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80326-01 r0 Manual, Quad Series, PX-Q300
80326-01 r0 Manual, Quad Series, PX-Q300
80326-01 r0 Manual, Quad Series, PX-Q300
MEMBRANES
PERMEATE
CIRCULATION
PUMP
HIGH
PRESSURE
PUMP
PX DEVICE
OR ARRAY
2. SAFETY
The PX device is designed to provide safe and reliable service; however, it is used in a high pressure industrial
process. Operations and maintenance personnel must follow the basic safety rules associated with high-pressure
equipment and seawater RO processes. Proper installation and maintenance of shutdown devices and over-pressure
and over-flow protection equipment are an essential part of any RO system. Operation of the PX device outside of
the designed operating range can result in damage and may be unsafe.
3.2. Installation
PX devices can be installed and operated in any orientation. Each unit has four connections labeled HP IN, HP
OUT, LP IN, and LP OUT.
• HP IN is the high-pressure concentrate inlet.
• HP OUT is the high-pressure feedwater outlet to the circulation pump.
• LP IN is the low-pressure feedwater inlet.
• LP OUT is the low-pressure concentrate outlet.
The PX unit must be supported by its housing and not by the pipe fittings. Prevent the PX unit from supporting
piping or manifolds.
The PX device should be kept in its original packing until the initial start up of the RO train. Proper piping, piping
support, and housing support must be employed to minimize external stresses on all pipe fittings. Use shims to
support and align the housing. Suitable flexible couplings should be used for joining fittings and piping. Use only
water-soluble lubricants such as glycerin on coupling gaskets; do not use grease. Please request dimensioned
drawings of a PX device and a piping detail for use for piping, manifold, and support rack design.
Prior to installation of the PX device, all associated piping should be thoroughly flushed to assure that no debris
enters and/or damages the PX unit. Temporary installation of basket strainers at both inlets to the PX device or PX
device array can be used.
Warning: Thoroughly flush associated piping with clean water before installing the PX unit. Foreign
material entering the unit may cause damage.
4. OPERATION
4.1. Feedwater Supply
Standard RO process chemicals are not harmful to the PX.
The low-pressure flow through the PX unit is controlled by the feedwater supply pump and a control valve in the
concentrate discharge from the PX unit(s). This valve also adds backpressure on the PX device required to prevent
cavitation. The low-pressure flow rate must be verified with a flow meter. The flow rate of the low-pressure
concentrate from the PX unit equals the flow rate of the low-pressure feedwater to the PX unit plus the bearing
lubrication flow rate.
4.5. Flushing
There are two types of flush: Feed Water Flush and Fresh Water or Permeate Flush. Regardless of the flush water
used, all parts of the PX device must be flushed, i.e. low-pressure flow channels, high-pressure flow channels, and
lubrication channels.
Feed Water Flushing is part of a normal shutdown sequence as described in Section 4. After both permeate and
concentrate production have ceased, flow on both the high-pressure and low-pressure sides of the PX devices
continues. The flow path of the Feed Water Flush, with reference to Figure 1, is B-D-E-F-G-H driven by the feed
water pump and the circulation pump. A Feed Water Flush is typically continued until conductivity measurements at
process locations G and H are satisfactory (TDS close to feedwater TDS).
A Permeate Flush or fresh water flush is performed on a partially- or fully-depressurized system. This is
accomplished by introducing permeate simultaneously to the PX device low-pressure inlet [B] and either to the
high-pressure pump inlet [A] or through some other injection point such as a clean in place (CIP) connection.
Permeate may be produced during this flushing process. If so, it may be necessary to block permeate flow to divert
lubrication flow through the PX devices. The circulation pump must be run to flush HP side of the PX device (s).
Warning: Entrained or trapped air must be purged from the RO system before every pressurization.
5. SERVICE
5.1. Spare part and tool kits
The PX-Q300 energy recovery device needs no scheduled periodic maintenance. However, in the event that
disassembly is desired or required, the PX-Q300 unit is designed so that it can be assembled and disassembled in the
field with only basic tools and equipment. These tools are listed in Table 2. These tools, with the exception of the
hoist and torque wrench, are included in the PX-Q300 tool kit (ERI Part Number 20037-01). In addition, the PX-
Q300 unit can be mounted on a stand or on blocks to facilitate service or the LP connection port can be unthreaded
in order to support the unit on the housing.
Replacement seals and alignment pins are included in ERIs standard spare parts kits (ERI Part Number 20033-01).
One spare parts kit should be used each time a PX unit is opened for service.
Replacements for other components in the PX assembly are available. Refer to assembly drawing for PX component
descriptions, part numbers and the bill of materials.
5.2.Disassembly procedure
Warning: Metal objects can chip or crack ceramic. Use caution when handling ceramic components
to avoid damage.
If a PX unit must be disassembled, the procedures provided in this section should be followed carefully. The tools
and fixtures listed in Table 2 are required. The procedures provided in this subsection are for complete disassembly
and subsequent assembly of a PX unit. Depending upon the reason for the maintenance work, complete disassembly
may not be required.
The following procedure is for the disassembly of a PX-Q300 device and inspection of the ceramic components. The
internal ceramic components can be reached through either end of the housing.
There are two recommended disassembly procedures for the PX-Q300 device, removing it from the piping and
disassembly in the rack.
1. Remove PX-Q300 unit from RO system. Ideally use an overhead crane to lift the unit by threading ERI lifting
strap into threaded hole in the bearing plate
2. Optionally unscrew and remove the LP OUT port (Fig 5.1 and 5.2). Otherwise use blocks or a stand to support
the unit by the LP OUT end of the fiberglass housing (fig 5.3). Do not support the unit or apply stress to the
PVC low pressure port.
Fig 5.1. Port removal Figs 5.2. or 5.3. Support unit by fiberglass shell
3. Remove all the 5/16-inch socket-head cap screws from the top of the PX unit using a 1/4-inch Allen wrench as
shown in Figure 5.5. Remove the fiberglass securing rings. (Fig 5.5)
4. Tap down on the port bearing plate to loosen the lock ring segments as shown in Figure 5.6. Remove the three
segmented lock rings.
Fig 5.5. Remove 5/16 inch socket head cap screws Fig 5.6. Tap down on the port bearing
5. Extract the port bearing plate assembly from the housing using an ERI-supplied head puller tool or a hoist as
shown in Figures 5.7. and 5.8. Take care not to apply stress to the PVC LP port if it is still in place. Always use
a wood block to protect the edge of the housing if force is necessary to remove the head assembly.
Fig 5.7. Use a hoist and Lifting Strap Fig 5.8. Using Head Puller Tool
6. Remove the thrust ring and LP interconnects. See Figures 5.9 and 5.10.
Fig 5.9. Inside of the housing after removing head Fig 5.10. Remove Trust ring and LP interconnects
Fig 5.11. Head Puller Tool Fig 5.12. Using Lifting Eye & Hoist Fig 5.13. Removing cartridge
8. The ceramic rotor subassembly must be returned to the housing in the same orientation it was removed. Mark
the housing and the ceramic cartridge with a pencil or marker to assure that correct orientation is retained upon
reassembly. Note the endcovers are marked either "feedwater" or "concentrate" and should be oriented to the
appropriate side of the housing.
a. Stand the ceramic rotor subassembly on blocks allowing clearance for the tension bolt and nuts on the
bottom of the assembly. See Figure 5.14 which illustrates correct rotor subassembly orientation.
Concentrate Endcover
Feedwater Endcover
b. Remove the hex nuts and washers from the top end of the tension rod.
c. Lift the endcover off the rotor and sleeve, be careful not to loose the alignment pins or replace as
required.
Thoroughly flush all PX components with clean water before assembling PX unit. Foreign
material may inhibit rotor movement.
5.2.2. Disassembly procedure for the PX-Q300 device on the rack or piping
1. Depressurize all high-pressure and low-pressure piping to and from the PX unit.
2. Close all valves to and from the PX-Q300 unit or PX-Q300 rack or drain system.
3. Disconnect and remove the low pressure piping from the upward facing end of the unit. See Figures 5.16 and
5.17
4. Proceed with disassembly as directed in section 5.2.1 above.
Fig 5.16. PX device on array rack Fig 5.17. Access head and cartridge while unit
remains on array rack
For best results pre-lubricate all new o-rings with a very thin coating of Dow Corning 111 Valve Lubricant and
Sealant prior to installation. Wipe off any excess lubricant using a lint free cloth. O-rings should appear wet but not
Always lubricate all o-ring mating surfaces immediately prior to assembly with a suitable water soluble lubricant
such as glycerine or liquid soap
Improperly lubricated
o-ring showing
excess lubricant
Properly lubricated
o-ring
Fig 5.18. O-Ring Comparison
6. Install both washers and one hex nut finger tight. The fiberglass washer should be against the ceramic followed
by the metal washer and then the nuts. See Figure 5.21.
Fig 5.19. Insert dowel pins Fig 5.20. Assembly Fig 5.21. Washer Sequence
7. Carefully inspect the contact lines between the sleeve and the endcovers to be sure there are no gaps. See Figure
5.22. Occasionally, the assembly process will shave one or more of the pins and the debris that is generated will
prevent the sleeve and the endcover from coming into intimate contact. If this occurs, remove the rotor and
sleeve assembly, rinse ceramics, and remove all debris. Repeat assembly.
8. Tighten the nut closest to the cartridge assembly and torque to 15 ft-lb (20 N-m)
9. Thread the second nut onto the tension rod. This nut will act as a lock nut. Torque to 40 ft-lb (56 N-m) while
holding the adjacent nut. Make sure that the tension the inner nuts apply on the cartridge does not change. See
Figure 5.23.
10. Verify that the rotor can spin freely. Use a wooden or plastic dowel to advance rotor as illustrated in Figure
5.24.
Fig 5.23. Tightening Lock Nut Fig 5.24. Verify The Rotor Spins Freely
11. Lubricate all o-rings on the LP interconnects as well as their receiving holes on the seal plate. Insert and fully
seat LP interconnects into seal plate
12. If it was removed re-install the thrust ring as shown in Figures 5.25 and 5.26. Make sure it is oriented such that
the key engages with the seal plate and the side port is not blocked.
Fig 5.25. Trust Ring Orientation Fig 5.26. Seated Trust Ring
13. Lubricate the cartridge o-rings, the 4 LP interconnect holes and the inside of the housing.
14. Attach the lifting eye to the cartridge assembly and attach to hoist.
15. Lower the cartridge assembly into the housing as shown in Figure 5.27. Make sure that the ceramic LP opening
are lined up with the LP interconnects. This can be done by using the cartridge installation tool from the toolkit
as shown in Figure 5.28.
Fig 5.27. Insert the ceramic cartridge Fig 5.28. Cartridge installation tool.
into the housing.
Cartridge
fully seated
19. Assemble the ports, the securing ring, the port bearing plate, the port locking rings, the seal plate and the O-
rings as shown in the assembly drawing. A completed port bearing plate subassembly is shown at the end of this
section. Be sure to lubricate all O-rings with a water-soluble lubricant or a non-abrasive liquid soap.
20. Lubricate the quad ring on the head assembly and the inside of the housing.
21. Insert the head assembly into the top of the housing. Make sure the low-pressure port lines up with the low-
pressure nipple. This can be verified by looking down through the low-pressure port while inserting the port
bearing plate subassembly. If the head does not insert fully, the low-pressure interconnects may not be correctly
aligned with their corresponding holes. Look down into the low-pressure port as illustrated in Figure 5.30. to
verify alignment. If the low-pressure port, low pressure interconnect, and endcover are not aligned, remove the
port bearing plate assembly completely, remount the quad ring, and try again.
22. Insert the 3-part segmented lock ring into the space between the port bearing plate and the housing as shown in
Figure 5.31. If the lock ring segments will not fit into the gap, make sure the segments are correctly oriented. If
the segments still do not fit, this may be an indication that the low-pressure nipple is not correctly aligned. If so,
remove the port bearing plate and repeat the previous step.
23. Insert the fiberglass securing ring. Bolt down the securing ring with three 5/16-inch socket-head cap screws.
See Figure 5.32
Fig 5.31. Insert 3-part segmented lock ring Fig 5.32. Bolt down securing ring
24. If removed thread LP connection port onto the bearing plate using the strap wrench (if necessary). See
Fig 5.33.
2. Line up the seal plate thread holes with bearing thread holes
3. Bolt down the bearing plate with two 5/16-inch socket-head cap screws.
Fig 5.34. Insert o-ring into seal plate Fig 5.35. Align holes on seal and bearing plates
6. TROUBLESHOOTING
This section is designed to guide the operator in identifying and correcting most of the problems that could occur in
the PX energy recovery device. The instructions provided below are intended for use by personnel with general
training and experience in the operation and maintenance of fluid handling systems. This is not intended as a
comprehensive maintenance guide. Conditions not covered in this section may be resolved by contacting ERI’s
Service Department.
Preliminary procedures:
• Always check for proper valve configuration for the operation mode selected.
• Always inspect and test equipment or apparatus for possible causes of malfunctions before performing
replacements.
Instrumentation:
The following list of instrumentation is useful in monitoring and diagnosing the operation of PX devices.
• ERI requires that one flowmeter be installed in the PX unit(s) HP flow circuit and one in the LP flow path.
• ERI requires a pressure instrument be installed between the low pressure outlet and any control valve to
monitor device backpressure.
• ERI recommends that high flow and pressure alarms/shutdowns be incorporated into the system design to
protect the PX unit(s) from potential damage by high flows.
• ERI suggest using a TDS meter to check the conductivity of the streams entering and exiting the PX device
to monitor device performance.
When using this troubleshooting guide, please read all the probable causes before taking any action. Use common
sense and select the cause that seems to best fit the given situation.
ERI’s Technical Services staff offers commissioning service for all ERI products during field installation and/or at a
RO system manufacturer’s location. Service rate quotes are available upon request.
8. REVISION LOG
Revision Description Date
0 Initial release 01/12