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Operation
&
Maintenance manual
OF
R.O plant

For

G.R WATER TECHNOLOGY,

239/20, Shanty nagar,
Near Beary bagh,Gurgaon.

Designed, Supplied and Commissioned by:

Aventura Pvt. Ltd..

A-1/152,Neb Sarai, IGNOU Road
New-Delhi-110068
Tel-+91-43100500/61 Fax-43100599
Website: www.fontuswater.com

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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OPERATION & MAINTENANCE MANUAL

FACILITY : R.O. PLANT (CAPACITY: 500LPH)

CLIENT : G.R WATER TECHNOLOGY,

239/20 , Shanty nagar,
Near beary bagh,Gurgaon.

PLANT SUPPLIED BY : Aventura Components Pvt. Ltd..

E.W HOUSE,
A1/152 IGNOU ROAD,
NEB SARAI
NEW DELHI -110 068

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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INDEX PAGE NO.

1. BASIC R.O.PLANT DATA -4-

2. INTRODUCTION TO REVERSE OSMOSIS -5-

3. EQUIPMENT SPECIFICATION -10-

4. MULTI GRADE FILTER -11-

5. CHEMICAL DOSING -13-

6. START-UP OF RO PLANT -15-

7. PLANT SHUT DOWN -16-

8. PLANT PERFORMANCE MONITORING -17-

9. MEMBRANE CLEANING AND STORAGE -18-

10. ELEMENTS PRESERVATION -21-

11. ELEMENT STORAGE -22-

12. WARRANTY CONDITION ON BOUGHT-OUT ITEMS -22-

13. PRECAUTIONS/CHECK-UP -23-

14. TROUBLESHOOTING OF RO PLANT -24-

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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1.0 BASIC R.O.PLANT DATA

PLANT SPECIFICATIONS

Welcome to the family of happy owners of R.O. Plants supplied by FONTUS

WATER LTD. The design criterions are as follows: -

1. RAW WATER

Source of water – Bore well

Parameter Result

TDS 2000 ppm

2. PRODUCT WATER

Parameter Result

TDS <100 PPM

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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2.0 INTRODUCTION TO REVERSE OSMOSIS

1. REVERSE OSMOSIS PROCESS DESCRIPTIONS

2. HOW REVERSE OSMOSIS WORKS

3. HOW TO USE REVERSE OSMOSIS IN PRACTICE

1. REVERSE OSMOSIS PROCESS DESCRIPTION

Out of the several existing desalination process such as Reverse Osmosis,

Ion Exchange, Distillation and Electro dialysis etc. Reverse Osmosis is the
most convenient, successful and widely used around the World.

Reverse Osmosis in general is the most economical process for desalination

of water containing dissolved impurities. As a widely accepted technology
Reverse Osmosis is superior to the traditional thermal process (such as
distillation) as this is more compact, reliable.

In Reverse Osmosis, the R.O. Membrane acts as a barrier to all dissolved

salts, inorganic and organic molecules with a molecular weight greater than
100(approx.). On the other hand Water molecules, pass freely through the
membrane creating a purified product stream. Rejection of dissolved salts is
typically as high as 95% to 99%.

The applications for R.O. technology are numerous and varied, and include
desalination of sea water or brackish water for drinking purposes, waste water
recovery, food and beverage processing, biomedical separations, purification
of drinking water and Industrial process water. Also R.O. is often used in the
production of Ultra Pure water for use in the semi conductor Industry, Power
Industry and Medical/Laboratory applications. Utilizing R.O. prior to Ion
Exchange dramatically reduces operating cost.

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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2. HOW REVERSE OSMOSIS WORKS

Osmosis is the phenomenon in which the solvent with less solute

concentration moves across a semi permeable membrane to a region of high
solute concentration.
Consider the following experiment to have a better understanding of the
osmosis process.
Take a container and place a semi permeable membrane in center to create
two compartments. Put pure water in one compartment and high
concentration salt solution in the other. What we observe after some time is
the water in the chamber containing pure water has passed to the other
chamber. The reason being the fundamental rule of nature that all systems
tend to attain equilibrium.

OSMOTIC PRESSURE

Water diffuses through a semi permeable membrane towards region of high

concentration to equalize solution strength. Ultimate height difference between
columns is OSMOTIC PRESSURE.

REVERSE OSMOSIS

Pressure applied in excess of osmotic pressure reverses water flow direction.

Hence the term REVERSE OSMOSIS.

Osmosis can cause a rise in the height of the salt solution. This height will
increase until the pressure of the column of water (salt solution) is so high that
the force of this water column stops the water flow. The equilibrium point of this
water column height in terms of water pressure against the membrane is called
OSMOTIC PRESSURE.

If a force is applied to this column of water, the direction of water flow through
the membrane can be reversed. This is the basis of the term REVERSE
OSMOSIS. Since the membrane is not Permeate to the sales. The reverse
flow produces pure water from the salt solution to flow the solution of lower
concentration.

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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3. HOW TO USE REVERSE OSMOSIS IN PRACTICE

With high-pressure pump, pressured saline feed water is continuously pumped

to the module system. Within the module, consisting of a pressure vessel
(housing) and a membrane element, the feed water will be split in a low saline
product, called permeate and a high saline brine called concentrate or reject. A
flow regulating valve called concentrate valve, controls the percentage of feed
water that is going to the concentrate stream and the permeate which will be
obtained from the feed. In case of a spiral wound module consisting of a
pressure vessel and several spiral wound elements, pressurized water flows
into the vessel and through the channels between the spiral windings of spiral
wound element. Up to seven elements can be connected together within a
pressure vessel. The feed water becomes more and more concentrated and will
enter the next element, and at last exit from the last element to the concentrate
valve where the applied pressure will be released. The permeate of each
element will be collected in the common permeate tube installed in the center of
each spiral wound element and flows to a permeate collecting pipe outside of
the pressure vessel.

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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Chemical cleaning procedure:

Membrane should be cleaned with suitable chemicals in any of the following

circumstances.

 Normalized permeate flow drops by 10 %

 Normalized salt passage increases by 5 %
 Normalized differential pressure increase by 15%

Chemical cleaning sequence

 Acid cleaning and flushing.

 Alkaline cleaning & flushing.
 Sanitizing & flushing.

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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Recommended cleaning chemicals

Details of chemicals, recommended flow & pressure, temperature & pH range

and equipment are detailed in the next page
.
RECOMMENDED CLEANING CHEMICALS

Name of chemical Concentration by Foulant

weight
Sodium Hydroxide (NaOH) 0.1% Biological and organic

Tetra sodium salt of Ethylene 1.0% Biological and organic

Diamine Tetracetic
acid(Na4EDTA)
Sodium salt of 0.025% Biological, organic and
Dedeocysulphate (Na-DDS) Silica
Hydrochloric acid(HCL) 0.2% Inorganic

Sodium 1.0% Inorganic and Iron

Hydrosulphite(Na2S2O4)
Phosphoric Acid (H3PO4) 0.5% Inorganic and Iron

Sulfamic Acid(NH2SO3H) 1.0% Metal Oxides

Hydrogen Peroxide 0.25% Bacterial (E-coil)

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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3.0 EQUIPMENT SPECIFICATION

S.No Equipment Specifications Make

1. Raw water/Backwash/pumps 1.5 m3/hr @ 3kg/cm2. Calpedia

Qty : 1 Nos.
2. Multi Grade filter 300 diax 1200 ht. ACPL
MOC: FRP 1 No.

3. Anti-scalant Dosing System 0 – 5 lph Dosing Pump Seko

100 liters HDPE Dosing Tank Sintex
1 Nos.(each)
5. Cartridge filter 20” Slim, 5micron PP ACPL
6. High Pressure Pump with 1.5 m3/hr@7 Kg/cm2 Calpedia
motor MOC: SS – 1 No
7. R.O Membranes 4” X 40” (CPA2-4040) Hydranautics
MOC: Thin Film Composite,
Polyamide 2 Nos.
8. R.O. Housing 4”-250-3 el. Qty : 1 Nos. ACPL

9. CIP Tank 100 liters MOC:HDPE Sintex

10. Necessary Instruments Flow indicator 0-1150 lph Qty. - Aventura

02nos, Panel mounted
11. Pressure Gauge 0-7 Kg/cm2 LM 01 Nos. Iota
0-21 Kg/cm2 PM 02 Nos. Iota
0-7 Kg/cm2 PM 02 Nos
12. R.O. Skid MS ACPL
13. Power / Control Cable - as required ISI
14. Electric panel Skid mounted Initiative
15 Interconnecting Piping and MOC: UPVC ACPL
Valve.

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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4.0 Multi Garde Filte

MULTI GRADE FILTER OPERATION PROCEDURE

As a normal consequence of the filtering process, the MGF gradually entrap

increasing amounts of agglomerated particulate matter. Hence, to ensure that
MGF is able to provide the required filtration flow rate, it will periodically need
to be taken off-line and backwashed to remove the entrapped filtrate. The filter
removes only total suspended solids (TSS), it does not removes total dissolves
solids (TDS).

BACKWASHING INITIATION

Backwash of the filter should be taken once in a day without fail. However, it
can be undertaken in case of any emergency whenever the pressure drop
increases beyond 1 Bar.

OPERATIONAL SEQUENCE OF MULTI VALVE

BACKWASH

The MGF is taken off-line. For backwashing the Multiport Valve should be in
back wash mode during back washing automatically all other port remain in
close position. The MGF vessel must now be backwashed for a period of 25
minutes after starting the Raw Water pump.

RINSE

The MGF vessel that has just been backwashed must now be rinsed to drain
before it can be brought back on line. The multiport valve should be in rinse
mode. The feed water should be allowed to rinse the media bed to drain for
15 minutes. Stop the raw water pump after rinse.

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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SERVICE

After rinsing the filter is ready for service. Change the Multiport valve in
forward mode.

IMPORTANT NOTE - Please note that the multiport valve should be

operated only when the pumps are not running, to avoid the damage.

AIR RELEASE

Air may be trapped into the vessel due to long shut down. After long shut
down, when the plant will starts. If the operator does not do it, there may be
some leakage at the manhole flange, as well as pressure will increased.

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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5.0 CHEMICAL DOSING

The chemical dosing rates and concentrations specified in this section could
differ if the feed water quality is significantly different from the feed water
analysis as shown in Section 1.0 of the O&M Manual. For this reason, the
figures stated in this section are not to be read as recommendations or
guarantees on Fontus behalf.
To prolong the service life of the membranes and increase the overall
efficiency of the process, it is necessary to dose selected chemicals into the
feed water of the reverse osmosis system.

IMPORTANT NOTE:

Because of the dependence of the process upon correct chemical

pretreatment, mistakes could prove seriously detrimental to the sensitive
membranes, particularly if the wrong chemical is dosed or the wrong
concentration made up. Hence, great attention to correct dosing procedures
must be taken during a dosing solutions make-up and dosing pump setting.

The storage and handling of chemicals are potentially dangerous activities

and as such should be treated with the greatest care and respect. Follow
the chemical manufacturers advice on storage and handling of their products
exactly and ensure all operators who deal with these chemicals fully
understand and adhere to this advice.

DOSING SUMMARY

The chemical dosing rates shown in Table 1 are based on the bulk chemical
and dilution water quantities required to make-up 50 liters of solution in 100
liters tank (the individual volume of the chemical dosing sets mixing and
dosing tanks) at the quoted ppm concentration.

These dosing rates and concentrations have been carefully worked out with
the following considerations:

a) The necessary required effective dose of chemical in water.

b) The flow range of the dosing pump.
c) The provision of at least 2 Days dosing mix per tank.

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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Consequently, the figures and procedures given in this manual should not
be changed without extremely good reason and prior notification to Fontus
Water Ltd.

TABLE 1

Antiscalant 50 GMS. In 24 ltrs.of Antiscalant 50 GMS. In 24 ltrs

water @3 lph for 8 hrs. hrs.

Note :- Plant Warranty/Guarantee is null & void if Recommended

chemical Will not be used in the Plant.

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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6.0 START- UP OF RO PLANT

PLANT START UP

MGF is thoroughly washed in forward and back washing mode by raw water.
Back wash process is as mentioned above.

Chemical dosing solutions should be prepared for the pre - treatment as per
instructions given above.

Ensure cartridge filter is loaded with the element and properly tightened.

Check and adjust the valve positions such that:

1. DMF valves should be in filter mode.

2. RO reject line valve to be fully open.

3. Once Raw water tank is full, Start Raw water pump.

4. Check that the flow is coming through RO reject line and also check the
pressure indicator readings.

5. Start the dosing at the rate provided and ensures that the liquid is being
pumped into the system.

6. Now the start HP Pump.

7. RO reject valve to be gradually closed to adjust the pressure

8. Flushing of RO membranes should be carried out during startup & shut down
with RO product water.

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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7.0 PLANT SHUT DOWN

1. Check and confirm that CIP tank is filled with RO permeate.

2. Stop the H.P pump.

3. Immediately open the R.O. Reject valve fully.

4. Close suction valve of raw water tank to raw water pump and open outlet
valve of CIP tank to raw water pump.

5. Allow Raw Water Pump to run for 5 to 10 minutes for membrane flushing.

6. Stop raw water pump now in service. Thereafter close the HP pump
discharge valve along with stoppage of all dosing pumps and reject valve.

7. In case plant has to remain idle for more than 48 hrs. Preservation of the
membranes is to be made as the details given in section 10.0.

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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8.0 PLANT PERFORMANCE MONITORING

Accurate records of plant performance are essential for two reasons:

1. The changing trends in performance are used to predict when cleaning

operations may become necessary. For example, increasing filter pressure
drop is an indication that backwashing is required; or rising product water
conductivity or permeate flow is reduced to less than 10% of original flow may
indicate that membrane cleaning is required.

2. Comprehensive records of plant operation are obligatory should any warranty

claims be made.

PLANT LOG SHEETS

A full set of log sheet readings should be taken at 1-2 hour of intervals.
Readings of all instrumentation on the plant should be noted, along with the
date, the time and the identity of the plant operator. An example of a blank
log sheet is attached. Even during periods of complete shut down, the
operator giving date and time and an explanation given in the note section
should complete a log sheet. This procedure ensures that a complete record
of the plant history is kept.

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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9.0 MEMBRANE CLEANING AND STORAGE

CLEANING PROCEDURE FOR REVERSE OSMOSIS ELEMENTS

CLEANING REQUIREMENTS

 In normal operation, mineral scale, biological matter, colloidal particles and

insoluble organic constituents can foul the membrane in reverse osmosis
elements. Deposits build up on the membrane surfaces during operation until
they cause loss in water output, loss of salt rejection or both.

 Elements should be cleaned whenever the normalized water output rate drops
by 10 percent, the salt content in the product water rises noticeably, or the
Feed pressure increases by 10 percent from the reference conditions. (The
flow rate and Pressure established during the 25 to 48 hours of operation).

 Feed Pressure should be measured and recorded if the element becomes

fouled, the Feed Pressure will increase.

 It should be noted that the water output rate would drop if feed water
temperature decreases.This is normal and does not indicate membrane
fouling.A malfunction in the pretreatment pressure control or pump can cause
a drop in product water output or an increase in salt passage. If a problem is
observed, these causes should be considered.The element may not require
cleaning.

Cleaning is indicated whenever the following conditions become apparent.

1. Product flow rate drops by 10% on what amount to the same thing, the
pressure has to be increased by 10% to maintain the same flow.

2. The product water quality falls significantly, i.e. the conductivity rises by 20-
30% over initial conditions.

3. The Feed Pressure rises by 10 - 15%.

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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Irrespective of the above, the membranes must be cleaned after every three
months of operation of the R.O. plant.

The above will emphasize the importance of maintaining operating data LOG
SHEETS. Without the data contained in the LOG SHEETS, it will become difficult
to predict early enough when cleaning becomes necessary.

SAFETY PRECAUTIONS

In using any chemicals indicated in this section, follow accepted safety practices.
Consult the chemical manufacturer for detailed information about safety handling
& disposal.

When preparing cleaning solutions, ensure that all chemicals are dissolved and
well mixed before circulating the solutions to the elements.

It is desirable to flush the elements with good quality chlorine free water (20*C
minimum temperature) after cleaning. The RO product water is recommended,
but pre filtered feed water may be used provided that there are no corrosion
problems in the piping system.

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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CLEANING AND DISINFECTION PROCEDURES

Enclosed is membrane manufacturers recommendation for various cleaning

program. Disinfections of the system are usually included in cleaning programs.

Selection of effective cleaning chemicals and procedures depends upon the

quality and variability of the incoming feedstock.

These types of foul ant can occur singly or together and the cleaning procedure is
tailored to a particular foul ant. The following properties of the cleaning solution
are measured before and after the clean with pH being monitored continuously
(pH, E/C, Turbidity, Fe, MgH, CaH, SO4) to determine removal rate of these

Contaminants and hence effectiveness of cleaning. A rise in pH shows that

inorganic iron is being removed and the pH will need to be adjusted throughout
the cleaning cycle. An increase in E/C with a reduction in pH shows that
bioactivity has been removed. Selection of effective "Recipes" for cleaning is a
matter of continuous development and may utilize proprietary chemicals with
commodity chemicals or a combination of both.

CEANING OPERATION

Pour and mix the cleaning solution in the flushing tank to requisite strength.

Ensure the position of the valves so as to circulate the cleaning solution into the
membranes.

NOTE:

When starting-up after cleaning care should be taken to operate initially at

reduced flow and pressure to flush the bulk of the cleaning solution from the
elements before resuming normal operating pressures and flows. Despite this
precaution, cleaning chemicals will be present on the permeate side following
cleaning. Therefore, the permeate must be dumped to drain for at least 10
minutes, or until the water is clear.

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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10.0 ELEMENTS PRESERVATION

Elements are shipped either dry, packed in a double plastic bag, or soaked in a
solution of 1% Sodium Bisulphite in a double plastic bag, the inner one of which is
made from an oxygen barrier material.

Any element that has been used and removed from the pressure vessel for
storage must be preserved in a preservation solution - likewise a train, shut down
for more than 48 hours should be soaked and stored in a preservation solution.

Preservation solution can be 1% sodium Bisulphite. Bisulphite should be food

grade not cobalt activated.

The element should be soaked for 1 hour in the solution, allowed to drain and
then be sealed into an oxygen barrier plastic bag and finally into a second
polythene bag.

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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11.0 ELEMENT STORAGE

Dry elements have no limit of storage life.

Elements packed in preservation solution may be kept in sealed bags or a

maximum of 12 months. Although it is desirable to visually inspect for biological
growth every 3 months, re-soak and re-seal in double polythene bags as above.
Elements must be stored in a warehouse out of direct sunlight in temperature
range 4*C (with propylene glycol) to 45*C.

12.0 WARRANTY CONDITION ON BOUGHT-OUT ITEMS

The system is warranted for TWELVE MONTHS from the date of supply against
any manufacturing defect. However Electronics items and consumables
(Cartridge filter, Chemical, Filter media etc.) will not be covered under this
warranty. Electrical components and equipment burnt out due to faulty power will
not be covered under warranty and the associated replacement cost will be
charged extra. This warranty would not be valid for the losses due to system
mishandling and operational mistake etc. In any such event, the repair /
replacement of the system or the components will be charged extra.

Membranes and pumps will be covered as per the rules laid down by the actual
manufacturer.

The warranty will be null and void

1. IF PAYMENT TERMS ARE VIOLATED.

2. YOU ARE USING SPARE PARTS AND CONSUMABLES RECOMMENDED BY US.
3. PREVENTIVE MAINTENANCE SHOULD BE AS SUGGESTED BY US.
4. MAINTAIN OPERATION AND MAINTENANCE DATA/ RECORDS/ LOG-SHEETS AND
THE SAME IS MADE AVAILABLE WHENEVER ASKED BY US. NORMALLY WE
SUGGEST TO SUBMIT THIS RECORD EVERY 15 DAYS BY COURIER TO US.
5. MAINTAINING RAW WATER SOURCE & QUALITY AND RO FEED WATER
LIMITING CONDITIONS MENTIONED IN OUR OFFER.
NO OXIDISESING SUBSTANCE LIKE FREE CHLORINE, OZONE ETC. SHOULD
ENTER IN RO MEMBRANES.

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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13.0 PRECAUTIONS/CHECK-UP

Make sure that the Filter is backwashed regularly at the specified flow rates.

Chlorine is very harmful to Membranes. If it enters Membranes, it causes

irreversible damage drastically reducing the life of Membranes. Make sure that
no chlorine enters the system. Raw Water entering the Membranes should be
regularly analyzed in the lab for any presence of FRC (Free Residual Chlorine).
Membrane inlet pressure should not exceed the design pressure.

Log Sheets should be properly maintained on regular basis.

Cartridges should be regularly checked for any chocking and should be changed
whenever required.
During change any position of multiport valve raw water pump must be off.

During start up of High Pressure Pump make sure that the R.O. Reject Valve is
100% open.

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68

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14.0 Troubleshooting RO Plant

Troubleshooting of any plant is carried when it performance does not meet the
Specification or when there has been abrupt change in its performance. Similarly
RO plants also require troubleshooting if there is unacceptable change in quality
and quantity of water produced.

Troubleshooting of RO Plant is done whenever the plant deviates from its normal
operation. We have provided troubleshooting chart

Troubleshooting chart

CHECK VERIFY EFFECT

Pressure drop Has not increased by more More than 15% indicates
between feed and than 15%. fouling of feed path and
reject. membrane surface.
Requires cleaning
Pressure drop Has not increased by More indicates fouling of
between feed and more than 15%. membrane surface.
permeate Requires cleaning.
Permeate conductivity Has not increased by More indicates fouling of
more than 15%. membrane surface. Requires
cleaning.
Instruments Reading Verify by calibration and Wrong operation
carryout of lab check of False sense of security that
the parameters the everything is OK.
instrument is monitoring.

EW HOUSE, A1/152 , NEB SARAI IGNOU ROAD,NEW DELHI -68