installation operating and maintenance guidelines t-rack vario 3(2012-05) e inge

7/16/2019 Installation Operating and Maintenance Guidelines T-Rack Vario 3(2012-05) E Inge

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inge GmbH

Installation, Operation and Maintenance Guidelines

inge T-Rack® vario



Installation Operating and Maintenance Guidelines T-Rack vario 3(2012-05) E inge

© 2011 inge GmbH ▪ All rights reserved

Index

1. inge T-Rack® vario – Technical Data - Important Information 3 2. Storage and Shipment 4 3. T-Rack® vario assembly 5 4. Operating and Start-Up Guidelines 13 5. Recommendations Regarding Air Integrity Testing (Pressure Hold Test) –

inge T-Rack® vario 18 6. Operating Conditions 22 7. Documentation of Operating Conditions 26 8. Membrane Downtime Conditions 27 9. Transport Conditions for inge UF Modules and T-Rack® vario components 28 10. Warranty Policy 28 11. Contact Details 29

Appendix A “Principle Flow Diagram T-Rack PR-02-01-005-01 5(2012-05) E inge“

Appendix B “Process Specification UF 1(2012-05) E inge”





1. inge T-Rack® vario – Technical Data - Important Information

To keep the T-Rack in good condition and avoid any risk of damages, please observe thefollowing precautions:

Avoid Drying Out

If the module is put into storage for an extended period of time, the membrane will dryout. Dehydration of the membrane may cause it to suffer irreversible damage. It istherefore essential to protect the membrane from dehydration.

Avoid Potential Freezing Conditions

The module must be protected from freezing at all times, particularly duringtransportation and storage. Exposing the UF modules to freezing conditions may result inirreversible damage to the membrane and cause the outer shell to become brittle.

Protection from Direct Sunlight and Other UV Sources

Avoid long-term exposure of the module to direct sunlight or other UV sources.

Protection from Sudden Variations In Temperature

Avoid sudden variations in temperature. Temperature adjustment should be carried out ata maximum rate of 1°C/minute. The permissible temperature range is 1°C to 40°C.

Protection from Organic Solvents/Concentrated Acids

Ensure that the modules and membranes do not come into contact with polar organicsolvents, chlorinated solvents, or concentrated acids/bases.

Protection from Abrasive Materials

The membranes must be protected from abrasive materials (e.g. metal shavings) toprevent irreversible damage to the membrane.

Do Not Use Silicone, Lubricants Containing Silicone Or Pipe Threading Compound

Lubricants and other materials that contain silicone could cause irreversible blockage of the membrane and must be kept away from the membrane surface.

Only glycerine may be used as a lubricant for seals, O-rings, etc. Only Teflon tape may beused for thread sealing.

Careful Transportation

Mechanical damage or rupture of the module shell and connection ports could occur if themodules are dropped or struck against hard objects. Modules must therefore be handledwith extreme care. Particular care should be taken during transportation.





2. Storage and Shipment

All inge T-Racks are shipped in special cardboard boxes which provide full protectionduring transportation.

Each module is sealed with a plastic cover on the feed connectors and packed in separatecardboard boxes or packed in units of 10 modules.

It is not advisable to stack single modules end to end. To provide stability during transport, theindividual cardboard packing boxes can be stacked on top of each other:

● T-Rack: maximum 3 units (boxes) one above the other

● dizzer® XL, single module: maximum 3 modules in the lying position

● dizzer® XL, 10 pcs. package: no stacking

Handle the modules with care at all times (during transportation, rack assembly, andoperation).

All modules are integrity tested (wet tested) before shipment. To prevent dehydration andcontrol bacterial growth, the membranes are saturated with a non hazardous solution of water (potable water quality)/glycerin/sodium bisulfite solution [74.25:25:0.75 wt%]. Theconnection ports of the dizzer® modules are sealed with plugs and securely wrapped inplastic prior to shipment. In some cases the modules themselves are shrink-wrapped inplastic (depends on module type).

After removing the preservation solution from the membranes and module, the modulemust be protected from freezing at all times during transportation, operation and storage.Irreversible damage to the membrane and brittleness of the shell may result if the moduleor the membrane freezes.

Storage of the module in its original packing box at temperatures down to minus 15°C doesnot affect the module’s functionality or performance. However, due to the fact thatsynthetic materials tend to be more brittle at low temperatures, transportation of themodules during periods of cold weather with freezing temperatures should be carried outwith extreme care in order to avoid damaging the membranes or the module.

Modules must be stored in dry, moderately ventilated conditions, away from any sources of

heat, ignition and direct sunlight.

Sealed modules (in their original packaging) may be stored for up to 12 months at atemperature of between -15°C and +40°C.

To avoid abrupt variations in temperature the modules must be stored for at least twodays at a temperature above freezing before the original cardboard boxes can be opened.

Any warranty, implied or otherwise, shall expire after 12 months unless otherwise agreedby inge in writing.





3. T-Rack® vario assembly

Before assembling the T-Rack, make sure that you have received all the componentsand check that none of them show signs of mechanical damage. If you have anyconcerns or cause for complaint, please get in touch with your inge representativeimmediately.

The entire T-Rack is designed to be assembled without any of its components being undertension.

For T-Racks consisting of several sub-units, it is generally required to assemble the wholesystem from bottom to top, rather than sub-unit by sub-unit.

dizzer XL-W

Bottom cross brace

Pipe couplings

Upper feed/drain header

Top cross brace with filtrate

header clamp supports

Lower feed/drain headers

Filtrate header

Filtrate pipe with 90° elbowpieces and flexible 2“ couplings

All flanges according toISO 7005 PN 10, ANSI class 150





To ensure correct assembly of the inge T-Rack (max. 80 modules and max. 24 modules persub-unit), please proceed as follows:

1. Connect the lower feed/drain headers (screws M10 x 80, lock washers M10) to thebottom cross braces (60x40 mm) to form the base and fit the adjustable feet to thescrew heads as shown in Fig. 3.1.2.

Fig. 3.1.1

Fig. 3.1.2

Marking on lower feed/drainheaders





2. Rotate the base 180º, place it in the location in which the system will be installedand use a spirit level to check that the base is perfectly level both front to back

and side to side, adjusting the feet* as necessary. Take care that all feet are loadedequally. Next, fit the pipe couplings over the module discharge points on thebottom feed/drain headers, making sure that the inge logo on the pipe couplings isfacing outwards on both sides of the two-row layout [see Fig. 3.2.1]. In a four-rowarrangement, the screw head and inge logo on each pipe coupling should be facingin the same direction (outwards) in both rows [see Fig. 3.2.2] to ensure that you

can easily access the screws if you need to unfasten them at a later point in time.Tighten the screws on the pipe couplings to a sufficient degree to ensure that theycannot slip over the raised ribs of the feed/drain headers [see Fig. 3.2.3].

Fig. 3.2.1 Fig. 3.2.3

Fig. 3.2.2

*Do NOT fasten the feet to thefloor!

Raised ribs





3. Attach the transparent filtrate pipe and two elbow pieces to the filtrate connectionon the module using the three flexible 2” couplings [see Fig. 3.3.1]. Next, place a

dizzer XL module on the bottom module discharge point as shown in Fig. 3.3.2. Toensure the pipe coupling is correctly positioned, the pipe coupling housing isdesigned to abut against the raised ribs of the feed/drain header. Fasten the pipecoupling to a degree that still allows the module to be rotated (torque < 1Nm).Continue installing all the additional modules one by one, switching sides each timeyou install a module.

Fig. 3.3.1 Fig. 3.3.2





4. Push the top pipe couplings over the modules and fit the top feed/drain headers ontop one by one. In two-row layouts, the inge logo on each pipe coupling should be

facing outwards. In a four-row arrangement, the screw head and the inge logo oneach pipe coupling should be facing in the same direction (outwards) in both rowsto ensure that you can easily access the screws if you need to unfasten them at alater point in time (see point 2).

Fig. 3.4.1





5. Push the pipe coupling on until it abuts against the raised ribs of the feed/drainheader [see Fig. 3.5.2]. Fasten the pipe coupling to a degree that still allows the

module to be rotated (torque < 1 Nm). Next, fasten the top cross braces (M10 x 30screw, M10/30 washer) into their proper positions making sure to keep them freefrom tension [see Fig. 3.5.1].

Fig. 3.5.1 Fig. 3.5.2

Raised ribs

Top cross braces





6. After fastening the 2” coupling seal to the filtrate connection on the filtrateheader, place the filtrate header into the filtrate header clamp support from above

[see Fig. 3.6.1]. The flanges of the filtrate headers should be flush with the otherflanges. Align the dizzer XL module as shown in Fig. 3.6.2 by rotating the module asnecessary.

Fig. 3.6.1 Fig. 3.6.2

flush

level





7. Connect the 90° elbow pieces to the filtrate headers using flexible 2“ couplings[see Fig. 3.7.1 and Fig. 3.7.2]. Finally, make sure that all the “inge Ultra S 250”

pipe couplings are correctly positioned and tighten them to a torque of 40 Nm.Check that the flexible 2” couplings have been correctly mounted and fastened inplace.

Fig. 3.7.1 Fig. 3.7.2

8. The stainless steel components used in the system (pipe couplings to connect themodule bodies to the end caps/headers, cross braces, bolts and nuts) are suitablefor applications involving the treatment of fluids which contain corrosiveingredients (e.g. sea water treatment). However, the stainless steel componentscould still corrode if they come into direct contact with corrosive substances for alengthy period of time (e.g. due to leaks in pipes, couplings, etc.). To prevent therisk of corrosion in these situations, we recommend treating the stainless steelcomponents with an anticorrosive agent. The anticorrosive agent (e.g. BRUNOX®LUB & COR) should be silicone and solvent free, have good creep properties and beeasy to apply with a brush or spray bottle. The parts to be treated must be cleanand free from corrosion. Make sure to remove any existing corrosion by mechanicalmeans before applying the anticorrosive agent. Please also ensure you carefullyfollow the instructions provided by the manufacturer of the anticorrosive agent.





4. Operating and Start-Up Guidelines

4.1 General

Before operation:

Check that the scope of delivery is complete and that all the inge UF modules havebeen installed correctly;

Ensure that any dead spots within the piping have been eliminated duringconstruction/assembly of the ultrafiltration system. This is particularly important forthe filtrate header of the entire system;

Verify that all the system components and pipes have been cleaned prior to installingand connecting the module(s) to ensure there is no possibility of impurities, abrasivematerials or oily materials from the supply piping being rinsed into the module(s);

Check that all the air-bleed valves are fully functional and that there is no risk of airpockets forming in the header pipes;

Ensure that the installation of the connecting pipework with the inge T-Rack has beencarried out free from any tensions;

Confirm that the automatic program control system (programmable logic controller,PLC) is working properly and that there is no risk of pressure surges or shocks(pneumatic and/or hydraulic) or incorrect valve actuation.

Once all these points have been checked, please carry out the rinsing and disinfectionprocess described below. Once this process is complete, the filtrate can be used for itsintended purpose.





4.2 Rinsing the inge UF modules

To prevent dehydration and bacterial growth, all inge UF modules are preserved using anon toxic aqueous preservation solution (glycerin 25 wt% / sodium bisulfite 0.75 wt%). Thefollowing rinsing procedure must be performed to flush out the solution before use:

1. Flush the filtrate tank thoroughly and remove any impurities prior to filling the UFsystem / filtrate tank

2. FB = Filtration from bottom (operation of the system in “Filtration Bottom” mode,see Figure 4.1) at a flux rate of 50 l/(m2xh) for at least 20 minutes (be careful tofill the feed side of the system with raw water slowly in order to avoid waterhammers). Make sure that no valves are closed on the filtrate side. The filtrate

must be discharged before the filtrate tank.

3. FFB = direction of flow from bottom to top (module venting: start in “Forward FlushBottom” mode) at a flux rate of 80 l/(m2xh) for at least 10 minutes.

4. FB = Filtration from bottom (operation of the system in “Filtration Bottom” mode ata flux rate of 80 l/(m2xh) for at least 15 minutes. Make sure that no valves areclosed on the filtrate side. The filtrate must be discharged before the filtrate tank.

5. FT = Filtration from top (operation of the system in “Filtration Top” mode at a fluxrate of 80 l/(m2xh) for at least 15 minutes. Make sure that no valves are closed onthe filtrate side. The filtrate must be discharged before the filtrate tank.

6. If it is not possible to prevent filtrate from entering the filtrate tank, then the

filtrate tank must be drained completely (ensure that all residues are removed).

7. Fill the filtrate tank.

8. BWB = Backwash to top (operation of the system in “Backwash Bottom” mode at aflux rate of 230 l/(m2xh) for at least 60 seconds or until all the filtrate has beendischarged from the filtrate tank, respectively.

9. FB = Filtration from bottom (operation of the system in “Filtration Bottom” modeto completely fill the filtrate tank at a flux rate of 80 l/(m2xh) for at least 15minutes. Make sure that no valves are closed on the filtrate side.

10. BWT = Backwash to bottom (operation of the system in “Backwash Bottom” mode ata flux rate of 230 l/(m2xh) for at least 60 seconds or until all the filtrate has beendischarged from the filtrate tank, respectively.





11. FT = Filtration from top (operation of the system in “Filtration Top” mode at a fluxrate of 80 l/(m2xh) to fill the filtrate tank with fresh filtrate.

Figure 4.1: Operating modes of inge UF modules

FiltrationTop

(FT)

BackwashTop

(BWT)

ForwardFlush Bottom

(FFB)

FiltrationBottom

(FB)

BackwashBottom

(BWB)

O ForwardFlush Top

(FFT)





4.3 Disinfecting the inge T-Rack®

The entire system must be disinfected after completing the rinsing procedure describedabove (if necessary disinfection must be carried out several times).

Caution:

Disinfection is carried out using the chemical sodiumhypochlorite (13%).

Please familiarize yourself with the relevant safety measuresfor the storage and handling of the chemicals used for thisprocedure.

1. Disinfect the filtrate tank and the filtrate piping including all existing valves andinstalled equipment using a sodium hypochlorite solution of 100 mg/l (as activechlorine).

Add NaOCl to the filtrate tank, first making sure that the tank is completelyfilled with filtrate (calculate the amount of NaOCl based on the tank volume).

BWB = Backwash to top (operation of the system in “Backwash Bottom” mode,backwash with filtrate) at a flux rate of 230 l/(m2xh) for at least 30 seconds todisinfect the filtrate piping.

Alternatively, operate the system in “Chemical Enhanced Backwash Bottom” mode, which includes the injection of sodium hypochlorite during thebackwash mode [concentration 100 mg/l (as active chlorine)].

BWT = Backwash to bottom (operation of the system in “Backwash Top” mode,backwash with filtrate) at a flux rate of 230 l/(m2xh) for at least 30 seconds todisinfect the filtrate piping.Alternatively, operate the system in “Chemical Enhanced Backwash Top” mode, which includes the injection of sodium hypochlorite during thebackwash mode [concentration 100 mg/l (as active chlorine)].

Briefly open all the filtrate sampling valve(s) and all other valve(s) within thefiltrate piping/filtrate tank.

2. Make sure that all feed valves are closed.

3. Allow the NaOCl solution to act for at least 30 minutes (maximum 60 minutes).Ensure proper disinfection by monitoring the level of free chlorine (if readingsindicate that the level of chlorine has fallen below 5 mg/l repeat chlorination oradd fresh chlorine).

4. BWB = Backwash to top at a flux rate of 230 l/(m2xh) for at least 60 seconds.

5. FB = Filtration from bottom at a flux rate of 80 l/(m2xh) for at least 10 minutes.

6. BWT = Backwash to bottom at a flux rate of 230 l/(m2xh) for at least 60 seconds.





7. FT = Filtration from top at a flux rate of 80 l/(m2xh) until the filtrate tank is full.

8. Completely drain the filtrate tank, ensuring that all residues are removed.9. FB = Filtration from bottom at a flux rate of 80 l/(m2xh) for at least 10 minutes or

until the filtrate tank is completely full.

10. Completely drain the filtrate tank, ensuring that all residues are removed.

11. FB = Filtration from bottom (flux rate and filtration time as specified for theprocess, i.e. under normal operation).

12. The operator should now perform sampling to check the bacteriological filtratequality. If the test results are not satisfactory, repeat steps 1 to 12.





5. Recommendations Regarding Air Integrity Testing (Pressure

Hold Test)–

inge T-Rack®

vario

Air integrity test description (pressure hold test)

Integrity testing is an effective means of checking the quality of the membrane fibers inultrafiltration modules. This type of test forms an integral part of operating anultrafiltration plant, particularly in cases where ultrafiltration is being used as a barrieragainst viruses and bacteria in order to produce drinking water.

The integrity test (pressure hold test) is based on the phenomenon seen in ultrafiltrationmembranes whereby water can pass through the pores, but air is prevented from passingthrough until a certain pressure has been exceeded (the minimum pressure at which airbegins to flow is referred to as the “bubble point”). The bubble point pressure depends on

the membrane's pore size and on the surface tension at the air-liquid interface. The bubblepoint pressure of the pores is normally much higher than the applied test pressure (approx.1 bar) that is required to detect leaks.

Integrity testing can be performed both fully automatically (measurement of pressuredrop) and semi-automatically (measurement of pressure drop + visual inspection). Integritytests are carried out for each rack in turn, i.e. the modules of a rack are tested in parallel.There are no restrictions on the frequency of integrity testing for inge GmbH membranemodules.

The vertical installation of the membrane modules and the ergonomic configuration of theinge system enable integrity testing to be carried out in an automated fashion, making iteasy to detect any individual modules that may be affected. Integrity testing is carried outon installed modules (i.e. it is not necessary to remove any of the modules from thesystem). The frequency of integrity testing can be tailored to match the operator's specificrequirements and preferences.

We recommend carrying out integrity tests (including visual inspection) during/at the endof the plant commissioning phase, after conducting maintenance work, and in the event of any suspicion that the membrane system may be malfunctioning (e.g. increased bacteriacounts on the filtrate side).

Integrity testing can also be carried out regularly on an automated basis (for example oncea week or once a month) and seamlessly integrated in standard filtration operations.





The Air Integrity test (pressure hold test) process for inge Ultrafiltration modules withinthe T-Rack is shown in Fig. 5.1 and executed as follows:

1 Empty the feed line

Pressurize the complete feed side with dry, oil-free compressed air (1000 mbar). The rawwater side (top) of the module must be open to atmospheric pressure. The pressure willcause the water on the feed side to pass through the membranes to the raw water side. Inprinciple, air cannot pass through the intact membranes due to the surface tension of thewater in the membrane pores (note that this does not take diffusion processes intoaccount). The time required to empty a rack depends on total rack size, the volume of theconnected pipework and the compressor capacity. In our experience, the process of

emptying the feed side takes approx. 10 minutes.

2 Close the air pressure valve

When the feed side has been drained completely and a stable pressure of 1000 mbar hasbeen reached and maintained for at least 1 minute, close the air supply to the feed side.

3 Idle time

4 Measure the pressure drop

Measure the pressure drop on the feed side for at least 3 minutes. Due to the air diffusionprocess through the water-filled pores of the membranes, a slight pressure drop may beobserved which should not be regarded as membrane leakage. This diffusion effect mayalso result in a minor degree of bubble formation becoming visible in the transparent pipe.In practice, pressure drop rates are less than 10mbar/min for all rack sizes. In the eventthat this base value is exceeded, it is advisable to conduct a detailed examination toidentify the cause. The base value is dependent upon various factors, including the hold-upvolume, the tightness of all the valves and fittings and the diffusion component of themodule.

Determination of the base value must be performed using new modules (i.e. modules thatare being used for the first time) in the fully assembled rack. This value is then used as areference value (documentation).

Any leakage in the module can be detected using the integrated transparent pipe on thefiltrate side (Fig. 5.2). In the event of a leak, a continuous stream of air bubbles of asteady intensity will be visible during system air integrity testing. It is essential to ensurethat the upper filtrate side is open, unpressurised and completely filled with water duringair integrity testing.

If integrity testing has ruled out any other sources of error, a significant and permanentstream of air bubbles is visible in the transparent pipe, and the pressure drop is greaterthan 10 mbar/min, it can be assumed that the system has a capillary defect.





5 Release the air pressure on the feed side

6+7 Vent the system6 Operate in normal forward flush mode

7 Restart the regular filtration mode (at reduced flux rate, e.g. 40 l/m²h)

1 2 3 4 5 6 7*

Dewater feedside

Close feed airpressure

valve

Idle Measurepressure drop

P r e s s u r e

r e l e a s e

0

b a r

( f e

e d

s i d e ) Forward flush

for ventingVenting

filtration

* Venting filtration: low flux (e.g. 40 l/m²h)

Figure 5.1: Sequence of an integrity test (from feed side)

air

pressure

1000mbar





Figure 5.2: Monitoring and securing of defect free operation in build-up condition withintegrated transparent connector on the filtrate side.





6. Operating Conditions

General:

All inge T-Racks must be operated in compliance with the following operatingconditions:

1. Prefiltration: < 300 micrometer if there is a risk that the feed water may containparticles which could cause damage to the membranes. The actual cut-off valueselected in each case will depend on the application.The decision may be taken not to install a protective UF prefilter if thepretreatment process upstream from the UF system includes a final filtering step toremove particles bigger than 300 µm.If the UF prefilter is omitted, it is important to note that inge cannot be held

responsible for any membrane damage and/or consequential or indirect damagescaused by the intake of harmful external substances.

2. Ensure the membranes (feed/filtrate side) do not come into contact with abrasivematerials (e.g. metal or plastic shavings, sand, etc.).

3. The quality of the feed water must be measured after the addition of chemicalsand after prefiltration (to enable comparative analyses of feed water quality).

4. Permissible operating temperature: 1 °C to max. 40 °CTemperature adjustment: max. 1°C/minute

5. Permissible pH range of feed water during operation: pH 3 - 10

6. Ensure no precipitation (e.g. Fe, Mn, CaCO3) occurs within the membranes or on thefiltrate side due to process conditions.

7. Ensure that no water and air pressure surges occur (of pneumatic and/or hydraulicorigin) and prevent any siphoning effects

8. Tank and pipework/component designThe feed tank, filtrate/backwash (BW) tanks and CIP tank (as well as all connectingpipework and all components installed throughout the entire UF system) must beconstructed from non-corroding materials that will not leach contaminants orharmful matter into the water. it is important to protect the water in thefiltrate/BW tank from direct sunlight in order to avoid bacterial and/or algae

growth (it may be necessary to use closed tanks and air filters for drinking watersystems or in environments with highly polluted air).





9. Disinfection/cleaning chemicals and parameters:

a) Disinfection with NaOCl

Initial disinfection: see section 4.3

b) Feed chlorination with NaOCl (active chlorine concentration)

Continuous feed chlorination is not recommended.

Shock chlorination: max.: 100 ppm, 30 min, once per week.

c) Chemical enhanced backwash (CEB) procedure

NaOCl (concentration as active chlorine):20 – 50 ppm, 5 - 10 min soaking

NaOH (optional plus 20 – 50 ppm NaOCl as active chlorine)≤ pH 13, 10 - 60 min soaking

HCl, H2SO4 ≥ pH 1, 10 - 60 min soaking

CEB frequency should not exceed 2 CEBs per day for each of the types of chemicalmentioned above. Ensure proper distribution and mixing of the CEB chemicals in theBW water stream.

Backwash and CEB water quality: To avoid any risk of damaging the membranes

(from the filtrate side) the BW water should be free of particulates and should be of inge UF filtrate quality or better. Since BW and CEB are carried out solely with UFfiltrate, the decision may be taken not to install a protective inline BW strainer(max. pore size: 300 µm).

If the BW strainer is omitted, it is important to note that inge cannot be heldresponsible for any module/membrane damage and/or consequential or indirectdamages caused by the intake of harmful external substances.

d) Cleaning in place (CIP) procedure

NaOCl (+ NaOH for pH adjustment, active chlorine concentration):

200 ppm, pH 12.0max. 12h circulation/soaking

NaOH≤ pH 13, max. 12h circulation/soaking

HCl, H2SO4 ≥ pH 1 max. 12h circulation/soaking

Citric acid (+ HCl/H2SO4 for pH adjustment)

4 g/l, pH 2.0max. 12h circulation/soaking





Drinking water quality or better (e.g. RO permeate) is recommended as a basis forcleaning solutions.

CIP frequency should not exceed 4 CIPs per year for each of the cleaning stepsmentioned above.

The CIP solution must be introduced from the feed side of the modules/membranes.During CIP recirculation this will prevent any foulants and/or harmful substancesfrom entering the filtrate side of the membranes.A strainer must be installed to protect the membranes from particles which couldpotentially damage them (max. pore size 300 µm).

Caution:

Please familiarize yourself with the relevant safety measuresfor the storage and handling of the chemicals used in thisprocedure.

10. Permissible transmembrane pressure (TMP):

Filtration: max. 1.5 bar

Backwash: max. 3.0 bar

Air Integrity test: max. 1.0 bar air pressure

Operating the membranes at any combination of the maximum limits of temperature, pH, chemical concentration and/or pressure during production orcleaning will have an impact on the membrane service life. The permissibletransmembrane pressures are not based on limitations in membrane strength, butsimply on good operating practice for UF membranes. Compaction of fouling layerson the membrane surface should be avoided to enable stable long-term operation.The burst pressure of the Multibore membrane is higher than 10 bar.

11. Substances that may cause damage to the membrane or irreversible membrane

fouling:

Do not subject the membranes (feed or filtrate side) to elevated concentrations of oil, grease/fat or other elements of organic or inorganic origin that could result inthe chemical or physical destruction of module integrity or irreversible membranefouling. Ensure that the modules/membranes do not come into contact with polar,organic solvents, chlorinated solvents or concentrated acids/bases at any time.

Modules/membranes in the system that have been irreparably destroyed orirreversibly fouled by the substances cited above are not covered by the ingewarranty.





12. Rack design of inge UF modules:

All the modules must be operated under the same operating conditions. The basicrack design shown in Appendix A applies to all types of inge UF modules.

13. Adding coagulants prior to ultrafiltration:

Depending on the dissolved organic carbon (DOC) concentration and itscharacteristic structure in the feed water, it may be necessary to add inorganiccoagulants (FeCl3, polyaluminium chloride) to the feed system. Coagulants mayimprove or stabilize membrane performance and can help to reduce the silt densityindex (SDI), DOC and phosphate concentration in the filtrate.

The required coagulant contact time depends on the coagulant and the water

chemistry as well as the water temperature. It is important to ensure adequatemixing and contact time and proper distribution/mixing of the coagulant in thefeed water. Under no circumstances should the coagulation process take placewithin the membrane or on the filtrate side.

If the coagulants described above are added upstream from the UF system, thenacid CEBs must be performed on a regular basis, at least prior to each CEB withNaOCl.

Caution: The use of flocculation aids (e.g. polyelectrolytes) or flocculantswith organic components/functional groups may result in irreversiblemembrane fouling.

Use of any such substances is not permitted unless they have beentested and/or approved by inge in advance.

14. Ultrafiltration filtrate water quality

UF membranes cannot remove dissolved substances. This physical fact should betaken into account for all parameters (SDI, turbidity, etc.) when measuring UFfiltrate water quality.

15. Regular leak tests

Regular general maintenance conducted on the UF plant should include checking

the tightness of all connection fittings on the UF system (flanges, valves, etc.) andon the UF modules (couplings, Victaulic joints).

Fluid leakage – especially where corrosive mediums are involved – may causecorrosion on adjacent surfaces, components and equipment. Effectiveprecautionary measures must be taken to prevent corrosion (see section 3.8).

In the event of fluid spill or leakage, the affected area should be properly rinsedwith salt-free or low-salt water and rubbed dry.

16. Process logic control system / programming

The automatic operation of the UF plant and the control philosophy must be basedon the latest version of the document “Process Specification UF 1(2012-05 ) E inge”

(Appendix B).





7. Documentation of Operating Conditions

Proper and complete documentation is a mandatory requirement for warranty claims.

Documentation must be kept on the operating conditions and the amount of time the planthas been operated in each of the various operating modes from the moment the modulesare first put into operation.Any warranty claim must be accompanied by a complete set of documentation which mustbe provided to inge GmbH.

The following membrane system operating parameters must be recorded and documented.

1. pH value, temperature and turbidity prior to ultrafiltration (UF).

2. Permeability (@ 20°C), flow rate, transmembrane pressure (TMP) and absolute pressure

(feed/filtrate) per rack / per filtration line during filtration/backwash .Documentation of the data listed above must be guaranteed and certified by means of acontinuous data logging system (automatic data recording). The data must be logged atleast every 2 seconds (during the filtration cycles at least every 3 minutes) to ensure thatall the effects are registered of changes in pump operation and/or valve positions(changing modes and sequences). However, to ensure appropriate documentation can beprovided and to help optimize the membrane plant, we recommend logging data at theshortest possible intervals.

3. Chemicals

Use of chemicals for pretreatment:

type and concentration of oxidants,type and concentration of coagulants,measured directly prior to ultrafiltration (UF)

Use of chemicals for CEB cleaning:type, contact time and concentration of oxidants or other membrane cleaningagents,type, contact time and pH value of acid/caustic,measured within the rack (chemical in contact with the membrane)

Use of chemicals for CIP cleaning:type, contact time and concentration of oxidants or other membrane cleaning

agents,type, contact time and pH value of acid/caustic,measured within the rack (chemical in contact with the membrane)

The recording of the data listed above must be certified by an operating log. The minimuminterval for one complete set of information (lab measurements) is one per day (or onemeasurement per CEB/CIP).

4. In the event of a module defect, it is necessary to provide documentation of theposition of the defective module within the rack (line, rack/unit, side, position)together with details of the module serial number.

Removal of the original inge module serial number from the module automaticallyinvalidates any warranty that may have applied.





5. To verify and document the maximum permissible operating pressure (according to thedata sheet), analog pressure gauges with drag indicators (gauges provided with

documentation of the gauge serial number) must be installed in each unit/rack (feedand filtrate side).

8. Membrane Downtime Conditions

After use and during storage the membranes must be kept wet at all times.

To avoid microbiological growth during shutdown or storage of decommissioned modules,wet membranes must be treated with a compatible biocide/disinfectant solution. Pleaseobserve the following recommendations for different downtime conditions and durations:

Downtime up to 24 hours

It is generally sufficient to simply stop the system and then conduct a backwash ata minimum flux rate of 230 l/(m2xh) for at least 60 seconds. No other action isrequired.

Downtime > 24 hours

Perform a daily filtration sequence at a minimum flux rate of at least 50 l/(m2xh)for at least 10 minutes. Perform a CEB sequence with NaOCl (according to the CEBspecifications described in section 6.9) followed by rinsing with UF filtrate once perday.

Downtime > 7 days

Before taking steps to preserve the membranes, it is absolutely essential to removeany organic or inorganic impurities (fouling, scaling layer) from the membranes.After cleaning, rinse with a 0.75% sodium bisulphite solution in backwash mode(BWT, BWB). The quality of the water in this step must be UF filtrate waterequivalent or better. Leave the sodium bisulphite solution in the modules/rack.Replace the sodium bisulphite solution once every 4 weeks.

Whatever the situation, the modules should be kept hydraulically filled. The membranes

must be kept free of any oxidizing agents during plant shutdowns.If you wish to use any other biocides/disinfectants, please contact inge GmbH beforehand.It is essential to obtain prior written approval from inge GmbH regarding the chemicals andconcentrations that are permitted for use.





9. Transport Conditions for inge UF Modules and T-Rack® vario

componentsMechanical damage/rupture of the module shell, connection ports and other T-Rackcomponents may result if the modules/components are dropped or struck. Modules musttherefore be handled with care at all times, particularly during transportation.

Returning modules:

Modules shall only be accepted for return if this has been agreed in advance with ingeGmbH and authorized in writing.

Module returns agreed and authorized by inge are subject to the following mandatoryrequirements:

The modules must be cleaned before they are returned.

The modules must be protected from drying out and freezing at all times(temperature must be maintained between 4°C and 35°C).

Failure to meet any of these requirements will result in inge GmbH refusing to accept thereturn of the modules; inge GmbH reserves the right to invoice the sender for anytransport or disposal costs that may be incurred in this case.

10. Warranty Policy

Warranty claims may only be made on condition that the customer has properly followedall the instructions contained in the Installation, Operation and Maintenance Guidelines.

If you wish to deviate from these Guidelines, please consult inge GmbH in advance toobtain written approval in order to avoid any risk of voiding the warranty.





11. Contact Details

Please contact inge GmbH for further information:

inge GmbH

Flurstrasse 27

86926 Greifenberg

Germany

Phone: +49 (0) 81 92 – 9 97 – 700

Fax: +49 (0) 81 92 – 9 97 – 999

e-mail: [email protected]

web: www.inge.ag

Disclaimer

The utmost care has been taken in compiling the contents of these Installation, Operation and Maintenance Guidelines. ingeGmbH cannot accept any liability for loss or damage that may arise in connection with using our products. The quality of ingeUF modules is warranted in accordance with our general terms of sale.

These Installation, Operation and Maintenance Guidelines are a publication of inge GmbH. All rights, including translationrights, are reserved by inge GmbH ©.

mailto:[email protected]

http://www.inge.ag/

http://www.inge.ag/

mailto:[email protected]



Appendix B:

Process Specificationinge UF



Process Specification UF 1(2012-05) E inge Page 2

Subject to modifications and errors ▪ © 2012 inge GmbH ▪ All rights reserved

1 PROCESS DESCRIPTION .................................................... 3 1.1 Pretreatment .................................................................................. 3

1.1.1 Coagulation .......................................................................................................................... 3 1.2 Filtration........................................................................................ 6 1.3 Backwash and chemical backwash ......................................................... 7 2 OPERATING MODES ........................................................ 8 2.1 Filtration cycle ................................................................................ 8 2.2 Chemical Enhanced Backwash ............................................................. 11 2.3 Control philosophy ........................................................................... 15 2.4 Integrity tests ................................................................................. 19 3 PROGRAM PARAMETERS ................................................. 19 3.1 Operating modes ............................................................................. 19 3.2

Data logging ................................................................................... 21

3.2.1 Operating modes (index) ................................................................................................. 21

3.3 Miscellaneous ................................................................................. 22 3.3.1 Adjustment/switching of actuators ............................................................................... 22





1 Process description

Basically, the UF process consists of three key processes:1. Pretreatment

2. Filtration

3. Backwash/Chemical Enhanced Backwash (CEB)

The water to be treated first passes through an optional pre-treatment stage before it is

filtered by the UF membrane. During the pressure-driven filtration process, the pressure at

the membrane steadily increases due to the accumulation of fouling on the membrane

feed side. To clean the membrane, filtered water is held in a filtrate reservoir and made

available for backwashing. Backwashing serves to remove the accumulated fouling from

the membrane and return the admission pressure to its initial level. The option is also

available to boost the effects of the backwash by adding various different cleaning

chemicals.

1.1 Pretreatment

Before the water to be filtered reaches the UF membrane system, rough dirt particles are

removed by a screen prefilter. This prefilter offers automatic backwashing capabilities and

must be equipped with filter cartridges with wire mesh screens and a mesh size of less

than 300 µm.

1.1.1 Coagulation

Coagulation is an effective pre-treatment process employed in many applications that

make use of ultrafiltration technology. Its main effect is to reduce organic fouling by

incorporating dissolved organic compounds in ferric or aluminum flocs and by forming a

porous fouling layer on the membrane surface which encourages a stable filtration process

and ensures high backwash efficiency.

Proper implementation of the coagulation process can reduce the concentration of

dissolved organic carbon (DOC) by up to 60 percent. Optimized coagulation can also

improve filtrate quality by reducing SDI, DOC concentration and colloidal matter. The

coagulant metal residuals in the filtrate should not exceed more than 1 percent of the

added metal concentration.

If the type of coagulant and the raw water quality mean that pH adjustment is necessary,

acid or caustic must be added to ensure the optimum pH value for coagulation. To

optimize the coagulation process, it is important to adjust the chemical contact time to

reflect the feed water quality (e.g. temperature) in order to achieve the required UF

filtrate quality (e.g. DOC, Al or Fe residual).





Precise adjustment of the coagulation process is required to maximize DOC removal and

minimize coagulant residuals in the UF filtrate. It is advisable to perform jar tests in

advance to determine the optimum coagulation parameters, including pH value,concentration and contact time. The focus here is on analytical parameters such as

residual Me3+ and DOC removal, not on visual parameters such as floc formation.

Table 1.1 shows the key characteristics of different coagulants.

Table 1.1 Coagulation parameters

Coagulant

Dosage

[mg/l]Fe/Al1

Specific

dosage

(Me

3+

/DOC)

[mg/mg]

pH range

pH

optimum

Contact

time

2

[s]

DOC / COD

eliminationrate3 [%]

Me3+

residual

(as % of

dosage)4

Fe

(FeCl3)

0.7-

7.00.5-2.0 5.0–10.0 6.8 - 7.0 30 -60 10-60 1%

Poly-

aluminum

Chloride(PAC)

0.5–

5.0

0.25–0.5 6.5-7.5 6.8 - 7.0 30 -60 10-60 1%

1In pool applications the dosage amount can be lower ( > 0.03 mg/l Al/Fe)

2Contact time t depends on water temperature, pH value, water chemistry and treatment objectives and can

vary enormously (t << 30s as well as t >> 60s) subject of optimization.

3Removal of organic content strongly depends on water chemistry and coagulation parameters (pH value, etc.)

4Higher residual Me3+ indicates poorly configured coagulation parameters (mixing-in conditions, pH value,

contact time, dosage amount) and should therefore be strictly avoided.

The use of organic coagulation aids (anionic or cationic polyelectrolyte) or combined

coagulants (inorganic + organic compounds) should be strictly avoided since it may result in

heavy, irreversible fouling of the UF membrane which would necessitate intensive

chemical cleaning procedures.





The following process diagrams show various different inline coagulation configurations.

Figure 1.1: Example 1: Prefilter > coagulation > mixer > UF

Figure 1.2: Example 2: Coagulation > mixer > prefilter > UF

Figure 1.3: Example 3: Coagulation > feed pump > prefilter > UF





Using the prefilter as a mixer for the coagulant can cause irreversible fouling (e.g. Al

hydroxides) on the prefilter which cannot be removed mechanically but just by means of

chemical agents. It is therefore advisable to install the prefilter either upstream before

coagulant dosage or downstream after the coagulant contact time has elapsed.

If the required contact time cannot be achieved in the pipework, a contact tank can be

used to increase coagulant contact time as necessary.

To avoid an excessive dosage of coagulant, it is important to monitor the Me 3+

concentrations in the raw water, feed and filtrate. The Me3+ concentration in the filtrate

caused by the addition of coagulant should not exceed 1 percent of the quantity of Me 3+

added to the raw water (not including the dissolved Me3+

concentration in the raw water).

1.2 Filtration

The pretreated water is pumped into the membrane module by the frequency-controlled

feed pump. The flow rate is defined as a setpoint for the control system and is monitored

by means of inductive flow metering.

During filtration operation, the feed valves and filtrate valve are opened based on the

direction of filtration (bottom or top, see Figure 2.1). Furthermore, the valves prior to theautomatic air vent valves are opened to avoid feed-side and filtrate-side air intrusion in

the UF module installation.

Pressure sensors (PIT), which are located in the two feed lines and in the filtrate line, are

used to determine and record the transmembrane pressure (TMP). The operator can enter

both an alert and a threshold alarm value for TMP in the control panel. If the value set for

the threshold alarm is exceeded, filtration operation stops and the system is switched into

standby mode (pump off, valves closed).

The control system also continuously monitors and records the temperature in the filtrate

line. These readings are used to calculate temperature-corrected permeability.

Filtrate is held in the filtrate tank for backwashing. The filtrate tank is equipped with a dry

run protection device for the backwashing pump or an analog level measurement. To avoid

contamination of the filtrate, the filtrate tank is sealed; the ventilation system includes an

air filter to prevent contamination of the UF filtrate.





1.3 Backwash and chemical backwash

A backwash is performed once the filtration cycle has been completed. Based on the

direction of the backwash (bottom or top), the waste water valves are opened and the

filtration valves are closed. The air vent valves remain open.

The frequency-controlled backwash pump is activated for the specified backwash time

(control system setpoint) and runs until the backwash has been completed. The backwash

flux rate has to be min. 230 l/(m²h).

During backwashing, cleaning chemicals can be added to the backwash water to perform a

"Chemical Enhanced Backwash" (CEB). The backwash program can include a number of different CEBs with different cleaning chemicals which are implemented according to a

defined schedule. To reduce the size of the chemical dosing pumps, the flux rate during

the chemical enhanced backwash can be reduced to min. 120 l/(m²h).

After the addition of the cleaning chemical, the system remains in stand-by mode for the

"soaking time". The soaking time is a setpoint in the control system. Once the soaking time

has elapsed, the cleaning chemical is rinsed out by a backwash with filtrate at min.

230 l/(m²h). The rinse time is a variable setpoint in the control system.





2 Operating modes

The different operating modes are defined by the positions of the various valves and the

activated system components.

2.1 Filtration cycle

The ‘Filtration’ mode is the actual filtration process. Water is pushed through capillaries

from the inflow side (feed) to the filtrate side (Fig 2.1). The filtration mode functions in

one of two different ways: ‘Filtration Top’ (FT) and ‘Filtration Bottom’ (FB). The filtration

direction only changes from top to bottom or bottom to top after a backwash. The

filtration mode plus its corresponding backwash is referred to as a‘f

iltration sequence’

(this may also include an optional forward flush in the corresponding direction before

and/or after a backwash). A filtration cycle (Figure 2.2) comprises a ‘Filtration Bottom’

and a ‘Filtration Top’ sequence, including the corresponding backwashes and optional

forward flushes.

In ‘Forward Flush’ mode, the feed water only passes through the capillaries on the feed

water side. No filtration takes place (Fig 2.1).

Activation of the forward flush is optional. If activated, it will be performed before and/or

after a backwash. The forward flush is always performed in the same direction as the

previous filtration mode. This means that a ‘Filtration Bottom’ (FB) is followed by a

‘Forward Flush Bottom’ (FFB) and a ‘Filtration Top’ (FT) by a ‘Forward Flush Top’ (FFT).

In ‘Backwash’ mode, water is pumped from the filtrate side (filtrate) to the feed water

side and is then discharged as waste water.

The backwash mode also functions in one of two possible ways: ‘Backwash Bottom’ (BWB)

and ‘Backwash Top’ (BWT). The backwash is always performed in the same direction as the

previous filtration mode. This means that a ‘Filtration Bottom’ (FB) is followed by a

‘Backwash Bottom’ (BWB) and a ‘Filtration Top’ (FT) by a ‘Backwash Top’ (BWT). The

corresponding forward flush is also performed if this option has been activated.





Filtration

30–180 min, flux rate 50 – 160 l/(m²h) Bottom (FB) Top (FT)

Filtrationseque

nce=Filtrationmode+Fo

rwardFlush+Backwash

Optional: Forward Flush30-50 sec, flux rate 50 – 160 l/(m²h)

before/after backwash, degassing

Bottom (FFB) Top (FFT)

Backwash

40-90 sec, flux rate min. 230 l/(m²h)

Bottom (BWB) Top (BWT)

Filtration cycle = Filtration sequence Bottom + Filtration sequence Top

Figure 2.1: Operating modes

Drain

Filtrate Filtrate

Drain

Feed

Feed

Drain

Drain

FiltrateFiltrate

Feed

Feed





Figure 2.2: Example of a filtration cycle

Top filtration mode (FT) Bottom filtration mode (FB)

Filtration

Bottom

Forward Flush

Bottom (optional)

Backwash

Bottom

Filtration

Top

Forward Flush

Top

(optional)

Backwash

Top





2.2 Chemical Enhanced Backwash

To enhance the effects of a backwash it is possible to use various forms of Chemical

Enhanced Backwashes (CEBs) (Figure 2.3). A CEB essentially works in the same way as a

backwash, which means the filtrate is forced from the filtrate side to the feed water side.

Additionally, a cleaning chemical is added to the filtrate to enhance the backwash cleaning

effect. Unlike a standard backwash, a CEB is performed in both directions (first bottom-to-

top and then top-to-bottom) to make sure the cleaning solution is distributed as evenly as

possible in the UF rack. Once the rack has been completely filled with the cleaning

solution (controlled by the chemical injection time setting), chemical injection stops and

the plant shifts to stand-by mode during soaking time. Once the soaking time has elapsed,

the rack must then be rinsed with filtrate (Backwash Bottom followed by Backwash Top).

A CEB is performed at the end of a filtration sequence, which means a backwash with

filtrate will have been performed directly beforehand. This standard backwash removes

larger particles from the membrane, thereby boosting the effects of the cleaning solution

in the subsequent CEB.

Depending on the water quality and pretreatment process it may be necessary to run CEBs

with up to three different cleaning chemicals. The CEB’s effectiveness is not only

dependent on the chemical used but also on the sequence and time intervals between

CEBs. The CEB sequence should therefore be programmed as flexibly as possible (Chapter

2.3).





Figure 2.3: The Chemical Enhanced Backwash (CEB) process

Chem. Injection

Backwash Bottom

Flux rate min.

120 l/(m²h)

Chem. Injection

Backwash Top

Flux rate min.

120 l/(m²h)

Soaking Rinsing,

Backwash Bottom

Flux rate min.

230 l/(m²h)

Rinsing,

Backwash Top

Flux rate min.

230 l/(m²h)





A CEB is performed after a defined number of filtration cycles. Chemicals that can be

considered for CEB include caustic (NaOH), sulfuric or hydrochloric acid (H2SO4/HCl), and

sodium hypochlorite (NaOCl). Generally, a CEB with caustic is followed by a CEB with acidto remove any carbonates precipitated during the caustic cleaning. Only one filtration

sequence should be carried out between a caustic and acid CEB to refill the backwash tank

and neutralize the membranes. Other CEBs (acid, chlorine) can be performed in isolation

or in combination with the combined caustic/acid cleaning process.

In some applications, caustic and chlorine dosing in parallel can enhance cleaning

efficiency significantly (20 -50 ppm free chlorine @ pH>12.0)

The following chemicals are recommended for the CEB procedure (Table 2.1):

Table 2.1: CEB chemicals

Acid Caustic Oxidant

Inorganic fouling Organic Fouling

Hydrochloricacid HCl

Sulfuric AcidH

2SO

4

CausticNaOH(optional: +NaOCl)

Sodium hypochloriteNaOCl

pH range: 2.0 – 2.5 pH range: 12.0 – 13.0

(optional: + 20 - 50 ppmas free chlorine)

20 - 50 ppm asfree chlorine

Soaking: 10 – 60 min Soaking: 10 – 60 min Soaking: 5 – 10 min

The injection time for the chemical solution depends on the backwash flux rate, thelocation of the chemical dosage point and the rack size.To ensure complete and homogenous distribution of the CEB chemicals inside the UF rackinstallation, the following injection times are recommended (based on the example of aCEB flux rate of 120 l/(m²h) in an inge T-Rack installation, Figure 2.4):





Figure 2.4: Chemical injection time for CEB depending on rack size

The internal CEB injection time (tint) is calculated from the Backwash Top + the Backwash

Bottom time. To calculate the total injection time, it is necessary to take into account the

distance to the chemical dosage point in the peripheral pipework (tex): ttotal = tint + tex.

Figure 2.4 shows recommended injection times based on the example of a T-Rack

installation. As the figure shows, the injection time is split between a Backwash Bottom

and a Backwash Top, with the combination of the two ensuring homogeneous distribution

Chemical Dosing

tex

tint





of the chemical solution throughout the rack, including the ‘dead end’ areas of the

modules.

2.3 Control philosophy

The CEBs are allocated as follows:

CEB 1: Caustic followed by acid

CEB 2: Acid

CEB 3: Sodium hypochlorite

Because CEBs are performed after a defined number of filtration cycles (see explanation insection 2.1), counters must be used to record the number of completed filtration cycles. If

the application uses more than one type of CEB, these counters need to be programmed to

avoid two or more CEBs being performed at the same time. One helpful solution is to use a

master counter that is designed to allocate the highest priority to the CEB with the highest

cycle number. If two or more CEBs coincide, the CEB with the highest priority will be

performed. Once this CEB has finished all the counters are reset to zero. Figure 2.5 shows

an example where CEB1 = 9, CEB2 = 3 and CEB3 = 40. The CEB2 counter (highlighted in

yellow) resets itself after the completion of each CEB2 while the master counter continues

counting. After 9 filtration cycles, 2 CEBs are requested simultaneously: CEB1 and CEB2.

CEB1 has the higher priority and is therefore performed in preference to CEB2. As soon as

this CEB1 has been completed, the CEB1 and CEB2 counters are reset. CEB3 is performedafter 40 cycles, at which point all the other counters are reset since CEB3 is the highest

priority.

Figure 2.5: CEB program: CEB1 = 9, CEB2 = 3, CEB3 = 40

The numbers highlighted in green indicate the performance of a CEB. The number

highlighted in red illustrates a conflict: Although CEB2 has been requested, it will not be

performed because CEB1 is a higher priority and will therefore take precedence (setpoint

CEB1 = 9 > 3 (CEB2)).

If you prefer to develop your own CEB philosophy, please make sure to take the following

points into account:

Filtration cycle counters

Setpoints: CEB1 = 9

CEB2 = 3

CEB3 = 40

CEB 1: 1 2 3 4 5 6 7 8 9 1 2 3 4 5..........4 1 2…

CEB 2: 1 2 3 1 2 3 1 2 3 1 2 3 1 2……...1 1 2…

CEB 3: 1 2 3 4 4 6 7 8 9 10 11 13 14 15…….40 1 2…





1. An acid CEB should be performed as close to the caustic CEB as possible (max. 1

filtration sequence in between)2. Use separate acid and chlorine CEBs in addition to combined caustic/acid CEBs

3. Scheduling of the 3 CEB types should be completely independent, i.e. it should be

possible to implement CEB sequences such as the following: combined caustic+acid

once a day; acid only twice a day; NaOCl once a week.

.

Figure 2.6: Example 1: CEB 1, Combined Caustic + Acid, Cycle = 3

Start of operation

CEB Acid

SFB

SFT

C

CEB1 = 1

SFB

SFT

C CEB1 = 3

SFB

SFT

C CEB1 = 2

No. of cycles CCEB1 Caustic + Acid = 3

SFB = FB + (FFB) + BWB + (FFB)

SFT = FT + (FFT) + BWT + (FFT)

CEB Caustic

C CEB1 = 0

FB = Filtration Bottom FFB = Forward Flush Bottom BWB = Backwash Bottom

FT = Filtration Top FFT = Forward Flush Top BWT = Backwash Top

CEB Caustic = Chemically Enhanced Backwash

e.g. NaOH CEB Acid = Chemically Enhanced Backwash

e.g. H 2 SO

4 or HCl

C

E

B

1

SFB

CEB counter





Figure 2.7: Example 2: CEB1 = 0; CEB2 = 4, CEB3 = 40

Start of operation

SFB

SFT

SFB

SFT

C CEB 2

= 3

SFB

SFT

No. of cycles C CEB2 Acid = 3

No. of cycles C CEB3 NaOCl = 40

SFB = FB + (FFB) + BWB + (FFB) SFT = FT + (FFT) + BWT + (FFT)

CEB2 Acid


FT = Filtration Top FFT = Forward Flush Top

BWT = Backwash Top

CEB2 = Chemically Enhanced Backwash H2SO4 or HCl

CEB3 = Chemically Enhanced Backwash

NaOCl

CEB3 NaOCl

C CEB2 Acid= 0

C CEB Ac id

C CEB 2

= 2

C CEB 2

= 1

C CEB NaOCl

= 0

CEB NaOCl=

5

6

.

.

40

SFB/T = Sequence Filtration Bottom/Top

= 0 = 0

CEB2 counter

CEB3 counter





Figure 2.8: Example 3: CEB1 = 3, CEB2 = 9, CEB3 = 40

Start of operation

SFB

SFT

SFB

SFT

C CEB 1

= 3

SFB

SFT

No. of cycles C CEB1NaOH + Acid

= 3

No. of cycles C CEB2 Acid = 9

SFB = FB + (FFB) + BWB + (FFB) SFT = FT + (FFT) + BWT + (FFT)

CEB1 NaOH + Acid


FT = Filtration Top FFT = Forward Flush Top

BWT = Backwash Top

CEB1 = Chemically Enhanced Backwash Combined NaOH + Acid

CEB2 = Chemically Enhanced Backwash H 2 SO 4 or HCl

CEB2 Acid

CEB1

c CEB2 Ac id = 0

C CEB 1

= 2

C CEB 1

= 1

CEB1

= 0 c CEB1 NaOH+Acid = 0

c CEB1 NaOH+Acid = 0

No. of cycles C CEB3 NaOCl = 40

CEBAcid= 4

56

7

8

9

CEB NaOcl= 10

11

12

39

40

NaOCl CEB3

c CEB2 Ac id = 0

CEB1

= 0 c CEB1 NaOH+Acid = 0

c CEB3 NaOCl = 0

SFB/T = Sequence Filtration Bottom/Top

CEB3 = Chemically Enhanced Backwash

NaOCl

CEB1 counter

CEB2 counter

CEB3 counter





2.4 Integrity tests

To check that the UF membranes are in proper working order, pressure hold tests or

bubble tests can be performed. These integrity tests can be carried out automatically on a

regular basis or manually, depending on requirements.

Please find a detailed description of the test-procedure in the specific Installation,

Operation and Maintenance Guidelines.

3 Program parameters

3.1 Operating modes

DefinitionOperating modes are defined by valve positions and pump status.

Each operating mode requires input parameters to be defined as variable setpoints in the

control system.

Table 3.1: Input parameters

Operating mode Input parameters

FiltrationFiltration bottom (FB)

duration, flow rateFiltration Top (FT)

Forward flush

Forward flush bottom (FFB) duration, on/off, flow rate, before/after BW

Forward flush top (FFT) duration, on/off, flow rate, before/after BW

Backwash

Backwash bottom (BWB) duration, flow rate, duration and flow rate = BWT

Backwash top (BWT) duration, flow rate

Chemical enhanced backwash

Chemical backwash (CEB) cycles for CEB1; cycles for CEB2; cycles for CEB3(frequencies)

CEB1.1(NaOH)

Chemical backwash 1.1 bottom duration, flow rate, dosing flow

Chemical backwash 1.1 top duration, flow rate, dosing flow

Soaking (SCBW1) duration

Rinsing backwash bottom duration, flow rate,

Rinsing backwash top duration, flow rate

CEB 1.2 (Acid)

Same input mask as CEB1.1

CEB 2 (Acid)


CEB 3 (NaOCl)






Integrity test filtrate side (UF modules) Optional; automatic INT (Integrity) test

Dewater (DEW) interval between INT tests, time required to initializepressure

Measuring (ME) duration delta p measurement, critical delta p

Ventilation purge after int. (DPaINT) duration, flow rate

Ventilation filtration after int. (DFaINT) duration, flow rate

Integrity test feed water side (T-Rack)

Dewater (DEW)interval between INT tests, time required to initialize

pressure

Measuring (ME) duration delta p measurement, critical delta p

BW after feed integrity duration, flow rate

Pretreatment on/off

pH adjustment (dosage pump) on/off, HCl or NaOH, setpoint target pH

Coagulant dosing setpoint dosing amount/pump frequency

General parameters

TMP limits

TMP alert filtration TMP warning filtration

TMP alarm TMP alarm, stop operation

TMP alert backwash TMP warning backwash

TMP alarm backwash TMP alarm, stop operation

Temperature

Temperature alert Temperature warningTemperature alarm Temperature alarm, stop operation





3.2 Data logging

Measurements of the values listed in Table 3.4 are logged by the PLC/PC control system.

Volume readings must record both the flow rate and total volume.

To ensure the data in the logfile can be clearly identified and indexed, the date and the

time must be in the first column.

Table 3.4 Logging parameters

Data capture / logging

Date dd.mm.yy hh:mm:ss

Pressure 1 Pressure feed bottom

Pressure 2 Pressure feed top

Pressure 3 Pressure filtrateCalculated TMP Transmembrane pressure

Quality 1 Temperature

Quality 2 Turbidity feed

Quality 3 pH value feed

Flow 1 Flow rate feed

Flow 2 Volume feed

Flow 3 Flow rate backwash

Flow 4 Volume backwash

Calculated Permeability Permeability 20°C

Index Operating mode

x1 Reservex2 Reserve

x3 Reserve

3.2.1 Operating modes (index)

Data acquisition and recording requires clear and unambiguous allocation of the measured

values and the respective operating state.



3.3 Miscellaneous

3.3.1 Adjustment/switching of actuators

The switching circuit of the pumps and valves should be designed in a way that no pressure

pulses are produced in the system, i.e. the pumps and valves should be actuated in a

controlled sequence at intervals of approximately one second so that pumps are never

running against closed valves.

The actuators of all (butterfly) valves should be equipped with air throttling valves to

control the opening and closing procedure. Air/water hammers can occur if the valves

open or close too abruptly.

Any change of operating mode that involves a switch between feed and backwash pumps

(e.g. backwash to filtration) including the necessary valves must include an idle interval of

approx. 5-10 seconds between the completion of one operating mode and the activation of

the subsequent operating mode.

The frequency converters and PID controllers of the feed and backwash pumps must be

carefully adjusted to ensure that no pressure pulses are generated. For the backwash

pump controller, it is important to ensure that the flow setpoint is reached within 5-10

seconds (time depending on the pump capacity).

installation operating and maintenance guidelines t-rack vario 3(2012-05) e inge

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