ROCHEM RO-Wasserbehandlung GmbH.pdf

ROCHEM RO-Wasserbehandlung GmbH Knickberg 1a, D - 21077 Hamburg

( +49-(0)-40-7038577-0 4 +49-(0)-40-7038577-29

Operation Manual V 0.1 Date: 22.11.2008

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

Project: UAE Hull106

Order No.: P08027

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Serial No.: 2366

Page No. 1

INTRODUCTION I. Contents I. Contents II. Preface III. How to Use this Manual IV. Safety Remarks V. Log Sheet VI. Warranty VII. Notes VIII. Service Order Form for Spare Parts How to Contact our Service Department

Page 2 4 5 6 7 8 9 10

1) Functional Description 1.1 Description of Process

12

1.2 Unit Arrangement

13

1.3 Controls, Displays & Measurements 1.4 Safety and behavior rules

18 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

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 2

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

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 3

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 quality requirements, guaranteeing long life on a self-controlling 24 hours operation. ROCHEM systems are simple to operate and require a minimum of service. More than 2100 plants supplied worldwide confirm this. ROCHEM Reverse Osmosis Systems meet the requirements and specifications of the following organizations: Deutsches Institut für Normung Verband Deutscher Elektrotechniker e.V. Verein Deutscher Maschinen Anstalten Verein Deutscher Ingenieure Germanischer Lloyd Det Norske Veritas Registro Italiano Navale (RINA) Lloyd's Register of Shipping Bureau Veritas (French) ABS (American Büro of Shipping) Russian Maritim Register of Shipping They are also built to comply with military specifications and requirements.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 4

III. How to Use this Manual This manual should provide to you all the information required for operating and maintaining your ROCHEM Reverse Osmosis System. When designing this system great regard has been paid 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 maintenance minimizes any danger and maximizes availability. Any work of maintenance or repair, must be carried out correctly. Appropriate technical knowledge as well as any applicable regulations for safety and environment must be provided by the owner, operator and/or the maintenance personnel. THIS MANUAL DOES NOT REPLACE ANY PERSONAL TRAINING!

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 5

IV. Safety Remarks

F F F

The fresh water generator must not be operated within harbour area. Or in waters polluted with oil. When operating this equipment certain parts are electrified. Ignorance of operating procedure can cause death, injury or material damage. ANY WORK AT OR ON THE PLANT MUST ONLY BE DONE BY PERSONS TRAINED ON THE MACHINE AN D FAMILIARIZED WITH THE INFORMATION IN THIS MANUAL. REPAIR AND MAINTENANCE MUST ONLY BE DONE BY APPROPRIATELY QUALIFIED TECHNICAL PERSONNEL. PROTECTION, SUCH AS PULLEY / BELT GUARDS, MAY BE REMOVED ONLY FOR MAINTENANCE OR REPAIR AND MUST BE RE INSTALLED IMMEDIATELY AFTER ANY SUCH REPAI R OR MAINTENANCE HAS BEEN COMPLETED.

The owner and user, are responsible for complying to all prevailing laws to maintain a safe working environment. For plant protection please note the following important items:

F F F F F F

There must not be any visible movement (vibration/pulsation) of the pointer on pressure gauge PI160. If this occurs then one of the following is causing this fault: 1Some nitrogen gas has leaked from the pulsation damper. 2- The diaphragm in the pulsation damper is damaged. 3- High pressure pump valves or packing are defective. The PT modules will be damaged, if there is any vacuum in the feed water supply line or concentrate discharge line. Do not allow any back pressure on the permeate outlet, when there is no pressure on the feed supply, otherwise the membrane cushions will be damaged. 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 permanent pressure above this value is required then an additional booster pump will be necessary. 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. The membranes are not resistant against chlorine or any oxidizing agent. Deionized or distilled water in the unit will reverse the flow direction and destroy the membranes. Please take care of the feedwater quality conditions for the membrane module performance. 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.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 6

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

operating Feed hours water conductivity

FI130

TI130

PI130

PI140

PI150

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

PI160

PI180

CI180

Page No. 7

FI180

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 date of dispatch, provided that the system is operated on feed water of the minimum standard in accordance with the submitted reference analysis and that the operator adheres exactly to the installation, operating and maintenance instructions and recommendations. Components of the system supplied by ROCHEM RO-WASSERBEHANDLUNG which are found to be defective through poor workmanship or materials, will be repaired or replaced if 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 malfunctioning components 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 found to be defective due to bad workmanship or materials on a free of charge ex works Hamburg basis. A defective unit or component may be returned, freight prepaid, to ROCHEM RO-WASSERBEHANDLUNG for repair or replacement ex factory, as determined by ROCHEM RO-WASSERBEHANDLUNG, should the unit be found defective under this warranty. This warranty does not cover any system or component which fails, due to damage from mishandling, misuse, substandard feed water, improper maintenance or neglect of maintenance, poor or improper installation or incorrect electrical supply. This warranty may also 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 HP pumps 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.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 8

VII. NOTES

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 9

VIII. Service Order Form for Spare Parts To:

Rochem RO-Wasserbehandlung GmbH Knickberg 1a, D - 21077 Hamburg Telephone: + 49 (0) 40 7038577-0 Telefax: +49 (0) 40 7038577-29 e-mail:

Page No1. For Vessel

Unit Type

Authorised By:

Approved BY:

Delivery Instructions:

Serial No.

Date

Delivery Required By:

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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Qty

Part No.

Description

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Section

Page No. 10

Order Form for Spare Parts To:

Rochem RO-Wasserbehandlung GmbH

Knickberg 1a, D - 21077 Hamburg Telephone: + 49 (0) 40 7038577-0 Telefax: +49 (0) 40 7038577-29 e-mail:

Page No2. For Vessel

ITEM 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

Qty

Part No.

Unit Type

Serial No.

Description

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Date

Section

Page No. 11

1) FUNCTIONAL DESCRIPTION 1.1 Description of Process This fresh water generator uses the principle of the Reverse Osmosis. If two saline liquids are separated from another by a semi-permeable membrane, which does only allow molecules over a certain size to pass through, then, these liquids will tend to equalize their concentrations. This process is called Osmosis. Should one of these liquids be salt water and the other pure water, water molecules would diffuse through the membrane towards the salt water and dilute this. A certain pressure would occur in the system when this happens this pressure 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 molecule movement into the reverse direction: Only the water molecules diffuse from the salt water through the membrane to the pure water side. The ions of the salt water cannot pass through and remain on the salt water side. Within the ROCHEM PT modules the REVERSE OSMOSIS process takes place whilst the feed water is in motion, flowing over the membrane surfaces. About 30% of the water in the feed water passes through the membrane, the remaining 70% retaining the rejected salts. The feed water is gradually increasing in salt concentration as it flows through the module. The salts filtered out and left behind by the membrane are carried away and discharged, in case of sea water desalination they are returned to the sea as brine (concentrate). The pure water “permeate” 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 3½ %. whereas the Red Sea has a much higher salt content of approximately 4½ %, 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, assuming a feed water temperature of 25°C. For each 1°C drop in feed water temperature the permeate production drops by 3%. For example: Designed output at 25°C is 100 l/h. Then with a feed temperature of say 15°C the permeate output is 100-30% = 70 l/h. A rise in temperature above 25°C increases the pure water production only slightly. 25°C is the optimum feed temperature. Note: Some systems can be supplied to produce the required quantity with a low feed water temperature.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 12

1.2 Unit Arrangement The 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 (individual deviations not allowed for)

Sketch of operating principle

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 13

BRIEF DESCRIPTION OF MAJOR COMPONENTS The plant is controlled by a PLC unit Telemecanique “TSX-Micro”. The control program is stored on a microchip called “EEPROM“. When switching on the plant the processor loads the program automatically from the EEPROM into its Random Access Memory. By means of a programming device, connected to the serial interface of the processor unit, 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 -

sandfilter backwash - water rinse -

valves handle showing normal functional flow

valve closed

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 14

Pressure switch PS150 is activated by the water pressure before the high pressure pump and switches the plant off in the event of insufficient feed (to protect the pump against cavitation). It is de activated when the pressure 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 will show. Pressure switch PS170 (if installed) monitors the pressure in the concentrate line from the PT module. It stops the plant at a pressure of 6 bar, in order to avoid damage to the module. Most probable cause for this to be activated is that a valve on the concentrate discharge is closed. This pressure switch is activated when the pressure goes above the 6 bar setting. When activated fault will show. Pressure switch PS180 stops the plant when the pressure in the permeate line rises to 3 bar. This is to 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 a pressure of up to 4 bar through the cartridge filter and from there to the high pressure pump PP160. This centrifugal pump has its own integral electric motor.

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

Within cartridge filter FC140 sediment particles of 10 µm or more in size are retained within the filter element. These cartridge filter elements have to be replaced when dirty, they cannot be cleaned.

High-pressure pump PP160 is a positive displacement pump. (plunger pump) this pump delivers feed to the PT modules at a pressure of up to 65 bar. (note: pressure is controlled by VS160). The pump is powered through a belt drive from a three-phase motor. Minimum feed pressure to this pump is 0.5 bar.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 15

The pulsation damper fitted on the high-pressure pump discharge converts the pressure fluctuations, common for a plunger pump, into a steady pressure. It consists of a pressure vessel, internally separated by an diaphragm into two sections. The outermost section is filled with nitrogen at a pressure of 30 bar. The pulsation’s from the 3 plungers of the HP pump are absorbed by the gas pressurized membrane. It is normal to observe pulsation’s in the pointer of PI160 when pointer is rising through 25 to 32 bar, (resistance against gas pressure).

Innerhalb der ST-Module wird das Rohwasser unter dem angelegten Druck durch die Membrankissen gepresst. Das Wasser dringt durch die Membranen und wird als Permeat abgeführt; Salzmoleküle und andere Verunreinigungen des Rohwassers können die Membran größtenteils nicht passieren (Rückhaltung bei NaCl 98,5-99%), bleiben zurück und werden vom nachfolgenden Rohwasser mitgenommen, so dass sich dieses von Modul zu Modul weiter aufkonzentriert. Das Konzentrat wird (bei Seewasserentsalzung) in das Meer zurückgeleitet.

The pressure in the PT module or modules, is automatically controlled and adjusted by motor valve VS160, 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 HP pump discharge and the outlet of the modules. If this valve closes a fault will show. This valve can be manually operated by a hand wheel should the power unit 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 tank B111, (c) at closed position.

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

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 16

The pure water solenoid valve VE1801 is automatically controlled by the conductivity of the permeate. If the maximum pre-set value (1000 µS/cm for sea-water desalination, 50 µS/cm for mains water purification) is exceeded, VE1801 sends the permeate into the cleaning tank (from there 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), it automatically shuts down and a fault signal is displayed. As an option the plant can be equipped with a fresh water storage control. Starting and stopping the unit will then be actuated by 2 level switches fitted in the storage tank. When the low level switch is activated, the plant will start automatically. When the tank is full the high level switch will be activated and the unit stops and will be in a “stand by” mode waiting to be restarted either by remote (level switch) or manually by pressing the start button.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 17

1.3 Controls, Displays and Measurements The control panel is equipped with a main switch, a conductivity meter and 5 lamp buttons: lamp button 1 2 3 4 5

color

function

green yellow yellow yellow red

START STOP WITH RINSE CIRCUIT CLEANING SANDFILTER BACKWASH FAULT RESET / LAMP CHECK

The flow meter FI180 is installed in the permeate line from the PT module(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 pure water produced. The scale is marked in liters per hour on the front of the transparent plastic body. The floating indicator 1 is magnetic and actuates a eletrical siglal to the PLC. The PLC in turn sends a signal to the motor valve VS160. VS160 controlled the pure water flow.

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

The pressure gauges PI140 and PI150 (PI140-PI150) indicate the pressure loss across the cartridge filter, PI130-PI140 indicates the pressure loss across the sandfilter. If the pressure loss reaches an approx. value of 2 to 2.5 bar, the sandfilter must be backwashed. PI160 shows the operating pressure of the unit, shown as the inlet pressure to the PT Modules. The pressure gauges are filled with a glycerin type liquid, this is to minimize pointer vibration.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 18

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 procedure can cause death, injury or material damage. ANY WORK AT OR ON THE PLANT 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. Electrical endangerments During the operation of electrical devices some sections are energized dangerous. Neglect the warning notes can occur death, bodily injury, or damages to property. The cabinets and devices are 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 by regular 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 in the appropriate section.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 19

2) OPERATING 2.1 Commissioning Before commissioning the plant, please take note of the following: First, please read the safety remarks in the first pages of this manual! LIMITS OF PERFORMANCE Maximum flow rates

Feed Water: 800 l/h Permeate:

Designed + 30%

Note: High feed flow will cause an unacceptable pressure loss across the PT modules and a higher ampere loading on the HP pump motor

Operating pressure

65 bar

Maximum operating pressure

73 bar

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

CHECKS BEFORE FIRST COMMISSIONING

Control 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, pressure switches and level switches 24 V DC +/-5%. must be obtained.

PT Modules

Check torque loading.

Pressure switches PS150, PS170 and PS180

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

Flow meter

Check setting of magnetic switch behind flow meter.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 20

2.2 Starting the Unit Lamp signals :

l

lamp on

?

lamp flashing lamp off

¡

¡¡¡¡¡

Lamp signals when unit is shut-down: Action

Step No.

Effect

1

Open all valves to and from the RO unit.

2

Open VK111

3

Set valves to Normal operation:

Lamp signal

¡¡¡¡¡ - Drain all water from cleaning tank.

VK121

VK132

VK134

VK133

¡¡¡¡¡

VK171

normal operation

4

Turn master-switch (On).

5

Press lamp button 1.

to

“I” - Conductivity display illuminated. - Motor control valve VS160 is open.

¡¡¡¡¡

? ¡¡¡¡

- When WS161 sends signal "valve completely open“ to the PLC, filter pump PK130 starts. - High pressure pump PP160 starts 300 seconds. after pressure switch PS150 has given start signal. - Motor control valve VS160 runs towards close to bring up pressure. - Pressure transmitter PT160 stops pressure rise when maximum pressure or maximum permeate flow rate is reached. VE1801 sends permeate into tank B111, since conductivity limit is exceeded. - Conductivity of permeate drops below allowed maximum. VE1801 switches to permeate discharge, i.e. fresh water storage.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

l¡¡¡¡

Page No. 21

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

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 22

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

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 23

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 discharged concentrate

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 µS/cm (sea water) or 50 µS/cm (town mains water)

Amperage of electric motors

motor circuit-breakers

(see electric schematics and rating plates)

FUNCTIONS FOR MANUAL CONTROL Lamp check: By pressing lamp button 5 all button lamps will illuminate. Replace any faulty lamp immediately.

FAILURE OF UNIT In the event of an operating failure the plant is automatically stopped and a fault signal is displayed 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 the cause of the failure. A table of all fault signals is located at the front of the control cabinet. (Also refer to section “Fault Indication & Finding”). After correcting the problem the plant can be restarted after pressing lamp button 5 to clear the fault from the PLC.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 24

2.4 Stopping the Unit Lamp signals :

l

lamp on

?

lamp flashing lamp off

¡

¡¡¡¡¡

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 tank B111 with permeate.

? l¡¡¡

- Tank B111 full LS1113 activated - Motor control valve opens to reduce operating pressure. - Unit stops. 3

Set valves as below: VK121

¡? ¡¡¡

(to take suction from cleaning tank) VK132

VK134

VK133

VK171

stop rinse

4

5

Press lamp button 1

- Rinse with permeate starts.

¡l¡¡¡

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

¡¡¡¡¡

To protect the unit for external pressure fluctuations set the valves as below (delivery to cleaning tank) VK171 (suction from cleaning tank) VK121 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.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 25

1st Sequence after pressing of STOP/RINSE button. Solenoid Valves VE1801/2 change over to fill tank B111 with permeate.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 26

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

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 27

2.5 Sandfilter Backwash A sandfilter backwash is necessary, when the pressure loss across the sandfilter due to sedimentation exceeds 2 or - as a maximum - 2.5 bar. Note: Unit must be stopped to start this procedure Lamp signals : l lamp on

?

lamp flashing lamp off

¡

¡¡¡¡¡

Lamp signal at unit shut-down:

How to carry out a sandfilter backwash: Step No.

Action

Lamp signal

Effect

¡¡¡¡¡

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

sandfilter backwash - air rinse -

4

Air treatment: Connect air supply to connecting branch VF139.

5

Open VK136 and flush sandfilter If unsure about the low air pressure, Put your ear for 10 min. with air (max. pressure against the sand filter and listen. When air is 0.5 bar) heard “Bubbling” stop increasing the air pressure.

6

Disconnect air supply at connecting branch VF139.

7

Open valve VK121:

8 9

to sea suction

Close valve VK136 Water treatment: button 1 (START)

Press

lamp- Filter pump PK130 starts. Sandfilter is rinsed with raw water. Raw water passes the sandfilter and flows through brine outlet back to sea.

¡¡¡l¡

Unit stops automatically. 10

After approx. 10 to 15 min. of Unit is rinsed with water and stops afterwards. water rinse press STOP/RINSE.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

¡¡¡¡¡

Page No. 28

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

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 29

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

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 30

2.6 Circuit Cleaning Organic and inorganic substances within the feed water are deposited on the membrane surfaces (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 these sedimentation’s are flushed off and removed. A circuit cleaning is required, when the fresh water production has dropped by 10 to 15% (equal water 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 organic substances. Oxidizing agents are sometimes used in sea water pipe systems, to avoid fouling and kill bacterium’s.

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 come from 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 corresponds to 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 be minimal. This can also damage the membrane surfaces.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 31

F F 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. The feed water temperature should not exceed 30°C. When using 2 cleaners, to be fully effective they must be used in the following sequence: 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 cushions by hand or other soft equipment which will in any way affect the membrane layer surface and the membrane material will lose its salt rejection ability.

STARTING THE CLEANING PROCESS The cleaning can only be initiated from normal operating mode. Lamp signals :

l

lamp on

?

lamp flashing lamp off

¡ Lamp signal at unit shut-down: Step No.

Action

¡¡¡¡¡ Effect

1

Close valve VK111.

- To stop cleaning tank draining

2

Press lamp button 3 (CIRCUIT CLEANING).

- Magnetic valve VE1801 switches over and allows the permeate to be delivered into tank B111, until level switch LS1113 is actuated.

Lamp signal

l¡¡¡¡

? ll¡¡

- Motor control valve VS160 runs open. - Operating pressure drops. - Switch WS161 is made, when VS160 has completely opened. - Pumps PK130 and PP160 are stopped.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

¡¡? ¡¡

Page No. 32

3

Set valves for Circuit Cleaning: VK121

(for closed circuit operation) VK132

VK134

VK133

VK171

circuit cleaning

4

Open VK111 for a moment to - Cleaning agent get space for cleaner.

¡¡? ¡¡

Put injector hose into the can with 7.5 liters of cleaner and open valve V111 to allow the cleaner to be sucked in. (Make sure only 7.5 liters of cleaner are sucked in.) 5

Press lamp button 1 - Pumps PK130 and PP160 start. ¡¡l¡¡ (START). Close V111 when container is - Cleaner and permeate are being mixed, empty. pumps run intermittently (each 5 min. operation followed by 5 min. Stop). Cleaning cycle time: approximately 2 hrs.

6

Cleaning completed

7

Open VK111 to draining Tank B111

- Unit stops (approx. after 2 hours).

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

¡¡¡¡¡

? ¡? ¡¡

CAUTION:

F

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

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 33

RO CLEANER AA a.) Safety marks for the employer Sodium hydroxide solution, 2-5 % Hazards for human health and the environment Breathing 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 rules Work with good ventilation! Open seals cautiously! Do not leave vessels open! Limit stored quantities to one 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 as eye 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 diluting or filling: plastic apron!

Behaviour in danger situations Collect and dispose of with absorbent non-combustible material (e.g. kieselguhr, sand)! Caution! Spilt solution presents risk of slipping (by iwater contact)! Product is not combustible. Only fight fires with breathing apparatus independent of ambient air and 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 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 or heartbeat stops: immediately apply artificial respiration and heart massage. After swallowing: No domestic agents. Do not cause vomiting. If conscious, see that plenty of water is drunk a little at a time. First Aid specialist:

Proper disposal Do not pour into the sewage or a refuse bin! For disposal, collect in: _____________________________ Signature of the employer

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 34

RO CLEANER C a.) Safety marks for the employee Citric acid, 10-30 % Hazards for human health and the environment Breathing in, swallowing or absorption through the skin may result in health dam age. Causes burns. Temporary complaints (cough) are possible. Can cause laboured breathing, eye damage. Add to water when diluting, 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 rules Ensure 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 shift requirement! Avoid contact with eyes, skin and clothing! Preventive skin protection necessary. Use skin care agent! Thoroughly clean hands after completing work and before every work break! Store street clothing separately from work clothing! Immediately change wetted clothing! Observe restrictions on activity! Eye protection: Full protection goggles! Hand protection: Gloves made of: Butyl rubber It 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 situations Remove only after applying personal safety equipment! Clean objects and flooring which have become wetted or soiled immediately with plenty of water! Collect and dispose of with acid-binding material (e.g. limestone meal) and rinse remainders away with water! Product is combustible, suitable extinguishing agents: water in a jet, carbon dioxide, extinguishing powder, foam! In the event of a fire in the environment, cool the receptacle with sprayed water! Explosive mixtures can be generated if strongly heated! 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. Rinse with water for 15 minutes after burns. After breathing in: Fresh air. Keep airways clear: remove false teeth, vomit etc.. If breathing or heartbeat 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:

Proper disposal Do not pour into the sewage or a refuse bin! For disposal, collect in: _____________________________ Signature of the employer

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 35

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

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 36

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

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 37

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

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 38

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

l

lamp on

?

lamp flashing lamp off

¡

¡¡¡¡¡

Lamp signal at unit shut-down: Step No.

Action

Lamp signal

Effect

1

Close valve VK111

To stop cleaning tank draining

2

Press lamp button 3 (CIRCUIT - Solenoid valves VE1801/2 switch over CLEANING). and send permeate to tank B111.

l¡¡¡¡

? ll¡¡

- Tank full level switch LS1113 activated - Motor control valve VS160 runs open. - Operating pressure drops. - Switch WS161 is made, when VS160 has completely opened. - Pumps PK130 and PP160 are stopped. 3

Set valves for Preservation: VK121

¡¡? ¡¡

(for closed circuit operation) VK132

VK134

VK133

VK171

circuit cleaning

4

Open VK111 for a moment to - Preserve agent get space for biocide.

¡¡? ¡¡

Put injector hose into the can with 5 liters of biocide (ROCIDE) and open valve V111 to allow the biocide to be sucked in. (Make sure only 5 liters of biocide are sucked in.) 5

Press lamp button 1 (START). - Pumps PK130 and PP160 start.

¡¡l¡¡

Close V111 when container is - Preserve solution is mixed with permeate. empty. - Unit stops after approx. 2 hours.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

¡¡¡¡¡

Page No. 39

Note: A sufficient circulation of the preserve solution has already been reached after 30 min. , the process can now be aborted: 6

Press lamp button 2 (STOP).

7

Open VK111 to empty tank B111.

8

Turn off master-switch.

Preserve solution passes through the discharge line.

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

¡¡¡¡¡

? ¡? ¡¡

CAUTION:

F

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

The unit is now ready for normal operation.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 40

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 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.:

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 under the 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:

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

_____________________________ Signature of the employer

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 41

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

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 42

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

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 43

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

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 44

2.8 Disinfection If the permeate should be found contaminated of bacteriums, or generally after a longer still without a prior preservation), a disinfection should be carried out. Lamp signals :

l

lamp on

?

lamp flashing lamp off

¡

¡¡¡¡¡

Lamp signal at unit shut-down: Step No.

Action

Lamp signal

Effect

l¡¡¡¡

Unit is running in normal operating mode. 1 2

(to stop draining of cleaning tank B111) Press lamp button 3 (CIRCUIT Solenoid valves VE1801/2 switch over and CLEANING). send permeate to tank B111.

? ll¡¡

Tank full level switch LS1113 activated Motor control valve VS160 runs open to reduce operating pressure. Switch WS161 is made, when VS160 has completely opened. Pumps PK130 and PP160 are stopped. 3

Set valves for Disinfection: VK121

¡¡? ¡¡

For closed circuit operation VK132

VK134

VK133

VK171

circuit cleaning

4

Open VK111 for a moment to - Disinfect agent get space for biocide.

¡¡? ¡¡

Put injector hose into the can with 5 liters of biocide (ROCIDE) and open valve V111 to allow the biocide to be sucked in. (Make sure only 5 liters of biocide are sucked in.) 5

Press lamp button 1 (START). Pumps PK130 and PP160 start. Membrane ¡¡l¡¡ biocide is sucked in and mixed with Close V111 when container is permeate. empty. Unit stops after approx. 2 hours.

6

Open VK111.

¡¡¡¡¡

(to empty tank B111)

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 45

stand-

For re-start:

8

After approx. 10 hours turn valves back to Normal Operation: VK121

VK132

VK134

VK133

VK171

normal operation

9

Press lamp button 1 (START).

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

? ¡? ¡¡

CAUTION:

F

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

The unit is now ready for normal operation.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 46

3) FAULT INDICATION & FINDING 3.1 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 signals :

l

lamp on

?

lamp flashing lamp off

¡ Lamp signal at unit shut-down:

¡¡¡¡¡

Lamp signal

Meaning

Device

Possible causes

LAMP SIGNALS A: RED LAMP BUTTON IS ILLUMINATED PERMANENTLY 1

234 5

¡ l¡¡ l PS150

Feed pressure before PP160 too low

¡ ¡l¡ l PS180

Pressure in permeate line too high

¡ ll¡ l I

Electric motor load too high

¡ ¡¡l l VS160

Motor control valve closed during operation

- 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 - 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 - 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 - 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

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 47

¡ l¡l l PI160

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

¡ ¡ll l PS170

Over pressure in concentrate line

¡ lll l CS180

Permeate conductivity too high

- Discharge line valves not open - VK171 in wrong position during operation - PS170 defective - connection to processor defective - 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 35°C - magnetic switch on CIT180 defective - CIT180 not properly adjusted - connection to processor defective

PT160

LAMP SIGNALS B: RED LAMP BUTTON FLASHES 1

234 5

¡ l¡¡ ?

LS1111 Level switch LS1111: Tank empty

¡ ¡l¡ ?

UP

¡ ll¡ ?

Subroutine stopped Reserved

¡ ¡ll ?

VS160

Motor control valve malfunctioning

¡ l¡l ?

FT180

Permeate flow rate too high

¡ ¡ll ?

RF001

(Reserved)

¡ lll ?

LS1113 Max. filling time B111 exceeded

- high resistance in VS60 valve spindle due to gland packing - corrosion damage in VS60 - limit switch WS161 defective - limit switch WS162 defective - connection to processor defective - PT Module malfunction due to internal leakages (sealing or membrane damaged) - floating indicator jammed or damaged (corrosion) - operating pressure too high - low salinity feed water - too long filling time B111 - drain valve VK111 open - LS1113 defective - connection to processor defective

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 48

3.2 Faults without Lamp Indication Lamp signal

Device

Meaning

Possible causes

FAILURES WITHOUT FAU LT INDICATION Plant cannot be started High-pressure generation failed

Excessive pressure fluctuation during operation

PP160 valves malfunctioning

- Check energy supply and fuses - processor out of order - set value on PT160 wrong - permeate flow rate too high - no signal from PT160 to processor, e.g. due to defective cable - pulsation damper gas pressure wrong. Correct pressure (if possible) or replace pulsation damper - valves in HP pump worn or damaged - normal wear - particles between valve plate and valve seat. Dismantle valve and check. Replace, if necessary

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 49

4 ) MAINTENANCE, CLEANING & CALIBRATION In order to maximize availability the unit must be maintained regularly. Checks and maintenance works should be carried out according to the tables below. Detailed instructions, as far as necessary, 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 failures sooner 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

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 50

MAINTENANCE REQUIREMENTS OF UNIT AND COMPONENTS Device

Designation on P&I diagram

Electric motors

Recommended frequency

Chapter

(for plunger pump replace bearings PP160)

after approx. 20,000 operating hours

4.4

Cartridge filter

FC140

replace filter elements

as required

4.9

PT module

FM160

replace mem branes

(only if necessary)

4.11

circuit cleaning

every 500 operating hours or earlier, if required

2.5

check torque

150 hours after commissioning, then monthly

4.11

check plungers, pumping section and crankshaft section

every 3,000 operating hours

4.8

check valves and seals, replace as necessary

every 3,000 operating hours

4.8

check belt tension

weekly

check oil level, top up if necessary

weekly

4.8

replace oil filling

50 hours after first commissioning, then every 750 operating hours or monthly

4.8

replace

if necessary

4.13

check gas pressure

annually

Plunger pump

Pulsation damper

PP160

SP160

Required action

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 51

4.2 PLC This component can only be serviced by a ROCHEM engineer and the following is given for emergency use only except that the battery must be changed every 24 months. The inside door of the control panel should have a sticker giving the date of last battery change. The battery is Part No. 20417, it is a ½ AA 2.6 volt Lithium battery. Modicon TSX Micro Processor Analogue Converter

24V Input.

Function display

Battery Compartment,

Digital input card 1/2

Digital output Card 4

Battery Changing The power supply must be on before removal of the battery. Photographs are taken looking up and under the battery compartment. 1 – Press in and down to release the Battery compartment. 2 – Battery compartment open. 3 – Remove old battery and fit new Battery, ensure that the polarities are correct. Close Battery compartment.

+ _ © ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 52

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. Should this 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 made Before fitting. Switch sets C1, C2, C3 and C4 to be set. All switches to be set as shown below. C1 Switches set at 0 A – After setting all switches refit as in photo 4. C2 Switches set at 1 B – Secure the Analogue Converter with the 2 screws shown in photo 3. C3 Switches set at 0 C – Fit the Multi-pin plug and secure with the 2 screws. Photos 2 and 1. C4 Switches set at 0

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 53

Processor Card Replacement The Modicon TSX Micro Processor is fitted with 2 sizes of cards. 1 – 1 off Large Type: TSX DEZ32D2 2 – 1 off Small Type: TSX DSZ08R5 The following information on card removal and replacement is again for emergency use. 1 2 Removal is shown for Type DEZ32D2 card, the process of removing Type DSZ08R5 cards is the same. Do not remove any wires from the Terminal Blocks.

1 – Remove top screw.

4 – Pull up lever card

7 – Re-fit new card block

2 – Remove bottom screw

5 – Lift out card carefully

8 – Push down securing lever

3 – Lift off terminal block

6 – Type DEZ32D2

9 – Re-fit terminal 10 – Secure bottom screw. 11 – Secure top screw

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 54

Processor Function Display BASE LED

EXT. LED

WRD. LED

Diag. Diagnostic LED Button

Run LED

TER. LED I/O LED ERR.LED BAT.LED

Input Signals

Descriptive Function Of Parts Shown Above Function

ITEM Input Signals Output Signals BASE LED EXT. LED WRD. LED DIAG. LED TER. LED I/O LED ERR. LED BAT. LED RUN. LED DIAG. Button

Output Signals

Card 1, Digital Input signals. Cards 2 Digital Output signals. Alight when power is on. Not used. Not used. Not used. Communicating signal between unit and programming PC . Analogue error. Corrupted program. Battery requires replacement. Alight when unit is running Do not touch this button only for programming use.

LED Alight LED Flickering LED Flashing

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 55

4.3 Contactors Maintenance requires qualified personnel “ ACCESS ONLY BY ELECTRICIAN ” The control cabinet contains the PLC unit and all wiring and electrical components. Due to thermal load upon the contactors, the screws that tighten the wires could become loose 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 suitable screwdriver.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 56

4.4 Electric Motor Art. 11280 After about 20,000 operating hours, but no later than after 4 years, the roller-bearings should be checked and, if necessary, replaced. The type of bearings fitted do not allow for cleaning or regreasing.

1 2 3 4 5 6 7 8 9

stator feet rotor end shield drive end flanged end shield drive end end-shield, non-drive end V-ring drive end bearing, outer cap grease thrower roller-bearing DIN 625

10 11 12 13 14

bearing, inner cap V-ring non-drive end bearing, outer cap grease thrower roller-bearing DIN 625

15 16 17/18 19 20 21 22 23 24 25 26 27 28 29 30

bearing, inner cap external fan external fan sing (sheet steel) terminal board (according to DIN) terminal plate with insulators protective cable bushing for flameproof motor (stud terminal) terminal clamp for ex motors gland cover terminal box terminal box, bottom part terminal box lid entry section (A or B) single-entry sealing chamber (E) double-entry sealing chamber (F) 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

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 57

4.5 Pressure Switch Art. 12218 The pressure switches are fitted for safe operation of the unit, to avoid any unnecessary damage. They will stop the unit when certain pre determined pressures are not prevailing. These are fitted within the system at critical locations. Electrically connected as an opener or as a closer. The switching points of the pressure switches should regularly be checked and re-adjusted, if necessary. Pressure switch

Function

Switching value Connection

PS150

protects pump PP160 from cavitation

0,5bar

closer

PS170

protects concentrate pipe system from over pressure

6 bar

opener

PS180

protects permeate pipe system from over pressure

3 bar

opener

Adjusting the Switching Value:

Step No.

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

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.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 58

4.6 Pressure Transmitter

Art. 20480

The pressure transmitter measures the operating pressure before the module and passes it as a 4 to 20 mA signal on to the PLC. At a pressure 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 defective and needs replacement.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 59

4.7 Conductivity Meter

(Part No.: 20321/20322/20686)

Meters: CIS 180 Type LF 1010-3-2R-5-00µs/cm Conductivity Meter Part No.20321 Conductivity Probe Part No.20322 Sensor Cable Part No.20686

Meter Features Protection IP65. 14.2mm LED display. Indicating range 2000(0) digit. Measuring range programmable from 0…2.000µS/cm up to 0…2000mS/cm. This meter has been designed for the measurement of conductivity, as a degree of the purity or concentration of a liquid. In connection with 4-electrode conductivity cells a high accuracy and 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 (G1½").

Lid Opened

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 60

Connection Diagram

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 61

Controls and Indicators

Description Operating 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-voltage safe 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 outputs can 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 jumps back to the working level. Leaving the configuration level is possible at any time when pushing the button for 2 seconds. Error codes: Display If the input signal is more than 3% outside of the programmed measurement range the flashes 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 pushing the button a copy of the EEPROM will be reloaded and the device will work with the factory settings. If this copy does not work, please ship the device to factory for repair service.

Lo c Program lockout. See configuration page. Start-up note: Before the device can be used, it must be configured for the intended

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 62

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 parameters and if they are available. Factory settings are shown in [ ] .

Working Level Button

Display

Description Actual process value conductivity Output indication (only if installed and activated).

Actual process value temperature

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 63

Configuration Level Button

Display

Description

(displayed values are factory setting)

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 64

Button

Display

Description

(displayed values are factory setting)

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 65

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 check the 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”. Do not use abrasives on this probe.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 66

4.8 Filter Pump PK130

Part No. 21092

CRT4 – 5. Vertical Multistage Centrifugal Pump This pump is virtually maintenance free because of the materials used in its construction. If the mechanical seal leaks it should be replaced as soon as possible. The motor is a totally enclosed, fan-cooled, 2-pole Grundfos standard motor with principal dimensions inaccordance with 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 activate pressure 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 in the dismantling and assembling instructions Example 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 the pump. In normal operation this will not be a problem but in rough seas there could be a considerable amount of air entrapped in the feed water.

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 over as they must fit over and seal on the machined spigot.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 67

Pos. 37 105

Shaft Seal kit No. 21143 Description AUUE O-Ring 137.5 x 3.3 2 Shaft seal 1

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 68

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 69

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

Dismantling Sequence 1

2

3

4

5

6

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 70

Assembly 7

8

10

9

11

12

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

13

Page No. 71

Assembly 14

15

16

Replacement Seal Kit. Part Number:

When pump is reinstalled and the RO unit is started for the 1st time after removal. The pump must be purged of air.

Seal kit comprises of the parts shown alongside. (Add. 2 ORings Pos. 37)

Use the air release valve To remove air from the pump. Do not over tighten as this could damage the valve seat. It is preferred that it should only be “hand tight”.

17

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 72

4.9 Plunger Pump

Art. 12746

Type 3537 Part No.12746 is for this pump complete but without pulley and any additional fittings to the pump manifold. This pump is fitted with a Nickel Aluminum Bronze manifold. The other parts used in this pump are made from quality materials. When replacing any components use only original specified parts 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 Crankcase Only 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 across center of center dot on bubble gauge at back of pump. (Position A below). OIL Changing After the 1st 500 running hours drain crankcase, flush out with half liter of fresh oil and refill. Every 5,000 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 filler cap to be blocked. (Position B).

ROTATION If the pump has been disconnected for any reason, before restarting the unit check that the pump rotation is correct before running the unit. Correct rotation is shown here. ⇒ WARNING The oil bath crankcase assures optimum lubrication only when pump rotates in the correct direction.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 73

Type 3537 High Pressure Pump Access to Pump Power to the RO plant must be switched off before opening the front panel. Remove the 4 x 8mm and 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.

? Pump pulled out for Service

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 74

Oil filling Cap (unscrews)

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

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 75

High Pressure Pump. Type 3537 Adjusting Belt Tension Checking Tensions of Drive Belts Use a belt tension device to check the tension on the belts. After the correct tension has been obtained ensure that the pulleys are aligned correctly. Both outside faces of the pulleys have to be 100% in line with each other. Note: Photo here is turned 90º from

Belt Deflection Force: 3.8 to 5 lbs. Belt Deflection: ¼”

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 1st day 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 Pump Pulley: Remove the 3 Allen grub screws as shown Insert 2 of the screws into the 2 empty holes and screw 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 Taperlock bush will open. The Taperlock bush can now be removed by pushing off from the shaft. Motor Pulley: Remove the 2 Allen grub screws as shown Insert 1 screw into the empty hole and screw home The pulley will be pushed off the Taperlock bush towards the pump. Remove the screw. When the pulley is loose the Taperlock bush will open. The Taperlock bush can now be removed by pushing off from the shaft.

Refitting of Pulleys and Belts: Refit the pulleys in reverse order ( pulley on before taper bush). Ensure that 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 outer faces 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.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 76

High Pressure Pump. Type 3537 Drive Assembly

1- Motor 5 – “TAPERLOCK” pulley 9 – Hex. Socket grub screw flat point (3) DIN913 M12 x 35

2 – Back bearing Part of motor Item 1 6 – “TAPERLOCK” bush 10 – “TAPERLOCK” bush

3 – Front bearing Part of motor Item 1 7 – Hex. Socket grub screw flat point (2) 7/16” x 1.875” 11 – “TAPERLOCK” Pulley

4 – Shaft Key DIN 6885-A 10x8x100mm 8 – V-belt (5 belts) 12 – Shaft Key DIN 6885-A. 10x8x70mm

Pump Details

1- Die cast aluminum crankcase for strength and l ight weight. 3- Chrome-moly crankshaft for strength and long life. 5-Special stainless steel plunger rods for strength.

7- Abrasion resistant ceramic plungers for extended seal life 9- 100% wet seal design increases service life by allowing pumped fluid to cool and lubricate both sides. 11- Special V-Packings for performance and seal life.

2- Oversized crankshaft bearings for extended life. 4- Oversized connecting rods for strength. 6- Stainless steel slinger provides back up protection for crankcase seal keeping pumped fluids out of crankcase. 8- Nickel aluminum bronze manifolds for continuous duty 10- Special stainless steel valves, seats and springs provides corrosion resistance and long life. 12- Crossheads are 360º supported for alignment.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 77

High Pressure Pump. Type 3537 Cathodic Protection Fitted to this pump is a sacrificial anode to protect the pump head from corrosion i.e. (electrolytic action caused by different metals). The anode is fitted in the hexagonal plug in the top of the pump as shown below. This anode must be checked every 3 months and replaced when necessary. Use the socket for the DT modules to remove the plug BUT do not use the DT module torque spanner as it may be damaged. Use PTFE tape as thread sealant when securing back into the pump. Ensure that all water that has escaped when removing the plug is wiped off all surfaces before fitting front cover. Also check that none has spilled onto the lower RO unit.

1 – Part No. 10947 - Anode plug. 2 – Part No. 20451 3 – Part No. 13182 - Spring 5 – Part No. 11862 4 – Part No. 13424/13244 - M8 x 60 lg. cap screw and washer

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

- Anode - Protective cover

Page No. 78

High Pressure Pump. Type 3537 EXPLODED VIEW

Serial number of pump is stamped on side of crankcase

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 79

High Pressure Pump. Type 3537

Pump Head

Item

Part No.

106 107 110 112 117 126 127 128 141 142 155 156 157

44113 44754 45124 11379 18175 19086 44609 45368 54113 45382 701492 48362 45369

Description Seal, LPS w/SS-Spring Lo-Pressure Seal Spacer Inlet Manifold O-ring, Inlet Manifold Socket Screw M14x40 Female Adapter V-Packing Male Adapter Coil Springs Spacer with Coil Springs O-Ring, V-Packing Spacer Back-Up-Ring, Spacer Spacer, V-Packing

Qty

Item

Part No.

3 3 1 3 4 3 3 3 12 3 3 3 3

158 159 162 163 164 166 167 170 171 172 174 185

48362 18697 48363 26142 44612 44108 44109 44729 44644 89827 44643 15369

Part No.

00257

Qty. 3 3 6 6 6 6 6 6 6 6 1

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

00256

Description Back up ring, V Packing Spacer O-ring, V Packing Spacer Back up ring, Valve Seat O-ring, Seat Valve Seat, Stepped Valve Valve Spring Washer, Spring Retainer Coil spring, Valve Plug O-ring Valve Plug Valve Plug M70 Discharge Manifold

Valve Set Comprising of: 3-pieces of item 162, Back up Ring, Valve Seat 3-pieces of item 163, O-ring, Valve Seat 3-pieces of item 164, Valve Seat, 3 pieces of item 166, Valve.

3-pieces of item 127-V-Packing 6-pieces of item 155-O-ring, V-Packing Spacer 3-pieces of item 156-Back up ring, Spacer 3-pieces of item 158-Back up ring, V-Packing Spacer 3-pieces of item 159- O-ring, V-Packing Spacer 3 pieces of item 167, Valve Spring. 3 pieces of item 168, Retainer. Spring 3 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

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 80

High Pressure Pump. Type 3537

Pump Body

ITEM 2 5 6 7 8 9 10 11 15 20 21 22 23 25 31 32 33 34 35 36 37 38 40

Part No. 30055 11824 15847 19934 44542 44543 12398 13296 29326 46611

Description

Key M10 x 6 x 32 Screw, Hex head M10 x8x 70 Washer, Split lock M10 Washer M10 Cover, Bearing Shim, Split Bearing Cover O-ring, Bearing Cover 70D Oil Seal, Crankshaft Bearing Rod, Connecting Assembly (44941,43641,88155) 44940 Locking Washer (M10) 43641 Washer, (M10) 88155 Screw HH (M10 x60F) Items 21, 22 & 23 to be replaced as a set 29325 Crankshaft, Dual End 828710 Protector, Oil Cap 43211 Oil Filler Cap 14177 O-ring, Oil Filler Cap –70D 44319 Bolt, Eye (M12 x 1.75) 701144 Rivet 701147 Nameplate 92241 Gauge, Oil Bubble 44428 Gasket, Flat 89627 Screw, Hex Head M8 x 25

Qty 1 8 8 8 2 2 2 2 2 2 4 4 4 1 1 1 1 1 4 1 1 1 4

ITEM 48 49 50 51 53 55 56 58 59 64 65 69 70 75 88 90 95 96 97 98 99 100 101 250

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Part No. 25625 23170 45936 16612 44559 27488 27790 15849 89618 43864 45116 29338 29454 44752 45676 43921 89778 20189 701490 44085 44084 814279 44112 44516

Description Drain Plug O-ring, Drain Plug Crankcase Cover O-Ring Crankcase Cover Crankcase Guide Pins Oil Pan Lock Washer (split M6) Screw M6 x 10 Pin, Rist Plunger Rod Washer, Oil Seal Oil Seal, Crankcase Barrier Slinger Keyhole Washer M16 Plunger Stud, plunger ret. M10x135 Back-up Ring, plunger ret. O-ring, Plunger Retainer Gasket, Plunger Retainer Plunger Retainer M10 Retainer Seal (2 pc’s.)

Long Tab Wick Shaft Protector

Page No. 81

Qty. 1 1 1 1 1 2 1 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 1

High Pressure Pump. Type 3537

Fault Diagnosis. FAULT DIAGNOSIS PROBABLE CAUSE

PROBLEM Pulsation.

•

Faulty Pulsation Damper.

Insufficient Pressure. (Pressure Control Valve closed).

• • •

Damaged / Worn Suction Valves. Belts Slipping. Worn Packing.

• • •

Worn Inlet or Discharge Valves. Leaking Hi-Pressure Seals. Worn or Damaged Lo-Pressure Seals. Worn Male and Female Adapter

Water Leaking From Under Manifold.

•

SOLUTION • • • • • • • • • •

Oil Leak between Crankcase and pumping Section. Oil leaking in area of Crankshaft

Water in Crankcase

Oil Leaking from under-side of Crankcase Oil leaking from drain plug.

• • • • • • •

Install new male and female adapter. Lubricate and replace O-rings in seal area. Replace crankcase piston rod seals. Remove oil seal retainer and replace damaged O-ring and / or seals. Replace bearing. Change oil every 500 running hours.

Worn Crankcase Piston Rod seals. Worn crankshaft seal or improperly installed oil seal retainer O-ring. Bad bearing May be caused by humid air condensing into water inside the crankcase. Leakage of packing seals. Worn Crankcase seals.

•

• •

Repair with seal kit. Replace seals.

Loose drain plug or damaged Oring. Worn main bearing from excessive tension on drive belts

•

• • • •

Tighten drain plug or replace Oring. Replace bearing, Properly tension belt. Use only the correct type and length. Check key on crankshaft. Check taper bush assembly. Replace bearing. Align pulleys correctly, fit new drive belts and recheck alignment after setting belts to correct tension. Replace plungers.

Excessive play in the area of Crankshaft

•

Loud knocking noise in pump

•

Pulley loose on crankshaft.

Frequent drive belt failure

• •

Broken or worn bearing Pulleys on pump and motor are not in correct alignment.

•

Scored plungers.

Frequent or premature failure of the packing.

Check Gas Pressure. Replace Diaphragm. Check / Replace Suction Valves Tighten Or Replace Belts. Change Packing and inspect plungers for Damage. Replace Valves. Repair with Seal Kit. Repair with Seal Kit.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

• • •

•

•

Page No. 82

High Pressure Pump. Type 3537

Servicing SERVICING of Valves. The pump does not need to be removed for this operation and it is not necessary to disconnect the suction or discharge connections to the pump. Disassembly 1. Remove the six (6) M41 Hexagonal Valve Plugs. 3 on top and 3 on front. 2. Under the Valve Plug is a coil spring and washer. Remove these by hand. 3. Then screw a M8 bolt into the top of the Spring Retainer and pull out the valve assembly including Retainer, Spring, Valve Seat, O-ring and Back-up Ring) from the valve chamber. 4. Each valve assembly should be remain together, do not mix the components of each valve. 5. If the assembly separates, the parts will lift out without any tools. Re-assembly 1. Examine the O-rings on the Valve Seat, replace if cut or worn. Lubricate the O-rings before installing. Examine the surface of the Valve and Valve Seat for pitting, groves, wear or damage and replace if necessary. 2. Next assemble Valve Retainer, Spring, Valve and Seat by snapping together securely. Thread the M8 bolt into the spring retainer for installation. 3. Lubricate the O-Ring and Back-up-Ring surface and walls of valve chamber and press Valve Assembly squarely into chamber, Remove M8 bolt. Place the washer over the top of the Spring Retainer and then the Coil Spring on top of the Washer. 4. Examine the O-ring and Back-up-Ring on the valve plug and replace if cut or worn. Lubricate new O-ring and Backup-Ring before installing on Valve Plug to avoid damage as they are worked over the plug threads. 5. The Back-up-Ring must go on first, then the O-Ring. 6. Slowly thread the Valve Plug into valve chamber. Exercise caution to avoid extruding or cutting the Back-up-Ring or O-ring. 7. Torque to specifications given in Torque chart on page 15.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 83

High Pressure Pump. Type 3537

Servicing Removing The Discharge Manifold The discharge connections must be removed for this operation. 1. Remove the 8 M12 Hexagonal socket head screws. 2. To assure alignment use two M12 studs as guides while removing manifold. 3. Tap the backside of the discharge manifold with a soft mallet and gradually work the head from pump. 4. Properly support manifold to avoid damage to the ceramic plungers. 5. Remove the O-Rings from lower chambers of the face of the Inlet Manifold. Removing the Inlet Manifold

The inlet (suction) connections must be removed for this operation. 1. Remove the four (4) M14 hexagonal socket head bolts. 2. Rotate crankcase by hand (one to two turns) to separate the inlet manifold from the crankcase. 3. Carefully tap the rear of the inlet manifold with a soft mallet and gradually work off head from pump. 4. Note: Support the underside and exercise caution to keep manifold aligned with Plungers to avoid damage to the plungers as the manifold is being removed. 5. NOTE: 2 Screwdrivers on opposite sides of the manifold may be used to assist separation SERVICING THE PACKING Disassembly of the V-Packings 1. Place the crankcase side of the inlet manifold down on the work surface. 2. First remove the V-Packing Spacer. These may stay in either the Inlet or Discharge Manifold ports when the Discharge Manifold is removed. If they are extremely dirty or dry, remove the exposed O-Ring and Back-up-Ring and insert 2 screwdrivers on opposite sides to pry out of chamber. 3. Examine both front and rear O-Rings and Back-up-Rings on the V-Packing Spacer for cuts or wear and replace as needed.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 84

High Pressure Pump. Type 3537

Servicing Disassembly of the V-Packings Continued 4. To remove the V-Packing Cylinder, insert two screwdrivers on opposite sides of the V-Packing Cylinder and pry out. Examine the O-Ring for wear, replace as needed. 5. Next remove Spacer with coil springs. Examine for broken or fatigued springs or scale build up or pitting and replace as needed.

6. Then with reverse pliers remove the Male Adapter, V-Packings and Female Adapter. NOTE: Using the reverse pliers may damage the V-Packings or Female Adapter. 7. Examine female Adapter for worn inside diameter and replace if required. Re-assembly of the V-Packings Lubricate outer surface of V-Packi8ng Cylinder and install new O-Ring in groove. Press V-Packing Cylinder with O-Ring end down into the manifold chamber until completely seated. 2. Insert the Female Adapter into the Manifold Chamber with the “V” groove up. 3. Next fit the new V-Packings together, lubricate the outer surface of the packings and insert into Manifold Chamber with the “V” groove up. 1.

Then install the Male Adapter into the Manifold Chamber with the “V” groove down (notches up). 5. Lubricate outer surface of Spacer with coil springs and insert into Manifold Chamber with springs facing down, 6. Lubricate outer surface of V-Packing Spacer, install new O-Rings and Back-up-Rings in both the front and rear groove and press into Manifold Chamber with small diameter down until completely seated. 4.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 85

High Pressure Pump. Type 3537

Servicing Disassembly of the LO-Pressure Seal 1. With the Inlet Manifold on blocks and with the crankcase side down, insert screwdriver into seal chamber and tap opposite sides of the Washer Spacer to drive out seal assembly. (Spacer and LO-Pressure Seal). 2. Replace the LO-Pressure Seal and examine O-Ring for wear and replace as needed.

Re-assembly of the LO-Pressure Seal 1. With the crankcase side of inlet manifold up insert the Spacer into the seal chamber. 2. Install LO-Pressure Seal into seal chamber with garter spring facing down and press squarely into position.

SERVICING THE PLUNGERS Disassembly 1. Remove the seal retainers from the ceramic plungers. 2. Remove the inner collar from the front of the seal retainer. 3. Remove the used wick and install new wick. 4. Lubrication: Three drops per hole, twice per month. 5. Replace Inner Collar on Seal Retainer. 6. Loosen plunger retainer 4 to 5 turns. Push plunger towards crankcase until plunger retainer pops out. 7. Unscrew and remove plunger retainer, gasket, O-ring, back-up ring, ceramic plunger, keyhole washer and barrier slinger from the plunger rod.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 86

High Pressure Pump. Type 3537

Servicing Re-assembly 1. With these plunger items removed, examine the Crankcase Oil Seal for wear or deterioration and replace as needed. 2. Replace keyhole washer on plunger rod. 3. Carefully examine each plunger for scoring or cracks and replace if worn. NOTE: Ceramic plunger can only be installed in one direction (front to back). Do not force onto rod. 4. Examine gasket, O-ring and back up ring on plunger retainer and replace if cut or worn.

Lubricate O-ring for ease of installation and to avoid damaging O-rings. NOTE: First install gasket, then O-ring and back up ring. 5. Apply a small amount of “Loctite” 242 to the threads of the Plunger Retainer and thread Plunger Retainer onto plunger rod. Torque per specifications See Page 15. 6. Slip Seal Retainers over plungers. Insert smaller diameter first. NOTE: Line up wicks with the oil holes in the crankcase and tabs in the oil pan.

7. Rotate shaft and line up two outside plungers. 8. Lubricate the Plungers. 9. Carefully replace inlet manifold onto plungers and press towards crankcase. Keep manifold aligned to avoid damaging plungers. To assure alignment use two studs as guides and remove when manifolds are in place. 10.Replace four (4) hex socket screws and torque to specification. 11.Examine inlet port O-Rings at bottom of manifold and replace if cut or worn. 12.Lubricate the outer surface of V-Packing Spacer, O-Rings and valve chamber walls and carefully slip Discharge Manifold over V-Packing Spacer. 13.Hand tighten the two (2) hex socket head screws. Torque per chart and in the sequence below.

7

3

2

6

5

1

4

8

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 87

High Pressure Pump. Type 3537

Servicing SERVICING THE CRANKCASE SECTION 1. While manifold, plungers and seal retainers are removed, examine crankcase seals for wear. 2. Check oil level and for evidence of water in oil. 3. Rotate crankshaft by hand to feel for smooth bearing movement. 4. Examine crankshaft oil seal externally for drying, cracking or leaking. Consult ROCHEM if crankcase service is required.

ITEM Anode Plug Plunger Retainer Inlet Manifold Bolts Discharge Manifold Screws Valve Plugs Crankcase Cover Screws Bearing Case Screws Connecting Rods

TORQUE CHART THREAD TOOL SIZE M14 M16 M16 M70 M10 M10 M10

M22 M12 M10 M41 M17 M17 M17

TORQUE 70 Nm 75 Nm 75 Nm 150 Nm 21 Nm 21 Nm 43 Nm

Important Note: The suction hose must be checked at regular intervals to see if it is touching / rubbing on the pump motor or frame. It must not be in contact with either the frame or the motor. If the hose is touching any of these 2 surfaces then it must be moved to another position. To move the hose: Loosen the 2 cap screws 1 turn in the clamp. Slacken the union slightly to allow the hose tail fitting to be turned. Turn the hose tail Approximately 10º from the vertical. Check by looking under the motor to see that the hose is clear of the motor and frame as in photo below. Retighten the clamp and union. Union Air Vent Plug

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Clamp

Page No. 88

4.10 Sandfilter

(Part No.: 11476) with top and bottom connections

Maintenance: When the pressure loss across the sand filter reaches 2.5 bar, a sandfilter backwash will be required. (Please see chapter 2.5 "Sandfilter backwash"). The sand filter is filled with 3 sizes of quartz sand. The Sand in this filter normally never requires to be changed. However if the sand does have to be changed. Before filling the sand, fill the bottom with water to a level of approximately 50cm. This is to prevent damage to the collection filters during filling.

Replacing the Filter bed Step No.

Action

1

Stop the unit with rinse and remove power.

2

Close water inlet valve and manual valve before and behind the filter (if installed).

3

Open filter head.

4

Suck sand and water out of the filter vessel by means of an industrial vacuum cleaner.

5

Refill the filter with new sand as to the chart below.

6

Close filter head and check seals for correct seats.

7

Open water inlet valve and manual valves, respectively.

8

Start unit with a sandfilter backwash. Sandfilter with top and bottom connections Sandfilter - Article code

Size

Parts

Type installed

Diameter

610 mm

Total length L1

2010 mm

Vessel length L2

1980 mm

Volume

450 ltr.

Top connection

4“

Bottom connection

4“

Pressure vessel

C-2469-F7

0,3-0,7 mm

11530

Amount: 2,0-3,0 mm Amount 3,0-5,0 mm Amount

300kg (12bags) 11529 100 kg (4 bags) 11528 100 kg (4 bags)

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 89

Sand filter with top and bottom connections 1 Pressure vessel 2 Upper distribution system 3 Lower distribution system

4 Sand 0,3-0,7 mm 5 Sand 2,0-3,0 mm 6 Sand 3,0-5,0 mm

1 Distribution tube 2 Distribution head 3 O-ring 4 Adapter 5 O-ring 6 Angle

1 Angle 2 O-ring 3 Adapter 4 O-Ring 5 Distribution head

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 90

4.11 Cartridge Filter

(Art. 11488)

The cartridge filter elements must be replaced, when the pressure loss across the cartridge filter has reached 2 bars (PI140-PI150). The filter elements cannot be cleaned. The overall pressure loss must in no cases get that large that the plunger pump inlet pressure drops below 0.5 bar! A check should be carried out daily and after any circuit cleaning the filter elements should be replaced. (1) Filter Housing (2) Filter Element (10 µm) (3) O-ring

Replacing the Filter Elements:

Step No.

Action

1

Press lamp button 2 (Stop with rinse)

2

Close feed water inlet valve VK121 and discharge valve VK171.

3

Unscrew the filter housing bottom part from the top part using the belt spanner (part no. 13573).

4

Replace filter elements (part no. 20216).

5

Reassemble the filter housing, check O-ring (part No. 11533) and ensure it fits correctly. Torque only hand tight without the use of a belt spanner.

6

Open feed water inlet valve VK121 and discharge valve VK171.

The unit is now ready for restarting.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 91

4.13 Deacidification Filter

(Art. 21113)

Maintenance: The de-acidification filter is filled with dolomitic limestone. This is being continuously consumed and must be topped up at the latest when the filling height has dropped down to 50 %. In order to check this, the vessel must be opened. The maintenance interval depends of the concentration of available carbon acid.

Topping up the Filter Material Step No.

Action

1

Shut down the unit with STOP/RINSE and remove power from unit.

2

Close water inlet valve and manual valves before and behind the filter (if installed).

3

Open valve VK190

4

Open filling tube

5

Refill filter material up to a height of approx. 90% (for appropriate quantity of filter material see chart below).

6

Close filling tube properly

7

Close valve VK190

8

Re-open water inlet valve and manual valves before and behind the filter (if installed).

For the first 10 minutes after topping up the filter material, the produced permeate should not be used as drinking water. It is recommended, before re-commissioning the unit to by-pass the external fresh-water facilities and drain off the water. De-acidification filter

Size

Filter article number

21113

Diameter D

406 mm

Overall length L1

1449 mm

Vessel length L2

1370 mm

Volume

132 ltr.

Upper connection

4“

Lower connection

4“

Parts Pressure vessel Dolomitic filter material Total of filling material:

11521 175 kg

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 92

1 Verteilerrohr 2 Verteilerkopf 3 O-Ring 4 Adapter 5 O-Ring 6 Winkel

1 Angle 2 O-ring 3 Adapter 4 O-ring 5 Distribution head

Lower distributor

Upper distributor

Part. No.: 21113 Type C (with filling tube) 1 2 3 4

Pressure vessel Upper distributor, Lower distributor Dolomitic filter material Part No.:15151

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 93

4.13 ST Module

Art.02102

ST-Module

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 94

4.14 Motor Control Valve Art.22813 Actuator (see original maker instructions enclosed) General Valve Instructions

Remove or Separate

Turn (Counter clockwise)

Install or Insert

Turn (Clockwise)

Use standard wrench or tool.

Do NOT Rotate or turn

Use special tool or wrench

Examine

Lubricant

Special tool (brass)

Keep hands clear when valve is in operation. Shut off pressure before taking valve apart. 1

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 110

General Valve Instructions 2

3

4

5

6

7

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

8

Page No. 111

General Valve Instructions 9

10

11

12

13

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 112

General Valve Instructions 14 Best to replace with new components.

Assembly 1

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 113

General Valve Instructions 2

4

3

5

6

7

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 114

General Valve Instructions 8

9

10

11

Testing for leakage

If packing leaks, tighten just enough to stop leakage. Test packing by tightening gland 1/4 turn past finger tight.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 115

4.15 Pulsation Damper

Part. 22076

The function of the pulsation damper can be checked by observing the pointer motion on pressure gauge PI160, while the unit is starting up. From approx. 30 bar on the pointer vibration must decrease remarkably. If not, the pulsation damper needs refill or replacement of the membrane (both only possible for Type B dampers) or even of the complete damper. Maintenance: The gas pressure should be checked 2 days after first commissioning, repair or replacement, then once after 4 months and afterwards in 1 years intervals. The check is being performed by means of a special charging unit. The pressure should always be approximately 5 bar above the half operating pressure. If not, the nitrogen filling has to be topped up or the membrane needs replacement. Replacement of the whole pulsation damper is generally needed after 8,000 to 12,000 operating hours.

F F

Type A: Welded version (Art. 22076)

Type B: Threaded version (Art.)

The pulsation damper must only be filled with nitrogen, in no cases with oxygen!

If the gas pressure within the nitrogen bottle lies above 30 bar, a gas pressure reducing valve and a safety valve will be required.

Replacing the Pulsation Damper Step No.

Action

1

Switch unit off.

2

Close water inlet valve and manual valves before and behind the filter (if installed).

3

Unscrew pulsation damper and install the new one.

4

Open feed water inlet valve and manual valves, respectively.

5

Restart the unit at lamp button 1 and observe the pointer vibration. It must decrease from 30 bar on and tend to zero with rising pressure.

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 116

Check Gas Pressure and Make up Nitrogen Filling For filling the pulsation damper a charging unit (Art. 13615) will be required. Step No. 1

Action For filling up a cold damper first calculate the pressure to be set: pressure setting

= 30 bar x present temperature (K) / expected operating temperature

(K)

2

Switch off unit and remove power.

3

With a 6 mm socket spanner, loosen socket head screw at the pulsation damper gas valve slightly by half a turn.

4

Screw union nut D of the charging unit onto the pulsation damper gas valve. Turn the charging unit in such a way that the pressure gauge can be read easily.

5

Open valve V by turning the valve spindle A of the charging unit open by one turn. When pointer movement occurs turn ahead by one turn. The pressure gauge now shows the present pressure inside the pulsation damper.

If pressure is too high: Open pressure relieve valve B so nitrogen can escape. If pressure is too low: Top up nitrogen as follows:

6

With the union nut G1, attach the flexible filling hose to the pressure reducing valve of the nitrogen bottle. Connect the other end of the hose to the manifold C of the charging device.

7

Open the gate valve of the nitrogen bottle. While spindle A is screwed in, pass nitrogen slowly into the pulsation damper. Close bottle gate valve and read pressure from the pressure gauge. Repeat from step 6 on until the desired pressure has been established.

8

After 5 min. check pressure again.

9

If the desired pressure is reached and remains stable, close pulsation damper gas valve by tightening the socket head screw P.

10

Unscrew the charging unit and finally torque socket head screw to 25 Nm.

11

With soapy water, check water tightness of pulsation damper gas chamber. A

charging hose

charging unit

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

ß gas valve on pulsation damper

Page No. 117

5) SPECIFICATION CIRCUIT DRAWINGS, PARTS LISTS AND TECHNICAL DATA

5.1 Layout Diagram

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 118

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 119

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 120

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 121

5.2 Pipe & Instrument Diagram

Legend to the Pipe & Instrument Diagram The letters indicate the FUNCTION of the component: PK

Centrifugal Pump

VF

Safety Spring Valve

FC

Cartridge Filter

VK

Ball Valve

PP

Plunger Pump

VR

Non-return Valve

FM

PT Module

VS

Motor Control Valve with Electric Motor

VD

Globe Valve or Check Valve

VV

Valve (general)

TI

Thermometer

PT

Pressure transmitter

PI

Pressure gauge

FI

Flow gauge

VE

Solenoid Valve

CI

Conductivity meter

The numbers indicate the LOCATION of the component:: 110

Rinse and cleaning system

150

Behind cartridge filter but before plunger pump

120

External components of unit

160

High-pressure Section

130

Filter Pump

170

Concentrate

140

Cartridge Filter

180

Permeate

190

Post treatment permeate

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 122

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 123

St = piece(s) Satz = Set

5.3 Parts List Grp.

Art.

Designation

Specification

ANB ANB ANK ANS ANS ANZ ARD ARE ARH ARH ARH ARH ARH ARH ARH ARH

10001 10002 10041 22111 21053 10170 22076 22813 10292 21128 21128 20761 10248 10248 10248 10248

taper bush with keyway taper bush with keyway belt pulley pulley motor slides pulsation damper servo motor control valve 2-way ball valve 2-way ball valve 2-way ball valve 2-way ball valve 3-way ball valve 3-way ball valve 3-way ball valve 3-way ball valve

ARH ARM ARM

10302 2-way ball valve 21098 2/2 way solenoid valve 21097 2/2 way solenoid valve

ARÜ ARÜ ARÜ

10444 pressure maintaining valve 10512 non return valve 10458 spring safety valve

ARÜ ARV ARV ARV AZU AZU BEA

10472 10508 10508 10508 23426 20143 10556

non return valve 2-way valve 2-way valve 2-way valve pipe ellbow stand pipe pipe clip

Typ: 2012/42 GG Nut DIN6885/1 Typ: 3020/35 GG Nut DIN6885/1 XPA 1332 LW Typ: TB SPA 112 x 5 GG25 DIN2211 Typ: TB SPA 250 x 5 GG25 DIN2211 Typ: G132/10PM - 530mm (1 Sa.) BNr: 7210SS Typ: CAT 0,7l; NPT1" Typ: RC250 G3/4 230VAC BNr: 161.346.044, d32 PVC BNr: 161.546.722, d20 PVC BNr: 161.546.722, d20 PVC BNr: 161.546.723, d25 PVC BNr: 161.343.444, d32 PVC BNr: 161.343.444, d32 PVC BNr: 161.343.444, d32 PVC BNr: 161.343.444, d32 PVC Typ: DN5; G1/4"Edelstahl 03-125.5 mit Flügelgriff TYP: 5282-A 13,0 NBR MS G1/2 220V TYP: 5282-B 13,0 NBR MS G1/2 220V BNr:121.967; PN 10;Typ: DHV 716; DN 25; PVC-U BNr: 161.360.444 Typ: D012,5 G1 NPT-G1 85bar BNr: 149 B 1129 RV290P G3/8 Po/Vi/E BNr: 5.0110.00 G1/4- DN 4 - PP BNr: 5.0110.00 G1/4- DN 4 - PP BNr: 5.0110.00 G1/4- DN 4 - PP ZNr: 613.0823426-3a ZNr: 613.0620143-3a BNr: RANE-325, Ro 25mm

BEA BEA BEA DOS

10558 10560 10573 10818

pipe clip pipe clip bow type handle injector

DRT DRT

19611 pressure connection MCV 10900 pin for pump frame pressure connection HP19612 pump 10947 sealing plug 20451 zinc anode

DRT DRT DRT EMD FIG

11280 three-phase moto r 21113 pressure vessel

BNr: RANE-532, Ro 32mm BNr: RANE-540, Ro 40mm BNr: GN 565-26-192 SW BNr: 54389 SP820.20, Typ: d 25 PVC ZNr: 623.19611-4a Vic1" - NPT 3/4" 1.4539 ZNr: 623.10900-4a d20-id8,5 ZNr: 623.19612-4a VIC1" - NPT1" 1.4539 ZNr: 623.10947-4b11/2"NPT GBZ ZNr: 623.623.20451-4a Typ: B3, BG160L6, KKr, 480V/60Hz, 12,6 kW, 24,5A Typ: SP-16-043 D406xH1450 V0132

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Qty. 1 1 5 1 1 1 1 1 1 1 1 1 1 1 1 1

Unit

P+I diagram

St St St St St St St St St St St St St St St St

P S K K K K K K K K

S V V V V V V V V V

1 1 1 1 1 1 1 1 1 1

6 6 9 3 1 3 3 7 2 3

0 0 0 6 1 4 3 1 1 2

1 St 1 St V E 1 8 0 1 1 St V E 1 8 0 2 1 St V F 1 3 5 1 St V R 1 8 0 1 St V F 1 6 0 1 1 1 1 3 1 3 1 2 1 3 1

St St St St St St St

V R 1 3 9 V 1 3 0 V 1 8 0 V 1 1 1

St St St St V

1 1 1 2

1 St 2 St 1 St 1 St 1 St 1 St E M 6 0 1 St F D 1 9 0

Page No. 124

Grp.

Art.

FIG FIG FIG FIM FIM FIM FIM FIM FTE FTE FTE FTE FTE FTE FTE FTE FTE FTF FTF FTM FTM FTM FTM FTP FTP FTP FTP FTP FTP FTP FTP FTP FTP FTP FTP FTP FTP FTP FTP FTP FTP FTP FTP FTP FTP FTP

11476 11488 11488 11521 20216 11528 11529 11530 11657 11671 20954 11703 11704 11723 11672 11772 11681 11944 12097 20360 11800 20290 11810 11835 11837 11838 11838 11896 11903 11908 11910 11914 11930 11931 11864 11978 11979 11980 11994 12054 12056 12067 12068 12080 12075 12076

FTQ

Designation

pressure vessel cartridge filter housing cartridge filter housing dolomitic limestone cartridge filter element sand sand sand bend 90° double nipple gauge connection socket socket reducing bushing barrel nipple t-piece elbow male connector quick coupling angle coupling male hose nozzle reducing bushing quick acting coupling / hose union elbow hose nozzle hose nozzle hose nozzle hose nozzle socket reduction reduction reduction reduction reduction nipple reduction nipple covering cap for zinc anode t-piece t-piece t-piece thread socket union union elbow 45° elbow 45° elbow 90° elbow 90° elbow 90°

12116 pipe union

Specification Typ: C-2469-F7 D610xH19802010/V0450, gekürzt Typ: AVPP20 3/4"NPT Gew.bu. Typ: AVPP20 3/4"NPT Gew.bu. Typ: JW 00 Typ: WFMB010-20; 10µm Typ: 3 - 5 mm Typ: 2 - 3mm Typ: 0,3 - 0,7 mm BNr: 11-223E G1 i-1 a BNr: 11-207E G1/4" DIN2999 BNr: SS- 6MTA-7-8RG G1/2 BNr: 11 - 201, G1"x 43, 1.4571, BNr: 11 - 201, G11/4"x 48, 1.4571, BNr: 11-212e G1/2-3/8, 1.4571 BNr: 11-210 1/2" - 60E; L= 60 mm BNr: SS-6 MO-3 6mm BNr: SS- 6MO-2-4RT 6MM-G1/4A BNr: 6468 CK-3/8-PK-9-KU BNr: 6272 GCK-3/8-PK-9-KU BNr: 12-026 L.W. 6mm - MS BNr: 11-1541 G 1/4- 1/8 Ms BNr: 12-025 GA3/8-MS BNr: WE 6LLR, G1/8" Ms BNr: 721.960.409 Typ: d 40 PVC BNr: 721.960.407 Typ: d 25 PVC BNr: 721.960.408 d32 PVC BNr: d32 PVC BNr: d32 PVC BNr: d63 - 50 PVC BNr: d32 - 25 PVC BNr: d50 - 32 PVC BNr: d25 - 20 PVC BNr: d20 - 3/8" PVC BNr: d25 - 1/2" PVC BNr: d40 BNr: 721.200.107 d25 PVC BNr: 721.200.108 d32 PVC BNr: 721.200.109 d40 PVC BNr: d20 - 1/2" PVC BNr: 721.510.108 d32 PVC BNr: 721.510.107 d25 PVC BNr: 721.150.107 d 25 PVC BNr: 721.150.108 d 32 PVC BNr: 721.100.106 d20 PVC BNr: 721.100.107 d25 PVC BNr: 721.100.108 d32 PVC BNr: 1.0100.32-401400B1, DN 4/6 3/8" PP

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Qty.

1 1 1 8 2 4 4 12

1 1 1 2 2 1 2 1 1 7 3 1 2 1 2 1 2 6 6 3 4 8 4 8 10

1 1 2 12

1 2 15 20

8 8 1 15 50

Unit

P+I diagram

St St St St St St St St St St St St St St St St St St St St St St St St St St St St St St St St St St St St St St St St St St St St St St

F F F

S 1 3 0 C 1 4 1 C 1 4 2

F F F F

C S S S

1 1 1 1

4 3 3 3

0 0 0 0

2 St

Page No. 125

Grp.

Art.

Designation

FTQ FTQ FTQ

12147 T-hose coupling 12166 union elbow 12168 union elbow

FTQ 12174 union elbow KEN :: unit marking plates KEN 21090 operator control panel KEN 21070 valve position plate MDA 20480 pressure transmitter MDA 12218 pressure switch MDA 12218 pressure switch MDA 12218 pressure switch MFM 21091 rotameter MFM 12282 rotameter MFM 12418 limit transmitter MLF MLF

20322 20321

MLF MMG MMG MMG MMG MMG

20323 21161 21160 21160 21160 21160

MNS

12428

MNS MTM PPK PPP ROP ROP SCF SCF SCF SCF SCM SCM SCM SCM SCM SDA SMZ SMZ VIK VIK VIK

12428 12439 21092 12746 12969 12970 20585 20883 23213 22463 13119 13133 13134 13143 13146 17391 13182 13269 13515 13516 13515

Specification

Qty.

BNr: 1.0300.10-400000B1, DN 4/64/6-4/6 PP BNr: 1.0200.41, DN 4/6 - G 3/8" PP BNr: 1.0200.41 G1/2" DN 4 PP BNr: 1.0200.32-401400B1, DN 04/06 NPT 3/8" PP Diverse Schilder, Standard 1530-2000

Unit

4 St 4 St 4 St 4 1 1 1 1 1 1 1 1 1 1

St St St St St St St St St St St

ZNr: 643.0621090-3c ZNr: 643.0621070-4b BNr: 9073957, S-10, 100 bar, G1/2B BNr: 1010084 FF4 - 8 BNr: 1010084 FF4 - 8 BNr: 1010084 FF4 - 8 Typ: 807-50D-72114-1-73-10000 Typ: 817-32D-72114-1-62-02500 Typ: 1272/000/Z25/01, DN 25, 4-20mA TYP: LF4213A-C 0,5 MIT 8 conductivity electrode POL.STECKER 1 St conductivity meter TYP: LF-1010-3-2R-5-00-µS/cm, LED 1 St cable for conductivity TYP: SKM8E-02 2METER ,MIT electrode 8POL.STECKER einseitig offen 1 St pressure gauge - 100 bar BNr:RChgG 63-3,rFr 0-100 bar 1 St pressure gauge - 10 bar BNr: RChgG 63-3, rFr 0-10 bar 1 St pressure gauge - 10 bar BNr: RChgG 63-3, rFr 0-10 bar 1 St pressure gauge - 10 bar BNr: RChgG 63-3, rFr 0-10 bar 1 St pressure gauge - 10 bar BNr: RChgG 63-3, rFr 0-10 bar 1 St BNr: ERPP-3/8PPS-L100/12-PP44Alevel switch 5PVC, 3/8" 1 St BNr: ERPP-3/8PPS-L100/12-PP44Alevel switch 5PVC, 3/8" 1 St thermometer Typ: 0/60-G1/2-050-1.4571 1 St centrifugal pump Typ: CRT4-5, 2,2 kW / 60Hz/440V 1 St plunger pump Typ: 3537 Al-Bz; 136 l/min, 800 1/min 1 St Pipe Typ: 32,0 x 2,4 HL=5 Mtr.PVC 20 m Pipe Typ: 25,0 x 1,9 HL=5 Mtr.PVC 6 m hp-hose Typ: DN6 x 800 bds.BEL6/PF1 1.4539 1 St hp-hose Typ: DRS1/4-0,5 BEL6 1.4539 570mm 1 St hp-hose Typ: DN25x1800 bds. 1" Vic. 1.4539 1 St hp-hose Typ: DN25x2300 bds. 1" Vic. 1.4539 1 St rubber-water hose Typ: Goldschlange 32 x 5,5mm 6 m plastic water hose Typ: 2236 PL-4 id = 4mm 5 m plastic hose BNr: 12134, PU-9-SW 5 m plastic hose Typ: DN40 Perbunan Uniflex 2 m plastic hose Typ: DN25 Perbunan Uniflex 2 m megi damper stainless steel Typ: Ø 40x30 bds. IG M8 8 St spring for anode 5.332.001.0 1 St nut Typ: M28x1,5 -6mm hoch -A4 SW41 1 St victaulic coupling Typ: 77 Größe 33.7 od (1" ) 3 St victaulic coupling Typ: 77 Größe 42,4 od (1 1/4") 3 St victaulic coupling Typ: 77 Größe 33.7 od (1" ) 3 St

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

P+I diagram

P P P P F F FI

T S S S I I T

1 1 1 1 1 1 1

6 5 7 8 3 8 8

0 0 0 0 0 0 0

C I C I

S 1 8 0 S 1 8 0

C P P P P P

I I I I I I

S 1 1 1 1 1

L

S 1 1 1 1

L T P P

S I K P

1 1 1 1

1 6 3 4 5 8

1 4 3 6

8 0 0 0 0 0 0

1 3 0 0 0

Page No. 126

Grp.

Art.

Designation

Specification

XMO

ST0210 2

ST-module

Typ: ST Module Typ: 480V/60Hz, Vipa, 600 x 600 x 350 mm ZNr.: 627.0419557 -2b PE-HD V= 110l ZNr: 622.0621234-4b ZNr: 622.0621176-3a ZNr: 624.0416282-2c ZNr: 632.0621116-2a ZNr: 624.0419618-4a

XSS

23632 control cabinet

YTA YVS YVS YVS YVS YVS YVS YVS YVS YVS YVS YVS YVS YVS YVS YVS YVS YVS YVS YVS YVS YYY

19557 21234 21176 16282 21116 19618 19545 16328 21119 19546 22387 21121 21120 19558 21274 21123 10926 20878 19548 21270 21302

Cleaning tank damper holding device holder rotameter front sheet - pump frame base frame holder coductivity transmitter bracket motor control valve cartridge filter holding sand filter mounting sand filter mounting gauge sheet module safety bead module holder module frame ST04 pipe connections pump+motor plate belt guard suction connection cross-stur cartidge filter plate of valve supply frame feed connection CAT3537

Qty.

ZNr: 622.0419545-3a ZNr: 622.16328-3a id=610 ZNr: 622.0621119-3b id=410 ZNr: 624.0419546- 4a ZNr: 626.0722387-4c ZNr: 626.0621121-3b ZNr: 626.0621120-2b ZNr: 622.0419558-4b ZNr: 625.0421274-2a ZNr: 625.0621123-4a ZNr: 613.0610926-3a CAT3527-3537 ZNr: 622.0620878-4b ZNr: 624.0419548- 3b ZNr: 621.0621270-0a 1.4571 ZNr: 613.0621302-2a

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Unit

3 St F

P+I diagram

M 1 6 0

1 St 1 1 1 1 1 1 1 1 2 2 1 2 1 1 1 1 1 1 1 1 1 1

St B St St St St St St St St St St St St St St St St St St St St St

1 1 1

Page No. 127

5.4 Tools, Resources Part No./

Designation German

Designation English

Qty./

Artikel-Nr.

Bezeichnung deutsch

Bezeichnung English

Menge

FILTERMATERIALIEN

FILTER MATERIALS

11521

Juraperle 25Kg Sack

Dolomitic Limestone (25kg sacks)

25kg

20216

Filterkerzenelement (PP 10µm)

cartridge filter element (PP 10µm)

1

SONDERWERKZEUG

SPECIAL TOOLS

12339

Handmessgerät Leitfähigk./Temperatur

hand-meter conductivity /temp.

1

13578

Drehmomentschlüssel 1/2", 150Nm

torque spanner 1/2", 150Nm

1

13573

Bandschlüssel klein

belt spanner small

1

13672

Steckschlüssel für ST-Modul

socket spanner for ST module

1

13606

Maulschlüssel 50mm

Open-end spanner 50mm

1

13615

Füllvorrichtung Pulsationsdämpfer

Filling device for pulsation damper

1

BETRIEBSMITTEL

OPERATING MATERIALS

10629

Desinfektionslösung Typ D, 5 l

Membrane Biocide (Cleaner Type Rocide)

5l

10651

Reiniger A: Fouling-Reiniger, 5 l

Cleaner A: Fouling Remover, 5 l

5l

10653

Reiniger A: Fouling-Reiniger, 25 l

Cleaner A: Fouling Remover, 25 l

25l

10658

Reiniger C: Eisenreiniger, 5 l

Cleaner C Iron Remover, 5 l

5l

10660

Reiniger C: Eisenreiniger, 25 l

Cleaner C Iron Remover, 25 l

25l

VERSCHLEIßTEILE

WEARING PARTS

10041

Keilriemen

V-belt

5

21143

Gleitringdichtung PK130

Shaft seal PK130

1

15216

Dichtungssatz Plungerpumpe

HP-Pump seal kit

1

19615

Ventilsatz Plungerpumpe

HP-Pump valve kit

2

20451

Zinkanode Hochdruckpumpe

Zinc anode for HP pump

1

11533

O-Ring Kerzenfiltergehäuse

O-Ring Cartridge filter housing

1

© ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg.

Page No. 128

5.5 Unit Specification Unit Type: RO 1530-ST03-30S Raw Water Quality

:

Sea Water

Unit Type

:

RO 1530-ST03-30S

Quantity Of Modules

:

3

Raw Water Feed (l/h)

:

5,300

Voltage Supply 3 phase (V)

:

480

Frequency (Hz)

:

60

Semi-automatic

Control RAW WATER Raw Water Input nominal (l/h)

:

5,300

Raw Water Pre-Pressure min/max (bar)

:

0,5 – 2

Operation Pressure (bar)

:

60-70

Operation Pressure max. (bar)

:

73

Raw Water Temperature Nominal (°C)

:

25

Raw Water Temperature Range (°C)

5-35

Raw Water Quality

:

open sea water

Total Dissolved Solids (TDS) max (ppm)

:

44000

pH-Value nominal

:

7-8

pH-Value Range Cleaning

:

2 - 12

Silt Density Index Nominal (SDI) (%/min)

:

5

Turbidity Nominal (NTU)

:

1

Concentration Free Cl2 (ppm)

:

0

Concentration Free Cl2 Short Time (ppm)

0,1

PURE WATER Pure Water Output nom. (l/d)

:

30.000

Conductivity Designed (µS/cm)

: