ROCHEM RO-Wasserbehandlung GmbH.pdf

7/22/2019 ROCHEM RO-Wasserbehandlung GmbH.pdf

1/117

ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg. Page No. 1

ROCHEM RO-Wasserbehandlung GmbHKnickberg 1a, D - 21077 Hamburg

(+49-(0)-40-7038577-04+49-(0)-40-7038577-29

Operation Manual V 0.1Date: 22.11.2008

Type of Unit:RO-1530 ST03-30SSEA-WATER DESALINATION (S)

FSS

Project: UAE Hull106 Order No.:P08027 Serial No.:2366


2/117


I N T R O D U C T I O N

I. ContentsPage

I. Contents 2

II. Preface 4

III. How to Use this Manual 5IV. Safety Remarks 6V. Log Sheet 7VI. Warranty 8VII. Notes 9

VIII. Service 10Order Form for Spare PartsHow to Contact our Service Department

1) Functional Description

1.1 Description of Process 12

1.2 Unit Arrangement 13

1.3 Controls, Displays & Measurements 18

1.4 Safety and behavior rules 19

2) Operating

2.1 Commissioning 20

2.2 Starting the Unit 21

2.3 Monitoring during Normal Operation 24

2.4 Stop with Rinse 25

2.5 Sandfilter Backwash 28

2.6 Circuit Cleaning 31

2.7 Preservation 39

2.8 Disinfection 45

3) Fault Indication & Finding

3.1 Error Codes and Implication 47

3.2 Faults without Lamp Indication 49

4) Maintenance, Cleaning & Calibration

4.1 Schedule for Checks & Maintenance Works 50

4.2 PLC 52

4.3 Contactors 56


3/117


4.4 Electric Motor 57

4.5 Pressure Switch 58

4.6 Pressure Transmitter 59

4.7 Conductivity Meter 60

4.8 Filter Pump 67

4.9 Plunger Pump 72

4.10 Sand-Filter 79

4.11 Cartridge Filter 81

4.12 Deacidification-Filter 79

4.13 PT Module 82

4.14 Motor Control Valve 110

4.15 Pulsation Damper 117

5) Specification

5.1 Layout Diagram, Installation Plans 119

5.2 Pipe & Instrument Diagram 123

5.3 Parts List 125

5.4 Tools & Resources 128

5.5 Unit Specification 129

5.6 Water Feed Analysis 131

5.7 Electric Schematics 132

Annex:

Actuator for Motor-Control-Valve


4/117


II. Preface

ROCHEM Reverse Osmosis Systems have been designed as space-saving modular plants, in

order to provide to you a flexible system, where space is restricted.

All components and materials used have been manufactured to the highest qualityrequirements, guaranteeing long life on a self-controlling 24 hours operation. ROCHEMsystems are simple to operate and require a minimum of service. More than 2100 plantssupplied worldwide confirm this.

ROCHEM Reverse Osmosis Systems meet the requirements and specifications of thefollowing organizations:

Deutsches Institut fr NormungVerband Deutscher Elektrotechniker e.V.Verein Deutscher Maschinen AnstaltenVerein Deutscher IngenieureGermanischer LloydDet Norske VeritasRegistro Italiano Navale (RINA)Lloyd's Register of ShippingBureau Veritas (French)

ABS (American Bro of Shipping)Russian Maritim Register of Shipping

They are also built to comply with military specifications and requirements.


5/117


III. How to Use this Manual

This manual should provide to you all the information required for operating and maintaining yourROCHEM Reverse Osmosis System. When designing this system great regard has beenpaid for safety. When working on this or any other system there is always an element of danger,which the owner, operator and technician need to be aware of. Appropriate maintenanceminimizes any danger and maximizes availability.

Any work of maintenance or repair, must be carried out correctly. Appropriate technicalknowledge as well as any applicable regulations for safety and environment must be providedby the owner, operator and/or the maintenance personnel.

THIS MANUAL DOES NOT REPLACE ANY PERSONAL TRAINING!


6/117


IV. Safety Remarks

F The fresh water generator must not be operated within harbour area. Or inwaters polluted with oil.

F When operating this equipment certain parts are electrified. Ignorance of operatingprocedure can cause death, injury or material damage. ANY WORK AT OR ON THEPLANT MUST ONLY BE DONE BY PERSONS TRAINED ON THE MACHINE AND

FAMILIARIZED WITH THE INFORMATION IN THIS MANUAL. REPAIR AND

MAINTENANCE MUST ONLY BE DONE BY APPROPRIATELY QUALIFIED

TECHNICAL PERSONNEL.

F PROTECTION, SUCH AS PULLEY / BELT GUARDS, MAY BE REMOVED ONLYFOR MAINTENANCE OR REPAIR AND MUST BE RE INSTALLED IMMEDIATELYAFTER ANY SUCH REPAIR OR MAINTENANCE HAS BEEN COMPLETED.

The owner and user, are responsible for complying to all prevailing laws to maintain a safeworking environment.

For plant protection please note the following important items:

F There must not be any visible movement (vibration/pulsation) of the pointer onpressure gauge PI160. If this occurs then one of the following is causing this fault: 1-Some nitrogen gas has leaked from the pulsation damper. 2- The diaphragm in thepulsation damper is damaged. 3- High pressure pump valves or packing are defective.

F The PT modules will be damaged, if there is any vacuum in the feed watersupply line or concentrate discharge line.

F Do not allow any back pressure on the permeate outlet, when there is nopressure on the feed supply, otherwise the membrane cushions will bedamaged. Do not allow pressure on the permeate side of the modules when the

unit is stopped. The maximum pressure in the permeate line is 3 bar. If a permanentpressure above this value is required then an additional booster pump will benecessary.

F The feed pressure to the high pressure pump PP160 must not fall below 0.5 bar.If this happens, the pump will be damaged by cavitation.

F The membranes are not resistant against chlorine or any oxidizing agent. De-ionized or distilled water in the unit will reverse the flow direction and destroythe membranes.

F Please take care of the feedwater quality conditions for the membrane moduleperformance.Do not allow to operate the RO unit in areas of river esturiances,especially in regions with low draff where the water can be expected to carry a

high amount of suspended solids and silicates. This could cause unremovable

deposits on the membrane surfaces affecting the desalination process,

reducing capacity and finally requiring the membranes to be replaced.


7/117


V. Log Sheet

In order to make any troubleshooting as easy as possible, we recommend you to fill in thefollowing chart daily with the parameters measured on the unit.

Date operatinghours

Feedwater

conducti-

vity

FI130 TI130 PI130 PI140 PI150 PI160 PI180 CI180 FI180


8/117


VI. Warranty

ROCHEM RO-WASSERBEHANDLUNG GMBH.Warrants that this system will produce

pure water within its designed limitations for a period of twelve (12) months from the dateof dispatch, provided that the system is operated on feed water of the minimum standard inaccordance with the submitted reference analysis and that the operator adheres exactly tothe installation, operating and maintenance instructions and recommendations.

Components of the system supplied by ROCHEM RO-WASSERBEHANDLUNG which arefound to be defective through poor workmanship or materials, will be repaired or replacedif their performance is proven to be less than normal by industry standards.

This warranty will be considered null and void if a unit is operated with malfunctioningcomponents or controls which result in the system being unable to meet its designed

performance.

ROCHEM RO-WASSERBEHANDLUNG will repair or replace a unit or components foundto be defective due to bad workmanship or materials on a free of charge ex worksHamburg basis.

A defective unit or component may be returned, freight prepaid, toROCHEM RO-WASSERBEHANDLUNG for repair or replacement ex factory, asdetermined by ROCHEM RO-WASSERBEHANDLUNG, should the unit be found defectiveunder this warranty.

This warranty does not cover any system or component which fails, due to damage frommishandling, misuse, substandard feed water, improper maintenance or neglect ofmaintenance, poor or improper installation or incorrect electrical supply. This warranty mayalso be voided if serial numbers and or components are found to be mutilated or missing.

This warranty does not cover or apply to consumable items such as filter elements,lubricants, pulsation dampers, shaft seals of centrifugal pumps, valves, and seats of the HPpumps or chemicals used in the operation or maintenance of the system.The terms of this warranty become effective on dispatch of the equipment from our factory.

There are no warranties expressed or implied which go beyond the foregoing statement.


9/117


VII. NOTES


10/117


VIII. Service

Order Form for Spare PartsTo:

Telephone: + 49 (0) 40 7038577-0 Telefax: +49 (0) 40 7038577-29

e-mail:

Page No1.

For Vessel Unit Type Serial No. Date

Authorised By: Approved BY: Delivery Required By:

Delivery Instructions: Order No.

Additional Instructions

To Be Charged / Invoiced to:

To ensure that the correct parts are delivered, please complete each block. The section block

refers to the header number of the page that contains the description or servicing of the item (if

any).

ITEM Qty Part No. Description Section1234

5678910111213141516

17

Rochem RO-Wasserbehandlung GmbHKnickberg 1a, D - 21077 Hamburg


11/117


Order Form for Spare PartsTo:

Telephone: + 49 (0) 407038577-0

Telefax: +49 (0) 407038577-29

e-mail:

Page No2.

For Vessel Unit Type Serial No. Date

ITEM Qty Part No. Description Section19

20

21

22

23

24

25

26

27

28

29

30

3132

33

34

35

36

37

38

39

40

41

42

4344

45

46

47

48

49

50

Rochem RO-Wasserbehandlung GmbH

Knickberg 1a, D - 21077 Hamburg


12/117


1) FUNCTIONAL DESCRIPTION

1.1 Description of ProcessThis fresh water generator uses the principle of the Reverse Osmosis.

If two saline liquids are separated from another by a semi-permeable membrane, which doesonly allow molecules over a certain size to pass through, then, these liquids will tend to equalizetheir concentrations. This process is called Osmosis. Should one of these liquids be salt waterand the other pure water, water molecules would diffuse through the membrane towards thesalt water and dilute this. A certain pressure would occur in the system when this happens thispressure is called the Osmotic Pressure.

For water desalination or dechlorination this process is artificially reversed, Reverse Osmosis.

The system is subjected to a pressure above the Osmotic Pressure, causing a moleculemovement into the reverse direction: Only the water molecules diffuse from the salt waterthrough the membrane to the pure water side. The ions of the salt water cannot pass throughand remain on the salt water side.

Within the ROCHEM PT modules the REVERSE OSMOSISprocess takes place whilst thefeed water is in motion, flowing over the membrane surfaces. About 30% of the water in thefeed water passes through the membrane, the remaining 70% retaining the rejected salts. Thefeed water is gradually increasing in salt concentration as it flows through the module. The saltsfiltered out and left behind by the membrane are carried away and discharged, in case of seawater desalination they are returned to the sea as brine (concentrate). The pure waterpermeate produced flows to a fresh water storage facility.

The amount of pure water that can be produced depends on the following factors:

1- the operating pressure,2- the salt content of the feed water,3- the feed water temperature.

For example the oceans have a salt content of approximately 3 %. whereas the Red Sea hasa much higher salt content of approximately 4 %,To overcome the increase in salinity the operating pressure is increased.

Each standard system has been designed for a certain production rate of pure water, assuminga feed water temperature of 25C. For each 1C drop in feed water temperature the permeateproduction drops by 3%. For example: Designed output at 25C is 100 l/h.Then with a feed temperature of say 15C the permeate output is 100-30% = 70 l/h.

A rise in temperature above 25C increases the pure water production only slightly. 25C is theoptimum feed temperature.

Note: Some systems can be supp lied to p roduce the required quantity with a low feedwater temperature.


13/117


1.2 Unit ArrangementThe water desalination system consists mainly of the following components:

Sandfilter safety valve control panel

(master-switch)

conductivity

display

control cabinet

flowmeters

Sample valves

Deacidification

Filter

removable pump

carrier

(PK130, PP160,

VS160)

sandfilter cartridge filters manual valves gauges

General arrangement of the RO1530 (individ ual deviations not al lowed fo r)

Sketch of operat ing pr incip le


14/117


BRIEF DESCRIPTION OF MAJOR COMPONENTS

The plant is controlled by a PLC unitTelemecanique TSX-Micro. Thecontrol program is stored on a microchip called EEPROM. When

switching on the plant the processor loads the program automatically fromthe EEPROM into its Random Access Memory. By means of aprogramming device, connected to the serial interface of the processorunit, changes can be made to the program.

The following valves must be set manually for the different operating functions:

VK121 VK132 VK134 VK133 VK171

normal operation

stop rinse

circuit cleaning

sandfilter

backwash- air rinse -

sandfilterbackwash

- water rinse -

valves handleshowingnormal

functionalflow

valve closed


15/117


Pressure switch PS150 is activated by the water pressure before thehigh pressure pump and switches the plant off in the event of insufficientfeed (to protect the pump against cavitation). It is de activated when thepressure drops below a set value of 0.5 bar. High pressure pump will not

start if this pressure switch is not activated. When not activated fault willshow.

Pressure switch PS170 (if installed) monitors the pressure in theconcentrate line from the PT module. It stops the plant at a pressure of 6bar, in order to avoid damage to the module. Most probable cause for thisto be activated is that a valve on the concentrate discharge is closed.This pressure switch is activated when the pressure goes above the 6 barsetting. When activated fault will show.

Pressure switch PS180 stops the plant when the pressure in thepermeate line rises to 3 bar. This isto save the PT module from damage.This pressure switch is activated when the pressure goes above 3 bar.When activated fault will show.

Centrifugal pump PK130 filter pump, delivers the feed water at apressure of up to 4 bar through the cartridge filter and from there to thehigh pressure pump PP160. This centrifugal pump has its own integralelectric motor.

The sand filter retains all sediment particles over 50 m in size. As thedensity of these particles increases, the pressure drop across the inlet andoutlet increases. To reduce this pressure drop and remove these particles,the sandfilter is backwashed by air and feed water (generally when 2 to 2.5bar are reached).

Within cartridge filter FC140 sediment particles of 10 m or more in sizeare retained within the filter element. These cartridge filter elements haveto be replaced when dirty, they cannot be cleaned.

High-pressure pumpPP160 is a positive displacement pump. (plungerpump) this pump delivers feed to the PT modules at a pressure of up to65 bar. (note: pressure is controlled by VS160). The pump is poweredthrough a belt drive from a three-phase motor. Minimum feed pressure tothis pump is 0.5 bar.


16/117


The pulsation damper fitted on the high-pressure pump dischargeconverts the pressure fluctuations, common for a plunger pump, into asteady pressure. It consists of a pressure vessel, internally separated byan diaphragm into two sections. The outermost section is filled withnitrogen at a pressure of 30 bar. The pulsations from the 3 plungers of the

HP pump are absorbed by the gas pressurized membrane. It is normal toobserve pulsations in the pointer of PI160 when pointer is rising through 25to 32 bar, (resistance against gas pressure).

Innerhalb der ST-Module wird das Rohwasser unter dem angelegtenDruck durch die Membrankissen gepresst. Das Wasser dringt durch dieMembranen und wird als Permeat abgefhrt; Salzmolekle und andereVerunreinigungen des Rohwassers knnen die Membran grtenteils nichtpassieren (Rckhaltung bei NaCl 98,5-99%), bleiben zurck und werdenvom nachfolgenden Rohwasser mitgenommen, so dass sich dieses vonModul zu Modul weiter aufkonzentriert. Das Konzentrat wird (beiSeewasserentsalzung) in das Meer zurckgeleitet.

The pressure in the PT module or modules, is automatically controlled andadjusted by motor valveVS160, which in turn is controlled by the PLC.The plant is designed for a maximum operating pressure of 65 bar.

The operating pressure is 65 bar with normal sea water.

This valve should never be fully closed during operation. When in operation

this valve reduces the flow area to increase the pressure between the HPpump discharge and the outlet of the modules. If this valve closes a faultwill show.

This valve can be manually operated by a hand wheel should the powerunit fail.

The concentrate flows from the unit through the manually operated concentrate valve VK171,which allows three positions:

(a) at normal operation, discharge (e.g. sent overboard back to sea),

(b) at circuit cleaning, returning to cleaning tankB111,

(c) at closed position.

A conductivity sensortransmits the conductivity of the permeate to theconductivity meter, (measuring the remaining salt content). An increase inconductivity implies a higher salt content. The value displayed in theconductivity meter is in s/cm. As a rough guide, if the reading shown isdivided by 2 the figure obtained would be the approximate value of salts asp.p.m.(mg/l).


17/117


The pure water solenoid valveVE1801 is automatically controlled by the conductivity of thepermeate. If the maximum pre-set value (1000 S/cm for sea-water desalination, 50 S/cm formains water purification) is exceeded, VE1801 sends the permeate into the cleaning tank (fromthere to drain). When good permeate is produced, at a quality with a lower conductivity than the

maximum pre-set value, then VE1801 sends this water to fresh water storage.If the plant operates more than 15 to 20 minutes at high conductivity (over the set limit), itautomatically shuts down and a fault signal is displayed.

As an option the plant can be equipped with a fresh water storage control. Starting andstopping the unit will then be actuated by 2 level switches fitted in the storage tank. When thelow level switch is activated, the plant will start automatically. When the tank is full the high levelswitch will be activated and the unit stops and will be in a stand by mode waiting to berestarted either by remote (level switch) or manually by pressing the start button.


18/117


1.3 Controls, Displays and Measurements

The control panelis equipped with a main switch, a conductivity meter and 5 lamp buttons:lamp button color function

1 green START2 yellow STOP WITH RINSE3 yellow CIRCUIT CLEANING4 yellow SANDFILTER BACKWASH5 red FAULT RESET / LAMP CHECK

The flow meter FI180 is installed in the permeate line from the PTmodule(s). Inside the plastic body there is a floating indicator. When its top

edge aligns to the appropriate mark on the scale, indicates the rate of purewater produced. The scale is marked in liters per hour on the front of thetransparent plastic body.

The floating indicator 1is magnetic and actuates a eletrical siglal to thePLC. The PLC in turn sends a signal to the motor valve VS160. VS160controlled the pure water flow.

The conductivity meter displays the conductivity of the permeate,measured by the conductivity sensor. Conductivity provides a measure forthe salt content remaining: The higher the conductivity, the higher the saltcontent.

The pressure gauges PI140 and PI150 (PI140-PI150) indicate the

pressure loss across the cartridge filter, PI130-PI140 indicates thepressure loss across the sandfilter. If the pressure loss reaches anapprox. value of 2 to 2.5 bar, the sandfilter must be backwashed.

PI160 shows the operating pressure of the unit, shown as the inletpressure to the PT Modules.

The pressure gauges are filled with a glycerin type liquid, this is tominimize pointer vibration.


19/117


1.4 Safety and behaviour rules

Intended use

This system is use for drinking water processing.

Briefing

When operating this equipment certain parts are electrified. Ignorance of operating procedurecan cause death, injury or material damage. ANY WORK AT OR ON THE PLANT MUSTONLY BE DONE BY PERSONS TRAINED ON THE MACHINE AND FAMILIARIZED WITH

THE INFORMATION IN THIS MANUAL. REPAIR AND MAINTENANCE MUST ONLY BE

DONE BY APPROPRIATELY QUALIFIED TECHNICAL PERSONNEL.

Electrical endangerments

During the operation of electrical devices some sections are energized dangerous. Neglect thewarning notes can occur death, bodily injury, or damages to property. The cabinets and devicesare only to be opened by qualified personnel.

Mechanical endangerments

The system was designed in the state of the art. In order to ensure safe handling of the system,all preventive measures have to checked for effectiveness. The operator has to ensure byregular maintenance that the function of the respective protection devices will preserved.Detailed instructions, as far as necessary, can be found in the appropriate chapter.

Chemical endangerments

The operation of the unit and functions depending upon field of application different chemicals(e.g. cleaner, pH stabilizers, flocculant, disinfectant). The respective safety notes can be found inthe appropriate section.


20/117


2) OPERATING

2.1 CommissioningBefo re commis s ion ing the p lan t , p lease take no te o f the fo l low ing :

First, please read the safety remarks in th e first pages of this manu al!

LIMITS OF PERFORMANCE

Maximum flow rates Feed Water: 800 l/h

Permeate: Designed + 30%

Note:High feed flow will cause an unacceptablepressure loss across the PT modules and ahigher ampere loading on the HP pump motor

Operating pressure

Maximum operating pressure

65 bar

73 bar

Before first commissioning the plant the following checks must be made:

ASSEMBLY CHECKS BEFORE FIRST COMMISSIONINGControl cabinet

- Check voltage

- Check frequency

The voltage must be checked across each two phases:from L1 to L2

from L1 to L3

from L2 to L3

The plant must only be operated at the ratings it was designed for.

- Check control voltage Check transformer output voltage. For all PLC inputs, pressureswitches and level switches 24 V DC +/-5%. must be obtained.

PT Modules Check torque loading.

Pressure switchesPS150, PS170 and PS180

Check correct settings (for adjustment see chapter 4.5 in thesection for Maintenance, Cleaning and Calibration).

Flow meter Check setting of magnetic switch behind flow meter.


21/117


2.2 Starting the Unit

Lamp signals : l lamp on

? lamp flashing lamp off

Lamp signals when unit is shut-down:

Step

No.

Action Effect Lamp signal

1 Open all valves to and fromthe RO unit.

2 Open VK111 - Drain all water from cleaning tank.

3 Set valves to Normaloperation:

VK121 VK132 VK134 VK133 VK171

normaloperation

4 Turn master-switch to I(On).

- Conductivity display illuminated.

5 Press lamp button 1. - Motor control valve VS160 is open. ?

- When WS161 sends signal "valvecompletely open to the PLC, filterpump PK130 starts.

- High pressure pump PP160 starts300 seconds. after pressure switchPS150 has given start signal.

- Motor control valve VS160 runstowards close to bring up pressure.

- Pressure transmitter PT160 stops

pressure rise when maximumpressure or maximum permeate flowrate is reached. VE1801 sendspermeate into tank B111, sinceconductivity limit is exceeded.

- Conductivity of permeate drops belowallowed maximum. VE1801switches to permeate discharge, i.e.fresh water storage.

l


22/117


1st Sequence after pressing of START button and unit running. Permeate quality has not reached the set leveland made Permeate is being Dumped.


23/117


2nd Sequence, Permeate Conductivity has fallen below the set point and Permeate is now being sent toStorage.


24/117


2.3 Monitoring during Normal Operation

The following functions are continuously monitored:

Parameter Device Set values

Feed pressure pressure switch PS150 (min. pressure) 0,5 bar

Pressure at inlet to module pressure transmitter PT160 (max. pressure) 73 bar

Pressure of dischargedconcentrate

pressure switch PS170 (max. pressure) 6 bar

Pressure of delivered permeate pressure switch PS180 (max. pressure) 3 bar

Flow rate of permeate flow meter FIS 180 (nominal capacity), shut-down

delayed

1300 l/h

Conductivity of permeate conductivity sensor/meter CIT80 (max. value) 1000 S/cm (seawater) or 50S/cm (townmains water)

Amperage of electric motors motor circuit-breakers (see electricschematics andrating plates)

FUNCTIONS FOR MANUAL CONTROL

Lamp check:By pressing lamp button 5 all button lamps will illuminate. Replace any faulty lampimmediately.

FAILURE OF UNIT

In the event of an operating failure the plant is automatically stopped and a fault signal isdisplayed by the lamp buttons being illuminated in various sequences. Lamp button 5 flashes,the yellow lamp buttons 2,3 and 4 are either on or off in a certain combination indicating thecause of the failure.

A table of all fault signals is located at the front of the control cabinet. (Also refer to sectionFault Indication & Finding).

After correcting the problem the plant can be restarted after pressing lamp button 5 to clear thefault from the PLC.


25/117


2.4 Stopping the Unit



Lamp signal at unit shut-down:

Step

No.Action Effect Lamp signal

1 Close valve VK111. - To stop cleaning tank emptying l

2 Press lamp button 2

(STOP WITH RINSE)

- VE1801 changes over to fill tankB111 with permeate.

?l

- Tank B111 full LS1113 activated- Motor control valve opens to reduce

operating pressure.

- Unit stops. ?

3 Set valves as below: (to take suction from cleaning tank)

VK121 VK132 VK134 VK133 VK171

stop rinse

4 Press lamp button 1 - Rinse with permeate starts. l

- Low level switch LS1111 activated(tank empty). Unit stops.

5 To protect the unit for externalpressure fluctuations set thevalves as below

VK171

(delivery to cleaning tank)

VK121

(suction from cleaning tank)

Open valve VK111. Tank B111 is drained.

Note:

If a stand-still of more than 10 days is intended, a preservation must be carried out prior

to shut down. This is to prevent bacterial fouling on the membranes.


26/117


1st Sequence after pressing of STOP/RINSE button. Solenoid Valves VE1801/2 change over to fill tank B111with permeate.


27/117


2nd Sequence after pressing of STOP/RINSE button. Centrifugal Pump PK130 sucking permeate fromcleaning tank to rinse the Unit.


28/117


2.5 Sandfilter Backwash

A sandfilter backwash is necessary, when the pressure loss across the sandfilter due tosedimentation exceeds 2 or - as a maximum - 2.5 bar.

Note: Unit must be stopped to start this procedure




How to carry out a sandfilter backwash:

Step

No.Action Effect Lamp

signal

Unit is stopped 1 Close VK111, if open. (to stop draining of cleaning tank B111)

2 Press lamp button 4(SANDFILTER BACKWASH).

?

3 Set valves for air rinse:

VK121 VK132 VK134 VK133 VK171

sandfilterbackwash- air rinse -

4 Air treatment:Connect air supplyto connecting branch VF139.

5 Open VK136 and flush sandfilterfor 10 min. with air (max. pressure0.5 bar)

If unsure about the low air pressure, Put your earagainst the sand filter and listen. When air isheard Bubbling stop increasing the air pressure.

6 Disconnect air supply atconnecting branch VF139.

7 Open valve VK121: to sea suction

8 Close valve VK136

9 Water treatment: Press lamp-button 1 (START)

Filter pump PK130 starts. Sandfilter is rinsedwith raw water. Raw water passes the sandfilterand flows through brine outlet back to sea.

Unit stops automatically.

l

10 After approx. 10 to 15 min. ofwater rinse press STOP/RINSE.

Unit is rinsed with water and stops afterwards.


29/117


1st Sequence after pressing of SFB button.Air-Rinse


30/117


2nd Sequence after pressing of SFB button.Water-Rinse


31/117


2.6 Circuit Cleaning

Organic and inorganic substances within the feed water are deposited on the membranesurfaces (described as Fouling and Scaling). This causes an increased salt content in the

permeate and a reduction in the fresh water production. By circuit cleaning thesesedimentations are flushed off and removed.

A circuit cleaning is required, when the fresh water production has dropped by 10 to 15% (equalwater temperature assumed). Generally, it should be carried out every 3 to 4 weeks.

CHOICE OF CLEANER:

The ROCHEM cleaning solutions are specially formulated and made for the membranes

used in our PT modules. Use of other chemicals can cause damage and loss in

performance. The membranes can be damaged by oxidizing agents (e.g. free chlorine, Cl2,ozone O3). In the sea water these contents are normally neutralized by other existing organicsubstances. Oxidizing agents are sometimes used in sea water pipe systems, to avoid foulingand kill bacteriums.

Cleaner Application

Type AA For organic sedimentation and fouling

Type C To remove iron fouling.

For normal cleaning cleaner AA would be used.

It is recommended that C is used every 4 months to remove iron deposits. These would comefrom the sea water and also from pipe lines, suction chest and vessels hull.

If the type of deposits / fouling is not known, all cleaners C and AA should be used consecutively.Run the unit for a minimum of 3 hours between cleanings to check results.

Maximum concentration of cleaner: 5 liters of cleaner per 100 liters of water (which correspondsto 5 liters of cleaner per cleaning cycle for this unit).

CAUTION:

F NEVER MIX DIFFERENT CLEANERS!If done, this will only neutralize the cleaning solution and the cleaning results will beminimal.This can also damage the membrane surfaces.


32/117


F Never pass any external water (e.g. distilled, chlorinated or de-ionized water)into the RO unit. This would cause damage to the membranes by osmosis.

FThe feed water temperature should not exceed 30C.

F When using 2 cleaners, to be fully effective they must be used in the followingsequence:1st Cleaner C (acidic cleaner).

2nd Cleaner AA (alkaline cleaner).

Acidic cleaner should always be used before the alkaline cleaner. This removes

the deposits nearest the membrane surface making it easier for the alkaline

cleaner to remove the organic deposits.

F Never disassemble the membrane modules for cleaning the membrane cushionsby hand or other soft equipment which will in any way affect the membrane layersurface and the membrane material will lose its salt rejection ability.

STARTING THE CLEANING PROCESS

The cleaning can only be init iated from normal operating m ode.




Step


signal

1 Close valve VK111. - To stop cleaning tank draining l

2 Press lamp button 3(CIRCUIT CLEANING).

- Magnetic valve VE1801 switches overand allows the permeate to be delivered

into tank B111, until level switch LS1113is actuated. ?ll

- Motor control valve VS160 runs open.

- Operating pressure drops.

- Switch WS161 is made, when VS160 hascompletely opened.

- Pumps PK130 and PP160 are stopped. ?


33/117


3 Set valves for Circuit Cleaning: (for closed circuit operation)

VK121 VK132 VK134 VK133 VK171

circuit cleaning

4 Open VK111 for a moment toget space for cleaner.

Put injector hose into the canwith 7.5 liters of cleaner andopen valve V111 to allow thecleaner to be sucked in.(Make sure only 7.5 liters ofcleaner are sucked in.)

- Cleaning agent ?

5 Press lamp button 1(START).

- Pumps PK130 and PP160 start. l

Close V111 when container isempty.

- Cleaner and permeate are being mixed,pumps run intermittently (each 5 min.operation followed by 5 min. Stop).Cleaning cycle time: approximately 2 hrs.

6 Cleaning completed - Unit stops (approx. after 2 hours).

7 Open VK111 to draining Tank

B111

For the first start after cleaning the unit is programmed to rinse with rawwater. First the plant is flushed for 5 minutes without pressure increasing,then for another 5 minutes under pressure. During this time the permeateproduced is not supplied to the fresh water storage, this is to avoid thepossibility of any chemicals being in the permeate.

??

CAUTION:

F After every cleaning cycle the cartridge filter elements must be replaced.


34/117


RO CLEANER AA

a.) Safety marks for the employer

Sodium hydroxide solution, 2-5 %

Hazards for human health and the environmentBreathing in and swallowing may result in health damage. Causes burns. Can cause bronchitis.

Add to water when diluting, never the other way round. Reacts with acids under the formation of heat, risk of splashing!Forms hazardous vapours with ammonium compounds and light metals (hydrogen Danger of Explosion!).Hazardous to water - avoid ingress into the ground, water and sewage!

Protective measures and behaviour rulesWork with good ventilation! Open seals cautiously! Do not leave vessels open! Limit stored quantities toone shift requirement! Avoid contact with eyes, skin and clothing!

Preventive skin protection necessary. Remove product residues from the hands immediately!Thoroughly clean hands after completing work and before every work break! Avoid splashes!Use skin care agent! Immediately change wetted clothing! Change clothing after completing work!Store street clothing separately from work clothing! Observe restrictions on activity!Eye protection: Full protection goggles! If there is a risk of being sprayed: wear a face guard as well aseye shields.Hand protection: Gloves made of: Natural rubber, Polychloroprene, Nitrile rubber, Butyl rubber,Flourinated rubber It is advisable to wear cotton gloves underneath protective gloves.

Breathing protection: particulate filter. P2 (white)Skin protection: Use skin protection ointment containing grease for all uncovered parts of the body.:

Body protection:Alkali-resistant protective clothing! When dilut ing or filling: plastic apron!

Behaviour in danger situationsCollect and dispose of with absorbent non-combustible material (e.g. kieselguhr, sand)! Caution! Spilt solution presentsrisk of slipping (by iwater contact)!Product is not combustible. Only fight fires with breathing apparatus independent of ambient air and Responsiblephysician or clinic:

Accident phone:

First AidDuring all First Aid assistance: protect yourself and immediately inform a doctor.After eye contact: Rinse for 10 minutes with water or with eye-wash solution.After skin contact: Take off soiled clothing immediately. Clean with abundant amounts of water and

soap. Rinse with water for 15 minutes after burns.After breathing in: Fresh air. Keep airways clear: remove false teeth, vomit etc.. If breathing orheartbeat stops: immediately apply artificial respiration and heart massage.After swallowing: No domestic agents. Do not cause vomiting. If conscious, see that plenty of water isdrunk a little at a time.First Aid specialist:

Proper disposalDo not pour into the sewage or a refuse bin!For disposal, collect in:

_____________________________Signature of the employer


35/117


RO CLEANER C

a.) Safety marks for the employee

Citric acid, 10-30 %

Hazards for human health and the environmentBreathing in, swallowing or absorption through the skin may result in health damage. Causes burns.Temporary complaints (cough) are possible. Can cause laboured breathing, eye damage.

Add to water when dilut ing, never the other way round. Reacts with alkalis under the formation of heat, risk of splashing!Hazardous to water - avoid ingress into the ground, water and sewage!

Protective measures and behaviour rulesEnsure a fresh air supply when working! In the event of vapours, work only with exhaust ventilation!

Keep away from ignition sources! Do not smoke! No naked lights! Do not leave vessels open!Avoid splashes! Limit stored quantities to one shif t requirement! Avoid contact with eyes, skin andclothing! Preventive skin protection necessary. Use skin care agent!Thoroughly clean hands after completing work and before every work break! Store street clothingseparately from work clothing! Immediately change wetted clothing! Observe restrictions on activity!Eye protection: Full protection goggles!Hand protection: Gloves made of: Butyl rubberIt is advisable to wear cotton gloves underneath protective gloves.

Breathing protection: partikular filter P2 (withe)Skin protection: Use skin protection ointment containing grease for all uncovered parts of the body.:

Body protection: When diluting or filling: plastic apron! Spray processes: protection suits!

Behaviour in danger situationsRemove only after applying personal safety equipment! Clean objects and flooring which have become wetted orsoiled immediately with plenty of water! Collect and dispose of with acid-binding material (e.g. limestone meal) andrinse remainders away with water!Product is combustible, suitable extinguishing agents: water in a jet, carbon dioxide, extinguishing powder, foam! In theevent of a fire in the environment, cool the receptacle with sprayed water! Explosive mixtures can be generated if stronglyheated!Responsible physician or clinic:

Accident phone:

First AidDuring all First Aid assistance: protect yourself and immediately inform a doctor.After eye contact: Rinse for 10 minutes with water or with eye-wash solution.After skin contact: Take off soiled clothing immediately. Rinse with water for 15 minutes after burns.After breathing in: Fresh air. Keep airways clear: remove false teeth, vomit etc.. If breathing orheartbeat stops: immediately apply artificial respiration and heart massage.After swallowing: Do not cause vomiting. If conscious, see that plenty of water is drunk a little at a time.No domestic agents.First Aid specialist:


_____________________________Signature of the employer


36/117


1st Sequence after pressing of CLEAN button. Solenoid Valves VE1801/2 change over to fill tank B111 withpermeate.


37/117


2nd Sequence after pressing of CLEAN button. Cleaner is sucked into cleaning tank B111.


38/117


3rd Sequence after pressing of CLEAN button. Unit is now running in Closed Circuit Cleaning Mode.


39/117


2.7 Preservation

To prevent fouling during a stand-still of more than 10 days, the unit must be preserved.




Step


signal

1 Close valve VK111 To stop cleaning tank draining l

2 Press lamp button 3 (CIRCUITCLEANING).

- Solenoid valves VE1801/2 switch overand send permeate to tank B111.

?ll

- Tank full level switch LS1113 activated

- Motor control valve VS160 runs open.

- Operating pressure drops.

- Switch WS161 is made, when VS160 hascompletely opened.

- Pumps PK130 and PP160 are stopped. ?

3 Set valves for Preservation: (for closed circuit operation)

VK121 VK132 VK134 VK133 VK171

circuit cleaning

4 Open VK111 for a moment toget space for biocide.

Put injector hose into the canwith 5 liters of biocide(ROCIDE) and open valveV111 to allow the biocide to be

sucked in. (Make sure only 5liters of biocide are sucked in.)

- Preserve agent ?

5 Press lamp button 1 (START). - Pumps PK130 and PP160 start. lClose V111 when container isempty.

- Preserve solution is mixed with permeate.

- Unit stops after approx. 2 hours.


40/117


Note: A suffic ient circu lation o f the preserve solution has already been

reached after 30 min . , the process c an now be aborted:

6 Press lamp button 2 (STOP).

7 Open VK111 to empty tankB111. Preserve solution passes through thedischarge line.

8 Turn off master-switch.

For the first start after Preservation the unit is programmed to rinse with rawwater. First the plant is flushed for 5 minutes without pressure increasing,then for another 5 minutes under pressure. During this time the permeateproduced is not supplied to the fresh water storage, this is to avoid thepossibility of any chemicals being in the permeate.

??

CAUTION:


The unit is now ready for normal operation.


41/117


RO Membrane Biocide (ROCIDE)

a.) Safety marks for the employee

Sodiumbisulfit

Hazards for human health and the environment

Breathing in and swallowing may result in health damage.Irritating (respiratory tract, eyes, skin, organs of digestion).Eye damage possible.Hazardous to water - avoid ingress into the ground, water and sewage!

Protective measures and behaviour rules

Avoid dust development! Avoid contact with eyes, skin and clothing!Thoroughly clean hands after completing work and before every work break!Use skin care agent! Immediately change wetted clothing!Eye protection: Full protection goggles!Hand protection: Gloves made of: Natural rubber, Polychloroprene, Nitrile rubber, Butyl rubber,Flourinated rubberIt is advisable to wear cotton gloves underneath protective gloves.

Breathing protection: particulate filter. P2 (white)Skin protection: Use skin protection ointment containing grease for all uncovered parts of the body.:

Behaviour in danger situations

Collect and dispose of, avoiding dust in the process! Product is not combustible.In the event of a fire in the environment, cool the receptacle with sprayed water! Hazardous vapours are produced underthe influence of heat!Responsible physician or clinic:

Accident phone:

First Aid

During all First Aid assistance: protect yourself and immediately inform a doctor.

After eye contact: Rinse for 10 minutes with water or with eye-wash solution.After skin contact: Take off soiled clothing immediately. Clean with abundant amounts of water.After breathing in: Fresh air. Keep airways clear: remove false teeth, vomit etc..After swallowing: Do not cause vomiting. If conscious, see that plenty of water is drunk a little at a time.No domestic agents.First Aid specialist:


_____________________________

Signature of the employer


42/117


1st Sequence after pressing of CLEAN button. Solenoid Valves VE1801/2 change over to fill tank B111 withpermeate.


43/117


2nd Sequence after pressing of CLEAN button. Biocide is filled into cleaning tank B111.


44/117


3rd Sequence after pressing of CLEAN button. Unit is now running in Closed Circuit Cleaning Mode.


45/117


2.8 Disinfection

If the permeate should be found contaminated of bacteriums, or generally after a longer stand-still without a prior preservation), a disinfection should be carried out.

Lamp signals : l lamp on? lamp flashing lamp off


Step


signal

Unit is running in normal operating mode. l

1 (to stop draining of cleaning tank B111)

2 Press lamp button 3 (CIRCUITCLEANING). Solenoid valves VE1801/2 switch over andsend permeate to tank B111. ?ll

Tank full level switch LS1113 activated

Motor control valve VS160 runs open toreduce operating pressure.

Switch WS161 is made, when VS160 hascompletely opened.

Pumps PK130 and PP160 are stopped. ?

3 Set valves for Disinfection: For closed circuit operationVK121 VK132 VK134 VK133 VK171

circuit cleaning

4 Open VK111 for a moment toget space for biocide.

Put injector hose into the canwith 5 liters of biocide

(ROCIDE) and open valveV111 to allow the biocide to besucked in. (Make sure only 5liters of biocide are sucked in.)

- Disinfect agent ?

5 Press lamp button 1 (START).

Close V111 when container isempty.

Pumps PK130 and PP160 start. Membranebiocide is sucked in and mixed withpermeate.

l

Unit stops after approx. 2 hours.

6 Open VK111. (to empty tank B111)


46/117


For re-start:

8 After approx. 10 hours turnvalves back to NormalOperation:

VK121 VK132 VK134 VK133 VK171

normal operation

9 Press lamp button 1 (START).

For the first start after disinfectionthe unit is programmed to rinse with rawwater. First the plant is flushed for 5 minutes without pressure increasing,then for another 5 minutes under pressure. During this time the permeateproduced is not supplied to the fresh water storage, this is to avoid thepossibility of any chemicals being in the permeate.

??

CAUTION:


The unit is now ready for normal operation.


47/117


3) FAULT INDICATION & FINDING3.1 Error Codes, Implication and Faults

Fault conditions are indicated by lamp buttons 2 to 5 (lamp button 1 is off).A plate describing all fault displays is located on the front of the machine.




Lamp signal Device Meaning Possible causes

LAMP SIGNALS A: RED LAMP BUTTON IS ILLUMINATED PERMANENTLY

1 2 3 4 5

ll PS150 Feed pressure before PP160 too low - Insufficient feed supply- pre filters / strum box blocked- external pump required- VK121 not in correct position- pump PK130 defective- pressure loss in cartridge filter too high- pressure switch PS150 defective- connection to processor defective

ll PS180 Pressure in permeate line too high - permeate line to external tank not open- excessive back pressure on discharge- deacidification filter blocked- wrong flow direction in deacidification

filter (correct: from top to bottom)- pressure switch PS180 defective- connection to processor defective

lll I Electric motor load too high - Circuit-breaker not properly adjusted- connection to processor defective- circuit-breaker defective

motor malfunctioning due to...- damage to bearings- short circuit- ambient temperature too high- insufficient cooling

- voltage or frequency wrong- phase broken

ll VS160 Motor control valve closed duringoperation

- Pipe damaged in high-pressure section- to high resistance in VS160, valve gland

packing too tight- corrosion, damage spindle/seat in VS160- limit switch WS162 defective- high pressure pump drive belts not

correct- damaged / worn packing in high

pressure pump.- PT module damaged


48/117


lll PI160PT160

Over pressure in PT module - PT160 does not stop pressure rise- VS160 does not open- relay output to VS160 defective- set value at PT160 wrong- PT160 damaged

- connection to processor defective

lll PS170 Over pressure in concentrate line - Discharge line valves not open- VK171 in wrong position during operation- PS170 defective- connection to processor defective

llll CS180 Permeate conductivity too high - Module dirty(circuit cleaning required!)

- torque on module not correct- sealing or membrane in module

damaged

- operating pressure too low- feed water conductivity extremely high- feed water temperature above 35C- magnetic switch on CIT180 defective- CIT180 not properly adjusted- connection to processor defective

LAMP SIGNALS B: RED LAMP BUTTON FLASHES

1 2 3 4 5

l? LS1111 Level switch LS1111: Tank empty

l? UP Subroutine stopped

ll? Reserved

ll? VS160 Motor control valve malfunctioning - high resistance in VS60 valve spindledue to gland packing

- corrosion damage in VS60- limit switch WS161 defective- limit switch WS162 defective- connection to processor defective

ll? FT180 Permeate flow rate too high - PT Module malfunction due to internalleakages (sealing or membranedamaged)

- floating indicator jammed or damaged(corrosion)

- operating pressure too high- low salinity feed water

ll? RF001 (Reserved)

lll? LS1113 Max. filling time B111 exceeded - too long filling time B111- drain valve VK111 open- LS1113 defective- connection to processor defective


49/117


3.2 Faults without Lamp Indication

Lamp signal Device Meaning Possible causes

FAILURES WITHOUT FAULT INDICATION

Plant cannot be started - Check energy supply and fuses- processor out of order

High-pressure generation failed - set value on PT160 wrong- permeate flow rate too high- no signal from PT160 to processor, e.g.

due to defective cableExcessive pressure fluctuation duringoperation

- pulsation damper gas pressure wrong.Correct pressure (if possible) or replacepulsation damper

- valves in HP pump worn or damaged

PP160 valves malfunctioning - normal wear- particles between valve plate and valveseat. Dismantle valve and check.Replace, if necessary


50/117


4 ) MAINTENANCE, CLEANING &

CALIBRATIONIn order to maximize availability the unit must be maintained regularly. Checks and maintenanceworks should be carried out according to the tables below. Detailed instructions, as far asnecessary, can be found in the following chapters.

The check list at the end of this manual should be filled in daily. This assists to detect failuressooner and easier.

4.1 Schedule for Checks & Maintenance Works

REGULAR CHECKS

Frequency Action

daily - visually inspect all sections for leakages

- check if motors or pumps make unusual noises

- check oil levels (pump motors and compressors, if installed)

- check pressure losses across cartridge filters and modules

- fill in log sheet

monthly - check calibration of conductivity meters by comparing with readings taken with

a manual measurement

- check and update stock of spares and consumables- visually check all safety devices, such as overfill couplings

half-yearly - check contactors for lose screws or wires

biannual -. Change PLC-battery


51/117


MAINTENANCE REQUIREMENTS OF UNIT AND COMPONENTS

Device Designation on

P&I diagram

Required action Recommended

frequency

Chapter

Electric motors (for plunger pumpPP160)

replace bearings after approx. 20,000operating hours

4.4

Cartridge filter FC140 replace filter elements as required 4.9

PT module FM160 replace membranes (only if necessary) 4.11

circuit cleaning every 500 operatinghours or earlier, ifrequired

2.5

check torque 150 hours aftercommissioning, thenmonthly

4.11

Plunger pump PP160 check plungers, pumpingsection and crankshaftsection

every 3,000 operatinghours

4.8

check valves and seals,replace as necessary

every 3,000 operatinghours

4.8

check belt tension weekly

check oil level, top up ifnecessary

weekly 4.8

replace oil filling 50 hours after firstcommissioning, thenevery 750 operating

hours or monthly

4.8

Pulsationdamper

SP160 replace if necessary 4.13

check gas pressure annually


52/117


4.2 PLC

This component can only be serviced by a ROCHEM engineer and the following is given foremergency use only except that the battery must be changed every 24 months. The inside doorof the control panel should have a sticker giving the date of last battery change. The battery isPart No. 20417, it is a AA 2.6 volt Lithium battery.

Modicon TSX Micro Processor

Analogue Converter Function display Digital input card 1/2

24V Input. Battery Compartment, Digital outputCard 4

Battery ChangingThe power supply must be on before removal of the battery.

Photographs are taken looking up andunder the battery compartment.

1 Press in and down to release theBattery compartment.

2 Battery compartment open.

3 Remove old battery and fit newBattery, ensure that the polarities are correct.Close Battery compartment.

+_


53/117


The instructions given on the next two pages are for basic information only.ROCHEM MUST be consulted before any of the following replacements or

removals are made.

Analogue Converter

The analogue converter changes the 0 - 20ma inputs to 0 10VDC inputs. Shouldthis Converter fail and in an emergency have to be replaced by Ships Personnel the following

procedure given below must be carried out:

Power Supply MUST be switched off when carrying Out This Operation.

Removal of Analogue Converter

1 Remove Multi-pin Plug with screwdriver.2 Plug removed.3 With screwdriver loosen the 2 securing screws.4 Remove the converter.

Fitting of New Analogue Converter

The new Analogue Converter MUST have all switch setting madeBefore fitting. Switch sets C1, C2, C3 and C4 to be set.

All switches to be set as shown below.

C1 Switches setat 0

C2 Switches set at 1



A After setting all switches refit as inphoto 4.

B Secure the Analogue Converter withthe 2 screws shown in photo 3.

C Fit the Multi-pin plug and secure withthe 2 screws. Photos 2 and 1.


54/117


Processor Card Replacement

The Modicon TSX Micro Processor is fitted with

2 sizes of cards.1 1 off Large Type: TSX DEZ32D22 1 off Small Type: TSX DSZ08R5

The following information on card removaland replacement is again for emergency use.

1 2Removal is shown for Type DEZ32D2 card, the process of removing Type DSZ08R5 cards isthe same. Do not remove any wires from the Terminal Blocks.

1 Remove top screw. 2 Remove bottom screw 3 Lift off terminal block

4 Pull up lever card 5 Lift out card carefully 6 Type DEZ32D2

7 Re-fit new card block 8 Push down securing lever 9 Re-fit terminal

10 Secure bottom screw.

11 Secure top screw


55/117


Processor Function Display

BASE EXT. WRD. Diag. Diagnostic RunLED LED LED LED Button LED

TER. LED

I/O LED

ERR.LED

BAT.LED

Input OutputSignals Signals

Descriptive Function Of Parts Shown Above

ITEM FunctionInput Signals Card 1, Digital Input signals.Output Signals Cards 2 Digital Output signals.BASE LED Alight when power is on.EXT. LED Not used.WRD. LED Not used.DIAG. LED Not used.TER. LED Communicating signal between unit and programming PC .I/O LED Analogue error.ERR. LED Corrupted program.BAT. LED Battery requires replacement.RUN. LED Alight when unit is runningDIAG. Button Do not touch this button only for programming use.

LED Alight

LED Flickering

LED Flashing


56/117


4.3 Contactors

Maintenance requires qualified personnel

ACCESSONLY BY ELECTRICIAN

The control cabinet contains the PLC unit and allwiring and electrical components.

Due to thermal load upon the contactors, thescrews that tighten the wires could becomeloose after some time.

Step

No.Action

1 Turn off master-switch.

2 Check, if necessary re-tighten, screws L1, L2, L3 and T1, T2, T3 with a suitablescrewdriver.


57/117


4.4 Electric Motor Art. 11280

After about 20,000 operating hours, but no later than after 4 years, the roller-bearings should bechecked and, if necessary, replaced. The type of bearings fitted do not allow for cleaning or re-greasing.

1 stator feet

2 rotor

3 end shield drive end

4 flanged end shield drive end

5 end-shield, non-drive end

6 V-ring drive end

7 bearing, outer cap

8 grease thrower

9 roller-bearing DIN 625

10 bearing, inner cap

11 V-ring non-drive end

12 bearing, outer cap

13 grease thrower14 roller-bearing DIN 625

15 bearing, inner cap

16 external fan

17/18 external fan sing (sheet steel)

19 terminal board (according to DIN)

20 terminal plate with insulators

21 protective cable bushing for flameproof

motor (stud terminal)

22 terminal clamp for ex motors

23 gland cover

24 terminal box

25 terminal box, bottom part

26 terminal box lid

27 entry section (A or B)

28 single-entry sealing chamber (E)29 double-entry sealing chamber (F)

30 compression gland

Please notice:

These parts have no part numbers. For part orders, please state

designation (pos. from above drawing) for three-phase motor [motor part number as from parts list]

Example: bearing, outer cap - (Pos. 7) for three-phase -motor 11280


58/117


4.5 Pressure SwitchArt. 12218

The pressure switches are fitted for safe operation of theunit, to avoid any unnecessary damage. They will stop theunit when certain pre determined pressures are notprevailing. These are fitted within the system at criticallocations.

Electrically connected as an opener or as a closer.

The switching points of the pressure switches shouldregularly be checked and re-adjusted, if necessary.

Pressure switch Function Switching value Connection

PS150 protects pump PP160 from cavitation 0,5bar closerPS170 protects concentrate pipe system from

over pressure6 bar opener

PS180 protects permeate pipe system from overpressure

3 bar opener

Adjusting the Switching Value:

1 stress relief device

2 adjusting screw for scale

3 red pointer for upper pressure

4 green pointer for lower pressure

5 adjusting screw for green pointer

Step

No.Action

1 Remove cover from pressure switch.

2 By turning screw 2 the scale is moved up or down. This sets the switching value.

3 Adjust screw 5 in such a way that the green pointer is level with the red pointer.


59/117


4.6 Pressure Transmitter Art. 20480

The pressure transmitter measures the operating pressure before themodule and passes it as a 4 to 20 mA signal on to the PLC. At apressure of 0 bar it will give a 4 mA signal, at 100 bar a 20 mA signal.

Between these limits pressures and output signals are proportional.If the transmitter does not function as described above, it is defectiveand needs replacement.


60/117


4.7 Conductivity Meter (Part No.: 20321/20322/20686)

Meters: CIS 180

Type LF 1010-3-2R-5-00s/cm

Conductivity MeterPart No.20321

Conductivity ProbePart No.20322

Sensor Cable

Part No.20686

Meter FeaturesProtection IP65. 14.2mm LED dis play. Indicating range 2000(0) digit.Measuring range programmable from 02.000S/cm up to 02000mS/cm.

This meter has been designed for the measurement of conductivity, as a degree of the purityor concentration of a liquid. In connection with 4-electrode conductivity cells a high accuracyand intensitivity of contaminations can be achieved..

Sensor Cable

8 pole stainless steel 1.4571socket, PVC cable, IP67, 2m long.

Conductivity Probe

4- Electrode Conductivity cell. Probe includes cap nut (G1").

Lid Opened


61/117


Connection Diagram


62/117


Controls and Indicators

DescriptionOperating of the device is arranged in 2 levels. The requested parameter can be called by button.Selection within a parameter or entering data, use buttons and . Parameters are stored zero-voltagesafe in the EEPROM.After switching on the supply voltage, the device initializes itself. The display shows the message I n i t .After the initializing procedure the device is working in the Working level. Set points of the alarm outputscan be pre-selected if available.Activating the button for more than 2 seconds, the program is jumping into the Configuration level.Now all the parameters defining the function of the device can be programmed.After finishing the configuration or when longer than 2 minutes no button was pushed, the program jumpsback to the working level. Leaving the configuration level is possible at any time when pushing the buttonfor 2 seconds.Error codes:

Display If the input signal is more than 3% outside of the programmed measurement range theflashes A/D- converter is over driven and the display flashes with appr. 1Hz

E r r o r1 EEPROM test. Reading this message, a program error has been occurred. When pushingthe button a copy of the EEPROM will be reloaded and the device will work with thefactory settings. If this copy does not work, please ship the device to factory for repairservice.

Lo c Program lockout. See configuration page.Start-up note:

Before the device can be used, it must be configured for the intended


63/117


Notes to representation

Parameter is only displayed when configured

Parameter is only displayed when feature is included (see order code)

Please note: All parameters can be called if they are not blocked by other programmed parametersand if they are available. Factory settings are shown in [ ] .

Working LevelButton Display Description

Actual process value conductivity

Output indication

(only if installed and activated).

Actual process value temperature


64/117


Configuration LevelButton Display Description (displayed values are factory setting)


65/117


Button Display Description (displayed values are factory setting)


66/117


End of configuration.

The actual values and alarm outputs are displayed again

Checking the accuracy of Display

A portable hand conductivity meter similar to ROCHEM part No.12339 should be used to checkthe functioning of the meter and probe.Obtain a sample of water (not sea water), immerse both the probes of the unit and hand meter.Recheck with another water sample with a different conductivity.

Service:The display should be checked as described above every 6 months.If unable to recalibrate the meter then the most likely cause of this fault would be the conductivity

probe and this should be replaced before replacing the conductivity meter.

Service:Every 3 months remove the probe and clean with a little detergent and a soft bottle brush. Donot use abrasives on this probe.


67/117


4.8 Filter Pump PK130 Part No. 21092

This pump is fitted with Victaulic couplings as shown.Care must be taken when fitting the seal. Ensure that the lips of the seal are not pushed overas they must fit over and seal on the machined spigot.

CRT4 5. Vertical Multistage Centrifugal PumpThis pump is virtually maintenance free because of the materials used in its construction. If themechanical seal leaks it should be replaced as soon as possible. The motor is a totallyenclosed, fan-cooled, 2-pole Grundfos standard motor with principal dimensions inaccordancewith the IEC and DIN standards.Electrical tolerances according to IEC 34/EN 60034.

This pump is used to boost the seawater through the sand and cartridge filters and to activatepressure switch PS150.If this pressure switch is not activated by 0,5bar pressure, the unit will not start.

When ordering spare parts. The following details must be given:Pump Serial Number + quantity and part that may be required given in the drawings shown inthe dismantling and assembling instructions

Exam le CRT4-5 Serial No.85805906 1off Part No. 37.

The pump should be checked regularly for air that may be trapped in the upper chamber of thepump. In normal operation this will not be a problem but in rough seas there could be aconsiderable amount of air entrapped in the feed water.


68/117


Shaft Seal kit No. 21143Pos. Description AUUE

37 O-Ring 137.5 x 3.3 2105 Shaft seal 1


69/117



70/117


The pump in the photo on the 1stpage is the pump fitted to your RO unit.The pump shown in the service dismantling / assembly section has a different base otherwise it isthe same pump.

Dismantling Sequence

1 2 3

4 5 6


71/117


Assembly7 8

9

10

11 12 13


72/117


Assembly14 15

16

17

Replacement

Seal Kit.

Part Number:

Seal kit comprises ofthe parts shown

alongside. (Add. 2 O-Rings Pos. 37)

When pump is re-installed and the RO unitis started for the 1sttimeafter removal. The pumpmust be purged of air.

Use the air release valveTo remove air from thepump. Do not overtighten as this coulddamage the valve seat.It is preferred that itshould only be handtight.


73/117


4.9 Plunger Pump Art. 12746

Type 3537

Part No.12746 is for this pump complete but without pulley and any additional fittings to thepump manifold.

This pump is fitted with a Nickel Aluminum Bronze manifold. The other parts used in this pumpare made from quality materials. When replacing any components use only original specifiedparts otherwise damage can be caused.

PUMP MUST NEVER BE RUN DRY

Any leakage from the pump and or pump connections must be attended to immediately.

LUBRICATION CrankcaseOnly use SAE 15W40 oil. (engine oil).The volume of oil required to fill the crankcase to the correct level is 4 liters.Correct oil level can only be seen when pump is stopped. Correct oil level is when level is acrosscenter of center dot on bubble gauge at back of pump. (Position A below).

OIL ChangingAfter the 1st 500 running hours drain crankcase, flush out with half liter of fresh oil and refill. Every5,000 running hours change oil as described above.

Check oil level daily and top up if required.Do not allow the breather hole on the oil fillercap to be blocked. (Position B).

ROTATIONIf the pump has been disconnected for any reason,before restarting the unit check that the pumprotation is correct before running the unit.

Correct rotation is shown here.

WARNINGThe oil bath crankcase assures optimumlubrication onlywhen pump rotates in the correct

direction.


74/117


Type 3537 High Pressure Pump

Access to PumpPower to the RO plant must be switched off before opening the front

panel.

Remove the 4 x 8mmand 2 x 10mm Cap Screws (using 8 & 10mm hexagonal

keys) from the Front Panel and lift off panel,

Remove the 2 x 12mm bolts

(2 x 19mm spanners)

Pull out the Pump Unit by pulling evenly on the pump pulley and base of the safety valve.

? Pum ulled out for Service


75/117


Oil filling Cap (unscrews)

Oil drain valveOil level sight glass, correct oil level to be in middle of sight glass when pump is stopped


76/117


High Pressure Pump. Type 3537

Adjusting Belt Tension

Belt Deflection Force: 3.8 to 5 lbs. Belt Deflection:

Notes: 1 - The best tension for a V-belt drive is the lowest tension at which the belts will not slip.2 - Check the tension frequently during the 1stday of operation after fitting new belts.3 - Too much tension shortens belt and bearing life,

4 - Keep belts and sheaves free of any foreign material that may cause the belts to slip.

Unlock the lock nuts before attempting to adjust the belt tension. Secure these lock nuts after belts have been

tensioned and correctly aligned.Motor adjusting screws. Lock nuts

Pulley Removal

Checking Tensions of Drive Belts

Use a belt tension device to checkthe tension on the belts.After the correct tension has beenobtained ensure that the pulleysare aligned correctly. Bothoutside faces of the pulleys have tobe 100% in line with each other.

Pump Pulley:Remove the 3 Allen grub screws as shownInsert 2 of the screws into the 2 empty holes andscrew in each screw 1 turn alternately.The pulley will be pushed off the Taperlock bush towards the pump.Remove the 2 screws. When the pulley is loose the Taperlockbush will open. The Taperlock bush can now be removed bypushing off from the shaft.

Motor Pulley:Remove the 2 Allen grub screws as shown

Insert 1 screw into the empty hole and screw homeThe pulley will be pushed off the Taperlock bush towards the pump.Remove the screw. When the pulley is loose the Taperlock bushwill open. The Taperlock bush can now be removed by pushing off

Refitting of Pulleys and Belts: Refit the pulleys in reverse order ( pulley on before taper bush). Ensurethat the screw holes in the pulleys are aligned before pulling together with screws. Fit the 2 middle belts

first. Belts to be tensioned and aligned. Align pulleys by using a strait edge to check that the outerfaces of both pulleys have full surface contact with the :staight edge.

NOTE: If this pulley alignment is not carried out then the belts will wear very quickly.


77/117



Drive Assembly

1- Motor 2 Back bearingPart of motor Item 1

3 Front bearingPart of motor Item 1

4 Shaft KeyDIN 6885-A 10x8x100mm

5 TAPERLOCK pulley 6 TAPERLOCK bush 7 Hex. Socket grub screwflat point (2) 7/16 x 1.875

8 V-belt (5 belts)

9 Hex. Socket grub screwflat point (3) DIN913 M12 x 35

10 TAPERLOCK bush 11 TAPERLOCK Pulley 12 Shaft KeyDIN 6885-A. 10x8x70mm

Pump Details

1- Die cast aluminum crankcase for strength and light weight. 2- Oversized crankshaft bearings for extended life.3- Chrome-moly crankshaft for strength and long life. 4- Oversized connecting rods for strength.5-Special stainless steel plunger rods for strength. 6- Stainless steel slinger provides back up protection for

crankcase seal keeping pumped fluids out ofcrankcase.

7- Abrasion resistant ceramic plungers for extended seallife

8- Nickel aluminum bronze manifolds for continuous duty

9- 100% wet seal design increases service life by allowingpumped fluid to cool and lubricate both sides.

10- Special stainless steel valves, seats and springsprovides corrosion resistance and long life.

11- Special V-Packings for performance and seal life. 12- Crossheads are 360 supported for alignment.


78/117



Cathodic Protection

Fitted to this pump is a sacrificial anode to protect the pump head from corrosion i.e. (electrolytic action causedby different metals).The anode is fitted in the hexagonal plug in the top of the pump as shown below. This anode must be checkedevery 3 months and replaced when necessary. Use the socket for the DT modules to remove the plug BUT do notuse the DT module torque spanner as it may be damaged. Use PTFE tape as thread sealant when securing backinto the pump.

Ensure that all water that has escaped when removing the plug is wiped off all surfacesbefore fitting front cover. Also check that none has spilled onto the lower RO unit.

1 Part No. 10947 - Anode plug. 2 Part No. 20451 - Anode3 Part No. 13182 - Spring 5 Part No. 11862 - Protective cover4 Part No. 13424/13244 - M8 x 60 lg. cap screw and washer


79/117



EXPLODED VIEW

Serial number of pump is stamped on side of crankcase


80/117



Pump Head

Item Part No. Description Qty Item Part No. Description Qty.106 44113 Seal, LPS w/SS-Spring 3 158 48362 Back up ring, V Packing Spacer 3107 44754 Lo-Pressure Seal Spacer 3 159 18697 O-ring, V Packing Spacer 3110 45124 Inlet Manifold 1 162 48363 Back up ring, Valve Seat 6112 11379 O-ring, Inlet Manifold 3 163 26142 O-ring, Seat 6117 18175 Socket Screw M14x40 4 164 44612 Valve Seat, Stepped 6126 19086 Female Adapter 3 166 44108 Valve127 44609 V-Packing 3 167 44109 Valve Spring 6128 45368 Male Adapter 3 170 44729 Washer, Spring Retainer 6141 54113 Coil Springs 12 171 44644 Coil spring, Valve Plug 6142 45382 Spacer with Coil Springs 3 172 89827 O-ring Valve Plug 6155 701492 O-Ring, V-Packing Spacer 3 174 44643 Valve Plug M70 6156 48362 Back-Up-Ring, Spacer 3 185 15369 Discharge Manifold 1

157 45369 Spacer, V-Packing 3

Part No. Description

00257 Seal Kit Comprising of :3-pieces of item 97 O-ring Plunger retainer3-pieces of item 106 Lo-Pressure Seal3-pieces of item 112 O-ring, Inlet Manifold

3-pieces of i tem 127-V-Packing6-pieces of item 155-O-ring, V-Packing Spacer3-pieces of item 156-Back up ring, Spacer3-pieces of item 158-Back up ring, V-Packing Spacer3-pieces of item 159- O-ring, V-Packing Spacer

00256 Valve Set Comprising of:3-pieces of item 162, Back up Ring, Valve Seat3-pieces of item 163, O-ring, Valve Seat3-pieces of item 164, Valve Seat,

3 pieces of item 166, Valve.

3 pieces of item 167, Valve Spring.3 pieces of item 168, Retainer. Spring3 pieces of item 170, Washer, Spring Retainer.3 pieces of item 172, O-ring, Valve Plug.3-pieces of item 173, Back up Ring, Valve Plug


81/117



Pump Body

ITEM Part No. Description Qty ITEM Part No. Description Qty.2 30055 Key M10 x 6 x 32 1 48 25625 Drain Plug 15 11824 Screw, Hex head M10 x8x 70 8 49 23170 O-ring, Drain Plug 16 15847 Washer, Split lock M10 8 50 45936 Crankcase Cover 17 19934 Washer M10 8 51 16612 O-Ring Crankcase Cover 18 44542 Cover, Bearing 2 53 44559 Crankcase 19 44543 Shim, Split Bearing Cover 2 55 27488 Guide Pins 210 12398 O-ring, Bearing Cover 70D 2 56 27790 Oil Pan 111 13296 Oil Seal, Crankshaft 2 58 15849 Lock Washer (split M6) 215 29326 Bearing 2 59 89618 Screw M6 x 10 220 64 43864 Pin, Rist 346611 Rod, Connecting Assembly

(44941,43641,88155)2

65 45116 Plunger Rod 3

21 44940 Locking Washer (M10) 4 69 29338 Washer, Oil Seal 322 43641 Washer, (M10) 4 70 29454 Oil Seal, Crankcase 323 88155 Screw HH (M10 x60F) 4 75 44752 Barrier Slinger 3

Items 21, 22 & 23 to be replaced as a set 88 45676 Keyhole Washer M16 325 29325 Crankshaft, Dual End 1 90 43921 Plunger 331 828710 Protector, Oil Cap 1 95 89778 Stud, plunger ret. M10x135 332 43211 Oil Filler Cap 1 96 20189 Back-up Ring, plunger ret. 333 14177 O-ring, Oil Filler Cap 70D 1 97 701490 O-ring, Plunger Retainer 334 44319 Bolt, Eye (M12 x 1.75) 1 98 44085 Gasket, Plunger Retainer 335 701144 Rivet 4 99 44084 Plunger Retainer M10 336 701147 Nameplate 1 100 814279 Retainer Seal (2 pcs.) 337 92241 Gauge, Oil Bubble 1 101 44112 Long Tab Wick 338 44428 Gasket, Flat 1 250 44516 Shaft Protector 140 89627 Screw, Hex Head M8 x 25 4


82/117



Fault Diagnosis.

FAULT DIAGNOSIS

PROBLEM PROBABLE CAUSE SOLUTIONPulsation. Faulty Pulsation Damper.

Damaged / Worn Suction Valves.

Check Gas Pressure. Replace Diaphragm. Check / Replace Suction Valves

Insufficient Pressure.(Pressure Control Valve closed).

Belts Slipping. Worn Packing.

Worn Inlet or Discharge Valves. Leaking Hi-Pressure Seals.

Tighten Or Replace Belts. Change Packing and inspect

plungers for Damage. Replace Valves. Repair with Seal Kit.

Water Leaking From UnderManifold.

Worn or Damaged Lo-PressureSeals.

Worn Male and Female Adapter

Repair with Seal Kit.

Install new male and femaleadapter.

Lubricate and replace O-rings inseal area.

Oil Leak between Crankcase andpumping Section.

Worn Crankcase Piston Rodseals.

Replace crankcase piston rodseals.

Oil leaking in area of Crankshaft Worn crankshaft seal orimproperly installed oil sealretainer O-ring.

Bad bearing

Remove oil seal retainer andreplace damaged O-ring and / orseals.

Replace bearing.

Water in Crankcase May be caused by humid aircondensing into water inside thecrankcase.

Documents

ROCHEM RO-Wasserbehandlung GmbH.pdf