OPERATION & MAINTAINANCE MANUAL

OF

1 M3/HR REVERSE OSMOSIS PLANT

CLIENT : : Ion Exchange Environment Management( BD )

Ltd

SUPPLIED BY:ION EXCHANGE LTD

HAMRIYA FREE ZONE
SHARJAH-U.A.E
P.O.BOX :49247
TEL :+971 6 5261606
FAX :+971 6 5261607
 TABLE OF CONTENT

CHAPTER 1: PROCESS DESCRIPTION

CHAPTER 2: TECHNICAL DATA
CHAPTER 3: SALIENT ERECTION INSTRUCTIONS
CHAPTER 4: MEMBRANE FILTRATION
CHAPTER 5: FUNDAMENTALS OF RO UNIT
CHAPTER 6: COMPONENTS OF RO UNIT
CHAPTER 7: FACTORS AFFECTIONG RO MEMBRANE
CHAPTER 8: PRETREATMENT
CHAPTER 9: TROUBLESHOOTING OF RO PLANT
CHAPTER 10: OPERATION OF PUMPS
CHAPTER 11: ACTIVATED CARBON FILTER
CHAPTER 12: MULTIGRADE FILTER
CHAPTER13 : CARTRIDGE FILTER
CHAPTER 14: FILTER MAINTAINANCE
CHAPTER 15: MOTOR TROUBLESHOOTING
CHAPTER 16 : CONTROL LOGIC & LOG SHEET
CHAPTER 17 : EQUIPMENT CATALOGUE & P & ID
CHAPTER 18 : WARRANTY CERTIFICATE

1
Chapter 1
Process Description

Please refer P & I Diagram No. A2-IEH/RO/09/153-01-01-Rev.0.

1.1 RO PLANT:

RO Plant can be operated by Control Panel by switching it in Auto mode or also by

manually.

RO FEED PUMPS :

RO Feed Pumps feed the Filtered water to the RO plant

ANTISCALANT DOSING:
The water is dosed with Antiscalant. Antiscalant dosing is done to prevent the RO
membranes from scaling. Antiscalant is added prior to the cartridge filter to increase
the solubility threshold limitation of sparingly soluble salts such as CaCO3 etc.

NaOCl DOSING:
The water is dosed with NaoCl. NaOCl dosing is done to prevent the smell coming
from the water.

SMBS DOSING:
The water is dosed with Sodium Meta Bisulphite. SMBS dosing is done to reduce the
pH from water. SMBS is added after the pressure vessel outlet means at product
water.

MULTIGRADE FILTER:

Multigrade Sand Filters are used for removal of suspended matters from raw
water.The Filter media is a fine mixture of coarse & fine particles of sand.This allows
the complete utilisation of the large spaces between the sand particles for removal of
the suspended impurities. The pressure drop across the filter starts rising as the the
filter run proceeds ; cleaning of the filter media is done by reversing the flow through
the bed when the pressure drop exceeds the allowable value.

ACTIVATED CARBON FILTER:

Activated Carbon Filters are used for removal of free chlorine from water , also
removal of organic matter. Normally the activated carbon filters are placed

2
downstream of Multigrade filters. If the raw water is already filtered , they can used
as a first unit.

Activated Carbon used as a media provides a large pore surface area which by the
process of adsorption , helps in removal of organic molecules. The large surface area
is also helps in a catylic action in removal of chlorine.

Activated carbon filter needs to be regularly bachwashed by reversal of flow so as to

keep the surface of the carbon particles clean.

MICRON CARTRIDGE FILTER:

The Filtered water from bag filter will pass through micron cartridge filter to ensure
removal of fineparticulate matter. The chemically conditioned water will then be fed
into RO unit via RO high-pressure pumps.
Pressure difference across the micron cartridge filter has to be monitored
manually.When the pressure difference across the cartridge filter goes beyond limit, it
indicates the requirement of replacement of cartridges.

REVERSE OSMOSIS SYSTEM (RO):

The pressurized flow enters to RO system through RO high pressure pump. Due to
high pressure, feed stream gets divided into a ‘permeate’ stream-low in dissolved salts
and brine (or reject) stream very high in dissolved salts content. Dissolved salts
rejected by the membrane are continuously flushed from the system viz. brine stream.
Thus the RO system helps to remove dissolved impurities from water.
The auto dump valve is provided after the cartridge filter to drain the water if the
same is not acceptable in pH etc.
The pressure switches are provided at RO high pressure feed pump delivery, which
provides protection for dry running of pump, and also protect the membranes from
high-pressure exposure. Similalry the low pressure switch at the suction will ensure
that there is sufficient head avaialble at the suction of the pump.
A flow meter is provided on the RO skid on product line shall give indication about
the permeate flow. The conductivity transmitter is provided on the RO permeate
line, which monitors the product water quality. The auto dump valve is provided to
drain the product water if the conductivity at RO outlet is not within the set limits.

1.2 Checklist for RO Operation.:

1. Before starting the RO pump check the bag filter & cartridge filter. If not properly
installed in can damage the High pressure pump or foul the membrane element. It
should be replaced whenever the headloss exceeds the recommended specification
or if the effluent turbidity exceeds 1NTU.
2. Start and check the scale inhibitor feeder equipment and adjust feed rate to
desired dose (2 to 5mg/L)
3. Remember that if scale inhibitor is not added membrane can get scaled because of
calcium salts and other inorganics. Inhibitor commonly employed is Sodium hexa
meta phosphate (SHMP).
4. Add chlorine. The dose rate is so adjusted that the chlorine residual is between 1
to 2 . For small plants chlorine is dosed through metering pump but in large plant
gas chlorinators are used.

3
5. Depending on the type of membrane and the recommendation adjust the pH to
desired level and bypass the feedwater till pH is adjusted. The acid dosing pump
should stop when the high pressure pump stops. In most RO plants acid dosing
start and stop is directly linked to High pressure pump.
6. Check the suction pressure. The high pressure should not start till the desired
pressure is reached. Low pressure tripping is generally included in all RO plants.
7. RO pump should trip if the discharge pressure is higher than recommended. High
pressure switch is provided for tripping for protecting the membranes.
8. Adjust permeate and concentrate flow to establish the desired recovery rate.
9. Check the following after the desired flow rate have been achieved.
Check the differential pressure (p) = Feed pressure – concentrate pressure. This
should be noted. Bigger plants have recorder which records this continuously.
Increase in p indicates that the system requires cleaning. p should not increase
more than 414 kpa or 4.1 kg / sq cm
10. With the system online monitor all flows , pressure , level and the quality of
water being produced.
11. It is very necessary and also proves very useful if pretreatment is monitored and
record maintained. More problems in RO membranes are caused by faulty
pretreatment.

1.3 Chemical Cleaning :

Most RO plants are provided with cleaning skid called CIP (Cleaning in Place).
The skid contains a cleaning tank , pump, cartridge filter , heater instrumentation and
sample valves.
Reverse osmosis units should be cleaned when they show evidence of fouling ,or just
before a long shut down or as a matter of schedule maintenance. RO cleaning
frequency may vary site to site but roughly once every three to twelve months is
acceptable.
In this chapter we are not describing why cleaning should be done or other aspects of
cleaning. Here we are considering cleaning as a part of operation which the operator
has to do , The procedure mentioned below is just a guideline for the operator.
1. Connect the cleaning skid to the appropriate stage of selected RO unit with
flexible hoses.
2. Carry out low pressure flush with feed water or permeate water to remove
foulants. Do this for 15 minutes at 50 psig and at 75 % of the maximum flow
for that size (diameter ) of the element.
3. The cleaning is done stage by stage.
4. Prepare the cleaning solution as per manufacturer’s instruction.
5. Cleaning solution should be properly mixed and pH and temperature adjusted
according to recommendation.
6. Introduce the cleaning solution at high flow rate and drain. When you observe
the solution in the drain, stop the pump and close all valves. Allow the unit to get
soaked for 15 minutes.
7. Repeat procedure 6 , three or four times and observe the colour change of spent
chemical. If colour pick up is significant continue the process , other wise stop.
8. Recirculate the brine to cleaning tank for 45 minutes after the above process is
over.

4
9. Empty the cleaning tank.
10. Flush the unit with RO product water for 15 minutes at moderate flow rate(at
50%) and at 50 psig . Flush water temperature should be above 20*C.
11. Continue flushing but now at higher flow (75%) with product water or feed water
for 30 minutes.
12. Check the following
a) Brine pH is within 1 unit of feed pH
b) Brine conductivity is within 100 micromhos /Cm of feed
conductivity.
c) Brine is not foamy
13. Cleaning is completed if all the above three condition is met.
14. Repeat the procedure for the next unit with fresh chemicals
15. This is a general guideline and specific procedure can be obtained from the
supplier of chemicals if proprietary otherwise from the manufacturer.
16. This guideline is adapted from the book “REVERSE OSMOSIS” edited by Dr
Zahid Amjad.

5
Chapter 2
Technical Data

A) Reverse Osmosis Plant

Please refer

P & I Diagram No. : A2-IEH/RO/09/1153-01-01

EQUIPMENTS

1) FILTER FEED PUMPS

Numbers : Two

Type : Horizontal Centrifugal

Flow : 2.6 m3/hr

Discharge Head : 37.2 m

Material of Construction (Wetted Parts) : Cast Iron

Make : Grundfos (CHN2-60)

2) MULTIGRADE FILTER (MF)

Number Offered : One

Diameter : 16”

Height on Straight : 65”

Material of Construction : FRP

Make : Aquanomics

3) ACTIVATED CARBON FILTER (ACF)

Number Offered : One

Diameter : 16”

Height on Straight : 65”

Material of Construction : FRP

6
 Make : Aquanomics

4) MICRON CARTRIDGE FILTER (CF1-A/B )

Number Offered : 2

Diameter : 2.5”

Height on Straight : 20”

Material of Construction : PP

Make : Pentair USA

5) HIGH PRESSURE PUMP (P2)

Numbers : One

Type : Vertical Centrifugal

Flow : 3 m3/hr

Discharge Head : 140m

Material of Construction (Wetted Parts) : SS316L

Make : Grundfos( CRN3-29)

6) RO MEMBRANE ELEMENT

Number Offered : 6

Diameter : 4”

Maximum Operating Pressure : 400 psi

Model No. : TM710

Make : Toray Japan

7
7) RO MEMBRANE VESSEL

Number Offered : 5

Diameter : 4”

Maximum Operating Pressure : 400 psi

Model No. : A4E400-2

Make : Aquanomics

Nos. of Elements : 2 Nos.

8) NaOCl DOSING TANK - (DT-1)

Number Offered : One

Capacity : 100 Litres

Chemical Handled : NaoCl

Material of Construction : LDPE

Make : SCICHEMTECH

9) NaOCl DOSING PUMP (DP-1)

Numbers : One

Type : Diaphragm Type

Flow : 2.21 LPH

Discharge Head : 6 kg/cm2

Material of Construction (Wetted Parts) : PP

Make : Jesco

10) SMBS DOSING TANK - (DT-2)

Number Offered : One

Capacity : 100 Litres

Chemical Handled : SMBS

Material of Construction : LDPE

8
 Make : SCICHEMTECH

11) SMBS DOSING PUMP (DP-2)

Numbers : One

Type : Diaphragm Type

Flow : 2.21 LPH

Discharge Head : 6 kg/cm2

Material of Construction (Wetted Parts) : PP

Make : Jesco

12) ANTISCALANT DOSING TANK - (DT-2)

Number Offered : One

Capacity : 100 Litres

Chemical Handled : SMBS

Material of Construction : LDPE

Make : SCICHEMTECH

13) ANTISCALANT DOSING PUMP (DP-2)

Numbers : One

Type : Diaphragm Type

Flow : 2.21 LPH

Discharge Head : 6 kg/cm2

Material of Construction (Wetted Parts) : PP

Make : Jesco

9
 Instruments :

1) PRESSURE GAUGES (PG)

Numbers off : 7

Make : Wika

Sr. No. Tag No. Range Qty

1. PG 0-150 psi 4 Nos.

2. PG 0-500 psi 3 Nos.

2) pH METER (PH01)

Numbers off : 1

Make : Blackstone

pH meter : BL983329-1

pH electrode : HI7634

3) TDS METER (TDS01)

Numbers off : 1

Make : Blackstone

TDS meter : BL981411-1

TDS electrode : HI1001

4) ORP METER (ORP01)

Numbers off : 1

Make : AlphapH/ORP190

5) FLOW METER (FI)

Numbers off : 2

Make : Flowmeter Instruments

10
 Sr. No. Tag No. Range Qty

1. FI01 0-10 GPM 1 No.

2. FI02 0-10 GPM 1 No.

6) PRESSURE SWITCH (PS)

Numbers off : 1

Range : 0-12 Bar

Make : Saginomiya

11
Chapter 3
Salient Erection Instructions

3.0 SALIENT ERECTION INSTRUCTIONS

GENERAL :

1. Check all the materials are received as per schedule of supplies\consignment

notes. Any damage noticed on receipt of equipment at site should be
reported to IEL immediately.

2. Any damages incurred during transportation or erection should be recorded

immediately on receipt and action regarding insurance claim initiated as all
items are insured either by us or by the purchase. Its replacement should be
asked for immediately or it should be repaired before erection.

3. Sort out the material and keep them as per unit requirement as this will help
to keep erection going smoothly and fast. Please refer equipment layout,
pipe drawings, internal arrangement drawings and flow diagram for the plant
and manufacturer's catalogues.

4. Special care should be taken in handling delicate items like

instruments/PVC/Glass items.

5. Check all the civil foundation work are ready in accordance with the
equipment layout drawing and foundation drawings. The detailed
dimensions should be checked before proceeding for the erection. This is
very important.

INSTRUMENTS :

a) Mount the pressure gauges and other instruments in the location given in the
flow diagram .

b) Please refer manufacturer's manual for erection/operation and maintenance.

12
 PUMPS :

a) When the pumps are installed, Do not pull the pump for the sake of
completion of delivery/suction pipework.

b) Ensure the suction and delivery pipes are supported properly before they are
connected to the pump.

c) Before the pump is grouted, make sure that :

1. It is levelled properly by using MS packings underneath the base plate if

required. The pump should be aligned accurately with dial gauge
(preferably) for long and smooth operating life. Rough and fine alignments
to be done before and after piping.

2. Foundation bolts are free and do not touch the sides of foundation pockets.

d) Please do not grout till the pipe installation is completed.

13
Chapter 4
Introduction To Membrane filtration

1.0 Introduction
Demineralizing is a process of removing dissolved inorganic solids also called
Total Dissolved solids (TDS) from water. There are various processes by which this
can be achieved. They are :
Freezing
Distillation
Reverse Osmosis
Electrodialysis
Ion Exchange
Freezing and distillation are phase change method primarily used for sea water
distillation.
Reverse Osmosis (RO) , Electrodialysis (ED) and Ion Exchange (IX) are systems are
the most commonly employed systems in Industry.
The selection of the process depends on the following factors
1. TDS of water
2. Product water quality desired.
3. Brine disposal facilities
4. Pretreatment required
5. Need to remove other material like bacteria & viruses.
6. Availability of energy and chemicals required for the process
7. Cost.
The basic process for all the three demineralizing system is same and is

Feed water supply - Source of water and quality

Pretreatment Removal of impurities which may foul demineralizing

Process.

Pump Pumping water to the demineralizing process

Process IX , RO , ED

Post Treatment pH adjustment, further demineralizing

Degasification and disinfection.

The End use determines the quality of water to be produced. For example
semiconductor industries require ultrapure water, whereas potable water may be of
higher TDS value. Remember that better the quality , higher will be the cost.
Ion exchange process was the most widely used process for demineralizing. This
process is economical at low salinity. Today RO and ED are gaining advantage over
Ion exchange because of deteriorating water quality , water recycling etc
RO and ED are more economical at higher TDS.

14
Chapter 5

Fundamentals of Reverse Osmosis unit

Reverse osmosis is a membrane separation unit. It is the forced passage of water
through a membrane against the natural osmotic pressure to accomplish separation of
water and ions.

5.1 Osmosis
Osmosis is a process which can be defined as a passage of liquid from weak solution
to a more concentrated solution across a semipermeable membrane.
The semipermeable membrane allows the passage of liquid(solvent) but does not
allow solids (solutes) to pass through.

5.2 Explanation.
Let us consider pure water It is in contact with both side of semipermeable membrane.
Pressure and temperature are equal on both side. It is in equilibrium because there is
no net flow across the membrane. This means that the chemical potential is equal on
both side. If the soluble salt is added on one side , the equilibrium is disturbed and
there will be an osmotic flow till the chemical potential is disturbed.
When does the equilibrium occur
Equilibrium occurs when the hydrostatic pressure differential resulting from the
volume changes on both side is equal to osmotic pressure. This is a solution property
independent of membrane.

5.3 Reverse Osmosis (RO)

Application of external pressure to the salt solution side equal to osmotic pressure will
also cause equilibrium. Additional pressure will raise the chemical potential of water
in the salt solution and cause a solvent flow to pure water side, now at a lower
chemical potential. This phenomenon is called Reverse Osmosis
(from Hydranautics)
Applied pressure
Dilute Concentrated
Solution solution

Osmosis Reverse Osmosis

15
5.4 Membrane Characteristics
The basic behavior of Reverse osmosis and Nanofiltration membrane can be
described by the following characteristics
1. Water flux
2. Salt flux
3. Salt rejection rate
4. Recovery rate
5.4.1 Flux
Flux is the amount of water or salt that passes through, a permeates through a unit
area of membrane.
5.4.2 Water flux
The flow of water (product) through a membrane can be expressed by equation

Fw = A(p-) equation 1

Where Fw = water flux (gm/sqcm –sec)

A = water transport coefficient
p = differential pressure applied across the membrane (atm)
 = Osmotic differential pressure across the membrane.(atm)
5.4.3 Salt flux
The flow of salt through the membrane can be expressed by the equation

Fs = B (C1-C2) equation 2
Where Fs = salt (mineral) flux
B = Mineral permeability constant
C1-C2 = Concentration gradient across the membrane.
Refer equation 1 & 2
Water permeability constant A and salt permeability constant B are a characteristic of
a particular membrane that is used and processing it has received .
Water flux is dependent on the applied pressure.
Salt flux is dependent on concentration gradient but is independent of applied
pressure.
5.4.4 Mineral Rejection
The purpose of demineralization is to separate minerals from water. The ability of
membrane to reject mineral is called mineral rejection. Mineral rejection is defined by
the equation
Rejection % = ( 1- Pc/Fc) *100% equation 3
Where Pc = product concentration
Fc = Feed concentration
5.4.5 Recovery
Recovery is defined as the percentage of feed flow which is recovered as product
water.
Recovery % = (Pf/Ff ) * 100 % equation 4
Where Pf = product flow
Ff = feed flow.

16
5.5 Parameters affecting feed water performance
Apart from feed water concentration , the membrane performance is affected by the
following performance

1. Applied feedwater pressure

2. Feedwater temperature
3. Permeate recovery ratio
4. Membrane life
5. pH
6. Oxidants

5.5.1 Effect of pressure

Refer to equation 1 from which it is clear that water flux is directly proportional to
applied pressure.
The equation says that if pressure increases then both quality and quantity should
increase. This does happen because there is more water for dilution for the same
amount of mineral.
From equation 2 we can see that if feedwater concentration increases ,  also
increases . this will reduce water flux.
If presser is increased there will be force against the membrane at a higher velocity,
forcing greater amount of foulants in the stream to interact at membrane surface. This
can increase the scaling potential of membranes.

5.5.2 Effect of Temperature

Temperature has a significant effect on membrane performance. It is taken into
consideration when designing and therefore should considered during operation.
Essentially the value of water transport coefficient is constant for the given
temperature. As the temperature increases the flux increases. Membrane
manufacturers generally provide Temperature correction factor (TCF)
The TCF is proportional to change in pressure needed to maintain the 25*C flux rate
and is equal to 1 at 25*C.

5.5.3 Effect of pH
The pH of feed water can effect the membrane structure and scaling potential of
brine stream. Cellulose Acetate membrane (CA membrane) are very sensitive to pH
change. It operates in a narrow pH range of 4-6. Infact some CA membrane are so
sensitive that operate in range of 5.5 to 6. Thin film composite membrane made of
polyamide material can withstand higher pressure.
Membrane can hydrolyze at both lower and higher pH. Hydrolysis results in lessening
of mineral rejection capability.
At higher pH (above 7.7) and higher temperature solubility of silica increases
At lower pH(<8) and lower temperature calcium carbonate is soluble. Thus if brine is
saturated with both silica and calcium carbonate , changes in temperature and pH will
cause one or the other to precipitate. Therefore care must be taken to find the best
condition for scale prevention.

17
5.5.4 Effect of Recovery

The recovery rate is affected by two condition

1. Desired product water quality is influenced by the difference in concentration
between the brine and product. There is a possibility of exceeding product quality
criteria with excessive recovery.
2. Brine should not be concentrated to a degree that would precipitate minerals on
membrane. This effect is known as Concentration polarization.

5.5.5 Tolerance to Oxidants.

Oxidants like chlorine and ozone are added to water to control microbiological
growth and to improve taste and odor. These oxidants can affect membrane.
CA membrane are more chlorine tolerant. TFC membrane do not tolerate Chlorine
and if TFC membrane is used , dechlorination should be included in pretreatment.

5.6 Types of Membrane

Increased use of Reverse Osmosis process and other membrane process has led to
development of variety of membranes. Membranes most widely used in water
treatment are :
1) Cellulose Acetate or CA membrane
2) Polyamide membrane or PA membrane
3) Thin film composite membrane or TFC membrane.

5.6.1 Cellulose Acetate Membrane (CA)

CA membranes are constructed of cellulose acetate or cellulose triacetate or blend.
Though these membranes achieved acceptable results with brackish water but not
with sea water due to compressibility of Membrane at high pressure.
Its use is also limited for the following reason :-
1) Works under a narrow pH range.
2) Is temperature sensitive
3) Performance limitation

5.6.2 Polyamide Membrane (PA)

Polyamide membranes are made of aromatic polyamides, PA membranes works in a
broader pH range and hence it is more resistant to hydrolysis has better salt rejection
and organic rejection and they are non biodegradable. The feed water to PA
membrane should be free from chlorine as they are subject to attack by Chlorine.

5.6.3 Thin film Composite Membrane

The above two membranes are of asymmetric structure are dense, thin layer (salt
rejecting layer) supported by a thick, porous layer. They are both composed of the
same polymer.
TFC membrane consists of three layers are based on polyamide membrane and
consists of poly sulfone membrane as a support for very thin polyamide layer.
Advantage of TFC membrane are :-
1) High flux rate
2) Wider pH range
3) More resistant to chlorine than PA
4) High silica rejection.

18
5.7 Configuration of membrane
Major configuration of membranes are :-
1) Spiral wound
2) Hollow fiber
3) Tubular frame

5.7.1 Spiral Wound

In spiral wound configuration are assembled from flat sheet polymer Membrane and
spacers are wound around the permeate collection tube to produce flow channels for
permeate and feed water. These are the most commonly used in Industrial
application. The advantage of this configuration are :-
1) Simpler plumbing system
2) Easier maintenance
3) Greater design freedom
4) Less prone to fouling
5) Can withstand higher level of pre-treatment upsets.

2.7.2 Hollow Fibre

Hollow fiber contain a bundle of extremely small diameter Membrane tubes which
creates a tremendous membrane area in a small volume. Feed water is fed to the
center of vessel through a porous pipe. The ions get rejected through these hollow
fibers when water permeates the wall and is discharged as product water.
Concentrated reject is collected at the opposite end of the vessel.
One major advantage of CA membranes are that they are more resistant to chlorine
and foulants and is still considered as a first choice for many application.

2.7.2 Tubular Membrane

Tubular membranes are inserted into or coated onto the inside surface of a porous
tube and are designed to withstand the operating pressure. Feed water enters the end
of the tube permeates through the membrane and is collected and discharged through
a concentrator concentrated reject water leaves through the end of porous tube.

19
 Permeate

Reject brine

Permeate flow
In collectors
Saline water

Fig 2 Schematic of spiral wound module

Saline Permeate
water

Reject Brine
Permeate tube

20
Chapter 6

Components of Reverse osmosis unit

Reverse osmosis unit comprises of following components. The schematic is shown
below. (see fig 3). The unit includes the following components.
1. Pressurization pump
2. Piping
3. Concentrate control valve
4. Sample valve
5. Flush connection
6. Cleaning connection
7. Permeate rinse valve
8. Permeate draw back tank
9. Energy recovery device
10. Membrane
Cleaning
connection
Separate
Flush water
inlet

Membrane
From Array
Pretreatment
PERMEATE

Pump
Discharge
Control Drain
valve
CONCENTRATE
Pressurization
pump

Concentrate
Control valve

Flush
Cleaning outlet
connection

Fig 3 Schematic of Reverse Osmosis unit

21
3.1 Pressurization pump
The pressure required for RO unit can range from 100 psi ( ) to about 1200 psi
( ). The feed pump used for pressurizing feed water is called the pressurizing pump
and is either a centrifugal pump or a positive displacement pump. Centrifugal pumps
are used for lower pressure. Positive displacement pumps are preferred for higher
pressure. For sea water desalination it is the preferred pump.
The output of centrifugal pump may be throttled by use of throttling valve. This is
often done for new system or after membrane cleaning.
The output of positive displacement pump is not throttled. The pump discharge line
should contain a pressure relief mechanism.

3.2 Piping
Choice of piping material is generally based on the salinity of water. For sea water
desalination high grade stainless steel is used for high pressure lines .
Brackish water use 304 or 316 SS and low pressure plant (House old RO) use PVC
piping.

3.3 Pressure vessel housing

Spiral wound membrane are housed in pressure tube generally called as pressure
vessel housing. The elements are connected in series and held in
Pressure vessel. Generally six elements are housed in one vessel. With later design
of spiral wound membrane seven 40 inch long elements have been placed in single
unit. A seventh element housing is useful if it is necessary to increase the system
recovery marginally.

3.4 RO Array
The array structure is determined during the design process by the hydraulics of the
system. The most common arrangement has six membranes in each pressure vessel.
This arrangement recovers as permeate 50% of the water fed to it. For a 75%
recovery, two stages are required. When using two stages, 50% of the feed is
recovered in the first stage. The remaining 25% is recovered by the second stage, as it
yields a 50% recovery on the concentrate from the first stage. The largest number of
stages normally used is a three-stage unit. If pressure vessels with fewer than six
elements are used the recovery per stage is decreased

3.5 Valves
Various valves are used in RO. The major valves are
1. Pump inlet
2. 1st stage inlet
3. Product outlet
4. Reject outlet
5. System flush inlet & outlet
6. Stage isolators
7. Cleaning connection
8. Permeate rinse
9. Sample valves

22
 3.5.1 Concentrate control valve
A regulating valve located in the concentrate line (reject) provides a means of
applying backpressure to membranes. Positioning this valve in conjunction with
pump discharge valve will set the permeate and concentrate flow rate.

3.5.2 Sample Valve

Sample valve is located on feed , permeate and concentrate line . It is so located
that sampling is possible during all mode of operation like servicing, flushing or
cleaning.

3.6 Cleaning connection

All units should have cleaning connections for each bank of permeators or pressure
vessels connected in parallel , isolation valves for each bank would allow for one
bank to soak while the upstream or downstream bank is cleaned.
Permeate Rinse
Provision for sending the permeate from one bank or unit proves useful when
troubleshooting. Some process require that permeate achieve quality by rinsing after
shutdown period.

3.7 Membranes
RO membranes are commercially available in the following configuration
1. Spiral wound
2. Hollow fiber
3. Tubular
4. Plate & frame
Tubular & plate & frame are used more in food and dairy industries.
Spiral wound and hollow fiber are the most widely used Membranes in water
treatment.

3.7.1 Spiral Wound

The spiral wound module as shown is constructed of large membrane sheets

covering both sides of a porous backing material that collects the permeate
and is sealed with glue on three of the four edges of the laminate. The laminate is
also sealed to a central tube which has been drilled to allow the demineralized water
to enter. A spacer material separating membrane surface is added which acts as a
brine spacer. Several of these membrane envelopes with brine spacer are rolled up to
form a spiral wound module. The modules are then loaded into pressure vessel.
Saline water enters the end of the module through voids between membrane
envelopes provided by mesh spacer. Under high pressure , water is forced from the
brine in the spacer voids through the membranes and conveyed by the enclosed
porous permeate collectors to the perforated tube in the center of module. Reject
brine discharge from the spacer voids at the outlet end of tube.

3.7.2 Hollow fine Fiber

The hollow fine fiber membranes are made of aromatic polyamide. The fiber is
about the size of human hair. The outside diameter of the fiber is approximately 85
to 100 m and inside diameter of 42 m . This membrane bundle is contained in a
cylindrical housing called permeator. Saline water enters the module through a
central perforated feed tube and flows readily through the fiber bundle toward the

23
 outer shell of the cylinder . Under high pressure , water from the surrounding brine
enters the hollow fibers and exits from their open ends at the outlet end of module.
Reject brine arriving at the outer shell of the pressure vessel is collected by flow
screen and conveyed by the module.

3.8 Membrane element construction.

The membrane element is constructed of parts mentioned below

3.8.1 The Center Tube (CT)

The center tube is also called permeate collection tube. The membrane leaves ,
permeate carrier and spacer material is wound around this. The CT provides structural
strength to the element.

3.8.2 Anti telescopic device(ATD)

Anti telescopic device are attached to the end of element. This can be either bonded or
loosely attached top the CT to form an integral part of interconnector. ATDs fills
space between elements in a pressure vessel. It also facilitates in flow of feedwater
from one element to next which helps in preventing pressure build up.

3.8.2 The Interconnector (IC)

The IC connects the center tubes of neighboring elements and directs the flow to one
or both ends of pressure vessel. The IC is connected to CT by O rings.

3.8.2 Product end adapter(EA)

The product end adapter is (EA) is used at both ends if the permeate volume is high.
Otherwise it is provided at only one end. It is more common to find membrane
element with one end plug. The other is sealed with dead end plug (DEP).

3.8.3 Permeate carrier

This is a sheet of material inserted between the backsides of the membranes , forming
a membrane envelope to promote the flow of permeate toward the center tube for
discharge at the ends of the vessel.

3.8.4 Feed spacer

This is the material inserted between neighboring membrane surfaces to create the
best possible flow conditions over the membrane.

24
Chapter 7

Factors affecting RO Membranes

4.1 Scale
Membranes can clog through the formation of scale.
The scale could be due to
1) Calcium carbonate
2) Calcium sulfate
Calcium carbonate scale is normally prevented by proper pH control. pH is normally
kept between 5.5 - 6.0.
Polyphosphate such as SHMP is normally used for preventing sulfate scaling. A
common concentration of polyphosphate is around 4-6 (4 –6 mg/L). The use of poly
phosphate is made to control Fe and Mn is in very low concentration. Poly
phosphate oxidizes the iron and manganese. If concentration of Fe is greater than 1
mg/L then some iron removal method is employed. Poly phosphate also prevents
fluoride crystals.

4.2 Suspended matters, micro organism

Membranes can be affected because of the suspended matter, colloids, coagulants &
flocculent. Filtration and micro filtration, depending upon the suspended matter and
colloidal matter is used as pretreatment of RO feed water. It is also possible for
membrane to get fouled due microorganism . Thus to prevent this, some kind of
disinfectant is used for pretreatment. Chlorination followed by activated carbon is
one of the most common disinfectant used.

4.3 Membrane age

Irrespective of operating conditions, all membranes deteriorate with age.
Manufacture normally suggests membrane replacement after every three years. Good
maintenance may increase the membrane age.

4.4 Membrane deterioration

The reasons for the premature membrane deterioration are

4.4.1 Chlorine
Membrane are very sensitive to Chlorine. CA membranes can resist. Some amount
of chlorine generally less than 1 ppm. PA and TFC membrane are very sensitive to
even trace amount of chlorine. The feed water containing free chlorine should be
dechlorinated either by activated carbon or sodium bi sulfite.

4.4.2 pH
pH assumes a very important role in RO operation. CA Membranes are highly pH
sensitive. CA membranes are normally operated in 4-6 pH range and Optimum pH is
5.5. Above 8.5 CA membrane deteriorates. PA/TFC membranes have wider pH
compatibility but pH is normally kept around 6 to avoid scaling.

25
4.4.3 Hydrolysis
CA membrane can get hydrolyzed at low or high pH. CA membrane hydrolyses with
time but can be accelerated due to high temperature. PA membrane do not hydrolyze
but deteriorate due to physical failure.

4.4.4 High pressure

Membrane compacts when high pressure is applied. The amount of product water
falls (reduces) of to a point where membrane has to be replaced.

4.4.5 Bacteria
CA Membranes are prone to bacterial attack. PA membranes are not attacked by
bacteria but substance formulating at surface can act as a nutrient.

4.5 Foulants affecting RO membrane

Monitoring of R.O plant is very critical since it helps in recognizing a problem and
taking a timely remedial action. R.O Membranes even during normal operation over
a period of time is subject to fouling by suspended or sparingly soluble material which
may be present in the feed water. Monitoring of plants helps in identifying the foulant
and also cleaning procedure to be adopted.
Typical foulant encountered in R.O are the following :-
1) Calcium carbonate or calcium sulfate
2) Iron oxides
3) Silica
4) Suspended or colloidal impurities
5) Organic
6) Biocide, fungi or slime.

26
Chapter 8

Pretreatment
Water to be demineralized always contains impurities which should be removed by
pretreatment to protect the membrane and to ensure maximum efficiency in the RO
process. Membrane can get clogged or fouled by undissolved impurities or by
impurities that precipitates during the process.
The pretreatment used with RO system are the following
1. Coagulation & Clarification
2. Clarification for removal of colloidal impurities.
3. Media filters for removing suspended solids.
4. Ultra filtration for removal of oil & grease.
5. Acid addition
6. Lime softening & Softening..

5.1 Coagulation and flocculation

Suspended matter of colloidal nature are too small to be removed by media filtration.
Coagulating and flocculating chemicals are added prior to filtration for removing
colloidal impurities.

5.2 Clarification
Clarification is a process which is followed after coagulation and flocculation.
Clarification is done to water which is high in turbidity (generally greater than >100
unit of turbidity). If turbidity is less , media filter follows coagulation and
flocculation.

5.3 Media filtration

Media filtration is used for removal of suspended impurities. Media filters contain
sand and anthracite. Filtration is the process of passing liquid containing suspended
matter through a suitable porous material (filtering medium) to effectively remove the
suspended impurities in the liquid.

5.4 Ultra filtration

Ultra filters can tolerate higher turbidity and SDI values than RO membranes and
hence used as a polishing filters for a RO unit. It also helps in reducing silica.

5.5 Cartridge filters

This is provided to almost all RO system irrespective of size to prevent particles in feed water ,
chemical feed equipment or pretreatment media from entering the RO membrane. This is the last stage
of pretreatment step. Generally used pore size is 5 micron . But when better filtration is required 5
micron is followed by 1 micron. Remember that cartridge filters are not replacement for media filters
but only last stage protection to RO membranes.

27
5.6 Scale control
Feed water which comes as product water is pure water but the waste water which is
called brine or reject becomes more saline. As the salinity (TDS) increases some salts
precipitate and scale the membrane .
The following compounds are generally responsible for scaling
Calcium carbonate & Calcium sulfate
Silica complex
Calcium fluoride
Some compounds like hydroxides of iron and aluminum also form scale but generally
they precipitate before they contact membrane and do not crystallize on it.
The scale is controlled by one of the following methods
1. Removal of calcium & magnesium ions by softening
2. Addition of acid to remove bicarbonate alkalinity.
3. Use of scale control agents.
Note :- Softening has some drawback like a) more salt is required in comparison to
acid (b) Brine disposal problem (c) membrane rejects divalent compound better.

28
Chapter 9

Troubleshooting RO Plant
Troubleshooting of any plant is carried when it performance does not meet the
specification or when there has been abrupt change in its performance. Similarly RO
plants also require troubleshooting if there is unacceptable change in quality and
quantity of water produced.
The following indicates that RO plants need troubleshooting.
1. Normalized production changes by 15 %
2. Normalized salt passage changes by 50%
3. Differential pressure changes by 15 %
Troubleshooting steps for RO plant are

8.1 Checking and verifying instrument operation.

Conductivity , pressure and pH plays very important role in RO operation. It is
therefore very necessary that instrument measuring this should be accurate and
functioning properly. Recalibrate all instrument.
The recommended calibration schedule are
pH sensors, indicators and recorder 30 days
Conductivity sensors, indicators and recorders 90 days
Flow sensor indicators and recorders 90 days
All other instrument 180 days
Though this is recommended by most companies, I suggest that pressure monitoring
instrument should be recalibrated more often because it is an important measurement
in RO operation.
Once it is checked that all instrument are working properly go the next step

8.2 Reviewing operating Data

Check the operating log sheet. This will you in diagnosing whether there is a system
upset or fouling. RO may be working properly but changes in critical operating
parameters like TDS, Temperature, recovery or flux can mislead you.
The following points will help in identifying the problem.
1. Increase in feed water TDS increases feed pressure requirement .
2. Decrease in feed water temperature increases feed pressure requirement.
3. Increase in feed water TDS also increases peremeate conductivity.
( Remember RO rejects a fixed percentage of salts)
4. Increase in percent recovery of the system increases the reject TDS (This boosts
permeate conductivity)
5. We had mentioned earlier that passage of salt is independent of passage of water
through the membrane. Therefore if recovery is constant, a reduction in permeate
flow results in a lower water flux, which will increase conductivity.
RO operation can be done by examining operating logs and by normalizing the
logged operating data. Normalizing helps in predicting system performance and also
helps in scheduling the cleaning frequency.
Normalization is the mathematical procedure for correcting actual production and salt
rejection value to standard condition. Most membrane suppliers today have developed

29
computer software for projecting “Normalization”. The program graphically chart
normalized permeate flow , percent salt rejection and feed to reject pressure drop
called corrected p.

8.3 Checking for component failure

The system upset can also be due to mechanical problem
The mechanical failures can be
1. Damaged O rings
2. Damaged or missing feed tubes in hollow fiber premeators.
3. Damaged brine seals
4. Failure of high pressure pump
5. Failure of dosing pumps
6. Valve leakage
7. Piping failure
8. Cartridge filter

Checking for chemical upset

The chemical upset can be
1. Improper pretreatment
2. Improper acid addition : More acid can lead to membrane damage and sulfate
scaling if H2SO4 is used. Lower dosage can lead to metaloxide formation or
carbonate scaling.
3. Improper scale inhibitor dosing : High dosing leads to fouling and low leads to
scaling.
4. Higher than recommended dosing of coagulants and polymer can lead to
membrane fouling.
Once all the above problems – Mechanical, chemical upset and water chemistry have
been ruled out as the likely cause, the next step is to identify the foulants. This is
done by studying the water analysis of feed , brine and product stream over a period
of time which will help in verifying if any extraordinary changes have taken place.
This will help in identifying the problem and the likely foulant which caused the
problem.
Shutdown
Before shutting down RO plant , make sure that reject water from the service
operation from the system is flushed out.
If the unit is going to be shut down for long, carry out the recommended procedure of
storing.

30
8.7 Troubleshooting
Troubleshooting of RO Plant is done whenever the plant deviates from its normal
operation. In the next page we have provided troubleshooting chart which will help in
fault diagnosis

A troubleshooting chart is always helpful in fault diagnosis

CHECK VERIFY EFFECT

Pressure drop between Has not increased by More than 15% indicates
feed and reject. more than 15% . fouling of feed path and
membrane surface.
Requires cleaning
Pressure drop between Has not increased by More indicates fouling of
feed and permeate more than 15%. membrane surface.
Requires cleaning.
Permeate conductivity Has not increased by More indicates fouling of
more than 15%. membrane surface.
Requires cleaning.
Acid dosing Is within recommended More can cause
value. membrane damage or
sulfate scaling. Less can
cause carbonate scaling
or metal oxide fouling.
Instruments Reading Verify by calibration Wrong operation
and carryout of lab False sense of security
check of the parameters that everything is OK.
the instrument is
monitoring.
pH meter calibration & Acid dosing pumps are More or less acid dosing
control generally controlled by than required. Effect of
pH controller. pH this as already been
controller Should be mentioned earlier.
calibrated periodically
and tripping of dosing
pump to the set point
should be checked.
O ring Probing with ¼ ‘ plastic Failure can lead to
tube and by measuring increase salt passage ,
how far it has been increase permeate flow.
inserted. Decrease pressure drop.
Brine valve Should not be closed If fully closed,100%
fully. recovery will result and
cause membrane damage
due to precipitation of
inorganic salt.

31
Chapter 10
Operation of pumps
Pumps are one of the most widely used equipment in water treatment. It is used for
various application. Pumps in water treatment therefore get classified in different
ways.
By mode of operation --- Centrifugal, propeller , reciprocating etc
By condition of pumping --- high lift, low lift, high capacity and high pressure
By application --- Raw water pump , filtered water pump,
dosing pump.
In reverse osmosis systems, pumps are used for various purposes. In fact , the high
pressure pump apart from membrane, is the most important component of RO
system. The other widely used pumps are metering pumps for dosing chemicals and
generally referred as dosing pumps.

10.1 Centrifugal pump

A centrifugal pump is a simple device as shown. It consists of an impeller arranged to
rotate within a casing. The impeller is supported on a shaft which in turn is supported
by bearings. Liquid coming in at the center (*eye of an impeller ) is picked up by
vanes and by the rotation of the impeller and is thrown out centrifugal force into
discharge.

Discharge

Volute
Nozzle

Impeller
Pumps are costly and hence require proper maintenance. Preventive maintenance and
trouble shooting methods are described in the next section (see Section C –
Troubleshooting equipment). Starting and stopping of pumps also play a crucial role
in pump operation.

32
10.2 Starting a new pump
1. lubricate the pump as per suppliers instruction
2. Check alignment of pumps. The shaft should rotate freely when rotated by hands.
3. Check the motor characteristics and wiring
4. Set the thermal overload relay.
5. Start the motor for just enough time to observe the rotation. The rotation should be
in the same direction as that of pump. The direction of pump rotation is marked on
the pump.
6. Check that all lines are open
7. A new pump should never be started without priming.
8. After starting the pump check the following
a) recheck the direction of rotation
b) check stuffing box (packing glands) for slight leakage.
c) Check that bearing do not get overheated because of over or under lubrication
d) Check for noise. The reason for noises are misalignment improper adjustment
or clearance and low voltage.
e) Compare the pump performance with pump performance curve or with
specification provide.
The above is generally applicable to new pump or pump which is being reinstalled
after repair.

10.3 Starting and stopping pump running pumps

6.3.1 Starting the pump
1. Check the MCC (Motor control center) panel for lock and tag. Generally a danger
tag is provided for motor or pump which is not in operation.
2. Inspect the equipment
3. Check lubrication
4. Check all valves .
5. Check pipe routing to see that valves are in their proper position and the flow of
pump will discharge where intended.
6. Return to MCC and switch the supply on.
7. Open suction valve fully .
8. Start the pump through local pushbutton provided. In automatic plant this step
may not be necessary.
9. In most cases you can start a pump with discharge valve open provided check
valve is provided.

10.3.2 Stopping the pump

1. Record all reading
2. Stop the pump
3. Close all valves
4. Remember to close the discharge valve of pump which is not provide with check
valve before stopping.

10.4 Some points to observe in operation of centrifugal pumps

1. Do not operate the pump when safety guards are not installed over or around
moving parts
2. Never operate a pump which is tagged or locked . some body can get injured.

33
3. Never run a centrifugal pump when impeller is dry. Always prime the pump
before starting. (In water treatment most pumps have positive head or low suction
lift and hence this point may not be very significant )
4. Do not operate a pump whose impeller or shaft is spinning backward.
5. Never operate a pump which vibrates excessively. Check for blockage in suction
line or impeller

10.5 Improving Pump efficiency

Opportunities for savings in pump operation are often overlooked because
pump inefficiency is not readily apparent.
The following measures can improve pump efficiency:
1. Shut down unnecessary pumps.
2. Restore internal clearances if performance has changed significantly.
3. Trim or change impellers if head is larger than necessary.
4. Control by throttle instead of running wide open or bypassing the flow.
5. Replace oversized pumps
6. Use multiple pumps instead of one large pump
7. Use a small booster pump
8. Change the speed of the pump for the most efficient match of horsepower
requirements with output

10.6 Metering pumps

Metering pumps are required in RO operation for dosing various chemicals. These
pumps are generally positive displacement diaphragm pumps but there are times when
piston type pumps have been used. This type of pump deliver predetermined amount
of chemicals. Pumps of this kind are available from 0 to 100 liters/hour with
maximum injection pressure of around 20 kg/cm2 and powered by AC voltage of 120
or 240 volts or 12 or 24 volt DC. They are fitted with head made of different chemical
resistant material. Ball valve with o-ring seats in the suction inlet and discharge outlet
of the head provide tight seals when closed for positive displacement without
backflow. The four function valve with a return line to chemical container is primarily
for safety. An internal check valve prevents backflow into head of the pump.

10.7 Pump Operation

These type are started and stroke length adjusted to deliver a required quantity of
chemicals. Priming is required for pump which have high suction lift.
10.7.1 . Priming
Priming is done only against atmospheric pressure when using a suction lift
installation. Flooded suction installations allow the unit to prime itself even under
pressure.
1. Temporarily remove tube from injection check valve and hold the end of tubing so
that it is above pump level.
2. Set pump at 100 % stroke and start pump.
3. As soon as chemical is visible through translucent discharge tubing just past the
discharge tube, stop the pump.
4. Pump is now primed.
5. Reconnect tubing to injection check valve.
6. Pump is normally self priming if suction lift is below 1.5 Meter. Follow step 1 to
3.

34
7. If the pump does not self prime , remove discharge housing and ball and pour
water or chemical slowly into discharge port until it is filled . Follow step 2 to 5
thereafter.
Note :- In all cases priming will be assisted by releasing or reducing pressure on the
pump. This can be done by the pressure relief valve provided.
10.7.2 Output adjustment
In metering pump the most important operation is output adjustment. Adjustment of
output is necessary because more or less chemical can prove harmful to membrane.
This is done by adjusting the stroke length. Most pump catalogue give the method of
adjusting the stroke length.

35
Chapter 11
Operation of Multigrade Filter

11.1 MULTIGRADE FILTER:

Multigrade Sand Filters are used for removal of suspended matters from raw
water.The Filter media is a fine mixture of coarse & fine particles of sand.This allows
the complete utilisation of the large spaces between the sand particles for removal of
the suspended impurities. The pressure drop across the filter starts rising as the the
filter run proceeds ; cleaning of the filter media is done by reversing the flow through
the bed when the pressure drop exceeds the allowable value.

Operation
1. Open the inlet of Multiport Valve with adjusting the lever.
2. Open the outlet Multiport Valve with adjusting the lever.
3. Backwash the vessel with adjusting the lever.

The water will enter the vessel , flow through the media and then enter the RO
membrane unit.

36
Chapter 12
Operation of Activated Carbon Filter

12.1 ACTIVATED CARBON FILTER:

Activated Carbon Filters are used for removal of free chlorine from water , also
removal of organic matter. Normally the activated carbon filters are placed
downstream of Multigrade filters. If the raw water is already filtered , they can used
as a first unit.

Activated Carbon used as a media provides a large pore surface area which by the
process of adsorption , helps in removal of organic molecules. The large surface area
is also helps in a catylic action in removal of chlorine.

Activated carbon filter needs to be regularly bachwashed by reversal of flow so as to

keep the surface of the carbon particles clean.

Operation
1. Open the inlet of Multiport Valve with adjusting the lever.
2. Open the outlet Multiport Valve with adjusting the lever.
3. Backwash the vessel with adjusting the lever.

The water will enter the vessel , flow through the media and then enter the RO
membrane unit.

37
Chapter 13

Cartridge Filter
In RO systems cartridge filters are used as a last stage of pretreatment to remove any
suspended or particulate matter before the water enters the membrane unit.
The filter element are of standard diameter and are available in various length. For
industrial application the standard lengths are 30 or 40 inch. The flow rate of the
service water determines the length and number of filter elements necessary. Filter
elements are held between two plates inside a pressure vessel.

13.1 Operation
3. Open the inlet water valve
4. Open the outlet water valve
The water will enter the vessel , flow through the cartridge element and then enter
the RO membrane unit.

13.2 Removal of choked cartridge filter element

Over a period of time the cartridge filter element will get clogged with impurities.
This is indicated by the pressure drop across the cartridge.
1. Stop the cartridge filter system.
2. Close the inlet and outlet valve
3. Open the vessel in which the cartridge element is housed.
4. Take out the dirty filter element
5. Replace them with new elements.
6. Close the vessel .
7. Open the inlet valve but keep the outlet valve closed.
8. Open the drain valve provided
9. Rinse to remove dirt
10. Put the unit back into service by closing drain valve and opening outlet valve.

38
Chapter 14
Filter maintenance

14.1 Routine maintenance

The routine maintenance of pressure filter include the following
12.1.1 Valves
At periodic intervals (say one month ) open the valves and check for
seating, change gland packing or diphgram depending on the type of valve.
Carry out lubrication of spindle.

14.2 Vessel condition

Once a year vessel internal condition should be checked for paints and internals
Repaint the vessel after removing the media. Filter media replacement can also be
done if required. Filter media is replaced normally once a year.
The routine maintenance guidelines are given both for mild steel filters as well as PP
filters . PP filters normally require less attention once installed. Operational care is a
must for FRP Filter . the pressure should not be more than the recommended pressure
or it is likely to damage the filter. PP filters are of molded design and hence repair is
not possible and has to be replaced.

39
 Chapter 15

Electrical Motor Troubleshooting

Symptoms Cause Result Remedy

1 Motor does not A. Incorrectly connected Burnout Connect correctly per diagram
start.
(switch is on and B. Incorrect power supply Burnout Use only with correctly rated
not defective) power supply
C. Fuse out ,loose or open Burnout Correct open circuit condition
connection

D. Rotating parts of motors Burnout Check & correct

May jammed 1. Bent shaft
Mechanically 2. Broken housing
3. Damaged bearing
4. Foreign material in motor

E. Driven Machine may be Burnout Correct jammed condition

jammed

F. No power supply None Check for voltage at Motor and

work
G. Internal circuit open Burnout Back at power supply
Correct

2..Motor starts but A. Same as 1,2,3 above Burnout Same as 1,2,3 above
does not come up
to speed. B. Overload. Burnout Reduce load to bring current to
Rated limit. Use proper fuses &
Over Load protection.

C. One or more phases Burnout Look for open circuit

Out on 3 phase
Motor.

3. Motor noisy A. Same as 1,2,3 above Burnout Same as 1,2,3 above (Col. 1)
Electrically

40
Motor runs hot A. Same as 1,2,3 above Burnout Same as 1,2,3 above (Col. 1)
(Exceeds Rating)
B. Overload Burnout Reduce Load

C. Impaired Ventilation Burnout Remove obstruction

D. Frequent start &stop Burnout 1. Reduce number of starts or

Reversals
2. Secure proper motor for this
duty
E. Misalignment between Burnout
Rotor & stator Realign
Lamination

Noise (mechanical) A. Misalignment of Bearing failure Correct misalignment

coupling Or sprocket Broken shaft,
Stator burnt due
Motor drag

B. Mechanical unbalance Same as Find unbalanced part, then

of rotating parts Above Balance.

C. Lack of or improper Bearing failure Use correct lubricant, replace

Lubricant Parts as necessary

D. Foreign material in Bearing failure Clean out and replace bearing

Lubricant.

E. Overload Bearing failure Remove overload condition.

Replace Damaged Parts.

F . Shock loadin Bearing failure Correct causes and replace

Damaged parts
G. rotor dragging due to
Worn bearings, shaft
Or brackets Burnout Replace Bearing , shaft ,or
Bracket as needed

Bearing failure A. Same as 5A,B,C,D&E Burnout, Replace bearing and follow

Damage shaft, And follow remedial action
Damaged 5. A,B, C, D,E
Housing
Entry of water or foreign Same as above Replace bearing & protect
Material in bearing housing motors

41
 Symptoms Caused by Appearance
Shorted motor winding Moisture , chemicals, foreign Black or burned with
Material in motor, damaged winding
remainder of winding good
All windings completely a. Overload a. Burnt equally all around
Burned b. Stalled winding .
c. impaired ventilation b. Burnt equally all around
d. frequent winding .
e. reversal or stop c. Burnt equally all around
f. incorrect power winding .
d. Burnt equally all around
winding .
e. Burnt equally all around
winding .

Single phase condition a. Open circuit in one line a. If 1800 rpm motor –four
The most common causes are Equally burned groups at
loose connection, one fuse 90o intervals.
Out, loose contact in switch. b. If 1200 rpm motor – six
Equally burned groups at
60o intervals.
c. If 3600 rpm motor – two
Equally burned groups at
180o intervals.

NOTE
If Y connected each Burned
group consists of two adjacent
phase groups. If delta connected
each burned group will consist
of one phase
group.

Other a. Improper connection Irregularly burned groups or

b. ground spot burns

42
Troubleshooting / remedy chart for induction motors

A Motor will not start.

Overload control tripped ,Wait for overload to cool then try to start again. If motor still
does not start, Check for the causes outlined below
1. Open fuses; test fuses
2. Low voltage : check nameplate values against powerSupply characteristics . Also check
voltage at motor Terminals when starting under load to check for
Allowable voltage drop
3. Wrong control connections : check connection with Control wiring diagram.
4. Loose terminal – lead connection : turn power off and Tighten connection
5. Drive machine locked :disconnect motor from load. IfMotor starts satisfactorily, check
driven machine
6. Open circuit in stator or rotor winding; check
7. Short circuit in stator winding; check
8. Winding grounded ; test for grounded wiring
9. Bearing stiff; free bearing or replace
10. Overload; Reduce load

B. Motor noisy
1 Three phase motor running on single phase ; stopMotor , then try to start. It will not
start on single Phase. Check for open circuit in one of the line
2. Electrical load unbalanced ; check current balance.
3. Shaft bumping (sleeve bearing motor ) check alignment
4. Vibration ; Driven machine may be unbalanced, remove Motor from load , if motor is
still noisy , rebalance.
5. Air gap not uniform : Center the rotor and if necessary Replace bearing
6. Noisy ball bearing: check lubrication, replace bearing if noise excessive and persistent
7. Rotor rubbing on stator : Center the rotor and if necessary
Replace bearing.
8. Motor loose on foundation : tighten bolts , realignment may Be required.
9. Coupling loose : insert feelers at four places and check alignment

C. Motor at higher than normal temperature or smoking

1. Over load; Measure motor loading with ammeter. Reduce load
2. Electrical load unbalance : check for voltage unbalance.
3. Restricted ventilation: Clean air passage and windings.
4. Incorrect voltage & frequency: Check for nameplate values for power supplies and also
check voltage at motor terminals.
5. Motor stalled by driven tight bearings ; remove power from motor. Check machine for
stalling.
6. Stator winding shorted or grounded; test windings by standard method
7. Rotor winding with loose connection , if possible or replace with another rotor .
8. Belt too tight; Remove excessive pressure on bearing
9. Motor used for rapid reversing service ; replace with motor designed for the particular
service
D. Bearing Hot
1. End shields loose or not replaced properly ; Make sure end shield fit squarely and are
properly tightened

43
2 Bent Shaft : straighten shaft and realign.
E. Sleeve bearing
1. Insufficient oil: add oil –If supply is very low drain ,flush and refill.
2. Foreign material in oil or poor grade oil : drain oil , flush and relubricate using
industrial
lubricant as recommended by manufacturer of motor.
3. Oil ring rotating slowly or not rotating at all; oil too heavy; drain and replace worn out
oil ring.
4. Rings bent or otherwise damaged in reassembling ; replace rings.
5. Rings out of slot. (oil ring retaining clip out of place ).Adjust or replace retaining clip.
6. Defective bearing : replace.

F. Ball bearings
1. Too much grease : remove relief plug and let motor run. If excess grease does not com,
flush and relubricate.
2. Wrong grade of grease : flush bearing And relubricate withȠproper amount of grease.
3. Insufficient grease : remove relief plug and grease bearing.
4. Foreign material in grease : flush bearing and relubricate . Make sure grease supply is
clean.

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Chapter 16

CONTROL LOGIC & LOG SHEET

45
Chapter 17

Equipment Catalogues & P & ID

1. Dosing Pumps
2. Dosing Tanks
3. FRP Pressure Vessel
4. Cartridge Filter
5. Flow meter
6. Pressure Switch
7. pH Controller
8. TDS Controller
9. Membrane
10. Grundfos Pumps ( CHI8-30 & CRN5-24)
11. Membrane Housing
12. Pressure Gauge

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Chapter 18

Warranty Certificate

47