES:
NO. POLES 2 CONNECTION 2 x M20 x 1.5
TERMINAL BOX CONNECTION: 15
TERMINAL BOX POSITION (FROM SHAFT END): RH Side WEIGHT: N/A
ELECTRICAL DATA
SUPPLY: 440 V 3 Ph 60Hz RATED CURRENT:12.8 amps

ENCLOSURE: Standard INSULATION CLASS: F
IP RATING: IP55 ZONE: N/A GAS GROUP: N/A TEMP CLASS: B
POWER FACTOR: 0.79 - 0.9 COSØ
FRAME: Cast Aluminium FAN: Polypropylene

FAN COWL: Mild Steel TERMINAL BOX: Cast Aluminium
PROTECTIVE COATING
Manufacturers Standard
PERFORMANCE CURVES: Not Required ATEX CERTIFICATE: Not Required

1 05.08.09 Issued for Purchase/Manufacturer Phil Eccles Phil Eccles G Haworth

22/10/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
SS
S
DATA SHEET FOR: LP Feed Relief Valve
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: PSV103 SSS REF: AR419-09247/1.32
OPERATING DATA
FLUID: Brine (Concentrated Seawater) FLUID NATURE: Corrosive

FLUID TEMP: 5 to 40 FLUID pH: 2 to 12 FLUID SG: 1.025
RELIEVING FLOW: 40 m³/hr NORMAL LINE PRESSURE: 2.0 barg
VALVE DISCHARGE BACKPRESSURE: 0 barg LINE SIZE: 3" NB barg
MECHANICAL DATA

WEIGHT
WEIGHT: 11 4 kg
11.4 k
INLET CONNECTION: 1½" BSPP Female
BODY: Gunmetal BS1400 LG2 SPRING: St/St BS2056-302-S26 @Gr11

SEAT: Viton (Soft Seat) SEALS: Viton
DISC: Gunmetal BS1400 LG2

SIZING CALCULATIONS: Not Required SET PRESSURE TEST CERTIFICAT Required (by SSS)


24/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X

SS
S
DATA SHEET FOR: Plant Inlet Valve
GENERAL
OPERATING DATA

MECHANICAL DATA


SHAFT
D l Stainless
St i l Steel
St l PINS
D l Stainless
St i l Steel
St l
SEAT: Nitrile



22/10/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X

SS
S
DATA SHEET FOR: Plant Inlet Valve Pneumatic Actuator
GENERAL
OPERATING DATA

POSITIONAL INDICATOR: Optical Limit Switches Rating: 11A @ 24V DC
STROKE ADJUSTER: No
MANUAL OVERRIDE: Yes Gearbox Type

GENERAL

ENVIRONMENT
ENVIRONMENT: S lif
TEMP 5 to
t 50 ºC
MECHANICAL DATA
FLOW: 200N l/min @ 6 barg DESIGN PRESSURE: 8 barg DESIGN TEMP: -10 to 50 ºC
CONNECTIONS: 6 mm Push-In ORIFICE DIAMETER: 3 mm
7

ELECTRICAL DATA

IP RATING: IP20 ZONE: N/A GAS GROUP: N/A INSULATION CLASS: F


22/10/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X

SS
S
DATA SHEET FOR: Plant Overboard Discharge Valve
GENERAL
OPERATING DATA
FLUID: Seawater/Mild Detergents FLUID NATURE: Non Corrosive

MECHANICAL DATA

ACTUATION: Lever Gearbox Pneumatic Electric Actuator SEE EDS NO: S09247-DS47

SHAFT
D l Stainless
St i l Steel
St l PINS
D l Stainless
St i l Steel
St l
SEAT: Nitrile



30/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X

SS
S
DATA SHEET FOR: Plant Overboard Discharge Valve Pneumatic Actuator
GENERAL
OPERATING DATA

POSITIONAL INDICATOR: Optical Limit Switches Rating: 11A @ 24V DC
STROKE ADJUSTER: No
MANUAL OVERRIDE: No
GENERAL

ENVIRONMENT
ENVIRONMENT: S lif
TEMP 5 to
t 50 ºC
MECHANICAL DATA
CONNECTIONS: 6 mm Push-In ORIFICE DIAMETER: 3 mm
7

ELECTRICAL DATA

IP RATING: IP20 ZONE: N/A GAS GROUP: N/A INSULATION CLASS: F



30/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X

SS
S
DATA SHEET FOR: Reject Relief Valve
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: PSV102 SSS REF: AR419-09247/1.5
OPERATING DATA
FLUID: Brine(Concentrated Seawater) FLUID NATURE: Corrosive

RELIEVING FLOW: 30 m³/hr NORMAL LINE PRESSURE: 2.0 barg
VALVE DISCHARGE BACKPRESSURE: 0 barg LINE SIZE: 3" NB
MECHANICAL DATA

RATED CAPACITY: 52.9 m³hr EASING LEVER: Not Required
WEIGHT
WEIGHT: 11 4 kg
11.4 k
INLET CONNECTION: 1½" BSPP Female
BODY: Gunmetal BS1400 LG2 SPRING: St/St BS2056-302-S26 Gr11

SEAT: Viton (Soft Seal) SEALS: Viton
DISC: Gunmetal BS1400 LG2

SIZING CALCULATIONS: Not Required SET PRESSURE TEST CERTIFICAT Required (by SSS)


24/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X

SS
S
DATA SHEET FOR: Feed/Backwash Pump Inlet Pressure Gauge
GENERAL
REFERENCE DRAWING NO'S: S09247-01-01 Shts 1 & 2 TAG NO: PI1 SSS REF: AR441-09247/6.8
OPERATING DATA

MECHANICAL DATA
SCALE RANGE: -1 to 1.5 UNITS: barg

GLYCERINE FILLED: Yes MOUNTING: Direct
CONNECTION: ½" NPT Male Bottom PANEL MOUNT CUT OUT: N/A
CASE: 304 St/St MOVEMENT: 304 St/St

WETTED PARTS: 316 St/St WEIGHT: 0.95 kg
DESIGN CODE: Manufacturers Standard

CALIBRATION CERTIFICATE: Not Required (to be verified on reciept at SSS)


28/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X

SS
S
DATA SHEET FOR: Energy Recovery Device (HPB)
GENERAL
REFERENCE DRAWING NO'S: 09247-01-01 Shts 1 & 2 TAG NO: HPB SSS REF: AQ938/4.8
OPERATING DATA
FLUID: Seawater & Mild Detergents Occasionally FLUID NATURE: Corrosive

FLUID TEMP: 5 to 40 ºC 2 to 12
FLUID pH: FLUID SG: 1.025
LINE SIZE: 3" NB FLOWRATE NORMAL: 23.3m³/h MAXIMUM PARTICULATE SIZE: 20µm
RO FEED DEVICE INLET PRESSURE: 38 to 56 barg RO FEED DEVICE OUTLET PRESSURE: 59 to 78 barg
RO REJECT DEVICE INLET PRESSURE: 59 to 75 barg DEVICE OUTLET PRESSURE: >0.5 barg
MECHANICAL DATA
TYPE: HPBe-40 (Hydraulic Pressure Booster)

DESIGN PRESSURE: 87 barg DESIGN TEMP: 49°C
RO FEED INLET CONNECTION: 1½" NB Victaulic RO FEED OUTLET CONNECTION: 1½" NB Victualic
DEVICE REJECT INLET CONNECTION: 1¼" NB Victaulic DEVICE REJECT OUTLET CONNECTION: 1¼" NB Victaulic
CASING: Duplex Stainless Steel (22% Cr) NEEDLE/PLUG: Duplex Stainless Steel (22% Cr)
VALVE STEM: Duplex Stainless Steel (22% Cr) O' RINGS: Buna N
ROTOR: Duplex Stainless Steel (22% Cr) FASTENERS: A4 (316) Stainless Steel
OTHER
WEIGHT: TBC kg
MATERIALS CERTIFICATES:Not Required (Certifcate of Conformity Only)

HYDROSTATIC CERTIFICATES: Required
DEVICE PERFORMANCE TEST CERTIFICATES: Required
DATA SHEET NO: 09247-DS50 R01


Invalid signature
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X
EDS‐STD REV07 26.09.08

SS
S
DATA SHEET FOR: Backwash Control Valve
GENERAL
OPERATING DATA
FLUID: Seawater & Mild Detergent Occasionally FLUID NATURE: Corrosive

MAXIMUM WORKING PRESSURE: 6 barg
MECHANICAL DATA

ACTUATION: Gearbox Actuator SEE EDS NO: N/A
BODY: Cast Iron DISC: UNS S31803 Duplex St/St

SHAFT
D l St/St PINS
D l St/St
SEAT: Nitrile



30/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X

SS
S
DATA SHEET FOR: RO Plant Inlet Valve
GENERAL
OPERATING DATA

MECHANICAL DATA

DESIGN PRESSURE: 10 barg DESIGN TEMP: -10 to 80ºC
ACTUATION: Lever Actuator SEE EDS NO: N/A
BODY: Cast Iron DISC: UNS S31803 Duplex St/St

SHAFT
D l St/St PINS
D l St/St
SEAT: Nitrile



30/09/2009
COPYRIGHT
Thi d
This documentt is
i the
th property
t off Salt
S lt Separation
S ti Services
S i Ltd.
b copied,
i d nor the
th contents
t t communicated
i t d X

SSS
5.0 HEALTH AND SAFETY INFORMATION
All chemicals used in the operation of this plant are available from ‘Salt Separation
Services Ltd’.
5.1 SODIUM METABISULPHITE
5.2 GLYCERINE
5.3 GENESYS SW ANTISCALANT
5.4 GENESOL 38 ACIDIC MEMBRANE CLEANER
5.5 GENESOL 40 ALKALI MEMBRANE CLEANER
5.6 GENESOL 34 ALKALI MEMBRANE CLEANER (ALTERNATIVE)
5.7 JURAPERLE REHARDENING MEDIA
5.8 SODIUM HYPOCHLORITE SOLUTION (14-15%)
5.9 SILICONE GREASE
Recommended chemicals may change from time to time in keeping with technological
developments.
Alternative chemicals may also be recommended by Salt Separation Services for particular
applications and water qualities around the world.
In addition, an “Equipment/Machine Safety Assessment” has been produced for this equipment:
5.10 EQUIPMENT/MACHINE SAFETY ASSESSMENT
S846-40 400 m³/d SWRO PLANT 5/1 DATE : 23.02.10

SSS
SAFETY DATA SHEET
SODIUM METABISULPHITE
1. PRODUCT AND COMPANY IDENTIFICATION.
Trade Name Sodium Metabisulphite

Manufacture/Supplier Salt Separation Services
Address Grosvenor House
Gorrell Street
Rochdale
OL11 1AP
Phone Number +44 (0)1706 655522

Fax Number +44 (0)1706 654475
E-mail sss@saltsep.co.uk
Emergency Number 01706 655522

2. COMPOSITION/INFORMATION ON THE COMPONENTS
Product Formal Name Sodium Metabisulphite
Synonyms: Sodium Bisulphite * Disodium Disulphite
Chemical % Conc. CAS EINECS

Sodium Metabisulphite >90 7681-57-4 231-673-0
3. HAZARD IDENTIFICATION
Main hazards Harmful if swallowed. Contact with acid liberates toxic
gas.Irritating to respiratory system. Risk of serious
damage to eyes.
Other hazards Hygroscopic: readily absorbs water from air.

GROSVENOR HOUSE, GORRELL STREET, ROCHDALE, LANCS OL11 1AP
TEL : +44 (0)1706 655522 FAX : +44 (0)1706 654475
E-mail: sss@saltsep.co.uk Website: www.saltsep.co.uk
REGISTERED IN ENGLAND No. 2457981
SSS
SAFETY DATA SHEET
SODIUM METABISULPHITE
4. FIRST AID MEASURES
Inhalation There may be irritation of the throat with a feeling of
tightness in the chest. Nausea and stomach pain may occur.
There may be vomiting. Remove casulaty from exposure
ensuring ones own safety whilst doing so
Skin Contact There may be irritation and redness at the site of contact.
Remove all contaminated clothes and footwear immediately
unless stuck to the skin. Drench the affected skin with
running water for 10 minutes or longer if substance is still on
skin. Transfer to hospital if there are burns or symptoms of
poisoning
Eye Contact There may be irritation and redness. Bathe the eye with
Running water for 15 minutes. Transfer to hospital for
specialist examination.
Ingestion Nausea and stomach pain may occur. There may be

vomiting. Do not induce vomiting. If conscious, give 1 pint
of water to drink immediately. If unconscious, check for
breathing and apply artificial respiration if necessary. If
unconscious and breathing is ok, place in the recovery
position. Transfer to hospital as soon as possible.
5. FIRE FIGHTING MEASURES

Suitable Extinguishers Carbon dioxide. Alcohol or polymer foam.
Exposure hazards In combustion emits toxic fumes of sulphur oxides.
Protection of fire fighters Wear self contained breathing apparatus Wear

protective clothing to prevent contact with skin and eyes
6. ACCIDENTAL RELEASE MEASURES

Personal precautions Do not create dust
Environmental Precautions Do not discharge into drains or rivers. Contain the spillage
using bunding
Clean Up Procedure Cover the spillage with sodium bicarbonate or similar

powdered alkali. If inside, transfer outside building in
suitable containers. Wash down the drain with large amounts
of water
7. HANDLING AND STORAGE

Handling Ensure there is sufficient ventilation of the area. Avoid
direct contact with the substance.
Storage Store in cool, well ventilated area. Keep container tightly

closed.
Suitable storage media Polyethlene containers.
2 of 4
SSS
SAFETY DATA SHEET
SODIUM METABISULHITE
8. EXPOSURE CONTROL/PERSONAL PROTECTION
Engineering measures Ensure there is sufficient ventilation of the area.
Respiratory protection Self contained breathing apparatus must be available in case

of emergency
Hand protection Protective gloves
Eye protection Safety goggles
Skin protection Protective clothing with elasticated cuffs and closed neck.
Boots made of PVC
TWA 98hr exposre limit) 5mg/m³
9. PHYSICAL AND CHEMICAL PROPERTIES

Appearance White crystals
Odour Perceptible odour
pH 4.5 (5% solution)
Flammability Not flammable in normal conditions
Oxidising properties Non oxidising (by EC criteria)
Solubility in water Complete
Also soluble in Most organic solvents
Melting point range >300º
Relative density 1.48
10. STABILITY AND REACTIVITY

Stability Stable in normal conditions
Materials to avoid Oxidising agents
Hazardous decomposition products In combustion emits toxic fumes of sulpur oxides
11. TOXICOLOGICAL INFORMATION

Effects
Irritating to eyes, skin and mucous membranes. Harmful if swallowed.
12. ECOLOGICAL INFORMATION

Environmental effects
Mobility Soluble in water
Degradability Degrades to form sulphates
Other adverse effects Depletes oxygen levels in water course
3 of 4
SSS
SAFETY DATA SHEET
SODIUM METABISULHITE
13. DISPOSAL
Waste disposal Arrange for collection by specialised disposal company
Disposal of packaging Arrange for collection by specialised disposal company
N.B. The users attention is drawn to the possible existence of

regional or national regulations regarding disposal.
14. TRANSPORT INFORMATION

Not regulated for road transport
15. REGULATORY INFORMATION

Symbols Harmful
Risk Phrases: R22-31-37-41 Harmful if swallowed. Contact with acids

liberates toxic gas. Irritating to respiratory system. Risk of
serious damage to eyes.
Safety Phrases S25-26-39-45-46. Avoid contact with eyes. In case of contact
with eyes, rinse immediately with plenty of water and seek
medical advice. Wear eye/face protection. In case of accident
or if you feel unwell, seek medical advice immediately. If
swallowed seek medical advice immediately and show this
container or label.
Note The regulatory information given above only indicates the

principal regulations specifically applicable to the product
described in the safety data sheet. The users attention is
drawn to the possible existence of additional provisions
which complete these regulations. Refer to all applicable
national, international and local regulations or provisions
16. OTHER INFORMATION
Additional information This safety data sheet complies with the 28th adaption of EC
directive 67/548/EEC, known in th UK as CHIP 3.
Legal Disclaimer The above information is based on the present state of our
knowledge of the product at the time of publication. It is
given in good faith, no warranty is implied with respect to
the quality or the specification of the product. The user must
satisfy himself that the product is entirely suitable for his
purpose.
Date of Issue: 30.09.05

Revision No: 2
4 of 4
SSS
SAFETY DATA SHEET
GLYCERINE
Trade Name Glycerine

Synonyms: Pricerine * 1, 2,3 – Propanetriol * Glycerol
Manufacture/Supplier Salt Separation Services
Gorrell Street
Rochdale
OL11 1AP
Phone Number +44 (0)1706 655522

Fax Number +44 (0)1706 654475
Ingredient 1: 1, 2, 3 Propanetriol >90%

CAS: 56-81-5
Main Hazard: No significant hazard

TEL : +44 (0)1706 655522 FAX : +44 (0)1706 654475
SSS
SAFETY DATA SHEET
GLYCERINE
Inhalation There may be vomiting
Remove casualty from exposure ensuring one’s own safety

whilst doing so. If unconscious, check for breathing and
apply artificial respiration if necessary. If unconscious and
breathing is ok, place in the recovery position. If conscious,
ensure the casualty sits or lies down. If breathing becomes
bubbly, have the casualty sit and provide oxygen if availabel.
Transfer to hospital as soon as possible.
Skin Contact There may be mild irritation at the site of contact.
Remove all contaminated clothes and footwear immediately

unless stuck to skin. Drench the affected skin with running
water for 10 minutes or longer if substance is still on skin.
Transfer to hospital if there are burns or symptoms of
poisoning
Eye Contact There may be irritation and redness.
Bathe the eye with running water for 15 minutes. Transfer to

hospital for specialist examination.
Ingestion here may be irritation of the throat. There may be vomiting.
Do not induce vomiting. If substance swallowed is

corrosive, give 1 cup of water to drink every 10 minutes. If
unconscious, check for breathing and apply artificaial
respiraion if necessary. If unconscious and breathing is ok,
place in the recovery position. Transfer to hospital as soon
as possible.

Extinguishing media: Carbon dioxide. Dry chemical powder.
Protection of fire fighters: Wear protective clothing to prevent contact with skin
and eyes.
Personal precautions: Refer to section 8 of SDS for personal protection details.
Environmental precautions: Do not discharge into drains or rivers. Contain the spillage
using bunding.
Lean up procedures: Absorb into dry earth or sand. Transfer to a suitable

container. Wash the spillage site with large amounts of
water.
2 of 4
SSS
SAFETY DATA SHEET
GLYCERINE
Handling: Do not handle in a confined space.
Storage conditions: Store in cool, well ventilated area. Keep container tightly
closed.
Suitable packaging: Stainless steel. Polyethylene.
Engineering measures: Ensure there is sufficient ventilation of the area.
Respiratory protection: Self-contained breathing apparatus must be available in case

of emergency.
Hand protection: Protective gloves.
Eye protection: Safety goggles.
Skin protection: Protective clothing with elasticated cuffs and closed neck.
TWA (8 hr exposure limit): 5mg/m³

Appearance Colourless liquid
Flash Point >160ºC
Relative density 1.26
Solubility in water Miscible
Viscosity Viscous

Stability Stable in normal conditions
Materials to avoid Strong oxidising agents
Hazardous decomposition products Thermal decomposition may release acrolein – vary toxic by
inhalation

1,2,3 Propanetriol
LD50 > 2000 mg/kg oral – rat
Mobility Soluble in water
Persistence and degradability Biodegradable.
3 of 4
SSS
SAFETY DATA SHEET
GLYCERINE
13. DISPOSAL
Waste disposal: Dispose of in accordance with local regulations.
N.B. The users attention is drawn to the possible existence of

regional or national regulations.

Not regulated for road transport
Hazard symbols: No significant hazard.
Safety phrases: S37/39: Wear suitable gloves and eye/face protection.
Note: The regulatory information given above only indicates the

principal regulations specifically applicable to the procduct
described in the safety data sheet. The users attention is
drawn to the possible existence of additional provisions
which complete these regulations. Refer to all applicable
national, international and local regulations or provisions.
Additional information: This safety data sheet complies with the 28th adaption of EC
directive 67/548/EEC, known in the UK as CHIP 3
Local Disclaimer
The above information is based on the present state of our knowledge of the produce at the time of
publication. It is given in good faith, no warranty is implied with the respect to the quality or the
specification of the product. The user must satisfy himself that the product is entirely suitable for his
purpose.
Date of Issue: 03.12.2005
4 of 4
SSS
Salt S eparation Services
SAFETY DATA SHEET
GENESYS SW
Trade Name Genesys SW

Manufacturer/Supplier Salt Separation Services
Gorrell Street
Rochdale
OL11 1AP
Phone Number +44 (0)1706 655522

Fax Number +44 (0)1706 654475

Hazardous Ingredients
Conc. CAS EINECS Symbols/Risk Phrases

Caustic soda Trace 1310-73-2 215-185-5
Description, aqueous solution of neutralised polymeric acrylic acid
3. HAZARDS INDENTIFICATION
Main Hazards: No Significant Hazard
Other Hazards: The product is classified as non hazardous
Skin Contact Wash with soap and water. Remove contaminated

clothing.
Eye Contact May cause irritation to eyes. Rinse immediately with

plenty of water for 15 minutes holding the eyelids open.
Seek medical attention if irritation or symptoms persist.
Inhalation Considered to be not hazardous by inhalation. In case of

accident by inhalation, remove casualty to fresh air and
keep at rest. Seek medical attention if irritation or
symptoms persist.
Ingestion Rinse mouth thoroughly. DO NOT INDUCE

VOMITING. Seek medical attention if irritation or
symptoms persist.

TEL : +44 (0)1706 655522 FAX : +44 (0)1706 654475
SSS
SAFETY DATA SHEET
GENESYS SW
Extinguishing Media Use extinguishing media appropriate to the surrounding

fire conditions. Carbon dioxide (CO2) Dry chemical.
Water spray.
Protective Equipment Wear suitable respiratory Equipment when necessary.
Personal Precautions Avoid contact with skin and eyes. Ensure adequate
ventilation of the working area.
Environmental Precautions Do not allow product to enter drains. Prevent further

spillage if safe.
Clean Up Methods Absorb with inert, absorbent material. Sweep up.

Transfer to suitable, labelled containers for disposal.
Clean spillage area thoroughly with plenty of water.
Dispose of in compliance with all local and national
regulations.
Handling Avoid contact with eyes and skin. Ensure adequate

ventilation of the working area. Adopt best Manual
Handling Considerations when handling, carrying and
dispensing.
Storage Store in a cool, dry area. Keep container tightly closed.
Suitable Packaging Plastic containers.

Exposure Limits:
Caustic soda WEL 8-hr limit ppm WEL 8-hr limit mg/m3
(Sodium Hydroxide) WEL 15 min limit ppm WEL 15 min limit mg/m3: 2
Engineering Measures Ensure adequate ventilation of the working area.
Respiratory Protection Not normally required.
Hand Protection Chemical resistant gloves (PVC).
Eye Protection Approved safety goggles.
Protective Equipment Wear protective clothing.
2 of 4
SSS
SAFETY DATA SHEET
GENESYS SW
Description Liquid.
Colour Light. Yellow.
pH 8.0 – 8.6
Boiling Point 102ºC
Relative Density 1.15 – 1.17
Freezing Point 0ºC
Stability Stable under normal conditions.
Conditions to avoid Do NOT allow to freeze.
Materials to avoid Strong acids.
Hazardous Decomposition Carbon oxides.

Products
Genesys SW Oral Rat LD50 = >10,000 mg/kg
Genesys SW Algae EC50/72h = >260 mg/l

Rainbow trout LC50/96h = >2000 mg/l
Degradability Not readily biodegradable.
13. DISPOSAL
General information Dispose of in compliance with all local and national

regulations.
Disposal Methods Contact a licensed waste disposal company. Dispose of

in compliance with all local national regulations. For
disposal within the EC, the appropriate code according
to the European Waste Catalogue (EWC) should be
used.
Disposal of Packaging Empty containers can be cleaned with water. Empty

containers can be sent for disposal or recycling.
3 of 4
SSS
SAFETY DATA SHEET
GENESYS SW
Further Information The product is not classified as dangerous for carriage.
Risk Phrases NSH – No Significant Hazard.
Safety Phrases S24/25 – Avoid contact with skin and eyes.
The information supplied in this Safety Data Sheet is designed only as guidance for the safe
use, storage and handling of the product. This information is correct to the best of our
knowledge and belief at the date of publication however no guarantee is made to its accuracy.
This information relates only to the specific material designated and may not be valid for
such material used in combination with any other materials or in any other process.
Revision Date: 29.12.07
4 of 4
SSS
SAFETY DATA SHEET
GENESOL 38
Trade Name Genesol 38

Gorrell Street
Rochdale
OL11 1AP
Phone Number +44 (0)1706 655522

Fax Number +44 (0)1706 654475
Description: Partially neutralised aqueous solution of

polycarboxylic acid.
Main hazards: No significant hazard.
Other hazards: The product is classified as non hazardous.
Skin contact: Wash with water. Remove contaminated clothing.
Eye contact: May cause irritation to eyes. Rinse immediately

with plenty of water for 15 minutes holding the
eyelids open. Seek medical attention if irritation or
symptoms persist.
Inhalation: Considered to be not hazardous by inhalation.
Ingestion: Rinse mouth thoroughly. DO NO INDUCE

symptoms persist.

TEL : +44 (0)1706 655522 FAX : +44 (0)1706 654475
SSS
SAFETY DATA SHEET
GENESOL 38
Extinguishing media: Use extinguishing media appropriate to the

surrounding fire conditions. Carbon dioxide (CO2)
Dry chemical. Foam. Water spray.
Protective equipment: Wear suitable respiratory equipment when

necessary.
Personal precautions: Avoid contact with skin and eyes.
Environmental precautions: Do not allow product to enter drains. Prevent

further spillage if safe.
Clean up methods: Absorb with inert, absorbent material. Sweep up.

regulations.
Handling: Avoid contact with skin and eyes. Adopt best

Manual Handling considerations when handling,
carrying and dispensing. Ensure adequate
Storage: Store in a cool, dry area. Keep containers tightly

closed.
Suitable packaging: Plastic containers.
Description: Liquid.
Colour: Yellow. Clear.
Odour: Slight.
pH: 3.5 – 4.0
Boiling point: 102ºC
Relative density: 1.18 – 1.20
Freezing point: 0ºC
2 of 5
SSS
SAFETY DATA SHEET
GENESOL 38
Stability: Stable under normal conditions.
Hazardous decomposition: None.

products
Corrosivity: No irritation expected.
Sensitization: No sensitization effects reported.
Mutagenic effects: No mutagenic effects reported.
Carcinogenic effects: No carcinogenic effects reported.
Reproductive toxicity: No teratogenic effects reported.
13. DISPOSAL
General information: Dispose of incompliance with all local and national

regulations.
Disposal methods: Contact a licensed waste disposal company.

regulations. For disposal within the EC, the
appropriate code according to the European Waste
Catalogue (EWC) should be used.
Disposal of packaging: Empty containers can be cleaned with water. Empty

Further information: The product is not classified as dangerous for

carriage.
Risk phrases: NSH – No Significant Hazard.
Safety phrases: S24/25 – Avoid contact with skin and eyes.
3 of 4
SSS
SAFETY DATA SHEET
GENESOL 38
Further information: The information supplied in this safety Data Sheet is

designed only as guidance for the safe use, storage
and handling of the product. This information is
correct to the best of our knowledge and belief at the
date of publication, however, no guarantee is made
to its accuracy. This information relates only to the
specific material designated and may not be valid
for such material used in combination with any
other materials or in any other process.
Revision date: 26 November 2007
4 of 4
SSS
SAFETY DATA SHEET
GENESOL 40

Gorrell Street
Rochdale
OL11 1AP
Phone Number +44 (0)1706 655522

Fax Number +44 (0)1706 654475
Conc. CAS EINECS Symbols/Risk Phrases

Potassium Hydroxide 1-10% 1310-58-3 215-181-3 Xn: R22 C: R35
Description Aqueous blend of mixed cleaners.
Skin Contact Causes burns. Wash off immediately with plenty of

soap and water. Remove contaminated clothing. Seek
medical attention if symptoms persist.
Eye Contact Causes burns. Causes serve inflammation and may

damage the cornea. Rinse immediately with plenty of
water for 15 minutes holding the eyelids open. Seek
medical attention.
Inhalation Move the exposed person to fresh air. Seek medical

attention.
Ingestion Ingestion causes burns to the respiratory tract. DO NOT

INDUCE VOMITING. If swallowed, seek medical
advice immediately and show this container or label.
General information In case of accident or if you feel unwell, seek medical

advice immediately (show the label where possible).
Keep the affected person warn and at rest.

TEL : +44 (0)1706 655522 FAX : +44 (0)1706 654475
SSS
SAFETY DATA SHEET
GENESOL 40
Extinguishing Media Use as appropriate: carbon dioxide (CO2), dry

chemical, foam.
Fire Hazards Corrosive.
Protective Equipment Wear suitable respiratory equipment when necessary.
Personal Precautions Ensure adequate ventilation of the working area.

Evacuate personnel to a safe area. Wear suitable
protective equipment.
Environmental Precautions Do not allow product to enter drains. Prevent further

spillage if safe.
Clean up Methods Absorb with inert, absorbent material. Transfer to

suitable, labelled containers for disposal. Clean spillage
area thoroughly with plenty of water. For small spills,
Neutralise with sodium bicarbonate in excess.
Handling Avoid contact with eyes and skin. Ensure adequate

ventilation of the working area. Keep away from acids.
Wear suitable protective equipment.
Storage Keep in a cool, dry, well ventilated area. Keep

containers tightly closed. Do not store with acids. Do
NOT allow to freeze.
Suitable Packaging Plastic containers.
Potassium Hydroxide WEL 8-hr limit ppm WEL 8-hr limit mg/m3
WEL 15 min limit ppm WEL 15 min limit mg/m3: 2
Engineering Measures Ensure adequate ventilation of the working area.
Occupational Exposure Keep away from food, drink and animal feedingstuffs.
Controls
Respiratory Protection Wear suitable respiratory equipment when necessary.
Hand Protection Chemical resistant gloves (PVC).
Protective Equipment Wear chemical protective clothing.

2 of 5
SSS
SAFETY DATA SHEET
GENESOL 40
Description Liquid.
Colour Colourless.
Odour Odourless.
pH >13
Relative Density 1.12 – 1.24
Freezing Point 0ºC
Stability Stable under normal conditions.
Conditions to avoid Do NOT allow to freeze.
Material to avoid Acids. Aluminium. Copper and its alloys.
Acute Toxicity No data is available on this product.
Corrosivity Causes burns.
Ecotoxicity No data is available on this product.
13. DISPOSAL
General Information Dispose of in compliance with all local and national

regulations.
Disposal Methods Contact a licensed waste disposal company. Dispose of

in compliance with all local and national regulations.
For disposal within the EC, the appropriate code
according to the European Waste Catalogue (EWC)
should be used.
Disposal of Packaging Empty containers can be cleaned with water. Empty

Containers must be recycled in compliance with
national legislation and environmental regulations.
3 of 5
SSS
SAFETY DATA SHEET
GENESOL 40
ADR/RID
UN: 3266
Class: 8
Proper Shipping Name: CORROSIVE LIQUID, BASIC, INORGANIC, N.O.S
(Solution contains potassium hydroxide)
Packing Group: III
Hazard ID: 80
IMDG
UN: 3266
Class: 8
EmS Code: F-A S-B
Packing Group: III
Hazard ID: 80
IATA
UN: 3266 Packing Group: III

Class: 8 Subsidiary risk -
Packing Instruction (Cargo): 820 Maximum Quantity: 60L
Packing Instruction (Passenger): 818 Maximum Quantity: 5L
Labelling: The product is classified in accordance with

67/548/EEC.
Symbols: C – Corrosive.
Risk Phrases: R34 – Causes severe burns.
Safety Phrases: S26 – in case of contact with eyes, rinse immediately

with plenty of water and seek medical advice.
S28 – After contact with skin, wash immediately with
plenty of water.
S36/37/39 – Wear suitable protective clothing, gloves
and eye/face protection.
S45 – In case of accident or if you feel unwell, seek
medical advice immediately (show the label where
possible).
R22 – Harmful if swallowed.
R35 – Cause severe burns.
4 of 5
SSS
SAFETY DATA SHEET
GENESOL 40
Text of risk phrases in R22 – Harmful if swallowed.

Section 2 R35 – Causes severe burns.
Further information: The information supplied in this Safety Data Sheet is

designed only as guidance for the safe use, storage and
handling of the product. This information is correct to
the best of our knowledge and belief at the date of
publication however no guarantee is made to its
accuracy. This information relates only to the specific
material designated and may not be valid for such
material used in combination with any other materials
or in any other process.
Revision Date: 21.02.08
5 of 5
SSS
SAFETY DATA SHEET
GENESOL 34

Gorrell Street
Rochdale
OL11 1AP
Phone Number +44 (0)1706 655522

Fax Number +44 (0)1706 654475
Description: Neutralised polycarboxylic acid.
Main hazards: No Significant Hazard.
Other hazards: The product is classified as non hazardous.
Skin contact: Wash with water. Remove contaminated clothing.
Eye contact: May cause irritation to eyes. Rinse immediately

with plenty of water for 15 minutes holding the
eyelids open. Seek medical attention if irritation or
symptoms persist.
Inhalation: Considered to be not hazardous by inhalation.
Ingestion: Rinse mouth thoroughly. DO NOT INDUCE

symptoms persist.
Extinguishing media: Use extinguishing media appropriate to the

surrounding fire conditions. Carbon dioxide (CO2)
Dry chemical. Foam. Water Spray.
Protective equipment: Wear suitable respiratory equipment when

necessary.
TEL : +44 (0)1706 655522 FAX : +44 (0)1706 654475
SSS
SAFETY DATA SHEET
GENESOL 34
Personal precautions: Avoid contact with skin and eyes.
Environmental precautions: Do not allow product to enter drains. Prevent

further spillage if safe.
Clean up methods: Absorb with inert, absorbent material. Sweep up.

regulations.
Handling: Avoid contact with skin and eyes. Adopt best

Manual Handling considerations when handling,
carrying and dispensing. Ensure adequate
Storage: Store in a cool, dry area. Keep containers tightly

closed.
Suitable packaging: Plastic containers.
Engineering measures: Ensure adequate ventilation of the working area.
Respiratory protection: Not normally required.
Hand protection: Chemical resistant gloves (PVC).
Eye protection: Approved safety goggles.
Protective equipment: Wear protective clothing.
Description: Liquid.
Colour: Yellow. Colourless.
Odour: Slight.
pH: 11.0 – 11.5
Boiling point: 102ºC
Relative density: 1.33 – 1.35

2 of 5
SSS
SAFETY DATA SHEET
GENESOL 34
Stability: Stable under normal conditions.
Hazardous decomposition Carbon oxides. Nitrogen oxides.

products:
Toxicological information
GENESOL 34 Oral Rat LD50 = >2000 mg/kg
Corrosivity: No irritation expected.
Sensitization: No sensitization effects reported.
Mutagenic effects: No mutagenic effects reported.
Carcinogenic effects: No carcinogenic effects reported.
Reproductive toxicity: No teratogenic effects reported.
Degradability: Readily biodegradable.
13. DISPOSAL
General information: Dispose of in compliance with all local and national

regulations.
Disposal methods: Contact a licensed waste disposal company.

regulations. For disposal within the EC, the
appropriate code according to the European Waste
Catalogue (EWC) should be used.
Disposal of packaging: Empty containers can be cleaned with water. Empty

Further information: The product is not classified as dangerous for

carriage.
3 of 4
SSS
SAFETY DATA SHEET

GENESOL 34
Risk phrases: NSH – No Significant Hazard.
Safety phrases: S24/25 – Avoid contact with skin and eyes.
Further information: The information supplied in this Safety Data Sheet is

designed only as guidance for the safe use, storage and
handling of the product. This information is correct to
the best of our knowledge and belief at the date of
publication however no guarantee is made to its
accuracy. This information relates only to the specific
material designated and may not be valid for such
material used in combination with any other materials or
in any other process.
Revision: This document differs from previous version in the

following areas:
9 – pH.
9 – relative density.
Revision date: 19 December 2007
4 of 4
SSS
SAFETY DATA SHEET
JURAPERLE
Trade Name Juraperle
Gorrell Street
Rochdale
OL11 1AP
Phone Number +44 (0)1706 655522

Fax Number +44 (0)1706 654475

Product Formal Name Juraperle
Chemical Identification CAS Number EINECS Number

Calcium Carbonate 7439-96-5 215-279-6
Identification of hazards
The main exposure routes for this product will include:
Ingestion of dust particles can cause irritation.
Contact with eyes/mucous membranes may cause temporary irritation.
Contact with the skin may cause temporary irritation.

Ingestion: Give water. Consult a physician if problem persists.
After Skin Contact Remove particles, flush with water
After Eye Contact Flush eye with water and remove all particles, consult a
physician if problem persist.

Suitable Extinguishing Media Material is non-combustible
Fire fighting procedure N/A

Personal Precautions Non-Hazardous
Environmental Precautions Non-Hazardous
Methods for cleaning up Take up mechanically

TEL : +44 (0)1706 655522 FAX : +44 (0)1706 654475
SSS
SAFETY DATA SHEET
JURAPERLE
Handling
Precautions for safe handling No special instructions
Measurements to protect from fire/Explosion: N/A
Protection against Fire/Explosion: N/A
Storage: Design for storage rooms and vessels: Store in dry place.
Room must be well ventilated.

Ingredients with OELs additional Advice:
Calcium carbonate total inhalation dust: 10mg/m³, 8hr TWA
Respirable Dust 4mg/m³. 8 hr TWA
Personal Protection
Respiratory protection Recommended for normal operation

Hand Protection Protective gloves recommended
Body Protection Overalls and eye protection recommended
Hygiene Measures High standards of personal hygiene must be encouraged.

Appearance Granular
Colour White
Odour None
Specific Gravity N/A
Bulk Density N/A

Stability and reactivity Material is stable under normal conditions
Conditions to avoid Contact with acids

Materials to avoid N/A
Hazardous decomposition products The product will react with acid solution and produce CO2.

Toxicological Information Product is none toxic
Toxicity Tests
Acute Toxicity N/A
Additional information: N/A
Experiences
Relevant observation None
2 of 3
SSS
SAFETY DATA SHEET
JURAPERLE
Information on elimination None
Behaviour in environment
Mobility and bioaccumulative None
Potential
Ecotoxicological effects
Aquatic Toxicity: N/A
13. DISPOSAL
Disposal considerations Dispose of via an authorised landfill site
Should be disposed of in accordance with Local and National Regulations and legal requirements.

Road/Rail ADR/RID
Comment Not Dangerous
Inland Sea AND/ANDR

Comment: Not Dangerous
Air Transport: ICAO/IATA

Comment: Not Dangerous

Labelling: Not classified hazardous
Note Industrial grade products are not intended for use in

analytical and medical applications without extensive
purification.

Data issued by Salt Separation Services
Revision Date: 11/05
17. NATIONAL LEGISLATION

National Legislation: HSE Guidance Note EH40/02
COSHH Regulations 1999
Environmental Protection Act 1990
Chemicals Hazard Information and Packing for Supply
Regulations 1993
All information provided herein is based on our present knowledge and experience and describes our
product with regard to their safety requirements. It is not considered as assurance of properties or
description of quality.
3 of 3
SSS
Salt S eparation Services
SAFETY DATA SHEET
SODIUM HYPOCHLORITE SOLUTION
Trade Name Sodium Hypochlorite
Gorrell Street
Rochdale
OL11 1AP
Phone Number +44 (0)1706 655522

Fax Number +44 (0)1706 654475

Product Formal Name Sodium Hypochlorite
Chemical % Conc Classification Exposure CAS EINECS

Sodium Hypochlorite 10-25 C; R31-34 7681-52-9 231-668-3
Causes burns to skin, eyes and respiratory system. Contact with acids liberates toxic gas (Chlorine).
Liberates oxygen on heating.

Exposure Route Symptom Treatment
Inhalation Mists will irritate breathing Remove from exposure, rest and
passages causing coughing and keep warm. In severe cases, or if
wheezing recovery is not rapid or
complete seek medical attention
Skin Contact Irritation, blistering on Drench the skin with plenty of

prolonged contact water. Remove contaminated
clothing and wash before reuse.
If large areas of the skin is
damaged or if irritation persists
seek medical attention.
Eye Contact Pain, reddening, watering Irrigate thoroughly with water

for at least 10 minutes. Obtain
immediate attention.
Ingestion Burns to upper digestive tract, If confined to mouth, wash out

stomach upset, nausea, mouth with water, if patient
vomiting feels unwell seek medical
advice. If swallowed, give water
to drink, do not induce vomiting.
Seek immediate medical
attention giving attention to
breathing difficulties
TEL : +44 (0)1706 655522 FAX : +44 (0)1706 654475
SSS
SAFETY DATA SHEET
Suitable Extinguishers Use extinguisher suitable to surrounding fire conditions
Unsuitable Extinguishers Sawdust or acidic media
Hazardous Combustion Products Oxygen and chlorine
Special Equipment for fire fighting Self contained breathing apparatus and full protective
clothing.

Safety Precautions Wear appropriate PPE – See section 8
Environmental Precautions Do not allow material to contaminate drains and

watercourses. Immediately inform authorities of uncontrolled
discharges.
Clean up Procedure Bund or absorb material with inert material (e.g. sand, NOT
sawdust). Transfer liquid if possible to a salvage tank;
otherwise absorb on inert material and transfer to suitable
containers for waste disposal

Handling Ventilation: Good general ventilation
Prohibited procedures and equipment Do not breathe mists. Do not use strong solutions on stainless
steel do not mix with other cleaning agent.
Storage Temperature Range: Keep Cool
Keep away from See section 10
Suitable storage media Vented container of glass, PVC, GRP, suitable lined mild
steel, high density polyethlene.

Exposure Limits None, in case of Chlorine release Type OES
0.5 ppm (1.5 mg/m3), 8 hr TWA 1 ppm
(3 mg/m3) STEL
Monitoring Method As Chlorine
Protective Measures
Respiratory Self contained breathing apparatus if dealing with major leak
Hand PVC or rubber gloves to BS 1651
Eye Safety goggles to BS 2092/C and /or face shield
Skin PVC overalls, Rubber boots to BS 1870
Hygiene Measures Always wash thoroughly after handling.
2 of 4
SSS
SAFETY DATA SHEET
Appearance Clear green/yellow or pink/purple solutions
Odour Faint chlorinous
PH >13
Boiling Point Range 110ºC
Melting Point Range -17ºC
Flammability Not flammable, but will liberate oxygen on heating
Oxidising Properties Strong oxidising agent
Vapour pressure 17.5mm Hg @ 20ºC
Relative Density 1.26
Solubility in water Stable

Stability Unstable, decomposes to form Sodium Chloride and Sodium
Chlorate liberating Oxygen.
Known Hazardous Reactions Contact with acids liberates toxic gas (Chlorine). Violent
reactions with Ammonia, Ammonium compounds and
Organic material.
Conditions to Avoid Heat, Strong Sunlight
Materials to Avoid Acids, Ammomium salts, Methanol, Hydrocarbons, Copper,

Nickle, Iron Monel Metals
Hazardous decomposition products: Oxygen, Chlorine

Effects Corrosive to eyes, skin and moucous membranes. Prolonged
eye contact may result in permanent damage or blindness.
Ingestion may lead to formation of chlorine gas by reaction
with stomach contents; inhalation of chlorine gas will cause
bronchial and pulmonary oedema. Symptoms may be
delayed for 48 hours or more.
LD50 LD50 8910 mg/Kg oral – rat

Environmental Effects
Mobility Soluble in water, will readily percolate through soil.
Degradability Material will degrade slowly to Sodium Chloride, Sodium

Chlorate and oxygen.
Aquatic Toxicity: Toxic to aquatic organisms. Very toxic to fish.
3 of 4
SSS
SAFETY DATA SHEET
13. DISPOSAL
Substance Via an authorised waste disposal contractor to an approved
disposal site, observing all local and national regulations
Container As substance. Used containers must not be cut up or

punctured until completely purged of product residues.

UN Number 1791
ADR Class/Item No: 8, 61ºC
Primary Hazard Corrosive
Packing Group III
Emergency Action Code 2X
H.I Number 80

Supply label details Ref: CHIP ‘3
Label Name Sodium Hypochlorite …..% Av CL2
Symbols Corrosive
Risk Phrases 31-34 contact with acid liberates toxic gas. Causes burns
Safety Phrases (1/2) – 28 -45 – 50 Keep locked up and out of reach of
children. After contact with skin, wash immediately with
plenty of soap and water. In case of accident or if you feel
unwell, seek medial advice immediately (show label where
possible). Do not mix with acidic materials.
E.C Number 231-668-3

Use of this material may be governed by the following regulations:
Users are advised to consult these regulations for further information.

The information in this data sheet does not constitute an assessment of workplace risk

This material is usually used for Water treatment, cleaning, disinfecting, bleaching
It must not be used for:
Legal Disclaimer
The above information is based on the present state of our knowledge of the product at the time of
publication. It is given in good faith, no warranty is implied with respect to the quality or the
specification of the product. The user must satisfy himself that the product is entirely suitable for his
purpose.
Revision No. 6 Dated November 2005
Replaces S.D.S Dated July 2003
4 of 4
SSS
SAFETY DATA SHEET
SGM494
Trade Name SGM 494

Gorrell Street
Rochdale
OL11 1AP
Phone Number +44 (0)1706 655522

Fax Number +44 (0)1706 654475
Inhalation Not relevant
Ingestion Immediately rinse mouth and drink plenty of water

or milk, keep person under observation. Do not
induce vomiting, if vomiting occurs keep head low.
Transport immediately to hospital and take these
instructions.
Skin Contact Promptly flush contaminated skin with soap or mild

detergent and water. Promptly remove clothing if
penetrated and flush the skin with water. Get
medical attention if irritation persists after washing.
Eye Contact Immediately flush with plenty of water for up to 15

minutes. Remove any contact lenses and open
eyelids widely. If irritation persists continue rinsing
and transport to hospital taking these instructions.
Extinguishing Media Use fire-extinguishing media appropriate for

surrounding materials. Water spray, foam, dry
powder or carbon dioxide.
Special Fire Fighting Procedures Avoid breathing fire vapours. Use pressurised air
mask if product is involved in a fire.
Unusual Fire & Explosion Hazards No unusual fire or explosion hazards noted.
Specific Hazards Fire creates, toxic gases/vapours/fumes of Carbon

monoxide (CO). Carbon dioxide.

TEL : +44 (0)1706 655522 FAX : +44 (0)1706 654475
SSS
SAFETY DATA SHEET
SGM494
Personal Precautions Wear protective clothing as described in Section 8

of this safety data sheet.
Environmental Precautions Avoid discharge into drains, water courses or onto

the ground.
Spill Clean Up Methods Absorb in vermiculite, dry sand or earth and place
into containers. For waste disposal, see section 13.
Usage Precautions Avoid spilling, skin and eye contact.
Storage Precautions Avoid contact with oxidising agents. Store in tightly

closed original container in a dry, cool and well-
ventilated place.
Engineering Measures No particular ventilation requirements.
Respiratory Equipment Not relevant
Hand Protection For prolonged or repeated skin contact use suitable

protective gloves.
Eye Protection Wear approved safety goggles.
Hygiene
2 of 5
SSS
SAFETY DATA SHEET
SGM494
Appearance Grease
Colour Milky. White
Odour Mild
Solubility Immiscible with water Miscible with Aromatic

solvents Chloroform Hydrocarbons.
Bulk Density 1.00
Flash Point (ºC) >150 CC (Closed Cup)
Viscosity 20 – 60,000 cSt 23
Auto Ignition >400
Stability No particular stability concerns.
Materials to Avoid Strong oxidising substances. Water, steam, water

mixtures.
Hazardous Decomposition Products Fire creates, toxic gases/vapours/fumes of: Carbon

monoxide (CO). Carbon dioxide (CO), Oxides of:
Silicon.
Inhalation No specific health warnings noted.
Ingestion No specific health warnings noted.
Skin Contact Skin irritation is not anticipated when used

normally.
Eye Contact May cause temporary irritation.
Health Warnings This product has low toxicity. Only large volumes
may have adverse impact on human health.
3 of 5
SSS
SAFETY DATA SHEET
SGM494
This product is not expected to be hazardous to the environment.
This product does not contain any substances expected to be bioaccumulating.
This product is expected to be slowly biodegradable.
13. DISPOSAL
General Information Waste to be treated as controlled waste. Disposal to

licensed waste disposal site in accordance with local
Waste Disposal Authority.
Disposal Methods Dispose of waste and residues in accordance with

local authority requirements.
No transport warning sign required.
Risk Phrases NC: Not Classified
Safety Phrases NC: Not Classified
EU Directives Dangerous Substance Directive 67/548/EEC.

Dangerous Preparations Directive 1999/45/EEC.
Approved Code of Practice Classification and Labelling of Substances and

Preparations Dangerous for Supply.
Guidance Notes Workplace Exposure Limits EH40
National Regulations The Chemicals (Hazard information and Packaging

for Supply) Regulations 2002. No 1689. Control of
Substances Hazardous to Health Regulations 2002
(as amended) The Carriage of Dangerous Goods and
use of transportable pressure equipment regulations
2004.
4 of 5
SSS
SAFETY DATA SHEET
SGM494
This information relates only to the specific material designated and may not be valid for
such material used in combination with any other materials or in any process. Such
information is, to the best of the company’s knowledge and belief, accurate and reliable
as of the date indicated. However, no warranty guarantee or representation is made to its
accuracy, reliability or completeness. It is the user’s responsibility to satisfy himself as to
the suitability of such information for his own particular use.
5 of 5
SSS
EQUIPMENT/MACHINE SAFETY ASSESSMENT
EQUIPMENT/MACHINE: S846-40 400 m³/day SWRO Plant – Crystal Symphony
DEFINITIONS
“Hazard” is something with the potential to cause harm. “Risk” is the likelihood that harm will occur from a particular hazard, and its severity. “Risk Assessment” means identifying the hazard present, evaluating the extent of the risks
involved, taking into account whatever precautions are already being taken, and identifying and prioritising the measures that need to be taken to eliminate or reduce the risk. “Existing Control Measures” Precautions taken,
Information/training provided to reduce the risk as low as reasonably practicable (ALARP).
RISK EVALUATION
LIKELIHOOD (L) CONSEQUENCES (C) RISK CATEGORY (likelihood x consequences = Risk Category)
1. Zero to very low 2. Very unlikely 1. None 2. Slight first aid/Slight illness 1-12 = LOW = Monitor any workplace precautions
3. Unlikely 4. Likely 3. Minor first aid/minor illness 4. 3 day injury/3 day illness (RIDDOR) 13-18 = MED = Monitor any workplace precautions and consider risk reduction measures
5. Very likely 6. Almost certain 5. Major injury/Major illness (RIDDOR) 6. Fatality or disabling injury (RIDDOR) 19-36 = HIGH = Urgent action to reduce risk (including stopping work)
HAZARD - FIRE
RISK EXISTING SAFEGUARDS/MITIGATION RISK

SOURCE, CAUSE CONSEQUENCE
L C CAT L C CAT
Feed/Backwash Pump
- Pump motor overheating. Could burst into flames, set fire to adjacent 3 5 Med Thermal and magnetic protection is provided 1 5 Low
equipment or cause burns to personnel. in the panel.
High Pressure Pump
Flushing Pump
Control Panel
- Panel could overheat. Could burst into flames, set fire to adjacent 3 5 Med Cooling fan and filter is installed in the panel 1 5 Low
equipment or cause burns to personnel. to dispense temperature build up.
- Electrical shorting Sparks could cause a fire, set fire to adjacent 3 5 Med Thermal and magnetic protection is provided 1 5 Low
Insulation Breakdown equipment or cause burns to personnel. in the panel.
CONTRACT NO: S09247 PAGE 1 OF 18 CLIENT: Crystal Cruises

CLIENT ORDER NO: M-2-09-0884-1
SSS
RISK RISK
SOURCE, CAUSE CONSEQUENCE EXISTING SAFEGUARDS/MITIGATION
L C CAT L C CAT
Chemical
- Combustible chemicals. Toxic fumes could be given off. Burns could 4 5 High Chemical is labelled correctly and COSHH 2 4 Low
be caused to personnel. Set fire to adjacent information is available. Segregation of
equipment chemicals
Fire in Vicinity
- Media filter over Pressure vessel could rupture causing flying 3 5 Med Vessel design pressure is higher than 1 5 Low
pressurisation. debris to injure personnel or damage maximum discharge pressure of the
equipment. Water from the vessel could cause feed/backwash pump.
flooding.
- Cartridge filter over Pressure vessel could rupture causing flying 3 5 Med Vessel design pressure is higher than
pressurisation. debris to injure personnel or damage maximum discharge pressure of the
equipment. Water from the vessel could cause feed/backwash pump.
flooding.
- Pressure gauge blow out due Flying glass could cause injury to personnel and 4 5 High Blow out plugs and safety glass fitted. Dead 1 3 Low
to over pressurisation. damage to equipment. head pressure of pump will never exceed
pressure gauge range. Gauges rated for 30%
over pressure.
- Rehardener over Pressure vessel could rupture causing flying 3 5 Med Relief valve fitted. 1 5 Low
pressurisation. debris to injure personnel or damage
equipment. Water from the vessel could cause
flooding.
- Flowmeter breaking. Water leaking could lead to flooding. 3 4 Med Relief valve fitted. 2 5 Low
- Sight glass breaking. Water leaking could lead to flooding. 3 4 Med Relief valve fitted. 2 5 Low

SSS
HAZARD - CHEMICAL
RISK RISK
L C CAT L C CAT
Antiscalant Dosing
- Dosing pump diaphragm May cause eye irritation or skin irritation. May 3 5 Med Use correct PPE, ensure safety data sheets 3 2 Low
leakage. cause surfaces to become slippery. have been provided. Routine maintenance of
pumps
- Dosing tank leak. May cause eye irritation or skin irritation. May 3 5 Med Tank is tested to ensure there are no leaks. 3 2 Low
cause surfaces to become slippery. .
- Chemical spill. May cause eye irritation or skin irritation. May 4 5 High Care should be taken when using chemical 3 2 Low
cause surfaces to become slippery. and any spillages should be cleaned up.
- Chemical fire. Could cause burns to personnel. 4 5 High Chemical must be correctly labelled and 2 6 Low
COSHH information available.
- Chemical placed in wrong Chemicals may react with each other. 3 5 Med Tanks should be clearly labelled and COSHH 2 6 Low
tank. Chemical may get into drinking water. information available.

SSS
RISK RISK
L C CAT L C CAT
Low pH Cleaner
cause surfaces to become slippery. and any spillages should be cleaned up.
- Chemical fire. Toxic fumes are given off. Could cause burns to 4 5 High Chemical must be correctly labelled and 2 6 Low
personnel. COSHH information available.
- Chemical placed in wrong Chemicals may react together 3 5 Med Tanks should be clearly labelled and COSHH 2 5 Low
Tank information available.
High pH Cleaner
cause surfaces to become slippery. and spillages cleaned up.
- Chemical fire. Toxic fumes are given off. Could cause burns to 4 5 High Chemical must be correctly labelled and 2 5 Low
personnel. COSHH information available.
- Chemical Placed in wrong Chemicals may react together 3 5 Med Tanks should be clearly labelled and COSHH 2 5 Low
tank information available.

SSS
RISK RISK
L C CAT L C CAT
Juraperle
- Chemical spill. Dust may be inhaled and cause nose or throat 4 4 Med Care should be taken when using chemical 3 2 Low
irritation. and any spillages should be cleaned up.
- Chemical fire. Chemical is non combustible. 1 1 Low Chemical must be correctly labelled and 1 1 Low
COSHH information available.
- Chemical placed in wrong Chemicals may react with each other, and 3 2 Low Tanks should be clearly labelled and COSHH 2 2 Low
tank. neutralise the water. information available.
Temperature
- Equipment may overheat. Could burst into flames, set fire to adjacent 4 5 High Thermal and magnetic protection is provided 2 5 Low
equipment, cause damage to the membrane, in the panel.
cause burns to personnel.
- Equipment may freeze. Membrane will freeze and be damaged. 4 4 Med Very unlikely in a ships engine room. 1 1 Low
Pipework may rupture and cause flooding.
Damage to pumps and possibly pipework
- Ventilation may be Heat will not dissipate and could lead to loss of 4 3 Low Very unlikely in a ships engine room due to 3 3 Low
inadequate. consciousness for personnel. extensive air-conditioning.

SSS
HAZARD - PRESSURE
RISK RISK
L C CAT L C CAT
Feed/Backwash Pump
- Media filter over Pressure vessel could rupture causing flying 3 5 Med Relief valve fitted. Design pressure of vessel 2 5 Low
pressurisation. debris to injure personnel or damage higher than maximum pump discharge
equipment. Water from the vessel could cause pressure. Routine maintenance/inspection
flooding.
- Cartridge filter over Pressure vessel could rupture causing flying 3 5 Med Relief valve fitted in pipework. Design 2 4 Low
pressurisation. debris to injure personnel or damage pressure of vessel is higher then maximum
equipment. Water from the vessel could cause pump discharge pressure.
flooding.
over-pressure
- Pipework failure. Pipework rupture causing injury to personnel, it 4 5 High Pipework tested to 1.5x the design to ensure it 2 3 Low
could cause flooding and equipment damage. is suitable for the working pressure.
- Pressure build up due to Pipework rupture causing injury to personnel, it 4 5 High Pressure switches and relief valve fitted. 2 3 Low
misoperation of valves could cause flooding and equipment damage.

SSS
RISK RISK
L C CAT L C CAT
High Pressure Pump
- RO pressure vessel over Vessel wrapping will expand and render the 3 5 Med Relief valve fitted. 1 4 Low
pressurisation. vessel useless, it could also cause flooding.
over pressure
- Rehardener over Pressure vessel could rupture causing flying 3 5 Med Relief valve fitted. 1 5 Low
flooding.
- High pressure pipework Pipework rupture causing injury to personnel, it 3 5 Med Pipework tested to 1.5x the design to ensure it 2 3 Low
failure. could cause flooding and equipment damage. is suitable for the working pressure.
- Pressure build up due to Pipework rupture causing injury to personnel it 4 5 High Pressure switches and relief valve fitted. 2 3 Low
misoperation of valves. could cause flooding and equipment damage.

SSS
RISK RISK
L C CAT L C CAT
Flushing Pump
pressure gauge range.
- Cartridge filter over Pressure vessel could rupture causing flying 3 5 Med Design pressure of vessel is higher than 2 4 Low
pressurisation. debris to injure personnel or damage maximum pump discharge pressure.
flooding.
- Pipework failure. Pipework rupture causing injury to personnel it 4 5 High Pipework tested to 1.5x the design to ensure it 2 3 Low
could cause flooding and equipment damage. is suitable for the working pressure.
- Pressure build up due to Pipework rupture causing injury to personnel, it 4 5 High Design pressure of pipework is higher than 2 3 Low
Misoperation of valves. could cause flooding and equipment damage. maximum pump discharge pressure.
Dosing Pump
- Pressure build up in dosing Could cause the connection of the tube to be 3 4 Low Design pressure of pipework is higher than 2 3 Low
tube. broken, and chemical to be spilled. maximum pump discharge pressure.

SSS
RISK RISK
L C CAT L C CAT
Fire
- Media filter over Pressure vessel could rupture causing flying 3 5 Med Highly unlikely – ABS pipework would fail 2 5 Low
pressurisation. debris to injure personnel or damage first.
flooding.
- Cartridge filter over Pressure vessel could rupture causing flying 3 5 Med Relief valve fitted. 2 5 Low
flooding.
- Pressure gauge blow out due Flying glass could cause injury to personnel and 4 4 Med Blow out plugs and safety glass fitted. Dead 1 4 Low
pressure gauge range.
- Rehardener over Pressure vessel could rupture causing flying 3 5 Med Auto air release valve fitted, relief valve 2 5 Low
pressurisation. debris to injure personnel or damage fitted.
flooding.

SSS
HAZARD - ELECTRICAL
RISK RISK
L C CAT L C CAT
Feed/Backwash Pump
Motor
- Water ingress. Electrical Sparks could cause a fire, set fire to adjacent 4 6 High Thermal and magnetic protection provided in 2 6 Low
short/insulation breakdown. equipment or cause burns to personnel. the panel. Motors rated IP55. Ensure motors
are earth bonded and that overloads and fuses
are sized correctly.
- Motor may overheat. May burst into flames, set fire to adjacent 4 6 High Thermal and magnetic protection provided in 2 6 Low
equipment or cause burns to personnel. the panel.
High Pressure Pump Motor
Flushing Pump Motor

SSS
RISK RISK
L C CAT L C CAT
Control Panel
short/insulation breakdown. equipment or cause burns to personnel. the panel. Motors rated IP55. Ensure
equipment is earth bonded and that overloads
and fuses are sized correctly.
- Panel may overheat.
May burst into flames, set fire to adjacent 4 6 High Thermal and magnetic protection provided in 2 6 Low
HAZARD - VIBRATION
RISK RISK
L C CAT L C CAT
Feed/Backwash Pump
- Pipework may vibrate. Pipework may split or connections could 4 4 Med Suitable brackets fitted to reduce the effects. 2 3 Low
become loose and cause a leak.
- Flowmeter may vibrate. Flowmeter may crack or connections could 4 4 Med Suitable brackets fitted to reduce the effects. 2 3 Low
- Sight glass may vibrate. Sight glass may crack or connections could 4 4 Med Suitable brackets fitted to reduce the effects. 2 3 Low
- Media filter may vibrate. Connections may become loose and cause a 4 4 Med Suitable brackets fitted to reduce the effects. 2 3 Low
leak.
- Cartridge filter may vibrate. Connections may become loose and cause a 4 4 Med Suitable brackets fitted to reduce the effects. 2 3 Low
leak

SSS
RISK RISK
L C CAT L C CAT
High Pressure Pump
Flushing Pump
- Flowmeter may vibrate. Flowmeter may crack or connections could 4 4 Med Suitable brackets fitted to reduce the effects. 2 3 Low
- Tank may vibrate. Connections could become loose and cause a 4 4 Med Suitable brackets fitted to reduce the effects. 2 3 Low
leak.

SSS
HAZARD - NOISE
RISK RISK
L C CAT L C CAT
Pumps
- Excessive noise when the Possible hearing damage 5 4 High Inform, instruct and train personnel on the 2 2 Low
plant is running. hearing risks. Provide hearing protection to
all staff at risk – for the upper action limit
(85dB average and 137dB peak) employers
MUST ensure employees use hearing
protection.
- Alarms when there is a Possible hearing damage 5 4 High Inform, instruct and train personnel on the 2 2 Low
running error. hearing risks. Provide hearing protection to
protection.

SSS
RISK RISK
L C CAT L C CAT
Motors
protection.
protection.
Valves
protection.
protection.

SSS
RISK RISK
L C CAT L C CAT
Media Filter
- Filter backwashing. Possible hearing damage 5 4 High Inform, instruct and train personnel on the 2 2 Low
hearing risks. Provide hearing protection to
protection.
HAZARD - FLOODING
RISK RISK
L C CAT L C CAT
Media Filter
- Media filter could rupture. Water and media may spill out of the filter. 3 5 Med Media filter is pressure tested to ensure that it 1 5 Low
Personnel may fall and be injured. is capable of withstanding pressures upto 1.5
times the design pressure.
Cartridge Filter
- Cartridge filter could Water may spill out of the filter. Personnel may 3 5 Med Cartridge filter is pressure tested to ensure 1 5 Low
rupture. fall and be injured. that it is capable of withstanding pressures
upto 1.5 times the design pressure.
RO Pressure Vessel
- Pressure vessel could expand Water may spill out of the vessel and the 3 5 Med System is pressure tested to ensure that it is 1 5 Low
and leak membrane may dry out. Personnel may fall and capable of withstanding pressures upto 1.5
be injured. times the design pressure.
Rehardener
- Rehardener could rupture. Water and media may spill out of the filter. 3 5 Med Rehardener is pressure tested to ensure that it 1 5 Low
Personnel may fall and be injured. is capable of withstanding pressures upto 1.5
times the design pressure.
SSS
RISK RISK
L C CAT L C CAT
Dosing Tank
- Tank could leak. May cause surfaces to become slippery. 3 5 Med Tank is tested to ensure there are no leaks. 2 5 Low
Personnel may fall and be injured.
- Tank could overflow. May cause surfaces to become slippery. 4 5 High Topped up by personnel so should not be 2 5 Low
Personnel may fall and be injured. overfilled.
Flushing Tank
- Tank could leak. May cause surfaces to become slippery. 3 5 Med Tank is tested to ensure there are no leaks. 2 3 Low
- Tank could overflow. May cause surfaces to become slippery. 3 5 Med Overflow fitted (to bilge) 1 3 Low
Pipework
- Pipework could rupture. Splits in pipework resulting in leaks may cause 3 5 Med Suitable brackets fitted to stop the pipework 1 5 Low
surfaces to become slippery. Personnel may from moving and reduce the risk of rupture.
fall and be injured. Pipework tested to 1.5 times the design
pressure

SSS
HAZARD – WATER CONTAMINATION
RISK RISK
L C CAT L C CAT
Feed Water
- Oil in the feed water. Sand filter will be fouled, cartridge filter will be 3 5 Med Inlet is positioned away from sewage outlet. 1 5 Low
fouled, and membrane will be damaged. Water suction from below water level.
- Sewage in the feed water. Sand filter will be fouled, cartridge filter will be 3 5 Med Inlet is positioned away from sewage outlet. 1 5 Low
fouled, and membrane will be damaged. Water suction from below water level.
- Heavy solids in the feed Damage to the pumps, filters will be fouled. 3 5 Med Inlet is positioned away from sewage outlet. 1 5 Low
water Water suction from below water level.
Chemical
- Cleaning chemicals present Water will make people sick if they drink it, 3 5 Med Plant run to drain for 30 minutes after a clean 1 5 Low
in the permeate water. water may cause skin or eye irritation if used to ensure all chemicals have been removed.
for washing.
- Antiscalant present in the Water may make people sick if they drink it, 3 5 Med Permeate automatic dump system in place. 1 5 Low
permeate water. water may cause skin or eye irritation if used
for washing.

SSS
COMMENTS:
ALARP STATEMENT: Risks considered to be As Low As Reasonably Practicable REVIEW DATE: In the event of an incident
26/02/2010
ASSESMENT COMPLETED BY: Phil Eccles DATE: 24.02.2010 REVIEWED BY: X

SSS
6.0 OPERATION
6.1 WARNINGS
6.2 PRE-START CHECKS
6.3 START UP PROCEDURE
6.4 ROUTINE OPERATION
6.4.1 Antiscalant Solution (Genesys SW)
6.4.2 Rehardener Top Up
6.4.3 Changing CO2 Cylinder
6.4.4 Day to Day Operation
6.4.5 High Feed Temperature Operation
6.4.6 Low Feed Salinity Operation
6.5 SHUTDOWN PROCEDURE
6.5.1 Shutdown - upto 24 hours
6.5.2 Shutdown - upto 2 days
6.5.3 Shutdown - periods greater than 2 days
6.6 MEMBRANE CLEANING PROCEDURE
6.7 SAND FILTER BACKWASHING PROCEDURE
6.8 EMERGENCY OPERATION
6.8.1 Partial RO Membrane Element(s) Failure
6.8.2 HP Pump/Motor Failure
6.8.3 Energy Recovery Device Failure

SSS
Refer to the following drawings in Section 10.0 of this manual:
Drawing No. Title
09247-01-01 Sht 1 P & I Diagram Pre-Treatment

09247-01-01 Sht 2 P & I Diagram RO Plant
09247-01-10 Shts 1 to 6 General Arrangement of RO Plant
09247-13-01 Shts 1 to 27 RO Control Panel Electrical Schematics
6.1 WARNINGS
1. Do not pass water through the plant if its temperature exceeds 45°C.
2. Ensure the plant is protected from frost.
3. Do not exceed the maximum plant permeate output of 18 m3/h. Nominal output
from the plant is 16.7 m3/h.
4. Do not exceed the maximum membrane inlet pressure of 79 barg.
5. After installation of new membranes, or if the plant has been preserved, allow the
permeate to run to waste for 1 hour before collecting it for drinking purposes.
If the membranes have been chemically cleaned allow the permeate to run to waste
for at least 30 minutes before collecting it for drinking purposes.
6. The water used for flushing and cleaning must not contain chlorine.
If necessary dechlorinate using Sodium Metabisulphite and test to ensure that there
is no chlorine present.
A teaspoon of Sodium Metabisulphite added to 50 litres of water will effectively

remove any chlorine present.
7. MCA NOTICE
The plant is not to be used in waters in which weeds or other organisms are present or
in waters affected by esturial discharge and in any case a 20 mile limit from any coast
must be observed.
8. Ensure that operators are familiar with the chemical safety and handling COSHH
sheets in section 5.0 of this manual.

SSS
6.2 PRE-START CHECKS
1. Check that a suitable raw water supply is available.
2. Check that power is available to the plant, and any emergency stops are unlocked.
3. Ensure all manual valves are closed.
4. Ensure that a cartridge filter element is fitted in the cartridge filter housing (see section
3.0 of this manual).
5. Ensure that the feed/backwash pump (P1) has been checked for freeness, correct direction
of rotation, and is fully primed.
6. Ensure that the HP pumps (P100, P101, P102 and P103) have been checked for correct
direction of rotation (see section 9.0 for manufacturers equipment literature), and are fully
primed.
7. If the plant has been shutdown for more than 72 hours or if new media has been installed,
the sand filter should have an extended backwash refer to sand filter backwashing section
6.7 of this manual.
8. Open ships side isolation valves.
9. Check that any valves in the feed and discharge pipework to and from the RO unit which
have been installed by others are open, particularly in the potable water line.
10. Ensure that the suction strainer (PV1) is clean.
6.3 START UP PROCEDURE
1. Switch the main panel isolator to 'ON'.
2. Depress 'ALARM ACCEPT/RESET' pushbutton to silence alarms.
3. Open instrument isolation valves (V12, V13 & V14).
4. Open permeate diversion valves (V250 to V257) to supply.
5. Open permeate supply isolation valve (V218).
6. Release the emergency stop and press 'ALARM ACCEPT/RESET' pushbutton and the
'EMERGENCY STOP RESET' pushbutton.
7. Open the actuated ships side valves (V60 & V61) by turning the selector switch to
‘OPEN’.
8. Fully open reject control valve (V101).

SSS
9. Fully open rehardener outlet isolation valve (V207).
10. Open RO plant inlet valve (V100).
11. Fully open rehardener inlet valve (V200).
12. Fully open rehardener outlet valve (V201).
13. If membrane elements have been newly installed, the plant has been preserved or the
membrane elements have been chemically cleaned, turn the dump system selector switch
‘DUMP’. If none of these have taken place switch to 'AUTO'.
14. Turn the CO2 selector switch to ‘AUTO’.
15. If the plant has been shutdown in excess of 24 hours: Carry out the step below, if the plant
has been shutdown for less than 24 hours continue to step 16.
a) Turn the sandfilter control selector switch to ‘MANUAL’.
b) Press the ‘BACKWASH INITIATE’ pushbutton for 2 seconds.
c) Press the 'SEQUENCE STEP' pushbutton until the ‘FLUSHING’ indicator illuminates.
Note
The 'SEQUENCE STEP' pushbutton has to be depressed for 2 seconds before a function
occurs.
d) Allow the filters to run to drain for 5 minutes - ensure that the feed/backwash pump
(P1) is primed.
e) A flow of 40 m3/h should be indicated on the feed flowmeter (FI1), this is pre-set to 20
m3/h through each vessel via stroke adjusted drain valves V7A and V7B.
f) Press the 'SEQUENCE STEP' pushbutton until the ‘FLUSHING’ indicator goes out and
the ‘STANDBY’ indicator flashes.
16. Turn the sandfilter control selector switch to ‘FILTER’.
17. Start the feed/backwash pump (P1). The sand filter ‘FILTERING’ indicator should
illuminate.
Note
Allow pressure to build up through the sand filter and cartridge filter, this will ensure the HP
pumps are fully primed before starting. On initial start-up or after any maintenance, the
pumps must be manually primed in accordance with the manufacturers instructions.
18. Start the HP pumps (P100, P101, P102 and P103) by depressing the common ‘START’
pushbutton.
SSS
19. Allow the feedwater to flow through the plant for 2 to 3 minutes to remove entrained air
from the system.
Note
The RO plant will run normally with the reject control valve (V101) nearly fully closed.
If the permeate flow is low, additional feed pressure can be achieved by gradually closing
the back pressure valve (V114) up to a maximum of 5 barg (on pressure gauge PI106).
This should normally be set at a minimum of 0.5 barg to help prevent cavitation damage
to the energy recovery device.
20. Gradually close the reject control valve (V101) until the permeate flowmeter (FIS101)
reads 16.7 m3/h (max. 18 m³/h) or until the membrane stack inlet pressure gauge (PI102)
reads a maximum of 79 barg, whichever is the sooner (the HP pumps will trip at a stack
inlet pressure of 80 barg).
21. Make up the antiscalant solution as described in section 6.4 of this manual. Ensure
dosing pump is running correctly and dosing at the correct rate (see 6.4.1).
22. Check the permeate quality as indicated on conductivity analyser (DIC100) and ensure
that the dump system selector switch is in ‘AUTO’, unless new membranes have been
installed or the plant has been preserved in which case the dump system selector switch
should be left in ‘DUMP’ for at least 1 hour. If the plant has been chemically cleaned the
dump system selector switch should be left in ‘DUMP for at least 30 minutes.
If the permeate quality is not less than 1,000 μS/cm refer to ‘High Temperature
Operation’ section 6.4.7 of this manual.
23. Check the potable water hardness and pH values.
To comply with World Health Organisation guidelines the pH should be between 6.5 and
8.5 and the hardness between 40 and 80 mg/l as CaCO3. See section 7.3.1 for methods of
hardness testing.
To achieve the correct values adjust the flow of water through the rehardener using
bypass valve (V202) and inlet valve (V200), at the same time adjust the CO2 flowrate
using the CO2 control valve (integral to the CO2 flowmeter FI201 – screwdriver slot).
6.4 ROUTINE OPERATION
See also ‘Routine Maintenance’ section 7.0 of this manual.
6.4.1 Antiscalant Solution (Genesys SW)
Refer to the ‘Health & Safety Information’ in section 5.0 of this manual.
With the RO plant running:
1. Stop the antiscalant dosing pump (P105) by turning the 'multifunction switch' on the
pump to ‘STOP’. If necessary, mute the dosing pump fault alarm by depressing the
'ALARM ACCEPT/RESET' pushbutton.

SSS
2. Remove the lid from the antiscalant dosing tank (T100).
3. Discard any unused contents of the tank by opening drain valve (V112).
4. Fill the tank with 50 litres of permeate via the flexible hose and using the fill valve
(V139).
5. Add 10 litres Genesys SW and replace the tank lid.
6. Fill the tank to the 100 litre mark with permeate.
7. Agitate the contents thoroughly with the hand agitator.
8. Start the antiscalant dosing pump (P105) by turning the 'multifunction switch' to 100%.
Reset the dosing pump fault lamp by depressing the 'ALARM ACCEPT/RESET'
pushbutton for 2 seconds.
9. Ensure that the pump is primed by opening the pump head vent valve until fluid is seen
flowing from the vent pipe.
Note
The antiscalant solution when made up has a limited life of approximately 14 days. If the
plant is running continuously, the plant should use 1 tank full every 8 days.
Antiscalant dosing should be dosed at 0.57 l/h, approximately 60% stroke length and 60%
stroke frequency.
6.4.2 Rehardener 'Top Up'
Refer to Health and Safety information in section 5.0 of this manual.
The rehardener should be topped up with fresh media when the level drops to half of the
way down the sightglass.
With the RO plant shut down as per section 6.5.1.
1. Open rehardener flushing valve (V203).
2. Close rehardener outlet isolation valve (V207) and bypass valve (V202).
3. Open the rehardener drain cock (V217). Drain down the vessel, then close this valve.
WARNING
Ensure the vessel is not under pressure before opening.
4. Open the top filling flange.
5. Using a suitable container pour rehardener media into the vessel (periodically levelling)
until the media is level with the top of the sightglass.
SSS
Note
If the media is dry a dust mask should be worn.
6. Replace the filling flange ensuring the gasket and sealing faces are free from rehardening
media. Torque up to 21Nm (is 15 lbf ft) following good engineering practice.
7. Restart the RO plant as per section 6.3, once the permeate conductivity is in range and the
dump valve (V115) closes, permeate will begin to flow to drain through the rehardener
flushing valve (V203). This will wash any fines from the new media, once the flushings
appear clean, as seen in sightglass (SG200), fully open rehardener outlet isolation valve
(V201) and then close flushing valve (V203).
8. If necessary adjust bypass and inlet valves (V200 and V202) to give desired quality, i.e.
pH 6.5 to 8.5 (40 to 80 mg/l hardness as CaCO3) at rehardener outlet (potable water
sample valve). The CO2 flowrate should also be adjusted using the control valve (integral
to the CO2 flowmeter FI201 – screwdriver slot) with the ‘CO2 DOSING VALVE’ control
switched to ‘AUTO’.
6.4.3 Changing CO2 Cylinder
1. Switch the CO2 selector switch to ‘OFF’.
2. Close the CO2 bottle mounted isolation valve.
3. Disconnect the CO2 bottle discharge hose from the regulator assembly outlet.
4. Remove CO2 bottle clamp.
5. Remove bottle and regulator assembly.
6. Transfer regulator onto a new, full bottle and replace bottle.
7. Refit CO2 bottle clamp.
8. Connect CO2 bottle discharge hose.
9. Open CO2 bottle mounted isolation valve.
10. Check for leaks.
11. Check CO2 regulator (V206) set pressure, if necessary adjust to 4 Barg outlet pressure.
12. Switch the CO2 selector switch to ‘AUTO’.
13. Check and adjust CO2 flow as necessary using the integral needle valve on the CO2
flowmeter (FI201).

SSS
6.4.4 Day to Day Operation
1. Flowrates and pressures should be checked at regular intervals.
2. Readings should be logged at least once per day, always allow at least 30 minutes
between switching on the machine and taking a set of readings.
3. In normal operation the RO membrane elements will become fouled by mineral scale,
biological matter, colloidal particles and insoluble organic constituents.
Deposits build up on the membrane surface causing a loss in water output, loss of salt
rejection, (i.e. reduction in permeate quality) or both.
Membrane elements should be cleaned whenever the normalised permeate flow drops by
10% or the membrane differential pressure increases by 15% or the normalised permeate
total dissolved solids content (TDS) increases by 10% from reference figures.
It should be noted that temperature and feed water salinity will effect the output of the
plant. See section 1.0 ‘Permeate Output/Quality’ of this manual.
Reference figures are the figures established during the first 24 to 48 hours of operation
of new membranes or the figures obtained after a chemical clean.
In the event that performance has not been standardised an alarm will be initiated after
1,000 running hours.
Chemical cleaning should be carried out as per the instructions in section 6.6 of this
manual.
It should be noted that the membranes performance will degrade gradually over a period
of time and therefore chemical cleaning will not restore the membranes to an ‘As New’
condition.
4. If the plant is to be shutdown in excess of 24 hours, flushing/preserving operations should

be carried out as per the instructions in section 6.5 of this manual.
5. Keep a check on the differential pressure across the sand filter (PI2 & PI3) if the
differential pressure rises by 1.0 barg from the clean condition a backwash should be
carried out.
A backwash required alarm will be initiated by the PLC after 24 hours continuous
operation or when the DP exceeds 1.4 barg.
6. Keep a check on the differential pressure across the cartridge filter (PI100, PI101) the
filter elements should be changed when the differential pressure exceeds 1.4 Barg, or
once every 6 to 8 weeks, whichever is the sooner.

SSS
7. It is preferable to run the RO plant with the reject control valve (V101) more or less
closed. If the permeate flow is low, additional feed pressure can be achieved by gradually
closing the back pressure valve (V114) up to a maximum of 5 barg (on pressure gauge
PI106). This should normally be set at a minimum of 0.5 barg to help prevent cavitation
damage to the energy recovery device.
6.4.5 High Feed Temperature Operation
1. If, due to feed temperature increase, maximum permeate flow is achieved and/or a poor
quality permeate is produced, i.e. greater than 1,000 μS/cm, it could be due to high salt
passage across the membranes (refer to section 1.0 ‘Permeate Output/Quality’ of this
manual).
In order to achieve a potable quality permeate the salt passage must be reduced, this can
be effectively achieved by removing some of the operating membranes from service,
hence cutting down total amount of salt passage, and forcing the remainder, by increasing
the operating pressure, to produce more permeate and consequently dilute the salt passage
of the remaining membranes more effectively. In addition, permeate produced by the
‘isolated’ membrane vessel will be diverted into the feed, diluting the feed water, thereby
reducing the feed TDS and, subsequently, the permeate TDS.
This procedure can also be used if a membrane vessel is producing out of specification
permeate due to RO membrane failure.
2. The plant would normally be started with permeate diverter valves (V250 to V257) open
to supply. If the permeate conductivity is greater than 1,000 μS/cm and the maximum
output of 18 m3/h has been achieved proceed as follows:
a) Slowly open the reject control valve (V101) enough to reduce the membrane stack
inlet pressure gauge (PI102) by approximately 10 Barg.
b) Close one of the permeate diversion valves (V250 to V257) to divert the permeate
back into the feed. Flow should now be visible in the flow meter (FI101).
c) Gradually close the reject control valve (V101) until the permeate flowmeter
(FI100) reads 18 m3/hr (max) or until the membrane stack inlet pressure gauge
(PI102) reads a maximum of 79 barg.
3. It may be necessary to close more than one isolation valve, should high permeate
conductivity persist.
If high permeate conductivity is still a problem refer to section 7.0 ‘Fault Finding’.
4. When the temperature decreases the permeate output will decrease therefore permeate
isolation valves will have to be opened, proceed as follows:
Note
On opening an isolated vessel a surge of high salinity water may pass into the permeate
manifold and cause a ‘HIGH CONDUCTIVITY’ alarm.
SSS
a) Slowly open the reject control valve (V101) enough to reduce the membrane stack
inlet pressure gauge (PI102) by approximately 10 barg.
b) Open any closed permeate isolation valves (V250 to V257) to supply the permeate
back into the common permeate manifold.
c) Gradually close the reject control valve (V101) until the permeate flowmeter
(FI101) reads 18 m3/h (max) or until the membrane stack inlet pressure gauge
(PI102) reads a maximum of 79 barg.
6.4.6 Low Feed Salinity Operation
If operating the plant in areas where low feed salinities are likely (such as near ice flows
or river discharges) it will be found that to produce the design output the plant operating
pressures will be greatly reduced. This is quite normal, as explained in section 1.0 of this
manual. Along with this reduction in plant operating pressure it will probably be noted
that the permeate conductivity will be very low, this again is quite normal.
6.5 SHUTDOWN PROCEDURES
6.5.1 Shutdown - upto 24 hours
If the plant is to be shutdown for upto 24 hours the following procedure should be
adopted:
1. Open permeate return valve (V108) until the flushing tank (T101) is full, then close the
valve (V108).
2. If permeate diversion valves are closed to divert, slowly open reject control valve (V101)
enough to reduce the membrane stack inlet pressure gauge (PI102) by approximately 10
barg.
3. Open any permeate diversion valves that are closed and allow the plant to operate for 5
minutes to flush high salinity permeate from membrane elements. Any subsequent
'HIGH CONDUCTIVITY ALARM' will have to be muted.
4. Slowly fully open reject control valve (V101).
5. Allow plant to operate for 1 to 2 minutes, to flush out all the concentrated brine from the
membrane element stack.
6. Stop HP pumps (P100, P101, P102 & P103) by depressing the common ‘STOP’
pushbutton.
7. Wait 5 seconds.
8. Stop the feed/backwash pump (P1).
9. Close the RO inlet valve (V100).

SSS
10. Open the flushing inlet control valve (V103).
11. Ensure the flushing pump is primed using the bleed screw on top of the pump casing.
12. Start the flushing pump (P104) by depressing the green ‘START’ pushbutton. Check the
flushing flow (on the feed indicator F100), it should be no more than 32 m³/h, if it is higher,
adjust using the flushing inlet control valve (V103).
13. Allow the flushing tank (T101) to empty the flushing pump should stop on low level.
14. Close the flushing inlet control valve (V103).
15. Close ships side valves (V60 and V61) by turning the selector switch to the ‘CLOSE’
position.
16. Switch the main isolator to the ‘OFF’ position.
Note
1) It is imperative that the plant is flushed through with permeate on plant shutdown as
this helps preserve RO membrane and equipment life.
2) The membrane elements in the RO vessels must never dry out, ensure that the RO
vessels are full of liquid at all times.
3) Protect the plant from temperatures of less than 1°C to prevent freezing.
4) Protect the plant from temperatures in excess of 45°C.
6.5.2 Shutdown - upto 2 days
If the plant is to be shutdown for longer than 24 hours procedures should be instigated to
prevent biological growth inside the membrane elements. Both antiscalant and hypochlorite
dosing tanks should also be emptied.
If the operational regime of the ship will allow - i.e. at sea and not docked, the plant can
simply be flushed daily for 10 to 15 minutes, this method can be adopted for an unlimited
period of time.
If it is thought that flushing with seawater may be a problem due to the ship being in an area
of contaminated feedwater, freshwater may be preferable, again this method can be adopted
for an unlimited period of time, however, if it is envisaged a lengthy shutdown is imminent
we would recommend a full chemical preservation (see section 6.5.3 of this manual).
If freshwater flushing is to be carried out for some time it would be prudent to backwash the
sandfilters before shutting down.

SSS
1. Seawater Flushing
Assuming the plant has been shutdown in accordance with section 6.5.1 of this manual:
a) Set the mains isolator to the ‘ON’ position.

b) Open ships side valves (V60 & V61), reset the emergency stop and open the plant
inlet valve (V100).
c) ‘MUTE’ and ‘RESET’ alarms.
d) Start feed/backwash pump (P1).
e) Wait 30 seconds.
f) Start HP pumps (P100, P101, P102 & P103).
g) Wait 10 minutes.
h) Stop HP pumps (P100, P101, P102 & P103).
i) Wait 30 seconds
j) Stop feed/backwash pump (P1).
k) Close the ships side valves (V60 & V61).
l) Set the mains isolator to the ‘OFF’ position.
2. Freshwater Flushing
Assuming the plant has been shutdown in accordance with section 6.5.1 of this manual:
a) Set the main isolator to the ‘ON’ position.

b) Open ships side valves (V60 & V61) reset the emergency stop.
c) ‘MUTE’ and ‘RESET’ alarms.
d) Close RO plant inlet valve (V100).
e) Fully open flushing pump control valve (V103).
f) Fill the flushing tank (T101) with clean water via filling line (V142). Add 20g of
sodium metabisulphite to the tank (this helps prevent biological growth and
removes chlorine).
g) Ensure the flushing pump is primed using bleed screw on top of pump casing.
h) Start the flushing pump (P104) and wait until pressure has built up through the
cartridge filter. Check the flushing flow, it should be no more than 32m³/h.
i) Allow the flushing tank (T101) to empty.
j) The flushing pump (P104) will stop when the flushing tank reaches low level and
the low level alarm (LAL100) is initiated.
k) Close flushing pump control valve (V103).
l) Close the ships side valves (V60 & V61).
m) Set the main isolator to the ‘OFF’ position.
6.5.3 Shutdown - periods greater than 2 days
If the plant is to be shutdown for longer than 48 hours and flushing daily is not a viable
option, the plant should be chemically preserved to prevent biological growth inside the
membrane elements.
Depending on the operational history of the plant it may be prudent to perform a

membrane element chemical clean before the plant is preserved.

SSS
WARNING
Plant preservation involves the use of Sodium Metabisulphite, operators should read and
take the necessary handling precautions as detailed on the COSHH sheets in section 5.0 of
this manual.
The following procedure should be undertaken to chemically preserve the plant from a running
condition.
1. Open the flushing tank (T101) permeate return valve (V108).
2. Allow the tank to fill with permeate and then close the return valve (V108).
3. If any permeate diversion valves (V250 to V257) are closed slowly open reject control valve
(V101) enough to reduce the membrane stack inlet pressure (PI102) by approximately 10
barg.
4. Open diversion isolation valves to supply and allow the plant to operate for 5 minutes to
flush high salinity permeate from the membrane elements.
5. Slowly open reject control valve (V101).
6. Allow the plant to operate for 2 to 3 minutes, to flush out all the concentrated brine from the
membrane element stack.
7. Stop the HP pumps (P100, P101, P102, P103) by depressing the common ‘STOP’
pushbutton.
8. Wait 30 seconds.
9. Stop the feed/backwash pump (P1).
10. Close RO plant inlet valve (V100).
11. Fully open flushing inlet/control valve (V103).
12. Ensure the flushing pump is primed using bleed screw on top of pump casing.
13. Start the flushing pump (P103) and wait until pressure has built up through the cartridge
filter.
14. Check the flushing flow (FI100), it should be no more than 32 m3/h. If necessary, adjust
using the flushing inlet/control valve (V103).
15. Allow the flushing tank (T101) to empty.
16. The flushing pump (P104) will stop when the flushing tank reaches low level and the low
level alarm (LAL100) is initiated.
17. ¾ fill the flushing tank with clean dechlorinated water via filling valve (V142).
18. Close the reject back-pressure valve (V114).

SSS
19. Open the flushing return valve (V102).
20. Open the flushing tank permeate return valve (V108).
21. Start the flushing pump (P104) and wait until pressure has built up through the cartridge filter.
22. Check the flushing flow (FI100), it should be no more than 32 m3/h.
Notes
a) The water should now be recirculating.
b) The flow of liquid through the flushing tank permeate return valve (V108) will be very
low, it may even be a no flow situation. This is due to the fact that any liquid passing
through this valve has to pass through the membranes, at a low pressure this passage will
be minimal.
23. Steadily add 15 Kg of Sodium Metabisulphite to the water in the flushing tank (T101).
24. Allow the solution to circulate for 10 to 15 minutes.
25. Open the reject back-pressure valve (V114).
26. Close the flushing return valve (V102).
29. Close the flushing permeate return valve (V108).
30. Close flushing inlet/control valve (V103).
31. Open the flushing/cleaning tank drain valve (V113). Allow the tank to drain down and close
the drain valve. Rinse out the tank with fresh water via filling valve (V142).
32. Backwash the sand filter by turning the sandfilter control selector switch to ‘AUTO’ and
depressing the backwash initiate pushbutton.
See section 2.0 ‘PLC Control Sequence’ of this manual for the backwash sequence.
Notes
a) The plant is now preserved for upto 3 months after which time the preservation
procedure should be repeated.
b) The pH of the preservation solution should be checked weekly to ensure that it does not
fall below pH 3. This can occur if the Sodium Metabisulphite is oxidised (due to
ingress of air) to Sulphuric Acid. Solution can be checked using a calibrated hand-held
pH meter with samples being taken from the sample valve (V351).
SSS
If the pH does fall below pH 3, the preservation solution should be changed

immediately as the salt rejection of the membranes will be affected at low pH storage.
c) The membranes must never be allowed to dry out, ensure the vessels are full of liquid
at all times.
d) Protect the plant from temperature of less than 1°C to prevent freezing.
e) Protect the plant from temperatures in excess of 45°C.
6.6 MEMBRANE CLEANING
When the membrane elements become fouled they are cleaned by recirculating chemical
solutions through the plant.
The control panel incorporates a built-in timer which annunciates a 'MEMBRANE CLEAN
REQUIRED' alarm every 1,000 hours of operation. The alarm can be muted by depressing
the 'ALARM ACCEPT/RESET' pushbutton. During the chemical clean, the alarm can be
reset by depressing the 'ALARM ACCEPT/RESET' pushbutton for 10 seconds. This will
reset the 1,000 hour timer.
Chemical cleaning is more effective when performed at elevated temperatures, however care
must be taken not to exceed recommended pH and temperature limitations during chemical
cleaning as the membranes may be irreversibly damaged.
It is not recommended to use cleaning solutions at less than 20°C because of the very slow
cleaning rate.
If the cleaning solution (acid or alkali) becomes turbid or discoloured from removed material,
etc… then drain the tank and prepare a fresh solution.
These cleaning instructions are for guidance only. Please read the ‘Hints for RO Membrane
Cleaning’ at the end of this section.
WARNING
Membrane cleaning involves the use of acidic and alkaline membrane cleaning
chemicals. Operators should read and take the necessary handling precautions as
detailed on the ‘Health and Safety Information’ in section 5.0 of this manual.
From a normal operating condition the following procedure should be followed to clean the
RO membrane elements:
1. Open the flushing tank (T101) permeate return valve (V108).
2. Allow the flushing tank to fill with permeate and close permeate return valve (V108).
3. Slowly fully open reject control valve (V101).

SSS
4. Allow water to flow through the plant for 2 to 3 minutes.
5. Stop the HP pumps (P100, P101, P102 & P103).
6. Stop feed/backwash pump (P1).
7. If any permeate isolation valves (V250 to V257) are closed to divert these must be opened
to supply.
8 Close RO plant inlet valve (V100).
9 Fully open the flushing inlet control valve (V103).
10 Ensure the flushing pump is primed using bleed screw on top of pump casing.
11 Start the flushing pump (P104) and wait until pressure has built up through the cartridge
filter.
12 Check the flushing flow (FI100), it should be no more than 32 m3/h.
15. Open the flushing return valve (V102).
16. Fully close reject back-pressure valve (V114).
17. Fill the flushing tank (T101) with 500 litres of hot, clean dechlorinated water via hot and
cold filling valves (V142 & V143) Add 20g of sodium metabisulphite (for
dechlorination). The ideal temperature is 30 to 35°C.
DO NOT ALLOW THE WATER TEMPERATURE TO EXCEED 35°C.
18. Open flushing permeate return valve (V108).
filter.
Notes
b) The flow of liquid from the flushing permeate return valve (V108) will be very
low, it may even be a no flow situation. This is due to the fact that any liquid
passing through the valve has to pass through the membranes, at low pressure this
passage will be minimal.

SSS
21. Steadily add 37.5 Kg (1½ pails) of Genesol 40 (or Genesol 34) cleaner to the water in the
flushing tank (T101).
22. The solution in the flushing tank (T101) should now have a pH value of 10.5. This can
be checked (whilst recirculating) using a calibrated hand-held pH meter with samples
being taken from sample valve (V351).
23. Allow the solution to circulate for at least 1 hour.
24. Open reject back-pressure valve (V114).
25. Close flushing return valve (V102).
27. Fill the flushing tank (T101) with hot, clean dechlorinated water add 20g of sodium
metabisulphite (for dechlorination).
DO NOT ALLOW THE WATER TEMPERATURE TO EXCEED 35ºC.
filter.
32. Repeat steps 27 to 31 until all the alkaline cleaner has been flushed from the system.
Flush until the discharge pH is less than 8.5. This will involve copious amounts of warm,
dechlorinated water - approximately 3 to 4 tankfulls.
33. Open flushing return valve (V102).
34. Close reject back-pressure valve (V114).
35. Fill the flushing tank (T101) with 500 litres of hot, dechlorinated water. Add 20g of
sodium metabisuphite (for decholrination) the ideal temperature is 30 to 35°C.
filter.

SSS
Notes
b) The flow of liquid from the flushing permeate return valve (V108) will be very
low, it may even be a no flow situation. This is due to the fact that any liquid
passing through the valve has to pass through the membranes, at low pressure this
passage will be minimal.
38. Steadily add 50 Kg (2 pails) of Genesol 38 membrane cleaner to the water in the flushing
tank (T101).
39. The solution in the flushing tank (T101) should now have a pH value of 3.7 If it is more
than 3, continue to add acidic cleaner (Genesol 38).
Note
The pH of the acidic cleaning solution should be checked every 5 minutes whilst
cleaning. The acid is consumed when it dissolves inorganic precipitates. Therefore, if
the pH increases by more than 0.5 (above the normal value of 3.7) add more acidic
cleaner. Solution can be checked using a calibrated hand-held pH meter with samples
being taken from sample valve (V351).
40. Allow the solution to circulate for 20 minutes.
41. Open reject back-pressure valve (V1141).
42. Close the flushing return valve (V102).
44. Fill the flushing tank (T101) with hot, dechlorinated water. Add 20g of sodium
metabisulphite (for dechlorination) the ideal temperature is 30 to 35°C.
filter.
49. Repeat steps 44 to 48 until the acid cleaner has been removed from the system. Flush
until the discharge pH is greater than 6. This will include copious amounts of warm, de-
chlorinated water - approximately 3 to 4 tankfulls.

SSS
50. Close flushing control valve (V103).
51. Close flushing permeate return valve (V108).
52. Install a new set of cartridge filter elements into the cartridge filter (see section 3.7).
53. Restart the plant as per section 6.3 ‘Start Up Procedures’.
54. Allow the plant to stabilise and take a new set of running parameters to enable
normalisation of the plant operating parameters.
Note
It is important that the flushing tank is thoroughly cleaned out and drained before and
after membrane cleaning.
Hints for RO Membrane Cleaning
Frequency of Cleaning: Membranes should always be cleaned when the flux has declined
by 10-15% or the differential pressure (ΔP) or driving pressure has increased by 10-15%.
Allowing conditions to deteriorate significantly worse than these values are a major cause
or permanent membrane damage. Clean the membranes when necessary, not when
convenient.
Temperature: Most chemical reactions proceed faster at high temperature, so it is strongly

recommended that cleaning be done at the maximum temperature allowable. Washing
clothes in hot water gives better results than washing them in cold water.
Flows: A typical flow rate for a single 8” pressure vessel is 160 – 180
litres/minute/pressure vessel. It is good operating practice to alternate between circulating
and standing on a 15 minute cycle. Standing allows chemical penetration, whilst
circulation removes non-soluble deposits.
Pressure: Cleaning should always be carried out at low pressure, <4 barg or 60 psi.
pH: Most cleaning is done under alkaline or acid conditions. Most organic deposits, such
as biofilm respond to an alkaline clean at 30 to 35°C and most inorganic deposits are
removed under acid conditions at similar temperatures.
Time: Premature termination of the cleaning programme is a common cause of cleaning

failure. It can also be detrimental to the removal of organic matter. Just because nothing
‘seems’ to be happening does not mean that nothing is happening.
Flushing: Always flush the membrane thoroughly between cleaning programmes.

Flushing is a much under-rated activity in membrane management.
Programmes: There are numerous combinations of cleaning chemical and cleaning

conditions and experience will show what is best for a specific system. It is good practice
to carry the cleaning schedule, and from time to time use different cleaners.

SSS
6.7 SAND FILTER BACKWASHING PROCEDURE
In normal operation the sand filter will become increasingly fouled by solid particles
which are filtered from the raw feedwater. To remove the deposits a filter cleaning
procedure is used, this is known as backwashing and comprises passing an increased flow
of water through the media in the opposite direction of the normal flow of raw water
through the filter.
Backwashing should be carried out when the differential pressure across the filter,
determined using filter inlet (PI2) and filter outlet (PI3) pressure gauges increases by 1.0
barg from clean or every 24 hours whichever is the sooner.
An alarm is incorporated in the plant to inform operators when the filters require
washing.
Under exceptional circumstances in particular when new media has been installed or
during commissioning is may be necessary to carry out an extended backwash.
Backwash the filter until the backwash water turns clear or a minimum of 30 minutes.
From a normal filtering position:
1. If the RO plant is running:
a) Slowly fully open reject control valve (V101).
b) Allow plant to operate for 2 to 3 minutes, to flush out all the concentrated brine
from the membrane stack.
c) Stop HP pumps (P100, P101, P102 & P103) by depressing red ‘STOP’ button.
d) Stop feed/backwash pump (P1) by depressing red ‘STOP’ button.
Note
If the RO plant is to remain shutdown after the backwash is complete, it is recommended

that the RO plant is flushed through with permeate (see 6.5.1).
2. Turn the sand filter control selector switch to ‘AUTO’.
3. Press the ‘BACKWASH INITIATE’ pushbutton.
Note
The PLC will now take control, the backwash sequence is described in detail in section
2.0 ‘PLC Control Sequence’ of this manual.
The backwash flowrate will vary depending upon the feedwater temperature.
It is critical that the correct flowrate is used otherwise a satisfactory wash may not be
achieved if it is too low of on the other hand media may be washed away if the wash
water flow is too high.

SSS
The varying flowrates are as follows:
Temperatures Flowrate Required
5°C 23.2 m3/h

10°C 26.4 m3/h
15°C 29.3 m3/h
20°C 32.9 m3/h
25°C 35.8 m3/h
30°C 39.5 m3/h
35°C 42.7 m3/h
The backwash flowrate can be controlled using the backwash control valve (V24).
Note
If media can be seen discharging to waste through the backwash sightglass (SG1), reduce
the backwash flowrate slightly using the backwash control valve (V24).
4. When the ‘BACKWASH COMPLETE’ indicator illuminates switch the sandfilter control
selector to ‘FILTER’.
5. Restart the plant as per section 6.3 'Start Up Procedures'.
6.8 EMERGENCY OPERATION
The plant can be operated and produce potable water at a reduced output if the following
scenario’s occur:
a) Partial RO membrane element(s) failure.
b) HP pump/motor failure.
c) Energy recovery device failure.
6.8.1 Partial RO Membrane Element(s) Failure
In the case of RO membrane element failure, individual vessels are fitted with three way
permeate diverter valves which can be used to divert out of specification permeate from
any malfunctioning vessel(s) back into the feed, see section 6.4.7 ‘High Feed
Temperature Operation’.
6.8.2 HP Pump or Motor Failure
If a HP pump or motor should malfunction, the plant can be run at reduced output
(maximum permeate flow 14 m³/h). In order to configure the plant to run, the following
must be carried out (with the RO plant shutdown):
WARNING
Only qualified personnel should carry out the following procedure.

SSS
1. Electrically isolate the plant and tag out.
2. Mechanically isolate the plant and tag out.
3. Disconnect the malfunctioning HP pump motor inside the control panel and ensure
that the terminals and removed cables are left in a safe place.
4. Remove the malfunctioning HP pump suction flexible hose and fit a Victaulic blank
into the low pressure feed pipework (Victaulic blanks are available from Salt
Separation Services). Ensure removed components are stored safely.
5. Remove the malfunctioning HP pump discharge flexible hose and fit a Victaulic
blank into the high pressure feed pipework (Victaulic blanks are available from Salt
Separation Services). Ensure removed components are stored safely.
6. Disconnect and blank the energy recovery device (the unit can be damaged if used
on flowrates outside of its design parameters). See 6.8.3
7. The RO plant can now be operated as normal but note that the feed flow will only
be 30 m³/h. Ensure maximum permeate flow (14 m³/h) is not exceeded. Ensure that
the HP pumps are fully primed before running.
Notes
1. If the failed HP pump is to be left in-situ and the plant is to be run, only items 1 to 3
need to be carried out.
2. Running the plant at this reduced feed flow and permeate flow will not result in any
detrimental performance with respect to permeate quality.
6.8.3 Energy Recovery Device Failure
If the energy recovery device fails, the unit can be removed from the system and spool
pieces and Victaulic blanks can be fitted as follows:
a) Remove energy recovery device from system.

b) Connect HP pump discharge pipework to RO membrane inlet pipework using high
pressure spool piece.
c) Blank energy recovery device reject inlet pipework using high pressure Victaulic
blank.
d) Blank energy recovery device reject outlet pipework using low pressure Victaulic
blank.
e) Ensure back pressure valve (V114) is left FULLY OPEN.

SSS
7.0 ROUTINE MAINTENACE/DATA NORMALISATION/POTABLE WATER

TESTING/LUBRICATION/SPARES
7.1 ROUTINE MAINTENANCE
7.1.1 Introduction
7.1.2 Suction Strainer (PV1)
7.1.3 Feed/Backwash Pump (P1)
7.1.4 Sand Filters (PV2A & B)
7.1.5 Cartridge Filter (PV100)
7.1.6 HP Pumps (P100/P101/P102/P103)
7.1.7 HP Pump Motors (M100/M101/M102/M103)
7.1.8 RO Membrane Element Vessels (PV101 to PV108)
7.1.9 Reverse Osmosis Membrane Elements
7.1.10 Antiscalant Dosing Pump (P105)
7.1.11 Dosing Tank (T100)
7.1.12 Valves
7.1.13 Flexible Hoses
7.1.14 Pressure Gauges
7.1.15 Low Suction Pressure Switch (PS100)
7.1.16 High HP Pump Discharge Pressure Switch (PS102)
7.1.17 Sand Filter Differential Pressure Switch (DPS1)
7.1.18 Flow Transmitters (FT100 & FT101)
7.1.19 Flowmeters (FI1 & FI200)
7.1.20 Conductivity Analyser (DIC100, QT100 & QT101)
7.1.21 Relief Valves (PSV100, PSV101, PSV102 & PSV103)
7.1.22 Panel Lamps
7.1.23 Flushing Tank Level Control (LS100)
7.1.24 Control Panel Air Filters

SSS
7.1.25 Air Preparation Equipment
7.1.26 Motor Overloads
7.1.27 Energy Recovery Device
7.1.28 High Membrane Inlet Pressure Switch (PS101)
7.2 NORMALISATION OF RO PLANT PERFORMANCE
7.2.1 Introduction
7.2.2 Normalised Permeate Flow
7.2.3 Normalised Permeate Salinity
7.2.4 Membrane Differential Pressure
7.3 POTABLE WATER TESTING
7.3.1 Hardness Testing
7.3.2 Chlorine Testing
7.4 LUBRICATION SCHEDULE
7.5 SPARES, CONSUMABLES, SPECIAL TOOLS
7.5.1 Consumables
7.5.2 Special Tools
7.5.3 Spares

SSS
7.1 ROUTINE MAINTENANCE
7.1.1 Introduction
This section contains instructions for routine maintenance of the plant. Section 7.3 of this
manual should be consulted for lubrication schedules.
These instructions are not intended as a substitute for the manufacturers literature (refer
to section 9.0 of this manual) but are to compliment the operating instructions for routine
plant checks.
Whilst performing routine maintenance procedures, the operator should be constantly

looking for the potential failure of equipment. Failure of a piece of equipment is often
preceded by noise vibration or lack of response.
If the operator suspects that a malfunction is about to occur, he should report his opinion
immediately to the relevant Maintenance Staff.
WARNING
This system operates a very high pressure. Unqualified personnel must not be
allowed to adjust or repair any of the equipment.
7.1.2 Suction Strainer (PV1)
Weekly : Open and clean strainer basket.
6 Monthly : Change-out lid 'O' ring seal.
WARNING
Ensure plant is shutdown and ships side valve is closed before attempting to open
the strainer.
7.1.3 Feed/Backwash Pump (P1)
Each Use : Ensure pump is fully primed/vented. Check gland for leakage. Check
motor for excessive heat, noise and vibration.
7.1.4 Sand Filters (PV2A & B)
Daily : Backwash the filter as per instructions in this manual (see Operation,
section 6.0 of this manual).
6 Monthly : Shock dose with sodium hypochlorite to eliminate barnacles, encrustations

& biological growth.
12 Monthly : Check media level and condition, check coating integrity.

SSS
WARNING
Extreme care must be taken when shock dosing with chlorine as strong oxidants can
irreversibly damage the RO membrane elements.
7.1.5 Cartridge Filter (PV100)
Daily : Check the differential pressure, if it has increased by 1.0 barg from the
clean condition change the filter cartridge.
Ensure there are no signs of leakage.
6 to 8 Weeks: Change the filter cartridge regardless of differential pressure (see

Operation, section 6.0 of this manual).
12 Monthly : Check integrity of vessel/internals.
7.1.6 HP Pumps (P100/P101/P102/P103)
Daily : Inspect for leakage, excessive vibration, noise or overheating.
Note When carrying out maintenance on the plant, ensure that the HP pumps are
fully primed prior to running - refer to equipment literature in section 9.0
of this manual.
4,000 hours: Carry-out pump inspection and replace components where necessary. Pay
particular attention to pistons and shaft seal.
8,000 hours: Change-out pumps for new replacement or reconditioned and return
removed pumps to Salt Separation Services for overhaul.
7.1.7 HP Pump Motors (M100/M101/M102/M103)
Daily: Inspect for excessive vibration noise or overheating.
11,000 hours: The motor is fitted with grease lubricated bearings which require
recharging. Refer to lubrication schedule in section 7.4 of this manual.
6 Monthly: Electrically check the motor (earthing, load, etc…)
7.1.8 RO Membrane Element Vessels (PV101 to PV108)
Daily : Inspect the end plugs for signs of leakage.
6 Monthly : Inspect the retaining rings of each vessel end.
Note On assembly of the end caps use only a light application of silicon grease
as an 'O' ring lubricant.

SSS
7.1.9 Reverse Osmosis Membrane Elements
Daily : Check the membrane stack differential pressure and permeate flowrate,
adjusting as necessary with reject control valve (V101).
Fill in a daily log sheet so as trends can be determined (see data

normalisation, section 7.2 of this manual).
Membrane Element Care
It is important that the operator is aware that membrane elements will require attention
when the plant is to be shutdown or when they become fouled.
When the plant is shutdown, the membrane elements must be flushed and preserved
following the instructions in section 6.0 of this manual.
When the membrane elements become fouled, their performance (or ability to desalinate)
reduces. When this happens, the membrane elements must be chemically cleaned
following the instructions in section 6.0 of this manual.
Plant preservation and cleaning includes the use of chemicals, information for the various
chemicals used should be understood by all operating personnel and is given in section
5.0 of this manual.
7.1.10 Antiscalant Dosing Pump (P105)
Daily : Check for diaphragm leakage, excessive overheating/noise and fouled

inlet/outlet valves.
Monthly : Check and clean as necessary, foot valve and suction strainer.
12 Monthly: Overhaul pump liquid ends.
7.1.11 Dosing Tank (T100)
Daily : Check level, top up as necessary.
Monthly : Empty tanks and thoroughly wash out.
Note Do not mix the tank contents as dosing the incorrect chemical can result in
irreversible RO membrane damage or possible contamination of potable
water.
7.1.12 Valves
Weekly : Check all valve glands for leakage, adjust/replace as necessary.
Monthly : Operate all valves to prevent seizing.

SSS
WARNING
Never adjust valve glands whilst the plant is running. If the plant is running never
operate any valve unless it is in a correct sequence in accordance with Instructions
in section 6.0 of this manual.
7.1.13 Flexible Hoses
Weekly : Inspect all hoses for signs of cracking, abrasion, creep or leakage.
WARNING
If the hoses show any signs of damage they should be replaced immediately.
7.1.14 Pressure Gauges
Weekly : Check the glycerine level in each gauge, top up if required.
6 Monthly : Check the membrane stack inlet (PI102), membrane stack outlet (PI103)
and HP pump discharge (PI105) pressure gauges for calibration.
12 Monthly : Check the feed pump suction (PI1), sand filter (PI2, PI3), cartridge filter
(PI100, PI101) and permeate (P104) pressure gauges for calibration.
7.1.15 Low Suction Pressure Switch (PS100)
6 Monthly : Check the set point is correct: 2.0 barg falling. Ensure that on low suction
pressure the HP pumps stop.
12 Monthly : Completely dismantle, clean and inspect all parts. Replace/repair as

necessary.
7.1.16 High HP Pump Discharge Pressure Switch (PS102)
6 Monthly : Check the set point is correct: 80 barg rising, ensure that on high pressure
the HP pumps stop.
12 Monthly : Complete dismantle, clean and inspect all parts. Replace/repair as

necessary.
7.1.17 Sand Filter Differential Pressure Switch (DPS1)
6 Monthly : Check the set point is correct: 1.4 barg rising. Ensure that on high
pressure the sand filter backwash required lamp illuminates.
12 Monthly : Completely dismantle, clean and inspect all parts. Replace/repair as

necessary.

SSS
7.1.18 Flow Transmitters (FT100 & FT101)
12 Monthly : Remove the transmitter, wash in warm soapy water and refit.
7.1.19 Flowmeters (FI1 & FI200)
12 Monthly: Remove the tube and float, wash in warm soapy water and refit.
7.1.20 Conductivity Analyser (DIC100, QT100 & QT101)
3 Monthly : Check calibration of conductivity analyser against calibrated portable

meter, or utilising standard solution (refer to manufacturers literature in
12 Monthly : Remove the cells, wash in warm soapy water, calibrate as per instructions
in section 9.0 of this manual.
7.1.21 Relief Valves (PSV100, PSV101, PSV102 & PSV103)
Daily : Ensure that relief valves are not passing at normal plant pressures.
Note If the HP relief valve is passing, feed water flow on to the membranes will
be reduced which could lead to membrane fouling problems and loss of
permeate flow.
12 Monthly : Check the set pressure of all relief valves.
WARNING
Relief valves must be removed from the plant and checked by suitably qualified
personnel only. If the valves are incorrectly set a catastrophic failure could occur.
7.1.22 Panel Lamps
Weekly : Test all indicator lamps (LED’s) and audible alarm on the control panel by
depressing the lamp test button. Replace as necessary.
7.1.23 Flushing Tank Level Control (LS100)
During Flush : During the cleaning/flushing procedure check that the flushing pump
(P104) stops when the level falls below the switch (LS100).
7.1.24 Control Panel Air Filters
Monthly : Remove, clean and replace filter pads located under louvres. Fit new filter
pads as necessary.

SSS
7.1.25 Air Preparation Equipment
Daily: Check liquid level in bowls and drain-out as necessary.
Ensure there are no signs of leakage.
12 Monthly: Change-out filter element and oil removal filter element (or sooner if
necessary).
7.1.26 Motor Overloads
12 Monthly: Test the motor overloads to ensure correct operation. Ensure that the
overloads are set to trip at the correct trip current as indicated on the motor
identification plate, i.e. full load current.
7.1.27 Energy Recovery Device
Daily: Check for signs of leakage and that the unit is operating correctly.
12 Monthly: Strip down, inspect and overhaul as required (see supplier literature in
7.1.28 High Membrane Inlet Pressure Switch (PS101)
6 Monthly : Check the set point is correct: 80 barg rising, ensure that on high pressure
the HP pumps stop.
12 Monthly : Complete dismantle, clean and inspect all parts. Replace/repair as

necessary.
7.2 NORMALISATION OF RO PLANT PERFORMANCE
7.2.1 Introduction
One of the most important aspects of efficiently running a Reverse Osmosis plant is
effective monitoring of the plant performance. Reverse Osmosis plants are a very
vulnerable type of machine, it is not all that difficult to do extensive damage to the
membrane elements in a relatively short time by allowing the membrane elements to
operate on an incorrectly treated feed water or under conditions outside their safe
operating envelope. It is therefore essential that early detection of any deviation from
normality of the plants operation is made.
It is natural for RO membrane elements to change in performance with time, but once the
elements have stabilised, these changes should occur slowly. There are a number of
variables which also affect the performance of RO membrane elements on a day to day
basis such as feedwater temperature, pressure, recovery and water chemistry. For
example, a feed temperature drop of 4°C will cause a permeate flow decrease of around
10%. It is often difficult to determine whether a change is to be naturally expected or if
the observed change is indicative of a problem.

SSS
In order to distinguish between such normal phenomena and real performance changes,
the measured permeate flow and salt passage have to be normalised, that means compared
to a given reference performance while the influence of normally varying operating
parameters are taken into account. The reference performance may be the designed
performance or the measured initial performance (be it as new or after a chemical clean).
Implicit in a program of this nature is a well maintained instrument calibration program
and accurate data collection. The purpose of normalisation is to reduce the daily
operating data to a standard set of conditions, thereby allowing detection of trends in the
performance of the RO membrane elements.
The normalisation procedure is strongly recommended because it allows early

identification of potential problems e.g. scaling or fouling. Consequently early corrective
measures are more likely to reverse the debilitating effects of such problems.
By its very nature, data normalisation for a system is not an exact science. It is necessary
to treat a system from an average point of view and make a number of assumptions for
such things as pressure drop, conductivity to TDS relationships, etc...
Our objective is to correct the data for temperature, concentration and net driving
pressure, thereby adjusting for the day to day variations of known factors that affect a
system’s performance.
It is vital, in order to be able to make full use of the normalisation procedures described,
that proper and full records of the plants performance be kept - preferably on a daily
basis. These should include both the raw and normalised data. Only major plant output
parameters are monitored, each of these might be expected to vary under normal
operating conditions.
Essential data required for full plant normalisation is:
a) Membrane element feed temperature

b) Membrane element feed flow
c) Membrane element feed pressure
d) Membrane element reject pressure
e) Membrane element feed salinity (from conductivity)
f) Permeate flow
g) Permeate salinity (from conductivity)
h) Permeate back pressure
Using this raw data and following the membrane element manufacturers procedures the
normalised permeate flow, normalised permeate salinity and membrane differential
pressure can be calculated.
Membrane elements should be cleaned whenever the normalised permeate flow drops by
10%, the normalised salt content of the permeate increases by 10% or the differential
pressure across the membranes increases by 15%. It is the operators choice which
method is adopted, however, we feel the most accurate method is normalised permeate
flow.

SSS
7.2.2 Normalised Permeate Flow
The calculation falls into five distinct parts.
a) Temperature correction factor - The water flux through an RO membrane element

varies with temperature due to two different mechanisms. Firstly, water becomes
less viscous as its temperature increases and so it tends to pass through the
membrane surface more easily at high temperatures. Secondly, the membrane
surface changes with temperature (the pores ‘expand’) and this also increases the
permeability. The viscosity variation is much the larger effect and the
temperature correction factor allows for and negates its effect in the normalisation
procedure.
b) The recovery of the plant - Simply the ratio of permeate produced to feed water
supplied, an indicator of how hard the plant is being pushed.
c) Concentration factor of the feed - Shows just how much the feed water is
concentrated as it passes along the length of the membrane elements and permeate
is ‘removed’ from it.
d) Osmotic pressure of the feed - As explained earlier when a semi-permeable

membrane separates high salinity water from low salinity water a ‘natural’
pressure is set up (osmosis). This osmotic pressure has to be overcome in the
opposite direction before any permeate can be ‘driven’ through the membrane.
e) Normalised permeate flow - the above are calculated for both the start up/standard
conditions and the actual day to day condition.
The calculated normalised permeate flow is then compared against the

standard/start up permeate flow. When the normalised flow has decreased by
10% from standard conditions a chemical clean should be undertaken.
Calculating the normalised permeate flow :-
1. Calculate the temperature correction factor (TCF)
⎡ ⎡ ⎡ 1 ⎤ ⎡ 1 ⎤⎤ ⎤
TCF = ex ⎢2640 × ⎢ ⎢ ⎥−⎢ ⎥⎦ ⎥ ⎥ Where T ≥ 25°C
⎣ ⎣ ⎣ 298 ⎦ ⎣ 273 + T ⎦ ⎦
⎡ ⎡ ⎡ 1 ⎤ ⎡ 1 ⎤⎤ ⎤
TCF = ex ⎢3020 × ⎢ ⎢ ⎥−⎢ ⎥ ⎥ ⎥ Where T ≤ 25°C
⎣ ⎣ ⎣ 298 ⎦ ⎣ 273 + T ⎦ ⎦ ⎦
Where T = Feedwater Temperature (°C)
ex = Antilogarithm of natural logarithm

SSS
2. Calculate the recovery ratio of the plant (R)
PF
R=
FF
Where PF = Permeate flow (m3/h)

FF = Feed flow (m3/h)
3. Calculate the concentration of the feed (CF)
⎡ ⎡ 1 ⎤⎤
⎢1n ⎢ ⎥
⎢ ⎣ (1 − R ) ⎥⎦ ⎥
CF = SF ×
⎢ R ⎥
⎢ ⎥
⎢⎣ ⎥⎦
Where 1n = natural logarithm

R = plant recovery ratio
SF = salinity of feedwater (TDS, mg/l - from TDS Vs conductivity tables)
4. Calculate the osmotic pressure of the feed (OF).
For water with a CF of less than 20000 mg/l.
CF × (T + 320)
OF = barg
491000
For water with a CF of more than 20000 mg/l.
⎡ (0.0117 × CF) − 34 ⎤ ⎡ T + 320 ⎤

OF = ⎢ ⎥ × ⎢⎣ 345 ⎥⎦ barg
⎣ 14.23 ⎦
5. From the above we can now calculate the normalised permeate flow (PFs)
⎡ ⎡ FPs − RPs ⎤ ⎤
⎢FPs − ⎢ ⎥ − PPs − OFs ⎥
⎣ 2 ⎦ ⎡ TCFs ⎤
PFs = ⎣ ⎦ ×⎢ ⎥ × PFa
⎡ ⎡ FPa − RPa ⎤ ⎤ ⎣ TCFa ⎦
⎢FPa − ⎢ 2 ⎥ − PPa − OFa ⎥
⎣ ⎣ ⎦ ⎦
Where
PF = Permeate Flowrate (m3/h)

FP = Feed Pressure (barg)
RP = Reject Pressure (barg)
PP = Permeate Back Pressure (barg)
OF = Osmotic Pressure Feed (barg)
TCF = Temperature Correction Factor
Subscript s = Standard Start Up Condition
Subscript a = Actual Current Operating Condition

SSS
This permeate flow (PFs) is compared against the 'Start Up' permeate flow, if it has
decreased by 10% a chemical clean should be carried out.
7.2.3 Normalised Permeate Salinity
Involves using some of the previously calculated parameters along with the calculated
permeate osmotic pressure.
The calculated actual operating normalised permeate salinity is then compared against the
standard/start up permeate salinity. When the normalised salinity has increased by 10%
from standard/start up conditions a chemical clean should be undertaken.
Calculation of the normalised permeate salinity:
1. Calculate the concentration of the permeate factors (CP)
⎡ ⎡ 1 ⎤⎤
⎢1n ⎢ ⎥
⎢ ⎣ (1 − R ) ⎥⎦ ⎥
CP = SP ×
⎢ R ⎥
⎢ ⎥
⎢⎣ ⎥⎦
Where 1n = natural logarithm

R = plant recovery ratio
SP = salinity of permeate (TDS, mg/l - from TDS Vs conductivity tables)
2. Calculate the permeate osmotic pressure (OP).
CP × (T + 320)
OP = barg
491000
Where T = feedwater temperature (°C)
3. From the above we can now calculate the normalised permeate salinity (PS)
⎡ ⎡ FPa − RPa ⎤ ⎤
⎢ FPa − ⎢ 2 ⎥ − PPa − OFa + OPa ⎥
⎣ ⎦
PS s = ⎣ ⎦ CFs
× × PS a
⎡ ⎡ FPs − RPs ⎤ ⎤ CFa
⎢ FPs − ⎢ 2 ⎥ − PPs − OFs + OPs ⎥
⎣ ⎣ ⎦ ⎦
Where
PS = Permeate Salinity (mg/l)

FP = Feed Pressure (barg)
RP = Reject Pressure (barg)
PP = Permeate Back Pressure (barg)
OF = Osmotic Pressure Feed (barg)
OP = Osmotic Pressure Permeate (barg)
CF = Concentration Feed

SSS
Subscript s = Standard Start Up Condition

Subscript a = Actual Current Operating Condition
This permeate salinity (PSs) is compared against the 'Start Up' permeate salinity, if it has
increased by 10% a chemical clean should be carried out.
7.2.4 Membrane Differential Pressure
The differential pressure across the membranes (through the feed/brine space) is
monitored using the stack inlet (PI102) and reject (PI103) pressure gauges. When the
differential pressure increased by 15% from the clean start up differential pressure, a
chemical clean should be undertaken.
7.3 POTABLE WATER TESTING
7.3.1 Hardness Testing
Introduction
To comply with World Health Organisation guidelines the hardness level of potable water
should be between 40 and 80 mg/l as CaCO3.
Hardness testing is used to check the set-up of the rehardener. This hardness test
provides a simple on site method of checking low levels of water hardness over the range
of 0 - 500 mg/l (CaCO2).
Method
Calcium and magnesium ions, which cause water hardness, are complexed by reaction
with ethylenediaminetetraacetic acid (EDTA). Excess calcium and magnesium ions react
with a specific indicator to produce a to produce a distinctive coloration. The hardness
test uses a tablet reagent containing a standardised amount of EDTA with eriochrome
black as an indicator. The test is carried out by adding tablets one at a time to a sample
of water held in a calibrated container, until the colour changes from plum red to blue.
The result is calculated from the number of tablets used in relation to the volume of water
sample taken.
Test Range
The table below indicates the sample size appropriate to different hardness test ranges:
Test Range Sample Size Tablet Type
0 - 25 mg/l (CaCO) 100 ml Low Range

25 - 50 mg/l (CaCO3) 50 ml Low Range
50 - 75 mg/l (CaCO3) 20 ml * Low Range
75 - 100 mg/l (CaCO3) 200 ml ** High Range
100 - 250 mg/l (CaCO3) 100 ml High Range
250 - 500 mg/l (CaCO3) 50 ml High Range

SSS
* Dilute to 50ml with deionised water if possible
** Use the container provided to measure 2 x 100 ml samples into a suitable clear
container which is thoroughly clean.
Test Procedure
1. Select the sample size appropriate to the hardness range under test. Take a sample
of the correct size in the pre-cleaned sample container.
2. Add one of the appropriate hardness tablets, secure the lid and shake the container
until the tablet disintegrates.
3. Continue adding tablets one at a time in this manner until the colour of the
solution changes from plum red to blue.
4. Note the number of tablets used and calculate the result from the formula below
appropriate to the sample volume taken:
Low Range Sample Size Calculation Hardness mg/l (CaCO3)
100 ml = (No. of Tablets x 2) - 1

High Range Sample Size

Cleaning : Thoroughly rinse out sample container and lid after use.
Notes
a) The expression of hardness results sometimes causes confusion. It is normal

practice to express the result of hardness tests as mg/l CaCO3 (calcium carbonate).
This is merely a convention to allow the comparison of different results and does
not necessarily indicate that the hardness is present in the water in this form.
b) This test measures total hardness, i.e. the total content of calcium and magnesium
ions in the water.
c) For accurate determination it is important to select the correct test range. Try not
to use too many or too few tablets. If the colour changes in only a few tablets
select a lower range, if the test requires so many tablets as to render the colour
change difficult to detect select a higher range.

SSS
7.3.2 Chlorine Testing
Introduction
The most commonly used water treatment sterilising agent is chlorine. When water is
chlorinated (this is termed the total residual chlorine level) some of the chlorine is
consumed in oxidising the biological and organic material present. Many waters also
contain traces of ammonia which reacts with the chlorine to form chloramines.
The addition of further chlorine tends to destroy the chloramines and then once this stage
is passed further chlorine will remain as 'free' dissolved chlorine.
The chlorine test method utilised is of the 'Lovibond' tablet/comparator type. Discs for
0.1 to 1.0 and 1.0 to 4.0 mg/l are available.
The 'Total Residual Chlorine' is tested for using the DPD No 4 tablets. The remaining
'Free Chlorine' is tested for using the DPD No 1 tablets.
Method for Free Chlorine
1) Place a clean 13.5mm/10ml moulded cell, containing the sample, in the left-hand
compartment of the comparator.
2) Rinse out another cell with sample and leave a few drops in the bottom.
3) Add to this cell a DPD No 1 tablet (do not handle) and crush with a clean stirring
rod.
4) Make up the volume to 10ml with sample water, mix rapidly to dissolve the
remains of the tablet and place the cell in the right-hand compartment of the
comparator.
5) Hold the comparator against a source of white light (e.g. fluorescent lighting) and
rotate the disc until a colour match is obtained in both windows of the comparator,
the disc reading represents the chlorine in mg/l. Record the reading as free
chlorine.
Method for Total Residual Chlorine
1) Place a clean 13.5mm/10 ml moulded cell, containing the sample, in the left-hand
compartment of the comparator.
2) Rinse out another cell with sample and leave a few drops in the bottom.
3) Add to this cell one DPD No 4 tablet (do not handle) and crush with a clean
stirring rod.
4) Make up the volume to 10ml with sample water, mix rapidly to dissolve the
remains of the tablet and place the cell in the right-hand compartment of the
comparator.

SSS
5) After two minutes match the colours and record the reading as total residual
chlorine.

SSS
7.4 LUBRICATION SCHEDULE
ITEM LUBRICANT TOP UP CHANGE QUANTITY COMMENTS

FREQUENCY FREQUENCY
'O' ring seals (for Silicone Grease (Molycote 111 or -------- -------- -------- Use no oily substances on any
assembly purposes) M494) wetted parts due to risk of
contaminated the membranes
Brine seals on RO Glycerine -------- -------- -------- Use no oily substances on any
membrane elements (for wetted parts due to risk of
installation purposes) contaminating the membranes.
Do not use Silicone Grease on
brine seals otherwise vessel
will be coated with grease
allowing bacteria/dirt to attach
itself to the vessel.
Note
All motor bearings are sealed for life – refer to motor manufacturers literature in section 9.0 of this manual.

SSS
7.5 SPARES, CONSUMABLES, SPECIAL TOOLS
7.5.1 Consumables
Consumables
One Years Estimated
Part Description Part No. Comments
Quantity
10µm Absolute Cartridge Filter Element AR505/7.1 10
25Kg Antiscalant GENSW-25 20
25Kg Acidic RO Membrane Cleaner GEN38-25 7
25Kg Alkali RO Membrane Cleaner GEN40-25 7
20Kg Rehardener media JURAP-20 140
10Kg Sodium Metabisulphite SMBS-10 1
5Kg Glycerine GLYC-5 1
Silicone Grease, 125ml Tin LUB-SIL-125 As required
CO₂ (Carbon Dioxide) N/A (by client) As required Dosed at 5 mg/l

SSS
7.5.2 Special Tools
Special tools required for the operation and maintenance of this plant in addition to ‘standard’ tools found in a marine engineering environment are
as follows:
Special Tools
Carried On-
Part Description
Board Comments
Chlorine/Hardness Test Kit 1 For testing permeate hardness and chlorine levels
SDI Test Kit 1 For testing feed water fouling index
Conductivity Analyser c/w Case & Standard 1 For fault-finding and testing feed, permeate and CIP
Solutions solutions.
End Cap Extraction Tool Kit 1 RO pressure vessel end cap removal
HP Pump Tool Kit 1 For servicing HP pumps

SSS
7.5.3 Spares
The following spare parts listings are not exhaustive – for fully comprehensive manufacturers spare parts, please refer to the information in section
9.0 of this manual.
Recommended Valve Spares

Carried Two Years
Equipment Part Description Part No. Comments
On-Board Spares Quantity
HP Pressure Relief Valve HP Pressure Relief Valve AQ936/1.2 0 1 Set at SSS
Reject Pressure Relief Valve Reject Pressure Relief Valve AR419/1.5 0 1 Set at SSS
Permeate Pressure Relief Valve Permeate Pressure Relief Valve AR419/1.4 0 1 Set at SSS
Feed Pressure Relief Valve Feed Pressure Relief Valve AR419/1.32 0 1 Set at SSS
CO₂ Non Return Valve CO₂ Non Return Valve AR492/6.30 0 1
HP Ball Valve Seal Kit 1 1
HP Pump By-Pass Non Return Valve HP Pump By-Pass Non Return Valve AR632/4.5-MOD 0 1 Machined End Connection
by SSS
HP Pump Discharge Non Return Valve HP Pump Discharge Non Return Valve AR422/4.2 0 1
Non Return Valve 3" NB 3" NB Type CD Non Return Valve AR458/1.13 0 1
Reject Control Valve Bonnet Gasket S09247-09-01 0 2
Reject Control Valve Body Seat Gasket S09247-09-01 0 2
Reject Control Valve Stem Packing Set S09247-09-01 0 2
Reject Control Valve Plug/Stem S09247-09-01 0 1
Reject Control Valve Cage S09247-09-01 0 1
Reject Control Valve Packing Spacer S09247-09-01 0 1
Reject Control Valve Gland Follower S09247-09-01 0 1
Butterfly Valves 3" NB Bareshaft Valve AR419-3" B/F-B/S 0 1
Butterfly Valves 4" NB Bareshaft Valve AR419-4" B/F-B/S 0 1
Butterfly Valves 4" Actuator Repair Kit ES65-RK 0 1
Butterfly Valves 3" Actuator Repair Kit ES40-RK 0 1
Butterfly Valves Switchbox Circa 1000 0 1
Butterfly Valves Gear Operator WW-232-Gear 0 1
Butterfly Valves Lever Handle WW-Lever 0 1
ABS Diaphragm Valves 2" NB Manual Valve AR418/1.16 0 1 Union Ends Fitted at SSS
ABS Diaphragm Valves 1½" NB FSC Valve c/w Stroke Adjuster AR418/1.17 0 1 Union Ends Fitted at SSS

SSS
Recommended Valve Spares
ABS Diaphragm Valves 2" NB FSC Valve AR418/1.18 0 1 Union Ends Fitted at SSS
ABS Diaphragm Valves 2" NB FSO Valve AR418/1.19 0 1 Union Ends Fitted at SSS
ABS Non Return Valves 2" NB Non Return Valve AR418/1.20 0 1

Non Return Valve 3" NB 1½" NB Non Return Valve AR418/1.21 0 1
ABS Ball Valves 2" NB Ball Valve AR418/1.22 0 1
ABS Ball Valves 1" NB Ball Valve AR418/1.23 0 1
ABS Ball Valves ½" NB Ball Valve AR418/1.24 0 1
ABS Ball Valves 1" NB 3-Way Ball Valve AR418/1.26 0 1
ABS Air Release Valves 1" NB Auto Air Release Valve AR418/1.27 0 1

SSS
Recommended Piping Spares
Carried Two Years
1¼" NB Victaulic Coupling 1¼" NB Victaulic Coupling 1-25HPC-SS 1 2
1½" NB Victaulic Coupling 1½" NB Victaulic Coupling 1.5HPC-SS 1 6
2" NB Victaulic Coupling 2" NB Victaulic Coupling 2.0HPC-SS 1 2
2½" Victaulic Coupling 2½" Victaulic Coupling 2.5HPC-SS 1 2
3" NB Victaulic Coupling 3" NB Victaulic Coupling 3.0HPC-SS 1 2
1¼" NB Victaulic Coupling 1¼" NB Victaulic Gasket SEAL 1.25 VIC 1 2
1½" NB Victaulic Coupling 1½" NB Victulic Gasket SEAL 1.5 VIC 1 6
2" NB Victaulic Coupling 2" NB Victaulic Gasket SEAL 2.0 VIC 1 2
2½" NB Victaulic Coupling 2½" NB Victaulic Gasket SEAL 2.5 VIC 1 2
3" NB Victaulic Coupling 3" NB Victaulic Gasket SEAL 3.0 VIC 1 2
HP Pipework 'U' Bend TBC 0 2
HP Pipework HP Pump Discharge Flexible Hose 09247-04-05 1 2
LP Pipework HP Pump Suction Flexible Hose 09247-04-03 0 1
LP Pipework ABS Glue Kit TBC 0 1 Includes Cement, MEK &
Brushes
LP Pipework 2" NB Union 'O' Ring BS332-EPDM 2 5
LP Pipework 1½" NB Union 'O' Ring BS328-EPDM 2 5
LP Pipework 1" NB Union 'O' Ring BS219-EPDM 2 5
LP Pipework ½" NB Union 'O' Ring BS211-EPDM 2 5
LP Pipework 3" NB EN1092-1 PN10 Gasket RG-3.0NP16 1 5
LP Pipework 1 mtr 3" NB ABS-E Pipe ABS-E-3.0 0 1
LP Pipework 1 mtr 2" NB ABS-E Pipe ABS-E-2.0 0 1
LP Pipework 1 mtr 1½" NB ABS-E Pipe ABS-E-1.5 0 1
LP Pipework 1 mtr 1" ABS-E Pipe ABS-E-1.0 0 1
LP Pipework 1 mtr ½" NB ABS-E Pipe ABS-E-0.5 0 1
LP Pipework 3" NB Socket ABS 01-100-109 0 4
LP Pipework 1½" NB Socket ABS 01-100-106 0 4

SSS
Recommended Piping Spares
Equipment Part Description Part No. Carried Two Years Comments
LP Pipework ½" NB Socket ABS 01-100-102 0 4
LP Pipework 3" NB Tee ABS 01-122-109 0 4
LP Pipework 2" NB Tee ABS 01-122-107 0 4
LP Pipework 1½" NB Tee ABS 01-122-106 0 4
LP Pipework 3" NB Flange Adaptor ABS 01-135-109 0 4
LP Pipework 1½" NB Flange Adaptor ABS 729-791-110 0 1
LP Pipework 2" NB Union ABS 729-511-111 0 4
LP Pipework 1½" NB Union ABS 729-511-110 0 4
LP Pipework 1" NB Union ABS 729-511-108 0 4
LP Pipework ½" NB Union ABS 729-511-106 0 4
LP Pipework 3" NB Victaulic Adaptor ABS TBC 0 4
LP Pipework 2" NB Victaulic Adaptor ABS TBC 0 4
LP Pipework 1½" NB Victaulic Adaptor ABS TBC 0 4
LP Pipework 1¼" NB Victaulic Adaptor ABS TBC 0 4
LP Pipework 2" BSP Plain/Thread Nipple ABS 01-316-107 0 4
LP Pipework 1½" BSP Plain/Thread Nipple ABS 01-316-106 0 4
LP Pipework 1" BSP Plain/Thread Nipple ABS 01-316-104 0 4
LP Pipework ½" BSP Plain/Thread Nipple ABS 01-316-102 0 4
LP Pipework 3" NB 45° Elbow ABS 01-119-109 0 4
LP Pipework 1½" NB 45° Elbow ABS 01-119-106 0 1
3" NB x 2½" NB Reducing Bush
LP Pipework ABS 01-109-136 0 4
2½" NB x 2" NB Reducing Bush
LP Pipework ABS 01-109-131 0 4

SSS
Recommended Electrical Spares

RO Control Panel 10A Fuse NS10 2 5
RO Control Panel Motor Breaker 3RV1041-4JA10 1 2
RO Control Panel Contractor 3RT10-45-1AF00 0 2
RO Control Panel Auxiliary 3RH1921-1FA22 0 2
RO Control Panel Power Supply Unit DPS-1-120-24 0 1
RO Control Panel Safety Relay G75-4A2B 1 1
FX3U-128MR
RO Control Panel PLC ES/UL 0 0 Programmed by SSS
RO Control Panel Relay HY41PN-24VDC 1 2
RO Control Panel Relay HY41PN-110AC 1 2
RO Control Panel MCB C10C1002 0 1
RO Control Panel MCB C10C1004 0 1
RO Control Panel Transformer HTE1000400110 0 1
RO Control Panel Auxiliary 3RV 19 01-1E 0 1
RO Control Panel Contactor 3RT1034-1AF00 0 1
RO Control Panel Contactor 3RT1026-1AF00 0 1
RO Control Panel Valve 81-513-100 1 4
RO Control Panel Solenoid 81-519-632 1 4
RO Control Panel Pressure Switch 81-513-552 0 1
RO Control Panel Breaker 3RV10-31-4DA10 1 1
RO Control Panel Contractor 3RT10 35-1AF00 0 1
RO Control Panel Breaker 3RV10 21-4AA10 0 1
RO Control Panel LED (Blue) LMB24-BLUE 1 2
RO Control Panel LED (Red) LMB24-RED 1 2
RO Control Panel LED (Amber) LMB24-AMBER 1 2
RO Control Panel LED (Green) LMB24-GREEN 1 2
RO Control Panel NO Block E22 B2 1 2
RO Control Panel NC Block E22 B1 1 2
SSS
Recommended RO Pressure Vessel Spares

Carried Two Years
RO Pressure Vessel Head Seal 800000/17 2 16
RO Pressure Vessel Permeate Port -1¼" NB Groove 4080072-1.25VJ 1 2
RO Pressure Vessel Permeate Port -½" NPT-F 4080072-½ NPT 1 2
Adaptor FilmTec
RO Pressure Vessel Adaptor SW 2 4
PWT Seal FilmTec
RO Pressure Vessel Adaptor Seal SW 4 16
RO Pressure Vessel Permeate Port-Adaptor Seal 6110221 4 16
RO Pressure Vessel Permeate Port-Sealing Plate Seals 6110229 4 16
RO Pressure Vessel Retaining Ring w/Finger Pull 4080320 1 4
RO Pressure Vessel Permeate Port Retaining Ring 6121200 1 4
RO Pressure Vessel Thurst Cone 900001/13 0 1
Vessel Head 1200psi
RO Pressure Vessel Entire Vessel Head EP 0 1
RO Pressure Vessel 1½" NB Victaulic Coupling 1.5HPC-SS 1 4
RO Pressure Vessel Permeate Sample Valve TBC 2 4
RO Pressure Vessel RO Membrane Element SW30HRLE-400 0 8

SSS
Recommended Filter Spares
Carried Two Years
Inlet Strainer Cover Seal 740184 2 4
Inlet Strainer Basket 720340 0 1
Sand Filter Body Flange Gasket 1200NB-Special 0 1
Sand Filter Inspection Hole Gaskets 200-PN6-6 0 2
Sand Filter Lateral Arm AR468/11.1-ARM 0 0
Sand Filter Lateral Hub AR468/11.1-HUB 0 0
Sand Filter 16/30 Sand - 25 Kg AS323/11.3 0 0
Sand Filter 2-3mm Gravel - 25 Kg AS323/11.4 0 0
Sand Filter 3-6mm Gravel - 25 Kg AS323/11.5 0 0
Cartridge Filter Head Seal 96000 2 4
Cartridge Filter Product Port Seal 17128 2 4
Cartridge Filter Upstream Plug Seal 45312 2 4
Cartridge Filter Head Retaining Ring 96355 1 2
Cartridge Filter Retaining Ring 17127 1 1
Cartridge Filter Bearing Plate Upstream 17102 0 1
Cartridge Filter Sealing Plate Upstream 96160 1 2
Cartridge Filter Bearing Plate Downstream 17103 0 1
Cartridge Filter Sealing Plate Downstream 17126 1 2
Sand Filter Sight Glass Assembly AR582/1.14-MOD 0 1 Ends by SSS
Rehardener Body Flange Gasket 1100NB-Special 0 1
Rehardener Inspection Hole Gaskets 200-PN6-6 0 2

SSS
Recommended Energy Recovery Spares

Carried Two Years
Energy Recovery Device Thrust Bearing Kit 8-H0040-TBE 1 1
Energy Recovery Device Centre Bearing Kit 8-H0040-CBK 1 1
Energy Recovery Device Overhaul Kit 8-H0040-OKE 0 1

SSS
Recommended Pump Spares

Feed/Backwash Pump Pump Shaft 5790 0 1
Feed/Backwash Pump Impeller 43041 0 1
Feed/Backwash Pump Gasket 93078 1 2
Feed/Backwash Pump Mechanical Seal 35362 1 1
Flushing Pump Seal Kit 96525458 1 1
Flushing Pump Wear Parts Kit 96416728 0 1
Flushing Pump Gasket Kit 96416597 0 1
High Pressure Pump Bareshaft Pump c/w Coupling AR422/4.1 to 4.4 1 1
Connector & NRV inc.
High Pressure Pump Piston Set 180B4155 1 4
High Pressure Pump Retainer Service Set 180B4157 1 2
High Pressure Pump Swash Plate Service Set 180B4133 1 2
High Pressure Pump Valve Plate Set 180B4159 1 2
High Pressure Pump Shaft Seal Kit 180B4161 4 4
Antiscalant Dosing Pump Service Kit 1001645 2 4
Antiscalant Dosing Pump Injection Valve 924681 1 1
Antiscalant Dosing Pump Liquid End Valve Spring 469406 2 4
Antiscalant Dosing Pump 6 mm Dosing Tube AR534/9.7 20 mtrs 60 mtrs

SSS
Recommended Instrumentation Spares

Carried Two Years
Pressure Gauges 0 to 6 Barg Pressure Gauge AR441/6.9 1 1 Calibrated at SSS
Pressure Gauges 0 to 100 Barg Pressure Gauge AR441/6.10 1 1 Calibrated at SSS
Pressure Gauges -1 to + 1.5 Barg Pressure Gauge AR441/6.8 0 1 Calibrated at SSS
Pressure Gauges ¼" OD x ¼" NPT-F Adaptor Fitting SS-400-7-4 1 1
6mm OD x ¼" BSPP-F Adaptor
Pressure Gauges Fitting PM450612E 2 2
HP Instrument Impulse Flexible
Pressure Gauges Hose TBC 1 1 Pressure Tested at SSS
Diffrential Pressure Switch DP Switch (set at 1.4 Barg) AR455/6.17 0 1 Set at SSS
6mm OD x ¼" BSPT-M Adaptor
Diffrential Pressure Switch Fitting PM010602E 1 1
Low Pressure Switch LP Switch (Set at 2 Barg) AR455/6.18 0 1 Set at SSS
6mm OD x ¼" BSPT-M Adapter
Low Pressure Switch Fitting 1 1
High Pressure Switch HP Switch (Set at 81 Barg) AR455/6.19 0 1 Set at SSS
High Pressure Switch ¼" OD x ¼" NPT-M Adaptor Fitting SS-400-1-4 1 1
High Pressure Switch HP Switch (Set at 81 Barg) AS367/6.35 0 1 Set at SSS
Feed/Permeate Flowmeter Paddlewheel Flow Sensor AR422/6.5 1 2
Feed/Backwash Flowmeter Flow Meter, 200 to 1000 1pm AR420/6.12 0 0
Rehardener Flowmeter Flow Meter, 2 to 18 m³/hr AR420/6.13 0 0
Permeate Recycle Flowmeter Flow Meter, 1 to 9 m³/hr AR420/6.22 0 0
CO₂ Flowmeter Flow Meter, 0.2 to 2 1pm AR420/6.14 0 0

SSS
8.0 FAULT FINDING
8.1 FAULT FINDING SCHEDULE
8.2 MEASUREMENT OF SILT DENSITY INDEX
8.3 MEMBRANE VESSEL PROBING
8.3.1 Interpretation of Results
8.3.2 Element Probe Typical Results (Co-Current)
8.3.3 Element Probe Typical Results (Counter - Current)
8.3.4 Vessel Conductivity Record Sheet
8.4 RAW WATER ANALYSIS LOG SHEET
8.5 RO PLANT LOG SHEET

SSS
FAULT FINDING SCHEDULE
FAULT CAUSE REMEDY
1. High pressure drop across sand filter (increase Dirty filter Backwash as per instructions in section 6.0 of this
of 1.0 barg from clean) manual
2. Sand filter fouling excessively, i.e. hourly Excessive colloidal material, suspended solids or Contact Salt Separation Services for advice
rather than daily organics in feed water Tel : +44 (0)1706 655522
Fax : +44 (0)1706 654475
E-mail : sss@saltsep.co.uk
3. Antiscalant usage too high or too low Antiscalant dosing pump adjustment incorrect. Adjust as necessary – with the dosing pump
running, slowly increase or decrease the frequency.
One tank (100 ltrs) should last approximately 7 Set points are stoke length 60% and frequency 60%
days, based on 24 hours continuous operation. (0.57 l/h). Refer to section 6.4.1 of this manual.
Antiscalant pump valves blocked. Remove, clean and replace.
Antiscalant pump strainer blocked. Remove, clean and replace.

4. High pressure drop across cartridge filter Cartridge filter element dirty Replace with new cartridge filter element (refer to
(increase of 1.0 barg from clean) section 6.0 of this manual)
5. HP pump will not run Low suction pressure or high discharge pressure Press common alarm reset
alarms not reset
HP pump inlet pressure low Check position of valves

Check cleanliness of suction strainer
Check raw water supply - valves/strainers
Check sand filter differential pressure
Check cartridge filter differential pressure
HP pump low suction or high discharge pressure Investigate/repair or replace

switches not functioning correctly
Motor circuit breaker tripped Investigate cause, replace, restart
Feed/backwash pump faulty, not correctly primed Investigate (refer to manufacturers literature
section 9.0 of this manual) fully prime pump

SSS
FAULT CAUSE REMEDY
6. HP pump stops Low suction pressure See fault No 5
High discharge pressure Reject control valve (V101) closed too much
Motor breaker tripped See fault No 5

3
7. Low feed flow (should be 40 m /h with HP Motor speed low Check voltage (each phase), current draw (each
pump running) or discharge pressure phase) and frequency
Flowmeter inoperative or not registering correctly Check calibration, repair/replace as necessary

8. HP Pump run extremely rough/noisily Low suction pressure on air entering inlet pipework Check position of plant valves
Check differential pressure of sand and cartridge
filters.
Check feed water supply
9. HP pump leaking water at shaft end. Worn/failed mechanical seal Replace pump and return old pump to Salt
Separation Services for overhaul
10. Rapid increase in differential pressure across Scaling increased by: Review operation
RO membranes
Plant over-recovery. Clean membranes see section 6.0 of this manual. If
cleaning has no effect inspect the leading and
trailing membrane in the RO stack for evidence of
suspended matter or precipitation badly fouled
membranes should be replaced
Analyse feed water/check silt density index, see

section 8.2 of this manual
11. Gradual increase in permeate flow Change in feed water temperature/salinity Reduce system pressure with reject control valve to
compensate. Permeate flow not to exceed 18 m3/h

SSS
FAULT CAUSE REMEDY
12. Gradual decrease in permeate flow Change in feed water temperature/salinity Increase system pressure with reject control valve
to compensate. Stack inlet pressure not to exceed
80 barg
Membrane fouling Normalise data, if necessary. Check membranes,

see section 6.0 of this manual
13. Excessive requirements for chemical cleaning Membrane feed flow low, HP relief valve passing Repair/replace HP relief valve, check HP pump
or low pump flow flow, see fault No 7.
Plant over recovery Review operation
Poor/partial clean Repeat chemical clean as per correct procedures

(refer to section 6.0 of this manual)
Dirty feed water Analyse feed water. Check silt density index of
feed water. See section 8.2 of this manual
14. Permeate conductivity high Defective membrane element Replace membranes
Defective membrane seals or broken adaptor Replace seals or adaptor

15. Very sudden increase in permeate conductivity Front end/rear end membrane deterioration Replace membranes as required
and permeate flow
Element glue line failure Replace membranes as required
Chemical attack Replace membranes
End cap 'O' ring leaks, parts (i.e. adaptor) failure Replace 'O' ring seals and parts as necessary, see
fault No 14

SSS
FAULT CAUSE REMEDY
16. Rapid decline in permeate flow increase in Oil contamination Replace membranes
conductivity
Severe iron oxide attack Replace membranes
Severe biological attack Sterilise system. Replace membranes
HP pump damage or wear, HP relief valve passing Check feed flowrate, repair/replace pump or HP
relief valve and clean membranes. See section 6.0
of this manual
Over recovery of permeate Clean membranes. See section 6.0 of this manual
and ensure design permeate flowrate is not
exceeded (18 m3/h maximum)
17. Potable water very aggressive causing system RO permeate hardness levels very low Increase flow through rehardener by adjusting by-
corrosion and 'Red Water' pass flow (FI200). Re-check hardness level. If
necessary increase CO2 injection

SSS
8.2 MEASUREMENT OF SILT DENSITY INDEX (SDI)
The silt density index is a measure of the un-dissolved particulate and colloidal content of
water. Feed water to the RO membranes must have a silt density index of less than 5.
The SDI is calculated from the rate of plugging of a 0.45 micron filter membrane when
the water is passed through the filter at 2.07 barg (30 psig). Equipment for measuring the
SDI is shown in Figure 1. The procedure for measuring the SDI follows ASTM method
D4189 and is as follows :
1. Assemble the apparatus as shown in Figure 1 below and set the pressure regulator at 2.07
Barg (30 psig).
2. Before installing the filter, flush the water to be tested through the apparatus to remove
entrained contaminants.
3. Measure and record the water temperature.
4. Open the membrane filter holder and place a 0.45 µm filter (47mm in diameter) on the
support plate of the holder. Handle filter membrane only with dull tweezers to avoid
puncturing. Avoid touching the filter membrane with fingers.
5. Make up the 'O' ring is in good condition and properly positioned. Replace the top half of
the filter holder and close loosely.
6. Bleed out trapped air by cracking the ball valve. Close valve and tighten filter holder.
7. Open ball valve. Simultaneously, using a stop-watch, begin measuring the time required
for the flow of 500ml through the filter. Record time (ti). Leave the valve open for
continued flow.

SSS
8. Measure and record time to collect a 500ml volume (tf) after 5, 10 and 15 minutes (tt) of
total elapsed flow time.
Note
Pressure must remain at (30 ± 1 psig) throughout the test.
9. Measure and record the water temperature.
Note
Water temperature must remain constant throughout the test.
10. After completion of the test, the filter membrane may be dried and retained for future
reference. Ensure the apparatus is thoroughly flushed through with 'clean' potable water.
The SDI is calculated using :
⎡ ti ⎤
100⎢1 − ⎥
% P30 ⎣ tf ⎦
SDI = =
tt tt
Where :
%P30 = SDI x tt (percentage plugging at 2.07 barg (30 psig) pressure).
tt = total test time in minutes (usually 15, but may be less if 75 plugging occurs in
less than 15 minutes).
ti = initial time (sec) required to collect 500ml sample
tf = time (sec) required to collect 500ml sample after test time tt (usually 15
minutes)
For accurate SDI measurements %P30 should not exceed 75%. If %P30 exceeds this
value use the time taken at 10 minutes to take the 500ml sample.
If %P30 still exceeds 75% use 5 minutes, if the %P30 still exceeds 75% the SDI test is
not valid for such a severely laden water.
Example
ti = 40 secs
tf(5) = 65 secs
tf(10) = 105 secs
tf(15) = 155 secs
tt = 15 minutes

SSS
⎡ ti ⎤
100⎢1 − ⎥
% P30 ⎣ tf ⎦
SDI = =
tt tt
Check %P30 SDI x tt = 4.94 x 15
= 74% therefore OK
If %P30 had been greater than 75% SDI would be calculated using tf of 10 minutes the
%P30 would then be checked, if it was still greater than 75% the SDI should be
calculated using the tf of 5 minutes.
8.3 MEMBRANE VESSEL PROBING
This technique determines the condition and performance of a complete RO vessel.
Probing a vessel involves removing the permeate collection pipework to allow a length of
flexible nylon/PVC tube to be inserted along the full length of the vessel. The technique
invariably results in a considerable amount of water spray, precautions should be taken to
minimise this and to protect any sensitive items of plant.
The probe consists of a length of flexible nylon/PVC tube about ¼" (6mm) OD, marked
off at 250mm intervals, and should be longer than the vessel under test.
First the problem vessel is discovered [with the plant running assuming all permeate 3-
way diverter valves are in the normal ‘to supply’ position] as follows:
1) Ensure all permeate diverter valves (V250 to V257 inclusive) are open (i.e. to
permeate not diverting to feed).
2) Open all permeate sample valves (V300 to V307 inclusive) and take conductivity
readings from each vessel in turn, record each reading on the 'Vessel Conductivity
Record Sheet'.
Alternatively, the problem vessel may be found by operating each permeate diverter valve
in turn and seeing which valve (and consequently vessel) causes the permeate
conductivity (on the conductivity meter DIC100) to fall, thereby indicating the problem
vessel.
Once the malfunctioning vessel has been found it must be examined in greater detail,
probing is carried out as follows:
1) On the malfunctioning vessel only, turn the 3-way diverter valve to the ‘divert to
feed’ position.
2) At the opposite end of the vessel, open the permeate sample valve.

SSS
Note
Insert a length of flexible nylon/PVC tubing above ¼" (6mm) OD into the
permeate port of the suspect vessel and feed it into the vessel until the marks on
the tube indicate the probe end is aligned with the vessel outlet.
3) Allow sufficient time for water to flush the probe, collect a sample from the probe
and measure the conductivity. Record the result on the 'Element Probe Record'
sheet.
4) Withdraw the tube 250mm, allow sufficient time for permeate to flush the probe,
collect a sample and measure the conductivity.
Record the result on the 'Element Probe Record' sheet.
4) Repeat this procedure until the tube is fully withdrawn from the vessel.
5) The data obtained should be examined for inconsistencies and compared to the
'Element Probe Typical Results' graph. Attention should be noted to which way
the feed water flow is in the vessel in relation to the permeate flow when
comparing results of the graphs.
8.3.1 Interpretation of Results
1) Stub Tube 'O' Ring Leak
A sharp increase in conductivity will be apparent in the region of the element stub
tube. This and interconnector leaks are the most common cause of elevated
conductivity in an isolated vessel. The vessel must be opened and the 'O' rings
inspected/renewed.
2) Element Glue Line Failure
This is a rare occurrence, very high conductivity will be apparent in the area
occupied by the element. The cause of this may be operating at a high vessel
differential pressure, or by the application of excessive permeate back pressure.
3) Element Deterioration
This may be the result of fouling or scaling or in extremely bad cases of

chlorine/chemical attack.
4) Partial Element Deterioration - Back End Element
This is characteristic of precipitation within the element, normally caused over

recovery of permeate. If caught early, performance may often be restored by
prolonged operation at reduced system recovery.

SSS
5) Partial Element Deterioration - Front End Element
Caused by colloid/particulate deposition in the feed end of the element. Checks

should be made on the pre-treatment system.

SSS

SSS
SSS
VESSEL CONDUCTIVITY RECORD
CONTRACT NO DATE TAKEN
FEED CONDUCTIVITY μS/cm
FEED TEMPERATURE °C
PLANT FEED PRESSURE barg
PLANT REJECT PRESSURE barg

3
PLANT FEED FLOW m /h
TOTAL PERMEATE CONDUCTIVITY μS/cm
PV102…. …….. μS/cm PV101 ….....μS/cm PV108 ..……μS/cm
PV104…. …….. μS/cm PV103 ….....μS/cm PV107… ……μS/cm
PV106….. …….. μS/cm PV105 ….....μS/cm

SSS
RAW WATER ANALYSIS
SAMPLE IDENTIFICATION :
WATER SOURCE :
*Conductivity : *pH : *Temperature : Deg C
WATER ANALYSIS mg/l As Ion
*NH4+ : CO 2: *Cl - :
*K+ : CO 3
-
: *F - :
*Na+ : *HCO 3
2-
: *SO 42- :
*Mg2+ : NO 3
-
: PO 42- :
*Ca2+ : Fe 2+
: S 2- :
Ba2+ : *Fe(tot) : SiO2(Colloidal) :
Sr2+ : Mn 2+
: *SiO2(Soluble) :
OTHER IONS :
*TDS (By Method) :
TOC : BOD : COD :
*Total Alkalinity (M-Value) : *Silt Density Index (SDI) :
*Carbonate Alkalinity (P-Value) : Bacteria (Count/ml) :
*Total Hardness : *Residual Chlorine :
*Turbidity (NTU) : Free Chlorine :
COMMENTS (Odour, Smell, Colour, Biological Activity, Etc) :
ANALYSIS BY : DATE :
Note : Items Marked * Are Essential for Complete Determination

SSS
REVERSE OSMOSIS PLANT LOG SHEET
DATE
TIME
PLANT RUNNING HRS
FEED PUMP SUCTION

PRESSURE (barg) PI1
SAND FILTER INLET
(barg) PI2
SAND FILTER OUTLET
(barg) PI3
CARTRIDGE FILTER
INLET (barg) PI100
CARTRIDGE FILTER
OUTLET (barg) PI101
MEMBRANE STACK
INLET (barg) PI102
MEMBRANE STACK
OUTLET (barg) PI103
RO FEED WATER FLOW
(m3/h) FI100
FEED WATER TEMP (°C)
DIC100
FEED CONDUCTIVITY
(mS/cm) DIC100
PERMEATE COND'Y
(µS/cm) DIC100
PERMEATE FLOW (m3/h)
FT100
PERMEATE PRESSURE
(barg) PI104
HP PUMP DISCHARGE
(barg) PI105
REJECT DISCHARGE
(barg) PI106
REHARDENER BY-PASS
FLOW (m3/h) FI200
CO2 FLOW (l/min)
FI201
PRODUCED WATER
HARDNESS
NORMALISED
PERMEATE FLOW
NORMALISED SALT
PASSAGE
COMMENTS (ANTISCALANT MAKE-UP, CARTRIDGE FILTERS CHANGED, ETC...)

SSS
9.0 EQUIPMENT LITERATURE
9.1 RO MEMBRANES (SW30HRLE-400)
9.2 MEMBRANE PRESSURE VESSELS (PV101 to PV108)
9.3 HP PUMPS (P100, P101, P102 & P103)
9.4 FEED BACKWASH PUMP (P1)
9.5 ANTISCALANT DOSING PUMP (P105)
9.6 LP & HP PRESSURE SWITCHES (PS100 & PS101)
9.7 REJECT CONTROL VALVE DRAWING (V101)
9.8 PUSH-FIT FITTINGS
9.9 SAND FILTER DIFFERENTIAL PRESSURE SWITCH (DPS1)
9.10 CONDUCTIVITY ANALYSER (DIC100, QT100, QT101)
9.11 FLUSHING PUMP (P104)
9.12 PROGRAMMABLE LOGIC CONTROLLER (PLC)
9.13 FLOWMETERS/TRANSMITTERS (FI100, FT100 & FT101)
9.14 ELECTRIC MOTORS
9.15 SUCTION STRAINER (PV1)
9.16 CARTRIDGE FILTER (PV100)
9.17 CONTROL PANEL PILOT VALVE
9.18 CO₂ SOLENOID VALVE (V208)
9.19 ENERGY RECOVERY DEVICE
9.20 RPZ VALVES (V134, V204)
S846-40 400 m³/d SWRO PLANT 9/1 DATE: 23.02.10

Product Information
FILMTEC Membranes
FT30 Membrane Description
FILMTEC® FT30 thin-film composite

reverse osmosis (RO) membrane
gives excellent performance for a
wide variety of applications, including
low-pressure tapwater use, single-
pass seawater and brackish water
desalination, chemical processing,
and waste treatment. This membrane
exhibits excellent performance in
terms of flux, salt rejection, and
microbiological resistance. FT30
elements can operate over a pH
range of 2 to 11, are resistant to
compaction, and are suitable for
temperatures up to 45°C.
FILMTEC spiral-wound elements
of FT30 membrane have been
extensively used since 1980 both in
the United States and abroad. In
numerous installations under actual
seawater conditions, FT30 elements
have provided salt rejections of
better than 99.5 percent and fluxes of
10 gfd (24 l/h m2). On a 0.2 percent
salt solution at 225 psi (1.6 MPa),
rejections above 99 percent and
fluxes of 26 gfd (51 l/h m2) are
routinely obtained.
Several long-term tests have been
completed. A continuous three-year
test operating at about 25°C and 350
psi on 3000 ppm feed did not show Nonwoven web
any membrane compaction or
deterioration in salt rejection. Ultrathin membrane
Polysulfone layer
Elements have also operated in
shipboard seawater systems with
normal intermittent use for over three FT30 Membrane Composite
years with no significant loss in
performance.
FILMTEC FT30 thin-film web, a microporous polysulfone produce a hard, smooth surface free
composite RO membrane complies interlayer, and an ultrathin barrier of loose fibers. Since the polyester
with Food Additive Regulation 21 coating on the top surface. web is too irregular and porous to
CFR 177.2550 for use in processing A schematic diagram of the provide a proper substrate for the salt
foods and purifying water for food membrane is shown above. barrier layer, a microporous layer of
applications. engineering plastic (polysulfone) is
Description of the cast onto the surface of the web. The
Thin-Film Composite FT30 Membrane polysulfone coating is remarkable in
Configuration The major structural support is that it has surface pores controlled to
The membrane composite consists of provided by the nonwoven web, a diameter of approximately 150
three layers: a polyester support which has been calendered to angstroms. The FT30 barrier layer,
S846-40 400 m³/day SWRO PLANT 9.1.1 DATE : 23.02.10

FILMTEC Membranes
For more information about FILMTEC membranes,
call Dow Liquid Separations:
North America . . . . . . . . . . .1-800-447-4369
Latin America . . . . . . . . . . .(+55) 11-5188-9277
Europe . . . . . . . . . . . . . . . .(+31) 20-691-6268
Japan . . . . . . . . . . . . . . . . .(+81) 3-5460-2100
Australia . . . . . . . . . . . . . . .(+61) 2-9776-3226
http://www.dow.com/liquidseps
about 2000 angstroms thick, can free chlorine, which attacks the Cleaning
withstand high pressures because of membrane. The FT30 membrane is Because of the FT30 membrane’s
the support provided by the permeable to chloramine and to combination of pH stability and
polysulfone layer. Because of its chlorine dioxide. Either of these will temperature resistance, cleaning can
barrier layer thickness, FT30 is very pass through the membrane be done very effectively. Both acidic
resistant to mechanical stresses and resulting in a small residual and alkaline cleaners can be used at
chemical degradation. disinfectant in the permeate. temperatures to 50°C. Acid cleaning
The membrane has only limited to remove mineral scale is best done
Biological Protection and resistance to free chlorine. Chlorine at pH 2 or lower with phosphoric,
Disinfection attack is slowest at neutral and hydrochloric, sulfamic or nitric acid.
Various storage tests have been acidic pH levels and fastest at Citric acid can also be used. Alkaline
conducted on FT30 elements to alkaline pH levels. It is noteworthy, cleaning to remove organic fouling is
determine biological protection however, that short-term exposure of generally done with sodium hydroxide
procedures. The best procedure the membrane to chlorine does not and sodium lauryl sulfate. Various
recommended for storage is to destroy the membrane. Thus, it can combinations of agents such as
immerse the element in a protective be used effectively in installations sodium EDTA, sodium
solution which contains 1.5 percent where system upsets may result in tripolyphosphate, and trisodium
(by weight) sodium metabisulfite temporary exposure of the phosphate can also be used.
(food grade). This treatment membrane to free chlorine. Generally, anionic surfactants can
maintains initial membrane flux and Alternative disinfectants that may be used for alkaline cleaning. Cationic
performance. be used are hydrogen peroxide and surfactants cause an irreversible flux
Disinfection with chlorinating peracetic acid. Hydrogen peroxide or loss and must be avoided. Nonionic
agents can be practiced within limits peracetic acid can be used at surfactants can sometimes be used,
but is not recommended. The concentrations up to 0.2 percent at but they must be used sparingly and
FT30 membrane is resistant to 25°C as specified in the warranty on thoroughly rinsed out before the
chloramine, chloramine-T, FILMTEC membranes but not at membrane is pressurized.
N-chloroisocyanurates to the extent higher temperatures. Continuous See bulletins Cleaning Procedures
that these mild agents can be used, exposure to hydrogen peroxide at (Form No. 609-23010/CH 172-086-E)
but their disinfectant properties are this concentration will eventually and Biological Protection and Disinfection
not very great. Pure chlorine dioxide damage the membrane. (Form No. 609-24010/CH172-120-E)
can be used successfully at 500 ppm Copper sulfate can be used to for further information.
concentration if the storage period is control algae growth. Iodine,
less than one week, but it is not an quaternary germicides, and phenolic
effective biocide for longer periods. compounds should not be used as
Chlorine dioxide that is generated on tests show that all of these agents
site from chlorine and sodium cause flux losses.
chlorate is always contaminated with
Notice: No freedom from any patent owned by Seller or others is to be inferred. Because use conditions and applicable laws may differ from one
location to another and may change with time, Customer is responsible for determining whether products and the information in this document are
appropriate for Customer’s use and for ensuring that Customer’s workplace and disposal practices are in compliance with applicable laws and other
governmental enactments. Seller assumes no obligation or liability for the information in this document. NO WARRANTIES ARE GIVEN; ALL
IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED.
Published April 1998.
S846-40 400 m³/day SWRO PLANT 9.1.2 DATE : 23.02.10

Product Information
FILMTEC Membranes
FILMTEC SW30HR LE-400 Seawater Reverse Osmosis Element
Features FilmTec offers various premium seawater reverse osmosis (RO) elements designed to reduce
capital and operation cost of seawater RO systems. FILMTEC™ products combine premium
membrane performance with automated precision fabrication and maximize system output to
unprecedented performance.
FILMTEC SW30HR LE-400 element (named SW30HR LE-380 until June, 2004) offers very
high productivity and rejection, enabling the lowest total cost of water for seawater
desalination. Benefits of FILMTEC SW30HR LE-400 include:
• Enables systems to be designed and operated to optimize operating cost through lower
energy consumption or to optimize capital cost through higher productivity at lower
operating fluxes.
• Highest NaCl and boron rejection to help meet World Health Organization (WHO) and other
drinking water standards.
• Can effectively be used in permeate staged seawater desalination systems without impairing
the performance of the downstream stage.
• High performance over the operating lifetime without the use of oxidative post-treatments
like many competitive products. This is one reason FILMTEC elements are more durable
and may be cleaned more effectively over a wider pH range (1-12) than other RO elements.
• Automated, precision fabrication with a greater number of shorter membrane leaves reduces
the effect of overall fouling and maximizes element efficiency, lowering your cost of operation.
Product Specifications
Part Active area Maximum operating Permeate flow Stabilized boron Minimum salt Stabilized salt
Product number ft2 (m2) pressure psig (bar) rate gpd (m3/d) rejection % rejection % rejection %
SW30HR LE-400 217822 400 (37) 1,200 (83) 7,500 (28) 91 99.60 99.75
1. The above values are normalized to the following conditions: 32,000 ppm NaCl, 5 ppm boron, 800 psi (5.5 MPa), 77°F (25°C), pH 8, 8% recovery.
2. Permeate flows for individual elements may vary +/-15%.
3. Product specifications may vary slightly as improvements are implemented.
4. Active area guaranteed +/-5%. Active area as stated by FilmTec is not comparable to the nominal membrane area figure often stated by some element suppliers.
Measurement method described in Form No. 609-00434.
A
Figure 1
B DIA
C DIA FilmTec supplies
coupler part number
129768 with each
element. Each coupler
includes two 3-912
Feed Fiberglass Outer Wrap EPR o-rings (FilmTec
End Cap part number 151705).
U-Cup Brine Seal Brine Permeate
Dimensions – Inches (mm)

Product Feed Spacer (mil) A B C
SW30HR LE-400 28 40 (1,016) 1.125 (29) 7.9 (201)
1. Refer to FilmTec Design Guidelines for multiple-element systems. 1 inch = 25.4 mm
2. Elements fit nominal 8-inch (203 mm) I.D. pressure vessel.
Operating Limits • Membrane Type Polyamide Thin-Film Composite
• Maximum Operating Temperaturea 113°F (45°C)
• Maximum Element Pressure Drop 15 psig (1.0 bar)
• pH Range, Continuous Operationa 2 – 11
• pH Range, Short-Term Cleaning (30 min.)b 1 – 12
• Maximum Feed Silt Density Index (SDI) SDI 5
• Free Chlorine Tolerancec <0.1 ppm
a. Maximum temperature for continuous operation above pH 10 is 95°F (35°C).
b. Refer to Cleaning Guidelines in specification sheet 609-23010.
c. Under certain conditions, the presence of free chlorine and other oxidizing agents will cause premature membrane failure.
Since oxidation damage is not covered under warranty. FilmTec recommends removing residual free chlorine by
pretreatment prior to membrane exposure. Please refer to technical bulletin 609-22010 for more information.
Important Proper start-up of reverse osmosis water treatment systems is essential to prepare the
Information membranes for operating service and to prevent membrane damage due to overfeeding or
hydraulic shock. Following the proper start-up sequence also helps ensure that system
operating parameters conform to design specifications so that system water quality and
productivity goals can be achieved.
Before initiating system start-up procedures, membrane pretreatment, loading of the

membrane elements, instrument calibration and other system checks should be completed.
Please refer to the application information literature entitled “Start-Up Sequence” (Form No.
609-00298) for more information.
Operation Avoid any abrupt pressure or cross-flow variations on the spiral elements during start-up,
Guidelines shutdown, cleaning or other sequences to prevent possible membrane damage. During start-
up, a gradual change from a standstill to operating state is recommended as follows:
• Feed pressure should be increased gradually over a 30-60 second time frame.
• Cross-flow velocity at set operating point should be achieved gradually over 15-20 seconds.
• Permeate obtained from first hour of operation should be discarded.
General • Keep elements moist at all times after initial wetting.

Information • If operating limits and guidelines given in this bulletin are not strictly followed, the limited
warranty will be null and void.
• To prevent biological growth during prolonged system shutdowns, it is recommended that
membrane elements be immersed in a preservative solution.
• The customer is fully responsible for the effects of incompatible chemicals and lubricants
on elements.
• Maximum pressure drop across an entire pressure vessel (housing) is 50 psi (3.4 bar).
• Avoid static permeate-side backpressure at all times.
Notice: The use of this product in and of itself does not necessarily guarantee the removal of cysts and pathogens from water.
Effective cyst and pathogen reduction is dependent on the complete system design and on the operation and maintenance of
the system.
Notice: No freedom from any patent owned by Seller or others is to be inferred. Because use conditions and applicable laws
may differ from one location to another and may change with time, Customer is responsible for determining whether products
and the information in this document are appropriate for Customer’s use and for ensuring that Customer’s workplace and
disposal practices are in compliance with applicable laws and other governmental enactments. Seller assumes no obligation or
liability for the information in this document. NO WARRANTIES ARE GIVEN; ALL IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED.
Dwg. No. 101012 1200 PSI
Rev. E/3 END PORT
ENGINEERING DRAWING PACKET
MODEL PRO-8-1200-EP
DESIGN PRESSURE at 120ºF 1200 PSI OPERATING pH RANGE 3-11

MINIMUM OPERATING TEMP.* 20ºF CLEANING pH RANGE 2-12
(Less than 30 minutes)
MAXIMUM OPERATING TEMP. 120ºF APPLICATION TYP. SEAWATER
FACTORY TEST PRESSURE 1320 PSI
BURST PRESSURE 7200 PSI
INTENDED USE
The PROTEC Model PRO-8-1200-EP Pressure Vessel is The filament-wound reinforced plastic shell of this vessel must
designed for continuous use as a housing for membrane filtration be allowed to expand under pressure. Any undue restraint at the
elements to purify typical seawater at any positive pressure up to support points or piping connections can cause non-repairable
1200 PSI. The PRO-8-1200-EP will accommodate any make of leaks to develop in the shell. This vessel must not be subjected
eight-inch nominal diameter spiral-wound element as well as to excessive stress caused by bending moments acting at the
many hollow fiber elements. The element interface hardware for side ports in the fiberglass shell.
the specified element is supplied with the vessel.
The end closures of the vessel must be kept dry and free of
The Model PRO-8-1200-EP has been designed to meet the corrosion at all times. Failure to do so may result in deterioration
standards of the American Society of Mechanical Engineers that can lead to catastrophic failure of the vessel heads.
(ASME), Boiler and Pressure Vessel Code, Section X. At an
additional cost, vessels can be inspected during fabrication by an When requested, Bekaert Progressive Composites will assist the
ASME Authorized Inspector and Code stamped. purchaser in determining the suitability of this standard vessel
design for their operating environment. However, the final
The Model PRO-8-1200-EP must be installed, operated and determination including the evaluation of the materials of
maintained using good industrial practice and following the construction for use in the specific corrosive environment shall
precautions listed in order to help assure safe operation and a be the responsibility of the purchaser. Alternate materials of
long service life. Misuse, improper installation or operation may construction may be available on special order.
result in severe bodily harm or property damage and will void the
Before using this engineering packet for system design or vessel
vessel warranty. Therefore, review and follow the safeguards installation, please verify that it is the latest revision by consulting
listed below before placing the vessels into service. the factory. Specifications are subject to change without notice.
PRECAUTIONS
Follow all instructions. Do not over tighten the Permeate Port connection.
Failure to take every precaution listed will void the vessel warranty Tightening the connection more than one turn past hand tight will
and may result in vessel failure. damage the port.
Mount shell using furnished hardware. Ensure that the Thrust Ring is installed downstream.
Following the recommended span(s), mount the vessel on saddles Operating without a thrust ring may cause membrane damage.
provided. Tighten straps to one ft-lb maximum. Double check end closure installation
Use flexible type groove-end pipe couplings. Ensure that retaining ring is in place and fully seated.
Use Victaulic™ style 77 or equal couplings at each port and allow Never operate the vessel in excess of its ratings.
a gap between each port /manifold connection as specified by This practice will void the vessel warranty, shorten vessel life and
coupling manufacturer. could lead to bodily harm or property damage.
Maximize the connection flexibility. Do not operate the vessel permeate port over 125 psi.
Position the vessel and the piping so that the vessel can grow in Permeate pressure in excess of 125 psi must be approved by the
length and diameter under pressure without any undue restraint. factory prior to operation.
∆DIA = 0.014 in. (0.4mm) and ∆L = 0.25 in. (6mm) for a length Operate the vessel in only positive pressure applications.
code –7 vessel. This vessel is not designed for vacuum conditions.
Provide overpressure protection. Some components in the vessel are not compatible with
Set the safety device at not more than 105% design pressure. hydrocarbons. Contact factory for alternate material options
Inspect end closures regularly. Flush the vessel before system shut down.
Replace damaged or deteriorated components and correct the Some feed waters may cause corrosion under static conditions.
cause of any corrosion. Flushing with non-corrosive permeate is recommended.
Relieve system pressure before working on the vessel. Operate the vessel within the recommended pH range.
Working on vessels that are under pressure may result in bodily The vessel is designed for continuous use at a pH of 3-11 and for
harm and/or property damage. intermittent cleaning (less than 30 min. at a pH of 2-12).
Never support other components with the vessel. Do not install the vessel in direct sun light.
Hanging piping manifolds or supporting other components with the
vessel may result in vessel damage.
HEAD LOADING PROCEDURE
Step 1 Inspect the Shell Step 5 Remove Head
Before installing the head, check the inside surface of the shell While holding the permeate port with your hand, simply pull the
for any imperfections or foreign matter. Remove all foreign matter head from the shell. In some instances it may be required to
using a mild soap solution and rinse with clean water. To remove thread a connection onto the permeate port and gently rock the
imperfections, lightly sand the surface of the vessel with 600-grit head up and down to release the head from the shell.
sandpaper and soapy water and then rinse with water.
HEAD REBUILDING
Step 2 Head Seal and Shell Lubrication
Ensure that the head seal is covered with a thin layer of glycerin
and is free from any dirt or dust contamination. Then lubricate the Prior to following this procedure, remove the head following the
inside of the shell starting directly inboard of the retaining ring procedure listed.
groove and up the energizing ramp into the vessel bore. Only a Step 1 Remove Adapter
thin layer is required. Silicone lubricants can also be used; Pull the adapter from the permeate port by slowly pulling on the
however, care should be taken to use as little as possible. Check adapter body.
with your membrane supplier before using these lubricants as
they can foul membranes. Step 2 Remove Permeate Port
Carefully remove the metal retaining ring from the permeate port
Step 3 Install Head as to not damage the ring or the port. A new retaining ring may
Holding the head square to the axis of the shell, slowly push the be required to assemble the head. After the ring is removed,
head into the shell until the seal passes the retaining ring groove. carefully slip the bearing plate off the permeate port and set it
As a resistance is felt, two hands may be required. Push the aside. Then simply pull the permeate port from the sealing plate.
head into shell until the head clears the retaining ring groove.
Step 4 Install Retaining Ring Step 3 Inspect Feed Port
Remove any moisture from the retaining groove before Push the port into the Bearing Plate to inspect the retaining
proceeding. Carefully place the end of the retaining ring into the ring and port for corrosion or damage. If none is found, the
groove on the shell. After the ring is started, slowly push the ring assembly should not be tampered with. If for any reason,
towards the groove. As the ring enters the groove, continue the retaining ring is removed, please contact the factory as a
pushing as your hand slowly rotates counter-clockwise around new ring is required with special assembly instructions to
the inside diameter of the shell. Be careful to prevent the ring ensure proper performance.
from snapping against your finger as it enters the groove.
Step 4 Remove Seals
Step 5 Reconnect Piping Remove the seal from the permeate port and set aside. Using a
Reconnect the feed and permeate manifolding to the vessel. small tool, such as a s crewdriver or a paper clip, remove the seal
from the inside of the permeate port and set aside.
Step 6 Pressurize System
Before starting the system, double check that each head has Step 5 Clean All Components
been correctly installed and that all piping connections are in Using a mild soap solution, clean each component, rinse with
place. After ensuring that all required precautions have been fresh water and then dry with compressed air or a lint free towel.
taken, start the system. Step 6 Inspect Components
Step 7 Check for Leaks Examine each component for corrosion or damage that may
After system start up, verify that all connections are leak free. Fix affect the performance of the vessel. Replace any components
any leaks at this time to prevent corrosion that may lead to that have corrosion or visual damage. In addition, carefully
component deterioration and possibly unsafe operation. inspect each seal for damage or wear. It is recommended to
replace each seal at this time. Please be aware that seal
condition may affect system performance.
HEAD REMOVAL PROCEDURE Step 7 Lubricate Seals
Using extreme care, coat each seal with a thin layer of glycerin.
Step 1 Shut Down System Only a thin layer is required. Silicone lubricants can also be used;
Shut down system and take all steps necessary to relieve however, care should be taken to use as little as possible. Check
system pressure from the vessel. with your membrane supplier before using these lubricants as
Step 2 Disconnect Piping they can foul membranes.
Carefully disconnect the feed and permeate piping from the Step 8 Reassemble Head
vessel. Reversing the removal procedure, reassemble the head. Please
Mark the feed port location by marking the shell for easier note that a new permeate port retaining ring may be required to
installation. Set this piping in a secure place for re-assembly. ensure correct component performance.
Step 3 Check End Closure
Examine the end closure for any corrosion or damage. Remove
any corrosion with a wire brush and flush away the deposits with
clean water. Order replacement components as required.
Step 4 Remove Retaining Ring
Pull the retaining ring out of the groove in the shell. After the ring
is removed from the groove for ¼ turn, stop pulling. Finish
removing the ring by running your finger behind the ring and
carefully pulling the ring from groove. It is best to follow the ring
in a clock-wise direction while removing to avoid stretching the
ring.
INSTRUCTIONS
Water Pump
type APP 5.1/5.6/7.2/8.2/10.2
180R9072
180R9072
Contents Contenu
1. Identification 1. Identification
2. System design 2. Conception du système
3. Building up the pump unit 3. Montage de la pompe
4. Initial start up 4. Mise en route initiale
5. Operation 5. Fonctionnement
6. Service 6. Service
Inhalt Contenidos
1. Bezeichnung 1. Identificación
2. Systemaufbau 2. Diseño del sistema
3. Aufbau der Pumpeneinheit 3. Montaje de la unidad de bombeo
4. Erste Inbetriebnahme 4. Arranque de la bomba
5. Betrieb 5. Operación
6. Wartung 6. Servicio Técnico
1. Identification 1. Identification
1. Bezeichnung 1. Identificación
2. System design 2. Conception du système

2.1 Open-ended systems with water supply from a tank. 2.1 Systèmes ouverts avec réservoir d’eau
2.2 Open-ended systems with direct water supply. 2.2 Systèmes ouverts avec alimentation directe
2.3 Problems with reversing pumps 2.3 Pompes réversibles
The design of the system must ensure that self-emptying of the pump La conception du système doit garantir que la pompe ne puisse se vider
during standstill is avoided. lorsque l’installation est à l’arrêt
The inlet pressure of the pump must never exceed the outlet pressure. La pression à l’entrée de la pompe ne peut jamais excéder la pression
This may typically occur in boosted or open-ended systems with direct à la sortie. Ceci peut survenir lorsque la pompe est alimentée par une
water supply. pompe de gavage ou dans des systèmes ouverts avec alimentation
In order to avoid this, it is recommended to install a prestressed check directe.
valve or a pressure switch in the pump inlet. Afin d’éviter tout problème, il est recommandé d’installer un clapet
The opening pressure of the check valve must be bigger or equal to the anti-retour pré-taré en sortie de pompe ou un pressostat à l’entrée de la
inlet pressure. pompe.
La pression d’ouverture du clapet anti-retour doit être supérieure ou
égale à la pression mesurée à l’entrée de la pompe.
2. Systemaufbau 2. Diseño del sistema

2.1 Offene Systeme ohne Rückführung mit Versorgung aus einem Tank. Los sistemas pueden ser de dos tipos:
2.2 Offene Systeme ohne Rückführung, mit direkter Wasserversorgung. 2.1. Sistema abierto a presión atmosférica con suministro de agua de un
2.3 Umkehrpumpen tanque.
2.2. Sistema abierto a presión atmosférica con suministro directo de
Der Systemaufbau muß sichern, daß sich die Pumpe im Stillstand nicht agua.
entleert. 2.3. Problemas con bombas reversibles
Der Druck am Pumpeneinlaß darf den Druck am Pumpenauslaß nicht
übersteigen. Dies mag typisch in “boosted” oder offenen Systemen mit El diseño del sistema debe asegurar que la bomba de agua no se vacíe
direkter Wasserversorgung auftreten. cuando esté parada.
Um dies zu vermeiden, empfehlen wir die Montage eines vorgespann-
ten Rückschlagventils oder eines Druckschalters in der Pumpeneinlass- La presión de la entrada de agua a la bomba nunca debe de ser superior
Seite. Der Öffnungsdruck des Rückschlagventils muß den Einlaßdruck a la presión de salida. Esto puede ocurrir normalmente en sistemas con
übersteigen oder diesem gleich sein. una bomba booster o en sistemas abiertos a presión atmosférica con
un suministro directo de agua. Para evitar esto, se recomienda instalar
una válvula antiretorno pretensionada o una válvula de seguridad
entre la bomba y la válvula bypass. La presión de apertura de la válvula
antiretorno debe ser mayor o igual a la presión de entrada del agua.
Re 2.1 Open-ended systems, water supply from tank Re 2.1 Systèmes ouverts avec réservoir d’eau
(The numbers 1- 3 refer to the drawing below) (Les numéros 1- 3 se réfèrent au schéma repris ci-dessous)
In order to eliminate the risk of cavitation, observe the following Pour éliminer tout risque de cavitation, observez les recommandations
guidelines: suivantes:
1) Place the tank above the pump (water level in the tank should 1) Placer le réservoir au-dessus de la pompe (le niveau de l’eau dans le
always be above the pump). réservoir devra toujours être plus haut que la pompe).
2) Place the inlet filter before the tank. 2) Placer le filtre d’aspiration avant le réservoir.
3) Dimension the inlet line to obtain minimum pressure loss (large 3) Dimensionner la conduite d’aspiration de manière à obtenir une
flow area, minimum pipe length, minimum number of bends/ perte de charge minimale (grand diamètre, conduite courte, un
connections, fittings with small pressure losses). minimum de courbes, raccords avec faibles pertes de charge).
4) If noise has to be considered, the inlet line must be a flexible soft
hose.
Re 2.1. Sistema abierto a presión atmosférica, suministro de un
tanque de agua.
2.1 Offene Systeme mit Wassertank (Los números 1-3 se refieren al gráfico adjuntado)
(Die Nummern 1- 3 beziehen sich auf die unten abgebildete Zeichnung) Para eliminar los riesgos de cavitación, observe las siguientes
Um das Risiko der Kavitation zu vermeiden, befolgen Sie folgende instrucciones:
Richtlinien:
1) Den Tank über der Pumpe hoch anbringen (der Wasserstand im 1) Coloque el tanque por encima de la bomba (el nivel del agua del
Behälter sollte immer über Pumpenniveau sein). tanque siempre debe estar por encima del nivel de la bomba).
2) Das Zulauffilter vor dem Behälter anbringen. 2) Coloque el filtro de entrada antes del tanque.
3) Die Saugleitung im Hinblick auf minimalen Druckverlust 3) Dimensione la línea de la entrada de manera que se obtenga la
dimensionieren (großer Durchströmungsbereich, minimale menor pérdida de presión (una máxima sección de tubería, un
Rohrlänge, minimale Anzahl von Winkelverschraubungen und mínimo de tuberías, un mínimo de recodos/conexiones, juntas con
Verschraubungen mit kleinem Druckverlust). pocas pérdidas de presión).
4) Falls Geräusch berücksichtigt werden muss, muss die Saugleitung 4) Si hay que tener en cuenta el ruido, entonces la línea de entrada
ein flexibler Schlauch sein. debe ser una manguera flexible.
Re 2.2 Open-ended systems with direct water supply Re 2.2 Systèmes ouverts avec alimentation directe
The pump is supplied with water direct from from a booster pump. La pompe est alimentée en eau par une pompe de gavage.
The water pressure must not exceed 5 bar abs. (72,5 psi). La pression d’alimentation ne peut excéder 5 bar abs. (72.5 psi).
2.2 Offene Systeme mit direkter Wasserversorgung Re 2.2. Sistema abierto a presión atmosférica con suministro
Die Pumpe wird direkt von einer Zwischenpumpe versorgt. directo de agua.
Der Wasserdruck darf 5 bar abs. nicht übersteigen. La bomba se abastece con agua procedente de una bomba “booster”. La
presión del agua no debe exceder los 5 bar absolutos (72,5 psi).
Re 2.3 Reversible pumps Re 2.3 Pompes réversibles
If exposed to high pressure in the outlet while the electric motor is not En cas de contre pression lors de l’arrêt du moteur électrique, la pompe
energized, the pumps will start spinning backwards. This will not harm commencera à tourner en sens inverse. Ceci n’endommagera pas la
the pumps as long as the pressure in the inlet does not exceed the max. pompe pour autant que la pression à l’entrée de la pompe ne dépasse
pressure of 5 bar. pas 5 bar.
If a non-return valve is mounted in the inlet line, a low-pressure relief Si un clapet anti-retour est monté dans la conduite d’aspiration de la
valve will also be required. pompe, une soupape de sécurité basse pression devra également être
Alternatively a high-pressure check valve could be mounted in the montée.
pump discharge line to prevent the pump from reversing. Solution alternative : le montage d’un clapet anti-retour dans la
The dotted setup ensures that the inlet pressure does not exceed the conduite haute pression (refoulement) évitera une rotation inverse de la
5 bar abs., when a non-return valve is mounted in the inlet. pompe.
Les recommandations précitées garantissent que la pression à l’entrée
de la pompe ne dépassera pas 5 bar abs. lorsqu’un clapet anti-retour est
Re 2.3 Umkehrpumpen monté dans la conduite d’aspiration de la pompe.
Wenn Umkehrpumpen hohem Druck in der Auslassleitung ausgesetzt
werden – während der Elektromotor nicht eingeschaltet ist – werden
die Pumpen rückwärts larufen. Re 2.3. Bomba reversible
Solange der Einlassdruck den max. Druck von 5 bar nicht übersteigt, Si se expone la salida de la bomba a alta presión mientras que el motor
werden die Pumpen vom Rückwärtslauf nicht beschädigt. no esté en marcha las bombas empezarán a girar al revés. Esto no daña
Wenn ein Rückschlagventil in der Saugleitung montiert ist, ist ein Nieder las bombas a no ser que la presión de la entrada supere los 5 bares. Si se
druckbegrenzungsventil auch erforderlich. pone una válvula antiretorno en la entrada, también se debe colocar una
Als Alternative kann ein Hochdruck-Rückschlagventil im Auslass der válvula de seguridad- Otra alternativa es poner una válvula antiretorno
Pumpe montiert werden, um Rückwärtslauf zu verhindern. a la salida de la bomba para impedir que se invierta. La línea discontinua
Der mit den punktierten Linien gezeigte Aufbau sichert, dass der Ein- del gráfico asegura que la presión no excedera los 5 bares cuando se
lassdruck die 5 bar abs nicht übersteigen wird, wenn ein Rückschlag- monte una válvula en la entrada de la bomba.
ventil im Einlass montiert ist.
General guidelines for calculation of pressure losses Recommandations générales pour le calcul des pertes de charge.
1) In smooth pipes and hoses 1) Dans les tubes lisses et les flexibles
In order to avoid the risk of cavitation, the inlet pressure at the Afin d’éviter tout risque de cavitation, la pression dans la conduite
pump must be min. 0.9 bar (13 psi) abs. d’aspiration de la pompe sera de min. 0.9 bar (13 psi) abs.
The inlet line connection must be properly tightened, as possible La conduite d’aspiration doit être étanche afin d’éviter une possible
entrance of air will cause cavitation. entrée d’air qui causerait de la cavitation.
The suction conditions can be optimized according to below guidelines Des conditions d’aspiration optimales peuvent être obtenues en suivant
on page 4. les recommandations décrites page 4.
Generelle Richtlinien für die Berechnung von Druckverlusten. Instrucciones generales para calcular las pérdidas de presión
1) In geraden Rohren und Schläuchen 1) En tuberías lisas y mangueras
Para evitar el riesgo de cavitación, la presión de entrada en la

Um die Gefahr der Kavitation zu vermeiden muß der Druck am bomba debe ser como mínimo de 0,9 bar (13 psi) abs.
Pumpeneinlaß min. 0,9 bar abs. sein. La línea de la conexión de la entrada debe estar sellada correctamente,
Die Montage der Einlaßleitung muß korrekt ausgeführt werden, da ya que en caso de que entre aire se producirá cavitación. Las
ein evtl. Lufteintritt Kavitation verursachen wird. condiciones de succión pueden ser optimizadas siguiendo las
Die Saugverhältnisse können gemäß Richtlinien auf Seite 4 optimiert instrucciones de la página 4.
werden.
2) In 90° bends 2) Dans les coudes 90°
2) In 920° Winkeln 2) En codos de 90°
2.4 General comments on 2.4 Généralités concernant
Filtration La filtration
A good filtration is vital to ensure a long and trouble free life of Une bonne filtration est vitale pour garantir une longue durée de
the pump. vie exempte de problème.
When selecting a filter or strainer, please note that filter materials Lors de la sélection d’un filtre ou d’une crépine, il est primordial que les
should be compatible with water, i.e. should neither corrode or dissolve. matériaux utilisés soient compatibles avec l’eau (pas de corrosion ou
Also be aware of the electrochemical series of the applied materials. d’érosion).
Main filter must have a fineness of 10 µm abs.ß 10 >5000. Vérifiez également les caractéristiques électrochimiques des matériaux.
The pressure loss across the filter should be monitored. Le filtre principal doit présenter une finesse de 10 µm abs. ß 10 >5000.
La perte de charge au travers du filtre doit être contrôlée.
Water tank
Must be made of corrosion-proof material such as stainless steel or Le réservoir d’eau
plastic and must be sealed to prevent entrance of impurities from Doit être construit dans des matériaux à l’épreuve de la corrosion (acier
the environment. inoxydable ou plastique) et étanche pour éviter l’intrusion d’impuretés
Automatic pressure equalization between tank and surroundings en provenance de l’extérieur.
must be ensured. Une égalisation automatique de la pression entre le réservoir et
Inlet from the water supply and inlet to the pump should be placed in l’environnement doit être assurée.
opposite ends of the tank to calm and deaerate the water, and to ensure La conduite d’alimentation du réservoir et la conduite d’aspiration de
optimum opportunity for particles to settle. la pompe seront placées chacune à une extrémité du réservoir afin
d’éviter les turbulences, de permettre une désaération du système et de
permettre aux particules de se déposer au fonds du réservoir.
2.4 Generelle Bemerkungen über 2.4. Comentarios generales sobre:
Filtrierung La filtración
Eine gute Filtrierung ist für eine lange Lebensdauer der Pumpe Una buena filtración de la bomba es vital para un funcionamiento
unerläßlich. sin problemas y una larga vida para la bomba.
Wenn Sie Filter oder Sieb wählen, beachten Sie bitte, daß das Filter- Para seleccionar un filtro o rejilla, por favor tenga en cuenta que los
material Wasserverträglich sein muß, d.h. es darf weder korrodieren materiales del filtro deben ser compatibles con el agua, por ejemplo
noch wasserlöslich sein. Beachte auch die elektrochemischen no se deben corroer ni disolver. También hay que tener en cuenta los
Ausführungen der verwendeten Materialien. potenciales electroquímicos de los materiales empleados.
Das Hauptfilter muß eine Feinheit von 10 µm Abs. ß 10 >5000 El filtro principal debe de tener un corte de 10 μm absolutas. β 10 /5000.
haben. La pérdida de presión a través del filtro debe controlarse.
Der Druckverlust über das Filter sollte überwacht werden.
El tanque de agua
Wassertank Tiene que estar compuesto de materiales que no se corroan, como el
Muß aus nichtrostendem Material wie rostfreiem Stahl oder Plastik acero inoxidable o el plástico, y tendrá que sellarse para prevenir la
sein. Um das Eindringen von Schmutzpartikeln aus den Umgebungen entrada de impurezas del medio.
zu verhindern, muß der Behälter verschlossen sein. La presión entre el tanque y su medio debe regularse de manera
Der Druckausgleich zwischen Tank und Umgebung muß gewährleistet automática.
sein. La entrada de agua del suministro de agua y la entrada a la bomba de
Wasserversorgungseinlaß und die Saugleitung der Pumpe sollten agua se deben colocar en extremos opuestos del tanque para calmar y
möglichst weit auseinander angebracht werden um das Wasser in desoxigenar el agua, y para asegurarse de que las partículas se asienten.
einem Zustand zu stillen und dadurch die best möglichen Voraus-
setzungen für das Absetzen von Partikeln zu schaffen.
Pump suction line should be placed relatively high above the tank La conduite d’aspiration de la pompe sera placée relativement haut
bottom in order to prevent settled particles from being led into the dans le réservoir pour éviter l’aspiration de particules gisant sur le fonds
pump. du réservoir.
We recommend a separation (“wall”) to separate the inlet from the Nous recommandons le montage dans le réservoir d’une paroi afin de
outlet end of the tank. séparer le coté alimentation en eau du coté aspiration de la pompe.
Die Zulaufleitung sollte so hoch wie möglich über dem Tankboden La línea de succión debe colocarse a una altura suficiente dentro del
angebracht werden. Dies verhindert, daß bereits abgesetzte Partikel tanque para evitar que las partículas que se hayan asentado en el fondo
wieder aufgewirbelt und von der Pumpe angesaugt werden. no vayan a la bomba.
Wir schlagen eine Trennung („Wand“) vor, die den Einlaß von der Recomendamos una pared de separación entre la entrada y la salida de
Auslaßseite des Tanks trennt. agua del tanque.
Monitoring Contrôle
It is recommended to continuously monitor the following conditions: Il est recommandé de contrôler en permanence les paramètres suivants:
• water level in the tank • Niveau de l’eau dans le réservoir
• filter contamination • Niveau de contamination du filtre
• pressure (inlet- and outlet side of the pump) • Pression (entrée et sortie de pompe)
Überwachung Control
Wir empfehlen laufende Überwachung folgender Bedingungen: Recomendamos controlar continuamente las siguientes condiciones:
• Wasserstand im Tank • el nivel del agua dentro del tanque
• Verschmutzung des Filters • la contaminación del filtro
• Druck (Ein- und Auslaßseite der Pumpe) • la presión (de entrada y salida de agua de la bomba)
3. Building up the pump unit 3. Montage de la pompe
3.1 Mounting (Please also see “Hints in Right and Wrong”) 3.1 Montage (Voir également “Correct et incorrect”)
A: Elastic coupling / Accouplement flexible A: Accouplement flexible

B: Bell housing / Lanterne B: Lanterne
C: Motor shaft / Arbre moteur C: Arbre moteur
3. Aufbau der Pumpeneinheit

3. Montaje de la unidad de bombeo
3.1 Montage (Siehe bitte auch „Hints in Right and Wrong“
3.1. Montaje (Ver sección sobre “Pistas sobre posible fallos”)
A: Elastische Kupplung
B: Kupplungsgehäuse A: Acoplamiento Elástico
C: Motorwelle B: Campana
C: Eje del Motor
If alternative mounting is desired, please contact the Danfoss Sales Si vous désirez un autre type de montage, contactez l’organisation
Organization. commerciale de Danfoss.
Choose proper tolerances to ensure an easy mounting of the elastic Choisissez des tolérances correctes pour faciliter le montage sans outils
coupling without use of tools. de l’accouplement flexible.
Please take care to observe the recommended length tolerances of the Concernant la longueur de l’accouplement, respectez les tolérances
chosen coupling, as an axial force on the pump will damage the pump. recommandées car toute charge axiale endommagera la pompe.
Wünschen Sie eine alternative Montage, fragen Sie bitte Ihre Danfoss Para otro tipo de montaje contacte con el Departamento de Ventas de
Verkaufsorganisation. Danfoss.
Wählen Sie angemessene Toleranzen, um eine einfache Montage der Escoger una tolerancia apropiada para facilitar el montaje del
elastischen Kupplung ohne Einsatz von Werkzeugen zu sichern. acoplamiento elástico sin el uso de herramientas.
Beachten Sie bitte, daß die empfohlene Längentoleranz eingehalten Por favor, mantengan las longitudes recomendadas de las tolerancias de
wird, da eine Axialkraft auf die Pumpe schädlich für die Pumpe sein los acoplamientos que hayan escogido; de esta manera se evitará una
kann. fuerza axial sobre el eje de la bomba que la podría dañar.
3.2 Direction of rotation 3.2 Sens de rotation

Is indicated by means of an arrow at the inlet side of the pump. Est indiqué par une flèche située sur le coté aspiration de la pompe.
3.2 Drehrichtung 3.2 Dirección de rotación

Wird durch einen Pfeil seitlich der Einlaßseite der Pumpe angezeigt. Está indicada con una flecha en un costado de la bomba.
3.3 Orientation 3.3 Orientation

The pump can be mounted/orientated in any horizontal direction. La pompe peut être orientée/montée horizontalement dans toutes les
Vertically only with the shaft pointing upwards. directions.
En cas de montage vertical, l’arbre devra toujours être dirigé vers le haut.
3.3 Einbaulage
Die Pumpe kann willkürlich horizontal eingebaut werden. 3.3 Orientación
Vertikal aber nur mit der Welle nach oben. La bomba se puede montar u orientar en cualquier dirección horizontal.
Solamente se puede montar de manera vertical con el eje mirando hacia
arriba.
3.4 Protection from too high pressures 3.4 Protection contre des pressions trop élevées
The pump should be protected against too high pressure by means La pompe devra être protégées contre des pressions trop élevées à
of a pressure relief valve or a bypass/unloading valve placed on the l’aide d’une soupape de sécurité ou d’une vanne de by-pass/décharge
pressure side. placée sur le coté refoulement de la pompe.
The valve should be placed as close to the pump as possible. La vanne sera placée aussi près que possible de la pompe.
The opening characteristics of the valve must not result in peak Les caractéristiques d’ouverture de la vanne doivent permettre d’éviter
pressures higher than 100 bar (1450 psi). des pointes de pression supérieures à 100 bar (1450 psi).
If noise has to be considererd, the inlet line must be a flexible soft Au cas où le niveau sonore s’avérerait être un point critique, il est
hose. recommandé d’utiliser un flexible pour la conduite d’aspiration.
The valve outlet must not be connected directly to the pump La décharge de la vanne ne peut être raccordée à la conduite
suction line. It shall be connected directly to the tank. d’aspiration de la pompe. Elle sera raccordée directement au
réservoir.
3.4 Überdruckabsicherung 3.4 Protección contra las altas presiones

Die Pumpe sollte mit einem Überdruckventil oder einem Druckent- La bomba se debe proteger de las altas presiones por medio de una
lastungsventil auf der Druckseite gegen zu hohen Druck abgesichert válvula reguladora de presión o por medio de una válvula bypass
sein. colocada en el lado de alta presión.
Das Ventil sollte so nah wie möglich an der Pumpe montiert werden. La válvula se debe colocar lo más cerca posible a la bomba.
Die Öffnungscharakteristik des Ventils darf keine Höchstwerte über En la apertura de la válvula no deben superarse los 100 bares (1450 psi).
100 bar zulassen. Si el ruido es de consideración, la línea de entrada debe ser una
Falls Geräusch berücksichtigt werden muss, muss die Saugleitung manguera flexible.
ein flexibler Schlauch sein. La salida de la válvula no debe conectarse directamente con la
Der Ventilauslaß darf nicht direkt mit der Pumpesaugleitung, línea de succión de la bomba. Se debe conectar directamente con el
sondern direkt mit dem Tank verbunden werden. tanque.
3.5 Connections 3.5 Raccordement

I : Inlet I : Aspiration
O: Outlet O : Pression (décharge)
C : Bleeding C : Purge
D : Parallel key 5 × 5 × 20, DIN 6885 D : Clavette 5 × 5 × 20, DIN 6885
3.5 Anschlüsse 3.5 Conexiones

I : Einlass I: Entrada
T: Auslass O: Salida
C: Entlüftung C: Sangrado
D: Paßfeder 5 × 5 × 20, DIN 68853 D: Llave paralela 5 × 5 × 20, DIN 6885
APP 5.1 - APP 10.2
Thread connections / Victualic connections /
Gewinde Anschluss / Anschluss /
Filetage / Raccords Victaulic /
Conexiones rosca Conexiones Victaulic
O I C O I C
Thread size / Gewindegröße/ M6 Hexagon M6 Hexagon
1 ¼ x 23 × G 1 ½ x 20 × 1 ½“ 1 ½“
Dimension/Dimensión 5 mm 5 mm
Max tighten torque/
Max. Anzugsmoment/ 25 Nm 25 Nm 5 Nm 25 Nm 25 Nm 5 Nm
Couple de serrage max./ 18 (LBF-FT) 18 (LBF-FT) 3.5 (LBF-FT) 18 (LBF-FT) 18 (LBF-FT) 3.5 (LBF-FT)
Par máximo al apretar la rosca
Recommended torque values refer to steel washers containing a rubber sealing element.
Victualic® is a registered trademark of Victualic.
Die empfohlenen Werte beziehen sich auf Stahlunterlegsscheiben mit Gummidichtung.

Victualic® ist ein eingetragenes Warenzeichen von Victualic.
Los valores recomendados del par se refieren a las arandelas de acero inoxidable que contienen una junta de caucho.
Victualic es una marca registrada de Victualic.
4. Initial start-up 4. Mise en route initiale
Before start-up, loosen the top bleeding plug “C”. When water appears Avant la mise en route, desserrer le bouchon de purge supérieur “C”.
from the bleeding plug, retighten the plug. With its inlet line connected Lorsque l’eau apparaît, resserrer le bouchon.
to the water supply or the tank, the pump is now started with open Avec la conduite d’aspiration raccordée à l’arrivée d’eau ou au réservoir
outlet port. rempli d’eau, la pompe sera démarrée avec la conduite de refoulement
At the initial start of the system, the pump should be run without (haute pression) ouverte.
pressure for about 5 minutes, thus removing possible impurities from Lors du démarrage initial, la pompe fonctionnera environ 5 minutes sans
pipes, hoses, etc. However, the system should be flushed before start-up pression afin d’évacuer de possible impuretés des tubes, flexibles, etc.
– without the connected pump pump. Le système sera toujours rincé avant la mise en route sans que la pompe
ne soit raccordée.
Warning:
Make sure that the direction of rotation of the electric motor Attention:
corresponds to the direction of rotation of the pump. Otherwise the Vérifiez que le sens de rotation du moteur électrique corresponde à celui
pump will be damaged if a check valve is placed between pump and de la pompe. Dans le cas contraire, la pompe sera endommagée si un
tank. clapet anti-retour est installé entre la pompe et le réservoir.
Note: The pumps are preserved with antifreeze Dowcal N. Note : Les pompes sont protégées par de l’antigel Dowcal N.
4. Erste Inbetriebnahme 4. Arranque Inicial

Vor der Inbetriebnahme, lösen Sie die obere Entlüftungsschraube “C”. Antes de arrancar, afloje el tapón de sangrado C. Cuando aparezca agua,
Wenn Wasser aus der Entlüftungsschraube austritt, diese erneut enrosque el tapón. Con esta línea de entrada conectada al suministro
anziehen. Die Pumpe – die Einlaßleitung zur Wasserversorgung oder de agua o al tanque de agua, ahora se puede poner en funcionamiento
zum Tank angeschlossen – wird jetzt mit offenem Auslaßanschluß la bomba de agua con un puerto de salida abierto.
(Druckseite) angelassen.
Bei der ersten Inbetriebnahme sollte die Pumpe für etwa 5 Minuten La primera vez que ponga en funcionamiento el sistema, la bomba debe
drucklos laufen, um Schmutzpartikel aus Rohren, Schläuchen usw. funcionar sin presión durante unos 5 minutos para así eliminar las impu-
zu entfernen. Jedoch sollte das System vor der ersten Inbetriebnahme rezas que pueda haber en las tuberías, mangueras, etc. Sin embargo, el
– ohne die angeschlossene Pumpe - durchgespült werden. sistema deberá de ser enjuagado (flushed) antes del arranque inicial sin
conectar la bomba.
Warnung:
Beachten Sie, daß die Drehrichtung vom Elektromotor mit der Dreh- Advertencia:
richtung der Pumpe übereinstimmt, da anderenfalls die Pumpe zerstört Asegúrese de que la dirección de la rotación del motor eléctrico corres-
wird. ponda a la dirección de la rotación de la bomba. Si no, la bomba puede
dañarse si se coloca una válvula antiretorno entre la bomba y el tanque.
Bitte bemerken Sie: Die Pumpen werden mit Frostschutzmittel Dowcal N
konserviert. Nota: Las bombas se almacenan con el anticongelante Doweal N.
5. Operation 5. Fonctionnement
5.1 Temperature 5.1 Température
Fluid temperature: Min. +3°C to max. +50°C Température du fluide: Min. +3°C / max. +50°C
Ambient temperature: Min. 0°C to max. 50°C. Température ambiante: Min. 0°C / max. 50°C
Storage temperature: Min. -40°C to max. +70°C Température de stockage: Min. -40°C / max. +70°C
In case of lower operating temperatures, please contact the Danfoss En cas de températures minimales inférieures à celles indiquées,
Sales Organization. contactez l’organisation de vente Danfoss.
5. Betrieb 5. Operación
5.1 Temperatur 5.1 Temperatura
Druckmitteltemperatur: Min. +3°C bis max. +50°C Temperatura de los líquidos: Min. 3°C a max. 50°C
Umgebungstemperatur: Min. 0° bis max. 50°C. Temperatura del ambiente Min. 0°C a max. 50°C
Lagertemperatur: Min. -40° bis max. +70°C Temperatura de almacenamiento Min. –40°C a max. 70°C
Bei niedrigeren Betriebstemperaturen wenden Sie sich bitte an die En el caso de temperaturas de funcionamiento más bajas, por favor
Danfoss Verkaufsorganisation. contacten con el Departamento de Ventas de Danfoss.
5.2 Pressure 5.2 Pression

The inlet pressure must be min. 0.9 bar (13 psi) and max. 4 bar (58 psi) La pression à l’entrée de la pompe (aspiration) doit être comprise entre
abs. At lower pressures the pump will cavitate, resulting in damage of min. 0.9 bar (13 psi) et max. 4 bar
the pump. (58 psi) abs. Si la pression à l’entrée est inférieure à celle indiquée, la
Max. pressure on the pump’s outlet line should be limited at 80 bar pompe cavitera et sera endommagée.
(1160 psi) continuously. La pression max. en sortie de pompe sera limitée à 80 bar (1160 psi) en
Short-term pressure peaks (e.g. in connection with closing of a valve) of continu.
up to 100 bar (1450 psi) are acceptable. Pendant un court moment, des pointes de pression jusque 100 bar/1450
NB: The pump unit should include a pressure gauge on the high pressure psi sont acceptables(ex. lors de la fermeture d’une vanne).
side. NB: Le système sera toujours équipé d’un indicateur de pression installé coté
refoulement (haute pression) de la pompe.
5.2 Druck 5.2 Presión

Der Einlaßdruck muß min. 0,9 bar und max. 5 bar absolut sein. Ein La presión de la entrada deberá ser como mínimo 0,9 bares (13 psi) y
geringerer Druck wird zu Kavitation führen. máximo 5 bares (72,5 psi) absolutos. Con presiones más bajas la bomba
Der max. Druck in der Druckleitung der Pumpe sollte auf 80 bar konti- sufrirá cavitación, resultando en daños a la bomba.
nuerlich begrenzt werden. La presión máxima de la línea de salida se debe limitar a 80 bares (1160
Kurze Druckspitzen (z.B. in Verbindung mit dem Schließen eines Ventils) psi) en continuo.
sind bis zu 100 bar möglich. Las presiones altas de poca duración (por ejemplo, en relación con el
NB: An der Hochdruckseite der Pumpe sollte ein Manometer angeschlossen cierre de una válvula) hasta 100 bar (1450 psi) son aceptables.
werden. Nota: En la unidad de bombeo debería de estar incluida un indicador de
presión en el lado de alta presión.
5.3 Dry running 5.3 Fonctionnement à sec

When running, the pump must always be connected to the water supply En fonctionnement, la pompe devra toujours être raccordée à une
in order to avoid damage if it should run dry. alimentation en eau afin d’éviter d’endommager la pompe par une
In systems with water tank it is recommended to build in a level gauge rotation à sec.
in the tank to avoid the risk of running dry. Dans les systèmes avec réservoir, il est recommandé d’installer un
indicateur de niveau.
5.3 Trockenlauf 5.3 Funcionamiento en seco

Wenn die Pumpe läuft, muß sie immer an der Wasserversorgung ange- Una vez que está en funcionamiento, la bomba siempre tiene que estar
schlossen sein, um Schäden infolge des Trockenlaufes zu verhindern. conectada al suministro de agua para así evitar que se dañe si se pone
In Anlagen mit Wassertank empfehlen wir, daß ein Wasserstandsanzeiger en marcha.
in den Tank eingebaut wird, um das Risiko des Trockenlaufes zu En los sistemas con un tanque de agua, se recomienda construir un
vermeiden. indicador de nivel dentro del tanque para evitar que se ponga en
marcha sin agua.
5.4 Disconnection 5.4 Découplage

If the inlet line is disconnected from the water supply, the pump will Si la conduite d’aspiration est déconnectée de l’alimentation en eau, la
be emptied of water through the disconnected inlet line. pompe sera vidangée via la conduite d’aspiration.
When starting up again, follow the bleeding procedure described Lors de la remise en route, la procédure de purge décrite en section 4:
under section 4: Initial start up. Mise en route initiale sera respectée.
5.4 Demontage 5.4 Desconexión

Wenn die Anschlußleitung von der Wasserversorgung demontiert Si la línea de entrada está desconectada del suministro de agua, la
wird, entleert sich die Pumpe. bomba se vaciará por esta línea de alimentación.
Bei erneuter Inbetriebnahme, befolgen Sie bitte die Entlüftungsprozedur Cuando se empieza nuevamente, seguir las instrucciones de sangrado
unter Abschnitt 4: Erste Inbetriebnahme. en la sección 4: arranque inicial.
5.5 Storage 5.5 Stockage
When preparing the pump for long-term storage or for temperatures Lors de la préparation de la pompe pour une longue période de
below the freezing point, flush the pump with an anti-freeze medium stockage ou lorsque le stockage se fait dans des températures négatives,
type monopropylene glycol to prevent internal corrosion or frost in la pompe sera rincée avec un antigel type MPG (mono propylène glycol)
the pump. pour prévenir gel et corrosion de la pompe.
For further information on anti-freeze media, please contact the Pour plus d’informations concernant les antigels, contactez
Danfoss Sales Organization. l’organisation de vente Danfoss.
Recommended procedure: Procédure recommandée:
5.5.1 Open-ended systems with water supply from tank. 5.5.1 Systèmes ouverts avec réservoir d’eau.
5.5.2 Open-ended systems with direct water supply. 5.5.2 Systèmes ouverts avec alimentation directe.
5.5.1 Open-ended systems with water supply from tank. 5.5.1 Systèmes ouverts avec réservoir d’eau.
1. Empty the tank of water and empty the pump housing through 1. Vider le réservoir d’eau ainsi que la pompe via le bouchon de
the lower bleeding plug. When the pump is empty, retighten the purge inférieur. Lorsque la pompe est vide, resserrer le bouchon.
plug. 2. Au travers du bouchon de purge supérieur, remplir la pompe
2. Through the upper bleeding plug, fill the pump housing with avec l’antigel. Verser de l’antigel dans le réservoir. Raccordez un
anti-freeze medium. Pour anti-freeze medium into the tank. flexible entre la sortie haute pression de la pompe et le réservoir.
Connect a hose to the outlet of the pump and lead the other end 3. Démarrer/arrêter rapidement la pompe en vérifiant que la pompe
of the hose back to tank. ne tourne pas à sec
sec. Maintenant la pompe est protégée contre le
3. Quickly start and stop the pump. Make sure that the pump gel et la corrosion.
does not run dry
dry. The pump is now protected against internal
corrosion and frost. 5.5.2 Systèmes ouverts avec alimentation directe.
1. Déconnecter l’alimentation en eau de la pompe.
5.5.2 Open-ended systems with direct water supply. 2. Vider la pompe via le purgeur inférieur et refermer le bouchon de
1. Disconnect the water supply to the pump. purge.
2. Through the lower bleeding plug, empty the pump housing of 3. Raccorder la pompe à un réservoir d’un capacité de 25 litres (6
water and close it again. gal.) contenant l’antigel. Connecter un flexible entre l’aspiration
3. Connect the pump to a tank of eg. 25 litre 6 gal. of anti-freeze de la pompe et le réservoir contenant l’antigel et un autre flexible
additive. Connect a hose to the inlet port of the pump and via entre le refoulement de la pompe et le réservoir d’antigel.
another hose return the flow from the outlet port port to the tank 4. Démarrer/arrêter rapidement la pompe en vérifiant que la pompe
with anti-freeze additives. sec.
ne tourne pas à sec
4. Quickly start and stop the pump. Maintenant la pompe est protégée contre le gel et la corrosion.
Make sure that the pump does not run dry. The pump is now
protected against internal corrosion and frost.
5.5 Lagerung 5.5 Almacenamiento

Vor längerdauernder Lagerung der Pumpe, oder wenn die Temperatur Cuando se prepara la bomba para un almacenamiento de larga duración
unter dem Gefrierpunkt absinkt, sollte die Pumpe mit einem o debido a que las temperaturas están por debajo de 0º C (punto de
Frostschutzmittel Typ Monopropylen Glycol durchgespült werden, um congelación) se tiene que enjuagar la bomba con un anticongelante,
Korrosion oder Frostschäden im Inneren der Pumpe zu verhindern. como el monopropilen glicol para prevenir la corrosión interna o la
Für weitere Einzelheiten über Frostschutzmittel verständigen Sie formación de hielo dentro de la bomba.
bitte die Danfoss Verkaufsorganisation. Para más información sobre anticongelantes contactar con el
Departamento de Ventas de Danfoss.
Empfohlene Prozedur:
Instrucciones recomendadas
5.5.1 Offene Systeme ohne Rückführung mit Versorgung aus einem
Tank. 5.5.1 Sistemas abiertos a presión ambiental con suministro de agua de
5.5.2 Offene Systeme ohne Rückführung, mit direkter un tanque.
Wasserversorgung. 5.5.2 Sistemas abiertos a presión ambiental con suministro directo de
agua.
5.5.1 Offene Systeme mit Wassertank.
1. Das Wasser aus dem Tank ablassen, und das Pumpengehäuse 5.5.1 Sistemas abiertos a presión ambiental con suministro de agua de un
durch den unteren Entlüftungsstopfen entleeren. Den Stopfen tanque.
erneut anziehen, wenn die Pumpe leer ist. 1. Vaciar el tanque de agua y vaciar la bomba abriendo el tapón de
2. Das Pumpengehäuse durch den oberen Entlüftungsstopfen purga/sangrado inferior.
mit Frostschutzmittel auffüllen. Frostschutzmittel in den 2. Mediante el tapón de purga superior, llenar la bomba con
Tank einfüllen. Einen Schlauch an den Ausgang der Pumpe un anticongelante. Verter anticongelante dentro del tanque.
anschließen, und das andere Schlauchende zum Tank Conectar una manguera a la salida de la bomba y llevar el otro
zurückführen. lado de la manguera al tanque.
3. Die Pumpe nur kurzzeitig anlaufen lassen und abstellen. 3. Arrancar y parar la bomba rápidamente. Asegúrese de que la
Beachten Sie, dass die Pumpe nicht trocken läuft.
läuft Die Pumpe ist bomba nunca se ponga en marcha en seco.
jetzt vor Innenkorrosion und Frostschäden geschützt. Ahora la bomba está protegida contra la corrosión y el hielo.
5.5.2 Offene Systeme mit direkter Wasserversorgung. 5.5.2. Sistemas abiertos a presión ambiental con suministro directo de agua.
1. Die Trinkwasserversorgung an die Pumpe abstellen. 1. Desconectar el suministro de agua a la bomba.
2. Das Wasser aus dem Pumpengehäuse durch den unteren 2. Usando el tapón de purga inferior, vaciar la bomba y cerrar el
Entlüftungsstopfen ablassen und danach wieder schließen. tapón nuevamente.
3. Die Pumpe mit einem Behälter mit z.B. 25 Liter Frostschutzmittel 3. Conectar la bomba a un tanque de (por ejemplo de 25 litros)
verbinden. Einen Saugschlauch an den Eingang der Pumpe anticongelante. Conectar una manguera al puerto de entrada
anschließen und das Frostschutzmittel aus dem Pumpenausgang de la bomba y por vía de otra manguera devolver el caudal del
durch einen weiteren Schlauch in den Tank zurückleiten. puerto de salida al tanque con anticongelante.
4. Die Pumpe kurzzeitig anlaufen lassen und abstellen. 4. Arrancar y apagar la bomba rápidamente. Asegúrese de que la
läuft Die Pumpe ist
Beachten Sie, daß die Pumpe nicht trocken läuft. bomba no se ponga en marcha en seco.
jetzt vor Innenkorrosion und Frostschäden geschützt. Ahora la bomba está protegida contra la corrosión y el hielo.
6. Service 6. Service
6.1 Periodic maintenance 6.1 Maintenance périodique
The APP pump is designed so that lubrication follows from the water La pompe APP est conçue pour que la lubrification se fasse par le fluide
itself and there is thus no oil in the pump. lui-même, il n’y a donc pas d’huile dans la pompe.
The pump requires no periodic replacements of seals and valve parts. La pompe ne requière pas de remplacement périodique de joints ou
valves.
6.2 Repair
In case of irregular function in the pump, please contact the Danfoss 6.2 Réparations
Sales Organisation. En cas de fonctionnement irrégulier de la pompe, contactez l’organisation
de vente Danfoss.
6. Wartung
6 Servicio de Mantenimiento
6.1 Periodische Wartung
Die APP-Pumpe ist so konstruiert, daß die Schmierung durch das Wasser 6.1 Mantenimiento periódico
erfolgt; es gibt also kein Öl in der Pumpe. La bomba APP está diseñada de manera que se lubrica con agua, con lo
An der Pumpe ist kein periodischer Austausch von Dichtungen und cual no hay aceite en la bomba.
Ventilteilen erforderlich. La bomba no necesita recambios periódicos de sellos ni de partes de la
válvula.
6.2 Reparatur
Bei Funktionsstörungen setzen Sie sich bitte mit Ihrer Danfoss Verkaufs- 6.2 Reparación
organisation in Verbindung. En caso de un funcionamiento irregular de la bomba, por favor contacte
con el Departamento de Ventas de Danfoss.
SSS
Water Pumps, type APP: Hints in Right and Wrong

1. 2.
Grease Sealing
Correctly limited quantities of Too much grease may develop Fittings in screwed components Using teflon tape or packing yarn
grease prevent seizing. biofilm causing operational to be sealed with O-rings or in joints may cause damage.
failures. bonded seals.
3. 4.
Assembly of Coupling Coupling
min.3 mm 0 mm
The coupling must be easy and Never use force when assembling Ensure always to have 3 mm Insufficient distance and/or
simple to assemble (see product the coupling parts, as this will distance between coupling misalignment between the
instruction). damage the motor/pump. flanges. coupling flanges
will damage the pump.
5. 6.
Impurities Rotation Direction
1 ? 2
Prior to installation, burrs and Chips or other impurities in the Check pump drive motor rotation Incorrect rotation direction will
chips and other impurities must system may cause damage. direction matches that of the pump damage the pump.
be removed from pipes and hoses, prior to installation.
e.g. with a felt plug.
7. 8.
Pressure Relief Valve Bleeding
Pressure relief valve to be Coupling the pressure relief valve Bleeding the pump will ensure Insufficient bleeding may cause
mounted vertically or with vertical outlet directly to the pump inlet correct cooling and lubrication. damage (not applicable to Power
outlet and connected to return may damage the pump. Packs).
hose or tank.

SSS
Changing APP5.1-10.2
14
Shaft seal
Note! It is essential that the Pump is serviced in
conditions of absolute cleanliness.
1. Unscrew (counter clockwise) and remove the seal retaining ring. (Pictures 1 and 2)
2. Wet the shaft and shaft seal with clean (filtered) soap-water. Gently lever the shaft
seal assembly free with the aid of the supplied shaft-seal extractor (Pictures 3,4 and
5)
3. Ensure that no dirt enters the pump. If loose particles are observed on or around
the shaft, the pump should be dismantled and thoroughly cleaned with clean
(filtered) water.(Picture 5)
4. Fit the hollow bush (torpedo) to the shaft.(Picture 6)
5. Wet the torpedo and replacement shaft seal with soap. Do not use silicone
grease.
6. 15
Slide the new shaft seal over the torpedo with the carbon seal face pointing upwards.
Be careful not to damage the carbon seal face on the shaft seal. (Pictures 7 and
14) The carbon seal ring is loose in the seal assembly and is easily removed from the
shaft sealing during assembly.
7. Using the plastic assembly tool provided, large diameter first, press the seal home
against the shoulder. (Pictures 8 and 9)
8. Remove the ceramic ring from the seal retaining ring. (Pictures 10 and 11)
9. Push the new ceramic ring into the retaining ring, using the plastic tool provided.
(Picture 12), make sure the face with the rubber seal is positioned against the
shoulder in the retaining ring (picture 14). Wet the parts with clean (filtered) soap-
water before assembly.
10. Fit the new O-ring on the retaining ring. (pictures 11and 14)
11. To prevent cold welding, lubricate the thread and O-ring on the retaining ring
with grease and screw it into the pump and tighten by hand. Use Molykote® D
paste from Dow Corning or Klüber UH1 84-201 from Klüber lubrication.
12. Tighten the retaining ring to a torque of 50 +10 Nm. (Picture 13)
SSS
1 22
1
Shaft-seal
extractor 3 4
5 6
4
77
8 9
10 11
6 O-ring
12 13
14
Seal retaining ring Ceramic-ring

Rubber seal
Carbon-ring
O-ring
shoulder
SSS
Changing internal Pump Elements in APP5.1-10.2

Note! It is essential that the pump is serviced in conditions of absolute cleanliness.
To better understand the pump design, please see exploded view in enclosure A.
1. Unscrew (counter clockwise) and remove the seal-retaining ring. (Pictures 1 and 2)
2. Wet the shaft and shaft seal with clean (filtered) soap-water. Gently lever the shaft seal assembly free with the aid of
the supplied shaft-seal extractor (Pictures 3, 4 and 5)
3. Unscrew the 8 screws in the mounting flange and gently lever the mounting flange from the casing. (Picture 6 and 7)
4. Lift out the whole cylinder barrel and gently place it on a suitable clean surface. (Picture 8)
5. Remove the pistons, retaining plate, distance ring and the retaining ball from the cylinder barrel (Pictures 9 and 10)
6. Gently lever the valve plate assembly free with the aid of a screwdriver. (Picture 11)
7. Remove the O-rings and the back-up rings on the valve plate. Assemble the new back-up rings on the new valve plate
first and then assemble the new O-rings (Picture 12).
8. Gently press, by hand, the valve plate onto the cylinder barrel (Picture 13).
9. Position the new port plate over the guide pin. IMPORTANT, make sure that the guide pin is located in the
locating hole in the port plate. (Picture 14 and 15)
10. Gently slide the cylinder barrel into the casing and fit the retaining ball onto the shoulder on the shaft (Picture 16
and 17)
11. Gently position all the pistons into the retaining ring first and then position all the pistons in each piston bore in the
cylinder barrel. It may be necessary to tilt the retaining ring to allow the pistons to fit into the piston bores. (Picture
18)
12. Position the distance ring on top of the retaining ball (Picture 19) and fit the new O-ring on the swash plate (picture
20).
13. Position the guide pin in the casing, position and gently press, by hand, the combined flange and swash plate into the
casing. Important, be aware of not to trap the O-ring (Picture 21).
14. Screw the 8 screws into the flange and the casing. To prevent cold welding, lubricate threads on the 4 screws with
grease and screw them into the pump and tighten by hand. Use Molykote® D paste from Dow Corning or Klüber
UH1 84-201 from Klüber lubrication.
15. Tighten the Screws to a torque of 30 + 3 Nm. (Picture 22)
16. Follow the Instruction ”Changing APP5.1-10.2 Shaft Seal” and assemble the new shaft seal.
SSS
1 2
1 2
Shaft-seal
extractor 3 4
6
5
7 8
7
S
9 10
11 12
Backup ring - first
O-ring -last
13 14
Guide Pin
15 16
Port Plate
17 18
19 20
Distance ring
Tiltet
retaining ring O-ring
21 22
Guide Pin
Enclosure A
Part list for APP5.1-10.2:
POS QNT. UNIT DESIGNATION Material

4 1 PC. Shaft seal Hasteloy/Monel/NBR
5 2 PC. Casing Duplex
6 3 PC. Swash plate Super duplex
7 4 PC. Pin PEEK
8 1 PC. Pin PEEK
10 1 PC. Retaining plate Super duplex
11 9 PC. Piston Super duplex
12 9 PC. O-RING NBR
13 9 PC. Back-up ring PEEK
14 1 PC. Valve plate Super duplex
16 1 PC. Retainer guide Super duplex
17 1 PC. Cylinder barrel Super duplex
18 1 PC. Spring Duplex
19 1 PC. Spring guide Super duplex
20 1 PC. Circlip Duplex
21 1 PC. Port plate Super duplex
22 1 PC. Guide-Pin PEEK
24 2 PC. O-RING NBR
25 1 PC. Port flange Super duplex
26 16 PC. Screw AISI316
29 2 PC. Bleed screw Duplex
30 1 PC. Key AISI302
34 1 PC. Screw AISI316
35 1 PC. Flange AISI316
36 2 PC. O-RING NBR
37 1 PC. Bush Super duplex
38 1 PC. O-RING NBR
39 1 PC. Stop-bush PEEK
40 2 PC. Port connection Duplex
100 1 PC. Instruction
101 1 PC. Identification label
105 1 PC. Transparent
107 1 PC. Warning
110 1 PC. Instruction
200 1 PC. Packing
Operating and Maintenance Instructions VM No.: 466.0004 GB
Edition: 06.03
Ident No.: 550 019
Volute Casing Centrifugal Pumps Retain

for future
Series NISM use!
Order No.: Pump Ident. No.:
Machine No.: Pump Type:
Operating data, dimensions and other additional information can be found in the order-specific part of the
documentation.
Contents
These Operating and Maintenance 1. General
Instructions contain information from
the pump manufacturer. They may need 2. Safety
to be supplemented by instructions of
the operator company for its personnel. 3. Transportation and Intermediate
These instructions do not take account Storage
of specific information relating to opera-
tion and maintenance of the process 4. Description
plant into which the pump is integrated.
Such information can only be given by 5. Installation/Mounting
the persons responsible for construc-
tion and planning of the plant (plant 6. Start-up/Shutdown
manufacturer).
Such specific instructions relating to 7. Maintenance/Repair
operation and maintenance of the
process plant into which the pump is
8. Operating Faults, Causes and
integrated have priority over the
Remedial Action
instructions of the pump manufac-
turer. The plant manufacturer must
on principle observe the limits of 9. Associated Documentation
use!
Refer to the operating instructions of

the plant manufacturer! Important note:
This operating manual is to be supplemented
by the order-related informations.
1
SSS
NISM
1 General
1.1 Pump designation
The exact designation can be found in the order-spe-
cific documents (see data sheet).
1.2 Proper use

Information on proper use of the pumps is provided in
the technical data sheet.
The pumped liquid must not contain any abrasive con-
stituents nor corrode the pump materials.
1.3 Types of construction

The pumps are supplied in various designs, differing
mainly in the shaft seals and the materials.
1.4 Performance data

The exact performance data can be taken from the or-
der data sheet and/or acceptance test report.
1.5 Warranty
Our warranty for shortcomings in the supply is laid
down in our delivery conditions. No liability will be un-
dertaken for damages caused by non-compliance with
the operating instructions and service conditions.
If at any later date the operating conditions change (e.g.
different fluid conveyed, speed, viscosity, temperature
or supply conditions), it must be checked by us from
case to case and confirmed, if necessary, that the
pump is suited for those purposes. Where no special
agreements were made, pumps supplied by us may,
during the warranty period, only be opened or varied by
us or our authorized contract service workshops; other-
wise our liability for any defects will cease.
1.6 Testing
Prior to leaving our factory, all pumps are subjected to
a leak test. Additional tests will only be performed on re-
quest.
1.7 Availability
As a matter of principle, we recommend stocking
replacement pumps and withdrawable units (hydraulic
action system) where the supplied pumps are a
decisive factor in maintaining a production or delivery
process. In this way downtimes can be avoided, or
reduced to a minimum.
1.8 Druckgrenze
Die Summe aus Eintrittsdruck und maximalem Förder-
druck darf nicht größer sein als der zulässige Pum-
peninnendruck (siehe Datenblatt).
VM 466.0004 GB/06.03 - Ident-Nr. 550 019 2

NISM
2 Safety
These operating instructions contain basic safety 2.3 Dangers in the event of non-compliance with safety
instructions for installation, operation and instructions
maintenance. It is therefore essential that they are read Failure to comply with the safety instructions may result
by fitters and all specialist staff and customer personnel in danger to persons, and place the environment and
prior to installation and start-up. They must always be the machine at risk. Non-compliance with the safety
kept at hand at the place of installation. instructions will lead to the loss of any claims for
damages.
The special safety instructions contained in the other Non-compliance may result in the following dangers:
chapters must be observed in addition to the general
safety instructions in this chapter. S Failure of important functions of the plant
2.1 Identification of safety instructions in the S Failure of specified methods for maintenance and
operating manual servicing
The safety instructions contained in these operating
instructions which represent a danger to personnel if S Danger to persons resulting from electrical,
not complied with are specially marked by the general mechanical and chemical effects
danger symbol:
S Danger to the environment resulting from leakage of
hazardous substances
2.4 Responsible working practices

The safety instructions contained in these operating
Warning symbol instructions, current national accident prevention
as per DIN 4844-W9 regulations, as well as internal working, operating and
safety rules of the customer, must be observed.
Warning of danger from electric voltage is indicated as
2.5 Safety instructions for the user/operator
follows:
S Hot or cold machine parts representing a danger
must be protected against accidental contact on
site.
S Protection against accidental contact for moving

Warning symbol parts (such as the coupling) must not be removed
as per DIN 4844-W8. while the machine is in operation.
S When operating pump aggregates in a dust-laden

Instructions which are essential to avoid endangering environment (e.g. milling, chipboard manufacture,
the machine and its operation are marked by the word bakeries), the surfaces of the pumps and motors
must be cleaned at regular intervals, depending on
ATTENTION local conditions, in order to maintain the cooling
effect and eliminate the possibility of spontaneous
combustion. Please also see explosion protection
Instructions affixed directly to the machine such as regulations (BGR 104).
S Directional markers S Leakage (e.g. from the shaft seal) of hazardous

substances being handled, such as explosive, toxic
S Signs for fluid connections or hot materials, must be discharged in such a way
that no danger to persons or the environment is
must always be observed and maintained in fully created. Legal regulations must be observed.
legible condition at all times.
S Dangers from electrical energy must be eliminated.
2.2 Personnel qualification and training For details in this regard, please refer to VDE and
The operating, maintenance, inspection and mounting local power company regulations.
personnel must be appropriately qualified for the duties
assigned to them. The scope of their responsibilities,
competency and supervisory duties must be closely
controlled by the customer. If the personnel do not have
the required knowledge, they must be trained and
instructed. If required, this may be provided by the
manufacturer/supplier on behalf of the customer. The
customer must additionally ensure that personnel fully
understand the content of the operating instructions.
VM 466.0004 GB/06.03 - Ident-Nr. 550 019 3

SSS
NISM
2.6 Safety instructions for maintenance, inspection 3 Transportation and Intermediate Stor-
and installation
The operating company must ensure that all
age
maintenance, inspection and installation tasks are 3.1 Packaging
performed by authorized and qualified specialist Attention must be paid to the figurative markings on the
personnel who have thoroughly studied the operating packaging.
instructions. The suction and pressure side and all auxiliary connec-
Work on the machine is only to be carried out when the tions must always be closed during transportation and
machine is at a standstill. The procedure for shutting storage.
down the machine described in the operating The coverings must only be removed im-
instructions must always be followed. mediately before connecting the pipeline.
Pumps or aggregates handling fluids which are
detrimental to health must be decontaminated. All 3.2 Transportation
safety and protective devices must immediately be The pump or pump aggregate is to be safely trans-
refitted and made operational on completion of the ported to the place of installation, if required by means
work. of lifting gear.
The instructions under Section 6.1, ”Preparation for
start-up”, must be observed before restarting. The regulations for lifting loads in accordance with
VBG 9a must be observed. Crane and sling equip-
2.7 Unauthorized conversion and production of ment must be adequately dimensioned. Sling
replacement parts equipment must not be secured to the lifting eyes
Conversion or modification of the machines is only of the motor, except as additional protection
permissible after consultation with the manufacturer. against overturning in the event of nose-heavi-
Original replacement parts and accessories approved ness.
by the manufacturer are intrinsic to safe operation. If
other parts are used the manufacturer cannot be held Transportation to and at the installation site
liable for the consequences. Make sure that the unit is transported safely and in a
stable position. Overturning due to nose-heaviness
2.8 Unacceptable modes of operation must be prevented.
The operational safety of the machine supplied is only
ensured when it is used in accordance with Section 1 of
the operating instructions. The limit values given on the
data sheet must not be exceeded under any
circumstances.
Transport damage
Check the pump for damage on receipt.
Any damage detected must be notified im-
mediately.
VM 466.0004 GB/06.03 - Ident-Nr. 550 019 4

SSS
NISM
3.3 Preservation / Storage of centrifugal pumps Note: The preservatives listed are to be regarded as a
recommendation. Alternatively, technically equivalent
3.3.1 Preservation products from other manufacturers can be used.
In the case of storage or prolonged standstill, the When handling preservatives, the safety hints con-
pumps must be protected against corrosion. In those tained in the relevant DIN safety data sheets and those
cases, an outside and inside preservation is to be proof the manufacturer must be complied with.
vided. The durability of the protection against corro-
sion, which is limited in time, depends on the composi- 3.3.1.4 Depreservation
tion of the preservative to be applied and the storage Prior to setting the pump in motion, the inside preserva-
conditions. tion must be removed.
Under normal circumstances the pumps Environmentally compatible disposal must be en-
have no special preservative. sured.
At an additional charge we can, however, supply
pumps and replacement parts ex factory with a preser- Preservatives can be removed with wax solvents, pe-
vative adequate to the planned storage period. troleum ether, diesel, petroleum or alkaline cleaners.
However, the simplest method is to use a steam clean-
3.3.1.1 Outside preservation er.
The outside preservative should be applied by painting Recommendation for Tectyl 506 EH: Allow petro-
or spraying with a spray gun. leum ether to act for 10 minutes before any further ac-
tion.
Points of preservation:
All bright and unvarnished parts (e.g. shaft ends, cou- Pumps that are used in the food or drinking water sector
plings, flange facings, valve and manometer connec- must be dismantled and thoroughly cleaned prior to de-
tions). preservation.
A suitable solvent that is compatible with the liquid to be
3.3.1.2 Inside preservation pumped (drinking water/food) can be used as the
(Not required for pumps made of stainless materials.) cleaning agent, e.g. Spiritus, Ritzol 155 or suds with a
high alkaline content. Steam cleaning is ideal.
Internal preservation is applied by painting, spraying
using spray guns, filling/dipping and subsequent drain- After a prolonged storage period (more
ing. Finally, the suction and outlet branches as well as than 6 months), all elastomers (O-rings,
all other supply and discharge branches must be shaft seals) must be checked for elasticity of shape.
sealed with dummy flanges or dummy plugs (plastic Embrittled elastomers must be replaced. EP rubber
caps). elastomers (EPDM) must be replaced on principle.
Points of preservation: 3.3.2 Storage
All bright parts inside the pump (e.g. pump casing in- During storage of the pump, the suction and outlet
side, bearing bracket, shafts, impellers and diffusers). branches and all other supply and discharge branches
must always be closed with dummy flanges or dummy
3.3.1.3 Storage times plugs.
Depending on the required storage period and the sur- Storage should be in a dry, dust-free room. During stor-
roundings, we recommend the use of preservatives age, the pump should be cranked at least once a
from Valvoline GmbH, Hamburg. month. During this process, parts such as the shaft and
bearings should change their position.
Storage in a closed, dry and dust-free room
3.3.3 Monitoring of preservation
Storage time up to 6 months up to 12 months over 12 months ➀ The preservation must be checked at regular intervals.
Internal preserrvation Tectyl 511 M Tectyl 511 M Tectyl 506 EH The preserved areas must be inspected every 6
External preservation Tectyl 511 M Tectyl 511 M Tectyl 506 EH months and re-treated, if necessary.
We cannot accept any liability for defects
Storage in the open-air, central European climate that arise due to incorrect preservation
treatment.
Storage time up to 6 months up to 12 months over 12 months
Internal preservation Tectyl 542 Tectyl 542 Tectyl 506 EH
External preservation Tectyl 542 Tectyl 506 EH Tectyl 506 EH
Storage in the open-air, tropical climate, aggressive industrial air or

proximity to the sea
Storage time up to 6 months up to 12 months over 12 months ➂

Intermal preservation Tectyl 542 Tectyl 542 Tectyl 506 EH
External preservation Tectyl 506 EH Tectyl 506 EH Tectyl 506 EH
➀ Internal and external preservation must be renewed after 48 months at the latest.
➁ External preservation must be renewed after 18 months at the latest.
Internal preservation must be renewed after 48 months at the latest.
➂ External preservation must be renewed after 12 months at the latest.
Internal preservation must be renewed after 48 months at the latest.
VM 466.0004 GB/06.03 - Ident-Nr. 550 019 5

SSS
NISM S alt S eparation S ervices
4 Description / Principle design of the pump
The pictorial presentation may not correspond with the pump supplied.
The actual design will be stated in the specific order documents.
Motor with locating

bearing at the driving
side
Contact protection Motor stool

to EN 809
Shaft seal space Plug-in shaft
Volute casing Impeller
Earthing connection to EN 809

must be attached by the customer
VM 466.0004 GB/06.03 - Ident-Nr. 550 019 6

NISM
5 Installation/Mounting
5.1 Installation 5.3 Alignment of the pump aggregate

For installation methods and locations, please see in- The pump aggregate must be aligned to its pre-set
stallation drawing. height and system dimensions. This is done using sui-
table steel shims, arranged directly adjacent to each fi-
Other methods of installation are not permissible xing bolt.
without prior consultation with the manufacturer. The overall height of the steel shims is determined by
the established system dimensions of the plant. The
steel shims and the base plate must be positioned
5.1.1 Place of installation evenly and securely.
Temperature: min. -20 ˚C If the fixing holes are more than 750 mm apart, we re-
max. +40 ˚C commend fitting additional steel shims in the middle of
the base plate.
relative air humidity: Base plate
permanent max. 85 %
temporary max. 100 %
Installation height: max. 1000 m above NN
For data differing from this, please consult the manu- Steel shims
= =
Foundation
facturer. > 750
Intensive vibrations in the vicinity of the Fig. 5.1: Alignment with steel shims
pump unit can lead to bearing damage and
must therefore be avoided.
Pumpes used for the delivery of water Horizontal alignment of the aggregate is produced by
must be installed so that they are protected way of flat-machined surfaces on the pump using a ma-
against freezing. chine spirit level. Measurements are taken in longi-tudi-
nal and transverse directions of the pump aggre-gate.
5.1.2 Protective devices Permissible deviation: max. 1 mm per 1 m length.
In order to prevent injuries due to burns, at pumping
liquid temperatures higher than 60˚C protective de- 5.3.1 Fixing the pump aggregate
vices in accordance with EN 809 must be provided on In order to prevent deformation of the base plate/pump,
site. this must first of all be screwed tightly at three points.
Before tightening the rest of the screws, spacers
Heat insulation should again be positioned around the screw, in order
Only the volute housing may be insulated to balance out the unevenness of the seating.
with heat insulating material. In order to The prescribed tightening torque (Section
enable optimum heat dissipation no other pump com- 7.2.3) must be observed.
ponents may be insulated.
Precise details on the shape and dimension of the fixing
5.2 Foundation are provided in the installation drawing.
5.2.1 General 5.3.2 Checking the alignment
The foundation may be a floor/concrete base or a load- After aligning and tightening the screws, it must be
bearing steel foundation frame. possible to turn the pump and drive by hand, without
The foundations must be constructed in any strain.
such a way that they can take the weight of Note: The pump unit should not be welded to the base
the pump unit and all operating forces that occur. for technical installation reasons.
5.2.2 Characteristics of a steel foundation frame 5.4 Assembly of pump and drive motor
A steel foundation frame must be constructed in such a If the aggregate is only assembled at the place of use,
way that the pump feet are supported evenly and can the coupling is assembled as follows:
be secured with screw fixings.
1. Remove the distance piece for shaft screwed to the
5.2.3 Characteristics of a floor/concrete foundation motor stool (341.01) for securing the pump shaft
The foundation must be horizontal, flat and clean, and (220...). For these purposes, loosen hexagon
be capable of bearing the full load upon it. screws (901.10).
Note: Concrete foundations must be executed with Note: The hexagon screws (901.10) serve for fixing
standard concrete of strength class B 25 as a minimum. the motor.
2. Screw out hexagon screws (901.07), remove

washers (554.07), and remove one half of the guard
plate (686.01) from the motor stool (341.01).T
VM 466.0004 GB/06.03 - Ident-Nr. 550 019 7

SSS
NISM
3. Loosen socket-head cap screw (914.06) in the 5.6.2 Changes in cross-section and direction
pump shaft (220...), and screw out completely. Sudden changes in cross-section and direction, as well
Note: The hexagon socket screw key required for as bends with a bend radius less than 1.5 times the in-
loosening the socket-head cap screw (914.06) is in- terior pipe width, must be avoided.
serted in one of the two cast-in recesses in the motor
stool. 5.6.3 Supports and flange connections
All pipelines must be connected to the
4. Mount flange motor and fix it. pump stress-free in accordance with
VDMA standard sheet 24277.
5. Mount the contact protection. The permissible pipeline forces must not
According to accident prevention regulations, the be exceeded in any operating status.
pump must only be operated with a protection We therefore recommend on principle that a calculation
against accidental contact. of the pipeline forces is performed, which takes into
consideration all operating status (e.g. cold/warm,
5.5 Space required for maintenance and repair
empty/full, depressurised/pressurised, etc.).
The pump must be accessible from all
Pipeline supports must always be free sliding and must
sides in order to be able to carry out
not rust in (check regularly).
necessary visual inspections.
Adequate space must be provided for maintenance How to assess a pipeline connection
and repair work, in particular for removal of the drive To conduct an assessment, the pipeline must be de-
motor or of the complete pump aggregate. It must also pressurised, completely drained and cooled. The
be ensured that all pipelines can be attached and pumping liquid must be disposed of with respect for the
removed without hindrance. environment.
5.6 Laying the pipelines S Disconnect the pipeline from the pump at the con-
necting flanges.
5.6.1 Nominal widths
S After disconnecting the connecting flanges, the
The nominal diameters of the pipelines need not
pipeline must be freely movable in all directions in
necessarily correspond to those of the inlet and outlet
the area of expected expansion.
branch, however, they must not be smaller. Different
Note: up to Ø 150 mm by hand
nominal diameters of suction branches and suction
from Ø 150 mm with small lever
pipelines are to be compensated by centric transition
pieces. Formation of air bags is to be avoided. S The flanges must lie plane-parallel.
5.6.4 Cleaning pipelines prior to attachment

Figure DN 1
Prior to assembly, all pipeline parts and valves must be
Recommendation for straight pipeline length
thoroughly cleaned.
before and after the pump
No impurities must reach the pump from
the pipeline system (e.g. welding beads,
residues from preservatives, etc.).
Flange gaskets must not protrude inwards. Blanking
flanges, plugs, protective film and/or protective paint on
flanges and seals must be removed completely.
Filters on suction side must be cleaned
regularly. We recommend monitoring with
differential manometer and/or contact manometer.
min. 5xDNs min. 5xDNd 5.6.5 NPSH observation

The NPSH conditions of the system must be adapted to
In these areas, pipe fittings such as gate valves, bends, the respective pump requirement (NPSHreq.).
compensators etc. should be avoided wherever possible. An essential condition is fulfilled if the system NPSH va-
lue (NPSHavail.) is at least 0,5 m above the pump
NPSH value (NPSHreq.). The NPSHreq. can be taken
from the characteristic curves of the relevant pumps.
Shorter pipelines on the suction side are
The applicable NPSH values in the char-
possible, but may lead to a deterioration of
acteristic curves are for water with 20˚C.
the hydraulic performance data. Shorter pipelines on
For other media and/or temperatures, the NPSH value
the discharge side are possible, but may lead to in-
may deviate from the characteristic curves.
creased noise development.
Uncertainties in the determination of
Compensators must not generate any un-
NPSH conditions, particularly for media
acceptable additional forces on the pump
connection branches. Special care is needed in cases other than water and/or other temperatures, must be
where compensators are used, whose pressurised di- compensated for by increased safety factors (please
ameter is greater than the nominal width of the pump consult the manufacturer).
connection branches.
VM 466.0004 GB/06.03 - Ident-Nr. 550 019 8

NISM
5.6.6 Suction and inlet pipeline 5.8 Electrical connections
In order to avoid the formation of air bags, the suction The power supply cables of the drive motor must be
and inlet pipeline must be laid rising to the pump. connected by a trained electrician, according to the
motor manufacturer’s circuit diagram. The valid VDE
5.6.6.1 Foot valve and suction basket (suction mode) regulations, the regulations of the local electricity board
For suction operation, the suction pipeline must be and the operating manual for the motor must be
equipped with a foot valve preventing the pump and complied with.
suction pipeline from running empty while at rest. Danger due to electrical power must be excluded and
an EMERGENCY STOP switch in accordance with EN
The suction basket must be attached so that neither dirt 809 must be provided.
from the sump nor air from the fluid level can enter.
The pump must not run dry, not even
5.6.6.2 Stop valve (inlet mode) for checking the sense of rotation.
A stop valve is to be installed in the inlet pipeline. It must
be fully open during operation (see figure DN 1). Refer 6.1... Control of drive motor sense of rotation
5.6.7 Pressure pipeline

5.9 Checking the pressure of the system with built-in
5.6.7.1 Stop valve in the pressure pipeline pump
A stop valve should be installed in the pressure pipe- If the whole system with built-in pump is to be subjected
line. to a final pressure test, the test pressure must not be
more than the maximum permissible internal pressure
5.6.7.2 Non-return valve in the pressure pipeline of the pump (see data sheet).
The pump must not run backwards. It is recommended
that a non-return valve is fitted between the pressure
branch and the stop valve.
5.6.7.3 Bleeding
In the pressure pipeline, bleeding facilities should be
provided at the highest point and in front of the non-re-
turn valve.
5.6.8 Auxiliary connections

The positions of the auxiliary connections on the pump
are shown in the installation drawing. All auxiliary
pipelines must be connected in accordance with the
installation drawing, stress-free and sealed.
5.7 Safety and control devices
5.7.1 Manometers
We recommend to provide suitable pressure gauges in
the inlet and pressure pipelines, and in the pressurized
auxiliary pipelines.
5.7.2 Safety devices in the inlet, delivery and auxiliary

pipelines
Safety devices in the form of stop valves must be
installed in the pipelines, if not already provided, to
allow the pipelines to be shut off and disconnected
during maintenance and repair work.
VM 466.0004 GB/06.03 - Ident-Nr. 550 019 9

SSS
NISM
6 Start-up/Shutdown
6.1 Preparations for (initial) start-up 6.2.1.2 Starting with air ejector A25A
Fully open the stop valve in the inlet pipeline and close
6.1.1 Filling and bleeding the pump the delivery-side valve.
Prior to starting up, the pump and the suction and inlet Initiate suction. (For description of function of air ejector
pipeline must be filled with delivery fluid. see separate Operating Instructions VM 490.0011/...).
During bleeding, the stop valves in the inlet and delivery After conclusion of the suction procedure, switch on the
pipelines must be open to allow air pockets to escape drive and open the pressure-side gate valve until the
into the piping system, and out from there via the minimum rate of flow is obtained (see Section 6.2.3).
bleeder pipeline.
If the pump fails to build up pressure when started up 6.2.2 Drive
(see manometer), bleeding must be repeated. Switch on the motor.
Refer to the operating instructions of the drive motor
During bleeding of the pump and the plant, hazardous manufacturer.
or environmentally harmful fluid and gas emerging
must be safely collected and discharged. 6.2.3 Minimum rate of flow
Immediately after reaching the operating speed, the
6.1.2 Control of drive motor sense of rotation pressure-side stop valve must be opened and the
The sense of rotation of the motor must match the pump operated up to at least the minimum rate of flow
sense of rotation arrow on the pump. To check the (see data sheet).
sense of rotation, the motor can be switched on briefly
when the pump is full. 6.2.4 Setting the pump power output values
The pump must not run dry, not even The pressure-side stop valve must be opened until the
for checking the sense of rotation. required pump power output values are obtained (see
In the case of pumps with a mechanical seal that is de- data sheet).
pendent on the sense of rotation, the motor must al-
6.2.5 Temperature
ways be disconnected in order to check the sense of
In order to prevent injuries due to burns, at pumping
rotation.
If the sense of rotation is incorrect, the sense of rotation liquid temperatures higher than 60˚C protective de-
of the three phase motor can be reversed by switching vices in accordance with EN 809 must be provided on
any two phases. site.
6.1.3 Switching on any additional devices It must be ensured that the pump housing
Before starting up the pump, any additional devices is evenly heated. Differences in tempera-
must be switched on and must have reached the nec- ture between the top and bottom of the pump, as well as
essary flow rates/temperatures/pressures. sudden temperature changes, should be avoided.
Note: Pay attention to the flow rates/temperatures/ Temperature changes in the material of more than
pressures quoted on the order data sheet or in the 50˚C per minute are not permissible.
manufacturer’s instructions.
6.2.6 Adjusting the stuffing box (if fitted)
External flushing, external blocking, quench Any increased leakages at the stuffing box in the initial
The liquids for external flushing, external blocking operating hours are normally eliminated in the course
and/or quench must be suitable for mixing with the ma- of the run-in period. If necessary, tighten the hexagonal
terial to be pumped. nuts on the gland slightly.
A slight leakage must be set at the stuffing
6.2 Start-up box. This will discharge any frictional heat
occuring at the sealing surface.
6.2.1 General
Before starting, all filling and venting openings must be 6.2.7 Spare pump
completely closed. A spare pump belonging to the plant must always be
kept ready for operation. For these purposes, the stop
6.2.1.1 Starting without air ejector valve on the supply side must be completely open. The
To avoid overloading the drive motor, the pump should stop valve on the outlet side must be opened to such a
be run up only against a closed pressure stop valve dur- degree that the pump, filled and bleeded, has operating
ing starting. temperature.
The stop valve in the inlet pipeline must be fully open.
In plants in which impermissible tempera-
ture may arise due to failure of the operat-
ing pump, a standby pump of sufficient output must be
provided.
Two independent energy sources must be provided for
the operating and standby pumps.
VM 466.0004 GB/06.03 - Ident-Nr. 550 019 10

SSS
6.3 Shutdown
S Pressure pipeline
If a non-return valve is installed in the pressure pipe-
line, the stop valve can remain open. Without non-
return valve, the stop valve must be closed.
S Drive
Switch off the motor. Make sure the pump runs down
smoothly and evenly.
S Inlet line
Close stop valve in inlet line.
S Additional devices
Switch off any additional devices (external flushing,
external sealing, quench).
In the case of double-acting mechanical

seals, the pump and system must be
depressurized before switching off the sealing pres-
sure.
It must be ensured that the pump does not run back-

wards after switching off. Otherwise, the pump may
reach unacceptably high speeds, and shaft seals de-
pendent on the direction of rotation will be severely da-
maged.
6.4 Measures in the event of standstills
Pumped liquid Measures in the event of Measures in the event of

... brief standstill prolonged standstill
May solidify
+ Hear or drain pump Drain pump
has a preservative effect ➀
May solidify
+ Drain and preserve pump
Hear or drain pump
does not have a preserva- ➀
tive effect
Does not solidify

+
- -
has a preservative effect
➀
Does not solidify

+ Drain and preserve pump
-
does not have a preserva- ➀
tive effect
➀ See section 3.3
VM 466.0004 GB/06.03 - Ident-Nr. 550 019 11

NISM
7 Maintenance/Repair
7.1 Maintenance 7.1.2.2 Shaft seal

The shaft is sealed either by a stuffing box or
S The instructions in Section 2, Safety, must be mechanical seal.
observed in maintenance and repair work.
S Stuffing box
S Regular monitoring and maintenance of the pump Any increased leakages at the stuffing box in the
and the drive motor are essential for optimum ser- initial operating hours are normally eliminated in the
vice life and safety. course of the run-in period. If necessary, tighten the
hexagonal nuts on the gland slightly.
7.1.1 General monitoring
Ensure that there is slight leakage at the stuffing
1. The pump must not run dry. box. This will discharge any frictional heat occurring
on the sealing surface.
2. The pump must not run in cavitation. If the leakage increases excessively, and if it also
cannot be reduced by repeated slight tightening of
3. The minimum delivery rate must always be main- the hexagonal nuts, the packing rings have lost their
tained (see Section 6.2..). elasticity of shape and must be replaced.
4. The drive motor must not be overloaded. S Mechanical seal

A maximum dripping rate of 10 g/h may occur during
5. The shaft seal must have no inadmissible leakage. operation and is normal. If the dripping is heavier,
the shaft seal must be replaced.
6. The pump unit must not experience or generate any
undue vibrations (e.g. as a result of incorrect align- S Additional devices
ment). International standard ISO 10816 must be re- Any additional device at the shaft seal (external
ferred to for assessment. flushing, external sealing, quencher) must be moni-
tored.
7. Changes to the normal operating data may indicate
faults. The causes must be established. A defective shaft seal can cause uncontrolled dis-
charge of pumping liquid.
8. Installed standby pumps must be started up once a
This constitutes a hazard to people (possibility of
week.
spraying liquid) and to the environment!
7.1.2 Maintenance of components
7.1.2.3 Drive
7.1.2.1 Bearing Refer to the operating instructions of the motor
Refer to the operating instructions of the motor manufacturer.0 m³/day S
manufacturer.
VM 466.0004 GB/06.03 - Ident-Nr. 550 019 12

NISM
7.2 Repair 7.2.1 Dismounting the centrifugal pump
Before dismounting, the following work must be carried
General out:
The system operator is responsible for ensuring that in-
struction in safety is provided. The personnel must be S Electrical danger must be eliminated! The motor
made aware of all hazards that can arise in connection must be secured against being switched on. If
with the pumped liquid or the plant. necessary, the power supply cable must be
disconnected from the motor by an authorized
Mounting and repair work electrician.
Trained Service fitters are available on request to carry
out mounting and repair work. S Close all stop devices in the inlet and delivery pipe-
For all repairs, it must be ensured that the pump is de- line, and in the auxiliary pipelines.
pressurised, completely drained and cool. The motor
must be protected against unintended switching on. S Allow the pump housing to cool to ambient
We must refuse acceptance of repair work on pumps temperature.
filled with fluid, for the protection of our staff and for
environmental reasons. The expenditures for disposal S Drain the fluid in flowable condition from the pump.
with respect to the environment are to be carry by the Note: Use a collecting tank.
customer/operating company.
S The pump must be depressurized and drained.
Hazardous substances
Where repairs are to be carried out on pumps which S Hazardous substances and/or environmentally
have been operated with hazardous substances ➀ harmful media must be drained off and collected
and/or environmentally harmful media, the such that no danger to life and limb is created.
customer/operator must inform its own personnel on Environmentally compatible disposal must be
site, or our personnel where repairs are returned to our ensured.
factory or a service workshop, without being
specifically requested to do so. S Remove auxiliary pipelines, if fitted.
Together with the request for a Service fitter a
verification of delivery material, for example in the form S Dismount manometer lines, manometers and hold-
of a DIN safety data sheet, must be submitted to us. ing devices.
Alternatively, you can request a certificate of safety
(form no. 448/191) from our Service department, filling S Dismount protection against accidental contact.
it out truthfully, correctly and in full. Send the completed
form to the center commissioned with carrying out the
repair, or hand it to our Service fitter. The pump must be dismounted by a qualified
technician using the pertaining drawings.
➀ Hazardous substances are: To prevent damage, it is especially important to ensure
that the components are dismounted concentrically
S Toxic substances and that they are not tilted.
S Health-endangering substances
S Corrosive substances Dismounting instructions:
S Irritants S The pumps are produced as standard in process de-
S Explosive substances sign. This means that the drive unit can be dis-
S Fire-inducing substances mounted without the need to remove the volute
S Highly flammable, easily flammable and normally housing and the pipes.
flammable substances
S Carcinogenic substances S The fitting position of all components must be accu-
S Substances impairing fertility rately marked before dismounting.
S Genetically distorting substances
S Substances in other ways hazardous to humans S In order to disassemble the motor, the pump shaft
(220…) must be expanded. To do this, unscrew
Pumps or units which pump hazardous substances or socket-head cap screw (914.06) and screw in a
substances that are dangerous to the environment socket-head cap screw M10 x 40 or M12 x 40 ISO
must be completely decontaminated. 1207 (not included in the scope of supply).
Notch is widened slightly
Tighten forcing screw with a

screwdriver, but not using
excessive force.
VM 466.0004 GB/06.03 - Ident-Nr. 550 019 13

SSS
7.2.2 Mounting the centrifugal pump 7.2.3 Tightening torque

Before remounting check all parts for wear
Note: With poor and lightly greased surfaces, the va-
and aging and, as necessary, replace with
original replacement parts. lues must be increased by 10-15%, in order to reach the
Clean all parts before mounting. Always fit new required performance.
gaskets.
Tightening
Part no. Thread Quality torque
The pump must be mounted by a qualified techni- [Nm]
cian using the pertaining drawings. The prescribed M8 4.6 8
tightening torque must be observed. 901.01 M 10 8.8 35
To prevent damage, it is especially important to ensure M 12 A4 45
that the components are mounted concentrically and
M8 22
that they are not tilted. 901.02 8.8
M 12 63
Mounting instructions: M8 8.8 22

M 10 8.8 35
901.10
S The pump shaft must be free of oil and grease. M 12 5.6 35
M 16 8.8 150
S To assemble the motor, the pump shaft (220…)
must be expanded. To do this, unscrew socket-head 902.01/920.01 M 10 27
A4
902.03/920.03 M 16 ➀ 45
cap screw (914.06) and screw in a socket-head cap
screw M10 x 40 or M12 x 40 ISO 1207 (not included 903.01
G 1/ 4 10
in the scope of supply). 903.02
G 3/ 8 A4 15
903.03
G 1/ 2 30
903.04
Notch is widened slightly
904.05 M8 A4 12
M8 25
914.06 12.9
M 10 50
M 10 12.9 50
914.10
M 16 8.8 167
M 12 x 1,5 20
Tighten forcing screw with a 922.01 M 20 x 1,5 1.4404 96
screwdriver, but not using
excessive force.
M 24 x 1,5 157
➀ not valid for pumps with stuffing box

The key groove of the motor shaft must
be located opposite the slit of the pump
shaft. The key is not required.
Following the mounting the centrifugal pump, the
S The pump shaft (220.01) must be pushed onto the following operations are to be performed.
motor shaft as far as the shaft collar of the motor lan-
tern and then secured with socket-head cap screw S Attach protection against accidental contact and
(914.06). supporting foot, if any.
S Screw socket-head cap screw (914.06) into the
S Attach auxiliary pipelines.
pump shaft (220…) and tighten with the dynamo-
metric key. S Attach manometer pipelines, manometer and hold-
S The markings applied when dismounting must be ing devices to the pump.
observed. The components must be put back in their
original fitting position. S Electrical danger must be eliminated! Power supply
cables must only be connected by qualified
S When assembling, screws and nuts must be painted electricians. Pay attention to sense of rotation.
with a suitable high-temperature screw paste (e.g.
Molykote P37). Start up pump as per instructions in Section 6.
S After tightening the screws, it must be possible to
turn the pump and drive manually without straining
points.
VM 466.0004 GB/06.03 - Ident-Nr. 550 019 14

NISM
7.3 Replacement parts 7.3.2 Allocation of the pump sizes to the diameters of the
The application guidelines in accordance with DIN 24 pump shaft at the shaft seal
296 can be taken as a basis for spare parts stock hold-
ing (see Section 7.3.2).
Diameter of the
Pump size pump shaft at the
However, for reasons of operational safety, we recom-
shaft seal
mend the stocking of complete insert units or spare
pumps. NISM
[mm]
Advantage: In the event of damage, a defective unit
can be replaced by a spare unit without great expendi- 20-160 16
ture and in a very short space of time.
32-160
7.3.1 Ordering spare/replacement parts 32-200
The following details are required for handling orders 40-160
for replacement and spare parts: 40-200
40-250 30
S Pump abbreviation ➀ 50-160
50-200 single-stage
S Pump number ➀ 50-250
S Year of construction ➀ 65-160
S Part number 65-200
80-160
S Denomination
S Quantity 2/32-200 30
2/40-250
2/50-250 two-stage
➀ refer to name plate
65-250
65-315
65-400
80-200
80-250
40
80-315
100-200
100-250
100-315
125-250
7.3.3 Replacement parts for two-year continuous operation as per DIN 24 296
Part No. Part denomination Number of identical pumps (including standby pumps)
2 3 4 5 6 and 7 8 and 9 10 and mehr
Set/Replacement parts quantity
171.01 Diffuser (all two-stage sizes) 1 1 1 2 2 3 30%
220.01 Plug-in shaft or

220.02 Plug-in shaft or
220.03 Plug-in shaft with
Socket-head cap screw 914.06 or 1 1 2 2 2 3 30%
Impeller nut 922... with
➀
Spring ring 936... and
Key 940...
230.01 Impeller (all single-stage sizes) 1 1 1 2 2 3 30%
230.02 Impeller first stage and

230.03 Impeller second stage with ➀
1 1 1 2 2 3 30%
514.01 Threaded ring and
904.05 Hexagon sockets with cup points
400.01 Gasket (Set) 4 6 8 8 9 12 150%

400.02 Gasket (for design with intermediate ring) 4 6 8 8 9 12 150%
433... Mechanical seal 2 3 4 5 6 7 90%
461.01 Stuffing box packing (set) 4 4 6 6 6 8 40%
➀ Can be purchased as assembly group/sale group.
VM 466.0004 GB/06.03 - Ident-Nr. 550 019 15

SSS
8 Operating Faults, Causes and Remedial Action
8.1 Faults with reference number for cause and remedial action
The table below is intended as a guide to identifying faults and their possible causes.
If faults occur which are not listed here, or which cannot be traced back to the listed causes, we recommend consulting the
factory, or one of our branch offices or sales offices.
The pump must be depressurized and drained when faults are being rectified.
Centrifugal pump faults Reference numbers for cause and remedial action
Delivery rate too low 1, 2, 3, 4, 5, 6, 7, 8, 9, 21, 22
Delivery head too low 2, 3, 4, 5, 6, 7, 8, 9, 21, 22
Power consumption of pump too high 9, 11, 12, 17, 21, 22
Delivery pressure too high 9, 12
Pump housing leaky 23
Heavy leakage of shaft seal 10, 13, 15, 17, 27
Pump not operating smoothly 1, 2, 3, 4, 5, 6, 8, 11, 17, 24, 26
Pump gets hot 2, 5, 26
8.2 Causes and remedial action
Ref. no.: Cause Remedial action

1 Delivery head higher than nominal delivery head 1. Open stop valve in pressure pipeline until operating point is
of pump. reached.
2. Install impeller with larger diameter.
3. Increase rotation speed (turbine, frequenzy control, ...). ➀
2 Pump or pipelines not properly bled or filled. Bleed and top up pump or pipelines.
3 Inlet pipeline or impeller blocked. Clean pipelines and impeller.
4 Air pockets forming in pipeline. Perhaps install a vent valve, or lay pipeline differently.
5 NPSHplant (inlet) too low. 1. Check fluid level in inlet tank.
2. Open stop valve in inlet pipeline fully.
3. Lay inlet pipeline differently if friction losses are too high.
4. Check filter in inlet pipeline, if fitted.
5. Check inlet flow conditions of pump.
6 Wrong direction of rotation of pump. Reverse polarity of any two phases on motor.
7 Rotation speed too low. Increase rotation speed (turbine, frequenzy control, ...). ➀
8 Excessive wear on inner pump parts. Replace worn parts.
9 Density or viscosity of delivery medium does not Consult the factory in the event of faults due to non-compliance
comply with pump design data. with design data. ➀
10 Shaft sleeve damaged. Mount new shaft sleeve.
11 Delivery head lower than nominal delivery head 1. Regulate operating point with stop valve in pressure pipeline.
of pump. 2. Turn off impeller in event of continuous overload.
12 Rotation speed too high. Reduce rotation speed (turbine, frequenzy control, ...). ➀
13 Shaft seal damaged. Check shaft seal parts for wear and replace if necessary.
14 - -
15 Packing material unsuitable for the delivery me- 1. Wrong packing material used. Repack pump with suitable
dium. material.
Gland is askew, or too loosely tightened. 2. Tighten gland evenly.
16 - -
17 Pump twisted. Check pipelines for twists in connections.
VM 466.0004 GB/06.03 - Ident-Nr. 550 019 16

SSS
NISM
18 - -
19 - -
20 - -
21 Motor voltage incorrect. Use motor with correct voltage.
22 Motor runs only to two phases. 1. Check cable connection.
2. Replace fuses.
23 Screws not tight. 1. Tighten screws.
2. Replace gaskets.
24 Impeller out-of-true. 1. Clean impeller.
2. Re-balance impeller.
25 - -
26 Delivery rate below minimum. Increase delivery rate to minimum.
27 Pumped liquid corroding mechanical seal mate- Check pumped liquid (e.g.: incorrect temperature, concentra-
rial. tion, dosing of additives, etc.)
➀ Consult factory
VM 466.0004 GB/06.03 - Ident-Nr. 550 019 17

SSS
9 Associated Documentation
Sectional drawing - Series NISM Denomination Part No.

single-stage sizes with shaft diameter 30 at the shaft seal -------------------------------
Volute casing 102.01
Stage casing 108.01
Casing cover 161...
Diffuser 171.01
Plug-in shaft 220.01
Plug-in shaft 220.02
Impeller 230.01
Impeller first stage 230.02
Impeller second stage 230.03
Motor stool 341.01
Gasket 400.01
Gasket 400.02
Joint ring 411.01
Joint ring 411.02
Joint ring 411.03
Joint ring 411.04
O-ring 412.01
O-ring 412.07
Mechanical seal 433...
Split ring 502.01
Split ring 502.02
Intermediate ring 509.01
Intermediate ring 509.02
Threaded ring 514.01
Spacer sleeve 525.01
Spacer sleeve 525.02
Washer 554.07
Washer 554.15
Rivet 565.01
Guard plate 686.01
Pipe 710.01
Shaft seal: uncooled, unbalanced mechanical seal Flange motor 801.01
Abbreviation: U3...D
Hexagon screw 901.01
Sectional drawing - Series NISM Hexagon screw
sizes with shaft diameter 40 at the shaft seal (Ribe-Triform) 901.07
Stud bolt 902.01
Stud bolt 902.03
Screw plug 903.01
Screw plug 903.02
Screw plug 903.03
Screw plug 903.04
Grub screw 904.05
Air release plug 913.05
Socket-head cap screw 914.06
Socket-head cap screw 914.10
Hexagon nut 920.01
Hexagon nut 920.03
Impeller nut 922.01
Spring ring 936.01
Key 940.01
Key 940.03
Name plate 971.01
-------------------------------
Connections
-------------------------------
FD Draining
FF Filling
LO Leakage discharge
PM1 Pressure measuring device
PM2 Pressure measuring device
V Air release
Shaft seal: uncooled, unbalanced mechanical seal

Abbreviation: U3...D
VM 466.0004 GB/06.03 - Ident-Nr. 550 019 18

SSS
SSS
SSS
SSS
T
SSS
SSS
SSS
SSS
T
SSS
T
SSS
SSS
SSS
ANT
SSS
SSS
SSS
SSS
SSS
-
SSS
T
SSS
SSS
SSS
SSS
ProMinent® beta/ 4 Solenoid Dosing Pump Operation & Settings
SSS
SSS
SSS
S
SSS
REV : 01
SSS
SSS
SSS
SSS
8860 Dual Channel Conductivity/Resistivity Controller English
*3-8860.090*
3-8860.090 Rev. E 3/06 English
C1 23.45 µS
CAUTION! C2 8.72 µS
Signet
• Remove power to unit before wiring input and output connections. Relay 1
Conductivity/Resistivity
Transmitter
Relay 2
• Follow instructions carefully to avoid personal injury.

• This product should only be used for the purposes and in the manner described in this manual. ENTER
Installation
1. Punch out panel and de-burr edges. Recommended clearance on all sides between instruments is 1 inch.
2. Place gasket on instrument, and install in panel.
3. Slide mounting bracket over back of instrument until quick-clips snap into latches on side of instrument.
4. Connect wires to terminals.
5. To remove, secure instrument temporarily with tape from front or grip from rear of instrument. DO NOT RELEASE. Press
quick-clips outward and remove.
6. If cleaning is necessary, wipe the front of the unit with a damp cloth.
7. The live contacts on the back of this unit must be covered to avoid accidental shock hazard.
gasket on
front side
96mm (3.8 in.) of panel
panel
Panel Cutout terminals

96 mm 92 x 92 mm mounting
(3.8 in.) Optional bracket
(+ 0.8, - 0 mm) AY 4
Rear Cover REL

AY 2
REL
AY 3
REL
AY 1
3.6 x 3.6 in.

REL
COM ER
N/O
N/C POW
COM
N/O
N/C L
COM
(+0.031, -0 in.)
N/O
N/C N
COM
N/O
OPEN COLL 3
N/C
- OPEN COLL 4
SGNL 2
TEMP 2
OUTPUT OPTION
ISO GND
SHLD
SGNL 1
COLL 3,4
TEMP 1
ISO GND
RELAY 3,4
OPEN
SHLD
56 mm
quick-clip
102 mm (2.2 in.)
(4.0 in.)
Specifications • Max loop impedance:

General 150 Ω @ 12 V, 450 Ω @ 18 V, 750 Ω @ 24 V
Compatible electrodes: Signet 2819 to 2823 • Update rate: ~100 mS
Standard or Certified • Accuracy: ±0.03 mA @ 25°C, 24 VDC
Conductivity/Resistivity Sensors Open-collector outputs (2 available, optically isolated):
Enclosure: • 50 mA sink or source, 30 VDC max. pull-up voltage
• Rating: NEMA 4X/IP65 front (NEMA 4X Rear cover available) • Programmable for:
• Case: PBT • High or Low setpoint with adjustable hysteresis
• Panel case gasket: Neoprene • Pulse operation (max. rate: 400 pulses/min)
• Window: Polyurethane-coated polycarbonate • USP standards
• Keypad: Sealed 4-key silicone rubber • Time delay: 0 to 6400 s.
• Weight: 8860-AC: 1.28 lb/0.58 kg 8860: 1.2 lb/0.55 kg Relay outputs (up to 4 SPDT relays available )
Display (Alphanumeric 2 x 16 LCD) : • Maximum resistive load: 5 A @ 250 VAC, 5 A @ 30 VDC
• Contrast: User selected, 5 levels • Isolation between open contacts: 500 V minimum
• Update rate: 1.5 seconds • Programmable for:
Sensor input range: • High or Low setpoint with adjustable hysteresis
• Conductivity: 0.01 µS/cm to 400 000 µS/cm • Pulse operation (max. rate: 400 pulses/min)
• Resistivity: 10 KΩ•cm to 100 MΩ•cm • USP standards
• TDS: 0.023 to 200 000 PPM nominal (adjustable µS/PPM) • Time delay: 0 to 6400 s
• Temperature:
-25 to 120°C (-13 to 248°F) PT 1000; 25ºC = 1096Ω Environmental
Accuracy: • Ambient operating temperature: -10 to 55°C (14 to 131°F)
• Conductivity/Resistivity: ± 2% of reading • Storage temperature: -15 to 80°C (5 to 176°F)
• Temperature: ± 0.5ºC (0 to 100ºC) • Relative humidity: 0 to 95%, non-condensing
• Maximum altitude: 2000 m (6562 ft)
Electrical • Insulation category: II
Power requirements: • Pollution degree: 2
3-8860-AC: 100 to 240 VAC ± 10% , 50-60 Hz, 20VA or
11 to 24 VDC ±10%, regulated, 0.5 A max Standards and Approvals
3-8860: 11 to 24 VDC ±10%, regulated, 0.5 A max • CE, UL listed
Three 4 to 20 mA Outputs: • Immunity: EN50082-2
• Passive, isolated, fully adjustable and reversible • Emissions: EN55011 Class B
4 to 20 mA outputs are independently source selectable • Manufactured under ISO 9001, ISO 14001
SSS
TROUBLE SHOOTING
Head Assembly
4. Feed/Concentrate Port Leak
1. Will not release from shell when pulled.
Refer the “Opening the Vessel” section
IMPORTANT
NOTE Please contact Pentair Water if any
If the head assembly will not release from Feed/Concentrate leaks are observed.
the shell after all recommendations have
been followed, call Pentair Water for
technical assistance. Sudden Drop in Product quality
If a system is started and stopped frequently and no

SEAL LEAKAGE
provision is made to raise the pressure slowly,
2. Head Seal Leak movement of the membrane column may damage
A. Carefully inspect the seal gland area in O-ring seals and reduce Product quality.
the shell and clean any contaminants
If the quality of the product suddenly drops, and
from the gland.
poor membrane performance is not suspected,
B. Clean the seal area on the head and re- remove the heads per instructions in the Users
lubricate. Guide (See “OPENING THE VESSEL”). Inspect
C. Install a new head seal that has been these O-ring seals carefully for breakage or other
properly lubricated. damage. If the seals have rolled out of the groove,
or are damaged, this may indicate excessive
3. Seal Plate Seal Leak movement during start-up and shutdown which may
A. Dismantle the Head by referring the be due to improper seating of the cartridge in the
“DISMANTLING & ASSEMBLING” vessel.
section. Open the Vessel and re-seat the membrane (refer
B. The seal is seated in the sealing plate. opening and closing of the vessel for details).
Run your fingers around the seal and
check for any seal damage. If the seal is
damaged replace the seal.
C. Check for any damage/scratches on the
sealing area. Replace the sealing plate if
found damaged.
Sensor Input Connections
Cooling Tower Deionization Regen. Chemicals
• The 8860 will accept two independent sensor input signals. UPW @ 25°C USP
Bottled
Water
Waste Waters Alkali Cleaners, Acids/Bases
The two sensors may be of different cell constant values.

• Do not route sensor cable in any conduit containing AC power Brackish Sea Water
Rinse 3-2823 (Salinity) (20.0 Cell)
wiring - electrical noise may interfere with the signal. Water
3-2822, 3-2842 (10.0 Cell)
• Cable shield MUST be maintained through cable splice.
3-2821, 3-2841 (1.0 Cell)
• Use three conductor shielded cable for cable extensions up
3-2820, 3-2840 ( 0.10 Cell)
to 30 m (100 ft) max. for measurements below 10 MΩ (above
0.10 µS). 3-2819, 3-2839 (0.01 Cell)
• Maximum cable length for resistivity measurements above 0.010mS 0.054mS 1mS 10mS 100mS 200mS 1,000mS 10,000mS 100,000mS 400,000mS
10 MΩ is 25 ft, and solution temperatures must be between 100 MΩ 18.3 MΩ 1MΩ 100KΩ 10KΩ 50,000mS 200,000mS
20°C and 100°C.

ISO GND
TEMP 1
SGNL 1
ISO GND
TEMP 2
SGNL 2
SHLD
SHLD
RED SILVER (SHLD)
WHITE BLACK
BLACK WHITE
SILVER (SHLD) RED
Relay and Open Collector Functions

The 8860 is equipped with 4 SPDT relays that can be configured • Pulse Operation
for High alarm, Low alarm, Proportional pulse or USP operation. The output emits a 100 mS pulse at a rate defined by the
Source, Pulse Range and Max PlsRate settings, and by the
• Low: Output triggers when process variable is less than process condition. The maximum pulse rate is 400 pulses per
setpoint. minute.
• High: Output triggers when process variable is higher than Example: As the process falls below 10 µS the output will
setpoint. start pulsing in relation to the process value, the max pulse
endpoint and the programmed pulses/min. Pulse rate
• Off: Disables output pulse. will increase as the process approaches the programmed
endpoint.
Process
The Pulse Rate determines what the

Hysteresis maximum rate will be. The 8860 maximum
capability is 400 pulses per minute.
Low Setpoint 100 pulses Re
la
y/
O
10 pen
0
Time Pu Col
lse lec
10 uS = 0 pulses/min. s/ tor
Pulse rate
m P
Relay energized in ls
7.5 uS = 50 pulses/min. > Ra
te
Relay relaxed 5 uS = 100 pulses/min. :
0 pulses
Process
µS ----->
5 Relay 1 Rng: uS 10
High Setpoint 10.00 --> 5.00 >
RANGE defines where the pulsing starts

Hysteresis and where it reaches the maximum rate.
Time
VIEW menu
• During normal operation, the ProcessPro displays the VIEW menu.
• When using the CALIBRATE or OPTIONS menus, the ProcessPro will return to the VIEW
menu if no activity occurs for 10 minutes. C1 23.45 µS
• To select the item you want displayed, press the UP or DOWN arrow keys. The items C2 8.72 µS
will scroll in a continuous loop. Changing the display selection does not interrupt system Signet
Conductivity/Resistivity
operations. Relay 1
Transmitter
Relay 2
• No keycode is necessary to change display selection.

• Output settings cannot be edited from the VIEW menu.
ENTER
View Menu
Display Description
C1 1000.00 µS/cm Monitor C1 Conductivity and C2 Conductivity simultaneously. This is the

C2 30.00 µS/cm permanent display when Channel 2 is ON.
C1 1000.00 µS/cm Monitor Channel 1 Conductivity and Channel 1 Temperature. This is the
25.0 º C permanent display when Channel 2 is OFF.
The VIEW displays below are temporary. The permanent display will return after 10 minutes
C2 30.00 µS/cm Monitor Channel 2 Conductivity and Channel 2 Temperature. This view is
25.0 ºC available only when Channel 2 is ON.
Reject C1 → C2 Monitor Percent Reject, Difference, or Ratio

97.00 (Channel 1 to Channel 2 or Channel 2 to Channel 1)
Loop 1 12.03 mA Monitor Loop 1 and Loop 2 current output simultaneously.

Loop 2 5.69 mA
Loop 3 13.7 mA Monitor Loop 3 and status of Relays 3 and 4 (Open Collector 3 and 4).
R3 ON R4 PLS
Last Cal Monitor date for scheduled maintenance or date of last calibration.
06-30-01
ProcessPro Editing Procedure:
Step 1. Press and hold ENTER key:
• 2 seconds to select the CALIBRATE menu.
• 5 seconds to select the OPTIONS menu.
Step 2. The Key Code is UP-UP-UP-DOWN keys in sequence.
• After entering the Key Code, the display will show the first item in the selected menu.
Step 3. Scroll menu with UP or DOWN arrow keys.
Step 4. Press RIGHT ARROW key to select menu item to be edited.
• The first display element will begin flashing.
Step 5. Press UP or DOWN keys to edit the flashing element.
• RIGHT ARROW key advances the flashing element.
Step 6. Press ENTER key to save the new setting and return to Step 3.
Notes on Step 1: Notes on Step 2:

• The View Menu is normally displayed. If no key is pressed for 5 minutes while display is showing "Enter
• The CALIBRATE and OPTIONS menus require a KEY CODE. Key Code", the display will return to the VIEW menu.
CALIBRATE: ----
Press & Enter Key Code
hold for ENTER
access: CALIBRATE: *---

Enter Key Code
CALIBRATE: **--
VIEW Enter Key Code
2s 5s CALIBRATE: ***-
CALIBRATE Enter Key Code
OPTIONS Chan 1 Cell: First item in CALI-

Standard > BRATE menu
Notes on Steps 3 and 4:

• Refer to pages 6 and 7 for complete listing of menu items and their use.
Chan 1 Cell:
• From the Step 3 display, pressing the UP and DOWN keys simultaneously will Standard >
return the display to the VIEW menu.
• If no key is pressed for 10 minutes, display will also return to the VIEW menu.
Step 3
Step 3: Finished Editing? Relay 1 Setpnt:

Press the UP and DOWN keys simultaneously after Step 4
20.00 us >
saving the last setting to return to normal operation.

Relay1 Setpnt:
• All output functions remain active during editing. 20.00 uS
• Only the flashing element can be edited.
Relay1 Setpnt:
• RIGHT ARROW key advances the flashing element in a continuous loop. 10.00 uS Step 5
• Edited value is effective immediately after pressing ENTER key.
• If no key is pressed for 10 minutes unit will restore the last saved value and return to step 3.
• Step 6 (pressing ENTER key) always returns you to Step 3. Relay1 Setpnt:
• Repeat steps 3-6 until all editing is completed. 10.00 uS
Relay Setpnt:
Step 5: Made an Error? 9
1 .00 uS
ENTER
Press the UP and DOWN keys simultaneously Step 6

while any element is flashing. This will recall the Relay1 Setpnt:
last saved value of the item being edited and Saving
return you to Step 3. Relay1 Setpnt:
19.00 uS >
Calibrate Menu
Display
Description
(Factory settings shown)
Chan 1 Cell: Select CUSTOM only if you are connecting a certified conductivity sensor. Select
Standard > STANDARD for all non-certified sensors.
Chan 1 Cell: For STANDARD sensors: Select the nominal cell constant: 0.01, 0.1, 1.0, 10.0 or 20.0.
1.0 >
Cell: Custom For CUSTOM sensors: Enter the precise cell constant from the certificate provided with your
1.0000 > sensor, or from the information label on the sensor.
Chan 1 Set: Adjust the temperature of the system based on an accurate external reference.
Temperature >
Chan 1 Set: This single-point wet calibration procedure requires a test solution of known value.
Conductivity > Enter all zeroes here to restore TEMPERATURE and CONDUCTIVITY to factory calibration.
Chan 1 Units: Select the units of measure: µS/cm, mS/cm, kΩ•cm, MΩ•cm, PPB, PPM
uS/cm >
Chan 1 TDS: If the Units selection is PPM or PPB, set the ratio of µS to Total Dissolved Solids. The factory
2.0000 uS/PPM > preset value is 2 µS per 1 PPM of TDS. (Always µS/PPM, even if units is PPB).
See page 10 for additional information.
Function: Select a functional relationship between C1 and C 2: • Ratio is (C1:C2) or (C2:C1)

Reject C1 → C2 > • Percent Reject is 100%(1-C2/C1) or 100%(1-C1/C2) • Difference is (C1-C2) or (C2-C1)
Loop 1 Source: Select the measured value or calculated FUNCTION you want Loop 1 to represent:
Chan 1 Cond > Chan 1 Cond, Chan 2 Cond, Chan 1 Temp, Chan 2 Temp, or Function
Loop 1 Range: uS Set the minimum (4 mA =) and maximum (20 mA =) range for Loop 1.
0.0000 → 100.000 > Make sure that the values are consistent with the units of the source.
Relay 1 Mode: Select operating mode for Relay 1: OFF, LOW, HIGH, USP or PULSE.
Low > For USP mode: • Relay 1 SOURCE must be Cond 1 or Cond 2
• Temp Comp (Options menu) must be set to None
Relay 1 Source: Select the INPUT SIGNAL (or FUNCTION) monitored by Relay 1:
Chan 1 Cond > • Cond 1 • Cond 2 • Temp 1 • Temp 2 • Function
Relay 1 Setpnt: Set Relay 1 activation point. The maximum value acceptable is 999999.
10.0000 uS > USP setpoints are high alarms, where the setpoint is a percentage below the USP limit.
Relay 1 Hys: Relay 1 will be deactivated at setpoint ± Hysteresis (depending on High or Low selection).
0.5000 uS > When the relay Mode is USP (defined as a HIGH alarm), Hysteresis is displayed in µS.
Relay 1 Delay: Set up to 6400 seconds delay time for relay response.
10.0 secs > Relay 1 will be activated only if the source value exceeds the setpoint for this time period.
If Relay 1 is PULSE mode, set the start and end point of the conductivity range and also set
Relay 1 Rng: uS the maximum pulse rate. (The maximum PULSE rate setting is 400 pulses per minute.)
10.0000 → 40.0000 >
The combined Relay 1 Range and Pulse rate settings shown here indicate:
Relay 1 PlsRate: "Start pulsing when the conductivity value is 10 µS and increase the pulse rate up to the
120 Pulses/Min > maximum of 120 pulses per minute when the conductivity value reaches 40 µS"
Last CAL: Use this "notepad" to record important dates, such as annual recertification or scheduled
06-30-01 > maintenance.
• All changes in this menu become effective when saved, except the "Set Cond" and "Set Temp" settings.
• All outputs affected by a change in the "Set Cond" and "Set Temp" settings are frozen until you exit the Calibrate menu.
Options Menu
Display
Description
Contrast: Adjust the LCD contrast for best viewing. A setting of 1 is lower contrast, 5 is higher. In
general, select lower contrast if the display is in warmer ambient surroundings.
3 >
Temp Display: Select ºC or ºF.
ºC >
Channel 2: Turn CH 2 OFF if not in use. This will remove all menu functions related to CH 2.
On >
Power: Select 50 Hz or 60 Hz electrical noise suppression, according to the AC power used in your
area. Select the proper setting for all applications, whether AC or DC powered.
60 Hz >
Chan 1 TC Mode: Set the method for temperature compensation to NONE, LINEAR or PURE WATER. You
must select NONE for USP systems. Select LINEAR for applications where the water is
Linear > less than 5 MΩ (or greater than 0.2 µS). Select PURE WATER for applications where the
water is greater than 5 MΩ (or less than 0.2 µS).
Chan 1 TC Slope: For LINEAR or PURE WATER temperature compensation, select a % per ºC slope.
Maximum slope setting is 9.99 % per ºC. If Temp Comp setting is NONE, this item will not
0.00 % > be displayed.
Averaging: OFF provides the most instantaneous response to process changes. Select LOW (4 sec)
or HIGH (8 sec) averaging if your process experiences frequent or extreme fluctuations.
Off >
Chan 1 Decimal: Set the decimal to the best resolution for your application. The display will automatically
scale up to this restriction. Select *****., ****.*, ***.** **.*** or *.****
*.**** >
Loop 1 Adjust: Adjust the minimum and maximum current output. The display value represents the precise
current output. Adjustment limits:
4.00 mA > • 3.80 mA < 4.00 mA > 5.00 mA
• 19.00 mA < 20.00 mA > 21.00 mA
Loop 1 Adjust: Use this setting to match the system output to any external device.
20.00 mA > These settings repeat for Loop 2 and Loop 3.
Relay 3 Active: Select active HIGH or active LOW operation for relay 3
Recommended: Use active LOW if OUTPUT OPTION switch is set for OPEN
High > COLLECTOR operation.
Active HIGH: Power is applied to relay coil when process value reaches SETPOINT.
Active LOW: Power is removed from relay coil when process value reaches SETPOINT.
Test Loop 1: Press UP and DOWN keys to manually change Loop 1output current.
Limits are 3.6 mA to 21.00 mA. Hold UP or DOWN keys to scroll the output value.
>
Test Relay 1: Press UP and DOWN keys to manually toggle the relay state.
>
Notes:
Channel settings will repeat when Channel 2 is enabled.
Loop settings will repeat for Loop 2 and Loop 3.
Check setting for related values when making changes (for example, if temp is set for ºC with a temp alarm at 25ºC, and you change
the temp to ºF, be sure to change the alarm setpoint to 77ºF.)
Relay settings will repeat for Relays 2, 3 and 4 (except "Relay Active" selection; applies to Relay 3 and 4 only.)
Calibration Procedure
The 8860 has been electronically calibrated at the factory.
• Procedure A verifies the accuracy and linearity of the 8860 by simulating temperature and conductivity values with precision (±0.1%)
fixed resistors.
• Procedure B is a wet calibration. This procedure uses the sensor input and NIST traceable test solutions.
A) Accuracy Verification with Precision Resistors (Electronic Calibration):

1. Simulate the Temperature
The temperature input to the 8860 is a PT-1000 thermistor, where 1000 Ohms (Ω) is equal to 0ºC and a change of 3.84 Ω equals a
1ºC change. (1000 Ω = 0ºC, 1003.84 Ω= 1.0ºC, 1007.68 Ω = 2.0ºC...................1096 Ω = 25ºC)
• Connect a resistor (1000 Ω to 1096 Ω ) between "Temp" and "Iso. Gnd" terminals.
• Set Temp; Adjust the temperature to exact value based on the measured resistance. (See Editing Procedure, Calibrate menu).
• To verify the 8860 temperature linearity, connect a second resistor value to the terminals.
• If the 8860 does not display the correct value, service is required. ( ± 0.5ºC)
2. Simulate the Conductivity

You may calculate the exact Resistance needed to simulate a specific conductivity value , or you may calculate the exact Conductivity
based on a resistor value:
Resistance = Cell constant e.g. 0.1 Cell = 5,000 Ω or 5 KΩ

conductivity (Siemens*) 0.000020 (Siemens*)
Conductivity = Sensor cell e.g. 0.1 Cell = 0.000001 Siemens*

Simulation resistance (Ω) 100,000 (Ω) or 1µS/cm
(*1 µS = 1 X 10-6 Siemens or 0.000001 Siemens)
• Connect the conductivity resistor between the "Sgnl 1 " and "Iso Gnd" (or Sgnl 2 and Iso Gnd) terminals.
• Set Cond: Adjust the conductivity value based on the resistor value. (See Editing Procedure and Calibrate menu).
• Verify the linearity of the 8860 by connecting a second Conductivity resistor of a different value.
• If the 8860 does not display the correct value (± 2% of reading), service is required.
B) Wet Calibration with NIST Traceable Solutions:

When using NIST traceable standards, review the temperature information provided with the test solution. Prevent contamination of the
test solution. The sensor must be at the temperature specified on the test solution label.
• Remove the sensor from the system. Rinse the sensor in a small amount of test solution.
• Place the sensor into the test solution.
• Place a reference thermometer into the same solution.
• Allow sufficient time for the temperature to stabilize.
• Set Temp: Adjust the temperature value based on the reference thermometer. (See Editing Procedure.)
• Set Cond: Adjust the conductivity value based on the test solution value. (See Editing Procedure.)
• Verify the linearity of the 8860 by placing the sensor into a second test solution of a different value.
• If the 8860 does not display the correct value (Temperature ± 0.5ºC, Conductivity ± 2% of reading), service is required.
Temperature Effects Calculating a Linear Temperature Coefficient
Conductivity measurement is highly dependent on temperature.
The basic rule is that higher temperatures result in greater 1. Set TC Mode to NONE (see OPTIONS menu, page 8).
conductance (less resistance). 2. Heat a sample solution close to the maximum process
Temperature effects are expressed as the percentage of temperature. Place sensor in the sample solution and
conductivity change (in µS) per °C. The conductivity value is allow several minutes for stabilization. Record the 8860
generally referenced to 25ºC. The 8860 has three temperature temperature and conductivity values in the spaces provided:
compensation options:
Displayed temperature: T1 = _______ °C
None
USP standards for pharmaceutical waters require that the Displayed conductivity: C1 = _______ µS
measurement be made without temperature compensation. USP
limits are discussed on page 7.
3. Cool the sample solution close to the minimum process
temperature. Place sensor in the sample solution allowing
Pure Water (Standard Compensation) several minutes for stabilization. Record displayed
This selection is used for measurements of very clean water,
temperature and conductivity values in the spaces provided:
less than 0.2 µS. Temperature effects are not linear in this
range, so the temperature coefficient is not easily determined.
Displayed temperature: T2 = _______ °C
This selection is recommended for all Resistivity applications
measuring from 5 MΩ to 18MΩ. This selection conforms to ASTM
Displayed conductivity: C2 = _______ µS
standard D1125 and D5391.
(A 10% change in conductivity between steps 2 and 3 is
Linear recommended.)
This selection allows you to calculate a custom temperature
compensation value for Conductivity measurements in the range 4. Substitute recorded readings (steps 2 and 3) into the following
of 0.2 µS and greater (Resistivity applications measuring less formula:
than 5 MΩ). The procedure is outlined in the section on the right.
TC Slope = 100 x (C1 - C2)
(C2 x (T1 - 25)) - (C1 x (T2 - 25))
Example: A sample solution has a conductivity of 205 µS @

48°C. After cooling the solution, the conductivity was measured
at 150 µS @ 23°C. (C1 = 205, T1 = 48, C2 = 150, T2 = 23)
The TC is calculated as follows:
TC Slope = 100 x (205 - 150) =5500 = 1.42%/°C

(150 x (48 - 25)) - (205 x (23 - 25)) 3860
TDS Factor
Some industries need to display a conductivity value as Total
Dissolved Solids (TDS), measured in units of parts per million
(PPM) or parts per billion (PPB).
• 1 PPM is equivalent to 1 mg per liter.
• 1 PPB is equivalent to 1 µg per liter.
• The 8860 calculates PPM or PPB by dividing the µS value
by a TDS Factor that you define. TDS factors can vary
widely, ranging from 1.50 to 2.50 µS per PPM. Methods
for establishing a TDS factor are beyond the scope of this
manual.
• The 8860 will accept TDS factor values from 0.01 to 99999.9
µS per PPM.
(factory preset = 2.00 µS per PPM)
NOTE: The 8860 TDS factor must be set in PPM.
TDS Factor = Conductivity (µS) ÷Total dissolved solids (PPM)
PPM = Solution conductivity (µS) ÷ TDS Factor
Example:
• Solution conductivity = 150 µS
• TDS = 80 PPM
• TDS Factor = 150 µS ÷ 80 PPM = 1.88 µS per
PPM
Troubleshooting
Display Condition Possible Causes Suggested Solutions
"- - - -" Display is over range. This may be a Check sensor for correct range.
normal condition if your process operates Check Decimal setting in OPTIONS menu.
at/near the limits of the sensor range. Check Calibrate menu settings for incompatible
SOURCE and RANGE values.
"Value Must be 100 or less" The menu item being set is a percentage Select a value from 0 to 100.
value and must be less than 100.
"Value must be more than 0" The menu item being set cannot be zero Select a value greater than zero.
or a negative value.
"Value must be 400 or less" The Pulse Rate for Relay and Open Select a pulse rate less than 400
Collector outputs cannot be greater than
400 pulses per minute.
"Reset to Factory Calibration" A value of "0" is being set into This will remove any user calibration from the
".. Set: Conductivity" menu item. "..Set Conductivity" and "..Set Temperature"
items in the Calibrate menu.
"Too Much Error The calibration offset entered is Check calibration procedure for accuracy.
CHECK SENSOR" beyond the allowable tolerances of the Check sensor for proper operation.
instrument. Check any cable extensions for poor splices or
termination.
Technical Note
If a Current Loop is locked at 3.6 mA, the problem is related to the temperature circuit:
This occurs only if the 8860 detects a resistance from the temperature sensor that is less than 250Ω or greater than 2800Ω.
• Check the sensor wiring for open/short or poor connections on white (TEMP IN) and black (ISO GND)wires.
• The PT1000 temperature device in the sensor is defective.
• The transmitter is defective.
Signet 2820 Series Conductivity Sensor Instruction Manual English
*3-2820.090*
3-2820.090-1 Rev. K 11/04 English
Warning! SAFETY INSTRUCTIONS FOR IN-LINE ELECTRODE INSTALLATION

1. Do not remove from pressurized lines.
2. Do not exceed maximum temperature/pressure specifications.
3. Wear safety goggles or face shield during installation/service.
4. Do not alter product construction.
5. Disconnect instrument power before wiring this sensor.
Failure to follow safety instructions may result in severe personal injury!
1. Wiring
Signet 5800CR Signet 9050CR
RLY3 RLY4 ANL2 SERIAL CH2 CH1
C NO C NO R+ R- Tx GND Rx S2 T2 S1 T1 SG
SILVER (SHLD)
BLACK
WHITE
1 2 3 4 5 6 7 8 9 10 11 12 13 14
RED RED
CH 2 WHITE
BLACK
SILVER (SHLD)
Iso. Gnd
Temp. IN
Signal IN
Shld
RED
WHITE
BLACK
CH 1 SILVER (SHLD)
• Use three conductor shielded cable for cable extensions up to 30 m (100 ft) max.
• Shield must be maintained through cable splice.
• Disable power to instrument before connecting this sensor.
2. Recommended Position 3. 2819/2820/2821 In-line Installation
In-line Submersible
Standard Mark hole Hole up 3/4 in. NPT

fitting kit position
Customer
supplied
pipe tee/
reducer
2821-1 Sealant
O-ring
Hand tighten only!
Optional Mark hole Hole up 1/2 in. NPT

OR fitting kit position
Customer
supplied
pipe tee/
Sealant reducer
Use caution to avoid air bubble O-ring
or sediment trapping inside the
electrode cavity.
Hand tighten only!
SSS GRUNDFOS INSTRUCTIONS
CR, CRI, CRN

Installation and operating instructions
7
5
3
1
Start-up
S alt
TM01 1409 4497 TM01 1407 4497 TM01 1405 4497 TM01 1403 4497
SSS
8
6
4
2
?
S eparation S ervices
TM01 9988 3600 TM01 1408 4497 TM01 1406 4497 TM01 1404 4497
SSS
Start-up
1 2
Close the isolating valve on the discharge side of the pump and open the Remove the priming plug from the pump head and slowly fill the pump with
isolating valve on the suction side. liquid. Replace the priming plug and tighten securely.
3 4
See the correct direction of rotation of the pump on the motor fan cover. Start the pump and check the direction of rotation.
5 6
Vent the pump by means of the vent valve in the pump head. At the same Continue to vent the pump. At the same time, open the discharge isolating
time, open the discharge isolating valve a little. valve a little more.
7 8
Close the vent valve when a steady stream of liquid runs out of it. For further information, see page 17.
Completely open the discharge isolating valve.
SSS
Declaration of Conformity
We Grundfos declare under our sole responsibility that the products
CR, CRI and CRN, to which this declaration relates, are in conformity with
the Council Directives on the approximation of the laws of the EC Member
States relating to:
– Machinery (98/37/EC).
Standard used: EN ISO 12100.
– Electromagnetic compatibility (89/336/EEC).
Standards used: EN 61 000-6-2 and EN 61 000-6-3.
– Electrical equipment designed for use within certain voltage limits
(73/23/EEC) [95].
Standards used: EN 60 335-1: 1994 and EN 60 335-2-51: 1997.
SSS
CR, CRI, CRN
Installation and operating instructions 14
SSS
CONTENTS 2. Type designation
Page
2.1 Pump key for CR, CRI, CRN 1s, 1, 3, 5, 10, 15 and
1. Handling 14 20
2. Type designation 14
2.1 Pump key for CR, CRI, CRN 1s, 1, 3, 5, 10, 15 and 20 14 Example CR 3- 10 X - X - X - X - XXXX
2.2 Pump key for CR, CRN 32, 45, 64 and 90 14
Pump range: CR, CRI, CRN
3. Applications 14
Nominal flow rate in m³/h
4. Technical data 15
Number of impellers
4.1 Ambient temperature 15
4.2 Liquid temperature 15 Code for pump version
4.3 Maximum permissible operating pressure and Code for pipework connection
liquid temperature for the shaft seal 15
Code for materials
4.4 Minimum inlet pressure 15
4.5 Maximum inlet pressure 15 Code for rubber pump parts
4.6 Minimum flow rate 15 Code for shaft seal
4.7 Electrical data 15
4.8 Frequency of starts and stops 15 2.2 Pump key for CR, CRN 32, 45, 64 and 90
4.9 Dimensions and weights 16
4.10 Sound level 16 Example CR 32- 2- 1 - X - X - X - X - XXXX
5. Installation 16 Pump range: CR, CRN
6. Electrical connection 16 Nominal flow rate in m³/h
6.1 Frequency converter operation 16
Number of stages
7. Start-up 17
Number of impellers with reduced
8. Maintenance 17 diameter
9. Frost protection 17 Code for pump version
10. Service 17 Code for pipework connection
10.1 Service kits 17
Code for materials
11. Fault finding chart 18
Code for rubber pump parts
12. Disposal 18
Code for shaft seal
Before beginning installation procedures, these in- 3. Applications

stallation and operating instructions should be stud- Grundfos multistage in-line centrifugal pumps, types CR, CRI and
ied carefully. The installation and operation should CRN, are designed for a wide range of applications.
also be in accordance with local regulations and ac-
Pumped liquids
cepted codes of good practice.
Thin, non-explosive liquids, not containing solid particles or fi-
bres. The liquid must not attack the pump materials chemically.
1. Handling
When pumping liquids with a density and/or viscosity higher than
The motors of the CR, CRI, CRN 1s, 1, 3, 5, 10, 15 that of water, motors with correspondingly higher outputs must be
and 20 pumps are supplied with lifting eyes which used, if required.
must not be used for lifting the entire pump. CR, CRI, CRN
When the entire pump is to be lifted, observe the following: For liquid transfer, circulation and pressure boosting of cold or
• CR, CRI, CRN 1s, 1, 3, 5, 10, 15 and 20 pumps fitted with hot clean liquids.
Grundfos MG motors should be lifted in the pump head by CRN
means of straps or the like. In systems where all parts in contact with the liquid must be made
• CR, CRN 32, 45, 64 and 90 fitted with Grundfos MG motors up of high-grade stainless steel, CRN pumps must be used.
to and including 11 kW should be lifted by means of the eye
nut fitted to the pump head.
• CR, CRN 32, 45, 64 and 90 fitted with Siemens motors of
15 kW and up should be lifted by means of the eye bolts fitted
to the motor flange.
• For other motor makes than those mentioned above, it is rec-
ommended to lift the pump in the pump head by means of
straps.
4. Technical data The maximum suction lift “H” in metres head can be calculated as
follows:
4.1 Ambient temperature H = pb x 10.2 – NPSH – Hf – Hv – Hs
0.37-0.75 kW motors (EFF 2, MG): Max. +40°C. pb = Barometric pressure in bar.
1.1-11 kW motors (EFF 1, MG): Max. +60°C. (Barometric pressure can be set to 1 bar.)
15-45 kW motors (EFF 1, Siemens): Max. +55°C. In closed systems, pb indicates the system pressure
in bar.
If the ambient temperature exceeds above maximum values or if
the motor is located 1000 metres above sea level, the motor out- NPSH = Net Positive Suction Head in metres head
put (P2) must be reduced due to the low density and conse- (to be read from the NPSH curve on page 147 at the
quently low cooling effect of the air. In such cases, it may be highest flow the pump will be delivering).
necessary to use a motor with a higher rated output. Hf = Friction loss in suction pipe in metres head at the
Fig. 1 highest flow the pump will be delivering.
Hv = Vapour pressure in metres head, see fig. E on page
P2 152. tm = Liquid temperature.
[%] EFF 1, Siemens
Hs = Safety margin = minimum 0.5 metres head.
100 EFF 1, MG If the calculated “H” is positive, the pump can operate at a suction
90
lift of maximum “H” metres head.
80 EFF 2, MG
If the calculated “H” is negative, an inlet pressure of minimum
70
“H” metres head is required. There must be a pressure equal to
60
TM03 1868 3305

the calculated “H” during operation.
50
20 25 30 35 40 45 50 55 60 65 70 75 80
Example:
t [°C] pb = 1 bar.
1000 2250 3500 4750 m Pump type: CR 15, 50 Hz.
Flow rate: 15 m³/h.
Example: NPSH (from page 147): 1.1 metres head.
Figure 1 shows that P2 must be reduced to 88% when the pump Hf = 3.0 metres head.
is installed 3500 metres above sea level. At an ambient tempera- Liquid temperature: +60°C.
ture of 70°C, P2 must be reduced to 78% of the rated output. Hv (from fig. E, page 152): 2.1 metres head.
H = pb x 10.2 – NPSH – Hf – Hv – Hs [metres head].
4.2 Liquid temperature H = 1 x 10.2 – 1.1 – 3.0 – 2.1 – 0.5 = 2.7 metres head.
See fig. A, page 149, which indicates the relationship between This means that the pump can operate at a suction lift of maxi-
liquid temperature and maximum permissible operating pressure. mum 2.7 metres head.
Note: The maximum permissible operating pressure and liquid Pressure calculated in bar: 2.7 x 0.0981 = 0.265 bar.
temperature ranges apply to the pump only. Pressure calculated in kPa: 2.7 x 9.81 = 26.5 kPa.
4.3 Maximum permissible operating pressure and 4.5 Maximum inlet pressure
liquid temperature for the shaft seal
Figure B, page 150, shows the maximum permissible inlet pres-
Fig. 2 sure. However, the actual inlet pressure + pressure when the
CR, CRI, CRN 1s to 20 and CR, CRN 32 to 90 pump is running against a closed valve must always be lower
than the “maximum permissible operating pressure”.
p [bar] The pumps are pressure-tested at a pressure of 1.5 times the
35 value stated in fig. B, page 150.
30
25
4.6 Minimum flow rate
H H Due to the risk of overheating, the pump should not be used at
20 Q Q
HQQE flows below the minimum flow rate.
15 Q Q
E HQQV E The curve below shows the minimum flow rate as a percentage of
10
the nominal flow rate in relation to the liquid temperature.
TM03 2107 3705
5
– – – – = air-cooled top.
0
Fig. 4
-60 -40 -20 0 20 40 60 80 100 120 140
t [°C] Qmin
[%]
30
4.4 Minimum inlet pressure 20

TM01 2816 2302
Fig. 3 10
40 60 80 100 120 140 160 180 t [°C]
Note: The pump must never operate against a closed discharge

Hf
valve.
4.7 Electrical data

See motor nameplate.
H NPSH
Pb
TM02 0118 3800
4.8 Frequency of starts and stops

Motors up to and including 4 kW: Maximum 200 times per hour.
Hv Motors of 5.5 kW and up: Maximum 100 times per hour.
4.9 Dimensions and weights 6. Electrical connection
Dimensions: See fig. C, page 151. The electrical connection should be carried out by an authorized
Weights: See label on the packing. electrician in accordance with local regulations.
Before removing the terminal box cover and before
4.10 Sound level any removal/dismantling of the pump, make sure that
See fig. D, page 152. the electricity supply has been switched off.
The pump must be connected to an external mains
5. Installation switch with a minimum contact gap of 3 mm in all
poles.
The pump must be secured to a solid foundation by bolts through
the holes in the flange or base plate. The operating voltage and frequency are marked on the motor
When installing the pump, follow the procedure below in order to nameplate. Make sure that the motor is suitable for the electricity
avoid damaging the pump. supply on which it will be used.
Single-phase Grundfos motors incorporate a thermal switch and
Step Action require no additional motor protection.
1 Three-phase motors must be connected to a motor starter.
The terminal box can be turned to four positions, in 90° steps:
TM02 0013 3800
Arrows on the pump base 1. If necessary, remove the coupling guards. Do not remove the
show the direction of flow of coupling.
liquid through the pump. 2. Remove the bolts securing the motor to the pump.
3. Turn the motor to the required position.
4. Replace and tighten the bolts.
2 Page 151 shows:
5. Replace the coupling guards.
• port-to-port lengths,
TM00 2256 3393
4xø The electrical connection should be carried out as shown in the

• dimensions of the base, diagram inside the terminal box cover.
• pipework connections and
L1 B1
L2 B2 • diameter and position of 6.1 Frequency converter operation
foundation bolts. Motors supplied by Grundfos:
3 The pump can be installed All three-phase motors supplied by Grundfos can be connected to
vertically or horizontally. En- a frequency converter.
TM01 1241 4097
sure that an adequate supply Dependent on the frequency converter type, this may cause in-
of cool air reaches the motor creased acoustic noise from the motor. Furthermore, it may
cooling fan. However, the mo- cause the motor to be exposed to detrimental voltage peaks.
tor must never fall below the
Note: Grundfos motors types MG 71 and MG 80 as well as
horizontal plane.
MG 90 (1.5 kW, 2-pole), all for supply voltages up to and includ-
4 To minimize possible noise ing 440 V (see motor nameplate), must be protected against volt-
from the pump, it is advisable age peaks higher than 650 V (peak value) between the supply
to fit expansion joints either terminals.
side of the pump and anti-vi-
It is recommended to protect all other motors against voltage
bration mountings between
peaks higher than 850 V.
foundation and pump.
Isolating valves should be fit- The above disturbances, i.e. both increased acoustic noise and
ted either side of the pump to detrimental voltage peaks, can be eliminated by fitting an LC filter
avoid draining the system if between the frequency converter and the motor.
the pump needs to be For further information, please contact the frequency converter or
TM02 0116 3800
cleaned, repaired or replaced. motor supplier.

The pump must always be
Other motor makes than those supplied by Grundfos:
protected against backflow by
means of a non-return valve Please contact Grundfos or the motor manufacturer.
(foot valve).
5
Install the pipes so that air

TM02 0114 3800
locks are avoided, especially

on the suction side of the
pump.
6 In the case of installations in

which:
• the discharge pipe slopes
downwards away from the
pump,
• there is a risk of siphon
effect,
TM02 0115 3800
• protection against backflow

of unclean liquids is neces-
sary,
a vacuum valve must be fitted
close to the pump.
SSS
7. Start-up 9. Frost protection
Note: Do not start the pump until it has been filled with liquid and Pumps which are not being used during periods of frost should be
vented. If the pump runs dry, the pump bearings and the shaft drained to avoid damage.
seal may be damaged. Drain the pump by loosening the vent screw in the pump head
Pay attention to the direction of the vent hole and and by removing the drain plug from the base.
take care to ensure that the escaping water does not Care must be taken to ensure that the escaping wa-
cause injury to persons or damage to the motor or ter does not cause injury to persons or damage to the
other components. motor or other components.
In hot-water installations, special attention should be In hot-water installations, special attention should be
paid to the risk of injury caused by scalding hot water. paid to the risk of injury caused by scalding hot water.
Follow the instructions on page 4. Do not tighten the vent screw and replace the drain plug until the
CR, CRI, CRN 1s to 5: pump is to be used again.
For these pumps, it is advisable to open the bypass valve during CR, CRI, CRN 1s to 5:
start-up. The bypass valve connects the suction and discharge Before replacing the drain plug in the base, screw the bypass
sides of the pump, thus making the filling procedure easier. When valve out against the stop, see fig. 5.
the operation is stable, the bypass valve can be closed.
Fit the drain plug by tightening the large union nut followed by the
When pumping liquids containing air, it is advisable to leave the bypass valve.
bypass valve open if the operating pressure is lower than 6 bar.
If the operating pressure constantly exceeds 6 bar, the bypass 10. Service
valve must be closed. Otherwise the material at the opening will
Note: If a pump has been used for a liquid which is injurious to
be worn because of the high liquid velocity.
health or toxic, the pump will be classified as contaminated.
Fig. 5
If Grundfos is requested to service the pump, Grundfos must be
contacted with details about the pumped liquid, etc. before the
pump is returned for service. Otherwise Grundfos can refuse to
accept the pump for service.
Drain plug
Possible costs of returning the pump are paid by the customer.
Bypass valve
However, any application for service (no matter to whom it may
be made) must include details about the pumped liquid if the
pump has been used for liquids which are injurious to health or
toxic.
10.1 Service kits

Service kits for CR, CRI and CRN, see www.grundfos.com
(WebCAPS), WinCAPS or Service Kit Catalogue.
TM01 1243 4097
8. Maintenance
Before starting work on the pump, make sure that all
power supplies to the pump have been switched off
and that they cannot be accidentally switched on.
Pump bearings and shaft seal are maintenance-free.

Motor bearings:
Motors which are not fitted with grease nipples are maintenance-
free.
Motors fitted with grease nipples should be lubricated with a high-
temperature lithium-based grease, see the instructions on the fan
cover.
In the case of seasonal operation (motor is idle for more than
6 months of the year), it is recommended to grease the motor
when the pump is taken out of operation.
SSS
8
11. Fault finding chart S alt S eparation S ervices
Before removing the terminal box cover and before any removal/dismantling of the pump, make sure that the electricity sup-
ply has been switched off and that it cannot be accidentally switched on.
Fault Cause Remedy

1. Motor does not run a) Supply failure. Connect the electricity supply.
when started. b) Fuses are blown. Replace fuses.
c) Motor starter overload has tripped out. Reactivate the motor protection.
d) Thermal protection has tripped out. Reactivate the thermal protection.
e) Main contacts in motor starter are not making Replace contacts or magnetic coil.
contact or the coil is faulty.
f) Control circuit is defective. Repair the control circuit.
g) Motor is defective. Replace the motor.
2. Motor starter overload a) One fuse/automatic circuit breaker is blown. Cut in the fuse.
trips out immediately b) Contacts in motor starter overload are faulty. Replace motor starter contacts.
when supply is
c) Cable connection is loose or faulty. Fasten or replace the cable connection.
switched on.
d) Motor winding is defective. Replace the motor.
e) Pump mechanically blocked. Remove the mechanical blocking of the pump.
f) Overload setting is too low. Set the motor starter correctly.
3. Motor starter overload a) Overload setting is too low. Set the motor starter correctly.
trips out occasionally. b) Low voltage at peak times. Check the electricity supply.
4. Motor starter has not a) Check 1 a), b), d), e) and f).
tripped out but the
pump does not run.
5. Pump capacity not a) Pump inlet pressure is too low (cavitation). Check the suction conditions.
constant. b) Suction pipe/pump partly blocked by impurities. Clean the pump or suction pipe.
c) Pump draws in air. Check the suction conditions.
6. Pump runs but gives a) Suction pipe/pump blocked by impurities. Clean the pump or suction pipe.
no water. b) Foot or non-return valve blocked in closed po- Repair the foot or non-return valve.
sition.
c) Leakage in suction pipe. Repair the suction pipe.
d) Air in suction pipe or pump. Check the suction conditions.
e) Motor rotates in the wrong direction. Change the direction of rotation of the motor.
7. Pump runs back- a) Leakage in suction pipe. Repair the suction pipe.
wards when switched b) Foot or non-return valve is defective. Repair the foot or non-return valve.
off.
8. Leakage in shaft seal. a) Shaft seal is defective. Replace the shaft seal.
9. Noise. a) Cavitation occurs in the pump. Check the suction conditions.
b) Pump does not rotate freely (frictional resist- Adjust the pump shaft.
ance) because of incorrect pump shaft position. Follow the procedure in fig. F, G or H at the end of
these instructions.
c) Frequency converter operation. See section 6.1 Frequency converter operation.
12. Disposal
Disposal of this product or parts of it must be carried out accord-
ing to the following guidelines:
1. Use the local public or private waste collection service.
2. In case such waste collection service does not exist or cannot
handle the materials used in the product, please deliver the
product or any hazardous materials from it to your nearest
Grundfos company or service workshop.
Subject to alterations.
SSS
CR, CRN 32, 45, 64 and 90 S alt S eparation S ervices
Fig. H
1.7 mm
1 2
TM01 2144 3600

B
M10x25 62 Nm (6.2 kpm)
TM01 9878 3300
C
TM01 2146 3600
SSS
Pos. Description
no.
1 Adapter flange Zwischenflansch Bride d’adaptation Flangie adattatrici Brida acoplamiento Flange do adaptador
1a Motor stool Laterne Lanterne moteur Lanterna del motore Acoplamiento Adaptador do motor
2 Pump head Kopfstück Tête de pompe Testa pompa Cabezal bomba Cabeça da bomba
3 Chamber, top Oberste Kammer Chambre supérieure Camera superiore Cámara superior Câmara superior
3a Chamber without neck Kammer ohne Spaltring Chambre sans bague Camera senza collarino Cámara sin anillo de junta Câmara sem aro
ring d’étanchéité
4 Chamber complete Kammer komplett Chambre complète Camera completa Cámara completa Câmara completa
4a Chamber with bearing Kammer mit Lagerring Chambre avec bague de Camera con cuscinetto Cámara con anillo Câmara com casquilho
ring palier cojinete
5a Chamber complete Kammer komplett Chambre complète Camera completa Cámara completa Câmara completa
6 Base Fußstück Pied de pompe Base Base Base
6a Stop pin Sperrzapfen Goupille d’arrêt Molla di arresto Pasador tope Pino
6d Guide plate for base Führungsplatte für Plaque pour pied de Guida per basamento Placa guía para base Prato-guia da base
Fußstück pompe
6g Bearing ring Lagerring Joint de palier Cuscinetto Anillo cojinete Casquilho
7 Coupling guard Schutzschirm Protège-accouplement Giunti di protezione Protector acoplamiento Protecção do
acoplamento
7a Screw Schraube Vis Vite Tornillo Parafuso
8 Coupling complete Kupplung komplett Accouplement complet Giunto completo Acoplamiento completo Acoplamento completo
9 Screw Schraube Vis Vite Tornillo Parafuso
10 Shaft pin Zylinderstift Goupille cylindrique Molla albero Pasador eje Pino do veio
18 Air vent screw Entlüftungsschraube Vis de purge Vite della ventola Tornillo purga aire Parafuso de purga
19 Pipe plug Stopfen Bouchon Tappo Tapón tubería Bujão da tubagem
21 Plug Stopfen Bouchon Tappo Tapón Bujão da tubagem
23 Plug Stopfen Bouchon Tappo Tapón Bujão da tubagem
25 Drain plug Entleerungsstopfen Bouchon de vidange Tappo spurgo Tapón purga Bujão de drenagem
26 Staybolt Stehbolzen Goujon Tiranti Espárrago sujeción Perno
26a Strap Spannband Tirant d’assemblage Tirante Tirante Tirante
26b Screw Schraube Vis Vite Tornillo Parafuso
26c Washer Unterlegscheibe Rondelle Rondella Arandela Anilha
32a Washer Unterlegscheibe Rondelle Rondella Arandela Anilha
36 Nut Mutter Ecrou Dado Tuerca Fêmea
36a Nut Mutter Ecrou Dado Tuerca Fêmea
37 O-ring/gasket O-Ring/Dichtung Joint/bague O ring/guranizione Junta tórica/junta O-ring/junta
38 O-ring O-Ring Joint O ring Junta tórica O-ring
38a O-ring O-Ring Joint O ring Junta tórica O-ring
44 Inlet part complete Einlaufteil komplett Partie aspiration complète Parte interna completa Parte aspiración completa Aspiração completa
45 Neck ring Spaltring Bague d’étanchéité Collarino Anillo tope Aro
45a Neck ring complete Spaltring komplett Bague d’étanchéité Colalrino completo Anillo tope completo Aro completo
complète
47 Bearing ring Lagerring Bague de palier Cuscinetto Anillo cojinete Casquilho
47a Bearing ring, rotating Lagerring, rotierend Bague de palier tournante Cuscinetto rotante Anillo cojinete giratorio Casquilho rotativo
47a Bearing with driver Lager mit Mitnehmer Bague de palier avec Cuscinetto con guida Cojinete con engranaje Casquilho com guia
driver
47b Bearing ring Lagerring Bague de palier Cuscinetto Anillo cojinete Casquilho
47c Bush Buchse Douille Boccola Manguito Manga
47d Retaining ring Haltering Bague de blocage Anello di arresto Anillo cierre Retentor
47e Retaining ring Haltering Bague de blocage Anello di arresto Anillo cierre Retentor
48 Split cone nut Mutter für Klemmbuchse Ecrou de cône de serrage Dado bussola conica Tuerca casquillo cónico Fêmea cónica
49 Impeller Laufrad Roue Girante Impulsor Impulsor
49a Impeller Laufrad Roue Girante Impulsor Impulsor
49b Split cone Klemmbuchse Cône de serrage Bussola conica Casquillo cónico Casquilho cónico
49c Wear ring Verschleißring Bague d’usure Anello di usura Anillo desgaste Aro de desgaste
51 Pump shaft Pumpenwelle Arbre de pompe Albero pompa Eje bomba Veio
55 Outer sleeve Mantel Chemise Camicia esterna Camisa exterior Camisa exterior
56 Base plate Grundplatte Plaque de base Basamento Placa base Base
58 Seal carrier Halter für Toc d’entraînement Porta tenuta Soporte cierre Suporte do empanque
Wellenabdichtung
60 Spring Feder Ressort Molla Muelle Mola
61 Seal driver Mitnehmer Toc d’entrainement Guida guarnizione Guía de cierre Batente do espaçador
62 Stop ring Stopring Bague d’arrêt Anello di arresto anillo de tope Mola de encosto
64 Spacing pipe Distanzhülse Douille d’entretoise Tubo distanziale Casquillo espaciador Espaçador
64a Spacing pipe Distanzhülse Douille d’entretoise Tubo distanziale Casquillo espaciador Espaçador
64c Clamp, splined Spannstück, Vielnut Pièce de serrage Giunto Casquillo ranurado Casquilho escatelado
64d Spacing pipe Distanzhülse Douille entretoise Tubo distanziale Casquillo espaciador Espaçador
65 Neck ring retainer Halter für Spaltring Support pour bague Fermo per collarino Retén anillo junta Retentor do aro
d’étanchéité
66 Washer Unterlegscheibe Rondelle Rondella Arandela Anilha
66a Washer Unterlegscheibe Rondelle Rondella Arandela Anilha
66b Lock washer Sicherungsblech Rondelle de blocage Blocco per rondella Arandela cierre Anilha retentora
67 Nut Mutter Ecrou Dado Tuerca Fêmea
69 Spacing pipe Distanzhülse Douille entretoise Tubo distanziale Casquillo espaciador Espaçador
76 Nameplate set Schildersatz Plaque d’identification Targhetta Juego placa identificación Chapa de identificação
105 Shaft seal Wellenabdichtung Garniture mécanique Tenuta meccanica Cierre Empanque mecânico
201 Flange Flansch Bride Flangia Brida Flange
203 Retaining ring Haltering Bague de blocage Blocca flangia Anillo cierre Anel retentor
SSS
CR, CRN 32, 45, 64 and 90 S alt S eparation S ervices
48
49b
49
28a 49c
51
65
26b 45 45a
26c
9
7 8
4
3
47c
47d
7a 47c
1a 47d
26a
48
28
49b
36a 7a
48 49
7 49b 49c
65
7a 49a
58a 49c
105 45 45a
58
36 65 44
66a
76 45 45a
100 2
18 23
100 4a
37
60
47 47b 51
26 47e 66
66b
47a 67
37
55
31
32
6g
21
6
38a
31 38
32
6g
21
38a 6
21 38
38a 203 201 25
TM01 9996 3600
25
38
25
203 201 56
Service parts CRN 32-2, Product No. 96122562
Efficiency 1 motor valid from 1.11.2005 (0544)
Pos Description Annotation Classification Data Partno Qty. Unit

+ Kit, coupling 96416591 1 PC
+ Kit, coupling guard 96505134 1 PC
+ Kit, lower bearing 96416580 1 PC
+ Kit, plugs 96505136 1 PC
+ Kit, seals 96416597 1 PC
+ Kit, shaft seal HQBE 96525457 1 PC
+ Kit, shaft seal HQQE 96525458 1 PC
+ Kit, wear parts 96416728 1 PC
+ Motor 85D17422 1 PC
1.a Motor stool 96547431 1 PC
2 Pump head 00290060 1 PC
+ 2.a Pump head complete 00290108 1 PC
+ 3 Chamber, top 96547324 1 PC
+ 4 Chamber complete 00290407 1 PC
6 Base 00290004 1 PC
+ 6.b Base complete Rubber type: EPDM 00290104 1 PC
26 Staybolt Length 01: 352 00290232 1 PC
Thread: M16
26.a Strap Length 01: 149 00290337 1 PC
Thread: M8
+ 44 Inlet part complete 00290409 1 PC
48 Split cone nut 00370098 1 PC
+ 49 Impeller 00290075 1 PC
+ 49 Impeller complete 96587706 1 PC
+ 51 Pump shaft complete Diameter: 22 96587857 1 PC
Length 01: 390
55 Outer sleeve Outer diameter: 197 00290217 1 PC
Length 01: 165,5
56 Base plate 96587691 1 PC
58 Seal carrier 00980927 1 PC
66.a Washer Designation: DIN 125 A2 00ID3104 1 PC
Internal diameter: 17
Outer diameter: 30
Thickness: 3
+ 80 Chamber stack 96416293 1 PC
201 Flange Diameter: DN 65 00290024 1 PC
Pressure: PN 40
203 Retaining ring 00290030 1 PC
Sectional drawing (tm018903 0900)
28b
1a 28a
7a 100
7
18
58a
58 2a
9
8 28 2
10a
60
36
66a
26c 26
37 65
26a 45 45a
26b
4a
47c
3 47d 47
47d
55 47a
48 65
49d/49e 49b
45 45a
49a/49
49c
48 4
49b
49e 47c
49 47d
49c
65
37 45 45a
31 44
32
6b 6g
6 47b
25 66 51
38 66b
203 67
201
TM018903
SSS

+ Kit, plugs 96505136 1 PC
+ Kit, seals 96416597 1 PC
+ Motor 85D17422 1 PC
6 Base 00290004 1 PC
Thread: M16
26.a Strap Length 01: 149 00290337 1 PC
Thread: M8
+ 49 Impeller 00290075 1 PC
Length 01: 390
Length 01: 165,5
Outer diameter: 30
Thickness: 3
Pressure: PN 40
SSS
Exploded view (tm018897 0900)
28b
28b
28
1a
28a
76 105
36
66a
2a
55
80
26
6b
201
203
TM018897

+ Kit, plugs 96505136 1 PC
+ Kit, seals 96416597 1 PC
+ Motor 85D17422 1 PC
6 Base 00290004 1 PC
Thread: M16
26.a Strap Length 01: 149 00290337 1 PC
Thread: M8
+ 49 Impeller 00290075 1 PC
Length 01: 390
Length 01: 165,5
Outer diameter: 30
Thickness: 3
Pressure: PN 40
Exploded view, detailed (tm018900 4900)
48
49b
49d/49e
49a/49
49c
51
65
26b
26c 45 45a
9
8
10a 3
7a 47c 4
28b 47d
28b
7 47c
26a 47d
28
1a 48
7a 49b
49e
48
28a 7
49b 49
7a 49d/49e 49c
109 58a
49a/49
58 65
105 49c
76
110 45 45a
36 65
66a
44
45 45a
2 2a
23
100
60 4a
100
18
26 37 47
47d 51
47b
47a 66
66b
67
55
37
25
38
31
32
6g
6
38 6b
25
56
203 201
SSS
SSS
SSS
SSS
SSS
SSS
SSS
Signet 8550-3 Flow Transmitter English
*3-8550.090-3*
3-8550.090-3 Rev. K 3/06 English
WARNING! Contents Flow1: 6.25 GPM

Flow2: 9.75 GPM
• Remove power to unit before wiring input and out- 1. Specifications Signet Flow
put connections. 2. Installation Transmitter
• Follow instructions carefully to avoid personal injury. 3. Electrical Connections ENTER
4. Menu Functions
1. Specifications
Dimensions
Optional
96 mm Rear 92 mm 82 mm
(3.8 in.) Cover (3.6 in.) (3.23 in.)
96 mm 56 mm 106 mm 102 mm
(3.8 in.) 41 mm (2.2 in.) (4.18 in.) (4.0 in.)
(1.6 in.)
97 mm
(3.8 in.)
FRONT VIEW
SIDE VIEW SIDE VIEW SIDE VIEW
Field Mount &
Panel Mount Panel Mount Field Mount w/ Field Mount w/
8050 Universal base 8051 Integral kit
General
Compatibility: Signet Flow Sensors (w/freq out) Current output:
Accuracy: ±0.5 Hz • 4 to 20 mA, isolated, fully adjustable and reversible
Enclosure: • Max loop impedance: 50 Ω max. @ 12 V
• Rating: NEMA 4X/IP65 front 325 Ω max. @ 18 V
• Case: PBT 600 Ω max. @ 24 V
Panel case gasket: Neoprene • Update rate: 100 ms
• Window: Polyurethane coated polycarbonate • Accuracy: ±0.03 mA
• Keypad: Sealed 4-key silicone rubber
• Weight: Approx. 325g (12 oz.) Open-collector outputs, optically isolated:
• 50 mA max. sink, 30 VDC maximum pull-up voltage.
Display: • Programmable for:
• Alphanumeric 2 x 16 LCD • High or Low setpoint with adjustable hysteresis
• Update rate: 1 second • Pulse proportional to rate or volume (max 300 pulses/min).
• Contrast: User selected, 5 levels
• Accuracy: ±0.5% of reading @25ºC Environmental
• Thermal sensitivity shift: ±0.005% of reading per ºC • Operating temperature: -10 to 70°C (14 to 158°F)
• Storage temperature: -15 to 80°C (5 to 176°F)
Electrical • Relative humidity: 0 to 95%, non-condensing
• Power: 12 to 24 VDC ±10%, regulated, 122 mA max. • Maximum altitude: 2000 m (6562 ft)
Sensor Inputs: • Insulation category: II
• Range: 0.5 to 1500 Hz • Pollution degree: 2
• Sensor power: 2-wire: 1.5 mA @ 5 VDC ± 1%
3 or 4 wire: 20 mA @ 5 VDC ± 1% Standards and Approvals:
• Optically isolated from current loop • CE, UL listed
• Short circuit protected • Immunity & Emissions: EN61326
• Manufactured under ISO 9001 and ISO 14001
2. Installation
ProcessPro transmitters are available in two styles: panel mount and field mount. The panel mount is supplied with the necessary
hardware to install the transmitter. This manual includes complete panel mounting instructions.
Field mounting requires one of two separate mounting kits. The 3-8051 integral kit joins the sensor and instrument together into a
single package. The 3-8050 Universal kit enables the transmitter to be installed virtually anywhere.
Detailed instructions for integral mounting or other field installation options are included with the 3-8051 Integral kit or the 3-8050
Universal kit.
2.1 Panel Installation
panel
gasket
mounting
1. The panel mount transmitter is designed for installation using a 1/4 DIN Punch. For terminals bracket
manual panel cutout, an adhesive template is provided as an installation guide.
Recommended clearance on all sides between instruments is 1 inch.
2. Place gasket on instrument, and install in panel.
3. Slide mounting bracket over back of instrument until quick-clips snap into latches on latch 7
sr Gnd
SenIELD)
(SH
sr IN
SenD)
- 6 (RE
Pwr Output sr V+
System 4 SenACK)
side of instrument.
p- (BL
2 Loo
Pwr
5
System
p+ +
1 Loo
Output
3
4. To remove, secure instrument temporarily with tape from front or grip from rear of
instrument. DO NOT RELEASE.
Press quick-clips outward and remove.
Panel Mount
Installation Detail
quick-clips
3. Electrical Connections
Caution: Failure to fully open terminal jaws before removing wire may permanently damage instrument.
Wiring Procedure 2
1. Remove 0.5 - 0.625 in. (13-16 mm) of insulation from wire end.
2. Press the orange terminal lever downward with a small screwdriver to open terminal jaws. 1
3. Insert exposed (non-insulated) wire end in terminal hole until it bottoms out.
4. Release orange terminal lever to secure wire in place. Gently pull on each wire to ensure a good connection.
Wiring Removal Procedure

1. Press the orange terminal lever downward with a small screwdriver to open terminal jaws.
2. When fully open, remove wire from terminal.
Terminals 3-6: Loop Power

12-24 VDC ±10% system power and current loop outputs. Terminals 11-16: Flow sensor inputs
Max. loop impedance:
50 Ω max. @ 12 V
325 Ω max. @ 18 V
600 Ω max. @ 24 V
Loop 2- Snsr 2 Gnd

6 10 Output 2- 16 (SHIELD)
Loop 2+ Snsr 2 IN
5 15 (RED)
System Pwr Snsr 2 V+
4 Loop - 9 Output 2+ 14 (BLACK)
System Pwr Snsr 1 Gnd
3 Loop + 8 Output 1- 13 (SHIELD)
AUX Snsr 1 IN
2 Power - 12 (RED)
AUX Snsr 1 V+
1 Power + 7 Output 1+ 11 (BLACK)
Terminals 1 and 2: AUXILIARY power Internal open-collector

Used only if the flow sensor requires more output circuit Outputs
than 1.5 mA current. For Signet sensors this S 15Ω 1 2
_
is limited to the following products:
• 2000 • 2507 • 2551
• Open-collector Input signals +
D
Isolation
Terminals 7-10: Open-collector Outputs

Two transistor outputs, programmable (see CALIBRATE menu) as:
• High or Low setpoint with adjustable hysteresis
• Pulse based on Volume.
• Frequency based on flow rate
• May be disabled (Off) if not used.
3.1 System Power/Loop Connections
Stand-alone application, no current loop used
Trans mitter
Terminals
Loop 2 – 6 NC
Loop 2 + 5 NC
System Power Loop 1 – 4 – P ower
S upply
System Power Loop 1 + 3 + 12–24 V DC
AUX Power – 2
AUX Power + 1
Connection to a PLC/Recorder, separate supply Connection to a PLC with built-in power supply
P L C or R ecorder Trans mitter

Trans mitter Terminals P L C Terminals
+ Channel 2
Terminals
– 4-20 mA
Loop 2 – 6 + Channel 2
Loop 2 – 6 – 4-20 mA
Loop 2 + 5
Loop 2 + 5 – Channel 1
System Power Loop 1 – 4 + Channel 1
4-20 mA
System Power Loop 1 – 4 + System Power Loop 1 + 3 – 4-20 mA
System Power Loop 1 + 3
AUX Power – 2 – Power
AUX Power – – P ower
2 Supply
S upply AUX Power + 1 + 12–24 VDC
AUX Power + 1 + 12–24 V DC
Internal
PLC Connection
Example: Two transmitters connected to PLC/Recorder with separate power supply

P L C or R ecorder
+ Channel 1
– 4-20 mA in
+ Channel 2
– 4-20 mA in
– Channel 3
+ 4-20 mA in
– Channel 4
Trans mitter 1 Trans mitter 2
+ 4-20 mA in
Terminals Terminals
Loop 2 – 6 6 Loop 2 –
Loop 2 + 5 5 Loop 2 +
System Power Loop 1 – 4 4 System Power Loop 1 –
System Power Loop 1 + 3 3 System Power Loop 1 +
AUX Power – 2 2 AUX Power –
AUX Power + 1 1 AUX Power +
– P ower
S upply
+ 12–24 V DC
Auxiliary Power Note:

Auxiliary power is necessary for flow sensors that require more than 1.5 mA of current.
This includes the following Signet flow sensors: 2000, 2507, 2551 and all Open Collector signal inputs
3.2 Sensor Input Connections

Maximum cable length is 200 ft. for 515/8510-XX,
Wiring Tips: 525, 2517 and any sinusoidal flow signal.
• Do not route sensor cable in conduit containing AC power wiring. 8550-3
Electrical noise may interfere with sensor signal. Flow
Flow1:
Flow2:
6.25 GPM
9.75 GPM
• Routing sensor cable in grounded metal conduit will help prevent B A

ENTER
electrical noise and mechanical damage.

• Seal cable entry points to prevent moisture damage. A ≤ 200 ft. (61 m)
• Only one wire should be inserted into a terminal. Splice double B ≤ 200 ft. (61 m)
wires outside the terminal.
Maximum cable length is 1000 ft. for
Terminals
Aux Power Required
2536/8512-XX, 2540/2541, vortex, and any
16 Snsr 2 Gnd No Aux Power
(SHIELD)
515/3-8510-XX 2000 open-collector flow signal.
Snsr 2 IN
15 2507
(RED)
525 8550-3
Snsr 2 V+
14 (BLACK) 2100 Open-collector input signals Flow1:
Flow
6.25 GPM
Flow2: 9.75 GPM
13 Snsr 1 Gnd
(SHIELD)
2517 B A
12 Snsr 1 IN 2536/3-8512-XX ENTER
(RED)
2540/2541
Snsr 1 V+
11 (BLACK) 7000 Vortex
A ≤ 1000 ft. (305 m)
B ≤ 1000 ft. (305 m)
3.3 Open Collector Output
The Open collector output can be used as a switch that responds Process
when the flow rate moves above or below a setpoint, or it can be
used to generate a pulse that is relative to the flow volume or to
the flow rate. Hysteresis
• Low
Low Setpoint
Output triggers when the flow rate is less than the setpoint.
The output will relax when the flow rate moves above the setpoint
plus the hysteresis value. Time
• High Relay energized

Output triggers when the flow rate is greater than the setpoint.
The output will relax when the flow rate drops below the setpoint Relay relaxed
plus the hysteresis value.
Process
• Frequency
Output is a pulse stream that is based on the input flow sensor
signal. Set for 1 (input frequency = output frequency). Set for High Setpoint
even numbers (2, 4, 6, 8, . . . . 254 maximum) to scale output
frequency.
Hysteresis
• Pulse
Output is a pulse based on the volume of fluid that passes the Time
sensor. Set any value from 0.0001 to 99999.
The output may be disabled (Off) if not used.
VIEW menu
• During normal operation, ProcessPro displays the VIEW menu.
• When editing the CALIBRATE or OPTIONS menus, ProcessPro will return to the VIEW menu if no activity
occurs for 10 minutes. Flow1:
Flow2:
6.25 GPM
9.75 GPM
• To select a VIEW display, press the UP or DOWN arrow keys. The selections will scroll in a continuous loop. Signet Flow
Transmitter
• Changing the VIEW display does not interrupt system operations.
• No key code is necessary to change display selection. ENTER
• Output settings cannot be edited from the VIEW menu.
View Menu
Display Description
Flow1: 123.4 GPM Monitor the flow rate of Channel 1 and Channel 2 simultaneously.
Flow2: 567.8 GPM This is the permanent view display.
Delta Flow: Monitor the delta flow rate (Channel 1 rate - channel 2 rate = Delta Flow)
10.5 GPM This is a permanent display.
All of the displays below are temporary. After ten minutes the display will return to the permanent display.
Tot1: 1234567.8 Monitor channel 1 and channel 2 Resettable Totalizers. Press the RIGHT
Tot2: 123456.78> ARROW key to reset the totalizer. If Reset is locked, you must enter Key
Code. Lock or Unlock function is in OPTIONS menu.
Perm1: 1234567.8 Monitor channel 1 Permanent Totalizer value.

Gallons
Perm2: 123456.78 Monitor channel 2 Permanent Totalizer value.

Gallons
Loop 1 Output: Monitor the 4-20 mA Loop 1 output.

12.00 mA
Loop 2 Output: Monitor the 4-20 mA Loop 2 output.

12.00 mA
Last CAL: Monitor date for scheduled maintenance or date of last calibration.
04-20-06 (See description in Calibrate Menu.)
ProcessPro Editing Procedure:
8 Step 1. Press and hold ENTER key:
• 2 seconds to select the CALIBRATE menu.
• 5 seconds to select the OPTIONS menu.
Step 2. The Key Code is UP-UP-UP-DOWN keys in sequence.
• After entering the Key Code, the display will show the first item in the selected menu.
Step 3. Scroll menu with UP or DOWN arrow keys.
Step 4. Press RIGHT ARROW key to select menu item to be edited.
• The first display element will begin flashing.
Step 5. Press UP or DOWN keys to edit the flashing element.
• RIGHT ARROW key advances the flashing element.
Step 6. Press ENTER key to save the new setting and return to Step 3.
Notes on Step 1: Notes on Step 2:

• The View Menu is normally displayed. If no key is pressed for 5 minutes while display is showing "Enter
• The CALIBRATE and OPTIONS menus require a KEY CODE. Key Code", the display will return to the VIEW menu.
CALIBRATE: ----
Press & Enter Key Code
ENTER
hold for
access: CALIBRATE: *---
Enter Key Code
CALIBRATE: **--
VIEW Enter Key Code
2s 5s CALIBRATE: ***-
CALIBRATE Enter Key Code
OPTIONS Flow1 Units: First item in CALI-

GPM > BRATE menu

• Refer to pages 6 and 7 for complete listing of menu items and their use.
• From the Step 3 display, pressing the UP and DOWN keys simultaneously will
Flow1 Units:
GPM >
return the display to the VIEW menu.
• If no key is pressed for 10 minutes, display will also return to the VIEW menu.
Step 3
Step 3: Finished Editing? Output1 Setpnt:

Press the UP and DOWN keys simultaneously after Step 4
20.0 GPM >
saving the last setting to return to normal operation.

Output1 Setpnt:
• All output functions remain active during editing. 20.00 GPM
• Only the flashing element can be edited.
Output1 Setpnt:
• RIGHT ARROW key advances the flashing element in a continuous loop. 10.00 GPM Step 5
• Edited value is effective immediately after pressing ENTER key.
• If no key is pressed for 10 minutes unit will restore the last saved value and return to step 3.
• Step 6 (pressing ENTER key) always returns you to Step 3. Output1 Setpnt:
• Repeat steps 3-6 until all editing is completed. 10.00 GPM
Output1 Setpnt:
Step 5: Made an Error? 9
1 .00 GPM
ENTER
Press the UP and DOWN keys simultaneously Step 6

while any element is flashing. This will recall the Output1 Setpnt:
last saved value of the item being edited and Saving
return you to Step 3. Output1 Setpnt:
19.00 GPM >
Calibrate Menu
Display
Description
Flow1 Units: The first three characters set the Flow Rate units of measure. They have no effect on
GPM > calculations. They may be any alpha or numeric character, upper or lower case. The last
character sets the Flow rate Timebase. Select S (seconds, M (minutes, H (hours) or D (days)
This setting tells the transmitter how to convert the input frequency from the flow sensor into
Flow1 K-Factor: a flow rate. The K-factor is unique to the sensor model and to the pipe size and schedule.
60.000 > Refer to data in the sensor manual for the correct value. Limits: 0.0001 to 99999. (The
K-factor cannot be set to 0.)
Total1 Units: This setting identifies the Totalizer units. It has no effect on any calculation. It serves as a
Gallons > label only. Each character can be any alpha or numerical selection, upper or lower case.
This setting tells the transmitter how to convert the flow sensor signal into a volumetric total.
Total1 K-Factor: It also is used as the basis for the Open Collector pulse mode.
60.00 > The setting is usually the same as the Flow K-factor, or different by x10 or x100.
Limits: 0.0001 to 99999. (The K-factor cannot be set to 0)
Loop1 Source: Select the input source to be associated with Loop output #1:
Flow1 > Flow sensor #1, Flow sensor #2, or Delta Flow.
Loop1 Range: GPM Select the minimum and maximum values for the Current loop output #1.
000.00 → 100.00 > The 8550 will allow any values from 0.0000 to 99999.
Output1 Source: Select the input source for Open Collector output #1: Flow sensor #1, Flow sensor #2, or
Flow1 > Delta Flow.
Output1 Mode: Select the mode of operation for Open Collector output #1.
Low > Options available are High, Low, Pulse (volumetric), or Frequency (based on rate).
The signal may be disabled if not in use.
Output1 Setpnt: In Low or High Mode, this Open Collector output will be activated when the Flow rate reaches
1.0 GPM > this value. Be sure to modify this setting if you change the Flow Units.
Output1 Hys: The Open Collector output will be deactivated at Setpoint ± Hysteresis, depending on High or
5.0 GPM > Low Setpoint selection. (See details on page 4.)
Output1 Volume: In Pulse mode, Open collector output #1 will generate one pulse when this volume of flow
100.00 Gallons > passes the sensor. (The measurement is based on the Total1 K-factor).
The 8550 will allow any value from 0.0001 to 99999.
Output1 PlsWdth: In Pulse mode, this setting defines the duration of Open Collector output pulse #1. The 8550
0.1 Seconds > allows any value from 0.1 seconds to 999.9 seconds.
Output1 Freq.: In Frequency mode, Open Collector output #1 will simulate the sensor frequency, divided
Divide by 1 > by this setting. Set for 1 (input frequency = output frequency). Set for even numbers
(2, 4, 6, 8 . . . 254 maximum) to scale output fequency.
Last CAL: Use this “note pad” to record important dates, such as annual recertification or scheduled
04-20-06 maintenance.
All functions labeled "1" will repeat for channel 2.

Options Menu
Display
Description
Contrast: Adjust the LCD contrast for best viewing. A setting of 1 is lower contrast, 5 is higher.
3 > Select lower contrast if the display is in warmer ambient surroundings.
Flow1 Decimal Set the decimal to the best resolution for your application. The display will automatically
scale up to this restriction.
*****. > Select *****., ****.*, ***.**, **.*** or *.****
Total1 Decimal Set the totalizer decimal to the best resolution for your application.
Select ********., *******.*, or ******.**
******.** >
Averaging 1: OFF provides the quickest output response to changes in flow.

Longer averaging period produces more stable display and output response.
Off > Select OFF, 8 s, 20 s, 50 s or 120 s.
Sensitivity 1: Sensitivity works in conjunction with Averaging to balance response time with signal
stability. Selections are 0 to 9. Select 0 (zero) for the minimum sensitivity, or 9 for the
0 > maximum sensitivity. The function is described below.
Total Reset: Lock Off : No key code required to reset the resettable totalizer.
Lock On : The Key Code must be entered to reset the resettable totalizer.
Lock Off >
Loop1 Adjust: Adjust the minimum and maximum current output. The display value represents the
precise current output.
4.00 mA > Adjustment limits:
• 3.80 mA < 4.00 mA > 5.00 mA
Loop1 Adjust: • 19.00 mA < 20.00 mA > 21.00 mA
Use this setting to match the system output to any external device.
20.00 mA >
Output1 Active: Active HIGH: This setting is used to turn a device (pump, valve) ON at the setpoint.
Low > Active LOW: This setting is used to turn a device OFF at the setpoint.
Test Loop1: Press UP or DOWN keys to manually order any output current value from 3.6 mA to
21.00 mA to test current loop output.
>
Test Output 1: Press UP or DOWN keys to manually toggle the state of open collector output.
All functions labeled "1" will repeat for channel 2.
No AVERAGING, no SENSITIVITY
With AVERAGING set to 0 (zero) and with SENSITIVITY set to zero,
the 8550 responds to every unstable shift in the flow. The dashed
red line represents the actual output of the flow sensor in unstable
flow conditions .
AVERAGING only
With AVERAGING set to 50 seconds and SENSITIVITY still set to
zero the flow rate is stabilized, but a sharp change in flow rate is not
represented for 50 seconds or longer. (dotted green line).
AVERAGING and SENSITIVITY

2s 10 s 20 s 30 s 40 s 50 s 60 s 70 s
With AVERAGING at 50 seconds and SENSITIVITY set to 4 OR 5,
the flow rate is stabilized, while the sudden shift in flow is reflected NOTE: The SENSITIVITY function is ineffective if the
very quickly. (Solid blue line) AVERAGING function is set to zero (seconds).
Troubleshooting
Display Condition Suggested Solutions Suggested Solutions
“- - - - -” Flow rate exceeds display capability • Increase Flow units timebase

• Move flow decimal one place to the right
“Pulse Overrun Output1” • Open Collector pulse rate exceeds • Increase Output Volume setting
“Pulse Overrun Output2” maximum of 300 pulses per minute. • Decrease Output pulse width
• Pulse width set too wide. • Reduce system flow rate
“Value must be more than 0” K-factors cannot be set to 0. Enter K-factor between 0.0001 to 99999
Open Collector output is always • Hysteresis value too large • Change the hysteresis value
activated • Defective transmitter • Replace transmitter
Signet 515/2536 Rotor-X Flow Sensors English
Instructions for all versions of: 515/8510-xx and 2536/8512-xx
*3-0515.090*
3-0515.090 E 8/04 English
SAFETY INSTRUCTIONS
1. Depressurize and vent system prior to installation or removal.
2. Confirm chemical compatibility before use.
3. Do not exceed maximum temperature/pressure specifications.
4. Wear safety goggles or faceshield during installation/service.
5. Do not alter product construction.
1. Specifications
2536 Sensor
General Data Signal:
Flow Rate Range: 515: 0.3 to 6 m/s (1 to 20 ft/s) Frequency: 49 Hz per m/s nominal (15 Hz per ft/s nominal)
2536: 0.1 to 6 m/s (0.3 to 20 ft/s) Supply voltage: 3.5 to 24 VDC regulated
Pipe Size Range: DN15 to DN1000 (½ in. to 12 in.) Supply current: <1.5 mA @ 3.3 to 6 VDC
Linearity: ±1% of full range <20 mA @ 6 to 24 VDC
Repeatability: ±0.5% full range Output Type: Open collector transistor, sinking
Cable Length: 7.6 m (25 ft) standard Output current: 10 mA max.
515: 60 m (200 ft.) maximum
2536: 305 m (1000 ft) maximum Fluid Conditions
Cable Type: 2-conductor twisted pair w/shield (22 AWG) Rotor-X Sensor Pressure/Temperature Ratings:
Minimum Reynolds Number Required: 4500
Cap Material: Glass Filled Polypropylene Polypropylene Body:
515: Red • 12.5 bar (180 psi) max. @ 20 °C (68 °F)
2536: Blue • 515: 1.7 bar (25 psi) max. @ 90 °C (194 °F)
Wetted Materials: • 2536: 1.7 bar (25 psi) max. @ 85 °C (185 °F)
• Sensor Body: Glass filled Polypropylene (black) or PVDF
(natural) PVDF Body:
• O-Rings: FPM (Std) or EPDM or FFKM • 14 bar (200 psi) max @ 20 °C (68 °F)
• Pin: Titanium or Hastelloy-C or PVDF; other • 515: 1.7 bar (25 psi) max @ 100 °C (212 °F)
material options available • 2536: 1.7 bar (25 psi) max @ 85 °C (185 °F)
• Rotor: Black PVDF or natural PVDF; optional Tefzel® bar psi
with or w/o Fluoraloy B® sleeve 14 200
Shipping Weight: -X0 0.454 kg (1 lb)
-X1 0.476 kg (1.04 lbs) 11 160
51
51
5/
-X2 0.680 kg (1.50 lbs) 5/

85
85
10
-X3 0.794 kg (1.75 lbs) 8 120 10

-X
-X
-X4 0.850 kg (1.87 lbs)
X
X
-P
-P
-X5 1.0 kg (2.20 lbs)
oly
6 80
VD
pr
3519 1.3 kg (2.86 lbs)

F
op
yle
515 Sensor 3 40
ne
Signal:
Frequency: 19.7 Hz per m/s nominal (6 Hz per ft/s)
Amplitude: 3.3 V p/p per m/s nominal (1 V p/p per ft/s) °F 0 40 80 120 160 200 240
Source Impedance: 8 kΩ °C -18 4 27 49 71 93 115
Dimensions
8510-XX/8512-XX bar psi
515/2536 Sensor Integral Sensor 14 200
shown with Transmitter
Standard and Integral Adapter Kit 11 160
25
7.6 m/25 ft.

25
cable (sold separately)

36
36
included
/85
/85
12
12
8 120
-X
-X
X
X
-P
-P
6 80
oly
VD
1-1/4" NPSM
pr
threaded cap 102 mm/ -X0 or

F
op
-X (0 thru 5) 4.0 in. -X1

3 40
yle
26.7 mm/
n
1.05 in.
e
°F 0 40 80 120 160 200 240

°C -18 4 27 49 71 93 115
Pipe Range:
1/2 to 4 in. -X0 = 104 mm/4.1 in.
5 to 8 in. -X1 = 137 mm/5.4 in. Standards & Approvals
10" and up -X2 = 213 mm/8.4 in. • Manufactured under ISO 9001 and ISO 14001
1/2 to 4 in. -X3 = 297 mm/11.7 in.
5 to 8 in. -X4 = 332 mm/13.1 in. Wet-tap -X0 = 152 mm/6.0 in. • CE
10" and up -X5 = 408 mm/16.1 in.
Lengths -X1 = 185 mm/7.3 in. • 515 Only: FM Class I, II, III/Div. I/Groups A-G
Inlet Outlet
2. Location of Fitting Flange Reducer 90° Elbow
Recommended sensor upstream/downstream 10x I.D. 5x I.D. 15x I.D. 5x I.D. 20x I.D. 5x I.D.
mounting requirements
2 x 90° Elbow
3 dimensions
2 x 90° Elbow Pump/Valve
25x I.D. 5x I.D. 40x I.D. 5x I.D. 50x I.D. 5x I.D.
0°
3. Sensor Mounting Position -45° +45°
• Horizontal pipe runs: Mount sensor in the upright (0°) position for best performance. Mount
at a maximum of 45° when air bubbles are present (pipe must be full). Do not mount on the Process
bottom of the pipe when sediments are present. Pipe
• Vertical pipe runs: Mount sensor in any orientation. Upward flow is preferred to ensure full
pipe.
4. Standard Sensor Installation 3. Engage one thread of the sensor cap then turn the sensor
until the alignment tab is seated in the fitting notch. Hand
1. Lubricate the sensor O-rings with a silicone lubricant (e.g. tighten the sensor cap. DO NOT use any tools on the
GE silicone compound #G632 or equivalent). Do not use sensor cap or the cap threads and/or fitting flange threads
will be damaged, see Figure B.
black conduit sensor bale black senso
cap conduit bale
cap
tab
PROCESS PIPE
(TOP VIEW) direction of flow
notch Figure B
Figure A
any petroleum based lubricant that will attack the O-rings.
sensor
2. Using an alternating/twisting motion, lower the sensor into cap
the fitting, making sure the installation arrows on the black

cap are pointing in the direction of flow, see Figure A.
5. Sensor Wiring 515 Sensor Connections to Signet Instruments
Technical Notes Black

Frequency (-)
• Use 2-conductor shielded cable for cable extensions.
• Cable shield must be maintained through cable splice. Red
Frequency (+)
• Refer to your instrument manual for specific wiring details.
Shield
Ground
2536 Sensor Connections to Other Brand Instruments
Other Brands
black
+ 3.3 to 24 515 Sensor Connections to Signet Instruments
shield
10 kΩ - VDC
Black
Gnd. Other Frequency (-)
red instrument Red
Input
Frequency (+)
DC sensor power supplied from Signet instrument.
Shield
10KΩ Pull-up resistor may be required for non Signet brand instrument.
Ground
6. Rotor Replacement Procedure

1. To remove the rotor, insert a small screwdriver between the rotor and the ear of the sensor.
2. Twist the screwdriver blade to flex the ear outward enough to remove one end of the rotor and pin.
DO NOT flex the ear any more than necessary! If it breaks, the sensor cannot be repaired.
3. Install the new rotor by inserting one tip of the pin into the hole, then flex the opposite ear back
enough to slip rotor into place.
2 Signet 515/2536 Rotor-X Flow Sensors
7. K-Factors
A K-Factor is the number of pulses a sensor will generate for each engineering unit of fluid which passes the sensor. K-factors for
water are listed below in U.S. gallons and liters. For example, in a 1-inch PVC pipe, the 515 paddlewheel generates 174.67 pulses
per gallon of water passing the rotor. K-factors are listed for pipes up to 12 inches. For pipes over 12 inches, consult your Signet
distributor.
PIPE 515/8510-XX 2536/8512-XX PIPE 515/8510-XX 2536/8512-XX PIPE 515/8510-XX 2536/8512-XX
SIZE FITTING U.S. U.S. SIZE FITTING U.S. U.S. SIZE FITTING U.S. U.S.
(IN.) LITERS LITERS (IN.) LITERS LITERS (IN.) LITERS LITERS
GAL GAL GAL GAL GAL GAL
SCH 80 PVC TEES FOR SCH 80 PVC PIPE CARBON STEEL TEES ON SCH 40 PIPE STAINLESS STEEL WELDOLETS ON SCH 40 PIPE
1/2 PV8T005 480.19 126.87 991.71 262.01 1/2 CS4T005 370.20 97.808 756.00 199.74 2-1/2 CR4W025 18.800 4.9670 37.600 9.9339
3/4 PV8T007 257.72 68.090 545.14 144.03 3/4 CS4T007 212.06 56.027 438.69 115.90 3 CR4W030 12.170 3.2153 24.340 6.4306
1 PV8T010 174.67 46.148 352.44 93.114 1 CS4T010 141.14 37.289 286.78 75.768 4 CR4W040 6.9600 1.8388 13.920 3.6777
1-1/4 PV8T012 83.390 22.032 177.18 46.812 1-1/4 CS4T012 60.655 16.025 121.22 32.026 5 CR4W050 5.2600 1.3897 10.860 2.8692
1-1/2 PV8T015 58.580 15.477 117.85 31.137 1-1/2 CS4T015 45.350 11.982 91.139 24.079 6 CR4W060 3.6900 0.9749 7.5200 1.9868
2 PV8T020 32.480 8.5812 66.739 17.633 2 CS4T020 26.767 7.0717 54.468 14.391 8 CR4W080 2.1300 0.5627 4.3400 1.1466
2-1/2 PV8T025 21.833 5.7683 42.994 11.359 STAINLESS STEEL TEES ON SCH 40 PIPE 10 CR4W100 1.3500 0.3567 2.7600 0.7292
3 PV8T030 13.541 3.5775 26.652 7.0414 1/2 CR4T005 358.96 94.838 734.20 193.98 12 CR4W120 0.9600 0.2536 1.9400 0.5125
4 PV8T040 7.6258 2.0147 15.006 3.9645 3/4 CR4T007 202.61 53.530 412.10 108.88 CARBON STEEL WELDOLETS ON SCH 40 PIPE
SCH 80 CPVC TEES FOR SCH 80 CPVC PIPE 1 CR4T010 127.14 33.590 252.70 66.764 2-1/2 CS4W025 18.800 4.9670 37.600 9.9339
1/2 CPV8T005 480.19 126.87 991.71 262.01 1-1/4 CR4T012 61.910 16.357 128.12 33.849 3 CS4W030 12.170 3.2153 24.340 6.4306
3/4 CPV8T007 257.72 68.090 545.14 144.03 1-1/2 CR4T015 40.410 10.676 77.320 20.428 4 CS4W040 6.9600 1.8388 13.920 3.6777
1 CPV8T010 174.67 46.148 352.44 93.114 2 CR4T020 22.300 5.8917 45.780 12.095 5 CS4W050 5.2600 1.3897 10.860 2.8692
1-1/4 CPV8T012 83.390 22.032 177.18 46.812 GALVANIZED IRON TEES ON SCH 40 PIPE 6 CS4W060 3.6900 0.9749 7.5200 1.9868
1-1/2 CPV8T015 58.580 15.477 117.85 31.137 1 IR4T010 104.54 27.619 213.01 56.277 8 CS4W080 2.1300 0.5627 4.3400 1.1466
SCH 80 PVC SADDLES FOR SCH 80 PVC PIPE 1-1/4 IR4T012 62.979 16.639 127.75 33.751 10 CS4W100 1.3500 0.3567 2.7600 0.7292
2 PV8S020 32.480 8.5812 66.739 17.633 1 1/2 IR4T015 46.688 12.335 94.401 24.941 12 CS4W120 0.9600 0.2536 1.9400 0.5125
2-1/2 PV8S025 21.833 5.7683 42.994 11.359 2 IR4T020 29.459 7.7832 59.420 15.699 COPPER/BRONZE BRAZOLETS ON SCH 40 PIPE
3 PV8S030 13.541 3.5775 26.652 7.0414 BRONZE TEES ON SCH 40 PIPE 2-1/2 BR4B025 18.800 4.9670 37.600 9.934
4 PV8S040 7.6258 2.0147 15.006 3.9645 1 BR4T010 104.54 27.619 213.01 56.277 3 BR4B030 12.170 3.2153 24.340 6.431
6 PV8S060 4.1623 1.0997 8.3246 2.1994 1-1/4 BR4T012 62.979 16.639 127.75 33.751 4 BR4B040 6.9600 1.8388 13.920 3.678
8 PV8S080 2.3705 0.6263 5.0164 1.3253 1-1/2 BR4T015 46.688 12.335 94.401 24.941 5 BR4B050 5.2600 1.3897 10.860 2.869
10 PV8S100 1.5300 0.4042 3.0600 0.808 2 BR4T020 29.459 7.7832 59.420 15.699 6 BR4B060 3.6900 0.9749 7.5200 1.987
12 PV8S120 1.0600 0.2801 2.1600 0.571 COPPER TEE FITTINGS ON COPPER PIPE SCH K 8 BR4B080 2.1300 0.5627 4.3400 1.147
SCH 80 PVC SADDLE ON SCH 40 PVC PIPE 1/2 CUKT005 443.21 117.10 917.84 242.50 10 BR4B100 1.3500 0.3567 2.7600 0.729
2 PV8S020 27.350 7.2259 54.700 14.452 3/4 CUKT007 212.16 56.052 428.27 113.15 12 BR4B120 0.9600 0.2536 1.9400 0.513
2-1/2 PV8S025 18.874 4.9866 37.159 9.8175 1 CUKT010 127.18 33.600 256.43 67.749 SCH 80 IRON SADDLES ON SCH 80 PIPE
3 PV8S030 12.638 3.3389 23.697 6.2608 1-1/4 CUKT012 88.218 23.307 176.44 46.615 2 IR8S020 32.360 8.5495 64.720 17.099
4 PV8S040 6.7282 1.7776 13.456 3.5552 1-1/2 CUKT015 56.962 15.049 115.69 30.565 2-1/2 IR8S025 22.220 5.8705 42.480 11.223
6 PV8S060 3.7297 0.9854 7.4594 1.9708 2 CUKT020 29.370 7.7595 63.385 16.746 3 IR8S030 13.420 3.5456 26.420 6.980
8 PV8S080 2.1527 0.5688 4.5292 1.1966 COPPER TEE FITTINGS ON COPPER PIPE SCH L 4 IR8S040 7.6600 2.0238 14.700 3.884
10 PV8S100 1.3500 0.3567 2.8000 0.740 1/2 CUKT005 414.41 109.49 858.22 226.74 5 IR8S050 5.8600 1.5482 12.180 3.218
12 PV8S120 0.9600 0.2536 1.9800 0.523 3/4 CUKT007 191.09 50.485 385.74 101.91 6 IR8S060 4.0900 1.0806 8.4400 2.230
PP CLAMP-ON SADDLE ON SCH 80 PP PIPE 1 CUKT010 119.84 31.662 241.64 63.841 8 IR8S080 2.3300 0.6156 4.9000 1.295
10 PPS100 1.5300 0.4042 3.0600 0.808 1-1/4 CUKT012 85.451 22.576 170.90 45.152 10 IR8S100 1.5300 0.4042 3.0600 0.808
12 PPS120 1.0600 0.2801 2.1600 0.571 1-1/2 CUKT015 55.160 14.573 112.03 29.598 12 IR8S120 1.0600 0.2801 2.1600 0.571
PP CLAMP-ON SADDLE ON SCH 40 PP PIPE 2 CUKT020 28.605 7.5575 61.74 16.310 SCH 80 IRON SADDLE ON SCH 40 PIPE
10 PPS100 1.3500 0.3567 2.8000 0.740 2 IR8S020 26.820 7.0859 53.640 14.172
12 PPS120 0.9600 0.2536 1.9800 0.523 2-1/2 IR8S025 18.800 4.9670 37.600 9.934
3 IR8S030 11.990 3.1678 23.220 6.135
K-Factors DIN Pipes 4 IR8S040 6.8500 1.8098 13.260 3.503
5 IR8S050 5.3300 1.4082 11.040 2.917
515/8510-XX 2536/8512-XX
PIPE 6 IR8S060 3.7600 0.9934 7.2400 1.913
FITTING U.S. LITERS U.S. LITERS CODE
SIZE
GAL GAL 8 IR8S080 2.1300 0.5627 4.4000 1.162
POLYPROPYLENE FITTINGS (DIN/ISO AND BS AND ANSI) 10 IR8S100 1.3500 0.3567 2.8000 0.740
DN 15 PPMT005 481.55 127.23 952.87 251.75 198.150.522 12 IR8S120 0.9600 0.2536 1.9800 0.523
DN 20 PPMT007 277.09 73.207 563.10 148.77 198.150.523
DN 25 PPMT010 141.18 37.300 291.60 77.042 198.150.524 8. H-Dimensions
DN 32 PPMT012 83.540 22.071 169.22 44.709 198.150.525
DN 40 PPMT015 51.265 13.544 103.90 27.450 198.150.526 "H"
DN 50 PPMT020 29.596 7.8193 60.789 16.060 198.150.527
The plastic sensor insert in the Weldolet
DN 65 PPMT025 20.658 5.4579 41.498 10.964 198.150.560 fitting MUST be removed during the
DN 80 PPMT030 13.330 3.5218 26.786 7.0769 198.150.561 welding process. When reinstalled, it is
DN 100 PPMT040 8.7077 2.3006 17.415 4.6011 198.150.562
DN 125 PPMT050 5.0667 1.3386 10.168 2.6864 198.150.563
important that the insert be threaded to
DN 150 PPMT060 3.6892 0.9747 7.3119 1.9318 198.150.564 the proper height ("H" dimension).
DN 200 PPMT080 2.0398 0.5389 3.9946 1.0554 198.150.565
PVDF FITTINGS (DIN/ISO AND BS AND ANSI)
DN 15 SFMT005 420.87 111.19 827.26 218.56 198.150.529
DN 20 SFMT007 228.15 60.277 489.87 129.42 198.150.530
DN 25 SFMT010 136.70 36.116 283.55 74.915 198.150.531
DN 32 SFMT012 79.294 20.950 158.59 41.899 198.150.532 Weldolet “H” dimension Weldolet “H” dimension
DN 40 SFMT015 43.490 11.490 86.980 22.980 198.150.533 part number inches mm part number inches mm
DN 50 SFMT020 25.908 6.8450 50.385 13.312 198.150.534
DN 65 SFMT025 18.067 4.7732 36.133 9.5465 198.150.571
CS4W020 2.38 60.45 CS4W240 4.16 105.66
DN 80 SFMT030 12.357 3.2648 24.715 6.5297 198.150.572 CS4W025 2.33 59.18 CS4W360 4.10 104.14
DN 100 SFMT040 8.0599 2.1294 16.120 4.2589 198.150.573
CS4W030 2.32 58.92
DN 125 SFMT050 4.4312 1.1707 8.8624 2.3415 198.150.574
DN 150 SFMT060 3.2271 0.8526 6.4543 1.7052 198.150.575 CS4W040 2.30 58.42 CR4W020 2.38 60.45
DN 200 SFMT080 2.0360 0.5379 4.0720 1.0758 198.150.576 CS4W050 3.09 78.48 CR4W025 2.33 59.18
PVC FITTINGS (DIN/ISO) - EUROPE ONLY
DN 15 PVMT005 486.18 128.45 972.37 256.90 198.150.480 CS4W060 2.96 75.18 CR4W030 2.32 58.92
DN 20 PVMT007 242.85 64.160 485.69 128.32 198.150.481 CS4W080 2.73 69.34 CR4W040 2.30 58.42
DN 25 PVMT010 148.64 39.270 297.274 78.540 198.150.482
DN 32 PVMT012 85.125 22.490 170.249 44.980 198.150.483
CS4W100 5.48 139.19 CR4W050 3.09 78.48
DN 40 PVMT015 51.855 13.700 103.709 27.400 198.150.484 CS4W120 5.25 133.35 CR4W060 2.96 75.18
DN 50 PVMT020 29.750 7.8600 59.500 15.720 198.150.485
CS4W140 5.10 129.54 CS4W080 2.73 69.34
DN 65 PVMT025 17.487 4.6200 34.9734 9.2400 198.150.538
DN 80 PVMT030 12.491 3.3000 24.9810 6.6000 198.150.539 CS4W160 4.85 123.19 CR4W100 5.48 139.19
DN 100 PVMT040 8.1377 2.1500 16.2754 4.3000 198.150.540
CS4W180 4.60 116.84 CR4W120 5.25 133.35
DN 150 PVMT060 4.0878 1.0800 8.1756 2.1600 198.150.543
DN 200 PVMT080 2.0439 0.5400 4.0878 1.0800 198.150.545 CS4W200 4.38 111.25
Signet 515/2536 Rotor-X Flow Sensors 3
SSS
Low Voltage Motors
Manual for Low Voltage Motors
Installation, operation and

maintenance manual GB 3
SSS
Example of the Declaration of Conformity
given by ABB.
GB
EC Declaration of Conformity
The Manufacturer :- (Name and address of the manufacturer)
hereby declares that
The Products :- (Product identification)
are in conformity with provisions of the following Council Directives :
Low Voltage Directive 73/23/EEC (amended by 93/68/EEC),
and, as components, with the essential requirements of the following :
EMC Directive 89/336/EEC (amended by 92/31/EEC and 93/68/EEC), regarding the intrinsic
characteristics to emission and immunity levels,
and are in conformity with :
EN 60 034-1
Additional Information :-
By design, the machines, considered as components, comply with the essential requirements of
Machinery Directive 98/37/EEC provided that the installation be correctly realised by the manufacturer
of the machinery (for example : in compliance with our Installation Instructions and EN 60 204 “Electri-
cal Equipment of Industrial Machines”).
Certificate of Incorporation (Directive 98/37/EEC, Art 4.2 and Annex II, Sub B) :
The machines above must not be put into service until the machinery into which they have
been incorporated have been declared in conformity with the Machinery Directive.
Year of CE marking : CE00.
Signed by ..................................................
Title ...........................................................
Date ..........................................................
Translations into other languages are available from ABB.

SSS
Low Voltage Motors
Installation, operation and maintenance manual
GB
Contents Page
1. General ................................................................................................................................. 4
1.1 Declaration of Conformity ............................................................................................ 4
1.2 Validity ........................................................................................................................ 4
2. Installation ........................................................................................................................... 4
2.1 Putting into service (starting) ....................................................................................... 4
2.1.1 Reception check .............................................................................................. 4
2.1.2 Insulation resistance check.............................................................................. 4
2.1.3 Direct-on-line or star/delta starting ................................................................... 5
2.1.4 Terminals and direction of rotation .................................................................. 5
2.2 Handling ...................................................................................................................... 5
2.2.1 Storage ............................................................................................................ 5
2.2.2 Transportation.................................................................................................. 5
2.2.3 Lifting ............................................................................................................... 5
2.2.4 Machine weights .............................................................................................. 6
2.3 Installation .................................................................................................................... 6
2.3.1 Cooling............................................................................................................. 6
2.3.2 Foundation ....................................................................................................... 6
2.3.3 Alignment ......................................................................................................... 6
2.3.4 Slide rails and belt drives ................................................................................. 6
2.4 Connection ................................................................................................................... 7
2.4.1 Connection for variable speed drive ................................................................ 7
2.5 Balancing ........................................................................................................................ 7
3. Operating ............................................................................................................................. 8
3.1 Use ............................................................................................................................... 8
3.1.1 Operating conditions ........................................................................................ 8
3.2 Safety considerations ................................................................................................... 8
3.2.1 Points to observe ............................................................................................. 8
3.3 Assembly and dismantling ........................................................................................... 8
3.3.1 General ............................................................................................................ 8
3.3.2 Bearings........................................................................................................... 8
3.3.3 Fitting coupling halves and pulleys .................................................................. 8
4. Maintenance ........................................................................................................................ 9
4.1 Maintenance and lubrication ........................................................................................ 9
4.1.1 General inspection ........................................................................................... 9
4.1.2 Lubrication ....................................................................................................... 9
4.1.3 Machines with permanently greased bearings ................................................ 9
4.1.4 Motors with regreasing nipples ........................................................................ 9
4.1.5 Lubrication intervals and amounts ................................................................... 10
4.1.6 Lubricants ........................................................................................................ 10
4.1.7 Frequency converter drives ............................................................................. 11
4.1.8 Spare parts ...................................................................................................... 11
4.1.9 Rewinding ........................................................................................................ 11
5. Environmental requirements ............................................................................................. 11
5.1 Noise levels .................................................................................................................. 11
6. Troubleshooting .................................................................................................................. 12
SSS
T
1. General 2. Installation
NOTE! 2.1 Putting into service (starting)
These instructions must be followed to ensure safe
GB
and proper installation, operation and maintenance of

the motor. They should be brought to the attention of
2.1.1 Reception check
anyone who installs, operates or maintains this Immediately upon receipt check the machine for external
equipment. Ignoring the instruction may invalidate damage and if found, inform the forwarding agent
the warranty. without delay.
Check all rating plate data, especially voltage and
1.1 Declaration of Conformity winding connection (star or delta). The type of bearing is
Declarations of Conformity with respect to the Low specified on the rating plate of all motors except the
voltage Directive 73/23/EEC amended by Directive smallest frame sizes.
93/68 EEC are issued separately with individual Remove transport locking if employed.Turn shaft by
machines. hand to check free rotation.
The Declaration of Conformity also satisfies the
Do not exceed permissible loading values of bearings
requirements of a Declaration of Incorporation with
stated in the product catalogue.
respect to the Machinery Directive 98/37/EEC, Art 4.2
Annex II, sub B Motors equipped with roller bearings: Running the
motor with no radial force applied to the shaft may
damage the roller bearing.
1.2 Validity
Motors equipped with angular contact bearing:
The instructions are valid for the following ABB
Running the motor with no axial force applied in the right
electrical machine types, in both motor and generator
direction to the shaft may damage the angular contact
operation.
bearing.
series MT*, MBT*, MXMA,
Motors equipped with regreasing nipples:
series M2A*/M3A*, M2B*/M3B*, M2C*/M3C*,
When starting the motor for the first time, or after long
M2F*/M3F*, M2L*/M3L*, M2M*/M3M*, M2Q*,
storage of the motor, apply the specified quantity of
M2R*/M3R*, M2V*/M3V*
grease until grease is forced out of the grease outlet.
in frame sizes 56 - 450.
For details see section “Manual lubrication" on page 9.
There is a separate manual for e.g. Ex motors ‘Low
voltage motors for hazardous areas: Installation, 2.1.2 Insulation resistance check
operation and maintenance Manual’ (Low Voltage
Motors/Manual for Ex-motors). Measure insulation resistance before commissioning
and when winding dampness is suspected.
Additional information is required for some machine
types due to special application and/or design Resistance, measured at 25°C, shall exceed the
considerations. Additional information is available for reference value, i.e. 10 M ohm (measured with 500 V dc
the following motors: Megger)
– roller table motors

– water-cooled motors WARNING
– open drip proof motors Windings should be discharged immediately after
– smoke venting motors measurement to avoid risk of electric shock.
– brake motors
– permanent magnet motors Insulation resistance reference value is halved for each
20°C rise in ambient temperature.
If the reference resistance value is not attained, the
winding is too damp and must be oven dried.
Oven temperature should be 90°C for 12-16 hours
followed by 105°C for 6-8 hours.
SSS
Drain hole plugs, if fitted, must be removed and closing
valve, if fitted, must be opened during heating.
2.2 Handling
Windings drenched in seawater normally need to be 2.2.1 Storage
rewound.
GB
The machine should always be stored indoors, in dry,
vibration free and dust free conditions.
2.1.3 Direct-on-line or star/delta
starting Unprotected machined surfaces (shaft-ends and
flanges) should be protected with anti-corrosive
The terminal box on standard single speed machines treatment.
normally contains 6 winding terminals and at least one
earth terminal. It is recommended that shafts be rotated periodically by
hand to prevent grease migration.
Earthing must be carried out according to local
regulations before the machine is connected to the Anti condensation heaters, if fitted, should preferably be
supply voltage. energised.
The voltage and connection are stamped on the rating The characteristics of electrolytic capacitors, if fitted to
plate. single-phase motors, will require “reforming” following
periods of storage exceeding 1-2 years.
Direct-on-line starting (DOL): Contact ABB Sales Office for details.
Y or D winding connections may be used.
e.g. 660 VY, 380 VD indicates Y-connection for 660 V
2.2.2 Transportation
and D-connection for 380 V. Machines fitted with cylindrical-roller and/or angular
contact bearings must be fitted with locking devices
Star/Delta starting (Y/D): during transport.
The supply voltage must be equal to the rated voltage
of the machine in D-connection. 2.2.3 Lifting
Remove all connection links from the terminal block. Lift the motor using the lifting lugs only, if not otherwise
For two-speed, single phase and special machines, stated in the separate lifting instruction.
supply connection must follow the instructions inside The center of gravity of motors with the same frame
the terminal box. may vary due to different outputs, mounting
If direct-on-line starting lasts for more than 10 seconds arrangements and auxiliary equipment.
or Y/D starting more than 30 seconds, consult ABB Check that eyebolts or the lifting lugs integrated with the
Sales Office or see the publication ‘The Motor Guide' motor frame are undamaged before lifting. Damaged
(also available on the internet on www.abb.com/ lifting lugs must not be used.
motors&drives).
Lifting eyebolts must be tightened before lifting.
If needed the position of the eyebolt must be adjusted
2.1.4 Terminals and direction of with suitable washers.
rotation
Ensure that proper lifting equipment is used and that
Direction of rotation is clockwise when viewing the shaft the sizes of the hooks are suitable for the lifting lugs.
face at the machine drive end, when the line phase
sequence L1, L2, L3 is connected to the terminals as Care must be taken not to damage auxiliary equipment
shown in the figure 1. and cables attached to the motor.
To alter the direction of rotation, interchange the

connection of any two line cables.
If the machine has a uni-directional fan, ensure that the
direction of rotation is according to the arrow marked on
the machine.
SSS
2.2.4 Machine weights Before mounting the motor, the foundation surface for
the shims or for the feet must be clean from thick paint,
Total machine weight can vary within the same frame paint drops and dirt. Then it should be checked in order
size (center height) depending on different output, to discover any height differences between the
mounting arrangements and added features.
GB
individual foot locations. Also, the smoothness within

The following table shows estimated maximum weights each footprint area has to be checked. The
for machines in their basic versions as a function of requirements are noted in the figure below.
frame material.
The actual weight of all our motors is stated on the Note! Height
Ruler difference shall not
rating plate except the smallest frame sizes.
exceed ± 0,1 mm
Aluminum Cast iron Steel referred to any other
Frame Weight Add. Weight Weight motor foot location
size kg for brake kg kg
56 4.5 - - -
63 6 - - -
71 8 5 13 -
Foot location
80 12 8 20 -
90 17 10 30 -
100 25 16 40 - Foundation studs
112 36 20 50 - Bolt the foundation studs to the feet of the motor and
132 63 30 90 - place a 1-to-2 mm shim between the stud and the feet.
160 110 30 175 - Align the motor directly using appropriate means.
180 160 45 250 - Grout the studs with concrete, check alignment and drill
200 220 55 310 - holes for locating pins.
225 295 75 400 -
250 370 75 550 - Drain holes
280 405 - 800 600 Always check that open drain holes face downward.
315 - - 1700 1000
355 - - 2700 2200 In extremely dusty environments, all drain holes should
400 - - 3500 3000 be closed.
450 - - 5000 4500
Table 1 2.3.3 Alignment
Correct alignment is essential to avoid bearing failures,
vibrations and possible fractured shaft extensions.
2.3 Installation
2.3.1 Cooling 2.3.4 Slide rails and belt drives
– Fasten the machine to the slide rails as shown in
Normal ambient temperatures should not exceed 40°C
figure 2.
(marine standard +45 or +50°C) if standard
– Place the slide rails horizontally on the same level.
performance is to be achieved. Check that the motor
– Check that the machine shaft is parallel with driven,
has sufficient airflow. Ensure that no nearby equipment,
or driving, shaft.
surfaces or direct sunshine, radiate additional heat to
– Any belt must be tensioned according to the
the motor. For more information about higher ambient
supplier's instructions.
temperatures and cooling, see “the Motor Guide” or
contact ABB Sales Office.
WARNING
2.3.2 Foundation Excessive belt tension will damage bearings and
can cause shaft breakage.
The purchaser bears full responsibility for preparation of
the foundation. Do not exceed the maximum belt forces (i.e. radial
Metal foundations should be painted to avoid corrosion. bearing loading) stated in the relevant product
catalogues.
Foundations must be even, and sufficiently rigid to
withstand possible short circuit forces. They shall be
dimensioned as to avoid the occurrence of vibration due
to resonance.
SSS
2.4 Connection Potential equalisation
Normal machine design has the terminal box on top
with cable entry possible from both sides. Plate/strip Cables/wires
GB
Some machines are available with top mounted terminal
boxes rotatable 4 x 90°, and some with side mounted
terminal boxes.
Driven machinery
Availability of these solutions is described in the product
catalogues.
Unused cable entries must be closed. To comply with EMC-requirements, use only cables and
As well as main winding and earthing terminals, the connectors approved for this purpose. (See instruction
terminal box can also contain connections for for frequency converters.)
thermistors, standstill heating elements, bimetallic, The highest permissible rotational speed of a cast iron
switches, or PT 100 resistance elements. motor used in variable speed drive (M2BA/M3BP) must
not exceed maximum permissible speeds as stated in
WARNING the table 2 below or the speed stamped on the rating
Voltage may be connected at standstill inside the plate. For information on the highest permissible
terminal box for heating elements or direct winding rotational speed for other motor sizes and types, please
heating. contact ABB. Bearing lubrication should follow the
directions mentioned later.
Connection diagrams for auxiliary elements are found Frame Speed r/min
inside the terminal box cover or in additional labels on size 2 pole 4 pole
the frame of the machine.
280 3600 2600
315 3600 2300
WARNING
The capacitor in single-phase motors can retain 355 3600 2000
a charge that appears across the motor terminals, 400 3600 1800
even when the motor has reached standstill. 450 3600 1800
2.4.1 Connection for variable Table 2

speed drive
If there is uncertainty concerning the suitability of the
Variable speed drives cause higher voltage stresses motor for the variable speed drive, please contact ABB.
than the sinusoidal supply on the winding of the motor
and may cause high frequency shaft voltages and
bearing currents. Therefore the winding and the bearing WARNING
insulation of the motor as well as the filter at the The maximum operating temperature of the
converter output must be dimensioned according to grease and bearings must not be exceeded.
"Selection rules for VSD applications/Insulation"
(3GZF500930-2), available on request from ABB. 2.5 Balancing
In variable speed drives the motor (Pn > 30 kW) must The rotor of the machine is dynamically balanced.
be cabled by using shielded symmetrical cables and
As standard, balancing has been carried out using half
cable glands providing 360° bonding (also called EMC
key, and the shaft is marked with a RED tape, with the
glands). More information can be found in ABB’s
text “Balanced with half key”. In case of motors
manual “Grounding and cabling of the drive system”
delivered without any tape defining the type of
(3AFY61201998).
balancing, these motors are also balanced with half
In frequency converter applications motor frame key.
external earthing must be used for equalising the
To avoid vibration the coupling-half or pulley must be
potential between the motor frame and the driven
balanced with half key after the keyway has been
machine, unless the two machines are mounted on the
machined.
same metallic base.
In the event of balancing with full key the shaft is
For motor frame sizes above IEC 280, use 0.75 x
marked with a YELLOW tape, with the text “Balanced
70 mm flat conductor or at least two 50 mm2 round
with full key”.
conductors. The distance of the round conductors must
be at least 150 mm from each other. In case balancing without key, the shaft is marked
with a BLUE tape, with the text “Balanced without
This arrangement has no electrical safety function; the
key".
purpose is to equalise the potentials. When the motor
and the gearbox are mounted on a common steel
fundament, no potential equalisation is required.
SSS
3. Operating 3.3 Assembly and dismantling
3.1 Use 3.3.1 General

GB
Dismantling and assembly of machines must be carried

3.1.1 Operating conditions out by qualified personnel using only suitable tools and
working methods. All repairs must be carried out
The machines are intended for use in industrial drive according to the standard IEC-60079-19.
applications.
Normal ambient temperature limits are -20° to +40°C.
Maximum altitude 1000 m above sea level.
3.3.2 Bearings
Special care should be taken with the bearings.
These must be removed using pullers and fitted by
3.2 Safety considerations heating or using special tools for the purpose.
The machine is intended for installation and use by How to replace bearings is described in detail in a
qualified personnel, familiar with relevant safety separate instruction leaflet available from ABB Sales
requirements. Office.
Safety equipment necessary for the prevention of
accidents at the installation and operating site must be 3.3.3 Fitting coupling halves and
provided in accordance with the local regulations.
pulleys
WARNING Coupling halves and pulleys must be fitted using
Small motors with supply current directly suitable equipment and tools that do not damage the
switched by thermally sensitive switches can bearings.
start automatically.
Never fit a coupling half or pulley by hammering into
3.2.1 Points to observe place or remove it using a lever pressed against the
body of the machine.
1. Do not use the machine to step on.
2. The temperature of the outer casing of the Mounting accuracy of coupling half:
machine may be hot to the touch during normal check that the clearance b is less than 0.05 mm and
operation. that the difference a1 to a2 is also less than 0.05 mm.
3. Some special machine applications require See figure 3.
special instructions (e.g. using frequency
converter supplies).
4. Lifting lugs must only be used for lifting the motor.
They must not be used to lift the motor when it is
attached to other equipment.
SSS
4. Maintenance Hours of operation for vertical motors are half of the
above values.
Motors with roller bearings have considerably shorter
4.1 Maintenance and lubrication grease life. For continuous operation regreasing nipples
GB
should be considered.
4.1.1 General inspection
– Inspect the machine at regular intervals. 4.1.4 Motors with regreasing nipples
– Keep the machine clean and ensure free
ventilation airflow. Lubrication information plate and general
– Check the condition of shaft seals (e.g. V-ring) and lubrication advice
replace if necessary.
If the machine is fitted with a lubrication information
– Check the condition of connections and mounting
plate, follow the given values.
and assembly bolts.
– Check the bearing condition by listening for On the lubrication information plate, regreasing intervals
unusual noise, vibration measurement, bearing with regard to mounting, ambient temperature and
temperature, inspection of spent grease or SPM speed of rotation can be defined.
bearing monitoring.
* When changes of condition occur, During the first start or after a bearing lubrication it may
dismantle the machine, check the parts appear a temporary temperature rise, appr. 10-20
and replace if necessary. hours. ABB policy is to have reliability as a vital issue in
bearing lubrication intervals. That is why we follow the
L1-principle.
4.1.2 Lubrication
A. Manual lubrication
WARNING Regreasing while motor is running
Beware of all rotating parts! – Remove grease outlet plug or open closing valve if
fitted.
WARNING – Be sure that the lubrication channel is open
Grease can cause skin irritation and eye – Press the specified amount of grease into the
inflammation. Follow all safety precautions bearing.
specified by the manufacturer. – Let the motor run 1-2 hours to ensure that all
excess grease is forced out of the bearing.
Close the grease outlet plug or closing valve if fitted.
4.1.3 Machines with permanently
Regreasing while motor is at a standstill
greased bearings Regrease motors while running. If this is not possible,
Bearings are usually permanently greased bearings of lubrication can be carried out while the machine is at a
either Z or 2Z types. standstill.
Bearing types are specified in the respective product – In this case, use only half the quantity of grease, then
catalogues and on the rating plate of all our motors run the motor for a few minutes at full speed.
except smaller frame sizes. – When the motor has stopped, press the rest of the
specified amount of grease into the bearing.
As a guide, adequate lubrication for sizes up to 200 can – After 1-2 running hours close the grease outlet plug
be achieved for the following duration, according to L1 or closing valve if fitted.
(i.e. that 99 % of the motors are sure to make the
interval time) at ambient temperature of 25°C. For B. Automatic lubrication
duties with ambient temperatures higher than 25°C, The grease outlet plug must be removed permanently
see the respective product catalogue. with automatic lubrication or open closing valve if fitted.
Some motors may be equipped with a collector for old
Frame size Poles Duty hours grease. Follow the special instructions given for the
56-80 2-8 for life equipment.
90-112 2-8 40 000
We recommend only the use of electromechanical
132 2-8 40 000
systems. Contact your local ABB Sales Office.
160 2-8 40 000
180 2-8 40 000 The amount of grease per each lubrication interval
200 2 27 000 stated in the tables 4-5 should be doubled if an
200 4 40 000 automatic regreasing system is used.
Table 3 If 2-pole motors are being automatically regreased, the
note (NOTE!) concerning lubricant recommendations
Depending on application and load conditions, see given for 2-pole motors in the chapter Lubricants shall
applicable product catalogue. be followed.
SSS
4.1.5 Lubrication intervals and Factors influencing the lubrication intervals
Lubrication intervals for vertical machines are half of the
amounts above values.
Frame Amount 3600 3000 1800 1500 1000 500-900 The lubrication intervals are based on bearing operating
GB
size of grease r/min r/min r/min r/min r/min r/min temperature 80°C (ambient temperature of about
g/bearing + 25°). Note! An increase in the ambient temperature
Ball bearings
raises the temperature of the bearings correspondingly.
Lubrication intervals in duty hours
112 10 10000 13000 18000 21000 25000 28000
The values should be halved for 15°C increase in
132 15 9000 11000 17000 19000 23000 26500 bearing temperature and may be doubled for 15°C
160 25 7000 9500 14000 17000 21000 24000 decrease in bearing temperature.
180 30 6000 8000 13500 16000 20000 23000
200 40 4000 6000 11000 13000 17000 21000
225 50 3000 5000 10000 12500 16500 20000
WARNING
250 60 2500 4000 9000 11500 15000 18000 The maximum operating temperature of the grease
280 70 20001) 35001) 8000 10500 14000 17000 and bearings must not be exceeded.
1) 1)
315 90 6500 8500 12500 16000
1) 1)
355 120 4200 6000 10000 13000
400 120 1)
1)
1)
1)
4200 6000 10000 13000 4.1.6 Lubricants
400 M3BP 130 2800 4600 8400 12000
450 140 2400 4000 8000 8800
WARNING
Table 4
Do not mix different types of grease.
Roller bearings Incompatible lubricants may cause bearing
Lubrication intervals in duty hours damage.
160 25 3500 4500 7000 8500 10500 12000
180 30 3000 4000 7000 8000 10000 11500
200 40 2000 3000 5500 6500 8500 10500 When regreasing, use only special ball bearing grease
225 50 1500 2500 5000 6000 8000 10000 with the following properties:
250 60 1300 2200 4500 5700 7500 9000 – good quality grease with lithium complex soap and
280 70 10001) 20001) 4000 5300 7000 8500
1) 1)
with mineral- or PAO-oil
315 90 3300 4300 6000 8000
355 120 1) 1)
2000 3000 5000 6500 – base oil viscosity 100-160 cST at 40°C
400 120 1) 1)
2000 3000 5000 6500 – consistency NLGI grade 1.5 - 3 *)
400 M3BP 130 1) 1)
1400 2300 4200 6000 – temperature range -30°C - +120°C, continuously.
450 140 1200 2000 4000 4400
*) For vertical mounted motors or in hot conditions a
Table 5 stiffer end of scale is recommended.
1)
Values for IEC sizes 280 to 450 (cast iron and steel motors) in certain
motor types (3600 and 3000 r/min), see tables 6-7. Grease with the correct properties is available from all
major lubricant manufacturers.
Lubrication intervals and amounts, 2-pole, Admixtures are recommended, but a written guarantee
IEC frame sizes 280 to 450 must be obtained from the lubricant manufacturer
Frame Amount 3600 3000 especially concerning EP admixtures, that admixtures
size of grease r/min r/min
g/bearing do not damage bearings or the properties of lubricants
Ball bearings at the operating temperature range.
280 M2B*, M2C*, M3B* 35 2000 3500
315 M2B*, M2C*, M3B* 35 2000 3500 WARNING
355 M2B*, M2C* 45 1200 2000 Lubricants containing EP admixtures are not
355 M3B* 35 1200 2000 recommended in high bearing temperatures in
400 M2B*, M2C* 45 1200 2000 frame sizes 280 to 450.
400 M3B* 40 1000 1600
450 M3B* 40 1000 1600
If the ambient temperature is below -25°C or above
Table 6 +55°C, or bearing temperature is above 110°C, consult
Roller bearings ABB Sales Office regarding suitable grease.
280 M2B*, M2C*, M3B* 35 1000 1800 The following high performance grease can be used
315 M2B*, M2C*, M3B* 35 1000 1800
355 M2B*, M2C* 45 600 1000 – Esso Unirex N2, N3 or S2 (lithium complex base)
355 M3B* 35 600 1000 – Mobil Mobilith SHC 100 (lithium complex base)
400 M2B*, M2C* 45 600 1000 – Shell Albida EMS 2 (lithium complex base)
400 M3B* 40 500 800 – SKF LGHQ 3 (lithium complex base)
450 M3B* 40 500 800
– Klüber Klüberplex BEM 41-132
Table 7 (special lithium base)
– FAG Arcanol TEMP110 (lithium complex base)
Lubrication intervals for other grease fullfilling the
required properties, contact your local ABB Sales
Office.
SSS
NOTE! 5. Environmental
Always use high speed grease for high speed
machines and some other models, e.g. M2BA 355
requirements
GB
and 400 2-pole machines, where the speed factor is
higher than 400 000 (calculated as Dm x n where 5.1 Noise levels
Dm = average bearing diameter, mm; n = rotational
speed, r/min). Most of our motors have a sound pressure level not
exceeding 82 dB(A) refer to 50 Hz sinusoidal supply
The following grease can be used: conditions, tolerance ± 3 dB(A).
– FAG L69 (polyurea base)
Values for specific machines can be found in the
– Klüber Klüber quiet BH 72-102 (polyurea base)
relevant product catalogues.
– Lubcon Turmogrease PU703 (polyurea base)
For sound pressure levels for 60 Hz sinusoidal supply
If other lubricants are used, check with the
and with non-sinusoidal supplies, contact ABB Sales
manufacturer that the qualities correspond to those of
Office.
the above mentioned lubricants, or if the compatibility of
the lubricant is uncertain, contact your local ABB Sales Sound pressure levels for all machines having separate
Office. cooling systems and for series M2F*/M3F*, M2L*/M3L*,
M2R*/M3R*, M2BJ/M3BJ and M2LJ/M3LJ are indicated
WARNING in separate Manuals.
Especially in high rotational speed (the speed
factor > 400000) over greasing may cause
damage.
4.1.7 Frequency converter drives

Higher speed operation, e.g. in frequency converter
applications, or lower speed with heavy load will require
shorter lubrication intervals. Consult your local ABB
Sales Office in such cases.
Typically a doubling of speed will require a reduction of
lubrication intervals to approx. 40 % of values tabulated
above.
WARNING
The constructional maximum speed of the motor
must not be exceeded (see table 2).
Suitability of bearings for high speed operation must be

checked.
4.1.8 Spare parts

When ordering spare parts, the full type designation
and product code, as stated on the rating plate, must be
specified.
If the machine is stamped with a serial manufacturing
number, this should also be given.
For more information, please visit our web site
www.abb.com/partsonline.
4.1.9 Rewinding
Rewinding should always be carried out by qualified
repair shops.
Smoke venting and other special motors should not be
rewound without first contacting ABB.
SSS
6. Troubleshooting
These instructions do not cover all details or variations in equipment nor provide for every possible condition to be
met in connection with installation, operation or maintenance. Should additional information required, please
GB
contact the nearest ABB Sales Office.
Motor troubleshooting chart

Your motor service and any troubleshooting must be handled by qualified persons with proper tools and equipment.
TROUBLE CAUSE WHAT TO DO

Motor fails to start Blown fuses Replace fuses with proper type and rating.
Overload trips Check and reset overload in starter.
Improper power supply Check to see that power supplied agrees with
motor rating plate and load factor.
Improper line connections Check connections with diagram supplied with
motor.
Open circuit in winding or control Indicated by humming sound when switch is
switch closed. Check for loose wiring connections.
Also, ensure that all control contacts are closed.
Mechanical failure Check to see if motor and drive turn freely.
Check bearings and lubrication.
Short circuited stator Indicated by blown fuses. Motor must be
Poor stator coil connection rewound. Remove end bells, locate with test
lamp.
Rotor defective Look for broken bars or end rings.
Motor may be overloaded Reduce load.
Motor stalls One phase may be open Check lines for open phase.
Wrong application Change type or size. Consult manufacturer.
Overload Reduce load.
Low voltage Ensure the rating plate voltage is maintained.
Check connection.
Open circuit Fuses blown, check overload relay, stator and
push buttons.
Motor runs and then Power failure Check for loose connections to line, to fuses and
dies down to control.
Motor does not come up Not applied properly Consult supplier for proper type.
to speed Voltage too low at motor terminals Use higher voltage or transformer terminals
because of line drop or reduce load. Check connections. Check
conductors for proper size.
Starting load too high Check load motor is supposed to carry at start.
Broken rotor bars or loose rotor Look for cracks near the rings. A new rotor may
be required, as repairs are usually temporary.
Open primary circuit Locate fault with testing device and repair.
Motor takes too long to Excessive load Reduce load.
accelerate and/or draws Low voltage during start Check for high resistance. Adequate wire size.
high amp
Defective squirrel cage rotor Replace with new rotor.
Applied voltage too low Get power company to increase power tap.
Wrong rotation Wrong sequence of phases Reverse connections at motor or at switchboard.
SSS
TROUBLE CAUSE WHAT TO DO
Motor overheats while Overload Reduce load.
running underloaded Frame or bracket vents may be Open vent holes and check for a continuous
GB
clogged with dirt and prevent proper stream of air from the motor.
ventilation of motor
Motor may have one phase open Check to make sure that all leads are well
connected.
Grounded coil Locate and repair.
Unbalanced terminal voltage Check for faulty leads, connections and
transformers.
Motor vibrates Motor misaligned Realign.
Weak support Strengthen base.
Coupling out of balance Balance coupling.
Driven equipment unbalanced Rebalance driven equipment.
Defective bearings Replace bearings.
Bearings not in line Line up properly.
Balancing weights shifted Rebalance motor.
Contradiction between balancing of Rebalance coupling or motor.
rotor and coupling (half key - full key)
Polyphase motor running single Check for open circuit.
phase
Excessive end play Adjust bearing or add shim.
Scraping noise Fan rubbing fan cover Remove interference.
Fan striking insulation Clear fan.
Motor loose on bedplate Tighten holding bolts.
Noisy operation Airgap not uniform Check and correct bracket fits or bearing.
Rotor unbalance Rebalance.
Hot bearings ball Bent or sprung shaft Straighten or replace shaft.
Excessive belt pull Decrease belt tension.
Pulleys too far away Move pulley closer to motor bearing.
Pulley diameter too small Use larger pulleys.
Misalignment Correct by realignment of drive.
Insufficient grease Maintain proper quality of grease in bearing.
Deterioration of grease or lubricant Remove old grease, wash bearings thoroughly
contaminated in kerosene and replace with new grease.
Excess lubricant Reduce quantity of grease, bearing should not
be more than 1/2 filled.
Overloaded bearing Check alignment, side and end thrust.
Broken ball or rough races Replace bearing, first clean housing thoroughly.
SSS
Figure 1. Connection diagram

Bild 1. Anschlußdiagram
Figure 1. Connection
Figura 1. Conexión
Figura 1. Collegamento
Figur 1. Anslutningdiagramm
Kuva 1. Kytkentäkaavio
Figure 2. Belt drive

Bild 2. Riementrieb
Figure 2. Glissières et entraînements à courroie
Figure 2. Carriles tensores y correas
Figura 2. Slitte tendicinghia e pulegge
Figur 2. Remdrift
Kuva 2. Hihnakäyttö
SSS
Figure 3. Mounting of half-coupling or pulley

Bild 3. Anbau von Kupplungshälften und Riemenscheiben
Figure 3. Montage des demi-accouplements et des poulies
Figura 3. Montaje de mitades de acoplamiento y poleas
Figura 3. Montaggio di semigiunti e pulegge
Figur 3. Montering av kopplinshalvor och drivskivor
Kuva 3. Kytkinpuolikkaan ja hihnapyörän asennus
SSS
Eaton Filtration, LLC Installation, Operation &
Service Manual
Model 72 Simplex
Basket Strainer
3/8” to 8” Sizes
Read all instructions before installation or

operation of equipment. Failure to comply
with these instructions could result in
bodily injury or property damage.
Table of Contents
Page No.
Introduction……………………………….. 1
Receiving, Handling & Inspection ……… 2
Installation ………………………………… 2
Operation …………………………………. 3
Shut-Down…….. …………………………. 3
Basket Removal/Replacement …………… 3
Basket Cleaning ……………………………. 4
Recommended Spare Parts ……………... 4
Exploded Parts Drawing ………………….. 4
Introduction
A simplex strainer is a device installed in a pipe-
line to remove dirt and other unwanted debris
from fluids. Straining is accomplished by direct-
ing the fluid through sized openings in a basket.
Simplex strainers are installed where fluid flow
can be interrupted while the basket is removed
for cleaning. Simplex strainers are designed to
withstand the rated pressure of the piping sys-
tem.
For additional information regarding Simplex Bas-

ket Strainers visit out website at:
www.filtration.eaton.com.com
SSS
Receiving, Handling, and Inspection Installation

Inspect strainer after unpacking for damage in- Position the strainer in the line so that the fluid
curred during transit. Report any damage to the enters the connection marked inlet.
carrier immediately. If the strainer is not to be
installed immediately, store indoors in a clean,
dry environment. CAUTION: Lift strainers with slings under the
inlet and outlet connections. DO NOT lift the
Remove preservative with solvent dampened strainer by the yoke screw located on the
cloth. Exercise care when using solvent. strainer cover.
Check to be sure the rated pressure and tem-

perature on the strainer nameplate is not less Be sure sufficient headroom is provided for easy
than the maximum pressure and temperature of removal of cover and basket.
the installation. The rated pressure shown on the
nameplate is the maximum pressure, including Support the strainer in the line as follows:
shock, at which the strainer may be operated.
4” size or under:
Remove cover by turning T-bolt counterclockwise Use pipe supports under the process piping near
to release yoke, swing yoke clear of cover and inlet and outlet connections. Use care to prevent
remove cover. Check for and remove any for- bending and expansion forces from acting on the
eign or loose materials that could be carried nozzles.
downstream when fluid is introduced into the
strainer. 6” size or larger:
Support on concrete or steel pads.
Replace strainer cover and yoke and tighten T-
bolt. The basket is held in place by pressure of Connect the strainer to the line. Use same type
the cover on the basket handle. If the basket is flange faces. For example: Do not bolt raised
loose, spring the handle to a higher position to face flanges to iron flat face flanges. Iron flanges
insure greater compression when the cover is must be flat face with full face gaskets.
seated.
SSS
Installation Cont. Operation

Cast strainers are subject to face-to-face varia- Open vent, if strainer is so equipped (See Fig. 2),
tions due to shrinkage and machining tolerances. to expel air from the strainer.
Prefabricated piping systems must allow adjust-
ment at the strainer connection. Slowly introduce fluid to be strained by opening
the outlet valve first, followed by opening the inlet
If strainer has threaded connections follow proper valve.
threaded specifications. If strainer has weld con-
nection follow proper ANSI weld specifications. CAUTION: Start system GRADUALLY. This
eliminates sudden shock to the strainer and
Be sure flange gaskets are in place and fasten- other equipment in the line.
ers are tight.
Close the vent when air is expelled and fluid be-
It is recommended that the drain plug be re- gins to flow.
moved and drain valve be installed at the bottom
of the basket chamber as shown in Fig. 1. Shut-Down
Tightly close valves on the inlet and outlet con-
CAUTION: A vent is required when fluids nections or the strainer.
other than water and with temperatures in ex-
cess of 120° F are to be handled by the Open vent (See Fig. 2) and/or drain valve (See
strainer. The vent must be piped to a safe Fig.1) to relieve liquid pressure in the strainer.
discharge point to protect the operator (see
Fig.2). Wear protective clothing which in- CAUTION: DO NOT loosen cover while
cludes gloves, vests, and goggles when han- there is liquid or air flow from the vent.
dling dangerous fluids.
Pressure gauges near the strainer inlet and outlet Basket Removal
are recommended. Cleaning frequency is deter- Follow shut-down procedure.
mined by the pressure drop across the strainer.
When pressure is relieved, loosen T-bolt. Drain
fluid through bottom drain to a level below the
basket seat.
Swing yoke clear of cover and remove cover and

dirty basket.
Basket Replacement
Place new or clean basket squarely on the bas-
ket seat. Be sure basket handle is sufficiently
high to be compressed by strainer cover.
Inspect O-ring and seal surface: clean seat or

replace cover O-ring as necessary. Always keep
spare O-rings in stock.
Replace cover, swing the yoke over the cover

and make full contact with the yoke stud.
Tighten the center T-bolt. If strainer is on suction
service, fill basket chamber from outside source
before installing cover.
Follow start-up procedure.

SSS
Basket Cleaning Shut –Down Periods

When to Clean During shut-down periods drain the fluid and
Clean basket when there is a 5 psi increase in clean the basket.
pressure loss across the strainer.
Recommended Spare Parts
CAUTION: To prevent damage to basket, DO 1 Eaton Replacement Basket
NOT permit strainer pressure differential be- 1 Eaton Replacement O-Ring
tween inlet and outlet connections to exceed
20 psi. When ordering spare parts specify all nameplate
data as well as the description and quantity of
How to Clean parts.
Invert basket and wash out debris by directing a
stream of air or water against the basket exterior. Always use genuine Eaton replacement parts for
Use solvent if strained fluid is fuel or a chemical. guaranteed fit and performance.
Follow manufacturer’s instruction when using a
solvent to clean the basket. Visit our web site, www.filtration.eaton.com for
information about the hundreds of different types
NOTE: Do not allow basket contents to dry as of Eaton Simplex Basket Strainers.
this will make cleaning most difficult.
Inspect basket at each cleaning for holes or tears

and replace as required.
SSS
USER’S GUIDE
80CF15
150
PSI
All information included in this publication is based on the latest information available at the
time of printing. Pentair reserves the right to make changes at any time without notice and
without incurring any obligation whatsoever. Photocopying of this publication by authorized
original equipment manufacturers who have purchased directly from Pentair, or by persons
using the materials for legitimate educational purposes, is approved by Pentair. Otherwise all
copyright protection afforded by the law applies.
SSS
PREFACE
The AquaLineTM Series
Family of Vessels
The AqualineT M is a standardized series of fiberglass pressure vessels designed for continuous, long-term use
as housings and provide the optimum fluid quality or cleanliness level required for the application at the lowest
overall operating cost in microfiltration.
The AqualineT M Series is designed for 150 psig pressure rating. They are unified in design and have maximum
number of parts in common. Each model has the appropriate strength and materials of construction to provide
years of continuous use in typical service when properly maintained.
The AqualineT M Series is designed and built in accordance with the Pentair standards and are Hydro tested as
per PED/97/23/EC standards,1.5 times the design pressure.
Aqualine Series model has passed rigorous qualification tests which require that the vessels do not burst at less
than six times their design pressure. Safe use is further assured in that vessels will not fail catastrophically;
overpressure is relieved by weeping through the fiberglass shell. Also, every production vessel is hydro-tested
to verify structural integrity.
AqualineT M system utilizes CodeLine T M FRP housing which can provide 50% reduction in Capital expenditure
over typical steel vessels. Further AqualineT M uses high efficiency media Polyflex ® with locked fibers to
deliver extended Element life.
While undertaking regular maintenance / repair / replacement of a pressure vessel it may be necessary to
remove the pressure vessel from a bank. Also ensure sufficient spares are available for replacement. Care must
be taken in installation / removal of the vessel to avoid damage to the shell. Damage to the shell can result in
catastrophic failure and possible injury to personnel. Any corrections or recommendation for improvement for
this manual should be addressed to:
SSS
CONTENTS
SECTION 1 OPERATION / MAINTENANCE GUIDE
• Introduction…………………………………… 3
• Safety Precautions…………………………… 4
• Pre-pressurization Checklist………………… 5
• Installation Notes…………………………….. 6
• Component Identification…………………….
80CF15 7
• Opening The Vessel…………………………. 8
• Replacing Elements…………………………. 10
• Closing The Vessel………………………….. 12
• Head Dis-Assembling & Assembling………. 15
• Preventive Maintenance…………………….. 21
• Trouble Shooting……………………………… 22
SECTION 2 INSTALLATION GUIDE
• Introduction…………………………………… . 24
• Handling, Receiving & Storage……………… 25
• Mounting Shell & Piping Connections……… 26
SECTION 3 APPLICATION GUIDE
• Introduction…………………………………… 28
• Suitability For intended Use………………… 28
• Elasticity And Mounting Requirements……. 29
• Corrosion……………………………………… 30
• Safety………………………………………….. 31
SSS
OPERATION AND MAINTENANCE GUIDE

INTRODUCTION
MODELS
80CF15
150
PSI
This section is a guide to proper operation and For technical specifications and dimensions,
maintenance of AqualineT M Series pressure refer to the Engineering Drawings of each
vessels. specific model.
Good industrial practice must be used in The information in all sections must be
applying this information to assure safe vessel carefully followed for the installation,
operation & maintenance of the vessel to
use. These guidelines are not intended to relieve provide safe, long service life for which it is
the user from full responsibility for correct designed.
operation and maintenance of the vessels.
DANGER – High Pressure Device
Incorrect Installation, Operation & maintenance Misuse, incorrect assembly or use of

of these vessels may cause loss of life, severe damaged or corroded components can
bodily harm, and / or property damage. Read result in explosive release of the end
and understand all guidelines given in this closure.
bulletin before attempting to open, service or We recommend that only a qualified
operate these vessels. technician experienced in servicing high-
Failure to follow these guidelines and observe pressure hydraulic systems, open, close and
every precaution may result in malfunction and service these vessels.
could result in catastrophic failure.
SSS
SAFETY PRECAUTIONS
DO
• Read, understand and follow every part of this section. Failure to take every precaution may void
warranty and could result in explosive head failure.
• Install in an area where water leakage resulting from a vessel or piping malfunction would not damage
sensitive equipment, such as electronic components.
• Installprotective covering over equipment located below pressure vessels when performing
maintenance.
• Verify that head locking components are properly placed and secured.
• Inspect end closures regularly, replace deteriorated components and correct causes of corrosion.
• Followcatridge/element recommendations for loading element into vessel (see Replacing Elements
on page no. 13).
• Mount the shell on horizontal members at Span “S” using compliant vessel supports furnished; tighten
hold down straps just snug
• Refer the Do’s List mentioned on the 2nd page of the Vessel Sales Drawing to ensure safe operation
and long life of the vessel.
DO NOT
• Operate vessel at pressures in excess of their specific rating.
• Service any component until you verify that pressure if fully relieved from the vessel.
• Use corroded components. Use of such components may result in catastrophic failure.
• Pressurize vessel until after visually inspecting to ensure that both locking segments are correctly
installed and seated in their grooves.
• Tolerate leaks or allow end closures to be wetted in any way.
• Allow petroleum or silicone based products to come in contact with catridge/elements during
installation or maintenance.
• Pressurize vessel without element in place, unless permeate ports are plugged properly.
• Over-tighten fittings in ports.
• Stand or climb on the pressure vessels or the feed / concentrate or permeate ports.
• Allow force in excess of 15 lbs to be applied laterally to feed/concentrate or permeate ports.
• Refer the Do Not List mentioned on the 2 nd page of the Vessel Sales Drawing to ensure safe operation
and long life of the vessel.
4
SSS
PRE-PRESSURIZATION CHECKLIST
DANGER – High Pressure Device
Incorrect Installation, Operation & maintenance Misuse, incorrect assembly or use of

of these vessels may cause loss of life, severe damaged or corroded components can
bodily harm, and / or property damage. Read result in explosive release of the end
and understand all guidelines given in this closure.
bulletin before attempting to open, service or We recommend that only a qualified
technician experienced in servicing high-
operate these vessels.
pressure hydraulic systems, open, close and
Failure to follow these guidelines and observe
service these vessels.
every precaution may result in malfunction and
could result in catastrophic failure.
This checklist is an aid intended to remind servicing and operating personnel of the detailed guidelines
given in the AquaLine TM series operation and maintenance guide. The checklist alone does not include
all the details needed for safe vessel operation. Use the checklist each time any service operation is
carried out to ensure that each step is completed before pressurizing the vessel.
CATRIDGE/ ELEMENTS HEAD
Installed as per recommendation on All components in as-new condition
pg13. clean and free of damage or corrosion.
Feed flow direction correctly noted and All components are properly assembled
elements correctly oriented. with new, freshly lubricated seals.
Product port locking ring/nut installed.
HEAD ASSEMBLY INTERLOCK
Retaining Ring groove at each end of Head marked with proper pressure
the shell is clean, free of corrosion and / rating for system.
or delamination with outboard face of
groove true and is in sound condition. Heads and cartridge/ element are installed in the
correct position in the vessel as specified in the
All components in as-new condition
General Arrangement Drawing of Aqualine vessel
clean and free of damage or corrosion.
PIPING CONNECTIONS
Retaining Ring is fully seated in the
vessel Retaining Ring groove. Properly aligned (strain free) and secured.
Leak free.
Assembled by:__________________________ Date of Assembly:_________________________

Checked by:____________________________ Date of Inspection:_________________________
The following vessels listed by serial number below were serviced under this checklist:
_____________ _____________ _____________ _____________ ____________
_____________ _____________ _____________ _____________ ____________
SSS
INSTALLATION NOTES
Even though your vessel may be installed by others, there are few installation checks that you
should make before system start-up. Vessels must be installed correctly to ensure safe use and
long service life.
Check that vessels are mounted on horizontal support frame using compatible
black urethane saddles with hold-down straps that are snug & not tight.
Check that each vessel is free to expand under pressure, shell is not rigidly
clamped in place, and piping to vessel is not connected using rigid connections.
WARNING
FAILURE TO ALLOW EXPANSION

IN DIAMETER OR LENGTH WILL
RESULT IN VESSEL DAMAGE.
Check that vessel does not support any other component; that piping manifolds
are separately mounted, and that interconnection piping is self supported and
connected to the pressure vessel with IPS grooved couplings.
If you have any question about the installation of vessel in your unit, contact your supplier.
For installation guidelines, refer to page no. 28-30.
Models 80CF15
Max Operating Pressure (PSI)
150
Operating Temp. Range
20 – 120
(degree F)
Factory Test Pressure (PSI) CE 225
(1.5X)
Prototype Min. Qualification
900
Pressure (PSI)
Engineering Drawing No.
100160
DWG PART
QTY DESCRIPTION MATERIAL
REF NUMBER
SHELL
Filament Wound Epoxy/Glass
1 1 17200 SHELL composites - Head locking grooves
integrally wound in place.
2 1 96327 3" Feed Port CD3MWCuN
3 1 96119 3" Port Seal Ethylene Propylene
4 1 17101 1" FNPT Port Zeron -100/CD3MWCuN
5 1 45340 1" Port Seal Ethylene Propylene
HEAD
6061-T6 Aluminum alloy - Hard
6 1 17102 Bearing Plate Upstream
anodized
7 1 96160 Sealing Plate Upstream Engineering Thermoplastic.
6061-T6 Aluminum alloy - Hard
8 1 17103 Bearing Plate Downstream
anodized
9 1 17126 Sealing Plate Downstream Engineering Thermoplastic.
10 1 17100 3" Product Port CD3MWCuN
11 1 17127 3" Port Retainer Ring 316 Stainless Steel
12 2 96000 Head Seal Ethylene Propylene - O - Ring
13 1 17128 Product Port Seal Ethylene Propylene - O - Ring
14 1 17104 Handle Assembly 316 Stainless Steel
15 1 45247 Plug Retainer Ring 316L Stainless Steel
16 1 17132 Plug Upstream Engineering Thermoplastic.
17 1 45312 Upstream plug seal Ethylene Propylene - O - Ring
HEAD INTERLOCK
18 2 96355 Quik Release Spiral Ring 316 Stainless Steel
VESSEL SUPPORT
19# 2 52169 Saddle Engineering Thermoplastic.
20# 2 45042 Strap Assy. 304 Stainless Steel-PVC Cushion
21# 4 46265 Strap screw. 5/16-18 UNC, 18-8 Stainless Steel.
# Marked Components not shown
COMPONENT IDENTIFICATION
SSS
OPENING THE VESSEL
STEP-BY-STEP GUIDE
Step 1. Relieve Pressure Step 4. Removing Head Retaining Ring
1. Shut off all sources of pressure and relieve 1. No special tools are required for this
pressure from the vessel, following the operation. Engage your fore finger in the
system manufacturer’s recommendations. end tab of the retaining ring, lift it up and
Step 2. Disconnect Piping out of the stainless steel groove in the
shell.
1. Disconnect piping as required at nearest
convenient joint, being careful not to place
undue stress on the Feed Concentrate Port
Caution: DO NOT tap on fittings as this could
damage the ports.
Step 3. Examine End Enclosure
1. Examine enclosure of vessel for corrosion.
Metal oxidation products and mineral deposits
can interfere with vessel disassembly. If any
is evident, proceed as follows:
a) Loosen any deposits with a small wire brush
Lifting end of retaining ring out of groove
and / or a medium grade piece of
ScotchBriteTM.
2. Remove the retaining ring from the
b) Flush away loosened deposits with clean stainless steel groove in the shell. This is
water. accomplished by running your fingers
behind the retaining ring as it continues
to exit the groove.
Loosening deposits Removing the retaining ring from the groove

SSS
T
OPENING THE VESSEL
Step 5. Removing Head Assembly

B. Removing head assembly on Tail End
A. Removing head assembly on the FEED (opposite end of the label) of the vessel
end of the vessel (On the end where the label
is placed). 1. Using a mallet tap the Bearing Plate
lightly. Do not use a metal component to
1. Hold the handle of the Head and provide a tap the bearing plate.
slight jerk/rock the Head assembly back
and forth to release the seal. 2. Hold the F/C port with your hand
2. Once the Head is freed, pull the head 3. Carefully rock the head assembly back
assembly out using the Handle. and forth to release the seal. (Care
should be taken to avoid placing too
much stress on the product port)
4. Once the head seal is broken, pull

straight outward to remove the head
assembly from the vessel.
Opposite end of the vessel.

LABEL WARNING
Removing Head Assembly Read all guidelines in this section

before attempting to open the vessel.
Do not attempt to service any
NOTE component without first verifying that
vessel PRESSURE is fully relieved
It may be necessary to rock the
head slightly and / or tap the head from the vessel. Attempting to remove
inboard to break head seal bond. any component before pressure is
relieved may result in EXPLOSIVE
release of the head.
SSS
REPLACING ELEMENTS
IMPORTANT
Read all parts of this section before replacing cartridge. These procedures are provided for
general information only. Cartridge/Element should be installed in accordance with the
cartridge/element loading recommendation.
Always remove and install cartridge using the handle attached to the membrane.
A record of cartridge/element serial numbers and locations should be made and checked during
loading.
Do not scratch or damage vessel bore when removing or installing elements.
AquaLine elements are disposable Cartridges. Elements need to be replaced once it reaches the
terminal ?p of 2.5 bars. The Operation philosophy of this element is: Outside –in Flow direction.
Preliminary Steps
Do not proceed with step by step instructions until…
5. All pressure has been relieved from the
vessel, following system manufacturer’s
recommendations.
6. Both heads have been removed from vessel
following step by step instructions in the
“Opening the Vessel” section.
Step 1. Element Removal
1. Remove element from the vessel. Clean off
any excess lubricant from vessel inside
diameter before removing elements. 3. Examine cartridge/ element surfaces for
Step 2. Element Loading any imperfection which could scratch the
vessel bore. Pay particular attention to
1. Examine the inside diameter of the vessel for
edges of anti-telescope device
scratches or imperfections that may affect sealing
(ATD/brine seal carrier).
capability of head or element seals. Corrosion
deposits or other foreign matter, including any NOTE:
excess lubricant, should be removed as Ø AquaLine elements are disposable Cartridges.
described in Section – Closing the Vessel. Elements need to be replaced once it reaches the
2. Flush out the vessel with clean water to remove terminal ?p of 2.5 bar. The Operation philosophy
any dust and debris. of this element is: Outside –in Flow direction.
Ø Using an approximate 50% mixture of glycerin in
water lubricates the inside of the vessel and can
be best accomplished using a suitably sized
swab soaked in the mixture. This procedure will
ease cartridge/element loading and reduce
chance of scratching the vessel bore.
10
SSS
OPENING THE VESSEL
Step 5. Removing Head Assembly

B. Removing head assembly on Tail End
A. Removing head assembly on the FEED (opposite end of the label) of the vessel
end of the vessel (On the end where the label
is placed). 1. Using a mallet tap the Bearing Plate
lightly. Do not use a metal component to
1. Hold the handle of the Head and provide a tap the bearing plate.
slight jerk/rock the Head assembly back
and forth to release the seal. 2. Hold the F/C port with your hand
2. Once the Head is freed, pull the head 3. Carefully rock the head assembly back
assembly out using the Handle. and forth to release the seal. (Care
should be taken to avoid placing too
much stress on the product port)
4. Once the head seal is broken, pull

straight outward to remove the head
assembly from the vessel.
Opposite end of the vessel.

LABEL WARNING
Removing Head Assembly Read all guidelines in this section

before attempting to open the vessel.
Do not attempt to service any
NOTE component without first verifying that
vessel PRESSURE is fully relieved
It may be necessary to rock the
head slightly and / or tap the head from the vessel. Attempting to remove
inboard to break head seal bond. any component before pressure is
relieved may result in EXPLOSIVE
release of the head.
SSS
CLOSING THE VESSEL

WARNING
Read all guidelines in this section before attempting to close the vessel.
CHECK THE HEAD ASSEMBLY FOR CORROSION AS DESCRIBED IN THE HEAD REBUILDING
SECTION. CORRODED PARTS CAN RESULT IN CATASTROPHIC FAILURE.
Do not pressurize vessel until after visual inspection to ensure that retaining ring is fully seated.
Never attempt to repair a fiberglass shell.
Preliminary Steps Using a medium or finer grade of

Do not proceed until… ScotchBriteTM and a mild soap solution,
1. Elements / cartridges have been installed clean each end of the vessel inner
in the vessel following guidelines in surface upto 8” from each end of the
“Replacing the Elements” section. vessel.
2. Head has been checked for correct Rinse away all loosened deposits from
component assembly by following step-by- the shell inside surface using clean fresh
step instructions in the Head Rebuilding water.
section.
2. Inspect the vessel inside surface for
scratches or other damage that could
cause leaks. Vessels that leak must be
replaced.
Step 1. Inspect Shell Inside Surface
1. Inspect the vessel inside surface for any 3. Inspect Feed/Concentrate port seals
corrosion deposits or other foreign matter. If and attachments for internal and
any are found, clean the surface as follows: external damage or deterioration.
Step 2. Shell & Head Lubrication
1. Work O-ring lubricant into shell area
behind the retaining ring groove and
approximately ½” into the vessel I.D.
2. Ensure entire head seal is covered with
a thin layer of O-ring lubricant, with no
dirt or dust contamination.
WARNING
Any remaining lubricant should be
cleaned from the vessel bore before
applying fresh lubricant. Glycerine is a
commercially available lubricant that
will not foul membranes.
Cleaning inside the vessel
*Contact Pentair Water for guidance if damage to the vessel’s internal surface or Feed/Concentrate port, seals or
attachments are discovered during inspection.
12
SSS
CLOSING THE VESSEL

Step 3. Installing Head and Cartridge
1. Slide the cartridge into the vessel until the feed

end of the cartridge is partially exposed.
2. Hold the head assembly square to the axis of

the shell by grasping the product port. Fix the
head on the cartridge and slide the cartridge
along with the head into the vessel
3. Grasp tightly and push the head in as far as it

will go. (A sharp, forceful thrust or may be light
tapping with a mallet may be necessary to
enter the head into the vessel bore). When the
head is correctly positioned, the locking
groove will be exposed. Step 4. Install Head Interlock
4. Once the downstream head is fixed into 1. Carefully wipe out any debris or
position fix the upstream head into position moisture from the head Retaining
ring groove. The groove must be
clear and dry before proceeding.
2. With the head assembly installed in

the shell, place the tip of the head
Retaining ring in the stainless steel
groove. (The non bent tab end).
3. Begin pushing the retaining ring into

the groove as you rotate your hand
around the I.D. of the shell.
4. Continue until the entire retaining ring is

installed in the groove.
5. Verify that the retaining ring is fully seated

in the groove before proceeding.
CAUTION
Incorrect assembly or installation
can result in EXPLOSIVE HEAD
failure.
SSS
CLOSING THE VESSEL
CAUTION
DO NOT PRESSURIZE THE VESSEL WITHOUT ELEMENTS INSTALLED.

Do not pressurize vessel until verifying that the Head Retaining Ring is properly installed.
Fixing the Retaining Ring into the Groove
CARTRIDGE ELEMENT
Verify that…
1. Elements are installed in the vessel as
per the recommendation specified on the
page 13.
PIPING CONNECTIONS
1. Check all piping connections to ensure
that they will provide a leak-free seal.
Step 7. Pressurization
1. After following the above pre-
Step 5. Reconnect Piping pressurization checks, pressurize vessel
in accordance with element
1. Reconnect manifold piping to the vessel Feed manufacturer’s specifications.
Concentrate port and Product piping manifold to the
2. Vessels should be filled slowly to assist
Product Port via IPS grooved Coupling.
trapped air in escaping.
Step 6. PRE_PRESSURIZATION CHECKS 3. Vessels should be pressurized slowly to
avoid damage to cartridge/ element and
It is vitally important that the following checks be carried vessel component.
out before any attempt is made to pressurize the vessel.
It is recommended that the Pre-Pressurization Checklist
(Page-05) be used to systematically verify that all steps
have been performed.
HEAD ASSEMBLY
Verify the following at each end of the vessel:
1. Head assembly is in good condition, with no evidence
of damage or corrosion. See the sections on Head
Rebuilding and Maintenance.
2. Head retaining Ring is properly placed.
SSS
HEAD – DISMANTLING & ASSEMBLING
NOTE
Read all guidelines in this section before attempting to rebuild the head.
Head rebuilding should be performed in a clean work area. Dust or dirt on O-rings or other parts can
scratch inner surfaces and cause subsequent leakage.
Replace any components not in “as -new” condition. Re-using corroded or damaged components can
result in explosive head failure.
Single Piece Engineering Thermoplastic Head

(80S15 / 30 / 45 / 60 Non-Coded)
Upstream Head Assembly components NOTE

A small screw driver or similar tool may be used to
Preliminary Steps remove the O-rings. However, do not damage the
Do not proceed until… sealing surfaces in any way or leakage may result.
1. All pressure has been relieved from the It is recommended that all seals be replaced each
vessel, following system manufacturer’s time the head is assembled.
recommendations.
2. Head has been removed from the vessel
following guidelines in “Opening the
Vessel” section.
To dis-assemble head
Upstream End Head Assembly
Step1. Remove Head seal from the head.
Step2.Remove the screw holding the handle
one at a time
Step3. Remove the retainer ring using Circlip
Plier
SSS

Step 4. Removing Bearing Plate
1. Remove bearing plate by pulling the Downstream End Head Assembly
bearing plate from Sealing Plate
Step 5. Removing Sealing Plate Step1. Remove Head seal from the head.
Step 6. Removing Seal from Sealing Plate

Using a sharp object i.e. Screw Driver the
seal can be plucked out from the sealing Step2.Remove the 3” Port Retainer Ring
plate groove
SSS
Step 3. Remove Bearing Plate Component Cleaning and examination

Step 1. Wash Components
1. Wash all components in fresh water.
2. Blow components dry with compressed
air, if available. Otherwise wipe dry with
a dry, lint-free cloth.
Step 2 Initial Component Inspections
2. Examine all components for any
damage that could affect structural
strength or sealing properties.
3. Replace any parts considered to be
structurally unacceptable.
Step 4. Remove Sealing Plate
The following example indicates when
replacement is required.
A. Product Port is corroded or damaged
B. Bearing Plate dented or distorted
(possibly from being dropped or hit).
C. Retaining Ring bent or damaged.
Any other details considered to be a
potential problem should be referred to
Pentair Water. If any component is cracked,
softened or discolored, it may indicate a
chemical resistance problem. These
components must be replaced. Alternate
Step 5. Remove Product Port Seal materials may be required in these
applications. Contact Pentair Water for a
solution.
CAUTION
Feed and Concentrate ports and attachments
to the shell must be carefully inspected to
ensure that connections and sealing
materials are sound and tight. Any questions
or evidence of deterioration of these areas
should be referred to Pentair Water
Engineers.
CAUTION Other than seal replacement, field repair

Removing the Head Seal should not be attempted by user maintenance
personnel without first contacting the
manufacturer for guidance.
SSS

Read all guidelines in this section before making any decisions on components structure or corrosion
problems and treatment.
Stepwith
This section is intended only to provide guidelines in dealing 4. corrosion
REMOVING DEPOSITS
or component FROM
damage. In
Engineering
combination with good industrial practice, these guidelines Thermoplastic
provide a basis for
CAUTION safe Components
system operation.
Any condition not covered in this section should be referred to Pentair Water.
Step 3: This procedure applies to the following Step4. Evaluating Corroded Metal Components
components: This procedure applies to the following parts:
A. Sealing Plate A. Bearing Plate
B. Plug Upstream Head Assy B. Retaining Ring
C. Product Port
1. Examine all plastic components for mineral 1. Examine these components for corrosion. For
deposits or other foreign matter. If any are any components not in “as-new” condition,
found, proceed as follows: proceed as follows:
A. Place components in a shallow container A. Loosen any large deposits with small wire
of soapy water and scrub entire surface brush.
with medium grade ScotchBriteTM until all
foreign matter is removed. B. Place components in shallow container of
soapy water and scrub entire surface with
B. Rinse components clean with fresh water.
medium grade ScotchBriteTM until all corrosion
C. Blow components dry with compressed air, is removed.
if available.
C. Rinse components clean with fresh water.
D. Re-examine components for any damage
that could affect structural strength or D. Blow components dry with compressed air, if
sealing properties. Any components not in available.
“as-new” condition must be replaced. E. Re-examine components for damage that could
affect structural strength or sealing properties.
Any components not in “as-new” condition
must be replaced.
CAUTION F. Inspect components for any condition that
The following procedure should be used on all might have promoted corrosion, (e.g. external
Engineering Thermoplastic Components damage, inappropriate material selection, etc.)
contaminated by minerals or other foreign
matter. If any component cannot be brought to
“as-new” standards, it must be replaced. CAUTION
This procedure for evaluating corroded
components is to be used on any
corroded metal parts. If this fails to bring
any component to “as-new” standards,
the part must be replaced.
SSS

To Re-Assemble Head
Assembling Downstream Head assembly
STEP1: Placing of seal on the
WARNING
Head must be carefully assembled
following these instructions. Incorrect
assembly can result in CATASTROPHIC
failure.
Step 1. Lubricate Seals
STEP2: Placing of sealing Plate
Lubricating Head Seals & O-rings
1. Lubricate Product Port seal / Plug Seal.

2. Lubricate and Install Head Seal on the
outer groove of the sealing plate. STEP3: Placing of Bearing Plate
CAUTION
It is recommended that all seal be
replaced each time the head is
assembled. A seal replacement kit is
available from Pentair Water.
Lubricate seals sparingly, using non-
petroleum based lubricants, i.e. Parker
Super O-lube®, Glycerine or suitable
silicone based lubricants. (Silicone
based lubricants, correctly used, will
ease head assembly and disassembly).
(Glycerine is a commercially available
lubricant that will not foul cartridge).
SSS
STEP4: Placing of Product Port Retaining Ring Assembling Upstream Head assembly
STEP1: Installing Seal into the groove of Sealing Plate
Step5: Installing Head Seal

STEP2: Installing Sealing Plate & Plug Upstream
STEP3: Installing Bearing Plate
WARNING
The sealing plate must sit flush against the
bearing plate. If any gap is evident, the
components have not been assembled
correctly.
Incorrect assembly can result in
CATASTROPHIC failure.
SSS

STEP4: Installing Handle STEP5: Installing Head Seal
PREVENTIVE MAINTENANCE
Corrosion prevention is essential for the maintenance of safe operating conditions and to ease
cartridge/ element servicing.
Attention to the points listed below will enhance long-term safe operation and will ease servicing.
For suggestions on cleaning corrosion deposits from the vessel inside surface, refer to “Closing
the Vessel” section.
For suggestions on cleaning corrosion deposits from head components, refer to the “Head - Dis-
assembling & Assembling” section.
PREVENTIVE CHECKLIST
End closures. Inspect for components that may have deteriorated. Replace
as needed.
Keep external head assembly components as dry as possible.
Do not tolerate leaks.
CAUTION
Any leakage indicates a potentially
dangerous condition. Failure to eliminate
leakage may void the warranty and could
result in vessel failure.
SSS
TROUBLE SHOOTING
This section is intended only to provide guidelines for dealing with problems that might arise
while working with AquaLine TM Series pressure vessels.
These guidelines are not in any way a replacement for the good industrial practice required to
ensure safe operation. We recommend that only a qualified engineer, experienced in servicing
high pressure hydraulic systems, carry out the following tasks.
Preliminary Inspection Head Retaining Ring

Inspect the vessel at each end for corrosion 1. Will not release from the Retaining Ring
which may interfere with head assembly Groove.
removal. If corrosion is evident, proceed as A. Apply penetrating fluid (such as WD-40 or
follows: LPS-1) to interfacing areas of retaining
1. Loosen any deposits with a small wire ring.
brush and/or a medium grade piece of B. With a screwdriver handle or similar tool,
ScotchBriteTM. tap the retaining ring to release the
bond.
C. Again attempt to remove the retaining
ring.
Loosening Deposits
WARNING
Do not use a wire brush on components made
from Engineering Thermoplastic.
2. Flush away loosened deposits with clean Applying penetrating fluid

water.
3. Proceed with instructions given in
“Opening the Vessel” section.
Difficulty in Opening Vessel
NOTE CAUTION
Recommendations listed here are intended When applying penetrating fluid, be careful
only as a guide. If the head assembly is still to avoid element contamination.
difficult to remove after all
recommendations have been followed, call
Pentair Water for technical assistance.
2
SSS
TROUBLE SHOOTING
Head Assembly
4. Feed/Concentrate Port Leak
1. Will not release from shell when pulled.
Refer the “Opening the Vessel” section
IMPORTANT
NOTE Please contact Pentair Water if any
If the head assembly will not release from Feed/Concentrate leaks are observed.
the shell after all recommendations have
been followed, call Pentair Water for
technical assistance. Sudden Drop in Product quality
If a system is started and stopped frequently and no

SEAL LEAKAGE
provision is made to raise the pressure slowly,
2. Head Seal Leak movement of the membrane column may damage
A. Carefully inspect the seal gland area in O-ring seals and reduce Product quality.
the shell and clean any contaminants
If the quality of the product suddenly drops, and
from the gland.
poor membrane performance is not suspected,
B. Clean the seal area on the head and re- remove the heads per instructions in the Users
lubricate. Guide (See “OPENING THE VESSEL”). Inspect
C. Install a new head seal that has been these O-ring seals carefully for breakage or other
properly lubricated. damage. If the seals have rolled out of the groove,
or are damaged, this may indicate excessive
3. Seal Plate Seal Leak movement during start-up and shutdown which may
A. Dismantle the Head by referring the be due to improper seating of the cartridge in the
“DISMANTLING & ASSEMBLING” vessel.
section. Open the Vessel and re-seat the membrane (refer
B. The seal is seated in the sealing plate. opening and closing of the vessel for details).
Run your fingers around the seal and
check for any seal damage. If the seal is
damaged replace the seal.
C. Check for any damage/scratches on the
sealing area. Replace the sealing plate if
found damaged.
SSS
INSTALLATION GUIDE
Introduction
The AquaLine TM Series fiberglass cartridge housing is designed for continuous long term use as
a housing for micro-filtration elements in typical water treatment systems at operating pressures
of 150 PSI.
The AquaLine TM Series is designed to accommodate any make of 8-inch nominal diameter
cartridge element.
Improper assembly, misuse, rigid clamping, impact, scratches, abrasion or corrosion can result
in mechanical failure, property damage and serious injury or death.
The information and guidelines incorporated in this User’s Guide are intended only as
supplement to good industrial practice. Full responsibility for correct operation and maintenance
of vessel remains with the user.
This guide should be used in conjunction with engineering drawings.
When properly installed and maintained, the AquaLineTM Series vessels can be expected to
provide safe operation over a long service life.
Should any information in this guide not agree with the system supplier’s instructions, call Pentair
Water for clarification.
Regardless of when and by whom your vessel may have been installed, there are a few
quick checks you should make before use. Check that each vessel is:
Ø Mounted with compliant material (Polyurethane Saddle) between the fiberglass shell and
any rigid frame.
Ø Free to expand under pressure – shell not clamped rigidly in place, no rigid piping
connection to port fittings.
Ø Not used in any way to support other vessels / objects.
SSS
HANDLING, RECEIVING AND STORAGE
Fiberglass reinforced plastic (FRP) Pressure vessels are extremely rugged and durable. They
are designed for safe, long-term service when they are handled and installed properly. However,
damage to the vessel shell or related components from improper handling or installation could
result in malfunction or explosive head failure while in service. Therefore exercise the following
precautions whenever handling vessel.
1. Never lift or move a vessel by placing anything inside it. The vessel is durable and ideally
suited to its purpose, but careless handling can permanently damage it.
2. Be careful not to scratch the inside wall of the shell, especially in the sealing area inboard of
locking segment groove near the end.
3. Do not drop vessel or allow it to hit hard on the ground or against other objects.
4. Do not apply undue stress to shell.
5. Before using a forklift to handle the vessel, pad the forks to lessen the chance of damaging
the shell. Severe scratches or gouging of the vessel can result in failure of the vessel wall.
NOTE ON IMPACT DAMAGE

Exterior vessel damage can lead to early vessel failure. Damage received in shipment should be
reported to the shipping company immediately upon receipt minor damage such as scratches
that go no deeper than the paint may be acceptable. Call the Pentair Water customer service
department for advice if in doubt.
STORAGE
Pentair Water recommends storing the vessel in the received packing or in a secure place.
Vessel should not be stored in such a manner that they will roll over and get damaged.
SSS
MOUNTING SHELL & PIPING CONNECTION
NOTE
If mounting vessel for the first time, see “piping
TM
recommendations for AquaLine ”,
This section is concerned with the mounting of AquaLine TM Models 80CF15 pressure vessels.
These guidelines must be integrated with any additional procedure required for your specific
installation.
Installation Guidelines
1. Provide adequate room for servicing at both ends of vessel. Elements are installed from the
upstream end (feed), pushed through towards the downstream end (concentrate) and,
eventually, removed from the downstream end.
2. Follow all applicable Handling Guidelines.
3. Position each vessel on its mounting frame such that it is centered between headers.
NOTE
It is important that each vessel be placed to minimize any
strain on piping / tubing that connects a vessel to a header.
Normally each vessel should be centered in the frame with
the feed and concentrate ports positioned such that piping /
tubing connections can be made easily, without undue
strain at each end of the vessel.
4. Mount vessels on urethane saddles (provided with the vessel) positioned in line with pre-
drilled frame holes for two supports as per the Span length specified in the GA drawing. Holes
for the mounting straps should be drilled at approximate center span ‘S’.
WARNING
DO NOT MOUNT VESSEL RIGIDLY. RESTRICTED
EXPANSION CAN RESULT IN DAMAGE TO THE VESSEL.
SEE ELASTICITY AND MOUNTING REQUIREMENTS IN THE
APPLICATION SECTION FOR FURTHER DETAILS.
SSS
S alt S eparation S ervices REV : 01
MOUNTING SHELL & PIPING CONNECTION
5. Place mounting straps over vessel with plastic strip against vessel.
6. Position screw through the frame mounting holes into strap nuts and run up to the frame
finger tight.
7. Connect vessel feed piping (See Piping Recommendations for more info)
8. Using a wrench, tighten mounting bolts one additional full turn. This should result in 25-50 lbs-
in. of torque.
CAUTION
To avoid damage to vessel shell DO NOT over-tighten
mounting nuts.
WARNING
TM
CodeLine straps are designed to secure the vessels
during operation. They are not designed to handle all loads
that might occur during shipment. Appropriate vessel
restraint should be employed considering such factors as
the mode of shipment, distance to be traveled and design of
the system.
The vessels and frame should be blocked to prevent any
differential movement which could be caused by the forces
experienced during shipment.
PIPING CONNECTIONS
The following are suggested guidelines to ensure that the vessel is allowed to expand and is
easily serviced:
1. Support the header and interconnecting piping in a manner that they are self-supporting.
2. Connecting piping alignment to feed and product ports should not exceed 0.030 inch (0.762
mm) misalignment.
3. Piping connections to the vessel’s feed and Product ports should be via flexible IPS grooved
Coupling.
SSS
APPLICATION GUIDE
Introduction
This Application Guide, together with the Installation Guide and the Operation and Maintenance
Guide, outlines the general conditions for safe use of AquaLine TM pressure vessels. Because of
the considerable risk inherent in high pressure vessels, it is the purchaser’s responsibility to
carefully evaluate each specified application to ensure that the AquaLine TM vessel selected is
appropriate to that application.
Pentair Water will assist the purchaser in determining the suitability of the standard vessel for
their specific operating conditions. For non-standard applications, alternate materials are
available on special order. The final determination, however, including evaluation of the standard
materials of construction for compatibility with the specific environment, is the responsibility of
the purchaser.
SUITABILITY FOR INTENDED USE
AquaLine TM Series cartridge housings are designed for continuous long-term use as housings for
micro-filtration cartridge elements. Models are available for 150 psi. Any make of eight-inch
nominal diameter spiral wound element is easily accommodated.
In a high pressure system there is considerable potential for catastrophic failure, which could
result in serious injury or loss of life. All decisions as to suitability for use must include full
consideration of the various safety aspects involved. These include, but are not limited to:
Process fluid compatibility (e.g. chemical and temperature consideration).
External environmental factors (e.g. corrosive atmosphere, remote or special environment
where certain material might be undesirable, etc.).
Abnormal back pressure which might result in pressurizing permeate port above the rated
pressure (alternate materials are available).
Capability of the user to maintain vessel properly.
Requirement for increased fire resistance in some circumstances.
Use of AquaLine TM pressure vessel for other than its intended application will void the warranty.
SSS
ELASTICITY AND MOUNTING REQUIREMENTS
Mounting design must allow for vessel expansion, both axially and radially. Although the
expansion under pressure is slight, undue restriction can result in damage to the vessel and to
other system components. Typically the vessel, would expand approximately 0.20 inch (6 mm) in
length and 0.015 inch (0.4 mm) in diameter. The following suggestions will help to ensure the
vessel is allowed to expand and will ease servicing.
1. Mount the vessel on the urethane support pads furnished. Do not mount directly to any rigid
structure.
2. Use the stainless steel straps furnished. Straps should be tightened sufficiently to hold the
vessel on the urethane support pads, but not so tightly so as to restrict expansion. (A torque
of 25-50 lbs-in. is sufficient.)
3. U-bolts should not be used for vessel mounting under any circumstances.
4. Provide flexible piping connection to permit de-coupling the header from the vessel.
Recommended Feed and Product connections are via flexible IPS grooved coupling.
5. Do not hard plumb any piping connections to the vessel.
6. Support the header independently. Piping should be self-supporting or supported by the
headers.
7. Include an expansion loop in the branch connection to allow for:
A. Elastic growth under pressure.
B. Thermal growth in vessel length.
8. The total weight of branch connection and fittings supported by the vessel should not exceed
8 lbs for either the Feed / Product port for AquaLine TM 80CF15 model vessels.
The above suggestions are intended to help prevent damage in typical applications. Unusual or
special applications may involve other considerations to be determined by the system designer.
SSS
CORROSION
Considerations relating to corrosion are an important factor in vessel application. Corrosion can
result in catastrophic failure and / or cause difficulty in removing head components from the
shell. Correct component material selection is essential for safe long-term use. Although the
process fluid is the main consideration, external environment conditions should also be taken
into account.
All reasonable precautions should be taken to protect head assemblies from external wetting,
particularly in corrosive atmospheres (e.g. salt-water areas or acid atmosphere such as near
lead acid battery arrays, etc.) Leaks from vessel or nearby components, which allow head parts
to be routinely wetted, should not be tolerated.
The following typical list of AquaLine TM model 80CF15 pressure vessel components indicating
the standard material of construction of each part is listed General Arrangement Drawing. An
evaluation of the possibility of corrosion damage to the metal head interlock components is of
critical importance. Alternate materials are available upon requests.
SSS
SAFETY
CAUTION
Pressure vessel may cause loss of life, severe bodily
harm or property damage if not correctly installed, operated
and maintained.
Safety in service of fiberglass vessel depends on proper application, installation, operation and
maintenance. This section is intended to provide guidance towards safe system design. The
safety information given in the installation and operation and maintenance section should also be
studied and used appropriately in conjunction with the precautions listed below.
Design Considerations for Safety
Fluid Compatibly
The materials of construction selected must be compatible with the process fluid and with
proposed preserving and cleaning fluids. Standard materials are listed on the engineering
drawings. In case where the standard materials are unacceptable, suitable alternative may be
available.
Pressure and Temperature design limits
Operation of a vessel outside its design limits will void the warranty and would result in vessel
fatigue with possible eventual catastrophic failure. Although each AquaLineTM 80CF15 model
vessel is tested as per Pentair/CE specifications, long term operation above the designed
pressure must be prevented. For product port pressure rating and maximum operating
temperature, refer respective sales drawings.
Over pressure protection
It is essential that over pressure protection be provided such that the pressure to which any
vessel is subjected cannot exceed 105% of design pressure.
Mounting
The pressure vessel should not be used as a support. Piping manifolds and other fittings should
be supported by properly designed system framework. Operating personnel should be
discouraged from applying from undue force to any fittings connected directly to a pressure
vessel.
Accessibility
Pressure vessel should be positioned within the system such that elements can be inserted at
the upstream end and removed from the downstream end (i.e. elements are installed and
removed in the direction of feed flow).
DWG PART
QTY DESCRIPTION MATERIAL
REF NUMBER
SHELL
Filament Wound Epoxy/Glass
1 1 SHELL composites - Head locking grooves
ORDER integrally wound in place.
2 A/R SECTION Inlet Port Epoxy Glass
3 A/R Outlet Port Epoxy Glass
HEAD
4 2 96156 Bearing Plate Epoxy Glass
HEAD INTERLOCK
5 2 47336 QuikRelease Spiral Ring 316 Stainless Steel.
VESSEL SUPPORT
6 4 52169 Saddle Engineering Thermoplastic.
7 2 45042 Strap Assy. 304 Stainless Steel-PVC Cushion.

8 4 46265 Strap screw. 5/16-18 UNC, 18-8 Stainless Steel.
SSS
SSS
Electro-pneumatic miniature control valves
Mounting cabinet
SSS
SSS
Miniature solenoid valves
Part numbers (and voltages)

Consumption Voltage
1W 24V … 81 519 032 81 519 332 81 519 632 81 519 132
2.5 VA 24V ~ 50-60Hz 81 519 074 81 519 374 81 519 674 -
2.5 VA 48V ~ 50-60Hz* - 81 519 375 81 519 675 -
2.5 VA 110V ~ 50-60Hz - 81 519 376 81 519 676 -
*on request 2.5 VA 220V - 230V ~ 50-60Hz - 81 519 377 81 519 677 -
Function 3/2 NC 3/2 NC 3/2 NC 3/2 NC
Version No manual With manual With maint. No manual
Override override by manual override
Impulse override
Characteristics
Operating_pressure Bars 1-8 1-8 1-8 1-8
Orifice diameter mm 0.8 0.8 0.8 0.8
Flow at 6 bars Nl/min 30 30 30 30
kV 0.3 0.3 0.3 0.3
Switching time ms 5 * 15 5 * 15 5 * 15 5 * 15
Mechanical life (operations) 1.5 107 1.5 107 1.5 107 1.5 107
Operating temperature °C -10+50 -10 + 50 -10 + 50 -10 + 50
Compressed air or inert gas - oil-free • • • •
Air filtered to 50 μ
Duty factor 100% ED 100% ED 100% ED 100% ED
Insulation class IEC 85 F F F F
Weight 35 35 35 35
Rotatable connector 4 positions in 90° steps • • • •
Degree of with sub-base (pg 5/5) IEC 529 IP 20 IP 20 IP 20 IP 20
Protection with connector 81 516 082 (pg 5/9) IEC 529 IP 65 IP65 IP65 IP65
UL and cUL approval MH 15085 MH 15085 MH 15085 MH 15085
Dimensions
81 519 6
SSS
Miniature power valves
Sub-bases for miniature pilot solenoid valves
Part numbers
Pair of end bases 81 514 101 ⎯
Intermediate sub-base ⎯ 81 514 161
Characteristics
Pneumatic indicator on output • •
Common supply • •
Common exhaust • •
Torque capacity
Push-in connection for semi-rigid tubing mm2 3 3
Ø 4mm (NFE 49100) mm • •
Mounting DIN rail 35mm DIN rail 35mm
EN 50022 EN 50022
UL and cUL approval MH-15085 MH-15085
Weight g 65 30
SSS
Part numbers
81 513 100 81 513 600 81 513 200 81 516 100 81 516 200
Function 3/2 NC 3/2 NO 4/2 4/2 pressure 4/2 pressure
monostable spring-return spring-return
Symbol
Characteristics
Width mm 17.5 17.5 17.5 17.5 17.5
Operating pressure bars 3-8 3-8 3-8 3.5-8 3.5-8
Orifice diameter mm 3 3 3 4 4
Flow at 6 bars with sub-base Ø 4mm (pg 5/7) Nl/min 200 200 200 300 300
with sub-base Ø 6mm (pg 5/7) 300 300 300 400 400
Operating temperature °C -10 to +50 -10 to +50 -10 to +50 -10 to +50 -10 to +50
kV with sub-base Ø 4mm (pg 5/7) 2.2 2.2 2.2 4 4
with sub-base Ø 6mm (pg 5/7) 2.5 2.5 2.5 5 5
Switching time of the relay only ms 5 5 5 10 10
Mechanical life (operations) 1.5 x 107 1.5 x 107 1.5 x 107 107 107
Weight g 38 38 38 106 106
SSS
Sub-bases and end bases for miniature valves
Part numbers
Mounting Cabinet Cabinet Cabinet
Mounting Mounting Mounting
Version 35mm ⎯ ⎯
Push-in connection for Sub-bases 81 517 201 ⎯ ⎯
semi-rigid tubing
(NFE 49100)
End bases (pair) Ø 6mm ⎯ ⎯ 81 513 011 ⎯
Intermediate Ø 6mm ⎯ ⎯ ⎯ 81 513 001
supply module
Characteristics
Torque capacity 3 ⎯ ⎯
UL and cUL approval MN 15085 ⎯ ⎯
Mounting Din rail 35mm Din rail 35mm Din rail 35mm
EN 50022 EN 50022 EN 50022
Weight 110 86 44
SSS
SSS
SSS
Hydraulic Pressure Booster

for Reverse Osmosis Service
MODELS
HPB-20
HPB-30
HPB-40
HPB-60
HPB-80
HPB-120
HPB-160
HPB-240
HPB-320
SSS
The Hydraulic Pressure Booster™ or HPB™ is designed to
provide brine energy recovery in reverse osmosis (RO)
systems. The HPB™ is the most advanced and sophisticated
energy recovery device in the world.
Table of contents
Unlike other energy recovery turbines, the HPB™ has no
shafts to connect to the feed pump or motor. Entirely Installation & Operation
energized by the high-pressure brine stream, the HPB™ Preparation 1
generates a large pressure boost in the feed stream Installation 2
independent of the high pressure feed pump. Startup 5
Please review this manual carefully before installing the Maintenance

HPB™. Keep the manual in a handy location for future Troubleshooting 6
reference. Inspection 7
Overhaul 9
Do not hesitate to contact FEDCO if there are any
questions or comments. Miscellaneous
Parts Drawing 10
Return & Warranty 11
Operating Records 13
Receiving and Inspection

The HPB™ was tested before shipping to ensure it meets all performance requirements. To make sure the unit
is ready for installation, please take the following steps:
• Promptly inspect the crates or boxes carefully for damage
• Report any damage to the freight company
• Please save any documents that may be enclosed.
Storage
The HPB™ must be protected from moisture, sand, grit, and other foreign matter. Please do not remove the
protective covers on the pipe connections until ready to install.
Application Range
The HPB™ should only be used within the following limits:
Maximum temperature: 120 degrees F (49 deg C)
Maximum particulate size: 20 micron
Specific application limits are provided on the nameplate of each HPB™.

Installation 2/14
Terminology
The following terminology is used to identify major components.
Brine inlet Casing Feed outlet
Brine outlet End cap
Brine control Feed inlet

valve
End cap bolt
Mounting feet Figure 1
Operating Principle
Figure 2 illustrates a typical RO system. Note that the HPB™ is installed between the high pressure feed pump
and the membrane. The feed passes through the pretreatment system and then passes through the feed pump
that raises the feed pressure. Next, the pressurized feed passes through the HPB™, which provides an
additional pressure increase before passing to the membrane.
The membrane produces a high-pressure brine stream, which is directed back to the HPB™. The HPB™
recovers the pressure energy and discharges the brine at low pressure for disposal. Note that the HPB™
eliminates the brine valve normally used to control brine pressure. Also, the HPB™ does not require a brine
disposal pump or gravity flow piping as the brine can be discharged against a backpressure.
The HPB™ reduces feed pump energy consumption and allows use of a smaller feed pump, smaller motor,
smaller motor starter, electrical wiring, etc. Thus the HPB™ saves energy and reduces pumping equipment
costs.
High
High pressure pressure feed
feed pump
Pretreatment Membrane
system
High pressure
Low pressure Feed brine
booster pump inlet Brine
outlet
NOTE
Brine Other piping and valves
may be needed for
membrane cleaning.
Low pressure brine

Installation 3/14
The first step in planning the installation is to determine the general piping arrangement. This depends on the
type of high pressure feed pump.
Centrifugal Feed Pump
Usually, a feed throttle valve is needed to help regulate the pump discharge pressure. The throttle valve should
be located between the high pressure feed pump and the HPB™ feed inlet as illustrated in Figure 3. If a
Variable Frequency Drive (VFD) is used to control pump speed, then a feed throttle valve is NOT required.
High Feed throttle

pressure valve
feed pump
Feed Figure 3
Positive Displacement (PD) Feed Pump

Do not use a feed throttle valve for RO systems using PD (positive displacement) pumps such as reciprocating
pumps, gear pumps, etc.
A pulsation dampener is required and should be installed between the outlet of the feed pump and the feed
inlet to the HPB™ as shown in Figure 4. The pulsation dampener should be adjusted to work at the feed pump
discharge pressure with the HPB™ in operation.
A pressure relief valve should be placed between the HPB™ feed outlet and the membrane feed inlet as
indicated in Figure 4.
WARNING – MAKE SURE THAT THE SAFETY VALVE IS SET AND OPERATES PROPERLY!
Pulsation Relief
dampener valve
IMPORTANT - If the feed pump and motor

are not rated for operation at full membrane
pressure then please install a second
Feed relief valve as shown in Figure 4. This
valve should be set to prevent overloading
Second relief of the pump and motor in case the HPBŖ is
valve not operating.
Figure 4
Installation 4/14
Piping
The piping attached to the HPB™ must not transmit piping strain to the unit.
The feed inlet pipe to the unit should be straight for at least a length equal to three times the pipe diameter.
See Figure 5. It is OK to use a pipe reducer next to the HPB™ feed inlet.
Low-pressure brine piping

Note that the HPB™ can discharge brine against a backpressure. Therefore, a brine sump, gravity flow piping
or a brine disposal pump is not needed.
To prevent possible cavitation, the brine backpressure should not be less than about 5 psi.
A spool piece installed in the brine outlet will aid the installation and removal of the HPB™. The spool piece
should be about the length of the HPB™.
Pressure gages
Pressure gages should be installed on all pipes to measure HPB™ performance. See Figure 5.
CAUTION - FLUSH THE PIPES!!
Pipe debris such as welding slag can damage the unit. Thoroughly flush all pipes before installing the HPB™.
Installing the Pipe Joints

Be sure to properly lubricate the Victaulic gaskets. Be sure all joints are properly made and tightened before
applying pressure to the system. Follow the manufacturers instructions at all times!
NOTE -The HPBŖ is equipped

with a built-in brine control
valve. Thus, a separate valve
to control brine flow and High pressure High pressure feed
brine from to membrane
pressure is not needed unless membrane
an usually high range of brine
pressure may occur. A bypass
Pressure Pressure
valve for cleaning may be
Gages Gages
required. Consult with FEDCO.
Feed from high

pressure feed
Low pressure pump
brine to disposal
Pipe length = to at least

Recommended spool piece 3 time pipe diameter.
to facilitate installation Reducing fittings are OK.
and removal of the HPBŖ
Leave clearance to allow
valve adjustment
Figure 5
Startup 5/14
The first startup is important for long-term efficiency and reliability of the HPB™. The unit is extremely simple
and startup is easy. Just be sure that the pipes have been flushed and the following items have been checked.
Before Startup
1. Verify that the feed and brine connections are correct;

2. Start the low pressure feed pump, purge air from all pipes and tanks and check for leaks;
3. With a Centrifugal Feed Pump
• Set the HPB™ brine valve to the closed position.
• Make sure other valves such as cleaning or brine bypass valves are closed.
• Make sure the feed throttle valve, if used, is about 50% open.
4. With a Positive Displacement Feed Pump
• Set the HPB™ brine valve to the open position.
• Make sure the pulsation dampener is properly set for the expected feed pump discharge
pressure.
Initial Operation
1. Start the high pressure feed pump;
2. Measure the following and save for future reference:
• feed and brine pressures;
• feed and brine flows;
3. With a centrifugal feed pump:
• to increase permeate flow - close the HPB™ brine valve and open the feed throttle valve;
• to reduce permeate flow - open the HPB™ brine valve and close the feed throttle valve.
4. With a positive displacement feed pump:
• to increase permeate flow - close the HPB™ brine valve;
• to reduce permeate flow - open the HPB™ brine valve.
Off-Design Operation of HPB
Your HPB was custom designed to meet the exact system conditions provided to FEDCO during the design
phase. Changes in system recovery, and to a lesser extent, system pressures can affect performance and
general operation of the HPB. The integrated brine control valve is a valuable tool to aid in system control. If
your system conditions deviate from the design conditions, the brine valve position will most likely need to be
changed to provide the best boost possible and prevent internal damage to the thrust bearing and rotor. If,
during startup, you notice that the flows and pressures vary from the design point, please contact FEDCO
immediately and we will perform an off-design calculation to provide you with the optimal position for the brine
valve.
Please note that the HPB should not be run in a system with an overall system recovery greater than 55% for
feed boost applications and 80% for interstage applications.
NOTE
Every HPB™ is tested for pressure integrity, efficiency, and vibration before shipping.
WARNING!
Never force the brine valve beyond its full open position. Use only hand operation.
WARNING!
If the brine valve retaining clip is not fastened to the casing, the valve can be completely
unscrewed and can come completely out of the casing resulting in a high-pressure brine leak.
See the parts identification drawing in this manual for more details.
Troubleshooting 6/14
The HPB™ has two major functions - the first is to produce a pressure boost in the feed stream. The second is
to help maintain brine flow and pressure at the desired values.
Pressure Boost
Pressure Boost Too Small or Membrane Pressure Too Low

The amount of pressure boost depends on the feed flow, brine flow, and brine pressure. Reductions in brine
pressure or brine flow, or increases in feed flow can all reduce the pressure boost. If you believe the pressure
boost is too low, please supply FEDCO with the following information:
•Serial number of HPB™
•Feed flow and brine flow
•Feed pressure at the HPB™ feed inlet, feed pressure at the HPB™ feed outlet
•Brine pressure at the HPB™ brine inlet, brine pressure at the HPB™ brine outlet
FEDCO will calculate the expected pressure boost.
No Pressure Boost
If the unit cannot generate a pressure boost under normal operating conditions then an internal inspection is
needed. Refer to the inspection section of this manual.
Brine Pressure Adjustment
Use the HPB™ brine valve to regulate brine flow and pressure as explained in the STARTUP procedure.
Contact FEDCO if the desired pressure cannot be obtained.
Leakage
HPB ™ Brine Valve

If brine leaks around the brine valve stem, the O-rings may need replacement. See the HPB™ Brine Valve
repair section in this manual.
Pipe Joints
Depressurize and drain the system. Check the pipe joints for damaged gaskets, debris that could prevent
sealing, etc. Reapply lubricant to the gaskets, reinstall, and tighten the joints.
Miscellaneous
Noise
The HPB™ may emit a high frequency sound. This is normal and is due to the high rotational rate of the rotor.
Sometimes, noise may be generated by resonance of pipe sections between Victaulic joints. This noise can
greatly exceed the noise generated by the HPB™.
Since the HPB™ has no cooling requirement, sound-absorbing material may be tightly packed around the
HPB™. Be sure to maintain access to the brine adjustment valve.
Inspection 7/14
Shutdown the system and relieve all pressure. Observe all normal safety precautions. Drain piping connected
to the HPB™. Disconnect the feed and brine pipes. Cover the openings of the RO piping to prevent entrance
of foreign material. In a clean work area, place the HPB™ in a horizontal position. Refer to Figures 13 and 14.
End Cap Removal

1. Remove end cap bolts.
2. Remove end cap. If needed, use two small pry bars or screwdrivers.
• For the HPB-160 units and larger, small machined recesses are provided for inserting small pry bars
(See Figure 8).
• Note that the diffuser may remain in the end cap. Be sure to save the O-ring.
Check Rotor Rotation

With removal of the end cap, the rotor should be visible. Grasp the feed impeller by hand and attempt to rotate.
The rotor should turn freely and smoothly. If the rotor rotates freely, reassemble the unit and try again. If the
rotor does not turn freely or the unit still does not operate even though the rotor turns freely, proceed with the
internal inspection.
Internal
Rotor andInspection
Center Bearing Removal
Using the rotor tool supplied with the HPB™ gently drive the rotor and center bearing assembly out of the
casing from the turbine end as illustrated in Figure 6.
Thrust Bearing Removal

Again using the rotor tool, place the shoulder of the tool against the backside of the thrust bearing. Gently drive
the thrust bearing through the casing bore. See Figure 7.
Push by Push by
hand hand
Rotor and center

bearing removal Figure 7
Thrust bearing removal
Machined recess for pry bar

(HPB-160 and larger) Figure 8
Inspection 8/14
With the unit disassembled, the parts may now be inspected. Refer to Figure 9.
Inspect the Bearings

Remove the two (2) center bearing O-rings. Separate the two bearing halves. Inspect the inner bearing
surfaces. Normally, the two ends of the bearing areas are shiny or polished. Slight grooves are acceptable.
Light grooving on the thrust bearing face is OK. Make sure the pressure ports are clear.
Inspect the Diffuser Ring

The diffuser ring is held in the end cap. There is no need to remove for inspection. Please look for chipped or
broken diffuser channels. An anti-roll pin is used (see page 10).
Inspect the Rotor

Examine the rotor in the bearing areas as shown in Figure 9 (feed bearing, shaft bearing, and thrust bearing
runner surfaces). Light scratching is OK. If a precision micrometer is available, measure the diameters of the
rotor and bearings and calculate the clearances. See Figure 12 and Table 1 for the acceptable clearance
range.
Please clean all parts and clean all casing bores, shoulders, etc. to ensure the parts will properly seat during
assembly.
HPB Brine Valve Repair – VERIFY ALL PRESSURE HAS BEEN REMOVED FROM THE HPB!
Perform this repair if brine is leaking around the valve stem. Refer to Figures 13 and 14. Remove the valve
stem retaining clip retaining screw (1 or 2 depending on the HPB model). Unscrew the valve stem to remove
from the casing. Remove the two O-rings and replace with new O-rings. Lubricate the bore with water. Screw
the brine valve into the casing and re-install the valve retaining clip and screw(s). The repair is complete.
Center Bearing
bearing surface
Diffuser channel Diffuser
Thrust Feed (4 to 10) ring
bearing Shaft impeller
O-ring bearing Diffuser
O-ring
Thrust
bearing
runner
Brine
impeller
Thrust Feed
bearing bearing
Center
Pressure bearing
port O-rings Figure 9
Overhaul 9/14
Diffuser Ring Replacement
• Gently work the old diffuser ring out of the end cap.
• Clean the end cap bore to remove any debris that could prevent seating.
• Install the O-ring and anti-roll pin (if used) on new diffuser ring. Lubricate the bore with water.
• Gently push the new diffuser ring into the end cap until fully seated.
Thrust Bearing Installation

• Install the O-ring on the thrust bearing.
• Gently insert the thrust bearing into the bearing bore. Lubricate the bore with water
- Make sure that the groove in the bearing face is facing the rotor
• Push the thrust bearing until it is fully seated. See Figures 9 and 10.
Rotor and Center Bearing Installation

• Place the split center bearing around the rotor shaft.
• Place the two O-rings around the center bearing. Lubricate the bore with water.
• Gently push the rotor and center bearing assembly into the casing bore using the rotor tool or
a screwdriver. See Figure 11. The bearing split line may be oriented in any direction.
Note that the center bearing may not fully seat. This is OK. During initial operation, hydraulic pressure will
automatically seat the center bearing.
Reassembly
• Install the O-ring on the end cap and gently push the end cap into the casing.
• Install the casing bolts and tighten to the torque value indicated in Table 1. Use a "star-
pattern" tightening sequence.
End Cap Bolts Maximum Clearances*

Size Torque Center Brg. Diffuser Ring
(inch) ft - lbf (inch) (inch)
HPB-20 & 30 3/8-16 22 0.006 0.008
HPB-40 & 60 1/2-13 54 0.007 0.009
HPB-80 & 120 5/8-11 107 0.008 0.010 Push by
HPB-160 & 240 7/8-9 193 0.009 0.012 hand
HPB-320 1-8 400 0.010 0.015
* clearances are diametral
Figure 10 Installation of thrust bearing

Diffuser
ring
clearanc
e
Push by
hand
Figure 11 Installation of rotor and center bearing

Figure 12
Part Identification Drawing 10/14
Feed End cap
Diffuser ring bolt
outlet O-ring
Rotor Diffuser
channel Anti-roll pin
Casing Center Diffuser End

bearing ring cap
Thrust
bearing Feed
inlet
Brine
outlet Pump
impeller
Turbine
impeller
End cap
Thrust bearing O-ring
O-ring
Center bearing
O-rings
N.T.S.
Figure 13
WARNING- brine valve

retaining clip and screw(s)
must be properly installed
Turbine nozzle before pressure is applied
to the HPB.
Brine valve
retaining
clip
N.T.S.
Figure 14
Threaded or Valve stem

Snap ring O-rings Brine valve
Pipe plug retaining
screw
11/14
Initial Installation Overhaul Record

Model #: ________________________ Overhaul Date: ____________________
Serial #: _________________________ Operating Hours: __________________
Installation Date: __________________ Reason for Overhaul: _______________
Startup Date: _____________________ _________________________________
Comments: _______________________ _________________________________
_________________________________ _________________________________
_________________________________ Operating Data Prior to Overhaul:
_________________________________ Feed Flow: _______________________
Feed Flow: _______________________ Feed Pressure into HPB: ____________
Feed Pressure into HPB: ____________ Feed Pressure to Membranes: ________
Feed Pressure to Membranes: ________ Brine Flow: ______________________
Brine Flow: ______________________ Brine Pressure into HPB: ____________
Brine Pressure into HPB: ____________ Exhaust Pressure out of HPB: ________
Exhaust Pressure out of HPB: ________ Operating Data After Overhaul:
Comments: _______________________ Feed Flow: _______________________
_________________________________ Feed Pressure into HPB: ____________
_________________________________ Feed Pressure to Membranes: ________
_________________________________ Brine Flow: ______________________
Brine Pressure into HPB: ____________
Exhaust Pressure out of HPB: ________

SSS
Salt Separation Services Seite / page 1
REV : 01
ARMATUREN TECHNOLOGIE
Einbauanleitung / Fitting Instructions
Ingolstadt-Systemtrenner
Bauart BA DN 15-65
mit DVGW-, SVGW und WRAS-Prüfzeichen
Ingolstadt-Controllable Backflow Preventer

Type BA DN 15-65 with
DVGW-, SVGW-and WRAS-Test Certificate
SSS
Seite / page 2
ARMATUREN TECHNOLOGIE ARMATUREN TECHNOLOGIE
Systemtrenner / Controllable Backflow Preventer Systemtrenner / Controllable Backflow Preventer
Verwendungszweck Application Inspection plan to DIN 1988, Part 8
Controllable Backflow Preventer Type BA

Systemtrenner der Bauart BA sind Controllable backflow preventers of the type BA
Sicherungsarmaturen bis zur Kategorie 4, gemäß are safety fittings up to category 4, in
Nominal width:___________ Series:________________________ Item-No.:_______________
EN 1717 (DIN 1988, Teil 4). accordance with EN 1717 (DIN 1988, part 4).
Installed by (name of firm):__________________________________________________________
Durch das Prinzip der hydraulischen Trennung, Through the principle of hydraulic separation,
Installation date: ____________________________________
wird ein Rückfließen, Rückdrücken und altered potable water is effectively prevented
Rücksaugen von verändertem Trinkwasser in from flowing back, being forced back or 6 monthly performance test:
das Trinkwassersystem wirkungsvoll verhindert. siphoned back into the potable water system.
Date: ___________________ Tested by: _____________________________________________
Name of firm: ___________________________________________________________________
Funktionsweise / Operation Appliance in ❏ yes

good order ❏ no Defects: ______________________________________________
Signature: ______________________________________________________________________
Date: ___________________ Tested by: _____________________________________________

Name of firm: ___________________________________________________________________
Appliance in ❏ yes
Signature: ______________________________________________________________________
Date: ___________________ Tested by: _____________________________________________

Name of firm: ___________________________________________________________________
Signature: ______________________________________________________________________
Date: ___________________ Tested by: _____________________________________________

Name of firm: ___________________________________________________________________
Signature: ______________________________________________________________________
SSS
Seite / page 14 Salt Separation Services Seite / page 3
Inspektionsplan nach DIN 1988, Teil 8 Funktionsweise Operation

Systemtrenner Bauart BA DN 15-65
Die Funktionsweise der Bauart BA mit The way in which the type BA works is by using
Rückflussverhinderer in der Vor- und three pressure zones. It is based on the principle
Nennweite:___________ Serie:________________________ Artikel-Nr.:__________________
Hinterdruckzone basiert auf dem Prinzip der of hydraulic separation. The different zones are
hydraulischen Trennung. Die unterschiedlichen separated from one another by two backflow
Einbau durch Firma:_______________________________________________________________
Zonen werden durch zwei Rückflussverhinderer preventers. In the middle zone there is a
Einbaudatum: ____________________________________
von einander getrennt. In der Mittelzone befindet diaphragm operated relief valve which maintains
Durchführung der halbjährigen Funktionspüfung: sich zusätzlich ein Entlastungsventil, das über a pressure difference of ≥0.14 bar between the
einen Membranantrieb eine Druckdifferenz von front and middle zone by operating and shutting,
Datum: ___________________ Prüfer: ______________________________________________
≥0,14 bar zwischen Vor- und Mittelzone durch depending on the pressure ratio.
Firma: _________________________________________________________________________
Öffnen und Schließen, je nach Druckverhältnis,
Gerät in ❏ ja
aufrecht erhält. - Position without water flow:
Ordnung ❏ nein Fehler: _______________________________________________
With no water flow, both backflow preventers as
Unterschrift: _____________________________________________________________________
- Stellung ohne Wasserentnahme: well as the relief valve are closed. A pressure
Datum: ___________________ Prüfer: ______________________________________________ Erfolgt keine Wasserentnahme, sind beide difference of ≥0.14 bar between the front and
Firma: _________________________________________________________________________ Rückflussverhinderer sowie das middle chambers is ensured through the spring
Gerät in ❏ ja Entlastungsventil geschlossen. Eine of the first backflow preventer.
Ordnung ❏ nein Fehler: _______________________________________________ Druckdifferenz zwischen Vor- und Mittelkammer
Unterschrift: _____________________________________________________________________ von ≥0,14 bar wird durch die Feder des ersten - Position with water flowing:
Rückflussverhinderers sichergestellt. If there is water flowing both backflow
Datum: ___________________ Prüfer: ______________________________________________ preventers are opened, depending on the
Firma: _________________________________________________________________________ - Stellung bei Wasserentnahme: quantity. The relief valve is closed. A pressure
Gerät in ❏ ja Bei Wasserentnahme sind beide difference of ≥0.14 bar between the front and
Ordnung ❏ nein Fehler: _______________________________________________ Rückflussverhinderer, je nach Entnahmemenge, the middle chamber is ensured through the
Unterschrift: _____________________________________________________________________ geöffnet. Das Entnahmeventil ist geschlossen. spring of the first backflow preventer.
Datum: ___________________ Prüfer: ______________________________________________ Eine Druckdifferenz zwischen Vor- und
Firma: _________________________________________________________________________ Mittelkammer von ≥0,14 bar wird durch die
Gerät in ❏ ja Feder des ersten Rückflussverhinderers
Ordnung ❏ nein Fehler: _______________________________________________ sichergestellt.
Unterschrift: _____________________________________________________________________
SSS
Seite / page 4

Ersatzteile / Spare parts
Funktionsweise Operation Ersatzteilliste Systemtrenner DN 32-65 Spare parts list DN 32-65
Pos. Bestell-Nr. Bezeichnung Item Order No. Name
- Stellung bei eingangsseitigen - Position in the event of fluctuations in pressure 1 5900126 Rückflussverhinderer Eingangsseite 1 5900126 Backflow preventer inlet side
Druckschwankungen: at the inlet side: DN 32-65 kpl. mit O-Ring und DN 32-65 complete with O-ring
Sicherungsring and securing ring
Bei eingangsseitigen Druckschwankungen öffnet If there are fluctuations in pressure at the inlet
2 5900125 Rückflussverhinderer Ausgangsseite 2 5900125 Backflow preventer outlet side
kurzfristig durch den Membranantrieb das side, the relief valve is opened momentarily by DN 32-65 kpl. mit O-Ring und DN 32-65 complete with O-ring
Entlastungsventil. Es tritt jeweils nur soviel operation of the diaphragm. Only enough water Sicherungsring and securing ring
Wasser aus, bis eine Druckdifferenz von ≥0,14 is discharged until a pressure of ≥0.14 bar 3 5900127 Membranantrieb DN 32-65 kpl. 3 5900127 Diaphragm drive DN 32-65
mit Innenlippendichtung und complete with inner lip seal
bar zwischen Vor- und Mittelkammer erreicht ist. between the front and the middle chamber is 4 5900128 Sitzbuchse mit O-Ring DN 32-65 4 5900128 Seating bush with O-Ring DN 32-65
achieved. 5100606 Anschlussflachdichtung 78x60x3 5100606 Connecting flat gasket 78x60x3
- Stellung bei Druckabfall auf der Eingangsseite: 5900129 Austauschset für Systemtrenner 5900129 Replacement set for controllable
DN 32-50 alle Verschleißteile kpl. backflow preventer DN 32-50 all parts.
Bei Absinken des Vordruckes unter 0,14 bar ist - Position in the event of a pressure drop at the 5102205 Flanschdichtung DN 65 5102205 Connecting flat gasket DN 65
die Mittelkammer gegen die Atmosphäre inlet side. 5900130 Austauschset für Systemtrenner 5900130 Replacement set for controllable
geöffnet. If the inlet pressure falls below 0.14 bar the DN 65 alle Verschleißteile kpl. backflow preventer DN 65 all parts.
middle chamber is opened to the atmosphere.
SSS
Ersatzteile / Hinweise zur Installation Installation Information

Spare parts
Systemtrenner vor dem Einbau auf Check controllable backflow preventer before
Transportschäden überprüfen. fitting for damage during transport.
Systemtrenner dürfen nur von Personen Controllable backflow preventers may only be
betrieben, überprüft, gewartet und operated, checked, serviced and repaired by
instandgesetzt werden, die mit den geltenden persons familiar with the current regulations.
Vorschriften vertraut sind.
Technical modifications to controllable backflow
Technische Veränderungen an Systemtrennern preventers may only be carried out by the
dürfen nur vom Hersteller durchgeführt werden! manufacturer! If this rule is not observed, or if
Bei Nichteinhaltung bzw. bei Entfernung des the nameplate is removed, the guarantee is no
Typenschildes erlischt die Garantie. longer valid.
Eine Inspektion der Sicherungsarmatur hat nach According to DIN 1988, part 8, there must be an
DIN 1988, Teil 8 durch den Betreiber oder durch inspection of the safety valve by the operator or
das Installationsunternehmen halbjährlich zu by the installing firm every six months. The
erfolgen. Dem Betreiber der Trinkwasseranlage operator of the potable water system is obliged,
obliegt im Rahmen seiner Sorgfaltspflicht die as part of his duty of care, to observe the
Einhaltung der Vorschriften. Wir empfehlen den regulations. We recommend that a service
Abschluss eines Wartungsvertrages. contract be agreed.
Ersatzteilliste Systemtrenner DN 15-25 Spare parts list DN 15-25
Pos. Bestell-Nr. Bezeichnung Item Order No. Name
1 5900096 Rückflussverhinderer Eingangsseite 1 5900096 Backflow preventer inlet side
Zur Durchführung der Funktionsprüfung, muss To carry out the performance test, a shut-off
DN 15-25 kpl. mit O-Ring und DN 15-25 complete with O-ring vor und nach dem Systemtrenner eine valve must be fitted in front of and behind the
Sicherungsring and securing ring Absperrarmatur eingebaut werden. Die controllable backflow preventer. The shut-off
2 5900095 Rückflussverhinderer Ausgangsseite 2 5900095 Backflow preventer outlet side
eingangsseitige Absperrarmatur muss mit einem valve at the inlet side must be combined with a
DN 15-25 kpl. mit O-Ring und DN 15-25 complete with O-ring
Sicherungsring and securing ring Entleerungsventil kombiniert sein (siehe drain valve (see fitting example, page 9).
3 5900097 Membranantrieb DN 15-25 kpl. 3 5900097 Diaphragm drive DN 15-25 Einbaubeispiel, Seite 9).
mit Innenlippendichtung complete with inner lip seal
4 5900098 Sitzbuchse mit O-Ring DN 15-25 4 5900098 Seating bush with O-Ring DN 15-25
5104463 Anschlussflachdichtung 44,7x34x2 5104463 Connecting flat gasket 44,7x34x2
5900099 Austauschset für Systemtrenner 5900099 Replacement set for controllable
DN 15-25 alle Verschleißteile kpl. backflow preventer DN 15-25 all parts.
SSS
Hinweise zur Installation Installation Information Störungsursachen

Störung Ursache Beseitigung
Zur Erhöhung der Betriebssicherheit muss ein To increase operating efficiency a strainer or fine
Schmutzfänger oder Feinfilter ≤250 µm vor dem filter ≤250 µm must be fitted before the Der Systemtrenner entlastet Eingangsseitige Druckschwankungen bzw. Ein Entlasten der Mittelkammer bei
kurzzeitig die Mittelkammer und kurzzeitiger Druckabfall auf der eingangsseitigen Druckschwankungen
Systemtrenner eingebaut werden. Bei controllable backflow preventer. We cannot erfüllt dann wieder seine Funktion Eingangsseite gehört zur Funktionsweise eines
verschmutzungsbedingten Ausfällen undertake any guarantee in the case of failures Systemtrenners. Abhilfe bringt ein
übernehmen wir keine Garantie. due to the accumulation of dirt. eingangsseitiger Druckminderer oder
Rückflussverhinderer.
Ständige Leckage am
Vor der Installation des Systemtrenners ist eine Before installing the controllable backflow Entlastungsventil Rückflussverhinderer oder Dichtung Verschmutzung beseitigen bzw.
gründliche Leitungsspülung vorzunehmen. preventer the pipes must be thoroughly rinsed. am Entlastungsventil verschmutzt Dichtungen oder kpl. Funktionseinheiten
oder defekt. (Rückflussverhinderer, Membranantrieb)
ersetzen.
Durchflussrichtung beachten! ->siehe Pfeil auf Note direction of flow! ->See arrow on housing.
dem Gehäuse.
Fitting position is horizontal with drain outlet
Einbaulage ist waagrecht mit Ablauf nach unten. facing downwards.
Eingangsseitige Druckschwankungen bzw. Variations in pressure at the inlet side and/or

positive oder negative Druckstöße, z.B. durch positive or negative pressure surges, e.g. due to
schnellschließende Absperrarmaturen, fast closing shut-off valves, cause a sporadic Cause of Malfunction
verursachen ein sporadisches Ansprechen des operation of the relief valve in the middle
Malfunction Cause How to correct it
Ablassventils in der Mittelkammer. Abhilfe bei chamber. A backflow preventer or pressure
durch Druckschwankungen erzeugtes reducer at the inlet side in front of the The controllable backflow Fluctuations in pressure at the inlet side Relieving the middle chamber in case of
preventer relieves the middle and/or momentary pressure drop at the variations in pressure at the inlet side is
Ansprechen des Ablassventils schafft ein controllable backflow preventer can remedy this chamber for a short time and then inlet side. part of the function of a controllable
eingangsseitiger Rückflussverhinderer oder actuation of the relief valve. A pressure reducer performs its function again. backflow preventer. This can be remedied
Druckminderer vor dem Systemtrenner. Ein provided by the customer should generally be by a pressure reducer or backflow
preventer at the inlet side.
bauseits vorhandener Druckminderer sollte fitted in front of the controllable backflow
generell vor dem Systemtrenner eingebaut preventer.
werden. Constant leakage at the bleeder Backflow preventer or seal on the relief Clean up contamination and/or replace
valve. valve contaminated or faulty. seal or complete units (backflow
preventer, diaphragm drive).
SSS
Funktionspüfung Performance Test Hinweise zur Installation Installation Information

a) Überprüfung auf Funktion: Eine dem a) To check it is working correctly: Slowly close Das Schaltwasser, das beim Ansprechen des The water that is discharged when the relief
Systemtrenner nachgeschaltete Absperrarmatur a shut-off valve connected to the controllable Ablassventils austritt, ist mit einer valve responds is to be drained off through a
langsam schließen. Es muss eine Druckdifferenz backflow preventer at the outlet side. A pressure entsprechenden Abflussleitung nach DIN 1986 suitable discharge pipe acc. to DIN 1986. The
von mindestens 0,2 bar zwischen Vor- und difference of at least 0.2 bar must remain abzuleiten. Der Ablauftrichter ist für den HT- discharge funnel is intended for the HT-pipe
Mittelkammer aufrecht erhalten bleiben. Die maintained between the front and middle Rohr-Anschluss vorgesehen. connection.
Druckdifferenz kann an den Prüfanschlüssen chamber. The pressure difference can be
(Prüfkugelhähne) gemessen werden. measured at the test connections (test ball Der Einbauort muss für die erforderliche The installation site must be accessible at all
valves). Funktionsprüfung jederzeit zugänglich, times for the required performance test and
b) Prüfung bei eingangsseitigem Druckabfall: Die überflutungs- und frostsicher sein, sowie den must be protected from flooding and frost. It
dem Systemtrenner vor- und nachgeschalteten b) Test in the event of a pressure drop at the Schutz vor Chemikalien, Farbstoffen, must also ensure protection against chemicals,
Absperrarmaturen schließen. Durch das Öffnen inlet side: Close the shut-off valves connected Lösungsmitteln und Dämpfen gewährleisten. dyestuffs, solvents and fumes.
einer dem Systemtrenner vorgeschalteten before and after the controllable backflow
Entleerungsarmatur ist das Ansprechen des preventer. By opening a drain valve connected in Die technischen Daten sind zu beachten. The technical data is to be observed.
Entlastungsventils in der Mittelkammer zu series before the controllable backflow preventer
überprüfen. Durch sporadisches Öffnen des the operation of the relief valve in the middle
Entlastungsventils muss eine Druckdifferenz von chamber is tested. Through sporadic opening of
≥0,14 bar zwischen Vor- und Mittelkammer the relief valve a pressure difference of ≥0.14 bar
aufrecht erhalten bleiben. Der Differenzdruck ist must always be maintained between the front
an den Prüfanschlüssen zu ermitteln. Bei and middle chamber. The differential pressure is
eingangsseitigem Druck ≤0,14 bar muss die measured at the test connections. If there is a
Mittelkammer durch das Entlastungsventil pressure of ≤0.14 bar at the inlet side, the
vollständig entleert sein. middle chamber must be completely emptied
through the relief valve.
SSS
Seite / page 8
Technische Daten / Technical Data Installation und Inbetriebnahme /

Installation and Commissioning
Werkstoffe / Materials
Einbaubeispiel / Fitting example:
Gehäuse / Housing: G-CuSn 7 ZnPb (Rotguss / Red bronze)
Rückflussverhinderer / Backflow Preventer: Armaturenkunstsoff / Fitting plastic
Dichtungen / Seals: EPDM
Membrane / Diaphragm: EPDM
Größe /
Size
Maße und technische Daten / Dimensions and Technical Data

Größe / Size DN 15 DN 20 DN 25 DN 32 DN 40 DN 50 DN 65 Einbauvorschriften und Fitting instructions and technical
d Rp /2”
1
Rp /4”
3
Rp 1” Rp 1 /4” Rp 1 /2”
1 1
Rp 2” technische Daten beachten! data must be observed!
L mm 210 210 216 285 287 297 226 1. Leitung gründlich spülen 1. Flush pipes thoroughly
H1 mm 137 137 137 188 188 188 188 2. Systemtrenner in Fließrichtung einbauen 2. Install controllable backflow preventer in
H2 mm 166 166 166 214 214 214 214 3. Abwasseranschluss herstellen direction of flow
h1 mm 48,5 48,5 48,5 73 73 73 73 4. Absperrventile langsam öffnen 3. Make waste water connection
h2 mm 72,5 72,5 72,5 96 96 96 96 5. Ausgangsseitige Leitung entlüften 4. Slowly open shut-off valves
D1 mm 103 103 103 148 148 148 148 6. Systemtrenner über Prüfanschlüsse 5. Vent pipes at output side
D2 mm 50 50 50 75 75 75 75 (Kugelhähne) entlüften 6. Vent controllable backflow preventer via test
Nenndruck / nom. pressure bar 10 10 10 10 10 10 10 7. Installation auf Dichtheit prüfen connections (ball valves)
max. Temp. / max. temp. °C 60 60 60 60 60 60 60 8. Systemtrenner ist betriebsbereit. 7. Test installation for leaks
Kv-Wert / Kv-value m3/h 3,05 4,9 7,88 16,1 29,5 33,2 42,2 8. Controllable backflow preventer is ready
for use.
SSS
10.0 DRAWINGS
Drg No Drg Title Drg Rev
10.1 STD-001 Engineering Symbols 07
10.2 09247-01-01 Shts 1 & 2 P & I Diagram of Pre-Treatment 03
10.3 09247-01-10 Shts 1 to 6 General Arrangement of RO Plant 03
10.4 09247-13-01 Shts 1 to 27 Electrical Schematic Diagram 03
10.5 09247-13-02 General Arrangement of Control Panel 01
10.6 09247-13-04 Sht 1 to 3 Electrical Connection Diagram 01


Plant

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Plant

Uploaded by

Copyright:

Available Formats

SSS

Salt Separation Services

OPERATION AND MAINTENANCE MANUAL

S846-40 400 m3/d SWRO PLANT

CLIENT : Crystal Cruises

CLIENTS ORDER NO : M-2-09-0884

SALT SEPARATION SERVICES CONTRACT NO : S09247

DATE OF ISSUE : April 2010

PLANT INSTALLED ON : Crystal Symphony

This document is the property of

S846-40 400 m3/d SWRO PLANT

SECTION CONTENTS REV

1.0 Process Description 01

2.0 Electrical Control 01

4.0 Plant Data Sheets 01

5.0 Health and Safety Information 01

7.0 Routine Maintenance/Data Normalisation/ 01

8.0 Fault Finding 01

9.0 Equipment Literature 01

Rev Comments on Revision

Rev 1 Rev 2 Rev 3 Rev 4

S846-40 400 m3/d SWRO PLANT CONTENTS DATE : 19.02.10

OPERATION AND MAINTENANCE MANUALS

Controlled copies of this manual are subject to updating.

FURTHER COPIES OF THIS MANUAL MAY BE OBTAINED FROM

SALT SEPARATION SERVICES LTD

Tel : + 44 (0) 1706 655522

Fax : + 44 (0) 1706 654475

S846-40 400 m³/d SWRO PLANT REVISIONS DATE : 19.02.10

1.0 PROCESS DESCRIPTION

1.2 REVERSE OSMOSIS

1.4 RAW WATER

1.5 FEED/BACKWASH PUMP

1.6 SAND FILTRATION

1.7 ANTISCALANT DOSING

1.8 CARTRIDGE FILTRATION

1.9 HP FEED PUMP AND ASSOCIATED EQUIPMENT

1.10 MEMBRANE ARRAY

1.11 PERMEATE OUTPUT/QUALITY

1.12 MEMBRANE ELEMENT FOULING

1.13 MEMBRANE ELEMENT PRESERVATION

1.14 POTABLE WATER HARDNESS

1.15 POTABLE WATER CHLORINATION

1.16 ENERGY RECOVERY

S846-40 400 M³/DAY SWRO PLANT 1/1 DATE : 19.02.10

1.0 PROCESS DESCRIPTION

Refer to the following drawings in Section 10.0 of this manual:

Drawing No. Title

09247-01-01 Sht 01 P & I Diagram of Pre-Treatment

Filtration of relatively large suspended solids (macro or particle filtration) is

S846-40 400 M³/DAY SWRO PLANT 1/2 DATE : 19.02.10

Microfiltration removes particles in the range of approximately 1000 to 10000 Angstroms

Ultrafiltration provides macro-molecular and molecular separation for particles in the 20

Nanofiltration provides molecular separation and operates in the Ionic/molecular size

10 Angstroms is one thousandth of a micron or one millionth of a millimetre.

1.2 REVERSE OSMOSIS

When two solutions of different concentrations are separated by a semi pemeable

S846-40 400 M³/DAY SWRO PLANT 1/3 DATE : 19.02.10

S846-40 400 M³/DAY SWRO PLANT 1/4 DATE : 19.02.10

1.4 RAW WATER

S846-40 400 M³/DAY SWRO PLANT 1/5 DATE : 19.02.10

1.5 FEED/BACKWASH PUMP

1.6 SAND FILTRATION