OSMO® PRO SERIES

CLEAN-IN-PLACE (CIP) SYSTEMS

OPERATION AND MAINTENANCE
MANUAL

5951 Clearwater Drive, Minnetonka, MN 55343-8995 USA

Phone (952) 933 - 2277 • (952) 988 - 6080
http://www.gewater.com
 TABLE OF CONTENTS

Page

1.0 GENERAL INFORMATION ……………………………………………………………………………… 1

2.0 COMPONENTS OF THE PRO CLEAN-IN-PLACE (CIP) SYSTEM ……………… 1

3.0 CONTROLS ……………………………………………………………………………………………………… 3

4.0 CIP INSTRUCTIONS ………………………………………………………………………………………… 3

5.0 CIP GUIDELINES FOR SPECIFIC FOULANTS ……………………………………………… 3

6.0 RIGGING/INSTALLATION/START-UP …………………………………………………………… 4

7.0 MAINTENANCE ………………………………………………………………………………………………… 5

8.0 TROUBLESHOOTING ……………………………………………………………………………………… 5

9.0 RETURN GOODS AUTHORIZATION (RGA) PROCEDURE ………………………… 5

LIST OF TABLES

Table Title Page

2.1 Specifications 2

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1.0 GENERAL INFORMATION

The PRO Series Clean-in-Place (CIP) systems are designed to accommodate the
various models of PRO Series Reverse Osmosis (RO) machines. The model
numbers selected correspond to the PRO RO machine model numbers.

The main purpose of the CIP system is to be used to periodically clean the
membrane elements in the RO machine. Since it is impractical to remove the
elements from the machine each time to clean them, the membranes are
"cleaned-in-place" inside the RO machine. To do this the normal process
connections of the RO machine need to be closed off while alternative cleaning
connections are opened up. The RO machine is provided with these extra cleaning
connections and a set of valves is then installed at these connections to allow the
change over when cleaning is required.

The basic components of the CIP system are a cone bottom storage tank and a
recirculation pump. The tanks are sized to provide a few minutes of buffering time
while the cleaning solution is recirculated from the tank, through the RO machine
and back to the tank again. The recirculation pump is designed to feed 30 - 40
psig (2.07 - 2.77 bar) of pressure to the main RO pump at the required flow for the
machine.

2.0 COMPONENTS OF THE PRO CLEAN-IN-PLACE (CIP) SYSTEM

All PRO Series CIP system tanks come equipped with a flange at the bottom.
When installed, the contractor will need to build a manifold to provide both a
connection to the recirculation pump and to a drain. The tank also has fittings on
top for the RO permeate return connection and for the RO concentrate return
connection. The pump is provided loose for field installation next to the tank.

The six CIP systems are as follows:

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 Table 2.1
CIP Systems

Model CIP-50 CIP-100 CIP-150 CIP-200 CIP-300 CIP-450

Feed Flow 70 gpm 135 gpm 200 gpm 270 gpm 400 gpm 600 gpm
Rate: (15.9 m3/hr) (30 m3/hr) (45 m3/hr) (61 m3/hr) (91 m3/hr) (136 m3/hr)

Tank Capacity: 250 Gal 250 Gal 400 Gal 600 Gal 1000 Gal 1000 Gal
(946 L) (946 L) (1514 L) (2271 L) (3785 L) (3785 L)
Tank CXC - 0250 CXC - 0250 CXC - 0400 CXC - 0600 CXC - 1000 CXC - 1000
(Terracon)
model number
Pump (Gould) 3657, 3657, 3657, 2x3-7 3657, 2x3-7 3657, 2x3-7 SSH, 3x4-8
model number 1.5x2-6 1.5x2-6
Motor Size 5 Hp 5 Hp 10 Hp 10 Hp 15 Hp 20 Hp
(Type: TEFC) (3.7 kW) (3.7 kW) (7.5 kW) (7.5 kW) (11.2 kW) (14.9 kW)

Tank 47 x 70 in 47 x 70 in 47 x 78 in 47 x 109 in 86 x 77 in 86 x 77 in
Dimensions (1.2 x 1.8 m) (1.2 x 1.8 m) (1.2 x 2.0 m) (1.2 x 2.8 m) (2.2 x 1.9 m) (2.2 x 1.9 m)
(DxH)
CIP Outlet 2.0 inch 3.0 inch 3.0 inch 4.0 inch 6.0 inch 6.0 inch
(IPS Flange)
CIP Permeate 2.0 inch 3.0 inch 3.0 inch 3.0 inch 4.0 inch 4.0 inch
(IPS Flange)
CIP 1.5 inch 1.5 inch 1.5 inch 2.0 inch 2.0 inch 2.0 inch
Concentrate
(IPS Flange)
Pump In/Out 2.0/1.5 inch 2.0/1.5 inch 2.0/3.0 inch 2.0/3.0 inch 2.0/3.0 inch 3.0/4.0 inch
(IPS Flange)

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3.0 CONTROLS

The system control narrative outlines the control of the CIP system. Refer to the
system control section of the water treatment system manual.

4.0 CIP INSTRUCTIONS

Instructions for cleaning the RO machine are located in the RO System Operation
and Maintenance manual in the Maintenance procedures section.

5.0 CIP GUIDELINES FOR SPECIFIC FOULANTS

In general, routine cleanings should be comprised of the following steps:

• Cleaning with an acidic cleaner for mineral scale.

• Rinsing clean with fresh water.
• Cleaning with an alkaline cleaner for organic foulants.
• Rinsing clean with fresh water.
• Returning to service.

This method will remove the most common materials that foul RO machines,
which are Calcium and Magnesium Carbonate, Iron hydroxide, bacterial growth,
and silt or dirt particles. If this method is used routinely every 2 - 3 months and
there is no evidence of additional fouling (poor water quality, low permeate flow,
high operating pressure, high pressure drop) then there is no need to investigate
alternative methods or cleaners.

If the methods listed above are not effective and other foulants have been
identified the following methods maybe successful:

Calcium Sulfate and Barium Sulfate: Use a Chelating detergent. GE Osmonics

cleaner ET-70 is a Chelating detergent formulated for Sulfate scale. If needed, use
a generic recipe of adding 1 lb (0.45 kg) of sodium salt of EDTA or 2.5 lbs (1.13 kg)
of 39% active ingredient (liquid) to the standard acid cleaner. EDTA additive is sold
commercially as "Versene" or "Hampene."

Iron Hydroxide: There are commercial cleaners available that are specially
designed for iron fouling. A standard acid cleaner can be somewhat effective in
removing iron. A generic recipe of citric acid and sodium bisulfite can be more
effective in removing iron. Add 2 lbs (0.91 KG) of citric acid per 10 gallons (37.8 L)
of CIP tank volume. Add 1 lb (0.45 kg) of sodium bisulfite per 10 gallons (3708 L) of
CIP tank volume.

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 Heavy Biofilm/Heavy silt/dirt/organic load: Repeated high pH cleanings may be
necessary. Spiking the cleaning solution with sodium hydroxide maybe necessary
to achieve the maximum pH limits (Do not exceed pH 12 for PA membrane
elements). A low pressure, high velocity cleaning may be necessary. The PRO RO
and CIP systems are designed for high-pressure cleanings. Contact GE Osmonics
if a low pressure cleaning is needed. Also, higher temperatures are required to
achieve the full effects of high pH cleaning. A tank heater or heat exchanger may
be necessary to achieve elevated temperatures of 105°F (40°C).

There are many commercial cleaners available that are specially formulated for
various types of foulants. Contact your chemical provider for information.

6.0 RIGGING/INSTALLATION/START-UP

The PRO Series CIP systems will typically be shipped with the tank and pump
separate.
The tank sits in a frame structure and can easily be lifted upright with a forklift.
Any loose components, such as a valve kit, CIP hose kit, motor starter, or test kits
will be packaged in boxes and secured to a pallet. The CIP pump will be shipped
loose in a shipping box or crate.

Follow the installation instructions found in the pump manufacturer's manual for
mounting instructions. Use the system flow drawing and electrical schematics for
the RO machine for information on interconnecting the CIP pump, CIP tank, and
RO machine. The CIP tank should be mounted in an area near the RO machine
with the CIP pump mounted on the floor very near the base of the CIP tank. The
pump suction connection should be at or below the elevation of the CIP tank
outlet connection. The CIP pump must be able to overcome any head pressure
created from higher elevation of the discharge piping and still provide at least 15
psig (1.03 bar) of pressure to the RO pump after passing through the cartridge
filters. Due to the corrosive nature of the cleaning chemicals used with this
system, inert plastic pipes (Sch 80 PVC, CPVC, Polypropylene, etc.) or stainless
steel pipes are recommended. If the CIP system is to be mobile or there are more
than one RO machines to be cleaned by the same CIP system, the use of
removable, flexible hoses maybe beneficial over hard piping. Verify the pressure
rating and compatibility of the hose are acceptable prior to use.

Follow the start-up instructions found in the pump manufacturer's manual for
lubrication and other requirements prior to operation. After the RO machine has
been thoroughly flushed, and operated on the water supply, walk through the
cleaning procedure outlined in the RO manual to verify the proper operation of
the CIP system.

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7.0 MAINTENANCE

Follow the maintenance guidelines provided with the CIP pump manufacturer's
operation and maintenance manual for information regarding the pump.

• Prior to using the CIP system each time, verify that the CIP pump is properly
lubricated and ready for operation.
• Verify the connections to and from the RO machine and the CIP system are
secure and ready for use.
• Tighten or repair the fittings in the CIP system as necessary.
• Follow the maintenance procedures in the RO manual for cleaning the
machine.
• Following the cleaning procedure, rinse out the CIP tank thoroughly by
diverting RO permeate through the tank and to the drain.

8.0 TROUBLESHOOTING

• Follow the pump manufacturers troubleshooting information regarding the

CIP pump.
• Follow the troubleshooting guide in the RO system manual for information
regarding the cleaning process and RO machine performance.

9.0 RETURN GOODS AUTHORIZATION (RGA) PROCEDURE

If you wish to return goods for repair, warranty evaluation and/or credit, please
have your original sales order or invoice available when you call GE Osmonics.
Call the GE Osmonics Field Service Group at (800) 909-3302. An GE Osmonics Field
Service representative will provide instructions and a return authorization
number, which needs to be clearly written on the outside of the box used to
ship your materials. All equipment must be shipped to GE Osmonics with the
freight prepaid by the customer. Call our Customer Support Center with any
questions or issues concerning freight claims and a representative will discuss
your situation.

All materials to be returned must be rendered into a non-hazardous condition

prior to shipping.