BANGGAI AMMONIA PLANT (BAP) PROJECT Boustead Salcon Water Solutions
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PROGRAM
DAY 1
Introduction
Pretreatment (Ultrafiltration)
Desalination (Seawater Reverse Osmosis)
Day 2
Desalination (Brackish Water Reverse
Osmosis)
Mixed Bed Polisher
PROGRAM
Fundamentals (covered under SWRO)
Design Basis
Process Flow Diagram
System Description
Operation Philosophy
Daily Operation, Monitoring and Maintenance
Start Up
Shut Down
Troubleshooting
Safety Precaution
DESIGN BASIS OF
BRACKISH
REVERSE OSMOSIS
(BWRO)
Design Basis
Feed Water Characteristic:
Source: SWRO Permeate
BWRO Configuration: (2 Duty, 1 Standby) x 50%
Design Flow Rate:
Feed of BWRO System 190 m3/h
Feed Water Quality (SWRO Permeate):
pH 6.5 – 8.5
Total Dissolved Solids (TDS) Max. 600 mg/L
Boron 2.4 mg/L
Treated Water Quality (After BWRO System):
Total Dissolved Solids (TDS) < 10 mg/L
Silica < 0.02 mg/L
Calcium < 0.10 mg/L
Magnesium < 0.15 mg/L
PROCESS FLOW DIAGRAM
&
SYSTEM DESCRIPTION
FOR BWRO SYSTEM
Process Flow Diagram
BWRO Module
RO CIP Tank & Pump
Location of Equipment for BWRO System
BWRO Skid
SWRO Product
Tank
BWRO HP Pump
RO CIP Pump
RO CIP Tank
System Description
BWRO HP Pump
To transfer SWRO permeate to BWRO System
Configuration: 3 x 50%
VFD is installed at BWRO HP Pump to maintain fix
permeate flow ( 80m3/h)
System Description
BWRO Modules
Design Recovery: 85% ( 2 stage)
Each train of BWRO consists of 7: 2 nos. of pressure
vessel ( 7 elements long)
8 inch diameter spiral wound polyamide RO
membrane
Membrane used is Toray’s brackish water RO
membrane, model TM720D-440.
Reject water (relatively low TDS than seawater)
recycle back to UF Filtrate Tank
System Description
Caustic Dosing
NaOH is dosed at BWRO feed water (SWRO
Permeate) to raise its pH
To improve boron and alkalinity rejection
Share storage tank with UF system, 2 x 100% Dosing
Pump is provided
BWRO SKID
PFD
1st Stage BWRO
Feed
BWRO Permeate
2nd Stage BWRO
Header
Reject
1st Stage BWRO
Reject/2nd Stage
BWRO Feed
BWRO SKID PHOTO
OPERATION PHILOSOPHY
OF
BWRO SYSTEM
Overview of BWRO System
BWRO HP Pump BWRO Module BWRO Module
Discharge Pressure Permeate Flow Permeate Conductivity
Switch Transmitter Analyzer
BWRO Module Feed
Conductivity Analyzer
BWRO Module 1st BWRO Module 2nd
Stage Feed Pressure Stage Reject
Transmitter Pressure Transmitter
Operation Parameter
BWRO Feed Water (SWRO Permeate) Quality:
Alarm when high Conductivity (detected by AIT-23027)
pH is adjusted to 8.2. Alarm when pH is > H or < L
BWRO Module in Auto Operation: Maximum 2
BWRO Operation Parameter shall be set:
Designed Capacity. Reference value
Reference value for to initiate “CIP”
BWRO HP Pump alarm
VFD to modulate
pump speed.
Reference value
BWRO Treated for BWRO train
Quality: < 10 switch over for
ppm of TDS duty
Operation Philosophy: Service
Step 1: Service (BWRO HP Pump Ramping Up) 1. Once service
start, Open
BWRO
Permeate Off
Spec Valve
3. BWRO
Reject Valve
close when
BWRO HP
Pump is started
2. BWRO HP
Pump start
ramp up
Operation Philosophy: Service
Step 2: Service (Dumping BWRO permeate prior conductivity check)
BWRO
permeate will
be dumped to
Outfall. After 5
mins, check
conductivity
BWRO HP
Pump VFD
modulate speed
to maintain
permeate flow
Operation Philosophy: Service
Step 3: Service (Conductivity below set point)
BWRO
Permeate
conductivity
below set
point,
permeate water
will be
directed to
Desalinated
Water Tank
Operation Philosophy: Shutdown
In case of Abnormal Critical Operation occurs, BWRO
will proceed to shutdown.
Parameter Instrumentations
BWRO HP Pump Discharge Pressure Switch Detected by PS-23031A/B/C
Activated
BWRO Module 1st Stage Feed Pressure > HH Detected by PIT-23034A/B/C
BWRO Module 2nd Stage Reject Pressure > Detected by PIT-23036 A/B/C
HH
Differential Pressure of BWRO Module > HH PIT-23034 A/B/C – PIT-23036 A/B/C
Permeate
Dumping,
BWRO Module Product Conductivity > H Detected by AIT-23040 A/B/C recheck
conductivity
Note: Shutdown procedures will proceed automatically without activation
by operator
Operation Philosophy: Shutdown
Step 1: Shutdown (BWRO HP Pump Ramp Down)
1. Close the
BWRO
Permeate
Outlet Valve,
but open
Permeate Off
Spec Valve
2. BWRO HP
Pump VFD
ramp down
slowly.
Operation Philosophy: Shutdown
Step 2: Shutdown (BWRO HP Pump Completely Stop)
1. Close
Permeate
Off Spec
Valve
2. Open
BWRO HP Pump Reject
completely stop Valve
BWRO CIP Operation
CIP operation shall be conducted manually by operator
Frequency: Every 6 months or High Differential Pressure
alarm is activated
At all time, only 1 train of BWRO modules in cleaning
For 2 stages RO shall cleaning 2 times
Running only 1 RO CIP pumps and flow shall be adjusted
and depending on which stage to be cleaned
Stage 1 : 5 nos. of pressure vessels: 56 m3/h
Stage 2: 2 nos. of pressure vessels: 16 m3/h
BWRO CIP Procedures
1. Update BWRO status to CIP “In Process”
2. Isolate from other system
3. Connect the CIP Inlet/Outlet by flexible hose
1st Stage RO
Modules
BWRO CIP Procedures
2nd Stage RO Modules
BWRO CIP Procedures
4. Prepare chemical, mixing by recirculate RO CIP Pump
discharge flow
CIP Chemical Design Dosage
CIP NaOH 1000 ppm
CIP Citric Acid 20000 ppm
5. Load new cartridges into RO CIP Cartridge Filter
6. Start RO CIP Cleaning steps. There is 5 steps of cleaning.
7. After completion of CIP, dismantle the flexible hose.
8. Update BWRO Status to “Completed”
BWRO CIP Cleaning Steps
Step 1: 1st Recycle
1. Running only 1 RO CIP Pump 30-60 minutes.
2. Adjust flowrate (Depending on which stage to
clean)
3. 1St Stage: Clean 5 nos. RO vessels
2nd Stage: Clean 2 nos. RO vessels
BWRO CIP Cleaning Steps
1st Stage
CIP Inlet
Must close this BWRO Permeate
Isolation Valve (BUV-
1004/1104/1204)
1st Stage
CIP Outlet Open this BWRO
Permeate Drain Valve
(BUV-1005/1105/1205)),
2nd Stage to drain out CIP chemical
CIP Inlet
waste
2nd Stage
CIP Outlet
BWRO CIP Cleaning Steps
Step 2: Soak
RO CIP Pump Stop, allow membrane to soak overnight for
10 to 15 hours
Step 3: 2nd Recycle
Repeat as per Step 1.
Step 4: Drain
Discharge chemical via Cartridge Filter Drain Valves (BAL-
1033 & BAL-1034). Close the CIP Cartridge Filter Outlet
Valve (BUV-1315).
CLOSE
`
OPEN
BWRO CIP Cleaning Steps
Step 5: Flushing
Top up BWRO Permeate into RO CIP Tank. Flushing the
membranes by running RO CIP Pump for 60 to 120 minutes
Check pH (AIT-23051) to ensure chemical is fully flushed
out
DAILY OPERATION
MONITORING &
MAINTENANCE
FOR BWRO SYSTEM
Daily Operation Monitoring
It is important for operators to follow daily
operation schedule
Small issue can be detected earlier and
rectification work can be done before problem
develop into major problem
Ensure proper operation of plant to achieve
performance
Instrument data or trending should be checked
if abnormal reading/trend is found
Maintain a log look where all relevant
operational events are recorded.
Daily Operation Monitoring
Parameter Instrumentation Action/Remark
Conductivity of SWRO AIT-23027 To ensure feed water quality do
Permeate not exceed design limit
BWRO Module 1st Stage PIT-23034 A/B/C To ensure operation of BWRO
Feed Pressure system is smooth.
BWRO Module Permeate FIT-23039 A/B/C To ensure BWRO system is
Flow operating as per designed.
BWRO Module Permeate AIT-23040 A/B/C To confirm water quality of
Conductivity BWRO Permeate meet
requirement
Note: For others parameter, please refer to Alarm Set Point List for details.
BWRO System Maintenance
Monitor flow, pressure, ORP, conductivity
Perform RO CIP when
Pre-set High differential pressure alarm is activated
Normalized permeate flow drop by 10%
Normalized salt passage increase by 20%
TorayTrak
To assist in RO System performance data
normalization. TORAY developed a RO Performance
Data Normalization Program called TorayTrak.
TorayTrak is available as free download at the Toray
web site [Link].
How to Use TorayTrak Excel Sheet
1. Select membrane type @ TorayTrak Elements And HELP
sheet
SWRO : TM820M-440
BWRO : TM720D-440.
-Click “YES” to confirm the membrane selection.
2. Copy the daily operation data and insert into ScadaData
sheet.
3. Go to Data sheet, to generate the normalized data.
Note: To confirm formula used is NormPermFlowBar.
4. Select CTRL+ALT+F9 to recalculate all the data.
5. Graphs are generated for analysis.
Example of Normalized Salt Passage
Salt Passage, Normalized vs Actual
1.4%
1.2%
If salt passage
1.0%
is continuous
exceed 20%
Salt Passage, %
0.8% (0.6%) then
CIP Cleaning
0.6% is required
Ref Data: 0.4%
Salt Passage
is 0.5% 0.2%
0.0%
5/25/2017 5/30/2017 6/4/2017 6/9/2017 6/14/2017 6/19/2017 6/24/2017 6/29/2017 7/4/2017 7/9/2017
Salt Passage Normalized, %
Example of Normalized Permeate
Flow
Permeate Flow
82.0
80.0
Ref Data:
Permeate 78.0
flow is about If permeate
Perm Flow, Units
80 m3/h flow drop
76.0
more than
10% ( below
74.0 72 m3/h),
mean CIP
required
72.0
70.0
6/18/2017 6/20/2017 6/22/2017 6/24/2017 6/26/2017 6/28/2017 6/30/2017 7/2/2017 7/4/2017 7/6/2017
Perm Flow Normalized
START UP OF
BWRO SYSTEM
Start-up Procedures
1. At the HMI, select “AUTO” mode for below equipment:
All On-Off Valves corresponding to BWRO system
BWRO High Pressure Pump (2301-L7JA/B/C)
2. Select BWRO Module to “Service” under “Auto” mode.
3. Throttle BWRO Reject Globe Valve (GV-1001/1101/1201) to
achieve 85% recovery
4. If membranes is newly loaded or start-up after long term
shutdown, activate the “Hold” button at permeate stream to
extend flushing period. (Minimum 4 hours of flushing)
5. Continue until all operating parameter reading are stable.
Monitor the conductivity of BWRO product and others
operation data, for e.g.: Recovery, Salt Rejection.
Brackish Water Reverse Osmosis
(BWRO) System
6. Check for any abnormalities.
7. After 24 hours operation, take sample from individual
BWRO vessel and check conductivity. All conductivity
shall same. (Out of specification is a sign of leaking of O-
ring, Stop the system and reload the membrane for that
particular vessel).
8. After 1 week operation, review if shimming is required.
Shimming Procedures
It is normal to have some movement of the RO element in the
RO Vessel. This is due to pressure drop across the element
can cause them to compress.
Movement can cause rubbing across the interconnector O-
rings, and over time and break it.
Potential of movement shall be minimized by ensuring that
elements are fit tightly in the RO vessel. Any unwanted gap
shall be eliminated by using shim.
To shim, simply place PVC “washers” of varying thickness
(1/8” to 3/8”) over the FEED side inboard adapter. Add as
many shims as necessary until the end plate fits snugly
against the shims. If necessary a shim may be removed if the
end cap is difficult to reinstall. A gap of 1.4 inch between the
end plate and the shims will not cause problems in
performance.
SHUT DOWN OF
BWRO SYSTEM
Shutdown Procedures
1. From the HMI, select “Off” to shutdown BWRO from service.
2. At MCC, switch to “Off” mode for all the motor that are stopped
to prevent accidental start during shutdown maintenance.
3. Check all pressure gauges. If some point is still pressurized,
open the sampling/vent/drain valve along the line to release
pressure.
4. BWRO system can be stopped for 48 hours without preservation
but precautions like daily flushing is needed to prevent
microbiological fouling.
BWRO System Shutdown
6. Daily flushing: Manual operate BWRO HP Pump (2301-
L7JA/B/C) in lower speed.
7. If the BWRO system has to be shutdown for extended period of
time longer than 48 hours, take care below:
The elements do not dry out. Dry elements will irreversible lose
flux
RO membranes are flushed with RO permeate every 24 hours
If no flushing is done, chemical preservation is necessary.
Shutdown Recommendations
Preservation of RO Membranes shall be as follow:
Type of chemicals: Formaldehyde, Sodium Bisulfite,
Hydrogen Peroxide
Recommended: 1000 ppm of Sodium Bisulfite Solution
Run the RO CIP Pump to replace the water in RO Module
with preservative.
Close all valves to retain the chemical in the RO Module.
This is to prevent oxidation of chemical, rendering it
ineffective.
Preservative solution shall > 3.2 , if pH srop, replace fresh
solution
Check the permeate pressure is not greater than feed
pressure.
Repeat the procedures to replace fresh solution:
Every 15 days if temperature > 27oC
Every 30 days if temperature < 27oC
TROUBLESHOOTING
OF
BWRO SYSTEM
Troubleshooting
Problems encountered in BWRO System is similar as
SWRO System
Basic steps of troubleshooting for BWRO system is
similar as SWRO system
Refer to SWRO System Troubleshooting section
For Equipment Troubleshooting, shall refer to its
Operation Manual.
SAFETY PRECAUTION
Safety Precaution
IN USING ANY CHEMICALS, FOLLOW ACCEPTED SAFETY
PRACTICES. ALWAYS WEAR EYE PROTECTION AS
MINIMUM, IN CASE OF HANDLING CORROSIVE
CHEMICALS, WEAR FULL FACE COVER AND PROTECTIVE
CLOTHING. REFER TO RELEVANT MATERIAL SAFETY
DATA SHEETS AS SUPPLIED BY CHEMICALS
MANUFACTURERS.
BEFORE DRAINING ANY CHEMICALS FROM STORAGE
TANKS, RUN SERVICE WATER TO THE CHEMICAL DRAIN
POINT. SLOWLY OPEN THE CHEMICAL DRAIN VALVE AND
FLUSH GENEROUSLY WITH SERVICE WATER.
Safety Precaution
ALWAYS WEAR SAFETY HELEMT AND BOOSTS
AT ALL TIME WITHIN PLANT AREA
QUESTIONS ??
QUIZ
Quiz: BWRO
1. There is how many BWRO train in BAP plant?
2. BWRO train consists of how many stage of RO?
3. BWRO reject is recycled back to where?
4. Why NaOH is dosed into SWRO Permeate (BWRO Feed)?
5. If during operation, permeate conductivity is >H, will the
system shutdown immediately?
6. For BWRO CIP, how many RO CIP Pump will be in operation.
THANK YOU
