Installation Operating and Maintenance Guidelines T-Rack Vario 3 (2012-05) E Inge

inge GmbH
Installation, Operation and Maintenance Guidelines inge T-Rack vario
Index
1. 2. 3. 4. 5. inge T-Rack vario Technical Data - Important Information Storage and Shipment T-Rack vario assembly Operating and Start-Up Guidelines Recommendations Regarding Air Integrity Testing (Pressure Hold Test) inge T-Rack vario 6. 7. 8. 9. Operating Conditions Documentation of Operating Conditions Membrane Downtime Conditions Transport Conditions for inge UF Modules and T-Rack vario components 18 22 26 27 28 28 29 3 4 5 13
10. Warranty Policy 11. Contact Details Appendix A Principle Flow Diagram T-Rack PR-02-01-005-01 5(2012-05) E inge Appendix B Process Specification UF 1(2012-05) E inge
Installation Operating and Maintenance Guidelines T-Rack vario 3(2012-05) E inge 2011 inge GmbH All rights reserved
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1.
inge T-Rack vario Technical Data - Important Information
To keep the T-Rack in good condition and avoid any risk of damages, please observe the following precautions:
Avoid Drying Out
If the module is put into storage for an extended period of time, the membrane will dry out. Dehydration of the membrane may cause it to suffer irreversible damage. It is therefore essential to protect the membrane from dehydration.
Avoid Potential Freezing Conditions
The module must be protected from freezing at all times, particularly during transportation and storage. Exposing the UF modules to freezing conditions may result in irreversible damage to the membrane and cause the outer shell to become brittle.
Protection from Direct Sunlight and Other UV Sources
Avoid long-term exposure of the module to direct sunlight or other UV sources. Protection from Sudden Variations In Temperature
Avoid sudden variations in temperature. Temperature adjustment should be carried out at a maximum rate of 1C/minute. The permissible temperature range is 1C to 40C.
Protection from Organic Solvents/Concentrated Acids
Ensure that the modules and membranes do not come into contact with polar organic solvents, chlorinated solvents, or concentrated acids/bases.
Protection from Abrasive Materials
The membranes must be protected from abrasive materials (e.g. metal shavings) to prevent irreversible damage to the membrane.
Do Not Use Silicone, Lubricants Containing Silicone Or Pipe Threading Compound
Lubricants and other materials that contain silicone could cause irreversible blockage of the membrane and must be kept away from the membrane surface. Only glycerine may be used as a lubricant for seals, O-rings, etc. Only Teflon tape may be used for thread sealing.
Careful Transportation
Mechanical damage or rupture of the module shell and connection ports could occur if the modules are dropped or struck against hard objects. Modules must therefore be handled with extreme care. Particular care should be taken during transportation.
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2.
Storage and Shipment
All inge T-Racks are shipped in special cardboard boxes which provide full protection during transportation. Each module is sealed with a plastic cover on the feed connectors and packed in separate cardboard boxes or packed in units of 10 modules. It is not advisable to stack single modules end to end. To provide stability during transport, the individual cardboard packing boxes can be stacked on top of each other: T-Rack: maximum 3 units (boxes) one above the other maximum 3 modules in the lying position no stacking dizzer XL, single module: dizzer XL, 10 pcs. package:
Handle the modules with care at all times (during transportation, rack assembly, and operation). All modules are integrity tested (wet tested) before shipment. To prevent dehydration and control bacterial growth, the membranes are saturated with a non hazardous solution of water (potable water quality)/glycerin/sodium bisulfite solution [74.25:25:0.75 wt%]. The connection ports of the dizzer modules are sealed with plugs and securely wrapped in plastic prior to shipment. In some cases the modules themselves are shrink-wrapped in plastic (depends on module type). After removing the preservation solution from the membranes and module, the module must be protected from freezing at all times during transportation, operation and storage. Irreversible damage to the membrane and brittleness of the shell may result if the module or the membrane freezes. Storage of the module in its original packing box at temperatures down to minus 15C does not affect the modules functionality or performance. However, due to the fact that synthetic materials tend to be more brittle at low temperatures, transportation of the modules during periods of cold weather with freezing temperatures should be carried out with extreme care in order to avoid damaging the membranes or the module. Modules must be stored in dry, moderately ventilated conditions, away from any sources of heat, ignition and direct sunlight. Sealed modules (in their original packaging) may be stored for up to 12 months at a temperature of between -15C and +40C. To avoid abrupt variations in temperature the modules must be stored for at least two days at a temperature above freezing before the original cardboard boxes can be opened. Any warranty, implied or otherwise, shall expire after 12 months unless otherwise agreed by inge in writing.
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3.
T-Rack vario assembly
Before assembling the T-Rack, make sure that you have received all the components and check that none of them show signs of mechanical damage. If you have any concerns or cause for complaint, please get in touch with your inge representative immediately.
Filtrate header Filtrate pipe with 90 elbow pieces and flexible 2 couplings
Upper feed/drain header
dizzer XL-W
Top cross brace with filtrate header clamp supports
Pipe couplings
Lower feed/drain headers
All flanges according to ISO 7005 PN 10, ANSI class 150
Bottom cross brace
The entire T-Rack is designed to be assembled without any of its components being under tension. For T-Racks consisting of several sub-units, it is generally required to assemble the whole system from bottom to top, rather than sub-unit by sub-unit.
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To ensure correct assembly of the inge T-Rack (max. 80 modules and max. 24 modules per sub-unit), please proceed as follows: 1. Connect the lower feed/drain headers (screws M10 x 80, lock washers M10) to the bottom cross braces (60x40 mm) to form the base and fit the adjustable feet to the screw heads as shown in Fig. 3.1.2.
Marking on lower feed/drain headers
Fig. 3.1.1
Fig. 3.1.2
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2. Rotate the base 180, place it in the location in which the system will be installed and use a spirit level to check that the base is perfectly level both front to back and side to side, adjusting the feet* as necessary. Take care that all feet are loaded equally. Next, fit the pipe couplings over the module discharge points on the bottom feed/drain headers, making sure that the inge logo on the pipe couplings is facing outwards on both sides of the two-row layout [see Fig. 3.2.1]. In a four-row arrangement, the screw head and inge logo on each pipe coupling should be facing in the same direction (outwards) in both rows [see Fig. 3.2.2] to ensure that you can easily access the screws if you need to unfasten them at a later point in time. Tighten the screws on the pipe couplings to a sufficient degree to ensure that they cannot slip over the raised ribs of the feed/drain headers [see Fig. 3.2.3].
Fig. 3.2.1 *Do NOT fasten the feet to the floor!
Fig. 3.2.3 Raised ribs
Fig. 3.2.2
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3. Attach the transparent filtrate pipe and two elbow pieces to the filtrate connection on the module using the three flexible 2 couplings [see Fig. 3.3.1]. Next, place a dizzer XL module on the bottom module discharge point as shown in Fig. 3.3.2. To ensure the pipe coupling is correctly positioned, the pipe coupling housing is designed to abut against the raised ribs of the feed/drain header. Fasten the pipe coupling to a degree that still allows the module to be rotated (torque < 1Nm). Continue installing all the additional modules one by one, switching sides each time you install a module.
Fig. 3.3.1
Fig. 3.3.2
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4. Push the top pipe couplings over the modules and fit the top feed/drain headers on top one by one. In two-row layouts, the inge logo on each pipe coupling should be facing outwards. In a four-row arrangement, the screw head and the inge logo on each pipe coupling should be facing in the same direction (outwards) in both rows to ensure that you can easily access the screws if you need to unfasten them at a later point in time (see point 2).
Fig. 3.4.1
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5. Push the pipe coupling on until it abuts against the raised ribs of the feed/drain header [see Fig. 3.5.2]. Fasten the pipe coupling to a degree that still allows the module to be rotated (torque < 1 Nm). Next, fasten the top cross braces (M10 x 30 screw, M10/30 washer) into their proper positions making sure to keep them free from tension [see Fig. 3.5.1].
Top cross braces
Raised ribs
Fig. 3.5.1
Fig. 3.5.2
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6. After fastening the 2 coupling seal to the filtrate connection on the filtrate header, place the filtrate header into the filtrate header clamp support from above [see Fig. 3.6.1]. The flanges of the filtrate headers should be flush with the other flanges. Align the dizzer XL module as shown in Fig. 3.6.2 by rotating the module as necessary. level flush
Fig. 3.6.1
Fig. 3.6.2
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7. Connect the 90 elbow pieces to the filtrate headers using flexible 2 couplings [see Fig. 3.7.1 and Fig. 3.7.2]. Finally, make sure that all the inge Ultra S 250 pipe couplings are correctly positioned and tighten them to a torque of 40 Nm. Check that the flexible 2 couplings have been correctly mounted and fastened in place.
Fig. 3.7.1
Fig. 3.7.2
8. The stainless steel components used in the system (pipe couplings to connect the module bodies to the end caps/headers, cross braces, bolts and nuts) are suitable for applications involving the treatment of fluids which contain corrosive ingredients (e.g. sea water treatment). However, the stainless steel components could still corrode if they come into direct contact with corrosive substances for a lengthy period of time (e.g. due to leaks in pipes, couplings, etc.). To prevent the risk of corrosion in these situations, we recommend treating the stainless steel components with an anticorrosive agent. The anticorrosive agent (e.g. BRUNOX LUB & COR) should be silicone and solvent free, have good creep properties and be easy to apply with a brush or spray bottle. The parts to be treated must be clean and free from corrosion. Make sure to remove any existing corrosion by mechanical means before applying the anticorrosive agent. Please also ensure you carefully follow the instructions provided by the manufacturer of the anticorrosive agent.
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4.
4.1
Operating and Start-Up Guidelines

General
Before operation:
Check that the scope of delivery is complete and that all the inge UF modules have been installed correctly; Ensure that any dead spots within the piping have been eliminated during construction/assembly of the ultrafiltration system. This is particularly important for the filtrate header of the entire system; Verify that all the system components and pipes have been cleaned prior to installing and connecting the module(s) to ensure there is no possibility of impurities, abrasive materials or oily materials from the supply piping being rinsed into the module(s); Check that all the air-bleed valves are fully functional and that there is no risk of air pockets forming in the header pipes; Ensure that the installation of the connecting pipework with the inge T-Rack has been carried out free from any tensions; Confirm that the automatic program control system (programmable logic controller, PLC) is working properly and that there is no risk of pressure surges or shocks (pneumatic and/or hydraulic) or incorrect valve actuation.
Once all these points have been checked, please carry out the rinsing and disinfection process described below. Once this process is complete, the filtrate can be used for its intended purpose.
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4.2
Rinsing the inge UF modules
To prevent dehydration and bacterial growth, all inge UF modules are preserved using a non toxic aqueous preservation solution (glycerin 25 wt% / sodium bisulfite 0.75 wt%). The following rinsing procedure must be performed to flush out the solution before use: 1. Flush the filtrate tank thoroughly and remove any impurities prior to filling the UF system / filtrate tank 2. FB = Filtration from bottom (operation of the system in Filtration Bottom mode, see Figure 4.1) at a flux rate of 50 l/(m2xh) for at least 20 minutes (be careful to fill the feed side of the system with raw water slowly in order to avoid water hammers). Make sure that no valves are closed on the filtrate side. The filtrate must be discharged before the filtrate tank. 3. FFB = direction of flow from bottom to top (module venting: start in Forward Flush Bottom mode) at a flux rate of 80 l/(m2xh) for at least 10 minutes. 4. FB = Filtration from bottom (operation of the system in Filtration Bottom mode at a flux rate of 80 l/(m2xh) for at least 15 minutes. Make sure that no valves are closed on the filtrate side. The filtrate must be discharged before the filtrate tank. 5. FT = Filtration from top (operation of the system in Filtration Top mode at a flux rate of 80 l/(m2xh) for at least 15 minutes. Make sure that no valves are closed on the filtrate side. The filtrate must be discharged before the filtrate tank. 6. If it is not possible to prevent filtrate from entering the filtrate tank, then the filtrate tank must be drained completely (ensure that all residues are removed). 7. Fill the filtrate tank. 8. BWB = Backwash to top (operation of the system in Backwash Bottom mode at a flux rate of 230 l/(m2xh) for at least 60 seconds or until all the filtrate has been discharged from the filtrate tank, respectively. 9. FB = Filtration from bottom (operation of the system in Filtration Bottom mode to completely fill the filtrate tank at a flux rate of 80 l/(m2xh) for at least 15 minutes. Make sure that no valves are closed on the filtrate side. 10. BWT = Backwash to bottom (operation of the system in Backwash Bottom mode at a flux rate of 230 l/(m2xh) for at least 60 seconds or until all the filtrate has been discharged from the filtrate tank, respectively.
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11. FT = Filtration from top (operation of the system in Filtration Top mode at a flux rate of 80 l/(m2xh) to fill the filtrate tank with fresh filtrate.
OFiltration
Top (FT)
Forward Flush Top (FFT)
Backwash Top (BWT)
Filtration Bottom (FB)
Forward Flush Bottom (FFB)
Backwash Bottom (BWB)
Figure 4.1: Operating modes of inge UF modules
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4.3
Disinfecting the inge T-Rack
The entire system must be disinfected after completing the rinsing procedure described above (if necessary disinfection must be carried out several times). Caution: Disinfection is carried out using the chemical sodium hypochlorite (13%). Please familiarize yourself with the relevant safety measures for the storage and handling of the chemicals used for this procedure. 1. Disinfect the filtrate tank and the filtrate piping including all existing valves and installed equipment using a sodium hypochlorite solution of 100 mg/l (as active chlorine).
Add NaOCl to the filtrate tank, first making sure that the tank is completely filled with filtrate (calculate the amount of NaOCl based on the tank volume). BWB = Backwash to top (operation of the system in Backwash Bottom mode, backwash with filtrate) at a flux rate of 230 l/(m2xh) for at least 30 seconds to disinfect the filtrate piping. Alternatively, operate the system in Chemical Enhanced Backwash Bottom mode, which includes the injection of sodium hypochlorite during the backwash mode [concentration 100 mg/l (as active chlorine)]. BWT = Backwash to bottom (operation of the system in Backwash Top mode, backwash with filtrate) at a flux rate of 230 l/(m2xh) for at least 30 seconds to disinfect the filtrate piping. Alternatively, operate the system in Chemical Enhanced Backwash Top mode, which includes the injection of sodium hypochlorite during the backwash mode [concentration 100 mg/l (as active chlorine)]. Briefly open all the filtrate sampling valve(s) and all other valve(s) within the filtrate piping/filtrate tank.
2. Make sure that all feed valves are closed. 3. Allow the NaOCl solution to act for at least 30 minutes (maximum 60 minutes). Ensure proper disinfection by monitoring the level of free chlorine (if readings indicate that the level of chlorine has fallen below 5 mg/l repeat chlorination or add fresh chlorine). 4. BWB = Backwash to top at a flux rate of 230 l/(m2xh) for at least 60 seconds. 5. FB = Filtration from bottom at a flux rate of 80 l/(m2xh) for at least 10 minutes. 6. BWT = Backwash to bottom at a flux rate of 230 l/(m2xh) for at least 60 seconds.
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7. FT = Filtration from top at a flux rate of 80 l/(m2xh) until the filtrate tank is full. 8. Completely drain the filtrate tank, ensuring that all residues are removed. 9. FB = Filtration from bottom at a flux rate of 80 l/(m2xh) for at least 10 minutes or until the filtrate tank is completely full. 10. Completely drain the filtrate tank, ensuring that all residues are removed. 11. FB = Filtration from bottom (flux rate and filtration time as specified for the process, i.e. under normal operation). 12. The operator should now perform sampling to check the bacteriological filtrate quality. If the test results are not satisfactory, repeat steps 1 to 12.
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5.
Recommendations Regarding Air Integrity Testing (Pressure Hold Test) inge T-Rack vario
Air integrity test description (pressure hold test)

Integrity testing is an effective means of checking the quality of the membrane fibers in ultrafiltration modules. This type of test forms an integral part of operating an ultrafiltration plant, particularly in cases where ultrafiltration is being used as a barrier against viruses and bacteria in order to produce drinking water. The integrity test (pressure hold test) is based on the phenomenon seen in ultrafiltration membranes whereby water can pass through the pores, but air is prevented from passing through until a certain pressure has been exceeded (the minimum pressure at which air begins to flow is referred to as the bubble point). The bubble point pressure depends on the membrane's pore size and on the surface tension at the air-liquid interface. The bubble point pressure of the pores is normally much higher than the applied test pressure (approx. 1 bar) that is required to detect leaks. Integrity testing can be performed both fully automatically (measurement of pressure drop) and semi-automatically (measurement of pressure drop + visual inspection). Integrity tests are carried out for each rack in turn, i.e. the modules of a rack are tested in parallel. There are no restrictions on the frequency of integrity testing for inge GmbH membrane modules. The vertical installation of the membrane modules and the ergonomic configuration of the inge system enable integrity testing to be carried out in an automated fashion, making it easy to detect any individual modules that may be affected. Integrity testing is carried out on installed modules (i.e. it is not necessary to remove any of the modules from the system). The frequency of integrity testing can be tailored to match the operator's specific requirements and preferences. We recommend carrying out integrity tests (including visual inspection) during/at the end of the plant commissioning phase, after conducting maintenance work, and in the event of any suspicion that the membrane system may be malfunctioning (e.g. increased bacteria counts on the filtrate side). Integrity testing can also be carried out regularly on an automated basis (for example once a week or once a month) and seamlessly integrated in standard filtration operations.
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The Air Integrity test (pressure hold test) process for inge Ultrafiltration modules within the T-Rack is shown in Fig. 5.1 and executed as follows: 1 Empty the feed line Pressurize the complete feed side with dry, oil-free compressed air (1000 mbar). The raw water side (top) of the module must be open to atmospheric pressure. The pressure will cause the water on the feed side to pass through the membranes to the raw water side. In principle, air cannot pass through the intact membranes due to the surface tension of the water in the membrane pores (note that this does not take diffusion processes into account). The time required to empty a rack depends on total rack size, the volume of the connected pipework and the compressor capacity. In our experience, the process of emptying the feed side takes approx. 10 minutes. 2 Close the air pressure valve When the feed side has been drained completely and a stable pressure of 1000 mbar has been reached and maintained for at least 1 minute, close the air supply to the feed side. 3 Idle time 4 Measure the pressure drop Measure the pressure drop on the feed side for at least 3 minutes. Due to the air diffusion process through the water-filled pores of the membranes, a slight pressure drop may be observed which should not be regarded as membrane leakage. This diffusion effect may also result in a minor degree of bubble formation becoming visible in the transparent pipe. In practice, pressure drop rates are less than 10mbar/min for all rack sizes. In the event that this base value is exceeded, it is advisable to conduct a detailed examination to identify the cause. The base value is dependent upon various factors, including the hold-up volume, the tightness of all the valves and fittings and the diffusion component of the module. Determination of the base value must be performed using new modules (i.e. modules that are being used for the first time) in the fully assembled rack. This value is then used as a reference value (documentation). Any leakage in the module can be detected using the integrated transparent pipe on the filtrate side (Fig. 5.2). In the event of a leak, a continuous stream of air bubbles of a steady intensity will be visible during system air integrity testing. It is essential to ensure that the upper filtrate side is open, unpressurised and completely filled with water during air integrity testing. If integrity testing has ruled out any other sources of error, a significant and permanent stream of air bubbles is visible in the transparent pipe, and the pressure drop is greater than 10 mbar/min, it can be assumed that the system has a capillary defect.
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5 Release the air pressure on the feed side 6+7 Vent the system 6 Operate in normal forward flush mode 7 Restart the regular filtration mode (at reduced flux rate, e.g. 40 l/mh)
1 Dewater feed side
2 Close feed air pressure valve
3 Idle
4 Measure pressure drop
5 Pressure release 0 bar (feed side)
6 Forward flush for venting
7* Venting filtration
air pressure 1000mbar

P
* Venting filtration: low flux (e.g. 40 l/mh)
Figure 5.1: Sequence of an integrity test (from feed side)
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Figure 5.2: Monitoring and securing of defect free operation in build-up condition with integrated transparent connector on the filtrate side.
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6.
Operating Conditions
General: All inge T-Racks must be operated in compliance with the following operating conditions: 1. Prefiltration: < 300 micrometer if there is a risk that the feed water may contain particles which could cause damage to the membranes. The actual cut-off value selected in each case will depend on the application. The decision may be taken not to install a protective UF prefilter if the pretreatment process upstream from the UF system includes a final filtering step to remove particles bigger than 300 m. If the UF prefilter is omitted, it is important to note that inge cannot be held responsible for any membrane damage and/or consequential or indirect damages caused by the intake of harmful external substances. 2. Ensure the membranes (feed/filtrate side) do not come into contact with abrasive materials (e.g. metal or plastic shavings, sand, etc.). 3. The quality of the feed water must be measured after the addition of chemicals and after prefiltration (to enable comparative analyses of feed water quality). 4. Permissible operating temperature: 1 C to max. 40 C Temperature adjustment: max. 1C/minute 5. Permissible pH range of feed water during operation: pH 3 - 10 6. Ensure no precipitation (e.g. Fe, Mn, CaCO3) occurs within the membranes or on the filtrate side due to process conditions. 7. Ensure that no water and air pressure surges occur (of pneumatic and/or hydraulic origin) and prevent any siphoning effects 8. Tank and pipework/component design The feed tank, filtrate/backwash (BW) tanks and CIP tank (as well as all connecting pipework and all components installed throughout the entire UF system) must be constructed from non-corroding materials that will not leach contaminants or harmful matter into the water. it is important to protect the water in the filtrate/BW tank from direct sunlight in order to avoid bacterial and/or algae growth (it may be necessary to use closed tanks and air filters for drinking water systems or in environments with highly polluted air).
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9. Disinfection/cleaning chemicals and parameters: a) Disinfection with NaOCl Initial disinfection: see section 4.3 b) Feed chlorination with NaOCl (active chlorine concentration) Continuous feed chlorination is not recommended. Shock chlorination: max.: 100 ppm, 30 min, once per week.
c) Chemical enhanced backwash (CEB) procedure

NaOCl (concentration as active chlorine):
20 50 ppm, 5 - 10 min soaking

NaOH (optional plus 20 50 ppm NaOCl as active chlorine)
pH 13, 10 - 60 min soaking

HCl, H2SO4
pH 1, 10 - 60 min soaking
CEB frequency should not exceed 2 CEBs per day for each of the types of chemical mentioned above. Ensure proper distribution and mixing of the CEB chemicals in the BW water stream. Backwash and CEB water quality: To avoid any risk of damaging the membranes (from the filtrate side) the BW water should be free of particulates and should be of inge UF filtrate quality or better. Since BW and CEB are carried out solely with UF filtrate, the decision may be taken not to install a protective inline BW strainer (max. pore size: 300 m). If the BW strainer is omitted, it is important to note that inge cannot be held responsible for any module/membrane damage and/or consequential or indirect damages caused by the intake of harmful external substances. d) Cleaning in place (CIP) procedure
NaOCl (+ NaOH for pH adjustment, active chlorine concentration):
200 ppm, pH 12.0 max. 12h circulation/soaking

NaOH
pH 13, max. 12h circulation/soaking

HCl, H2SO4
pH 1 max. 12h circulation/soaking
Citric acid (+ HCl/H2SO4 for pH adjustment)
4 g/l, pH 2.0 max. 12h circulation/soaking
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Drinking water quality or better (e.g. RO permeate) is recommended as a basis for cleaning solutions. CIP frequency should not exceed 4 CIPs per year for each of the cleaning steps mentioned above. The CIP solution must be introduced from the feed side of the modules/membranes. During CIP recirculation this will prevent any foulants and/or harmful substances from entering the filtrate side of the membranes. A strainer must be installed to protect the membranes from particles which could potentially damage them (max. pore size 300 m). Caution: Please familiarize yourself with the relevant safety measures for the storage and handling of the chemicals used in this procedure. 10. Permissible transmembrane pressure (TMP):

Filtration: Backwash: Air Integrity test:
max. 1.5 bar max. 3.0 bar max. 1.0 bar air pressure
Operating the membranes at any combination of the maximum limits of temperature, pH, chemical concentration and/or pressure during production or cleaning will have an impact on the membrane service life. The permissible transmembrane pressures are not based on limitations in membrane strength, but simply on good operating practice for UF membranes. Compaction of fouling layers on the membrane surface should be avoided to enable stable long-term operation. The burst pressure of the Multibore membrane is higher than 10 bar. 11. Substances that may cause damage to the membrane or irreversible membrane fouling: Do not subject the membranes (feed or filtrate side) to elevated concentrations of oil, grease/fat or other elements of organic or inorganic origin that could result in the chemical or physical destruction of module integrity or irreversible membrane fouling. Ensure that the modules/membranes do not come into contact with polar, organic solvents, chlorinated solvents or concentrated acids/bases at any time. Modules/membranes in the system that have been irreparably destroyed or irreversibly fouled by the substances cited above are not covered by the inge warranty.
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12. Rack design of inge UF modules: All the modules must be operated under the same operating conditions. The basic rack design shown in Appendix A applies to all types of inge UF modules. 13. Adding coagulants prior to ultrafiltration: Depending on the dissolved organic carbon (DOC) concentration and its characteristic structure in the feed water, it may be necessary to add inorganic coagulants (FeCl3, polyaluminium chloride) to the feed system. Coagulants may improve or stabilize membrane performance and can help to reduce the silt density index (SDI), DOC and phosphate concentration in the filtrate. The required coagulant contact time depends on the coagulant and the water chemistry as well as the water temperature. It is important to ensure adequate mixing and contact time and proper distribution/mixing of the coagulant in the feed water. Under no circumstances should the coagulation process take place within the membrane or on the filtrate side. If the coagulants described above are added upstream from the UF system, then acid CEBs must be performed on a regular basis, at least prior to each CEB with NaOCl. Caution: The use of flocculation aids (e.g. polyelectrolytes) or flocculants with organic components/functional groups may result in irreversible membrane fouling. Use of any such substances is not permitted unless they have been tested and/or approved by inge in advance. 14. Ultrafiltration filtrate water quality UF membranes cannot remove dissolved substances. This physical fact should be taken into account for all parameters (SDI, turbidity, etc.) when measuring UF filtrate water quality. 15. Regular leak tests Regular general maintenance conducted on the UF plant should include checking the tightness of all connection fittings on the UF system (flanges, valves, etc.) and on the UF modules (couplings, Victaulic joints). Fluid leakage especially where corrosive mediums are involved may cause corrosion on adjacent surfaces, components and equipment. Effective precautionary measures must be taken to prevent corrosion (see section 3.8). In the event of fluid spill or leakage, the affected area should be properly rinsed with salt-free or low-salt water and rubbed dry. 16. Process logic control system / programming The automatic operation of the UF plant and the control philosophy must be based on the latest version of the document Process Specification UF 1(2012-05 ) E inge (Appendix B).
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7.
Documentation of Operating Conditions
Proper and complete documentation is a mandatory requirement for warranty claims. Documentation must be kept on the operating conditions and the amount of time the plant has been operated in each of the various operating modes from the moment the modules are first put into operation. Any warranty claim must be accompanied by a complete set of documentation which must be provided to inge GmbH. The following membrane system operating parameters must be recorded and documented. 1. pH value, temperature and turbidity prior to ultrafiltration (UF). 2. Permeability (@ 20C), flow rate, transmembrane pressure (TMP) and absolute pressure (feed/filtrate) per rack / per filtration line during filtration/backwash . Documentation of the data listed above must be guaranteed and certified by means of a continuous data logging system (automatic data recording). The data must be logged at least every 2 seconds (during the filtration cycles at least every 3 minutes) to ensure that all the effects are registered of changes in pump operation and/or valve positions (changing modes and sequences). However, to ensure appropriate documentation can be provided and to help optimize the membrane plant, we recommend logging data at the shortest possible intervals. 3. Chemicals
Use of chemicals for pretreatment: type and concentration of oxidants, type and concentration of coagulants, measured directly prior to ultrafiltration (UF) Use of chemicals for CEB cleaning: type, contact time and concentration of oxidants or other membrane cleaning agents, type, contact time and pH value of acid/caustic, measured within the rack (chemical in contact with the membrane) Use of chemicals for CIP cleaning: type, contact time and concentration of oxidants or other membrane cleaning agents, type, contact time and pH value of acid/caustic, measured within the rack (chemical in contact with the membrane)
The recording of the data listed above must be certified by an operating log. The minimum interval for one complete set of information (lab measurements) is one per day (or one measurement per CEB/CIP). 4. In the event of a module defect, it is necessary to provide documentation of the position of the defective module within the rack (line, rack/unit, side, position) together with details of the module serial number. Removal of the original inge module serial number from the module automatically invalidates any warranty that may have applied.
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5. To verify and document the maximum permissible operating pressure (according to the data sheet), analog pressure gauges with drag indicators (gauges provided with documentation of the gauge serial number) must be installed in each unit/rack (feed and filtrate side).
8.
Membrane Downtime Conditions
After use and during storage the membranes must be kept wet at all times. To avoid microbiological growth during shutdown or storage of decommissioned modules, wet membranes must be treated with a compatible biocide/disinfectant solution. Please observe the following recommendations for different downtime conditions and durations: Downtime up to 24 hours It is generally sufficient to simply stop the system and then conduct a backwash at a minimum flux rate of 230 l/(m2xh) for at least 60 seconds. No other action is required. Downtime > 24 hours Perform a daily filtration sequence at a minimum flux rate of at least 50 l/(m2xh) for at least 10 minutes. Perform a CEB sequence with NaOCl (according to the CEB specifications described in section 6.9) followed by rinsing with UF filtrate once per day. Downtime > 7 days Before taking steps to preserve the membranes, it is absolutely essential to remove any organic or inorganic impurities (fouling, scaling layer) from the membranes. After cleaning, rinse with a 0.75% sodium bisulphite solution in backwash mode (BWT, BWB). The quality of the water in this step must be UF filtrate water equivalent or better. Leave the sodium bisulphite solution in the modules/rack. Replace the sodium bisulphite solution once every 4 weeks. Whatever the situation, the modules should be kept hydraulically filled. The membranes must be kept free of any oxidizing agents during plant shutdowns. If you wish to use any other biocides/disinfectants, please contact inge GmbH beforehand. It is essential to obtain prior written approval from inge GmbH regarding the chemicals and concentrations that are permitted for use.
Page 27
9.
Transport Conditions for inge UF Modules and T-Rack vario components
Mechanical damage/rupture of the module shell, connection ports and other T-Rack components may result if the modules/components are dropped or struck. Modules must therefore be handled with care at all times, particularly during transportation. Returning modules: Modules shall only be accepted for return if this has been agreed in advance with inge GmbH and authorized in writing. Module returns agreed and authorized by inge are subject to the following mandatory requirements:

The modules must be cleaned before they are returned. The modules must be protected from drying out and freezing at all times (temperature must be maintained between 4C and 35C).
Failure to meet any of these requirements will result in inge GmbH refusing to accept the return of the modules; inge GmbH reserves the right to invoice the sender for any transport or disposal costs that may be incurred in this case.
10. Warranty Policy

Warranty claims may only be made on condition that the customer has properly followed all the instructions contained in the Installation, Operation and Maintenance Guidelines. If you wish to deviate from these Guidelines, please consult inge GmbH in advance to obtain written approval in order to avoid any risk of voiding the warranty.
Page 28
11. Contact Details
Please contact inge GmbH for further information: inge GmbH Flurstrasse 27 86926 Greifenberg Germany Phone: Fax: e-mail: web: +49 (0) 81 92 9 97 700 +49 (0) 81 92 9 97 999 info@inge.ag www.inge.ag
Disclaimer
The utmost care has been taken in compiling the contents of these Installation, Operation and Maintenance Guidelines. inge GmbH cannot accept any liability for loss or damage that may arise in connection with using our products. The quality of inge UF modules is warranted in accordance with our general terms of sale. These Installation, Operation and Maintenance Guidelines are a publication of inge GmbH. All rights, including translation rights, are reserved by inge GmbH .
Page 29
Appendix B: Process Specification inge UF
1
1.1
PROCESS DESCRIPTION .................................................... 3

Pretreatment .................................................................................. 3 1.1.1 Coagulation .......................................................................................................................... 3 Filtration........................................................................................ 6 Backwash and chemical backwash ......................................................... 7
1.2 1.3
2
2.1 2.2 2.3 2.4
OPERATING MODES ........................................................ 8

Filtration cycle ................................................................................ 8 Chemical Enhanced Backwash ............................................................. 11 Control philosophy ........................................................................... 15 Integrity tests ................................................................................. 19
3
3.1
PROGRAM PARAMETERS ................................................. 19

Operating modes ............................................................................. 19
3.2 Data logging ................................................................................... 21 3.2.1 Operating modes (index) ................................................................................................. 21 3.3 Miscellaneous ................................................................................. 22 3.3.1 Adjustment/switching of actuators ............................................................................... 22
Process Specification UF 1(2012-05) E inge Subject to modifications and errors 2012 inge GmbH All rights reserved
Page 2
Process description
Basically, the UF process consists of three key processes: 1. Pretreatment 2. Filtration 3. Backwash/Chemical Enhanced Backwash (CEB) The water to be treated first passes through an optional pre-treatment stage before it is filtered by the UF membrane. During the pressure-driven filtration process, the pressure at the membrane steadily increases due to the accumulation of fouling on the membrane feed side. To clean the membrane, filtered water is held in a filtrate reservoir and made available for backwashing. Backwashing serves to remove the accumulated fouling from the membrane and return the admission pressure to its initial level. The option is also available to boost the effects of the backwash by adding various different cleaning chemicals.
1.1 Pretreatment
Before the water to be filtered reaches the UF membrane system, rough dirt particles are removed by a screen prefilter. This prefilter offers automatic backwashing capabilities and must be equipped with filter cartridges with wire mesh screens and a mesh size of less than 300 m.
1.1.1 Coagulation Coagulation is an effective pre-treatment process employed in many applications that make use of ultrafiltration technology. Its main effect is to reduce organic fouling by incorporating dissolved organic compounds in ferric or aluminum flocs and by forming a porous fouling layer on the membrane surface which encourages a stable filtration process and ensures high backwash efficiency. Proper implementation of the coagulation process can reduce the concentration of dissolved organic carbon (DOC) by up to 60 percent. Optimized coagulation can also improve filtrate quality by reducing SDI, DOC concentration and colloidal matter. The coagulant metal residuals in the filtrate should not exceed more than 1 percent of the added metal concentration. If the type of coagulant and the raw water quality mean that pH adjustment is necessary, acid or caustic must be added to ensure the optimum pH value for coagulation. To optimize the coagulation process, it is important to adjust the chemical contact time to reflect the feed water quality (e.g. temperature) in order to achieve the required UF filtrate quality (e.g. DOC, Al or Fe residual).
Page 3
Precise adjustment of the coagulation process is required to maximize DOC removal and minimize coagulant residuals in the UF filtrate. It is advisable to perform jar tests in advance to determine the optimum coagulation parameters, including pH value, concentration and contact time. The focus here is on analytical parameters such as residual Me3+ and DOC removal, not on visual parameters such as floc formation. Table 1.1 shows the key characteristics of different coagulants.
Table 1.1 Coagulation parameters Specific Dosage Coagulant [mg/l] Fe/Al1 dosage (Me3+/DO C) [mg/mg] pH range pH optimum Contact time2 [s] DOC / COD elimination rate3 [%] Me3+ residual (as % of dosage)4
Fe
(FeCl3)
0.77.0
0.5-2.0
5.010.0
6.8 - 7.0
30 -60
10-60
1%
Polyaluminum Chloride
(PAC)
0.5 5.0
0.250.5
6.5-7.5
6.8 - 7.0
30 -60
10-60
1%
1 2
In pool applications the dosage amount can be lower ( > 0.03 mg/l Al/Fe) Contact time t depends on water temperature, pH value, water chemistry and treatment objectives and can Removal of organic content strongly depends on water chemistry and coagulation parameters (pH value, etc.) Higher residual Me3+ indicates poorly configured coagulation parameters (mixing-in conditions, pH value,
vary enormously (t << 30s as well as t >> 60s) subject of optimization.

3 4
contact time, dosage amount) and should therefore be strictly avoided.
The use of organic coagulation aids (anionic or cationic polyelectrolyte) or combined coagulants (inorganic + organic compounds) should be strictly avoided since it may result in heavy, irreversible fouling of the UF membrane which would necessitate intensive chemical cleaning procedures.
Page 4
The following process diagrams show various different inline coagulation configurations.
Figure 1.1: Example 1: Prefilter > coagulation > mixer > UF
Figure 1.2: Example 2: Coagulation > mixer > prefilter > UF
Figure 1.3: Example 3: Coagulation > feed pump > prefilter > UF
Page 5
Using the prefilter as a mixer for the coagulant can cause irreversible fouling (e.g. Al hydroxides) on the prefilter which cannot be removed mechanically but just by means of chemical agents. It is therefore advisable to install the prefilter either upstream before coagulant dosage or downstream after the coagulant contact time has elapsed. If the required contact time cannot be achieved in the pipework, a contact tank can be used to increase coagulant contact time as necessary. To avoid an excessive dosage of coagulant, it is important to monitor the Me3+ concentrations in the raw water, feed and filtrate. The Me3+ concentration in the filtrate caused by the addition of coagulant should not exceed 1 percent of the quantity of Me3+ added to the raw water (not including the dissolved Me3+ concentration in the raw water).
1.2 Filtration
The pretreated water is pumped into the membrane module by the frequency-controlled feed pump. The flow rate is defined as a setpoint for the control system and is monitored by means of inductive flow metering. During filtration operation, the feed valves and filtrate valve are opened based on the direction of filtration (bottom or top, see Figure 2.1). Furthermore, the valves prior to the automatic air vent valves are opened to avoid feed-side and filtrate-side air intrusion in the UF module installation. Pressure sensors (PIT), which are located in the two feed lines and in the filtrate line, are used to determine and record the transmembrane pressure (TMP). The operator can enter both an alert and a threshold alarm value for TMP in the control panel. If the value set for the threshold alarm is exceeded, filtration operation stops and the system is switched into standby mode (pump off, valves closed). The control system also continuously monitors and records the temperature in the filtrate line. These readings are used to calculate temperature-corrected permeability. Filtrate is held in the filtrate tank for backwashing. The filtrate tank is equipped with a dry run protection device for the backwashing pump or an analog level measurement. To avoid contamination of the filtrate, the filtrate tank is sealed; the ventilation system includes an air filter to prevent contamination of the UF filtrate.
Page 6
1.3 Backwash and chemical backwash

A backwash is performed once the filtration cycle has been completed. Based on the direction of the backwash (bottom or top), the waste water valves are opened and the filtration valves are closed. The air vent valves remain open. The frequency-controlled backwash pump is activated for the specified backwash time (control system setpoint) and runs until the backwash has been completed. The backwash flux rate has to be min. 230 l/(mh). During backwashing, cleaning chemicals can be added to the backwash water to perform a "Chemical Enhanced Backwash" (CEB). The backwash program can include a number of different CEBs with different cleaning chemicals which are implemented according to a defined schedule. To reduce the size of the chemical dosing pumps, the flux rate during the chemical enhanced backwash can be reduced to min. 120 l/(mh). After the addition of the cleaning chemical, the system remains in stand-by mode for the "soaking time". The soaking time is a setpoint in the control system. Once the soaking time has elapsed, the cleaning chemical is rinsed out by a backwash with filtrate at min. 230 l/(mh). The rinse time is a variable setpoint in the control system.
Page 7
2 Operating modes
The different operating modes are defined by the positions of the various valves and the activated system components.
2.1 Filtration cycle

The Filtration mode is the actual filtration process. Water is pushed through capillaries from the inflow side (feed) to the filtrate side (Fig 2.1). The filtration mode functions in one of two different ways: Filtration Top (FT) and Filtration Bottom (FB). The filtration direction only changes from top to bottom or bottom to top after a backwash. The filtration mode plus its corresponding backwash is referred to as a filtration sequence (this may also include an optional forward flush in the corresponding direction before and/or after a backwash). A filtration cycle (Figure 2.2) comprises a Filtration Bottom and a Filtration Top sequence, including the corresponding backwashes and optional forward flushes. In Forward Flush mode, the feed water only passes through the capillaries on the feed water side. No filtration takes place (Fig 2.1). Activation of the forward flush is optional. If activated, it will be performed before and/or after a backwash. The forward flush is always performed in the same direction as the previous filtration mode. This means that a Filtration Bottom (FB) is followed by a Forward Flush Bottom (FFB) and a Filtration Top (FT) by a Forward Flush Top (FFT). In Backwash mode, water is pumped from the filtrate side (filtrate) to the feed water side and is then discharged as waste water. The backwash mode also functions in one of two possible ways: Backwash Bottom (BWB) and Backwash Top (BWT). The backwash is always performed in the same direction as the previous filtration mode. This means that a Filtration Bottom (FB) is followed by a Backwash Bottom (BWB) and a Filtration Top (FT) by a Backwash Top (BWT). The corresponding forward flush is also performed if this option has been activated.
Page 8
Bottom (FB)
Filtration 30180 min, flux rate 50 160 l/(mh) Top (FT) Feed Filtrate Filtration sequence = Filtration mode + Forward Flush + Backwash
Filtrate
Feed Optional: Forward Flush 30-50 sec, flux rate 50 160 l/(mh) before/after backwash, degassing Top (FFT) Feed
Bottom (FFB) Drain
Feed
Drain Backwash 40-90 sec, flux rate min. 230 l/(mh) Top (BWT)
Bottom (BWB) Drain Filtrate
Filtrate
Drain Filtration cycle = Filtration sequence Bottom + Filtration sequence Top
Figure 2.1: Operating modes
Page 9
Bottom filtration mode (FB)
Top filtration mode (FT)
Filtration Bottom
Forward Flush Bottom (optional)
Backwash Bottom
Filtration Top
Forward Flush Top (optional)
Backwash Top
Figure 2.2: Example of a filtration cycle
Page 10
2.2 Chemical Enhanced Backwash

To enhance the effects of a backwash it is possible to use various forms of Chemical Enhanced Backwashes (CEBs) (Figure 2.3). A CEB essentially works in the same way as a backwash, which means the filtrate is forced from the filtrate side to the feed water side. Additionally, a cleaning chemical is added to the filtrate to enhance the backwash cleaning effect. Unlike a standard backwash, a CEB is performed in both directions (first bottom-totop and then top-to-bottom) to make sure the cleaning solution is distributed as evenly as possible in the UF rack. Once the rack has been completely filled with the cleaning solution (controlled by the chemical injection time setting), chemical injection stops and the plant shifts to stand-by mode during soaking time. Once the soaking time has elapsed, the rack must then be rinsed with filtrate (Backwash Bottom followed by Backwash Top). A CEB is performed at the end of a filtration sequence, which means a backwash with filtrate will have been performed directly beforehand. This standard backwash removes larger particles from the membrane, thereby boosting the effects of the cleaning solution in the subsequent CEB. Depending on the water quality and pretreatment process it may be necessary to run CEBs with up to three different cleaning chemicals. The CEBs effectiveness is not only dependent on the chemical used but also on the sequence and time intervals between CEBs. The CEB sequence should therefore be programmed as flexibly as possible (Chapter 2.3).
Page 11
Chem. Injection Backwash Bottom Flux rate min. 120 l/(mh)
Chem. Injection Backwash Top Flux rate min. 120 l/(mh)
Soaking
Rinsing, Backwash Bottom Flux rate min. 230 l/(mh)
Rinsing, Backwash Top Flux rate min. 230 l/(mh)
Figure 2.3: The Chemical Enhanced Backwash (CEB) process
Page 12
A CEB is performed after a defined number of filtration cycles. Chemicals that can be considered for CEB include caustic (NaOH), sulfuric or hydrochloric acid (H2SO4/HCl), and sodium hypochlorite (NaOCl). Generally, a CEB with caustic is followed by a CEB with acid to remove any carbonates precipitated during the caustic cleaning. Only one filtration sequence should be carried out between a caustic and acid CEB to refill the backwash tank and neutralize the membranes. Other CEBs (acid, chlorine) can be performed in isolation or in combination with the combined caustic/acid cleaning process. In some applications, caustic and chlorine dosing in parallel can enhance cleaning efficiency significantly (20 -50 ppm free chlorine @ pH>12.0) The following chemicals are recommended for the CEB procedure (Table 2.1):
Table 2.1: CEB chemicals
Acid
Inorganic fouling
Caustic
Organic Fouling
Oxidant
Hydrochloric acid HCl
Sulfuric Acid H2SO4
Caustic NaOH (optional: +NaOCl)
Sodium hypochlorite NaOCl
pH range: 2.0 2.5
pH range: 12.0 13.0 (optional: + 20 - 50 ppm as free chlorine) Soaking: 10 60 min
20 - 50 ppm as free chlorine
Soaking: 10 60 min
Soaking: 5 10 min
The injection time for the chemical solution depends on the backwash flux rate, the location of the chemical dosage point and the rack size. To ensure complete and homogenous distribution of the CEB chemicals inside the UF rack installation, the following injection times are recommended (based on the example of a CEB flux rate of 120 l/(mh) in an inge T-Rack installation, Figure 2.4):
Page 13
Figure 2.4: Chemical injection time for CEB depending on rack size
The internal CEB injection time (tint) is calculated from the Backwash Top + the Backwash Bottom time. To calculate the total injection time, it is necessary to take into account the distance to the chemical dosage point in the peripheral pipework (tex): ttotal = tint + tex.
tint
tex Chemical Dosing
Figure 2.4 shows recommended injection times based on the example of a T-Rack installation. As the figure shows, the injection time is split between a Backwash Bottom and a Backwash Top, with the combination of the two ensuring homogeneous distribution
Page 14
of the chemical solution throughout the rack, including the dead end areas of the modules.
2.3 Control philosophy

The CEBs are allocated as follows: CEB 1: CEB 2: CEB 3: Caustic followed by acid Acid Sodium hypochlorite
Because CEBs are performed after a defined number of filtration cycles (see explanation in section 2.1), counters must be used to record the number of completed filtration cycles. If the application uses more than one type of CEB, these counters need to be programmed to avoid two or more CEBs being performed at the same time. One helpful solution is to use a master counter that is designed to allocate the highest priority to the CEB with the highest cycle number. If two or more CEBs coincide, the CEB with the highest priority will be performed. Once this CEB has finished all the counters are reset to zero. Figure 2.5 shows an example where CEB1 = 9, CEB2 = 3 and CEB3 = 40. The CEB2 counter (highlighted in yellow) resets itself after the completion of each CEB2 while the master counter continues counting. After 9 filtration cycles, 2 CEBs are requested simultaneously: CEB1 and CEB2. CEB1 has the higher priority and is therefore performed in preference to CEB2. As soon as this CEB1 has been completed, the CEB1 and CEB2 counters are reset. CEB3 is performed after 40 cycles, at which point all the other counters are reset since CEB3 is the highest priority.
Filtration cycle counters Setpoints: CEB1 = 9 CEB2 = 3 CEB3 = 40 CEB 1: 1 CEB 2: 1 CEB 3: 1 2 2 2 3 3 3 4 1 4 5 2 4 6 3 6 7 1 7 8 2 8 9 3 9 1 2 3 4 5..........4 1 2 3 1 2...1 10 11 13 14 15.40 1 1 1 2 2 2
Figure 2.5: CEB program: CEB1 = 9, CEB2 = 3, CEB3 = 40
The numbers highlighted in green indicate the performance of a CEB. The number highlighted in red illustrates a conflict: Although CEB2 has been requested, it will not be performed because CEB1 is a higher priority and will therefore take precedence (setpoint CEB1 = 9 > 3 (CEB2)). If you prefer to develop your own CEB philosophy, please make sure to take the following points into account:
Page 15
1. An acid CEB should be performed as close to the caustic CEB as possible (max. 1 filtration sequence in between) 2. Use separate acid and chlorine CEBs in addition to combined caustic/acid CEBs 3. Scheduling of the 3 CEB types should be completely independent, i.e. it should be possible to implement CEB sequences such as the following: combined caustic+acid once a day; acid only twice a day; NaOCl once a week.
. Start of operation
CEB counter
SFB SFT SFB SFT

C CEB1 = 0
C CEB1 = 1
SFB = FB + (FFB) + BWB + (FFB) SFT = FT + (FFT) + BWT + (FFT) FB = Filtration Bottom FFB = Forward Flush Bottom BWB = Backwash Bottom FT = Filtration Top FFT = Forward Flush Top BWT = Backwash Top
C CEB1 = 2
SFB SFT CEB Caustic SFB CEB Acid
C CEB1 = 3
CEBCaustic = Chemically Enhanced Backwash e.g. NaOH CEB Acid = Chemically Enhanced Backwash e.g. H 2SO4 or HCl
C E B 1
No. of cycles CCEB1 Caustic + Acid = 3
Figure 2.6: Example 1: CEB 1, Combined Caustic + Acid, Cycle = 3
Page 16
Start of operation
CEB2 counter
SFB/T = Sequence Filtration Bottom/Top SFB = FB + (FFB) + BWB + (FFB) SFT = FT + (FFT) + BWT + (FFT) FB = Filtration Bottom FFB = Forward Flush Bottom BWB = Backwash Bottom
SFB
C CEB
2
=1
SFT
SFB
C CEB
2
=2
SFT
C CEB2
Acid
=0
FT = Filtration Top FFT = Forward Flush Top BWT = Backwash Top CEB2 = Chemically Enhanced Backwash H2SO4 or HCl = Chemically Enhanced Backwash NaOCl
SFB
C CEB
2
=3
SFT
CEB3
No. of cycles CCEB2 Acid = 3 CEB2Acid

CEB3 counter
No. of cycles CCEB3 NaOCl = 40
C CEB C CEB
NaOCl Acid
=0 =0 =0
CEB3NaOCl
CEB NaOCl= 5 6 . . 40
Figure 2.7: Example 2: CEB1 = 0; CEB2 = 4, CEB3 = 40
Page 17
Start of operation SFB/T = Sequence Filtration Bottom/Top

CEB1 counter
SFB
C CEB
1
=1
SFB = FB + (FFB) + BWB + (FFB) SFT = FT + (FFT) + BWT + (FFT) FB = Filtration Bottom FFB = Forward Flush Bottom BWB = Backwash Bottom
SFT
SFB
C CEB
1
=2
SFT
CEB1
FT = Filtration Top FFT = Forward Flush Top BWT = Backwash Top CEB1 = Chemically Enhanced Backwash Combined NaOH + Acid = Chemically Enhanced Backwash H2SO4 or HCl = Chemically Enhanced Backwash NaOCl =3
CEB1NaOH + Acid
CEB1 NaOH+Acid
=0
SFB
C CEB
1
=3
SFT
CEB2
CEB3
CEB1NaOH + Acid
CEB2 counter
CEBAcid= 4 5 6 7 8 9
No. of cycles C
No. of cycles C =9 CEB2 Acid No. of cycles C CEB3 NaOCl = 40
CEB1 NaOH+Acid CEB1
=0 =0
CEB2Acid
CEB3 counter
CEBNaOcl= 10 11 12
CEB2 Acid
=0
39 40
CEB1 NaOH+Acid CEB1
=0 =0
c c
CEB2 Acid
=0 =0
CEB3 NaOCl
CEB3
NaOCl
Figure 2.8: Example 3: CEB1 = 3, CEB2 = 9, CEB3 = 40
Page 18
2.4 Integrity tests

To check that the UF membranes are in proper working order, pressure hold tests or bubble tests can be performed. These integrity tests can be carried out automatically on a regular basis or manually, depending on requirements. Please find a detailed description of the test-procedure in the specific Installation, Operation and Maintenance Guidelines.
3 Program parameters
3.1 Operating modes
Definition Operating modes are defined by valve positions and pump status. Each operating mode requires input parameters to be defined as variable setpoints in the control system.
Table 3.1: Input parameters
Operating mode
Filtration Filtration bottom (FB) Filtration Top (FT) Forward flush Forward flush bottom (FFB) Forward flush top (FFT) Backwash Backwash bottom (BWB) Backwash top (BWT) Chemical enhanced backwash Chemical backwash (CEB) CEB1.1(NaOH) Chemical backwash 1.1 bottom Chemical backwash 1.1 top Soaking (SCBW1) Rinsing backwash bottom Rinsing backwash top CEB 1.2 (Acid) Same input mask as CEB1.1 CEB 2 (Acid) Same input mask as CEB1.1 CEB 3 (NaOCl)
Process Specification UF 1(2012-05) E inge
Input parameters
duration, flow rate
duration, on/off, flow rate, before/after BW duration, on/off, flow rate, before/after BW duration, flow rate, duration and flow rate = BWT duration, flow rate cycles for CEB1; cycles for CEB2; cycles for CEB3 (frequencies) duration, flow duration, flow duration duration, flow duration, flow rate, dosing flow rate, dosing flow rate, rate
Page 19
Subject to modifications and errors 2012 inge GmbH All rights reserved
Same input mask as CEB1.1 Integrity test filtrate side (UF modules) Optional; automatic INT (Integrity) test interval between INT tests, time required to initialize Dewater (DEW) pressure Measuring (ME) duration delta p measurement, critical delta p Ventilation purge after int. (DPaINT) duration, flow rate Ventilation filtration after int. (DFaINT) duration, flow rate Integrity test feed water side (T-Rack) interval between INT tests, time required to initialize Dewater (DEW) pressure Measuring (ME) duration delta p measurement, critical delta p BW after feed integrity duration, flow rate on/off on/off, HCl or NaOH, setpoint target pH setpoint dosing amount/pump frequency
Pretreatment
pH adjustment (dosage pump) Coagulant dosing
General parameters
TMP limits TMP alert filtration TMP alarm TMP alert backwash TMP alarm backwash Temperature Temperature alert Temperature alarm Temperature warning Temperature alarm, stop operation TMP warning filtration TMP alarm, stop operation TMP warning backwash TMP alarm, stop operation
Page 20
3.2 Data logging

Measurements of the values listed in Table 3.4 are logged by the PLC/PC control system. Volume readings must record both the flow rate and total volume. To ensure the data in the logfile can be clearly identified and indexed, the date and the time must be in the first column.
Table 3.4 Logging parameters Data capture / logging Date Pressure 1 Pressure 2 Pressure 3 Calculated TMP Quality 1 Quality 2 Quality 3 Flow 1 Flow 2 Flow 3 Flow 4 Calculated Permeability Index x1 x2 x3 dd.mm.yy hh:mm:ss Pressure feed bottom Pressure feed top Pressure filtrate Transmembrane pressure Temperature Turbidity feed pH value feed Flow rate feed Volume feed Flow rate backwash Volume backwash Permeability 20C Operating mode Reserve Reserve Reserve
3.2.1 Operating modes (index) Data acquisition and recording requires clear and unambiguous allocation of the measured values and the respective operating state.
Page 21
3.3 Miscellaneous
3.3.1 Adjustment/switching of actuators The switching circuit of the pumps and valves should be designed in a way that no pressure pulses are produced in the system, i.e. the pumps and valves should be actuated in a controlled sequence at intervals of approximately one second so that pumps are never running against closed valves. The actuators of all (butterfly) valves should be equipped with air throttling valves to control the opening and closing procedure. Air/water hammers can occur if the valves open or close too abruptly. Any change of operating mode that involves a switch between feed and backwash pumps (e.g. backwash to filtration) including the necessary valves must include an idle interval of approx. 5-10 seconds between the completion of one operating mode and the activation of the subsequent operating mode. The frequency converters and PID controllers of the feed and backwash pumps must be carefully adjusted to ensure that no pressure pulses are generated. For the backwash pump controller, it is important to ensure that the flow setpoint is reached within 5-10 seconds (time depending on the pump capacity).
Page 22

Installation Operating and Maintenance Guidelines T-Rack Vario 3 (2012-05) E Inge

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Installation Operating and Maintenance Guidelines T-Rack Vario 3 (2012-05) E Inge

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inge GmbH

Installation, Operation and Maintenance Guidelines inge T-Rack vario

inge T-Rack vario Technical Data - Important Information

Avoid Drying Out

Avoid Potential Freezing Conditions

Protection from Direct Sunlight and Other UV Sources

Protection from Organic Solvents/Concentrated Acids

Protection from Abrasive Materials

Do Not Use Silicone, Lubricants Containing Silicone Or Pipe Threading Compound

Storage and Shipment

T-Rack vario assembly

Upper feed/drain header

Top cross brace with filtrate header clamp supports

Lower feed/drain headers

All flanges according to ISO 7005 PN 10, ANSI class 150

Bottom cross brace

Marking on lower feed/drain headers

Fig. 3.2.1 *Do NOT fasten the feet to the floor!

Fig. 3.2.3 Raised ribs

Top cross braces

Operating and Start-Up Guidelines

Rinsing the inge UF modules

Forward Flush Top (FFT)

Backwash Top (BWT)

Filtration Bottom (FB)

Forward Flush Bottom (FFB)

Backwash Bottom (BWB)

Figure 4.1: Operating modes of inge UF modules

Disinfecting the inge T-Rack

Air integrity test description (pressure hold test)

1 Dewater feed side

2 Close feed air pressure valve

4 Measure pressure drop

5 Pressure release 0 bar (feed side)

6 Forward flush for venting

air pressure 1000mbar

* Venting filtration: low flux (e.g. 40 l/mh)

Figure 5.1: Sequence of an integrity test (from feed side)

c) Chemical enhanced backwash (CEB) procedure

20 50 ppm, 5 - 10 min soaking

pH 13, 10 - 60 min soaking

200 ppm, pH 12.0 max. 12h circulation/soaking

pH 13, max. 12h circulation/soaking

pH 1 max. 12h circulation/soaking

Citric acid (+ HCl/H2SO4 for pH adjustment)

4 g/l, pH 2.0 max. 12h circulation/soaking

Filtration: Backwash: Air Integrity test:

Documentation of Operating Conditions

Membrane Downtime Conditions

Transport Conditions for inge UF Modules and T-Rack vario components

10. Warranty Policy

11. Contact Details

Appendix B: Process Specification inge UF

PROCESS DESCRIPTION .................................................... 3

OPERATING MODES ........................................................ 8

PROGRAM PARAMETERS ................................................. 19

vary enormously (t << 30s as well as t >> 60s) subject of optimization.

contact time, dosage amount) and should therefore be strictly avoided.

Figure 1.1: Example 1: Prefilter > coagulation > mixer > UF

Figure 1.2: Example 2: Coagulation > mixer > prefilter > UF

1.3 Backwash and chemical backwash

2.1 Filtration cycle