module j1 water treatment - infomine · module j1 water treatment 1. ... a. backwash/feed pump ......

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MODULE J1 WATER TREATMENT

1. GENERALIZATION

This Chapter contains a description of the water treatment plant and its

operation

2. STANDARDS OF PERFORMANCE

The operator will understand the water treatment plant layout and

water flows

3. PERFORMANCE OBJECTIVES

The operator will be able to:

• Locate and identify system components

• Describe system flows

4. EVALUATION

After completion of the module, the operator shall be able to:

• Describe the system with the aid of a blank diagram

• Describe process flows

• List the protective devices and alarms

• Explain how to operate and monitor systems

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CONTENTS

CHAPTER 1 – GENERAL DESCRIPTION ....................................................... 7

1. FUNCTION ......................................................................................... 7

2. MAIN COMPONENTS ....................................................................... 9

CHAPTER 2 – DESIGN, CONSTRUCTION, CAPABILITIES ....................... 10

1. RAW WATER SUPPLY ..................................................................... 10

A. Pumps ........................................................................................... 10

B. Motors ........................................................................................... 10

C. Heater ........................................................................................... 11

2. ZEEWEED® MICROFILTRATION .................................................. 11

A. Air Blower .................................................................................... 11

B. Air Blower Motors ........................................................................ 12

C. Permeate/Backpulse Pumps ........................................................ 12

D. Permeate/Backpulse Motors ........................................................ 13

E. Level Control Valve ..................................................................... 13

F. Vacuum Pumps ............................................................................ 14

G. Vacuum Pump Motors ................................................................. 14

3. SOFTENER ....................................................................................... 15

A. Backwash/Feed Pump .................................................................. 15

B. Backwash/Feed Pump Motors ..................................................... 15

C. Brine Pump .................................................................................. 16

D. Brine Pump Motors ...................................................................... 16

4. RO ...................................................................................................... 17

A. RO #1 First Pass Pumps .............................................................. 17

B. RO #1 First Pass Pump Motors ................................................... 17

C. RO #1 Second Pass Pumps .......................................................... 18

D. RO #1 Second Pass Pump Motors ............................................... 18

E. RO #2 First Pass Pumps .............................................................. 19

F. RO #2 First Pass Pump Motors ................................................... 19

G. RO #2 Second Pass Pumps .......................................................... 20

H. RO #2 Second Pass Pump Motors ............................................... 20

5. CIP TANK .......................................................................................... 21

A. Circ Pump ..................................................................................... 21

B. Circ Pump Motor .......................................................................... 21

C. Heater ........................................................................................... 21

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6. EDI ..................................................................................................... 21

A. Pumps ........................................................................................... 21

B. Motors ........................................................................................... 22

7. PRODUCT LINE ............................................................................... 22

A. Outlet Pumps ............................................................................... 22

B. Motors ........................................................................................... 23

8. DRAIN SUMP ................................................................................... 23

A. Pumps ........................................................................................... 23

B. Motors ........................................................................................... 24

9. MAKEUP AIR UNIT ......................................................................... 24

10. SPARE PARTS LIST ......................................................................... 25

A. Chemicals ..................................................................................... 25

B. Consumables ................................................................................ 26

C. Mechanical ................................................................................... 26

CHAPTER 3 - FLOWS ...................................................................................... 27

1. SYSTEM FLOWS .............................................................................. 27

CHAPTER 4 – SAFETY .................................................................................... 29

1. GENERAL PERSONAL PROTECTIVE EQUIPMENT (PPE)........ 29

CHAPTER 5 – PROTECTION DEVICES AND PERMISSIVES .................... 30

1. ALARM/ALERT HANDLING ........................................................... 30

A. General ......................................................................................... 30

B. Alarms vs. Alerts.......................................................................... 31

C. Shutdown Alarms ........................................................................ 32

D. Multiple Alarms ........................................................................... 32

CHAPTER 6 – PLACE IN SERVICE / TAKE OUT OF SERVICE ................. 34

1. SEQUENCE CHARTS ...................................................................... 34

CHAPTER 7 – OPERATE AND MONITOR SYSTEM .................................... 36

1. OPERATING PROCEDURES .......................................................... 36

A. Equipment Layout ....................................................................... 36

B. Raw Water Feed System .............................................................. 36

C. Chemical Pretreatment ............................................................... 37

D. ZeeWeed® Microfiltration System ............................................... 38

E. Dual Softener System .................................................................. 46

F. Reverse Osmosis (RO) Pretreatment .......................................... 47

G. Reverse Osmosis (RO) System .................................................... 48

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H. Electrodeionization (EDI) System ............................................... 51

I. Dual Mixed Bed Ion Exchange Polishing Unit ........................... 51

J. Distribution Break Tank with Outlet Feed Pumps .................... 51

K. Reserve Feedwater ....................................................................... 52

L. Sump Pumps ................................................................................ 52

2. OPERATING PROCEDURES .......................................................... 53

A. ZeeWeed® Operation .................................................................... 53

3. STANDARD OPERATING PARAMETERS ..................................... 65

A. Chemistry ..................................................................................... 65

B. ZeeWeed® ..................................................................................... 66

C. Softener ........................................................................................ 68

D. RO Units ....................................................................................... 68

E. EDI Unit ....................................................................................... 69

F. Transfer System ........................................................................... 70

4. ALTERNATING BETWEEN PRODUCTION MODES ................... 70

A. Switch from normal to double mode. ........................................... 70

B. Switch from double to normal mode. ........................................... 71

C. To switch from one RO to the other during extended NORMAL

MODE operation. .............................................................................. 72

D. To perform a Silt Density Index (SDI) test. ................................ 72

E. ZeeWeed® ...................................................................................... 74

F. Softeners ....................................................................................... 76

G. Reverse Osmosis .......................................................................... 79

H. EDI ............................................................................................... 82

I. Transfer System ........................................................................... 85

5. PLANT OPERATING CONTROLS .................................................. 86

A. Plant Operating Controls ............................................................ 86

6. DESIGN OF AUTOMATIC PLANT CONTROL .............................. 92

A. Plant Indicators ........................................................................... 92

B. Raw Water Feed System .............................................................. 96

C. Chemical Pretreatment ............................................................. 100

D. ZeeWeed® Microfiltration System ............................................. 102

E. Dual Softener System ................................................................ 116

F. Reverse Osmosis (RO) Pretreatment ........................................ 120

G. Reverse Osmosis (RO) System .................................................. 122

H. Electrodeionization (EDI) System ............................................. 127

I. Dual Mixed Bed Ion Exchange Polishing Unit ......................... 128

J. Break Tank with Outlet Feed Pumps ....................................... 128

K. Reserve Feedwater Tanks ......................................................... 129

L. Sump Pumps .............................................................................. 131

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CHAPTER 8 – OPERATE UNDER UPSET CONDITIONS ......................... 133

1. INTRODUCTION ............................................................................ 133

A. Power Up/ Power Interruption .................................................. 134

CHAPTER 9 – TROUBLESHOOTING .......................................................... 135

1. GENERAL ....................................................................................... 135

2. LAB TESTS ..................................................................................... 135

3. FEEDWATER .................................................................................. 138

4. ZEEWEED® .................................................................................... 138

5. SOFTENER ..................................................................................... 140

6. REVERSE OSMOSIS ...................................................................... 143

7. ELECTRODEIONIZATION (EDI) ................................................. 146

8. TRANSFER SYSTEM ..................................................................... 149

CHAPTER 10 – CHECKLISTS AND/OR READINGS .................................. 151

1. BEGINNING OF SHIFT CHECKLIST .......................................... 151

2. OPERATOR LOGSHEETS ............................................................. 153

CHAPTER 11 – SELF CHECK QUESTIONS AND ANSWERS ............ Error!

Bookmark not defined.

1. SELF CHECK EXERCISE – QUESTIONS .ERROR! BOOKMARK

NOT DEFINED.

2. SELF CHECK EXERCISE – ANSWERS .....ERROR! BOOKMARK

NOT DEFINED.

APPENDICES

APPENDIX 1 – FLOW DIAGRAMS AND CONTROL SCREEN

APPENDIX 2 – CONTROL LOGIC SUMMARY, SEQUENCE

CHARTS AND LOG SHEETS

APPENDIX 3 – MSDS SHEETS

APPENDIX 4 – NAG-O-GRAMS

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FIGURES AND TABLES

Figure 3-1 Process and Flow Diagram for High Purity………………………27

Water System

Figure 7-1 ZeeWeed® Membrane Schematic ................................................ 40

Figure 7-2 ZeeWeed® 500 Cassette ............................................................... 42

Figure 7-3 Spiral Wound Module Design ..................................................... 48

Figure 7-4 Reverse Osmosis .......................................................................... 49

Figure 7-5 Reverse Osmosis Membranes ..................................................... 49

Figure 7-6 Transmembrane Pressure Control Schematic ......................... 108

Figure 7-7 Process Pump (P-35) Speed Control ......................................... 110

Table 7-1 Normal Operating Expenses ......................................................... 93

Table 7-2 Backpulse Analysis Chart .......................................................... 113

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CHAPTER 1 – GENERAL DESCRIPTION

1. FUNCTION

This Boiler Feedwater Pretreatment System is designed to treat water

required for TransAlta Utilities Wabamun Generating Station. The system

consists of a ZeeWeed® Microfiltration System, water softening, a dual train

Double Pass Reverse Osmosis (RO) System, Electrodeionization (EDI) skid

and Mixed Bed (MB) Ion Exchange Bottles. Each skid is separately mounted.

The system is capable of delivering 80 USgpm at normal flow and 160 USgpm

at peaking flow.

The first process step utilizes a ZeeWeed® microfiltration system to remove

suspended solids and organic material prior to further reverse osmosis

membrane treatment. To ensure ZeeWeed® system reliability, the process

tank has been divided into two compartments. Each compartment has its

own aeration blower and permeate extraction pump with an additional

shared standby.

Raw water is pumped, pre-chlorinated (to prevent microbial growth), and has

ferric chloride added to enhance Total Organic Carbon (TOC) removal. Direct

steam injection is used, if required, to elevate the temperature prior to the

ZeeWeed®treatment. The permeate flows to the backpulse/break tank. The

majority of lake water TOC can be removed across the ZeeWeed®

microfiltration process.

Co-current Regeneration Softening is the next process in the system, where it

is used to ensure optimum ion rejection at elevated pH across the RO.

Softening ensures meeting the EDI feedwater hardness specification of <0.1

ppm, during both normal and peak flow conditions. Using strong acid cation

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exchange resin (sodium form), the softeners remove calcium and magnesium

from the lake water in preparation for RO separation. The charge pumps

take suction from the ZeeWeed® backpulse/break tank and supply flow to the

softeners. Bisulfite is injected to reduce chlorine prior to the softener and the

effluent water flows on to the reverse osmosis system. Caustic is added to the

process only when the mixed beds are in service to increase the pH level prior

to the RO units.

The primary means of reducing the total dissolved solids (TDS) is by dual

train Double Pass Reverse Osmosis system.

In the Double Pass Reverse Osmosis (RO) System, the feedwater flows to the

RO unit which produces a concentrate (waste) stream, and a permeate

(product) stream. The concentrate is diverted to drain, while the permeate

flows to the EDI System or Polishing Mixed Bed Bottles the collected in a

12,000 US gallon break tank.

Caustic (Sodium Hydroxide) is included as pretreatment for the RO. The

membranes on the RO system will periodically become 'fouled' and will

require a 'Wash', in which the feedwater is flushed from the system, and

various cleaning chemicals are recirculated through the membrane system

for a period of time. While the entire system will run automatically with very

little operator attention, a 'Wash' cycle for the RO is a manual operation

which requires operator intervention. These cleaning chemicals are flushed

from the systems and the water to be treated is re-introduced to the system.

One Clean-In-Place (C.I.P.) unit each services the RO system (which requires

membrane cleaning) and EDI (when required).

The Electrodeionization (EDI) System further purifies the RO permeate. EDI

is a membrane desalination process that uses direct current as the energy

source for desalting. The permeate from this process flows to the break tank.

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The EDI (supplied by others) has its own separate Operating and

Maintenance Manual.

Non-Regenerable Mixed Bed (MB) Ion Exchange Bottles are used as an

alternative to the EDI System should it be out of service. This skid is

composed of two banks of six (6) bottles in a parallel configuration. The

permeate from this process flows to the break tank.

The Outlet Feed Pumps deliver the permeate from the break tank to the

Reserve Feedwater System (RFW) system and recirculates 80 USgpm to the

EDI to optimize its performance (single mode).

2. MAIN COMPONENTS

A. Raw water canal

B. Raw water supply pumps

C. Pick steam injection heater

D. ZeeWeed® Microfiltration membranes

E. Zeolite softeners

F. Brine Injection

G. Reverse Osmosis membranes

H. Electrodeionization system

I. Non-Regenerable Mixed Bed Ion Exchange Bottles

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CHAPTER 2 – DESIGN, CONSTRUCTION, CAPABILITIES

The water treatment plant is designed to transform lake water into

demineralized water, for use as boiler feedwater, at the rate of 80 USgpm in

single mode or 160 USgpm in double mode.

The following lists the equipment in the plant and its design/manufacturing

information and ratings. If at any time information is required on a piece of

equipment, this section can be used as a reference to obtain information.

1. RAW WATER SUPPLY

A. Pumps

i) Equipment #: P-101

Vendor: Chamco Ind.

Manufacturer: Peerless Pump Co.

Model Number: 8LB-4STG

GPM: 250

Feet: 118

RPM: 1760

ii) Equipment #: P-102

Vendor: Chamco Ind.

Manufacturer: Peerless Pump Co.


GPM: 250

Feet: 118

RPM: 1760

B. Motors


Vendor: Chamco Ind.

Manufacturer: U.S. Electric Motors

Model Number: 809 9709 4820 001 F

HP: 10

RPM: 1760

Frame: 215TP

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Vendor: Chamco Ind.


Model Number: 809 9709 4820 001 F

HP: 10

RPM: 1760

Frame: 215TP

C. Heater

i) Vendor: Farrell Eng.

Manufacturer: Pick Heaters

Model Number 6X50-3153

Notes: 125-250 GPM, 32 F

2. ZEEWEED® MICROFILTRATION

A. Air Blower

i) Equipment #: B-85-1

Vendor: Zenon

Manufacturer: Hibon

Model Number XN2.5

ii) Equipment #: B-85-2

Vendor: Zenon

Manufacturer: Hibon

Model Number: XN2.5

iii) Equipment #: B-85-S

Vendor: Zenon

Manufacturer: Hibon

Model Number: XN2.5

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B. Air Blower Motors

i) Equipment #: B-85-1

Vendor: Zenon

Manufacturer: GEC Alsthom

Model Number: HOH32

HP: 10

RPM: 1765

Frame: 215T

ii) Equipment #: B-85-2

Vendor: Zenon


Model Number: HOH32

HP: 10

RPM: 1765

Frame: 215T

iii) Equipment #: B-85-S

Vendor: Zenon


Model Number: HOH32

HP: 10

RPM: 1765

Frame: 215T

C. Permeate/Backpulse Pumps

i) Equipment #: P-35-1

Vendor: Zenon

Manufacturer: Durco

Model Number: 1K3X2-62/60 RV

Man. Part #: 40005-5929

ii) Equipment #: P-35-2

Vendor: Zenon

Manufacturer: Durco


Man. Part #: 40005-5929

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iii) Equipment #: P-35-S

Vendor: Zenon

Manufacturer: Durco


Man. Part #: 40005-5929

D. Permeate/Backpulse Motors

i) Equipment #: P-35-1

Vendor: Zenon

Manufacturer: Reliance

Model Number: 903011-JA

HP: 5

RPM: 3500

Frame: 184T

ii) Equipment #: P-35-2

Vendor: Zenon


Model Number: 966080-HA

HP: 5

RPM: 3500

Frame: 184T

iii) Equipment #: P-35-S

Vendor: Zenon


Model Number: 903011-JA

HP: 5

RPM: 3500

Frame: 184T

E. Level Control Valve

i) Vendor: Zenon

Manufacturer: Samson

Model Number: P161, 2.5”, 150#

Notes: c/w act. & pos.

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F. Vacuum Pumps

i) Equipment #: P-36-A

Vendor: Zenon

Manufacturer: Atlantic Fluidics

Model Number: A5

RPM: 3450

ii) Equipment #: P-36-B

Vendor: Zenon

Manufacturer: Atlantic Fluidics

Model Number: A5

RPM: 3450

G. Vacuum Pump Motors


Vendor: Zenon

Manufacturer: Baldor

Model Number: 34H456-3226

HP: 1

RPM: 3450

Frame: 56CZ


Vendor: Zenon


Model Number: 34H456-3226

HP: 1

RPM: 3450

Frame: 56CZ

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3. SOFTENER

A. Backwash/Feed Pump


Vendor: Zenon

Manufacturer: Durco

Model Number 1K3X1.5-82/73 RV

Man. Part #: 400005-6041

GPM: 250

Feet: 172

RPM: 3600


Vendor: Zenon

Manufacturer: Durco

Model Number: 1K3X1.5-82/73 RV

Man. Part #: 400005-6041

GPM: 250

Feet: 172

RPM: 3600

B. Backwash/Feed Pump Motors


Vendor: Zenon

Manufacturer: Reliance Electric

Model Number: P25G0398J

HP: 20

RPM: 3525

Frame: 256T


Vendor: Zenon


Model Number: P25G0398J

HP: 20

RPM: 3525

Frame: 256T

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C. Brine Pump


Vendor: Zenon

Manufacturer: Durco

Model Number: 1K1.5X1-62/53 RV

Man. Part #: 4500005-6045

GPM: 21

Feet: 119

RPM: 3600


Vendor: Zenon

Manufacturer: Durco

Model Number: 1K1.5X1-62/53 RV

Man. Part #: 4500005-6045

GPM: 21

Feet: 119

RPM: 3600

D. Brine Pump Motors


Vendor: Zenon


Model Number: P18G3345K

HP: 3

RPM: 3520

Frame: 182T


Vendor: Zenon


Model Number P18G3345K

HP: 3

RPM: 3520

Frame: 182T

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4. RO

A. RO #1 First Pass Pumps

i) Equipment #: P-41A-1

Vendor: Zenon

Manufacturer: Grundfos

Model Number: CRN30-80/7 U-G-G-AUUE

Man. Part #: B 9838 34130067

GPM: 130

Feet: 436

RPM: 3450

ii) Equipment #: P-41B-1

Vendor: Zenon



Man. Part #: B 9838 34130067

GPM: 130

Feet: 436

RPM: 3450

B. RO #1 First Pass Pump Motors


Vendor: Zenon


Model Number: 09E586X461G1

Man. Part #: 85-60025

HP: 20

RPM: 3525

Frame: 281TSC


Vendor: Zenon



Man. Part #: 85-60025

HP: 20

RPM: 3525

Frame: 281TSC

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C. RO #1 Second Pass Pumps


Vendor: Zenon



Man. Part #: B 9838 34130067

GPM: 130

Feet: 436

RPM: 3450


Vendor: Zenon



Man. Part #: B 9838 34130067

GPM: 130

Feet: 436

RPM: 3450

D. RO #1 Second Pass Pump Motors


Vendor: Zenon



Man. Part #: 85-60025

HP: 20

RPM: 3525

Frame: 281TSC


Vendor: Zenon

Manufactuer: Baldor


Man. Part #: 85-60025

HP: 20

RPM: 3525

Frame: 281TSC

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E. RO #2 First Pass Pumps


Vendor: Zenon



Man. Part #: B 9838 34130067

GPM: 130

Feet: 436

RPM: 3450


Vendor: Zenon



Man. Part #: B 9838 34130067

GPM: 130

Feet: 436

RPM: 3450

F. RO #2 First Pass Pump Motors


Vendor: Zenon



Man. Part #: 85-60025

HP: 20

RPM: 3525

Frame: 281TSC


Vendor: Zenon



Man. Part #: 85-60025

HP: 20

RPM: 3525

Frame: 281TSC

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G. RO #2 Second Pass Pumps


Vendor: Zenon



Man. Part #: B 9838 34130067

GPM: 130

Feet: 436

RPM: 3450


Vendor: Zenon



Man. Part #: B 9838 34130067

GPM: 130

Feet: 436

RPM: 3450

H. RO #2 Second Pass Pump Motors


Vendor: Zenon



Man. Part #: 85-60025

HP: 20

RPM: 3525

Frame: 281TSC


Vendor: Zenon



Man. Part #: 85-60025

HP: 20

RPM: 3525

Frame: 281TSC

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5. CIP TANK

A. Circ Pump


Vendor: Zenon

Manufacturer: Durco


Man. Part #: 4500005-6072

GPM: 200

Feet: 163

RPM: 3600

B. Circ Pump Motor


Vendor: Zenon


Model Number: P25G0397K

HP: 15

RPM: 3530

Frame: 254T

C. Heater

i) Equipment #: H-83

Vendor: Zenon

Manufacturer: Caloritech

Model Number CX1309F337MRTY

Man. Part #: T98-06104A

Notes: 460V, 9kW

6. EDI

A. Pumps

i) Equipment #: P1-4

Vendor: Zenon


Model Number: CRN30-20 U-G-G-AUUE

Man. Part #: D 9821 34136062E

GPM: 130

Feet: 119

RPM: 3450

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ii) Equipment #: P2-4

Vendor: Zenon


Model Number: CRN30-30 U-G-G-AUUE

Man. Part #: A 9826 34136063E

GPM: 130

Feet: 178

RPM: 3450

B. Motors

i) Equipment #: P1-4

Vendor: Zenon


Model Number: 36H302W385C1

Man. Part #: 85-60017

HP: 7.5

RPM: 3450

Frame: 213TC

ii) Equipment #: P2-4

Vendor: Zenon


Model Number: 37F680X56F5

Man. Part #: 85-60022

HP: 10

RPM: 3450

Frame: 215TC

7. PRODUCT LINE

A. Outlet Pumps

i) Equipment #: P-71A

Vendor: Zenon

Manufacturer: Durco


Man. Part #: Military P4A

GPM: 160

Feet: 104

RPM: 3600

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ii) Equipment #: P-71B

Vendor: Zenon

Manufacturer: Durco


Man. Part #: Military P4B

GPM: 160

Feet: 104

RPM: 3600

B. Motors

i) Equipment #: P-71A

Vendor: Zenon


Model Number: P21G4900 YZ

HP: 7.5

RPM: 3500

Frame: 123T

ii) Equipment #: P-71B

Vendor: Zenon


Model Number: P21G4900 YZ

HP: 7.5

RPM: 3500

Frame: 123T

8. DRAIN SUMP

A. Pumps


Vendor: Chamco Ind.

Manufacturer: Chamco


GPM: 125

Feet: 82

RPM: 1760

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Vendor: Chamco Ind.

Manufacturer: Chamco


GPM: 125

Feet: 82

RPM: 1760

B. Motors


Vendor: Chamco Ind.


Model Number: 809 970947 89 001F

HP: 5

RPM: 1770

Frame: 184TP


Vendor: Chamco Ind.


Model Number: 809 970947 89 001F

HP: 5

RPM: 1770

Frame: 184TP

9. MAKEUP AIR UNIT

A.

i) Vendor: Willowridge

Manufacturer: I.C.E. Manufacturing

Model Number: BMA112MODE

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10. SPARE PARTS LIST

The following material can be ordered from stores at the warehouse

unless otherwise specified. Material set up in the warehouse has a

stock code number which can be referenced when the material is

required.

A. Chemicals

Sodium hypochlorite Stock code # 80295

Order through the water lab

Metabisulphite Stock code # 80297

Order through the water lab

Caustic Ordered as ‘one time buy’ and can be

ordered through the water lab.

Ferric chloride Ordered as ‘one time buy’ and can be


Pneumatic salt

for brine tank

Ordered as ‘one time buy’ and can be


MC-1 Cleaning solvent Stock code # 87347

MC-4 Organic Cleaner Stock code # 87348

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B. Consumables

RO CIP skid micron filters Stock code # 80365

ZeeWeed® blowers inlet filters Stock code # 40224

Softener micron filters Stock code # 80317

Note: Procedure for installing RO CIP skid micron filters:

a) In order to replace the double ended style filters, remove

the hold down place and the tope end cap from each filter

element.

b) Lift the old elements up to clear the center rods and

discard the elements.

c) Install the new elements over the center rods and the end

caps and install the hold down plate.

C. Mechanical

EDI brine pump Stock code # 80382

EDI product pump Stock code # 80381

1400E panel view Stock code # 80272

Pick heater internals Stored in operator locker in

water treatment plant

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CHAPTER 3 - FLOWS

1. SYSTEM FLOWS

The process flow diagram shown in Figure 3-1 summarizes the

process flows in the water treatment plant.

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CHAPTER 4 – SAFETY

1. GENERAL PERSONAL PROTECTIVE EQUIPMENT (PPE)

The following are mandatory when handling any of the chemicals in

the water treatment plant:

- face mask

- safety goggles

- boots (CSA approved)

- gloves

- overalls

One must also be familiar with and follow the Material Safety Data

Sheets (MSDS) for each chemical, located in Appendix 3 Material

Safety Data Sheets. The warehouse also has a copy available for

reference, and should be reviewed prior to job commencement.

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CHAPTER 5 – PROTECTION DEVICES AND PERMISSIVES

1. ALARM/ALERT HANDLING

A. General

a) All alarms/alerts are enunciated with a message, and/or

light and some audible indication (i.e. horn or steady

beep) at one or more of the MMIs, the PC or a Control

Panel. The alarms/alerts and corresponding times are

recorded.

b) The operator must clear (acknowledge) the alarm/alert to

clear the alarm banner before any push buttons on the

screen can be activated. The operator can, however,

silence the horn by pressing the Horn Silence push

button on the MMI. The Horn Silence push-button will

function without password access.

c) An Alarm Acknowledge ‘push-button’ is programmed

and accessible from the MMI. This push-button will

silence the horn and record the time the alarm/alert was

acknowledged. The Alarm Acknowledge ‘push button’

will not function without password access.

d) An Alarm Reset ‘push-button’ is also programmed, again

accessible from the screen. This push-button re-sets the

alarm/alert, presumably after the operator has done

something (mechanically or by adjusting a set point) to

clear the alarm/alert condition, preventing it from

immediately recurring. If the alarm condition still

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physically exists, the alarm horn will again sound and the

appropriate Alarm Message screen will again be

displayed. Touching the Alarm History button will

display previous alarms. The operator cannot reset the

alarm/alert without operator level password access.

B. Alarms vs. Alerts

a) All alarms shut off some devices to provide protection to

personnel and the major components such as the process

pump. Alerts do not shut down devices but only warn

that the plant needs attention. Alerts are provided to

protect less sensitive components. Rather than shutting

down equipment due to these alerts (e.g., low tank level),

continued operation is allowed with the intention that

immediate operator attention can provide uninterrupted

production of good quality water from this equipment.

Production quality and quantity will drop off quickly

without operator attention.

a) Alarms and alerts from instruments (e.g., pressure and

flow transmitters, or level instrumentation) that require a

pump or some device to be on (to generate the flow or

pressure, or protect a pump from running dry) will be

ignored if the device to be protected is not on. Some

devices may not be On or Open because they are

manually overridden or are awaiting the proper operation

sequence before being adjusted by the PLC.

J1 (32)

C. Shutdown Alarms

a) Some alarms shut down a Process unit or entire plant (i.e.

the appropriate valves will close and pumps will stop

running). Restarting after a shutdown will require:

(i) the alarm condition (cause) be physically cleared.

(ii) the alarm be reset via the Alarm Reset

‘push-button’.

The reader should refer to the Control Logic Summary

Chart in the Zenon Operations and Mainteance Manual,

Section 4, for all the unit shutdown alarms. Some of the

alarms / alerts only put a unit into Standby and allow

the unit to go back into Production once the alarm has

been cleared (e.g., if a blower shuts down on overload, the

PLC will put the ZeeWeed® units into Standby until flow

is once again detected at the flow switch).

D. Multiple Alarms

It is possible for two or more independent alarms to occur at the

same time. Multiple alarms / alerts can be silenced by touching

the Horn Silence or Alarm Acknowledge button multiple

times, and reset with one depression of the Alarm Reset Push-

button (this button clears all alarm conditions in the PLC); any

alarm conditions that still exist will, however, immediately re-

annunciate.

J1 (33)

Note: Horn Silence will disable the horn for all active alarms. When a new

alarm/alert condition is triggered or an existing alarm condition is

cleared then reset again, the horn is automatically re-activated.

J1 (34)

CHAPTER 6 – PLACE IN SERVICE / TAKE OUT OF SERVICE

1. SEQUENCE CHARTS

The tables presented in Appendix 2 define which pumps and actuated

valves will be running and open in any condition of operation

(automatically or manually controlled) as well as which manual valves

must be opened or closed for any of the same operating conditions.

This startup sequence chart shows the order in which the devices in

the plant will be started up after a power interruption or after an

emergency stop has been reset. Unless other wise indicated, there is a

5-second delay between each step.

1. Wait 60 seconds to allow transmitters to warm up and complete a

self-diagnostics.

2. Align all valves as per factory default (power up from E2 PROM) or

last position. Start B-85-1 if it was in Auto On.

4. Start B-85-2 if it was in Auto On.

5. Start B-85-S if it was in Auto On.

6. Start P-101 if it was in Auto On.




10. Start P-36A if it was in Auto On.

11. Start P-36B if it was in Auto On.



J1 (35)





18. Put RO Unit 1 into same mode as prior to power interruption or E-

Stop.

19. Put RO Unit 2 into same mode as prior to power interruption or E-

Stop.


21. Put ZeeWeed® Unit 1 into same mode as prior to power

interruption or E-Stop (enable P-35-1 or P-35-S when substituted).

Put ZeeWeed® Unit 2 into same mode as prior to power interruption or

E-Stop (enable P-35-2 or P-35-S when substituted).

J1 (36)

CHAPTER 7 – OPERATE AND MONITOR SYSTEM

1. OPERATING PROCEDURES

In this sub-section, major equipment functionality is described. This

subsection focuses on hardware and simple control of devices that are

not interlocked with other major equipment. At the end of this section,

the control of the plant and key devices is described.

The unit processes are consistent with and are more or less broken out

as per the P&IDs. Some devices such as pressure transmitters,

flowmeters, etc. are not described, as they are considered self-

descriptive.

A. Equipment Layout

Drawing 9348-P-001 shows the equipment layout and is located

in Appendix 1.

B. Raw Water Feed System

a) Raw Water Feed Pumps

Supply water is taken from the inlet canal south of the

Wabamun Generating Station. A pair of pumps P-101

and P-102 are used to provide feed to the ZeeWeed®

Microfiltration System. To prevent the pumps from

running dead-headed, a 3-way Yarway control valve FCV-

165 is installed at the common pump outlet to provide

bypass flow back to the sump. Pressure switch PSH-150

protects the feed pumps in case of malfunction of FCV-

165.

J1 (37)

b) Feed Temperature Control Devices

A stand alone steam injection system is installed on the

feed line to maintain the feed water temperature at 25º C.

The temperature control system is not connected to the

PLC and is not controlled by ZENON. An additional

temperature transmitter TT-7621 is installed for

membrane protection.

c) Feed Flow Control Devices

Since the feed pumps operate at a constant speed, a feed

control system is installed to control the level in

ZeeWeed® Membrane Tanks. The feed control system

consists of a flowmeter FIT-7620 and a flow control valve

FCV-7620.

C. Chemical Pretreatment

a) Hypochlorite Addition

Sodium Hypochlorite is added to the raw water feed to

inhibit any bacterial growth. This ensures there will be

no biological activity in the system. Sodium Hypochlorite

addition is achieved by the sodium hypochlorite inject

assembly complete with a chemical tank TK-24 and a pair

of metering pumps P-24A and P-24B.

b) Ferric Chloride Addition

Ferric Chloride is added to the raw water feed to promote

coagulation in the ZeeWeed® membrane tank. This

improves the TOC removal by the ZeeWeed®

Microfiltration System. Ferric Chloride addition is

achieved by the ferric chloride injection assembly

J1 (38)

complete with a chemical tank TK-26 and a pair of

metering pumps P-26A and P-26B.

D. ZeeWeed® Microfiltration System

The primary purpose of the ZeeWeed® Microfiltration System is

to remove suspended solids and organic material prior to further

hardness removal and Reverse Osmosis (RO) membrane

treatment.

a) ZeeWeed® Unit 1 and Unit 2

The reader should refer to the Process and

Instrumentation Diagrams 9348-D-001 to 9348-D-005

(located in Appendix 1) to follow the description of the

equipment described below. The plant includes two

membrane tanks that hold membrane cassettes for both

ZeeWeed® Unit 1 and ZeeWeed® Unit 2. The two

identical units (except for device tag suffixes -1 and -2) are

for the most part independent of each other.

i) Membrane Tank (TK-34)

The membrane tank holds the membrane aerators

and membrane cassettes. The tank is also

equipped the following devices:

• Level transmitter and switches to monitor tank

level.

• Cassette isolation valves.

J1 (39)

ii) Membrane Cassettes

The ZeeWeed® filtration surface is a neutral, strong

polymeric membrane cast on the outside surface of a

porous support fibre. Each membrane tank contains two

membrane cassettes. Each cassette is supplied with 6

membrane modules but can accommodate 8 membrane

modules. The membranes separate the feed stream into a

product (permeate) stream and a concentrate (reject or

waste) stream. The membranes (contained in cassettes)

are connected to a top and bottom headers that are used

to draw permeate from the membranes to the process

pump. The membrane racks also contain aerators that

maintain a turbulent flow pattern along the membrane

fibres. This helps to keep the filtration surface clear of

contaminant build-up, which would cause a reduction in

the efficient operation of the unit.

J1 (40)

Coarse BubbleDiffuser

Coarse BubbleDiffuser

PermeateTo Bottom

Header

PermeateTo TopHeader

Membrane

Bulk Fluid(containing solids)

Aeration Bubbles(for fluid agitation)

SupportMaterial

Figure 7-1 ZeeWeed® Membrane Schematic

Figure 7-1 shows a schematic of a ZeeWeed® membrane

fibre in operation. The filtrate (permeate) is drawn

through the membrane from the bulk fluid by a partial

vacuum applied within the membrane fibre lumens.

Periodically, the membranes are backpulsed by pumping

J1 (41)

a fraction of the permeate back into the membrane fibres,

forcing flow in the reverse direction, to remove fouling

material from the surface of the membrane.

The ZeeWeed®-500 membrane modules consist of

many hollow fibres which are coated on the outside

with the membrane and run vertically between top

and bottom permeate headers on the membrane

module. Figure 7-2 shows a typical module

assembly.

J1 (42)

Figure 7-2 ZeeWeed® 500 Cassette

iii) ZeeWeed® Process Pump (P-35)

Each ZeeWeed® unit has a dedicated process pump

P-35. In addition there is a backup process pump

P-35-S described later that can be used with either

ZeeWeed® Unit 1 or ZeeWeed® Unit 2.

J1 (43)

Each process pump draws permeate from the

membranes and then is used to backpulse the

membranes. During Production, the variable

frequency drives control pump speed to achieve

desired permeate flow without exceeding the

allowed transmembrane pressure (TMP). During

Backpulse a constant backpulse pressure is

maintained. Detailed pump control for these cases

is provided in Part 2 Chapter 2.

The variable frequency drive (VFD) is set up with a

maximum and minimum range of operation. This

will provide protection to both the motor and

ancillary equipment. The adjustable output range

on the PLC is programmed to be within this VFD

range.

The VFDs are protected from undervoltage or

overvoltage changes. If there is an unacceptable

voltage change, the VFD will cut out and send a

signal to the PLC. The PLC will attempt to restart

the process pump three times at 30 second

intervals before recording a pump fault. This delay

(not adjustable from the MMI) must be greater

than or equal to the delay programmed into the

VFD.

J1 (44)

iv) Membrane Aeration Blower (B-85)

Aeration agitates the membranes to improve

permeation. Each ZeeWeed® unit has a dedicated

membrane aeration blower B-85. In addition there

is a backup aeration blower B-85-S described later,

that can be used with either ZeeWeed® Unit 1 or

ZeeWeed® Unit 2.

b) ZeeWeed® Backpulse/Break Tank (TK-88)

The permeate from each ZeeWeed® Unit is stored in a

common tank where it is available as backpulse water

and Softener/RO feed. The tank is equipped with a level

transmitter used for pump protection and control of

ZeeWeed® and RO units.

c) ZeeWeed® Cip Tank (TK-81)

A Wash procedure is required when the membranes

become fouled and are not capable of producing the

designed permeate flow. The membranes can be cleaned

in place using the CIP tank TK-81 equipped with a set of

level switches for pump protection and control. A portion

of the permeate from a running ZeeWeed® Unit can be

sent into the common CIP tank, where it is available as

backwash solution once the cleaning chemicals are added

(manual addition).

J1 (45)

d) Spare Blower B-85-S

The spare blower B-85-S has a B-85-1 / B-85-2 / None

selector switch. The operator must select whether blower

B-85-S is to operate for ZeeWeed® Unit 1, Unit 2, or

None. This transfers all control logic (blower B-85-S will

show B-85-1 or B-85-2 at the MMI) from the normal

blower to B-85-S. Selecting blower B-85-S to operate for

another blower will also disable that blower.

e) Spare Process Pump P-35-S

The spare process pump P-35-S has a Unit 1 / Unit 2 /

None selector switch. The operator must select whether

process pump P-35-S is to operate for Unit 1, Unit 2, or

None. This transfers all control logic (process pump P-

35-S will show P-35-1 or P-35-2 at the MMI) from the

normal process pump to the spare process pump P-35-S.

Selecting process pump P-35-S to operate for a ZeeWeed®

unit will also disable the normal process pump for that

ZeeWeed® unit.

f) Vacuum Pumps (P-36A and P-36B)

The process pump (P-35-x) can lose its prime due to excess

air in the treated water. The system contains a pair of

vacuum pumps P-36A and P-36B. Only one pump is

required to remove air that is entrained in the permeate

before it is drawn into the process pumps for both

ZeeWeed® units. The air and water enter the Air

Separation Vessel TK-35-1 and TK-35-2 where the air is

allowed to separate from the water. The vacuum pump

removes the separated air from the water.

J1 (46)

One or two vacuum pumps can be operated at a time. The

first pump placed in Auto mode becomes the lead pump

and starts automatically. The other pump (when in

Auto) becomes the standby pump. If the operator presses

Stop for the pump that is running (or the pump fails), the

standby pump will become the lead pump and will come

on automatically. Start must be used for the second

(standby) pump to operate two pumps at the same time.

E. Dual Softener System

a) Bisulphite Addition

Sodium bisulphite is added to the softener feed water to

reduce any oxygen that may be present. Removing

oxygen makes the water less corrosive. Sodium bisulphite

addition consists of a tank (TK-23) and a pair of metering

pumps P-23A and P-23B.

b) Softeners

Softeners are provided to remove hardness (multivalent

cation removal) from the prefiltered water. These ions

are replaced with sodium and chloride. If hard water is

allowed to enter the Reverse Osmosis (RO) units, the

membranes would rapidly become fouled with

precipitated material. Two Softener units marked as unit

A and B are provided. Each Softener unit has a capacity

of approximately 185,000 gallons (24 hours during

NORMAL operating conditions). Only one Softener unit

J1 (47)

is On-line at a time (the other unit is either in Standby

or Regeneration).

c) Softener Regeneration System

A brine system is used to regenerate the softeners.

Pretreated water is continuously fed to the brine tank TK-

29 which dissolves rock salt to make brine. A level control

valve maintains a constant level in the brine tank. A pair

of pumps (P-29A and P-29B) are provided to pump brine

through the softener during a regeneration cycle (brine is

diluted before entering the softener), which lasts

approximately 1 ½ hours.

F. Reverse Osmosis (RO) Pretreatment

The RO Pretreatment equipment consists of a pair of cartridge

filters, caustic feed system (TK-25, P-25A, P-25B, AIT-2520) and

RO feed conductivity analyzer AIT-4131. The cartridge filters

are used to remove any residual suspended solids or

demineralizer resin beads (5 µm nominal).

Inlet and outlet filter pressure indicators allow verification of

the filter condition.

The addition of caustic hydroxide improves the quality of the

product water by promoting elimination of dissolved CO2.

J1 (48)

G. Reverse Osmosis (RO) System

This water treatment system employs a dual pass Reverse

Osmosis (RO) system as the primary means to eliminate

dissolved material in the softened feed water. The membranes

used are a spiral wound module design (see Figure 7-3).

Anti-Telescoping Device

Concentrate

Permeate

Perforated CentralTube

Feed Solution

Carrier Material

Sealed Edge(glue)

Outer Layer SpacerMaterial

Membrane

Feed ChannelSpacer

Membrane Backing Material

Permeate Flow(after passing thru membrane)

Figure 7-3 Spiral Wound Module Design

RO is a pressure induced reversal of the natural flow

phenomenon of osmosis. Osmosis is the spontaneous passage of

a liquid through a semi-permeable membrane from a dilute to a

more concentrated solution (see Figure 7-4).

J1 (49)

PI

Figure 7-4 Reverse Osmosis

The membranes then separate the feed stream into a 'purified' product

stream (called Permeate) and a concentrate stream (called

Concentrate), in which the bulk of the mineral salts, bacteria etc.

from the feed stream are now located (see Figure 7-5).

Figure 7-5 Reverse Osmosis Membranes

The system contains two trains tagged as RO Unit 1 and RO

Unit 2 (all devices within each train have tags with a suffix –1

J1 (50)

and –2 respectively. Each pump within RO system is duplicated

(duplicated pumps have a suffix A and B).

a) First Pass RO

The process pump P-41A/B pressurizes the feed water to

the design pressure required by the First Pass RO

membrane array (4:2 configuration). The operating point

for the First Pass RO is set by two manually adjusted

valves HCV-4181 and HCV-4082 (refer to drawing 9348-

D-006 Appendix 1). First Pass RO permeate is fed to the

Second Pass RO and the First Pass RO reject stream is

send to drain.

b) Second Pass RO

The process pump P-43A/B pressurizes the First Pass RO

permeate to the design pressure required by the Second

Pass RO membrane array (2:1:1 configuration). The

operating point for the Second Pass RO is set by two

manually adjusted valves HCV-4381 and HCV-4282 (refer

to drawing 9348-D-007 Appendix 1). Second Pass RO

permeate (RO product) is sent to the EDI System and the

Second Pass RO reject stream is diverted to the First Pass

RO feed.

c) RO Clean in Place (CIP) System

The CIP (Clean in Place) system is used to clean the RO

membranes when they become fouled. It may also be

used to recirculate membrane preservatives into the

membrane housings if the membranes are to be stored for

extensive periods of time. Both of the above procedures

J1 (51)

require the operator to place an RO unit in Wash mode

and to adjust the position of manual valves to configure

the required recirculation loop. Tank TK-83 is used to

prepare the cleaning solution (or preservative). The built-

in electric heater H-83 maintains proper temperature of

the cleaning solution. This unit is also used to provide

Cleaning Solution to the EDI.

H. Electrodeionization (EDI) System

The Electrodeionization (EDI-150) System provided by Ionics is

a stand alone unit that will further purify the RO permeate by

removing any residual silica and carbon dioxide. It has its own

Operating and Maintenance Manual.

I. Dual Mixed Bed Ion Exchange Polishing Unit

The mixed bed ion exchange system is used as a polishing to

replace the EDI unit should it fail to produce quality water and

require cleaning. This is a stand alone passive unit with no

controls associated with the unit.

Note: Caustic injection must be started prior to putting mixed

beds in service.

J. Distribution Break Tank with Outlet Feed Pumps

a) Break Tank TK-71

Break Tank TK-71 serves as a reservoir of treated water.

The treatment system will maintain this tank level at

above LYH1-7126. During NORMAL operation the 80

J1 (52)

USgpm will be recirculated through the EDI system (FV-

7184).

b) Outlet Feed Pumps P-71A/B

The pair of outlet pumps provide pressurized feed for

boiler feed tanks and recirculate the contents of the

Distribution Break Tank through the EDI system. When

in DOUBLE capacity mode (peak flow) due to high water

production/consumption the recirculation loop is closed.

K. Reserve Feedwater

The treated water from the Distribution Break Tank will be fed

to the existing RFW tanks TK#1a, TK#1b, TK#2a, TK#2b, TK#3,

and TK#4. From the control point of view the pair TK#1a and

TK#1b can be treated as a single tank. The same applies to

tanks TK#2a and TK#2b.

Each tank is equipped with a corresponding high level switch

that indicates when the tank is full.

Pressure switch PSH-153 installed on the common tank feed

header protects outlet feed pumps P-71A and P-71B from

running dead-headed.

L. Sump Pumps

A pair of pumps P-103 and P-104 are used to empty the local

sump. To prevent the pumps from running dead-headed, a 3-

way Yarway control valve FCV-166 is installed at the common

pump outlet to provide bypass flow back to the sump. Pressure

switch PSH-155 protects the feed pumps in case of malfunction

J1 (53)

of FCV-166. Sump level is measured by level transmitter LIT-

156.

2. OPERATING PROCEDURES

A. ZeeWeed® Operation

a) Cleaning Of The ZeeWeed® Membranes

i) Materials Required

Sequence Chart and P&ID: The system

Sequence Chart (Appendix 2) and P&ID’s

(Appendix 1) are required.

Chemicals: Depending on the type of cleaning

required and the fouling on the membranes, a

sodium hypochlorite solution, MC-1 (citric acid)

cleaning solution may be required. ZENON will

advise the customer what chemicals are suitable.

ii) Safety

Always wear safety goggles, boots and gloves when

handling the cleaning chemicals. Overalls are

mandatory. Also, be familiar with and follow the

MSDS for each chemical, included in Appendix 3

Material Safety Data Sheets.

iii) Cleaning in General

The frequency of cleaning will depend on the

specific operating conditions (operating time, feed

flow rates, permeate flow rates) and on the

particular chemistry of the fluid being processed.

J1 (54)

During normal operation, membranes can become

fouled by mineral salts (CaCO3, CaSO4, MgSO4), as

well as iron (Fe), insoluble organics (e.g., oil) or

biological matter (bacteria or products from

bacterial action). Deposits build up on the

membrane surface during operation and cause a

loss in flux. It should be noted that flux will drop if

the feed temperature decreases. This is normal

and does not necessarily indicate fouling.

In order to maximize membrane life and operation,

the system automatically undergoes backpulse

cleaning periodically to remove deposits from the

surface of the ZeeWeed® membrane. This

minimizes fouling and increases the time required

between chemical cleanings of the system.

Chemical cleaning of the ZeeWeed® membranes is

required whenever the transmembrane (TMP)

reaches -45.0 kPa (14.0 “Hg”). If the ZeeWeed®

membrane cleaning is not done at the

recommended time, further fouling may be

irreversible. Cleaning is facilitated by increased

temperature and reverse permeation. With

chemical cleanings, the ZeeWeed® membrane

CAUTION:

Proper data normalization is required to analyze

the parameters

J1 (55)

permeability must be recorded before and after a

cycle in order to determine the effectiveness of the

cleaning.

1) Cleaning Chemicals

Normally, a sodium hypochlorite (NaOCl)

solution is sufficient if a chemical washing of

the ZeeWeed® membranes is required. For

more severe fouling that can not be removed

with this solution, ZENON offers specifically

designed and formulated cleaning chemicals

for ZENON ZeeWeed® membranes. These

approved cleaning chemicals should be used

with the wash procedures given in this

manual. Safety and handling instructions

for these cleaning chemicals can be found in

Appendix 3: Material Safety Data Sheets.

WARNING

NEVER APPLY BACKWASH OR BACKPULSE PRESSURES

GREATER THAN 10 PSIG (24.7 PSIA) ACROSS THE ZEEWEED®

MEMBRANE. DELAMINATION MAY OCCUR RESULTING IN

IRREVERSIBLE DAMAGE TO THE MEMBRANE.

NOTE

The greater the pressure during the cleaning, the greater the

reverse permeation flow rate of the wash solution into the process

tank. Also, no treated water is being produced during any cleaning

method.

J1 (56)

APPROVED CLEANING CHEMICALS

SODIUM

HYPOCHLORITE

An oxidation agent used to remove organic fouling on the

membranes.

ZENON MC-1 An acidic cleaning agent used to clean the membranes in the

event of fouling due to mineral scales, iron or other metals

fouling.

The concentrations, amounts and design pH

of the approved cleaning chemical solutions

are given below. The total required quantity

is based on a wash solution prepared with

100 US gallons of potable water. The

chemical quantities should be adjusted if the

actual pH of the solution is different from the

design pH or a different volume of water is

used to prepare the solution. Also, the

amount of sodium hypochlorite required is

based on a 12% solution, this amount must

be adjusted if a different sodium hypochlorite

solution is used.

NOTE

Other cleaning chemicals may contain materials incompatible with

the ZeeWeed® membranes and should NOT be used. Use of non-

approved cleaning chemicals voids any membrane warranties.

J1 (57)

CHEMICALS REQUIRED PER WASH OF THE MF SYSTEM

Chemical Purpose Design Wash

Concentration

Approx. Quantity

Required

Design pH

During Wash

Sodium

Hypochlorite

Organic Cleaner 250 mg/L 800 mL

(0.2 US gal.)

n/a

MC-1 Scale Removal 20 g/L 7.6 kg 2.5 - 3.5

2) Cleaning Chemical Selection

A cleaning chemical’s effectiveness in

removing a particular foulant can only be

determined through experience with

operation of the system. Occasionally it may

be necessary to use different types of

cleaners during a cleaning cycle to remove

foulant mixtures or to determine the best

cleaning chemical for the wash.

Initially, the system should be cleaned

monthly with sodium hypochlorite solution,

carefully recording the data on the cleaning

log sheet (see Appendix 2). This data should

be faxed to the ZENON Service Department,

at (905) 639-1812, for a review and

recommendation each month. Depending

SAFETY NOTE

Handle the cleaning chemicals with care (refer to Appendix 3

Material Safety Data Sheets). Wear a face mask, rubber apron and

rubber gloves when handling these chemicals.

J1 (58)

on the performance obtained, the

cleaning intervals may then be

increased from once per month to

correspond with a permeate flux

decline of 20%.

If cleaning with the sodium hypochlorite

cleaning solution does NOT correct for

fouling, cleaning with the other cleaning

chemicals should be performed. Either or

both alternate cleaning chemicals may be

required.

ZENON also recommends that the system be

cleaned thoroughly with sodium hypochlorite

(and possibly MC-1, if experience finds either

to be necessary), and sanitized prior to any

shutdown longer than 72 hours.

iv) Backpulse Cleaning

Backpulse cleaning uses permeate from the effluent

stream stored in the Backpulse Tank. Chlorine (in

the form of sodium hypochlorite) is automatically

added to the ZeeWeed® Membrane Tank Feed for

disinfecting purposes, and the permeate is pumped

back through the membranes at low pressures and

NOTE

Proper data normalization is required.

J1 (59)

high flow rates (up to 200% of the normal

permeation rate). During a backpulse, the

permeate is pumped to the inside of the membrane

fibres and pressed backwards through the fiber and

membrane to remove any particles that may have

adhered to the membrane surface.

Backpulse cleanings occur automatically during

normal operation of the system, at an operator set

frequency and duration. This frequency and

duration will be continually optimized by the

operator for changes in operating conditions and

the feed to the system. During periods of high

permeation, the backpulse duration can be limited

by the capacity of the Backpulse Tank. If the

system runs out of stored permeate during a

Backpulse, the system will automatically stop the

cleaning, reset the system and Backpulse timer and

return to normal operating mode.

A backpulse can also be initiated by the operator of

the system, by touching the “Initiate Backpulse”

button on the Man-Machine-Interface (MMI). This

will cause a backpulse to occur for the duration

already set by the operator, and the backpulse

timer will be reset so that future backpulses will

occur at the set frequency. The “Initiate

Backpulse” button is only active in RUN mode.

J1 (60)

v) BackWash Cleaning

A backwash is similar to a backpulse except that

backwash does not return to production after time

expires but goes to WASH Standby. A backwash

can also be run through the membranes for as long

as the operator wants by touching the “Initiate

Backwash” button, which is only active in WASH

mode. The system will then backwash the

membranes until the time expires or low level alert

on the CIP Tank is reached (which can be

prolonged by adding potable water to the CIP

Tank) whichever comes first. For improved

cleaning of the membranes, warm water (80 -

100oF) and cleaning chemicals can also be added to

the CIP Tank to be pumped through the

membranes. Potable water (and additional

chemicals, if being used) will have to be added to

the CIP Tank if more than one backwash is desired,

and this process may be repeated as often as

required. Remember to thoroughly flush the

system and drain and rinse the CIP Tank if

switching cleaning chemicals.

vi) Process Tank Soak Chemical Cleaning

A soak chemical cleaning should be used if the

automatic backpulsing of the system does not

maintain membrane performance above the

specified level, or if the automatic switching detects

that the membrane suction pressure is too high.

J1 (61)

This cleaning uses potable water with sodium

hypochlorite (NaOCl) at 200 to 300 ppm, MC-1

cleaner at a pH of 2.5 - 3.0. Better results are

achieved if the water is allowed to warm up to room

temperature overnight. Caution: The cleaning

solution using NaOCl should be limited to a

maximum pH of 10.5. The procedure is as follows:

1. Initiate a Backpulse of the system, and record

the operating data of the system before and

after the Backpulse.

2. Drain Process Tank and refill with clean water.

3. Prepare and add the appropriate chemical

solution required for the cleaning procedure in

both the CIP Tank and the Membrane Tank,

and, in WASH mode, initiate a backwash of the

membranes to fill the membrane lumens with

the cleaning solution.

4. Turn the system to OFF and add the required

amount of cleaning chemical to the Membrane

Tank.

5. Allow the ZeeWeed® membranes to soak in the

cleaning solution. For best results, this solution

should be allowed to warm to room temperature.

Periodic cycling of the aeration blower for

agitation is recommended.

J1 (62)

6. Drain and flush the CIP Tank to the waste

sump. Neutralize or dechlorinate the cleaning

chemicals as required. Refill the CIP Tank with

potable water.

7. Drain the Membrane Tank to the waste sump.

Refill Tank and cycle blower to rinse chemicals

out of the system. Drain. This step may be

repeated several times as needed. In WASH

mode, backwash the membranes several times

with potable water.

8. Refill Membrane Tank and confirm the chlorine

residual in the membrane tank is less than 1

mg/L before returning the system to operation.

9. After chemical cleaning is finished, the system

can be returned to RUN mode and placed in

AUTO.

10. Neutralize or dechlorinate the spent cleaning

chemicals as required prior to discharging them

to the waste sump.

11. Repeat Step 1 so that effectiveness of the soak

chemical cleaning may be evaluated.

vii) Membrane “Empty Tank” Chemical Cleaning

If required, chemical cleaning of the membranes

can also be enhanced by lowering the tank level

below the bottom of the cassette before performing

the wash procedure. Please contact ZENON’s

J1 (63)

service department at (905) 639-6320 before

proceeding with this type of cleaning method.

1) Empty the tank contents (at least until the

level is below the bottom of the membrane

cassettes).

2) Close valves (HV-3483-1A/1B or HV-3483-

2A/2B) to bottom membrane permeate

header.

3) Prepare a cleaning chemical solution in the

CIP Tank and pump a portion of the cleaning

solution through the membranes until it has

coated the outer membrane surface. Allow

this to soak on the membranes for a short

period of time. Repeat this cycle several

times.

4) This cleaning cycle may be repeated with

either another or a fresh chemical solution

until the cassette has been sufficiently

cleaned. Remember to thoroughly flush

the system and drain and rinse the CIP

Tank if switching between cleaning

chemicals. The cleaning log sheet must be

completed before and after any cleaning

sequence.

CAUTION

Extreme caution must be used when performing this procedure to

ensure that the membranes are not allowed to dry out or freeze.

J1 (64)

viii) Membrane Permeability Restoration Monitoring

Membrane permeability is a calculated operating

parameter (flux/TMP) and should be recorded

before and after every membrane cleaning, and

several times daily before and after a Backpulse

cleaning.

The effectiveness of each cleaning procedure can be

verified by comparing the membrane permeabilities

from before and after the cleaning procedure is

performed, but these values must be temperature

corrected in order to give a useful comparison of

the values. Water temperature directly affects

water viscosity and, therefore, the permeability

observed, as do changes in the operating pressure

of the system. The following method can be

employed to correct the membrane permeability.

• Record the permeate flow rate of the system (in

L/s) and the membrane pressure (in kPa), from the

MMI, and the operating temperature from the

permeate temperature gauge.

• Convert to membrane flux (in USgpm/ft2/day, or

GFD) by dividing the flow rate by the total

membrane surface area, and multiplying by

Flow (US gpm) = Flow L/s x60sminx 3.7854 L

1 USGal

J1 (65)

1440 minutes/day. For this system, the

membrane surface area per train is:

• The observed flux must be corrected for

variations in temperature between

measurements. All recorded fluxes should be

corrected to a common reference temperature so

that future comparisons will be valid. This

reference temperature, Tref, should be selected

as a typical process temperature that the

membranes will operate in. The following

formula and water viscosity table can be used to

obtain the temperature corrected flux.

Flux @ TRef= Flux @ T1 x viscosity @ T1

viscosity @TRef

3. STANDARD OPERATING PARAMETERS

A. Chemistry

a) Free chlorine at the ZeeWeed® sample points should have

a value of between 0.4 and 0.8 mg/l. Values less than this

result in the possibility of insufficient free chlorine to

prevent bacterial fouling. More than this is a waste of

bleach.

Membrane Surface Area = 500ft

modulex 6Modules= 3000 ft 2

2

J1 (66)

b) Free chlorine at either RO inlet should measure between

0.0 and 0.06 mg/l. These values may be considered as

zero for all intents and purposes. The sodium

metabisulfite injection is used to reduce the free chlorine.

c) Hardness should always be at a value of less than 4 mg/l

of total hardness. Experience shows that normal values

of hardness will be at 0.0 to 0.85 mg/l. When values are

found as high as 1 mg/l the softener should be considered

as being near exhaustion and will probably be at

exhaustion in the next 30 to 60 minutes.

B. ZeeWeed®

a) TMP values on the screen should generally not exceed a

value of –6.5 during the production run at a set point of

134 gpm. If the TMP value is greater than this, fouling of

the ZeeWeed® membranes should be suspected.

b) Production flow rate on the ZeeWeed® is normally set at

134 gpm. The exception to this rule is when tank 88

reaches 91% full. At this time the set point will ramp

down to 70 gpm and will stay there until the tank level

drops to 90%. At this time it will ramp back up to 134

gpm again. If the production flow does not achieve the

134 gpm flow rate at any time during the production run,

the membranes are probably fouled and require cleaning.

c) Feed Temperature to the ZeeWeed® should be kept

between 25 and 28ºC.

J1 (67)

d) ZeeWeed® tank operating levels should be at a level

greater than 82%. If the level drops below this point the

ZeeWeed® will shut down to protect the membranes from

drying out. The ZeeWeed® will not restart until the

water level in the tank has recovered to 85%.

e) Backpulse flow rate on the ZeeWeed® should be at 212

gpm. This is 1.5 times the normal production flow rate.

If the backpulse flow rate does not reach 212 gpm, the

ZeeWeed® membranes probably need cleaning.

f) Production Mode duration is normally set at 12 minutes.

This value may change from time to time, especially

downwards if there is an unusually high level of

suspended solids in the feed water. This is most likely to

occur for a short time during spring run off.

g) Backpulse Mode duration is normally set at 30 seconds.

This value is not very likely to be changed.

h) Backpulse break tank level should range between 91%

and 25%. When the level reaches 91%, the ZeeWeed®

unit set point will ramp down to 70 gpm. When the level

reaches 25%, the softeners, RO units and EDI will all

shut down until the backpulse break tank level achieves a

value of 40%. At this time, these components will restart.

It is not unusual for the backpulse break tank level to be

depleted during continuous DOUBLE MODE operation.

Do not take the ZeeWeed® readings if the ZeeWeed® flow

rates are switching from 134 to 70 gpm and back again as

the readings will not have any value. Only take them

J1 (68)

when the flow rate set point will continuously be at 134.

This is generally when the backpulse break tank has a

level of 87% or less.

C. Softener

a) Backwash flow rate should be set between 90 and 100

gpm.

b) Instrument air pressure must be available at a minimum

of 60 psi during a backwash. Pressure less than this will

prevent the brine inlet valve from opening up because the

brine inlet valve actuator is spring loaded to close.

c) Micron filter back pressure should never be allowed to

exceed 5 psi with both micron filters in service or 10 psi

when only one filter is in service. Both filters should be

kept in continuous service, even though they are both

capable of 100% flow, to prevent the build up of bacteria

in an idle filter. The filter elements are replaceable and

should be replaced when the pressure differential is

higher than that indicated above, or whenever the service

duration has reached two months, whichever comes first.

D. RO Units

a) Recovery for the first pass should be set at between 69

and 71%. The recovery rate for the second pass should be

between 84 and 86%. The recovery is adjusted by opening

or closing the appropriate reject valve until the desired

recovery rate is achieved.

J1 (69)

b) Product flow for the second pass should be at 88 gpm for

NORMAL MODE operation and at 84 gpm for DOUBLE

MODE operation. The reason for the difference is that

the EDI unit blows down approximately 8 gpm regardless

of the mode of operation. Therefore in order to have a net

80 gpm in NORMAL MODE, a single RO unit will have to

produce 88 gpm. The product flow of the first pass will be

whatever is required to provide the second pass with its

product flow rate plus its reject flow rate.

c) Inlet pressure should be set at whatever level is required

to produce 84 or 88 gpm at the second pass outlet. If the

temperature of the water is lower than normal, the inlet

pressure would have to increase.

E. EDI Unit

a) Product flow rate on the EDI unit should be set at

approximately 160 gpm regardless of the mode of

operation. This is solely dependent on RO output when

the plant is in DOUBLE MODE and, therefore, subject to

a large degree on the water temperature because the RO

units may not be capable of full flow if the water

temperatures are low. In NORMAL MODE operation, the

flow through the EDI is determined by both the RO

production and the amount of recirculation water being

routed back to the EDI.

b) Stack amperage should be limited to 4.0 amps on stack 1.

A split on either side of the 4 amp mark between stack 1

J1 (70)

and stack 2 is acceptable. It is normal for stack 1 to have

the highest current flow.

c) Product resistivity on the EDI should always be greater

than 10 mega ohms while it is running. It is not

uncommon for the resistivity to drop below 10 mega ohms

for a few seconds during startup. Normal values for

product resistivity will be 16.5 to 17.3.

d) Brine conductivity on the EDI should range from 150 to

200 uS. The brine injection pump on the EDI is set to

start and stop as required to maintain this conductivity.

F. Transfer System

a) Transfer tank level should range between 21% and 89%.

At 20% the transfer will be suspended in order for the

tank level to be restored. At 90% the EDI RO units and

softener will shut down until the product tank level drops

to 84%. At this time, the shut down equipment will

restart automatically. While this operation will occur

without intervention, it is good practice for the operator to

be present to observe the startup.

4. ALTERNATING BETWEEN PRODUCTION MODES

A. Switch from normal to double mode.

There is no need to shut off the EDI anymore. From the

panelview, select F15 to bring up the NORMAL/DOUBLE

MODE screen. Press F2 to select DOUBLE mode. Press F21 to

J1 (71)

select the MAIN screen again. Press F5 to select the RO

SYSTEM screen. If RO #1 is not running, press F1 to start the

unit. If RO #2 is not running, press F8 to select the screen for

RO #2 and then press F1 to initiate a start. The display will

indicate production mode and after a brief flushing period the

first pass RO process pump will start. After a delay of 5

seconds, the second pass RO process pump will start. The RO

will operate with its product going to waste until the second

pass product has shown a conductivity of less than 20 uS for 30

seconds. At this time the RO product flow will divert from waste

to EDI inlet and the recirculation valve at the transfer pumps

will close. The RO units should both be balanced to allow a

maximum production of 84 gpm per RO and the rejects should

be adjusted to 70% for the first pass and 85% for the second

pass. The EDI should now be balanced on the brine and product

flows and the transfer rate should be balanced with the EDI

production rate.

B. Switch from double to normal mode.

There is no need to shut off the EDI anymore. From the

panelview, select F15 to bring up the NORMAL/DOUBLE

MODE screen. Press F1 to select NORMAL MODE. Return to

the main screen and press F5 to bring up the RO SYSTEM

screen. Press F2 to shut RO1 down or press F8 to select the

screen for RO2 and then press F2 to shut RO2 down. At this

point, the system will be in NORMAL MODE and the

recirculation valve to the EDI will open. The RO unit should

now be adjusted to a maximum flow of 88 gpm and the rejects

J1 (72)

should be adjusted to 70% and 85% for the first and second

passes. The EDI should also be balanced as necessary.

C. To switch from one RO to the other during extended

NORMAL MODE operation.

During extended NORMAL MODE operation, the RO units

should be switched every shift to prevent microbial growth in

the membranes. In order to do this, first switch from NORMAL

MODE to DOUBLE MODE as described above. After this has

been completed, switch from DOUBLE MODE to NORMAL

MODE also as described above. When switching back to

NORMAL MODE, shut down the RO which was running

previously.

D. To perform a Silt Density Index (SDI) test.

The SDI test is done in order to determine the effectiveness of

the microfiltration process. It consists of measuring the time

required to flow two 500 ml samples of water through a 0.45

micron filter with the samples being taken at 15 minute

intervals and the pressure held constant at 30 psi. Water is

flowed through the filter for the entire 15 minutes.

First, remove the hose from the filter housing and unscrew the

filter housing from the attached piping. Open the inlet valve to

the pressure regulator and ensure that the system is free from

air by briefly opening the valve at the end of the horizontal run

of piping attached to the pressure regulator outlet. Close the

vent valve and crack the admission valve for the filter housing

and allow the water to run in order to flush out the piping and

J1 (73)

regulator. Take the filter housing to the WTP control room and

open the housing by removing the three plastic screws from the

housing and separating the two halves. Remove the o-ring and

set aside for re-use. Remove the old filter paper and discard.

Wipe the filter housing outlet with a clean rag where the filter

paper sits in order to remove any water present on the outlet

screen. Use the tweezers to get a new filter paper from the

container and lay it carefully over the screen of the outlet half of

the filter housing. Ensure that the paper is centered in the

holder and that there are no holes in the paper, especially where

the tweezers were in contact with the paper. There are two

types of papers, glossy on one side and the same on both sides.

With the first variety, the glossy side should be on the water

inlet side, the other variety does not matter. Be careful to not

touch the paper with your fingers as fingerprints on the

paper could seriously affect the test results. Re-install the

o-ring with the tweezers and place the inlet half of the filter

housing carefully over the outlet half. Install the three plastic

screws, tightening all of them evenly and ensuring that the

knobs on each screw are arranged to allow maximum clearance

around the inlet hole. Bring the filter housing back to the test

apparatus and shut the water admission valve. Screw the filter

housing on under the admission valve and attach the hose to the

end of the adapter attached to the filter housing. Re-open the

admission valve and adjust the regulator screw until the

pressure on the gage reads 30 psi. Using an empty 500 ml

container and a stop watch, measure the time required to flow

500 ml into the container. Empty the container and allow the

stop watch and the water to continue running until the end of

J1 (74)

the test. When the time on the stopwatch reaches 15 minutes,

refill the 500 ml container and record the time required to flow

the next 500 ml. Enter these figures into the Logsheets

spreadsheet on the SDI worksheet. The spreadsheet will

automatically calculate and display the SDI value for the times

that have been recorded.

E. ZeeWeed®

a) To start a ZeeWeed® unit.

Prior to starting the ZeeWeed® units, check the

lubrication levels in all pumps and blowers. The

appropriate oil for the pumps is Teresso 46, while the

blowers use Spartan synthetic EP320. Ensure that the

manual valves connecting the pump suctions and

discharges to the ZeeWeed® modules and the backpulse

break tank are in the appropriate positions. If in doubt,

trace the lines for flow path. Ensure that the manual

valves connecting the air blowers to the ZeeWeed® tank

module headers are in the appropriate positions.

Proceed to the panelview in the control room. From the

main screen, press the F3 button to bring up the

ZEEWEED® SYSTEM screen. The screen will default to

the ZeeWeed® 1 system. To select the ZeeWeed® 2

system, press the F8 button. From the appropriate

screen, press the F1 button to initiate a start on the

ZeeWeed® unit. The screen should indicate that the unit

is in STANDBY MODE and will time out for 5 seconds.

The vacuum pump and blower will start running at this

J1 (75)

time. The unit will then go into BACKPULSE MODE and

the unit will backpulse for 30 seconds. When the

backpulse is complete, the unit will go into

PRODUCTION MODE until the next backpulse.

b) To shut down a ZeeWeed® unit.




the ZeeWeed® #1 system. To select the ZeeWeed® #2


screen, press the F2 button to initiate a stop on the

ZeeWeed® unit.

c) To perform a manual backpulse of a ZeeWeed®unit.






screen, press the F5 button to initiate a manual backpulse

on the ZeeWeed® unit. The unit will backpulse as usual

and will go back into normal service as soon as the

backpulse cycle is completed. This step is useful if you

wish to stagger the backpulses between the units or if the

unit is starting to foul but water demand will not allow a

proper clean to be done.

d) To start the second ZeeWeed® with one running and plant

in NORMAL MODE.

J1 (76)






screen, press the F1 button to initiate a start on the

ZeeWeed® unit. The unit will go to STANDBY MODE for

five seconds and will stay there. To complete the start,

press the F1 button again to complete the start. The unit

will now start up as described above.

F. Softeners

a) To start a softener.

Prior to starting the softener, check that all of the manual

valves are in the correct positions and that the softener

process pumps have adequate oil in them. The proper

lubricant for the pump is Teresso 46.

From the main screen on the panelview, press F4 to select

the SOFTENER SYSTEM screen. Press F1 or F6 to start

the appropriate softener. Once the appropriate button

has been pushed, the softener will go to STANDBY

MODE until the RO units call for water. When this

happens, one of the softener pumps will start and the unit

will flush for one minute prior to sending water to the

micron filters. For economy of salt consumption, select to

run the softener with the highest flow total which has not

exceeded the total gallons allowed. This value is 180,000

gallons. Do not choose to delay softener regenerations by

J1 (77)

switching softeners prior to reaching total gallons. This is

very bad operating etiquette and can lead to both

softeners being exhausted at the same time. If this

happens, the RO units must be shut down until at

least one of the softeners has been regenerated.

Also this can lead to poor regenerations because the brine

may not have time to reach full strength with back to

back regenerations.

b) To shut down a softener.

Prior to shutting off a softener, it is imperative that the

RO units, which are supplied by the softener, are not

running. From the main screen on the panelview, press

F4 to select the SOFTENER SYSTEM screen. Press F2 or

F7 to shut off the appropriate softener. The pump will

already be off because it will only run when called to do so

by RO or regeneration demand.

c) To regenerate a softener.

Prior to starting the softener, check that all of the manual

valves are in the correct positions and that the softener

process pumps have adequate oil in them. The proper

lubricant for the pump is Teresso 46. Also ensure that

there is at least 60 psi of instrument air pressure

available in order for the brine inlet valve to open, as this

valve is spring to close.


the SOFTENER SYSTEM screen. Press F2 or F7 to shut

off the appropriate softener. When the softener is in the

J1 (78)

OFF MODE, press F3 or F8 to initiate the regeneration

on the desired softener. The softener will immediately go

into BACKWASH MODE. During this period, it is

important that the backwash be observed through the

vessel window for bed lift. Also the backwash flow rate

should be at a value of 90 to 100 gpm. The BACKWASH

is followed by the REGEN BED SETTLE, BRINE

INJECTION, SLOW RINSE, and finally by the FAST

RINSE. At the end of the fast rinse, the regeneration is

complete and the unit will go to STANDBY MODE.

d) To switch from one softener in service to the other in

service.


the SOFTENER SYSTEM screen. One softener will be in

service and the other will be in either OFF MODE or

STANDBY MODE. If the softener is in OFF MODE,

press F1 or F6 to bring the softener to STANDBY MODE.

Then press F19 or F20 to bring the new softener online.

The new softener will flush for a short while and will then

go into PRODUCTION MODE. The original softener will

then go into STANDBY MODE. This method of switching

can only be done when the panelview is displaying the

alert TOTAL REACHED and can be done without taking

the RO units or the EDI unit out of service. It is not

normally recommended to switch softeners out of service

until the TOTAL REACHED alert has been displayed

unless the unit has exhausted prematurely. If this is the

J1 (79)

case, notify the Zenon representative on the next day

shift.

G. Reverse Osmosis

a) Start an RO unit.

This operation may be done in either the NORMAL

MODE or in the DOUBLE MODE. If it is desired to run

only one RO unit, the system should be set in NORMAL

MODE to allow for proper operation of the EDI unit. If

DOUBLE MODE is required, and no RO units are

running, RO #1 must be started first. The system may be

switched from NORMAL MODE to DOUBLE MODE and

back to NORMAL MODE at any time when the RO units

are running. It is preferred to leave the EDI running

during the switching process. The transfer/recirculation

valves are programmed to delay switching until the

appropriate RO functions have been completed. Prior to

starting an RO unit, ensure that all of the manual valves

are in the appropriate open or closed positions.


the RO SYSTEM screen. The panelview will default to

the RO-1 SYSTEM screen. If the RO-2 SYSTEM screen is

desired, press F8. To start an RO unit, press F1 from the

appropriate screen. This will initiate a softener process

pump to start flushing a softener unit and will cause the

inlet and reject bypass valves on the RO unit to open.

The softener will flush for one minute and then will start

to put flushing water to the RO unit. The RO will be in

J1 (80)

flush for a short while and then the first pass RO process

pump will start. After 5 seconds of running, the second

pass RO process pump will start. At the time of the

actual start up, the product water will dump to drain.

When the second pass product water conductivity has

been less than 20 uS for 30 seconds, the product water

will be sent to the EDI unit.

b) Start a second RO unit.

In order to start a second RO unit, it is essential that the

program be set to run in DOUBLE MODE. If the

DOUBLE MODE operation has not been selected, the

second RO unit will not start.




desired, press F8. To start the second RO unit, press F1

from the appropriate screen. The second RO unit will go

through the same start up sequence as indicated above.

The second unit will not initiate a start until the first unit

is producing water to the EDI unit rather than diverting

it to drain.

c) Stop an RO unit from NORMAL MODE Operation.

Whenever an RO unit is to be stopped during NORMAL

MODE operation, the EDI must be shut off prior to

stopping the RO to prevent unnecessary pressure surges

on the stacks.

J1 (81)




desired, press F8. To stop an RO unit, press F2 from the

appropriate screen.

d) Stop an RO unit from DOUBLE MODE Operation.

If only one RO is to be stopped from DOUBLE MODE

operation, refer to the topic “Switch from DOUBLE

MODE to NORMAL MODE”. If the intent is to shut

down both RO units, first switch the EDI to the off

position to prevent any unnecessary pressure surges to

the EDI stacks. From the main screen on the panelview,

press F5 to select the RO SYSTEM screen. Press F2 to

turn RO-1 off. Then press F8 to select the RO-2 SYSTEM

screen. Press F2 to turn RO-2 off.

e) Adjust the recovery rates for an RO unit.

The recovery on an RO unit is the ratio of production

water flow vs. the raw water flow. The target recovery

rates are 70% for the first pass and 85% for the second

pass. For general operating conditions, a range of plus or

minus 1% is considered acceptable on each of the values.

These values apply to both RO units and are displayed on

their respective panelview screens. The appropriate

reject flows for various product flow rates are also posted

on the second pass reject flow meters on each RO unit.

J1 (82)

In order to adjust the recovery rate, adjust the reject

valve for the appropriate RO pass until the reject flow

rate coincides with the appropriate product flow rate or

until the RECOVERY indicator on the RO system screen

is at the desired value. In order to increase recovery, the

reject valve would be closed in and to decrease recovery

the reject valve would be opened. In most cases, a very

small rotation of the valve handle will give the desired

reject flow change.

H. EDI

a) Start the EDI.

Prior to starting the EDI, check that all of the manual

valves are in the correct positions. One or both of the RO

units must be running, depending on the mode of

operation that has been selected.

From the main screen, press the F6 button to bring up the

EDI SYSTEM screen. Ensure that there are no alarms up

on the blue line at the top of the screen. If an alarm is up,

press F7 and F6 to silence and reset the alarms

respectively. This must be done with the

MANUAL/OFF/REMOTE switch on the EDI control panel

in the OFF position. Once the alarms are reset, the unit

may be switched to the REMOTE position.

Upon turning the switch to REMOTE, the inlet valve

should start to open. Once it has opened, both pumps

should start and the unit is on line. If no changes have

J1 (83)

been made to the RO operation or to the transfer valves,

the unit will required little or no balancing. If balancing

is required, refer to the paragraph below labeled “To

balance the EDI”.

b) Stop the EDI.

To stop the EDI unit, turn the MANUAL/OFF/REMOTE

switch to the OFF position. If the unit was at full rated

flow, it is likely that the relief valve on the pump skid will

function. This is normal.

c) To balance the EDI.

The purpose of the pump skid on the EDI is for hydraulic

balancing. It is very important for the ensured quality of

the product water that the product pressure is higher

than the brine pressure on both the inlet and outlet of the

stacks. The stacks are essentially made up of plastic

sheets compressed by six tie bolts. Any leakage which

occurs in the stacks will be of no consequence to the

product quality as long as the pressure differential is kept

between 60 and 100 inches as measured on the

differential pressure gage for both the stack in and stack

out headers.

If the pressure differential needs adjustment, turn the

selector valve for the differential pressure gage to the

STACK OUT position. Go to the product pump discharge

valve and open or close the valve in small increments,

checking the differential gage after each increment.

Continue to adjust as necessary until the desired

J1 (84)

differential is achieved. Closing the product pump

discharge valve will have the effect of increasing the

STACK OUT differential pressure. Turn the selector

valve to the STACK IN position. If the differential needs

adjustment, open or close the brine pump valve until the

desired differential is achieved. Opening the brine pump

valve will reduce the STACK IN differential. When the

plant is in NORMAL MODE adjustments to the pressure

differential can also be achieved by opening or closing the

product water transfer/recirculation valve. Opening this

valve will increase the water flow through the EDI unit

when the plant is operating in NORMAL MODE.

d) Add salt to the EDI brine makeup system.

Brine is used to replenish the dissolved minerals which

are blown down from the brine system. Without an

adequate brine concentration, current flow in the stacks

would be reduced and the ion transfer of the system

would be diminished. To make brine, add one bag of

Windsor 802 salt and 33 gallons of EDI product water.

Switch on the mixer, which is located on the top of the

brine tank, and allow it to run for about 30 minutes. This

will result in a saturated brine solution which will be fed

into the EDI as it is needed. Do not use any water

except EDI product water, as contaminants such as

Calcium and Magnesium will damage the EDI

stacks. Only use food grade salt such as Windsor

802.

J1 (85)

I. Transfer System

a) Initiate transfer to a low level tank.

Prior to starting the transfer system, check that all

manual valves are in the correct position and that the

pumps have adequate lubrication. The proper oil for the

pump is Teresso 46. From the main screen on the

panelview, press the F7 button to bring up the LLRFW

TRANSFER screen. Press the F1 or F2 buttons to move

the cursor to the low level tank that you intend to transfer

to. Press the F3 button when the appropriate tank is

indicated to enter the selection, then press the F7 and F6

buttons to initiate the transfer. The appropriate valve

will indicate open by turning from green to red. If the

system is already transferring and you wish to change the

destination, select the desired tank and press F3 to enter

the choice. Press F5 to abort the existing transfer and

then press F7 and F6 to initiate the new transfer. During

NORMAL MODE operation it is important to do the F5,

F7 and F6 sequence quickly as this will allow the transfer

change to be made without any large pressure swings on

the EDI unit.

b) Stop a transfer to a low level tank.

From the main screen on the panelview, press the F7 button to

bring up the LLRFW TRANSFER screen. Press the F5 button

to abort the transfer.

J1 (86)

5. PLANT OPERATING CONTROLS

A. Plant Operating Controls

The entire plant is controlled by the main PLC through the

MMI. Implemented security requires that the operator types in

a password to get access to control screens and make changes to

the system. The operator can only observe basic operating

parameters without the correct password.

a) Plant Control from the PanelView 1400E MMI

The Plant is controlled and monitored via two Allen-

Bradley PanelView 1400E screens – one in the plant, the

other in the water treatment plant control room. The

Process Summary Screen(s) on the MMI can be viewed

at any time (no password required). A screensaver will

blank the screen after ten minutes of inactivity. The

screen is reactivated by a single touch. Reactivation

cannot, however, select a device or operating mode.

In order to access the operator control screens, the

operator must enter a four digit password then press

enter on the Password Screen. This password is factory

set to be “9348”. This password is hard coded in the PLC;

it is not possible to modify it from the MMI. Once the

password is entered correctly, the operator has access to

the control screens for a period of 4 hours. If the operator

enters the wrong password, there is no limit to the

number of times another password can be attempted. If

an incorrect password is entered (or if the user presses

LOCK on the Main Screen), the operator can still move

J1 (87)

to (but only to) the Process Summary Screen(s) and back

to the Password Screen. Screen activity does not change

the password access time.

Note: Each of the two MMI screens requires a separate

log on (same password). Entering the password on one

MMI screen does not give access to the other.

After expiration of password access, the MMI will only

show the Process Summary Screen. The operator cannot

reset an alarm (the horn can however be silenced) if the

password has expired. The operator must re-enter the

password in order to use the MMI.

The MMI screens consist of at least the following:

i) A Main Screen - Shows mapping to other screens

available from the MMI.

ii) Process Summary Screen(s) - a tabular overview of

the entire plant showing status of each unit, plant

feed low, combined permeate flow, operating

pressures, etc.

iii) Process Unit Control Screens

iv) Setting Screens - allows the user to change some of

the alarms or alert set points. The user can step

through the screens by pressing the prompt in the

lower left corner.

v) ZeeWeed® Backpulse Data screen shows key

parameters at different phase of the

Production/Backpulse cycle.

J1 (88)

vi) An Alarm History screen shows the time of

alarms/alerts and when they were acknowledged.

A copy of each screen for this plant is included in Appendix 1.

b) Programmable Logic Controller

The PLC5/20 Programmable Logic Controller (PLC)

provides automated control of the plant. All the

programming for the control of the plant is stored in the

PLC. On initial plant startup or in the event that the

PLC memory is corrupted, the PLC will download the

program from the E2PROM (Electronically Erasable

Programmable Read Only Memory) module and sound an

alarm. All adjusted setpoints will be reset to their factory

default values. The operator should record all the

setpoints if they have been adjusted to ensure that those

setpoints can be easily adjusted to overwrite the default

setpoints if they have been reset. The plant will power up

with all process units in OFF mode. The operator must

select RUN on the MMI to activate each unit.

The PLC has a battery that needs to be replaced every

two to three years. The battery allows the PLC to retain

the program and any new setpoints in the event of an

extended power failure without having to download the

program from the E2PROM. If the battery needs

replacement, a message will be shown on the MMI (alert).

The length of time the plant can operate with a low

battery level will vary from plant to plant. The PLC has a

battery backup capacitor that will allow the user to

J1 (89)

remove and replace the battery with the power down

without loss of PLC memory (refer to the vendor data for

more information).

c) Control Panel Disconnect

A Control Panel Disconnect Switch on the face of the

Control Panel disconnects 120 V power to the Control

Panel and allows access to the interior of the Control

Panel. Disconnecting the power to the control panel also

disconnects the power to the CPU and therefore de-

energizes all CPU controlled devices on the entire plant.

d) Plant Shutdown

i) Plant Shutdown Push-button

The plant has shutdown software button on the

MMI. The shutdown button initiates an orderly

shutdown of the entire plant. The operator must

confirm the shutdown request. Upon

acknowledging and resetting this alarm, the plant

will be re-activated. The operator will have to

individually restart all process units.

ii) Local Emergency Stop Push-button

The Emergency Stop mushroom button, located on

the face of the control panel, will immediately de-

energize all PLC outputs and bring the devices on

the unit to the status shown in the Sequence Chart.

The last mode and sub-mode of operation will be

shown until the operator resets the alarm. The

devices will not, however, shut down in an orderly

J1 (90)

fashion. Upon resetting this mushroom button,

acknowledging the alarm and resetting the alarm,

all process units will be activated in OFF mode.

The devices will retain their settings. The

Emergency Stop should only be used in case of

emergency. The operator should remedy the

problem and reset the mushroom button (by pulling

on it) and PLC alarm.

iii) Individual Component Operation

Most controlled devices (pumps and valves) have a

manual override capability. Regardless of the

process unit mode, the capability exists to

manually override any pump running condition.

This is achieved by an Auto/Stop/Start selector

switch on the MCC panel for each pump. The

pump status for a pump is indicated as Auto On,

Auto Off, Failed, Local On, or Local Off. All

ALARMS/INTERLOCKS for each pump will

remain active even if a pump is locally started, but

can only annunciate an alarm.

Each air-operated valve can be manually opened by

using a manual override on the actuator. Since

there is no feedback from the valve (no limit

switches) the manual override can not be indicated

on the MMI screen. Valve status is always

indicated as Open or Closed based on automatic

operation (PLC output controlling the valve).

J1 (91)

The colour scheme for Panel View 1400E is defined

as per the table below:

i) Valve Closed Green

ii) Valve Open Red

iii) Pump Failed Green / Blinking

iv) Pump Auto Off Green/“A” displayed beside

the pump symbol

v) Pump Auto On Red/“A” displayed beside the

pump symbol

vi) Pump Local Off Green

vii) Pump Local On Red

The MMI panels do not provide manual override capabilities other than

described below.

i) All chemical addition pumps (P-22A, P-22B, P-23A, P-23B, P-

24A, P-24B, P-25A, P-25B, P-26A, and P-26B) have an Auto /

Manual / Off / Test selector switch. An Auto position indicates

that the pump is fully operational and can be used by the control

logic. The pump output is defined by the control logic. In

Manual mode the pump rate is defined by the operator (the

pump continues to start and stop as per control logic). These

devices may have a Proportional Integral Derivative (PID)

screen to allow the operator to control the device responsiveness

in Auto mode. Bumpless transfer between Manual and Auto

mode is always implemented. The Off position indicates that

the pump is not available. The Test mode is similar to Manual

mode with the exception that the pump is running regardless of

J1 (92)

any interlocks. After 20 minutes the pump mode is switched

from Test to Off mode.

ii) Other devices that accept a 4 to 20 mA analog signal such as

variable speed pumps or modulating valves have an Auto /

Manual selector switch. In Manual mode the operator can

control the pump speed or valve position manually. These

devices may have a Proportional Integral Derivative (PID)

screen to allow the operator to control the device responsiveness

in Auto mode. Bumpless transfer between Manual and Auto

mode is always implemented.

6. DESIGN OF AUTOMATIC PLANT CONTROL

Expected values for various process indicators are shown in Table 3-1

to provide the operator with rough guidelines as to how the equipment

should behave under normal operating conditions. The automatic

control of the plant is then described in the subsection after the

indicators are listed.

A. Plant Indicators

Table 3-1 shows typical production quality and flows (± 20%) for

the operating conditions with plant in Production. These

values will change with membrane life, water quality,

temperature, etc. Where parallel equipment (e.g. the two

ZeeWeed® units or two RO units) exists, and suffixes are not

shown (for the purpose of clarity), the operator should use the

same values for all those parameters with the same tag

numbers. If separate values are not shown for Production,

J1 (93)

Flush, and Backpulse then that parameter is not expected to

change by cycling between the three sub-modes.

J1 (94)

Indicator TAG Anticipated Value

Production Backpulse Flush

Transmembrane Pressure DPI-34231,2,3 -9 to -4 psid 2 to 8 psid N/A

Process Pump Flow

(instantaneous)

FIT-35201,2,3 100 to 500

gpm4

100 to 500 gpm 400 gpm

Pump/Membrane Header Pressure PI-35231,3 -12 to 0 psig 2 to 12 psig 8 - 20 psig

Process Pump Discharge Pressure PI-35403 A/B 0 to 5 psig 5 to 10 psig 8 - 20 psig

Membrane Blower Outlet Pressure PI-8540 ←------------------

-

3 to 5 psig 0 psig

Supplemental Blower Outlet

Pressure

psi. 6--------- ←------------------

-

5 to 7 psig 3 to 7 psig

Spare Blower Outlet Pressure PI-8740S ←------------------

-

3 to 7 psig -----------------

---→

Reactor Level LI-34261 ←------------------

-

164 to 206” 164 to 206”t

Vacuum PI-3641 ←------------------

---

10 to 25” Hg -----------------

---→

Production Regeneration

Softener Feed Flow FIT-1320 130 gpm 130 gpm

(Backwash,

Rinse)

Regeneration Feed Flow FIT-2943 N/a 60 gpm (Brining)

40 gpm (S. Rinse)

Dilution Feed Flow FIT-2942 N/a 40 gpm

Production

RO Feed pH AIT-2520 9.0

RO Feed Conductivity AIT-4131 950 µS

First Pass RO Membrane Inlet

Pressure

PT-4023 170psi

First Pass RO Reject Flow FT-4020 42 gpm

First Pass RO Permeate Flow FT-4021 100 gpm

First Pass RO Permeate Pressure PT-4024 50 psi

First Pass RO Permeate

Conductivity

AIT-4031 20 µS

Second Pass RO Membrane Inlet

Pressure

PT-4223 180psi

Second Pass RO Reject Flow FT-4220 15 gpm

Second Pass RO Permeate Flow FT-4221 84 gpm

Second Pass RO Permeate

Pressure

PT-4224 10 psi

Second Pass RO Permeate

Conductivity

AIT-4231 0.5 µS

Table 7-1 Normal Operating Expenses

J1 (95)

1. Parameter shown on the MMI.

2. These values are ± 20% and will change with temperature, feed water

quality, and membrane life.

3. For some instruments there are actually two of these indicators with

suffixes -1 and -2 on the two ZeeWeed® / RO Units. Only one is

shown (without suffix) in this table for purposes of clarity.

4. All flows in this table are USgpm.

a) NORMAL / DOUBLE Capacity Selector Switch

The water treatment system is designed to deliver 80 USgpm of

boiler feed water. This is considered the NORMAL mode of

operation. Occasionally (typically once a month) for a period of

up to 12 hours the system can be required to produce 160

USgpm of treated water. This is considered the DOUBLE

capacity mode of operation. The MMI screen has to provide the

above selector switch. This is a global switch that applies to

almost all process units.

i) NORMAL Mode of Operation

Assuming that all process units are in RUN mode

and not in Shutdown, during NORMAL mode of

operation only one ZeeWeed® Unit and one RO Unit

are in Production (the other ZeeWeed® Unit and

RO Unit are in Standby). Where there are

duplicate units (ZeeWeed® Unit 1 and 2 and RO

unit 1 and 2) the first unit placed in RUN mode

becomes the lead unit and goes into Production (if

required). If the second unit is placed in RUN

J1 (96)

mode it becomes the lag unit and goes into

Standby.

ii) DOUBLE Capacity Mode of Operation

Assuming that all process units are in RUN mode

and not in Shutdown, during DOUBLE Capacity

mode of operation both ZeeWeed® Units and both

RO Units go into Production. Softeners are

prevented from going into Regeneration. When the

capacity of the current softener is exhausted, the

softener will switch to the other unit but the

Regeneration of the exhausted unit is not triggered.

It is the operators responsibility to ensure that the

DOUBLE Capacity mode of operation is selected

when sufficient softener capacity exists (it is

recommended that the operator regenerate the

current softener, by switching to a fully

regenerated one, just before selecting the

DOUBLE Capacity mode).

Note: The operator is prevented from switching to

DOUBLE Capacity mode when Softener unit is in

Regeneration.

B. Raw Water Feed System

a) Raw Water Feed Pumps

The pair of feed pumps P-101 and P-102 provide

pressurized feed for the ZeeWeed® Microfiltration System.

A single pump can handle two ZeeWeed® units in

J1 (97)

DOUBLE Capacity mode or a single ZeeWeed® unit in

NORMAL mode. Only one pump is running at a time.

The first pump placed in Auto mode becomes the lead

pump and will start regardless of whether ZeeWeed® unit

is in Standby or not. The integrated 3-way Yarway

control valve FCV-165 is installed at the common pump

outlet to provide bypass flow back to the sump in case the

ZeeWeed® units do not accept feed water. The second

pump placed in Auto mode becomes the lag pump and is

not running. If both pumps are in Auto mode and not

Failed, at a time of day specified by KY-1010 the lag

pump should start and become the lead pump. After a 3

second delay the lag pump should stop. This alternating

operation will ensure that both pumps are used when

available. If the lag pump is not available (Failed or

OFF), the lead pump continues to run indefinitely.

b) Feed Temperature Control

The temperature control system is not connected to the

PLC and is not controlled by ZENON.

The additional temperature transmitter TT-7621 is used

for membrane protection. See Control Logic Summary

Chart for details (Appendix 2).

J1 (98)

c) Feed Flow Control

i) Normal Operating mode

Since the feed pumps operate at a constant speed, a

feed control system is required to control the level

in ZeeWeed® Membrane Tanks. The feed control

system consists of a flowmeter FIT-7620 and a flow

control valve FCV-7620. The primary purpose of

the feed flow control is to maintain ZeeWeed®

Membrane tank level at a setpoint defined by the

operator. This is achieved by two cascaded PID

loops. The fast acting Flow control loop and a slow

Level control loop that generates flow control

setpoint. The second loop is also used during

Backpulse to control the reject volume through

ZeeWeed® Membrane tank overflow. The following

diagram shows the ZeeWeed® Membrane Tank

level during a typical Production cycle.

ii) DOUBLE Capacity Operating mode

In DOUBLE Capacity mode both ZeeWeed® units

are running at the same time. The two ZeeWeed®

units are not synchronized as far as the Backpulse

/ Production cycle is concerned. The feed control

applies always to the ZeeWeed® Membrane Tank

with the lower level. The feed control is similar to

control in NORMAL mode during Production -

cascaded PID loop control. Flow control setpoint

FIC1-7620 adjusted by Level control loop to

maintain LIC-3426 level setpoint in a Membrane

J1 (99)

Tank with a lower level (adjustable by the

operator). The Backpulse cycles are ignored

(Backpulse will result in Membrane Tank level

increase - as a result the level control PID loop may

switch to the other Membrane Tank level). The

Membrane Tank with the higher tank level has no

impact on flow control. We are concerned only with

the Membrane Tank with the lower level.

Notes:

1. The level control PID loop is based on setpoint

and level measurement for the ZeeWeed® unit in

operation that has the lower Membrane Tank

level (switched from one tank to another as

required).

2. When ZeeWeed® units are in Standby (FV-7690

closed) both PID loops are disabled (“frozen”

outputs).

3. High temperature alarm TAH-7621 will cause

the flow control valve FCV-7620 to close.

d) Totalized Feed Flow

The feed flow FIT-7620 should be totalized over a 24 hour

period and during Backpulse and Production cycle.

The MMI provides access to:

FQI1-7620 Totalized feed flow since midnight.

FQI2-7620 Totalized feed flow over 24 hour period

(yesterday).

J1 (100)

FQI3-7620 Totalized feed flow during the last

Backpulse cycle.

FQI4-7620 Totalized feed flow during the last

Production cycle.

Note: Totalized Backpulse and Production flows are

applicable only during NORMAL operating mode.

Clear the indicators for DOUBLE Capacity mode.

C. Chemical Pretreatment

a) Hypochlorite Addition

Sodium Hypochlorite addition is based on the ZeeWeed®

feed flow FIT-7620. The Sodium Hypochlorite pump

dosing rate is calculated as follows:

SC-2400A/B [%] = (FT-7620) / (FYH1-7620) * 100

Where FYH1-7620 (field adjustable) is the feed flow at

which P-24A/B operates at its full capacity (100%).

The addition of Sodium Hypochlorite is achieved by using

one of the two metering pumps P-24A or P-24B. Only one

pump is running at a time. The flowmeter FT-7620 must

indicate flow above FYL-7620 for metering pump to be

enabled. The first pump placed in Auto or Manual mode

becomes the lead pump (the second pump becomes the lag

pump- if not in Off mode). Whenever the flow FIT-7620

drops below FYL-7620 and both pumps are available (not

in Off), pumps will toggle (the lead pump becomes the lag

one and vice versa).

J1 (101)

The Test mode is used for maintenance only (e.g. priming

the pump). In this mode the pump will be running with

all interlocks disabled with the ability to manually control

the pump rate. Note: After 20 minutes in Test mode, the

PLC will automatically switch the pump to Off mode.

In DOUBLE Capacity mode (both RO units and both

ZeeWeed® units running at the same time) only one

metering pump is running.

b) Ferric Chloride Addition

Ferric Chloride addition is based on the ZeeWeed® feed

flow FIT-7620. The Ferric Chloride pump dosing rate is

calculated as follows:

SC-2600A/B [%] = (FT-7620) / (FYH2-7620) * 100

Where FYH2-7620 (field adjustable) is the feed flow at


The addition of Ferric Chloride is achieved by using one of

the two metering pumps P-26A or P-26B. Only one pump

is running at a time. The flowmeter FT-7620 must








J1 (102)




the pump rate. Note: After 20 min in Test mode, the PLC

will automatically switch the pump to Off mode.




D. ZeeWeed® Microfiltration System

a) ZeeWeed® Unit Mode Selection - RUN/OFF/WASH

Each unit has a separate mode selector switch. With the

ZeeWeed® Unit Mode ‘Selector Switch’ the operator

(through the MMI with maintenance level password

access) can put each ZeeWeed® unit into one of four

general operating modes: RUN, OFF or WASH. The

ZeeWeed® unit modes are described below:

RUN OFF WASH

Unit responds to control logic.

Unit is shutdown. Unit responds to control logic.

b) ZeeWeed® Unit “RUN” Mode

RUN mode is the mode of operation that each ZeeWeed®

unit will be in for normal operation. The operation of

J1 (103)

each unit can best be described as automatic; that is,

during normal operation, no operator attention is

required unless an alarm/alert is activated. Each

ZeeWeed® unit is either in Production, Backpulse,

AutoWash, Flush or Standby at any given time. The

Production Cycle time, Backpulse duration as well as

Flush and AutoWash parameters can be adjusted by the

operator via the MMI. In AUTO, the PLC will start and

stop units based on the Membrane Tank levels.

c) ZeeWeed® Unit “OFF” Mode

The operator can shut off each ZeeWeed® unit by selecting

OFF from the MMI. As a unit is shut OFF, devices will

shut off in an orderly fashion. See the Operations

Sequence Chart (Appendix 2) for the device status and

sequence for the OFF procedure and status (some devices

may be On and valves may actually be Open).

d) ZeeWeed® “WASH” Mode


become fouled and are not capable of producing the design

permeate flow. When an operator decides (criteria

discussed in the Wash section of the manual) that a

particular unit needs to be washed, the operator can

perform a Clean in Place (CIP) procedure. They must

first put the unit into WASH. The WASH selector switch

can only be activated if the unit is in OFF mode. After

putting the unit into WASH, the unit will be in Standby.

Manually overridden devices (except for equipment that

has interlocks) will, however, still be active.

J1 (104)

The Wash Procedure or Clean in Place (CIP) is described

in detail in Section D i). The Control Logic Summary

Chart shows the setpoints for this mode (refer to

Appendix 2).

Note: The operator is prevented from placing a ZeeWeed®

unit in WASH mode when the system is in DOUBLE

Capacity mode.

e) Vacuum Pumps (P-36A and P-36B)

One or two vacuum pumps can be operated at a time. The

first pump placed in Auto mode becomes the lead pump

and starts automatically. The other pump (when in

Auto) becomes the standby pump. If the operator presses

Stop for the pump that is running (or the pump fails), the

standby pump will become the lead pump and will come

on automatically. Start at the MCC must be used for the

second (standby) pump to operate two pumps at the same

time.

f) Alternating ZeeWeed® Units

During NORMAL operation only one ZeeWeed® unit can

be in Production. The first ZeeWeed® unit placed in

RUN mode becomes the lead unit and goes into

Production (if required). The second unit placed in

RUN mode becomes the lag unit and goes into Standby

regardless of the demand. If both ZeeWeed® units are in

RUN mode and not in Shutdown, every time the lead

ZeeWeed® unit goes into Standby due to lack of demand

(TK-88 above LYH3-8820) or no water to process (TK-34

J1 (105)

below LYLL-3426) it becomes the lag unit. This will

ensure that both ZeeWeed® units are used and no

stagnant water is kept within ZeeWeed® unit for extended

period of time.

Occasionally, when balanced demand exists, the lead

ZeeWeed® unit may never go into Standby. To ensure

that under normal conditions ZeeWeed® units are

alternated at least once per day, the time in Production

for the lead ZeeWeed® unit is measured. If at a time of

day defined by KY-3500 the runtime is greater than 12

hours, the lead unit should go into Standby and the lag

ZeeWeed® unit should become the lead unit and begin

Production.

Whenever the lead ZeeWeed® unit goes into Shutdown

due to an alarm condition, the lag unit will become the

lead unit and will go into Production.

In DOUBLE Capacity mode described earlier (both

ZeeWeed® units and both RO units operate at the same

time) the startup of the lag ZeeWeed® unit should be

delayed by 10 seconds (staggered startup).

g) Overall ZeeWeed® Production and Control

The PLC controls the flow from the ZeeWeed® units

according to the liquid level in the Backpulse Break Tank.

All the setpoints and thresholds are defined in the Control

Logic Summary Chart (Appendix 2).

J1 (106)

The process pump P-35 will draw up to 150 USgpm from

the membranes in Production. The process pump is

equipped with a variable speed drive controlled by the

PLC. The control of pump speed throughout the

Production cycle will depend on the various conditions

defined below.

The PLC controls the flow from the ZeeWeed® units to

maintain the operator adjustable flow setpoint (in

Manual flow control) or calculated flow setpoint (in Auto

flow control) based on Backpulse Break Tank level.

A timer shows how much time is left in a Production, or

Backpulse cycle. The operator can adjust the

Production cycle time (also referred to as Backpulse

frequency) and the Backpulse duration time from the

MMI.

The Production and Backpulse step gain parameters

can be adjusted, but will probably not need to be adjusted

after the equipment is commissioned.

i) ZeeWeed® Production Flow Control

The ZeeWeed® Production flow control is based on

the Backpulse Break Tank TK-88 level transmitter

(LT-8820) indication.

J1 (107)

When the Backpulse Break Tank level is between

LYH1-8820 and LYH2-8820 the flow setpoint is

calculated as follows:

3520)(FYL3520)](FYL3520)[(FYH*8820)(LYH18820)(LYH2

8820)(LYH18820)(LIT3520FIC −+−−−

−−−−−−=−

When the Backpulse Break Tank level is at or

below LYH1-8820 the flow setpoint FIC-3520

remains at FYH-3520.

When the Backpulse Break Tank level is at or

above LYH2-8820 the flow setpoint FIC-3520

remains at FYL-3520.

The above-presented scenario applies when the

Flow Control Switch is in Auto position. When in

Manual, the operator can set the desired flow

setpoint FIC-3520 from the MMI to anywhere from

FYL-3520 to FYH-3520.

ii) Transmembrane Pressure (TMP) Control

The Transmembrane Pressure referred as TMP (in

psid) shown as DPI-3423 is calculated by the

equation below. During Production this number

is negative, during Backpulse this number is

positive.

TMP = (PIT-3523)+A x C – [(LIT-3426) – B] x C

where:

PIT-3523 is the pressure measured in psig

J1 (108)

LIT-3426 is the reactor liquid level in inches

A is the elevation of the pressure transmitter PI-

3523 above the top of the membranes measured in

inches (7” at time of printing).

B is the height of the top of membranes in the

Membrane Tank measured in inches (85” at time of

printing).

C is a conversion factor (inches to psig) equal to

0.03612.

TMP is an absolute term and the reader should be

aware that in Production, increased TMP means

a larger pressure differential (see Control Logic

Summary Chart, Appendix 2), because the pressure

inside the membranes is lower than outside the

membranes.

ZeeWeed® Tank

Water Elevation

ZeeWeed®

Cassette

FlowPI-3523

LI-3426

A

B

Figure 7-6 Transmembrane Pressure Control Schematic

J1 (109)

During the Production cycle the PLC will try to

achieve the desired flow setpoint (either calculated

or set by the operator as described earlier) by

increasing the Process Pump speed. Increasing the

pump speed will result in decrease of the TMP

value (the higher the pump's speed the more

negative the TMP value). To protect the integrity

of the membranes, there is a limit beyond which

the TMP is not allowed to drop (DPCLL-3423). See

the Control Logic Summary Chart, Appendix 2, for

details. The TMP control limit has priority over

flow control. Even when the flow setpoint has not

been achieved, once the TMP reached the limiting

value, the pump speed will not be increased.

During the Backpulse cycle the PLC will try to

achieve the desired TMP pressure DPCHH-3423.

iii) Process Pump (P-35) Speed Control

The Process Pump speed is controlled in a ramp-up

mode. Initially the Process Pump is started at the

minimum pump speed as defined by SY-3500.

During the Production cycle the Production Step

Gain (SF1-3500) is used, while the Backpulse

cycle is using the Backpulse Step Gain (SF2-3500).

The pump speed is increased at 0.1 second

intervals (SK-3500).

J1 (110)

There are two distinctive phases of pump speed

control. The first phase is the fast approach when

the pump speed increase is defined by the Step

Gain parameter. Once the controlled parameter

(flow in Production) or limiting parameter (TMP

in Production) are close to their respective

setpoint, the final trimming begins, where the rate

of pump speed increase is limited to 10% of the fast

approach. Please note that the trimming phase

begins when either of the two parameters is above

its approach setting. Figure 7-7 below illustrates

typical scenarios:

Flow SetpointFIC-3520

Flow ApproachFICH-3520

Time

TMP ApproachDPCL-3423

TMP limitDPCLL-3423

FIT-3520

DPI-3423

Clean membrane scenario: Flowsetpoint achieved

Fouled membrane scenario: TMPlimit reached

Figure 7-7 Process Pump (P-35) Speed Control

To improve the response time when ZeeWeed® unit

is restarted in Production after Backpulse, the

pump speed in Production is recorded and at the

J1 (111)

beginning of the new Production cycle, the pump

is restarted at 90% of the previous Production

cycle pump speed. This speed is held for 5 seconds,

then control is released to the above control

algorithm.

Please refer to the Control Logic Summary Chart,

Appendix 2, for details.

iv) Putting a ZeeWeed® Unit to Standby

Several triggers (see the Control Logic Summary

Chart for these triggers) may cause a unit to go to

Standby (rather than shutting it down). These

include a low level of the Membrane Tank (LYLL-

3426) or high level of the Backpulse Break Tank. If

the Standby trigger no longer exists, the unit will

go back into Production when level (LYL-3426) is

triggered.

v) Starting a Unit in Production after Standby

If a Production cycle was interrupted by a

Standby condition, the ZeeWeed® unit will

eventually be put back into Production based on

the level trigger points or utility requirements

defined in the Control Logic Summary Chart

(Appendix 2). Every time the ZeeWeed® unit is

taken out of Standby, the ZeeWeed® unit starts

the Production cycle by performing Backpulse

first.

J1 (112)

vi) Permeate Discharge

All permeate will be discharged to the

Backpulse/Break Tank TK-81. Occasionally, when

the other ZeeWeed® unit is in Wash mode, the

permeate will be diverted to the CIP Tank TK-88.

See Operations Sequence Chart (Appendix 2) for

details.

h) ZeeWeed® Backpulse Control

i) Backpulse

The Backpulse frequency (Production cycle

time), duration, and pressure for each ZeeWeed®

Unit can be set (see Control Logic Summary Chart,

Appendix 2, for Factory Default Setpoints) by the

operator through the MMI. These settings should

be, but are not restricted to, the same for each unit.

The operator can initiate a backpulse from the

MMI for either ZeeWeed® Unit. Initiating a

backpulse will also initialize the backpulse timer.

The subsequent Production / Backpulse cycles

will now start from the end of the operator initiated

backpulse.

Note: Every time the ZeeWeed® unit is taken out of

Standby, it performs a Backpulse before going

into Production.

ii) Backpulse Pressure Control

J1 (113)

During a backpulse sequence, the pump speed will

be ramped up, in an expedited mode and then

trimmed to maintain the backpulse pressure. The

PLC will increase the pump speed in a step-wise

fashion. The rate of acceleration of the pump is

coded into the PLC.

When the backpulse pressure reaches the

backpulse pressure approach setpoint (DPCH-

3423), the PLC will trim (reduce the step size to

10%) the stepwise approach to achieve the

backpulse pressure setpoint (DPCHH-3423). The

PLC will adjust and control pump speed during the

remainder of the backpulse sequence to maintain

the backpulse pressure setpoint by increasing or

decreasing the pump speed by one step (trimmed)

every time interval.

If the backpulse pressure setpoint is not

approached, the pump speed will continue to be

ramped up to 100% and held there for the

remainder of the backpulse. This ensures that the

backpulse pressure and flow rates are maximized

for the duration of the backpulse.

iii) Backpulse Analysis

The operator may want to determine the

effectiveness of the backpulse procedure. To

J1 (114)

simplify this analysis, the MMI will show the

following information for each ZeeWeed® unit:

Point in Cycle Process Pump Flow

(FIT-3520)

gpm

TMP

(DPI-3423)

psi Before the last backpulse 127 -7.7

During the last backpulse 360 8.1

After the last backpulse 130 -6.9

After the previous

backpulse

130 -6.9

Table 7-2 Backpulse Analysis Chart

This information will allow the operator and

ZENON to determine if the backpulse was actually

effective in reducing the TMP to maintain a certain

flux and if the TMP is measurably changing from

one cycle to the next. To improve backpulse

effectiveness, the operator can increase frequency

and duration of the backpulse (this will however

reduce the Production time and cause the

membranes to work harder for a shorter period of

time). For “After Backpulse” conditions, the table

shows the flow and pressure 30 seconds after a

backpulse to allow the process parameters to

stabilize.

J1 (115)

i) Membrane Wash Procedure



designed permeate flow, high pressure differential or

reduction in percent rejection. The clear indication of

fouled membranes is when during Production cycle the

flow setpoint cannot be achieved (the process pump speed

is limited by TMP limit). The membranes can be cleaned

in place by using the CIP Tank TK-81. If the operator

wants to carry out a Clean in Place procedure, they would

first put the unit into WASH. The WASH selector switch

can only be activated if the unit is in OFF mode. After

putting the unit into WASH, the unit will be in Wash

Standby. The operator must press the CIP Fill button

to divert the permeate from the ZeeWeed® unit in

Production to the CIP tank. Once the level switch LSH-

8105 is triggered the Fill routine is completed. The

operator must press the Initiate Backwash button to

start the process pump and perform the Backwash.

Note: The CIP Fill button applies to the ZeeWeed® unit

in Production not the ZeeWeed® unit being in Wash.

i) Backwash Pressure Control

Identical to Backpulse Pressure Control (same

settings and control).

J1 (116)

E. Dual Softener System

a) Bisulphite Addition

Sodium bisulphite addition is based on the softener feed

flow at the point of injection. A virtual flowmeter is

created:

FT-1321 = (FT-1320A) + (FT-1320B) + (FIT-2943)

The bisulphite pump dosing rate is calculated as follows:

SC-2300A/B [%] = (FT-1321) / (FYH-1321) * 100

Where FYH-1321 (field adjustable) is the feed flow at


The addition of bisulphite is achieved by using one of the

two metering pumps P-23A or P-23B. Only one pump is

running at a time. The virtual flowmeter FT-1321 must













J1 (117)




b) Softener Unit Mode Selection - RUN/OFF


Softener Unit Mode Selector Switch the operator (through

the MMI with maintenance level password access) can put

each softener unit into one of two modes: RUN, or OFF.

The softener unit modes are described below:

RUN OFF

Unit responds tointerlocks and controllogic.

Unit is shutdown (alldevices deactivated).

i) Softener Unit “RUN” Mode

RUN mode is the mode of operation that each

softener unit will be in for normal operation. The

operation of each unit can best be described as

automatic; during normal operation, no operator

attention is required unless an alarm/alert is

activated. Each softener unit is either in

Production, Standby, Regeneration or

Shutdown at any given time. The MMI will

indicate different steps during each of the above

states and time to complete each step (if based on

timer). In RUN mode, when the softener unit is

J1 (118)

not in Regeneration, the PLC will start and stop

softener unit based on the RO feed requirement.

(See Control Logic Summary Chart, Appendix 2, for

details).

When a softener unit is in Standby for a prolonged

period of time, an equalization process occurs in the

softener bed. This requires a Service Flush before

the unit can produce quality water. If the softener

unit is in Standby for a short period of time (less

than KY7-1300 - user adjustable) the Service Rinse

will be skipped (see Operations Sequence Chart,

Appendix 2, for details).

Only one softener unit can be On-line at a time.

When both softeners are placed in RUN mode, the

first unit that has been activated will become the

lead unit and come On-line (if the RO feed is

required). The second unit will be the lag unit and

will go into Standby regardless of RO feed

requirement.

When the softener unit is in On-line, the PLC will

totalize the softener feed flow (FQI-1320A/B). The

capacity of each softener unit is approximately

185,000 gallons (user adjustable). Once the

capacity of the unit has been reached, an alert will

be issued to prompt the operator to select the other

unit by pressing ON-LINE button on the MMI

screen. The unit that is in Production (lead unit)

J1 (119)

will continue Production until the unit in

Standby (lag unit) completes its Service Rinse and

goes into Production. At that time the lead unit

becomes the lag unit and goes into Standby. Since

the capacity of the unit placed in Standby has

been exhausted, the operator should initiate

Regeneration of this unit.

Note: If the system operates in DOUBLE Capacity

mode (Peak Flow) the REGENERATION button

on the MMI screen is inactive (the softener can be

regenerated in NORMAL mode only). When the

regeneration process has been initiated in

NORMAL mode, the mode selector switch cannot

be placed in DOUBLE Capacity mode.

The regeneration procedure is fully automated (see

Operations Sequence Chart, Appendix 2, for

details). Each step of the regeneration procedure is

timer based (user adjustable). The step description

and time to complete is displayed on the MMI

screen. During the regeneration procedure the

operator may use a toggle pushbutton HOLD /

RELEASE on the MMI screen to prolong any step

of the regeneration procedure indefinitely. They

may also use a momentary button ADVANCE to

terminate/skip a step during the regeneration

procedure. These two control buttons should be

used with extreme caution as improper use of any

of them may produce undesirable results.

J1 (120)

ii) Softener Unit “OFF” Mode

The operator can shut off each softener unit by

selecting OFF mode from the MMI. As a unit is

shut OFF, devices will shut off in an orderly

fashion. See the Operations Sequence Chart,

Appendix 2, for the device status and sequence for

the OFF procedure and status.

c) Alternating Softener Feed Pumps

The pair of softener feed pumps P-13A and P-13B provide

pressurized feed for the softener and RO units. A single

pump can handle two RO units in DOUBLE Capacity

mode or a single RO unit and regeneration of the second

softener unit in NORMAL mode. Only one pump is

running at a time. The first pump placed in Auto mode

becomes the lead pump and will start whenever an RO

unit requires feed (or softener in Regeneration requires

feed). The second pump placed in Auto mode becomes the

lag pump and does not run. If both pumps are in Auto

mode and not Failed, at a time of day specified by KY-

1300 the lag pump should start and become the lead

pump. After a 3 second delay the lag pump should stop.

This alternating operation will ensure that both pumps

are used when available.

F. Reverse Osmosis (RO) Pretreatment

a) RO Feed Conductivity

J1 (121)

The RO feed conductivity analyzer AIT-4131 is used for

monitoring the quality of the RO Feed. No control is

associated with the Feed conductivity. See Control Logic

Summary Chart (Appendix 2) for details.

b) RO Feed pH Control

The addition of caustic hydroxide in NORMAL mode

(single RO running) is achieved by using one of the two

metering pumps P-25A or P-25B. PID control of P-25

pumps is implemented using AIT-2520 as the process

variable. The setpoint is defined from the MMI screen

(see Control Logic Summary Chart, Appendix 2, for

details). In the event of the pH probe or transmitter

failure the caustic dose rate can be set manually (pump in

Manual mode). Only one pump is running at a time. An

RO unit must be running for the metering pump to be



pump if not in Off mode). Whenever an RO unit stops

and both pumps are available (not in Off), pumps will

toggle (the lead pump becomes the lag pump and vice

versa).






J1 (122)

In DOUBLE Capacity mode (both RO units running at

the same time) only one metering pump is running.

G. Reverse Osmosis (RO) System

a) RO Unit Mode Selection - RUN/OFF/WASH


RO Unit Mode Selector Switch the operator (through the

MMI with maintenance level password access) can put

each RO unit into one of three general operating modes:

RUN, OFF, or WASH. The RO unit modes are described

below:

RUN OFF WASH

Unit responds to interlocks and control logic.

Unit is shutdown (all devices deactivated).

Very limited control.Most devices deactivated.

i) RO Unit “RUN” Mode

RUN mode is the mode of operation that each RO

unit will be in for normal operation. The operation

of each unit can best be described as automatic;

during normal operation, no operator attention is

required unless an alarm/alert is activated. Each

RO unit is either in Production, Standby or

Shutdown at any given time. In RUN mode, the

PLC will start and stop RO units based on the tank

levels in TK-88 and TK-71 (see Control Logic

Summary Chart, Appendix 2, for details).

J1 (123)

ii) RO Unit “OFF” Mode

The operator can shut off each RO unit by selecting

OFF mode from the MMI. As a unit is shut OFF,

devices will shut off in an orderly fashion. See the

Operations Sequence Chart (Appendix 2) for the

device status and sequence for the OFF procedure

and status.

Note: The operator cannot switch directly between

RUN and WASH mode. Each mode can be selected

when RO is in OFF mode.

iii) RO Unit “WASH” Mode



designed permeate flow. When an operator decides

(criteria discussed in the Wash section of the

manual) that the RO unit needs to be washed, they

will place it in WASH mode. Wash mode has a

limited impact on the RO unit control (Permeate

Pressure Bleed valves activated to close).

Note: The WASH mode cannot be selected when

the system is in DOUBLE Capacity mode.

b) Alternating RO Units

As described earlier, during NORMAL operation only one

RO unit can be in Production. The first RO unit placed

in RUN mode becomes the lead unit and goes into

Production (if required). The second unit placed in

RUN mode becomes the lag unit and goes into Standby

J1 (124)

regardless of the demand. If both RO units are in RUN

mode and not in Shutdown, every time the lead RO unit

goes into Standby due to lack of demand (TK-71 above

LYH2-7126) or no water to process (TK-88 below LYL-

8820) it becomes the lag unit. This will ensure that both

RO units are used and no stagnant water is kept within

RO Unit for extended period of time.

Occasionally, when balanced demand exists, the lead RO

unit may never go into Standby. To ensure that under

normal conditions RO units are alternated at least once

per day, the time in Production for the lead RO unit is

measured. If at a time of day defined by KY-4100 the

runtime is greater than 12 hours, the lead units should go

into Standby and the lag RO unit should become the lead

Unit and begin Production.

Note: The lead RO unit should always be in Standby

before the lag unit goes into Production to prevent

Shutdown alarms due to low feed pressure if a Softener

unit is being rinsed as part of the Regeneration.

Whenever the lead RO unit goes into Shutdown due to

an alarm condition, the lag unit will become the lead unit

and will go into Production.

In DOUBLE Capacity mode described earlier (both RO

units operate at the same time) the startup of the lag RO

unit should be delayed by 10 sec (staggered startup).

J1 (125)

c) Alternating RO Process Pumps

Each RO unit has a pair of process pumps for the First

Pass (P-41A and P-41B) and the Second Pass (P-43A and

P-43B). During normal operation (both pumps in Auto)

only one pump is running from each pair. The first pump

from each pair placed in Auto mode becomes the lead

pump and will start whenever RO unit goes into

Production and a process pump is required (see

Operations Sequence Chart, Appendix 2). The second

pump from each pair placed in RUN mode becomes the

lag pump and is not running. If both pumps within a pair

are in Auto mode and not Failed, the RO unit goes into

Standby (or stops for any other reason) (lead becomes lag

and vice versa). This will ensure both pumps are used

when available.

When one of the RO units is not available (OFF, WASH,

or Shutdown) the other RO Unit will be permanently

designated as the lead unit. This may result in a

continuous operation of an RO unit for more than 24

hours. If at a time of day defined by KY-4100 the other

RO unit is not in Standby and both pumps within a pair

are in Auto mode and not Failed, the pair of pumps will

toggle while RO unit is running in Production. The lag

pump should come on, for 3 seconds both pumps should be

running together, then the lead pump should stop (as it

becomes the lag pump).

There should be a 10-second delay between alternating

pumps P-41A/B and P-43A/B.

J1 (126)

Whenever the lead pump fails due to an overload alarm,

the lag pump will become the lead pump and will restart

immediately.

d) RO Clean in Place (CIP) Control

When the RO membranes become fouled the permeate

flow will decline. The operator can modify settings for the

HCV-4181 and HCV-4082 (First Pass) or HCV-4381 and

HCV-4282 (second Pass) to compensate for some fouling

by increasing the membrane inlet pressure. At some

point the fouling of the membranes cannot be

compensated as the membrane inlet pressure reaches its

limit. To restore the membrane permeability a chemical

wash is required.

The Wash mode for an RO unit affects only two

components within this unit. Both Permeate Pressure

Bleed Valves are activated to close as long as the low

cross-membrane alarms are not active.

The operator must adjust the position of manual valves to

configure the required recirculation loop.

Tank TK-83 is used to prepare the cleaning solution (or

preservative). The built in electric heater H-83 maintains

proper temperature of the cleaning solution when the TK-

83 level is above LSL-8301 and the heater local selector

switch is in Auto.

The transition of the pump P-83 local selector switch from

Off to Auto starts the pump (if tank level above LSL-

J1 (127)

8301 and TSH-8303 not triggered) and runs it for a

duration defined by KY-8300 before stopping. To restart

the pump the operator must turn it Off then back to Auto

using the local switch or press the RECIRCULATION

button on the MMI screen (active only when local switch

is in Auto).

The details regarding preserving membranes and

washing the membranes are part of Zenon’s Operations

and Maintenance Manual.

H. Electrodeionization (EDI) System

The EDI System provided by Ionics is a stand alone unit. The

supplier provides the PLC code which is integrated into the

main PLC provided by ZENON. The supplier also provides MMI

screens for a standard user interface which are incorporated into

PanelView 1400e provided by ZENON.

a) CIP EDI

The EDI uses the RO CIP system for cleaning. The wash

pump is enabled from the EDI CIP screen on the MMI.

The pump P-83 local selector switch from Off to Auto

starts the pump (if tank level above LSL-8301 and TSH-

8303 not triggered) and runs it for time defined by KY-

8300 before stopping. To restart the pump the operator

must turn it Off then back to Auto using the local switch

or press the RECIRCULATION button on the MMI

screen (active only when local switch is in Auto).

J1 (128)

I. Dual Mixed Bed Ion Exchange Polishing Unit

The mixed bed ion exchange system is a stand alone passive unit

with no controls associated with the unit.

J. Break Tank with Outlet Feed Pumps

a) Break Tank TK-71

The Distribution Break Tank TK-71 serves as a reservoir

of high purity water.

During NORMAL operation the contents of the tank will

be recirculated through the EDI system at a rate of 80

gpm. The recirculation rate is adjusted manually by

using HCV-7183. Regardless of whether the RO unit is in

Production or Standby, as long as the tank level is

above LYL-7126, one of the outlet feed pumps P-71A/B is

running and the recirculation valve FV-7184 is open. If

the tank level drops below LYL-7126, the outlet feed

pump stops and 5-seconds later the recirculation valve

FV-7184 will close. The Distribution Tank Level must

rise above LYH-7126 to enable the outlet feed pumps and

the recirculation valve (the valve opens first, and after a 5

second delay the outlet feed pump starts).

In DOUBLE Capacity mode (peak flow) the recirculation

valve FV-7184 remains closed. The outlet feed pump is

controlled by levels LYL-7126 and LYH-7126 (disabled

J1 (129)

when level drops below LYL-7126, and enabled when level

rises above LYH-7126).

b) Outlet Feed Pumps P-71A/B

The pair of outlet pumps P-71A and P-71B provide

pressurized feed for boiler feed tanks and recirculate the

contents of the Distribution Break Tank through the EDI

system. Only one pump is running at a time. The first

pump placed in Auto mode becomes the lead pump and

will start whenever outlet feed pump is enabled. The

second pump placed in Auto mode becomes the lag pump

and is not running. If both pumps are in Auto mode and

not Failed, at a time of day specified by KY-7100 the lag

pump should start and become the lead pump. After a 3

second delay the lag pump should stop. This alternating

operation will ensure that both pumps are used when

available.

K. Reserve Feedwater Tanks

The MMI or external Bailey PCV operator station can send one

of six commands in a form of a single PLC word (binary). The

command will set the appropriate bit high, while the PLC detect

the positive transition of the bit. It will accept the command, set

the bit low, then execute the command. The commands are as

follows:

1. Transfer to Tank #1 (bit 00)


J1 (130)



5. Transfer to all tanks (bit 04)

6. Abort transfer (bit 05)

Notes:

1. Transfer to all tanks implies the following order: Tank #4,

Tank #3, Tank #2, Tank #1.

2. During transfer to one tank all other transfer requests are

ignored. Only the last request is remembered (transfer

request bit remains on) and accepted when current transfer

is completed.

a) Single tank transfer procedure

1. Accept transfer (clear transfer request bit).

2. Open tank transfer valve.

3. Continue transferring until tank high level switch

activated. Please note that one of the distribution

pumps is running all the time.

4. Close tank transfer valve.

5. Transfer completed (another transfer command can be

accepted).

b) Transfer procedure for all tanks

1. Accept transfer (clear transfer request bit).

2. Open tank #4 transfer valve.

3. Continue transferring until tank #4 high level switch

activated.


J1 (131)

5. Close tank #4 transfer valve.


activated.




activated.

10. Open tank #1 transfer valve



activated.


14. Transfer completed (another transfer command can be

accepted).

Pressure switch PSH-153 installed on the common tank

feed header protects outlet feed pumps P-71A and P-71B

from running dead-headed. Since the outlet pumps can

be dead-headed only in DOUBLE capacity mode (no EDI

recirculation), the shutdown alarm associated with PSH-

153 is active only in this mode.

L. Sump Pumps

A pair of pumps, P-103 and P-104, are used too. To prevent the

pumps from running dead-headed, a 3-way Yarway control valve

FCV-166 is installed at the common pump outlet to provide

bypass flow back to the sump. Pressure switch PSH-155

J1 (132)

protects the feed pumps in case of malfunction of FCV-166.

Sump level is measured by level transmitter LIT-156.

The pair of sump pumps, P-103 and P-104, empty the local

sump. Both pumps are controlled according to sump level LIT-

156. The first pump placed in Auto mode becomes the lead

pump and will start when the sump level is above LAH-156.

When the sump level drops below LALL-156, the second pump

placed in Auto mode becomes the lag pump. When the lead

pump is running but the sump level is nevertheless increasing,

the lag pump will start once the sump level reaches LAHH-156.

Whenever both pumps are running or both pumps are not

running (but in Auto and not Failed) the lag pump becomes the

lead one and vice versa. When both pumps are running and the

sump level drops below LAL-156 the lag pump stops. The lead

pump stops when the sump level drops below LALL-156.

The integrated 3-way Yarway control valve FCV-166 is installed

at the common sump pump outlet to provide bypass flow back to

the sump in case the drain line is blocked. In case of FCV-166

failure and drain line blockage, the pressure switch PSH-155

protects the sump pumps (stops both pumps when tripped).

J1 (133)

CHAPTER 8 – OPERATE UNDER UPSET CONDITIONS

1. INTRODUCTION

The entire plant is programmed to be completely automatic if all the

devices are in Auto. The MMI (Man Machine Interface) is provided for

monitoring and control of the entire plant.

Each ZeeWeed® unit and RO unit has a unit mode selector switch,

which enables the operator to RUN each unit, turns the unit OFF, or

put a unit in WASH mode. Each softener has a unit mode selector

switch, which enables the operator to RUN a unit or turn the unit

OFF.

A detailed summary of the major components in the plant and a

description of their functionality is first presented in this section.

Overall plant control and how the major components operate together

is then discussed at the end of this section. The user should also refer

to the Process and Instrumentation Diagrams (P&IDs), the Control

Logic Summary and the Operations Sequence Charts to understand all

the controls and interlocks. Appendix 2 includes the Control Logic

Summary and the Operations Sequence Charts.

The two ZeeWeed® units and two RO units are identical including

agging (except Unit 1 devices have a -1 suffix and Unit 2 devices have

a -2 suffix). For clarity, the suffixes are dropped altogether and when

referring to these units, the reader should be aware that there are in

fact multiple devices and that are suffixed -1 and –2. The two Softener

units are referred to as Unit A and Unit B. The logic and sequence

J1 (134)

charts show which devices are common to both units and which are

dedicated to each. Shared devices have no suffix.

A. Power Up/ Power Interruption

The PLC stores all the settings, and status of the devices and

plant from the last time the plant was powered up. After a

power interruption, the plant will restart automatically in an

orderly fashion. The PLC will wait 60 seconds after power up

before turning on devices (that are in Manual or Auto) or

monitoring signals to allow transmitters to warm up and

complete any self-diagnostics. The PLC will stagger start up of

the pumps as defined in the Startup Sequence Chart to avoid

putting excessive load on the power grid. A Start Up Sequence

Chart lists the order in which devices will power up after an

Emergency Stop or a power failure (refer to Appendix 2).

On initial power up or if the PLC memory is corrupted and the

PLC program is loaded from the E2PROM (Electronically

Erasable Programmable Read Only Memory) module, the plant

will power up with all devices in Auto. The PLC will sound an

alarm and all the units will power up OFF. The operator must

press RUN on the Man Machine Interface (MMI) to activate

each unit.

J1 (135)

CHAPTER 9 – TROUBLESHOOTING

1. GENERAL

A. Panelview not responding to commands.

A dialogue box will appear across the bottom of the screen

indicating “PLC currently controls screen change”.

B. Password timer expired.

This occurs every four hours. To enter the new password, press

F7 - a new screen will appear. Press the select button and type

in the digits 9348. Press the return button (down and left

arrow) and press the cancel button. The panelview will indicate

“PASSWORD IS VALID FOR 4 HRS” and should now

respond to your commands.

2. LAB TESTS

Note: Any time a lab test shows results that vary from what you

suspect is normal, the test should be repeated immediately. There are

a number of factors which can affect a given test result. The following

is a description of some of the problems which can affect a test.

A. The chlorine content after the softener is higher than

normal.

a) When performing the free chlorine test after the softener,

it is important that the glassware is not contaminated

with free chlorine from another source. Possible sources

of contamination are rinsing the glassware with tap

water, or performing the free chlorine test on a running

J1 (136)

ZeeWeed® output prior to the test after the softener.

Rinse the glassware with EDI product water and repeat

the test. Normal results should be at the bottom end of

the detection range, approximately 0.00 to 0.06 mg/l. If

the readings are higher than that, check the red eye on

the Sodium Metabisulphite pump and ensure there is

chemical for the pump in the lower tote.

b) Check the cholorine test powder pillows – some are for 25

ml samples and others are for 10 ml samples. While we

normally use the 10 ml sample units, the 25 ml samples

are acceptable if the appropriate sized samples are taken.

B. The chlorine content in the ZeeWeed® output is lower

than normal.

a) The most common cause of low chlorine content is to lose

the prime on the Sodium Hypochlorite pump. This

chemical has a fairly high vapor pressure so it tends to

develop bubbles in the pump suction. The volumetric rate

of flow in this pump is so low that the bubble will cause it

to lose prime. Re-priming is done by opening the priming

knob located on the back side of the pump head. The

primary knob should be turned just far enough to

allow the pump to expel the air. The primary knob

should be kept in this slightly open position to

allow future air bubbles to be expelled. The pump

has enough capacity to allow the bleach to slip

stream like this. The excess bleach is routed back

into the bottom tote. It is also possible to re-prime the

J1 (137)

pump by turning the relief valve release knob located on

the left-hand side of the pump discharge. This method,

however, is not recommended as it allows bubbles to be

re-introduced in the pump suction.

C. The softener is showing higher amount of hardness than

normal.

a) A possible cause is the softener may have been recently

regenerated and its efficiency may not be at its maximum.

The efficiency can be increased by flushing the softener

for a longer time during the regeneration. However, for

every gallon of water flushed, a gallon of production is

lost. As long as the hardness is less than 2 mg/l after

regeneration, this is not a problem. If it is greater than 2

mg/l, re-do the test after the softener has put through

approximately 1000 gallons of water during the

production run. If the hardness is greater than 4 mg/l, re-

do the regeneration. Check the instrument air pressure -

if it is too low, the brine inlet valve will not open.

(a) The glassware may have been rinsed with tap water. If

this is true, the hardness in the tap water will

contaminate the sample and the reading will show high.

Rinse the glassware with EDI product water and re-do

the test.

J1 (138)

3. FEEDWATER

A. The feed water inlet temperature is too low.

a) Check the set point on the pick valve controller; it has a

tendency to migrate downward over time.

b) Check if the steam control valve is opened fully. If it is

and the flow is not extremely high (i.e. 270 gpm), the

heater internals need to be acid cleaned. Notify the lab as

soon as it is convenient.

4. ZEEWEED®

A. The ZeeWeed® has shut down and the alarm annunciator

is sounding.

a) One of the ZeeWeed® tanks has lost its water level to the

point of shutdown. This can be caused by running the

ZeeWeed® units in NORMAL MODE with the ZeeWeed®

tank balance valve closed.

b) One of the ZeeWeed® tanks has lost its water level to the

point of shutdown. This can be caused by insufficient raw

water flow. Check that the inlet flow is at least equal to

the permeate flow. If the inlet flow is less than the outlet

flow, check to make certain that the raw water pumps are

each capable of making the required amount of water.

Both pumps may have to be run. If this is the case,

backwash the pumps to clean the screens. If this does not

work, put in a notification to have the pump inlet screens

cleaned.

J1 (139)

c) The feed water temperature is greater than or equal to

40°C; it is possible for the temperature to spike high

enough to cause a high temperature trip. Close the

manual steam supply valve to the pick heater and fox

open one of the ZeeWeed® solenoid valves to allow water

to enter the tank. Proceed to the raw water pumps and

put one of them on hand control for 20 seconds. The

pump should start on hand and force the slug of high

temperature water into the ZeeWeed® tank. It will mix

with the water already present in the tank and will not

endanger the membranes. Place the raw water pump

back into automatic control and restart the ZeeWeed®

units. When flow has been established to the ZeeWeed®,

reopen the manual steam supply valve.

B. ZeeWeed® is shut down, the above procedures have been

completed, and it still will not start.

a) Clear any alarms that may be displayed. This can be

done by pressing F17 to acknowledge the alarm and F18

to reset the alarm.

b) In the case of normal mode operation when running both

ZeeWeed® units is desired, giving a command to “RUN”

the second ZeeWeed® will bring the unit from “OFF” to

“STANDBY”. It is then necessary to give the “RUN”

command again to bring the unit from “STANDBY” to

“BACKPULSE”.

J1 (140)

c) The ZeeWeed® unit is probably fouled. The first thing

that should be checked is the inlet flow to the ZeeWeed®.

If it has not been equal to the production flow for a while,

the solids content in the tank will increase dramatically.

Simply increasing the inlet flow to maximum (around 300

gpm) for a few hours may be all that is needed. If this is

not the case, notify the Zenon representative so that a

clean may be done as soon as possible.

5. SOFTENER

A. The softener has been given a command to “RUN” but

will not go past “STANDBY”.

a) In order for the softener to go into full production, there

must be a RO unit calling for water. In order for the RO

to demand water, the RO must be in “STANDBY” and the

finished product tank must be at less than 90%. In the

softener startup cycle, the pump starts and flows water

up to, but not through, the softener for approximately one

minute before the RO inlet valves open.

b) The breaker has tripped for the softener process pump.

c) The softener process pump switch is in the off position.

B. The softener makes a loud noise.

a) The noise is coming from the relief valve. Limit stops are

installed on the service inlet valves and inlet bypass

valves to the softener vessels, and may be in need of

adjustment. If the noise occurs immediately after the

J1 (141)

pump starts, adjust the inlet bypass valve to limit the

inlet pressure to the softener, during the initial flushing

stage, to just under 100 psi. If the noise occurs when only

one RO unit is running, adjust the service inlet valve so

that the inlet pressure to the softener is just under 100

psi. These steps should not be required frequently.

b) The softener pump switch is selected to hand with no flow

through the softener or the bypass piping. Shut the pump

off or establish flow.

C. There is no brine flow during a softener regeneration.

a) The instrument air pressure is low. The instrument air

pressure is required because the brine inlet valve is

spring return. If the air pressure is below 60 psi the brine

inlet valve may not open.

D. The Backpulse break tank goes empty during a softener

regeneration.

a) During a softener regeneration, the plant must be

running in normal mode and second ZeeWeed® must be

running to supply water for the regeneration flows.

Otherwise, the tank will draw down and the softener

pump will trip. Remember to open the ZeeWeed® raw

water control valve bypass slightly until the backpulse

break tank reaches 89%. Otherwise ZW#1 will probably

trip on low tank level.

J1 (142)

E. The softener has a high pressure drop across it.

a) About 5 months after the commissioning of the water

treatment plant, a high pressure drops across the softener

vessels was noted. It was eventually discovered that

bacteria had begun to grow inside the softener vessel.

The bacteria caused a slime buildup covering the internal

vessel surfaces and probably also coated a significant

portion of the resin beads. The problem was attacked

through several methods, but the one that proved

successful was to drain the softener vessel, refill it with

brine from the brine tank by starting a regeneration and

advancing through to the brine cycle. Once the vessel was

full of brine, the top cover was removed and 20 liters of

12% bleach were added. The resin and chemical mixture

were air-lanced for one hour. This procedure was followed

by a normal regeneration. An improvement in the

softener pressure drop was immediately noticed. One side

effect of this procedure was that a lot of loose slime was

released and the micron filters were subject to rapid

plugging for the next several days. It should be noted

that at no time should the micron filter pressure

differential be allowed to exceed 10 psi.

J1 (143)

6. REVERSE OSMOSIS

A. One RO unit is running and the other one will not start

up.

a) The plant is running in single mode. Start the switching

process by shutting the EDI unit off. Switch to double

mode by selecting F15 from the main screen and select F2

to switch to double mode. Once the second RO unit has

been started and the offspec product to drain valve has

closed, the EDI can be restarted and balanced out.

b) The pump hand/off/auto switches are in the off position.

c) A softener regeneration is in progress. While a softener

regeneration may be started in DOUBLE MODE, it is not

possible to go into DOUBLE MODE while a softener

regeneration is in progress.

B. When starting the second RO, both of the ROs trip off.

a) The RO inlet pressure to the first stage may have gone

below 20 psi. This will trip the RO units to protect the

process pumps. The inlet valves on both ROs may have to

be closed somewhat. After closing them, readjust the

pressures to provide the desired second pass permeate

flow rates.

b) The inlet pressures on the RO second pass process pumps

may have dropped below 20 psi. In this case, re-initiate

the start and adjust the RO second pass inlet valve

J1 (144)

towards the closed position just enough to get the second

pass inlet pressure to above 20 psi.

C. When adjusting an RO inlet valve, the RO tripped off.

a) The first pass back pressure limits were exceeded. The

back pressure on the first pass of the RO must run

between 20 and 80 psi. It is possible to exceed these

limits when adjusting either the first or second pass inlet

valves. Check the alarm on the panel view or go from the

MAIN SCREEN to F10 DIAGNOSTIC SCREEN and

determine which alarm appeared. Reset the alarm and

readjust the valve that you were working with, usually in

the opposite direction that you were going, and attempt to

restart the RO. Remember that if the alarms are not

reset, the RO unit will not restart.

D. RO unit starts up but trips when the EDI unit is started.

second pass inlet pressure high alarm comes up.

a) This problem can occur when the temperature has been

dramatically reduced, say if the steam supply has been

removed from the pick heater. The reason for this is the

second pass of the RO may not be able to process the

water from the first pass quickly enough. This is

especially true if the first pass has been recently cleaned

and the second pass has not. Also, the EDI presents more

back pressure under cold conditions and this will

aggravate the water consumption of the second pass of

the RO. To correct the problem, reduce the inlet pressure

J1 (145)

to the first pass of the RO. If the inlet valve is getting

very close to fully closed, increase the amount of reject

flow to allow better control from the first pass inlet valve.

E. Not possible to run both RO units at the same time

without running both softener process pumps

simultaneously.

a) Check the micron filters for a high pressure differential.

The pressure differential across the micron filters should

not be in excess of 10 psi. If the differential is high,

switch to the spare micron filter and notify the Zenon

representative during the next day shift so the old filter

elements can be replaced.

b) Check the softener differential pressure. In single mode

operation, it is normal for the differential to be around 7

to 10 psi. In double mode, normal differential is around

20 to 30 psi. If the differentials are higher than this,

notify the Zenon representative as soon as possible so that

corrective action may be taken.

c) Check if there is a softener regenerating. If a softener is

regenerating during a high flow double mode operation,

one pump will not be able to maintain flow. Reduce the

flow through the RO units or run in single mode as you

will quickly run out of water in the backpulse break tank.

J1 (146)

7. ELECTRODEIONIZATION (EDI)

A. The EDI unit will not start.

a) If the plant is set to operate in single mode, check that

one of the RO units is running and the product water is

available as supply to the EDI unit. Upon RO start up,

valve FV4264 will be closed and FV4261 will be open to

divert RO product water away from the EDI until the

product quality from the RO is stabilized. It takes a few

seconds for the quality to stabilize and the EDI will hold

out until then.

b) If the plant is set to run in double mode, check to see if

both RO units are running and that the product quality is

stabilized. Sometimes one RO unit can trip and not be

readily noticeable.

c) Ensure there are no alarms on the EDI screen. An alarm

on the top band of the EDI screen (F6) on the panelview

will prevent the EDI from starting. Acknowledge and

reset the alarm. The “Manual, Off, Remote” switch on the

unit control must be set to the “Off” position to reset the

alarm.

d) If EDI inlet valve MOV1-4, will not actuate, or is

actuating erratically, check the contacts on the back of the

“Manual, Off, Remote” switch. The contacts may be loose.

If that fails, verify the contacts on the output card relay

are not stuck. The Zenon representative must be

contacted in the event of an output card problem. If that

J1 (147)

does not work, the relays inside the EDI junction box may

have fused relays. Replace the faulty relay with a spare.

B. The EDI unit crashes, and Motor Operated Valves 1-4 and

2-4 are both in the open position.

a) If this problem occurs, open the back of the PLC cabinet

and look to the right directly inside the door enclosure.

The problem is a blown fuse and it should be indicated

with a glowing red light adjacent to the fuse location. The

fuse is number FU16. Correct the cause of the blown fuse

and replace it with a 3 amp slow blow fuse.

C. The EDI unit runs but the display for the stack amps is

only showing stars.

a) There are two breakers which supply control power to the

EDI unit. This condition will occur when either of the

breakers are tripped. The first breaker is number 18A

and is located in the 110 volt panel situated in the MCC

panel. The second breaker is located in the upper left side

of the rectifier cabinet. Reset the breakers if they are

tripped.

D. The EDI unit starts, but trips off after a short time with

an alarm showing “MOV 2-4 Failure to Open”.

a) The failure to open is probably caused by the failure of the

relay which controls the operation of MOV 2-4. In the

event of this happening, go to the EDI screen and press

the F5 button to access the EDI set points. Reset the EDI

J1 (148)

Resistivity Setpoint to 18. This setpoint is virtually

impossible to achieve, therefore the MOV 2-4 will not try

to open to allow product to Tank 71. Once this is done,

remove the actuator for MOV 2-4 from the valve body and

actuate the valve with a wrench. Leave the valve in this

position unless the conductivity of the EDI is suspect.

Contact the Zenon representative immediately to notify

them of the situation.

E. The temperature of the inlet water is low, combined RO

output is too low to allow the EDI to run at its minimum

flow rate of 105 gpm in Double Mode, and the plant needs

all the water it can get.

a) It is possible under these conditions to “fool” the PLC into

believing that it is in “NORMAL MODE” and still allow

for both RO units to operate. To do this, first shut off the

EDI. Switch from “NORMAL MODE” to “DOUBLE

MODE”. At this time, the second RO unit may be

started. When the second RO is running stable, switch

back to “NORMAL MODE”. Both RO units will continue

to operate. The EDI unit may now be started with the

recirculation capability associated with “NORMAL

MODE” operation. Remember that the second pass RO

inlet pressure must be fairly low because starting the EDI

at low temperature will cause a considerable back

pressure increase. It is a good idea to open the product

flow valve on the EDI slightly and to close the

recirculation valve to the EDI slightly to compensate for

J1 (149)

the increased flow that the EDI will have to endure. Once

the EDI is running it may be re-balanced. Also, the

transfer to low level tankage in this circumstance should

be done by manually opening valves to the individual low

levels so that a high reading in a low level tank will not

terminate the transfer. Always remember to open one

valve before closing the next one so that the pressure does

not increase on the EDI and cause a trip. Ensure that a

good balance exists between the product tank inlet and

output so that the transfer pump will not trip on product

tank low level. When operating in this method, any trip

will cause the system to “realize” that it is in “NORMAL

MODE” and only one of the RO units will restart,

therefore, it is essential that nuisance tripping be

minimized.

8. TRANSFER SYSTEM

A. The transfer pumps will not function with the selector

switch in the “AUTO” position. They will work in the

“HAND” position.

a) The transfer system could be being held out by a BOILER

FEED HIGH PRESSURE (PAH-135) fault. This fault is

external to the Zenon system and is only shown on the

F10 screen under EXTRA FAULTS. This alarm can come

up while switching from NORMAL to DOUBLE mode if

the transfer of water to the low level tanks is interrupted

during the switch. For example, if transfer has been sent

to #1 low level tank and the tank has shut down the

J1 (150)

transfer due to high level, the transfer pump will still be

running as long as the plant is in NORMAL MODE.

When the switch is made to DOUBLE MODE, either to

run that way, or to switch RO units, the transfer pump

will briefly dead head and the high pressure alarm will

come up. The pumps will not run in auto until the alarm

has been acknowledged and reset, even if the pressure is

no longer high. The pressure switch is located adjacent to

the PLC cabinet on the product water line going to the

low level tanks.

J1 (151)

CHAPTER 10 – CHECKLISTS AND/OR READINGS

1. BEGINNING OF SHIFT CHECKLIST

As Of January 21, 2000

A. Check the temperature on the ZeeWeed® pump outlets. This

gives a longer term trend on the performance of the Pick heater.

Adjust the Pick heater setpoint as required. If the temperature

is too low, it will strongly affect the RO outputs. It seems that

the setpoint on the Pick heater controller will migrate

downwards over a period of a few hours.

B. Check the lubricant levels in the ZeeWeed® blowers (B85).

C. Check the lubricant levels in the ZeeWeed® process pumps

(P36).

D. Test the hardness of the output of softener in service. If it is

greater than 4 mg/l, or if the softener has reached total flow,

engage the other softener. Test the fresh softener after it has

flowed for a minimum of 1000 gallons to assure that the water

being tested is a representative sample.

E. Check the lubricant level in the softener process pumps (P13).

F. Check to ensure water is flowing through both micron filter

vessels. To do this, simply close the discharge valve on one of

the filters while observing the discharge gage. There should be

a noticeable dip in the pressure indication. Re-open the valve

and repeat the procedure on the other micron filter discharge

valve. The same pressure gage dip should be noticed.

J1 (152)

G. Check the indicators (red eye) on the chemical injection pumps.

If the indicator flashes when the pump strokes, the pump is

primed and sending chemical. If the indicator does not flash,

the pump is air bound and the priming port should be opened

until liquid comes out of the tube located on the right side of the

pump head. In the case of the sodium hypochlorite pump, the

priming port has been tied back into the bottom tote. If the

pump becomes air bound, open the priming port just enough to

re-establish flow (red eye indication) and leave the port open by

that amount. This will allow a continual release for trapped air

bubbles without significantly reducing the bleach flow to the

raw water.

H. Check the volume of the chemical in the bottom tote. If the

volume is getting low, open the valve between the top and

bottom totes to refill the bottom tote. If the top tote is empty,

notify the shift supervisor so more chemical can be ordered.

I. Check the operation of the RO units. Ensure that the pumps are

running fine and the reject flows are suitable for the production

flows. Flow rate charts are attached to each RO second pass

reject flow meter. Run in single mode whenever the plant

reserves are suitably high. Run in double mode when they are

not. The output of each RO should be approximately 84 USgpm

when the water temperature is 25ºC. Lower operating

temperatures will reduce the maximum RO output.

J1 (153)

J. Check the operation of the EDI unit. Balance the flows as

necessary. The recommended differential pressures are 60 to

100 inches on both stack in and stack out. The brine makeup

flow should be 7.5 to 8 gpm. The flow rate for the electrode

makeup should be 5.5 gpm. The brine blowdown should equal

the brine makeup minus the electrode makeup. The EDI stack

current should be limited to 4 amps, and the current peaks

should not exceed 6 amps. It is normal for Stack 1 to have the

highest current. The stack amperage is controlled by the stack

voltage.

2. OPERATOR LOGSHEETS

Logsheets are to be filled out during each shift. The logsheets cover

the ZeeWeed®, Softener, Reverse Osmosis and EDI units and are

described as follows.

A. ZeeWeed® - Note: If the backpulse break tank is at 87%

or higher, do not attempt to do the ZeeWeed® readings

because the set point will ramp down to 70 gallons per

minute as the break tank level climbs. This will cause

the readings on the log sheet to be meaningless.

a) Enter the current date.

b) Enter the time that the test was taken.

c) Raw water temperature refers to the inlet water to the

ZeeWeed® unit. It is available from the panelview screen,

however, it is best taken on the thermometers located on

the discharge lines located above the ZeeWeed® process

J1 (154)

pumps because the panelview reading is not buffered

against short term temperature fluctuations.

d) Process mode will always be “MF”. This stands for micro

filtration.

e) Vacuum pump pressure is read on the pressure gage

directly above the vacuum pumps. The gage can fluctuate

quite a bit, depending on whether the pump is currently

drawing air out of the system or not. The purpose of this

reading is to verify that the vacuum pump is working.

f) BP frequency is the duration in minutes between

backpulses. The number is displayed, in seconds,

immediately to the right of the “PRODUCTION MODE”

indicator when it is on. This variable is not likely to be

changed often.

g) BP duration is the length of time that the backpulse will

occur. This is indicated immediately to the right of the

“BACKPULSE MODE” indicator when it is on.

h) Raw feed pH is found on the water feed system screen.

The sensor is not currently operational.

i) Raw water flow. The raw water flow reading is found

near the upper left hand corner of the screen. During low

demand periods, this flow rate has a tendency to fluctuate

greatly. Pick an average reading.

j) Permeate flow rate. The permeate flow rate should match

the set point flow rate to within plus or minus 3 gallons

per minute. If the actual flow rate matches the set point

flow, simply record the set point flow. If the permeate

J1 (155)

flow does not closely match the set point flow rate, notify

the Zenon representative at the earliest possible chance.

Deviation in this flow could indicate the need for

membrane cleaning. If the backpulse break tank is at

87% or higher, do not attempt to do the ZeeWeed®

readings because the set point will ramp down to 70

gallons per minute as the break tank level climbs. This

will cause the readings on the log sheet to be meaningless.

k) BP flow rate. The backpulse flow rate is also controlled

by flow set point, however, it is set at 1.5 times the

permeate set point. In other words, if the permeate flow

rate is 134 gallons per minute, the backpulse should be at

1.5 x 134 or 212 gallons per minute. As with the

permeate flow, the value indicated here should be 212

gallons per minute unless there is a significant variance

from that value. If this occurs, record the measured flow

rate and notify the Zenon representative as soon as

possible. Deviation in this flow could indicate the need for

membrane cleaning.

l) TMP before BP. This is a measure of the amount of effort

required to draw water through the ZeeWeed®

membranes just prior to a backpulse. This value should

be negative. A large value for this variable can indicate

fouling of the ZeeWeed® membranes. This reading

should be taken approximately 10 seconds before the

beginning of a backpulse.

J1 (156)

m) TMP during BP. This is a measure of the amount of effort

required to push the water backwards through the

membranes at 1.5 times the normal production flow rate.

This reading should be taken as soon as the backpulse

flow rate reaches 1.5 times the normal flow rate. In the

case of a set point of 134 gallons per minute, backpulse

should be at 212 gallons per minute.

n) TMP after BP. This is a measure of the amount of effort

required to dray water through the ZeeWeed®

membranes just after a backpulse. It gives an indication

of the effectiveness of the backpulse for cleaning the

membranes. This reading should be taken as soon as the

flow rate reaches the production flow rate setpoint.

o) Blower discharge pressure. This is a misprint and should

read Blower discharge volume, measured in cfm. The

design flow for this is 20 cfm and is measured at the

rotometers located on each side of the ZeeWeed® box. In

order to achieve the initial 20 cfm, the air inlet valves to

the rotometers are opened wide and the air inlets to the

membrane cassettes are throttled back until 20cfm is just

exceeded on each side. The rotometer inlets are then

adjusted to control air flow to 20 cfm. If a significant

reduction of air flow is noted during the readings, it may

be assumed that inlet filters for the ZeeWeed® blowers

are plugging and need to be replaced.

J1 (157)

B. Softener Logsheets. Note: The softener logsheets are

currently set up for both softeners. We have set the

binder up for softener 1 and 2 to be kept in separate

locations in the log sheet binder.

a) PI1340A. This is the inlet pressure to number 1 softener.

b) PI1341A. This is the pressure on the number 1 softener

outlet. When considered against the inlet pressure, we

can determine if there is a high pressure loss across the

softener resin bed.

c) FI1320A. This is the flow indicator for #1 softener vessel.

The reading is available locally at the flow meter or it can

be found on the panelview on the F4 screen.

d) PI2940A. This gage is for the softener brine pump

discharge. It should only be read and recorded during the

brine injection portion of a regeneration.

e) PI2941A. This gage is also for softener regenerations. It

measures the pressure of the brine dilution water. It is

only meaningful during the brine injection portion of the

regeneration.

f) PI 1340B. This is the inlet pressure to number 2 softener.

g) PI1341B. This is the pressure on the number 2 softener

outlet. When considered against the inlet pressure, we

can determine if there is a high pressure loss across the

softener resin bed.

J1 (158)

h) FI1320B. This is the flow indicator for #2 softener vessel.

The reading is available locally at the flow meter or it can

be found on the panelview on the F4 screen.

i) PI8040. This is the pressure on the inlet to the micron

filters.

j) PI8041. This is the pressure on the outlet side of the

micron filters. When compared to the reading of -PI8040,

a good indication of the degree of plugging that exists in

the micron filter may be found.

k) AE2520. This is a pH indicator. The pH reading taken at

this point has an effect on the normalized flow

calculations for the RO membranes. This meter is not

functioning properly at the time of this writing. The lab

personnel are currently taking this reading.

l) AE4131. This is a conductivity meter. Like the pH

meter, this reading is important for the calculation of

normalized flow in the RO units. It is also not currently

in service and the lab is collecting and recording this data.

J1 (159)

module j1 water treatment - infomine · module j1 water treatment 1. ... a. backwash/feed pump ......

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