BANGGAI AMMONIA PLANT (BAP) PROJECT Boustead Salcon Water Solutions

Pte Ltd
PROGRAM

 DAY 1
 Introduction
 Pretreatment (Ultrafiltration)
 Desalination (Seawater Reverse Osmosis)

 Day 2
 Desalination (Brackish Water Reverse Osmosis)
 Mixed Bed Polisher
PROGRAM

 Fundamentals
 Design Basis
 Process Flow Diagram
 System Description
 Operation Philosophy
 Daily Operation, Monitoring and Maintenance
 Start Up
 Shut Down
 Troubleshooting
 Safety Precaution
FUNDAMENTALS OF
ULTRAFILTRATION
(UF)
Fundamentals of UF

 How it works?
 Physical separation using membrane as filter
 Membrane capture the solids and allow water
flow through
 Substances which larger than membrane
pore size will be removed
 Pore size: 0.01 to 0.1 µm
 UF do not reject any dissolved salts, organics
or other species like color, taste & odor
Fundamentals of UF– Filtration
Spectrum
Fundamentals of UF– Membrane

Make/ Model Inge/

Dizzer XL 0.9 MB 70
Flow path Inside- Out

Membrane material Polyethersulphone (PES)

Filtration mode Dead end

Membrane configuration Hollow fiber

Membrane area 70 m2

Module Height 1.72 m

Module Diameter 250 mm

Capillary Diameter 0.9 mm

Pore size 0.02 µm (nominal)

Fundamentals of UF– Membrane

Multibore technology combines

seven capillaries of the same
diameter into a single fibre. This
provides significantly higher
mechanical stability than
conventional single bore
Membrane Flow Design

Inge membrane operate

as Inside-Out
Inside-Out Flow Design
Membrane Operation Mode

Build up of
cake, cleaning
is required
Process Schematic of UF System

H2SO4
Ultrafiltration Process

 Filtration
To obtain clean filtrate.

 Backwash/Reverse Filtration
To remove filtered material from the membrane
surface

 Chemical Cleaning (CEB or CIP)

To remove foulants on the membrane surface

 Air Integrity Test

To test any leakage in the UF Modules
DESIGN BASIS OF
ULTRAFILTRATION
(UF)
Design Basis

Feed Water Characteristic:

Source: Sea Water
UF Configuration: (2 Duty, 1 Standby) x 50%
Design Flow Rate: 484 m3/h (Feed of UF System)
Feed Seawater Pressure: 3 kg/cm2G
Feed Seawater Temperature: 26 - 37oC

Inlet Sea Water Quality (Major Parameter):

pH 7.5 – 8.5

Total Dissolved Solids (TDS) 35, 720 mg/L

Total Suspended Solids (TSS) 30 mg/L

Oil and Grease 2 mg/L

COD 39.7 mg/L

Treated Water Quality (After UF System):

SDI15 <3
Turbidity < 0.1 NTU
PROCESS FLOW DIAGRAM
&
SYSTEM DESCRIPTION
FOR UF SYSTEM
 Process Flow Diagram

Chemical for UF CEB

UF
Bkw
FeCl3

UF Modules

UF CIP System UF Wastewater System

Location of Equipment for UF System
UF Filtrate Tank

UF Backwash
Pump

UF
Wastewater UF
Tank Wastewater
Pump

Auto Strainer & UF Skid

UF CIP
UF CIP Pump
Tank

H2SO4 NaOH NaOCl

 Ultrafiltration System

UF Filtrate
Header CIP Inlet

Backwash
Outlet Header
CIP Outlet

Sea Water Inlet

Backwash Inlet

Auto Strainer
System Description

Auto Strainer
 Rated at 150 microns to remove large suspended solids in
the seawater prior to the UF System
 Auto back-flushing of strainer is initiated by preset timer
or upon high differential pressure
 Configuration: 3 x 50%
 Material: GRP with UV Protection
System Description

Auto Strainer

Normal operation Flushing phase one Flushing phase two

The flushing valve is Cleaning is initiated either
closed and the piston through increase in
mounted in the end differential pressure or after
cover remains outside a preset time interval.
the filter basket. The flushing valve opens
and large matters are flushed
out.
The piston moves twice into the basket.
The increased flow velocity between
basket and the piston creates a reduction
in pressure that “vacuum” cleans the
inside of the basket. This reverses the
flow direction locally into the basket
and removes particles adhering to the
basket.
Auto Strainer

A short video to show how Auto Strainer operate.

Equipment
Video\Bernoulli
Filter.mp4
System Description

Coagulant Dosing
 FeCl3 is dosed before Auto Strainer to helps coagulate
suspended solids to bigger flocs which can be easily
retained on membrane surface.
 In addition to particulate substances, the flocculation
process also causes dissolved organics (DOC) in the water
to precipitate and accumulate on the arising metal
hydroxide flocs and thus removed by the membranes.
 Formation of porous layer of microflocs on the membrane
surface helps to promote a stable filtration process and
high backwash effectiveness.
 1 x 100% of FeCl3 Storage Tank and 2 x 100% of FeCl3
Dosing Pump are supplied.
System Description

UF Modules
 Configuration: 3 x 50%
 To produce filtrate with low turbidity (< 0.1 NTU) and low
suspended solids (SDI < 3)
 Hollow fiber membrane which made of PES Material at
rated as 0.02 micron
 In filtration, seawater is forced through membrane from
feed side to filtrate side, suspended solids are blocked and
accumulate on membrane surface
 Transmembrane pressure (TMP) increase gradually
 To remove build up of coating layer (or cake), backwash is
performed at regular intervals
 Alternating operation leads to consistent and uniform
loading and cleaning of UF Modules
 UF Operation

 Alternating Operation
FB → BWB → FT → BWT
Filtrate
Backwash
Out
In

Sea Water
Backwash
In
Out
UF Backwash & Chemical Enhanced
Backwash (CEB)
 Backwash: To remove build up of cake, backwash is
performed at regular intervals.

 CEB: To boost the effectiveness of Backwash by

adding chemical

 UF Backwash Pump ( 2 x 100%) to supply filtrate for

UF CEB, chemical shall be dosed into UF Backwash
Discharge piping

 Chemical: NaOH, H2SO4 and NaOCl

1 x 100% of Storage Tank & 2 x 100% of Dosing Pump
are provided for each type of chemical

 Frequency: Every 24 hours (to be tuned according to

actual fouling rate).
UF Backwash & Chemical Enhanced
Backwash (CEB)
 Alkaline CEB – Removing organic build up.
 Hypochlorite – Disinfection
 Acid – Removing inorganic fouling. Since there is
always the possibility of precipitation in an alkaline
CEB, this must always be followed by an acid CEB.
UF Cleaning in Place (CIP) &
Air Integrity Test (AIT)

Cleaning in Place (CIP)

 CIP: effective method to restore membrane
performance by tackling those fouling which is
difficult to remove by backwash or CEB
 CIP should be performed if permeability drop below
100-150 LMH/bar
 CIP to be conducted manually.
 1 x 100% UF Cleaning Tank & 1 x 100% UF CIP
Pump are provided

Air Integrity Test (AIT)

 Test manually to check any leakages in the UF
modules
UF Wastewater System

UF Wastewater Storage Tank

 UF Backwash/CEB wastewater shall be collected in
UF Wastewater Storage Tank

UF Wastewater Pump
 To discharge out the UF wastewater from UF
Wastewater Storage Tank to Final Check Basin
 Configuration: 2 x 100%
 UF Filtrate Tank & UF Wastewater Tank

UF Filtrate
Tank

UF Wastewater
Tank
OPERATION PHILOSOPHY
OF
UF SYSTEM
Overview of UF Skid

4 Row
Arrangement
Overview of UF System

UF Module Outlet
Pressure
Transmitter

Seawater Inlet UF Module Inlet UF Module Inlet

Turbidity Pressure Flow Transmitter
Transmitter
Operation Parameter

 Feed Water Quality:

Alarm when high Turbidity (detected by Seawater
Inlet Turbidity Analyzer, AIT-23001)

 UF Module in Auto Filtration: Maximum 2 trains

 Main UF Operation Parameter shall be set:

Parameter Set Point Remark
Filtration Flowrate 242 m3/h Constant flux as 50 lmh. Determine
the opening of FCV.
Filtration Volume 145.2 m3 Determine filtration time, 36
minutes
Backwash Time 40 s Backwash after every filtration
cycle
No. of Filtration Cycle 19 Determine the frequency of CEB
cleaning.
Operation Parameter

 Other UF Operation Parameter:

Parameter Set Point Remark
Backwash Flowrate 1095 m3/h Backwash flux as 230 lmh.
Reference value for VFD to
modulate pump speed.
CEB Flowrate 571 m3/h CEB flux as 120 lmh.
Reference value for VFD to
modulate pump speed.
Extended Filtration 10 min In case of no stand by UF modules,
Time UF can extend its filtration to
produce more filtrate before
proceeding to Backwash
Transmembrane H & HH: 1.5 kg/cm2 Reference value for below action:
HH Pressure H: 1.3 kg/cm2 HH: Shutdown UF Operation
H: Initiate “CIP Cleaning” message
Dosage of FeCl3

 Dosage of Coagulant (FeCl3) prior UF

Modules
Calculated
Automatically

Fix after Jar

Test

Subject to
Chemical
Supplied
Normal Filtration Cycle

No. of
Filtration Cycle
automatically
update
Filtration Cycle (Forward Flushing)

 A provision is provided to conduct Forward No. of Filtration

Flushing in case of high TSS in feed water Cycle
automatically
 Upon selection of Forward Flushing, the operation update

cycle will proceed as below:

UF Filtration Cycle
(Filtration Bottom)
UF Filtration Cycle
(Forward Flushing Bottom)
UF Filtration Cycle
(Backwash Bottom)
UF Filtration Cycle
(Filtration Top)
UF Filtration Cycle
(Forward Flushing Top)
UF Filtration Cycle
(Backwash Top)
UF Chemical Enhanced Backwash
(CEB)
 Frequency: Once per day or after 19 filtration
cycle
 CEB 1: NaOH + NaOCl
 CEB 2: H2SO4
 Set timing for each step before proceeding to
CEB process
UF Chemical Enhanced Backwash
(CEB)
 Designed timing for each step:
UF Chemical Enhanced Backwash
(CEB)
 Dosage of chemical

Chemical Design Dosage Remark

NaOH 96 ppm To adjust pH to 9.5
NaOCl 20 ppm
H2SO4 806 ppm To adjust pH to 2.3
UF CEB Dosing Points

CEB Chemical
Dosing Points
CEB 1 Operation (Alkaline)

Step 1: Dosing Top

Step 2: Dosing Bottom
Step 3: Soaking ( All valves are close)
Step 4: Backwash Top (refer to UF Filtration Cycle)
Step 5: Backwash Bottom (refer to UF Filtration Cycle)

Dosing
DosingBottom
Top
CEB 2 Operation (Acid)

Step 1: Dosing Top

Step 2: Dosing Bottom
Step 3: Soaking ( All valves are close)
Step 4: Backwash Top (refer to UF Filtration Cycle)
Step 5: Backwash Bottom (refer to UF Filtration Cycle)

Dosing
DosingBottom
Top
UF CIP Operation

 CIP is an effective method to recover membrane

performance
 Conduct Backwash process before performing CIP
cleaning (BWB & BWT)
 CIP operation shall be conducted manually by
operator
 Frequency: Every 6 months or High TMP alarm is
activated
UF CIP Procedures

1. Update UF status to CIP “In Process”

2. Isolate from other system. Close all the isolation valve.

3. Connect the CIP Inlet/Outlet by flexible hose
CIP
Inlet

CIP
Outlet
UF CIP Procedures

4. Prepare chemical, mixing by recirculate UF CIP Pump

discharge flow
CIP Chemical Design Dosage
CIP 1 H2SO4 806 ppm
CIP 1 Citric Acid 4000 ppm
CIP 2 NaOH 1360 ppm
CIP 2 NaOCl 200 ppm
CIP 3 H2SO4 806 ppm

5. Start CIP Cleaning Step

6. There is 6 steps of cleaning
7. Upon completion of cleaning, dismantle the flexible hose
from the CIP Inlet/Outlet
8. Update UF Status to “Completed”
UF CIP Cleaning Steps

Step 1: Recirculation on Feed Side

Note:
1. CIP In: BUV-0107/0207/0307
2. CIP Out Feed: BUV-0109/0209/0309
3. CIP Out Permeate:BUV-0108/0208/0308

BUV-1322

CIP Out
Filtrate

BUV-1317
CIP In
CIP Out
Feed
UF Cleaning UF CIP Pump UF Module
Tank
UF CIP Cleaning Steps

Step 2: Recirculation on Feed & Filtrate Side

Note:
1. CIP In: BUV-0107/0207/0307
2. CIP Out Feed: BUV-0109/0209/0309
3. CIP Out Permeate:BUV-0108/0208/0308

BUV-1322

CIP Out
Filtrate

BUV-1317
CIP In
CIP Out
Feed
UF Cleaning UF CIP Pump UF Module
Tank
UF CIP Cleaning Steps

Step 3: Soak

Note:
1. CIP In: BUV-0107/0207/0307
2. CIP Out Feed: BUV-0109/0209/0309
3. CIP Out Permeate:BUV-0108/0208/0308

BUV-1322

CIP Out
Filtrate

BUV-1317
CIP In
CIP Out
Feed
UF Cleaning UF CIP Pump UF Module
Tank
UF CIP Cleaning Steps

Step 4: Drain & Prepare Flushing

Note:
1. CIP In: BUV-0107/0207/0307
2. CIP Out Feed: BUV-0109/0209/0309
3. CIP Out Permeate:BUV-0108/0208/0308

Top Up
SWRO BUV-1322
Permeate

CIP Out
Filtrate

BUV-1317
CIP In
CIP Out
Feed
UF Cleaning UF CIP Pump UF Module
Tank
UF CIP Cleaning Steps

Step 5: Flushing on Feed Side

Note:
1. CIP In: BUV-0107/0207/0307
2. CIP Out Feed: BUV-0109/0209/0309
3. CIP Out Permeate:BUV-0108/0208/0308

BUV-1322

CIP Out
Filtrate

BUV-1317
CIP In
CIP Out
Feed
UF Cleaning UF CIP Pump UF Module
Tank
UF CIP Cleaning Steps

Step 6: Flushing on Feed & Filtrate Side

Note:
1. CIP In: BUV-0107/0207/0307
2. CIP Out Feed: BUV-0109/0209/0309
3. CIP Out Permeate:BUV-0108/0208/0308

BUV-1322

CIP Out
Filtrate

BUV-1317
CIP In
CIP Out
Feed
UF Cleaning UF CIP Pump UF Module
Tank
UF Air Integrity Test (AIT) Operation

 Integrity Test is a way to detect defective membrane.

 Pressure Hold Test:

 Air is used to displace all the water on either feed/filtrate side
of membrane
 Pressure is increased at air inlet side as air cannot pass
through the wetted pores
 Pressure up to test pressure, 1 barg
 Slightly pressure drop is expected due to natural air diffusion
 High Pressure drop indicate defective membrane fiber

 Bubble Test:
 Air escaping on the low pressure side due to defect is visually
confirmed by bubble in the transparent on the feed or filtrate
side
 T-RACK: High pressure is the feed side and transparent
pipe at the filtrate side of modules.
UF Air Integrity Test (AIT) Operation

Bubble will be
observed if there is
fiber defects

Transparent Pipe at
Filtrate Side
AIT Operation Procedures

1. AIT should be performed after maintenance work,

suspicion of malfunction or regularly basis.
2. Provision is provided to activate AIT notification.
3. When timer is up, an “AIT” alarm and message is
activated.
4. Put the UF Module into “Off” mode and update UF status
to “AIT “In Process.

4. Start AIT Steps.

5. Upon completion of AIT, update UF Status to
“Completed”.
6. Timer of AIT notification will be reset automatically.
 Air Integrity Test Procedures

1. Open Service Outlet Monitor the pressure drop

Valve Manually. When water in membrane at high side (feed) for at
2. Regulate Air Inlet is fully emptied and least 3 minutes.
Pressure to 1 barg. stable of 1 barg has been
3. Open UF AIT In Valve reached in feed side, Slightly pressure drop is
(BAL-0101/0201/0301) close UF AIT Valve. expected.
Air Integrity Test Procedures

Resume to normal
filtration start with
FB.

At the first 5 – 10
minutes, operate
the filtration at
reduced flux at 40
LMH ( 190 m3/h)

In case of leak, continuous After completion of Venting is required after

stream of bubble will be
visible on transparent pipe
(filtrate side).
Pressure Hold Test.
Release pressure at High
Pressure Side (feed) by
open UF Bottom Service
Inlet Valve manually.
Pressure Relief.
Conduct FFB under “Manual”
mode for 5 to 10 minutes.
Air Integrity Test Procedures

UF AIT In Valve
BAL-0101/0201/0301
DAILY OPERATION
MONITORING &
MAINTENANCE
FOR UF SYSTEM
Daily Operation Monitoring

 It is important for operators to follow daily

operation schedule

 Small issue can be detected earlier and

rectification work can be done before problem
develop into major problem

 Ensure proper operation of plant to achieve

performance

 Instrument data or trending should be checked

if abnormal reading/trend is found
Daily Operation Monitoring

Parameter Instrumentation Action/Remark

High Feed Water AIT-23001 Select Forward Flushing
Turbidity if high turbidity is
detected
High Differential DPS-23002 A/B/C Auto Strainer will go into
Pressure for Auto auto Flushing
Strainer
High High Feed PIT-23004 A/B/C Stop filtration. Maximum
Water Pressure Operating Pressure for
UF membrane is
5 kg/cm2G
High PIT-23004 A/B/C – Buildup of foulant, CIP is
Transmembrane PIT-23005 A/B/C required
Pressure
High High PIT-23004 A/B/C – Stop filtration. Might
Transmembrane PIT-23005 A/B/C damage membrane.
Pressure
Note: For others parameter, please refer to Alarm Set Point List
for details.
UF System Maintenance

 Perform SDI test for UF filtrate weekly

 Perform AIT test at least once every 6 months

 Perform CIP every 6 months or TMP > 1.3 bar

 Regular general maintenance work on UF racks

should including checking the tightness of all joints
and connection, repairing any damage that occurred

 Leaking area shall be properly sealed and rinse down

with salt-free water

 Repair or replace the damaged coated coupling, if

any.
CAUTION!

Following substances are prohibited being introduced

into either feed/filtrate side:
 Particles or foreign object > 300µm
 Abrasive, sharp edged particle which could cause
irreversible damage on membrane surface
 Corrosion or erosion products produced in water
treatment plant
 Foreign object such as metal or plastic shaving
 Polar, organic or chlorinated solvents
 Concentrated acid (pH < 1) or caustic (pH > 13)
 Ozone or any other hydroxyl radical producing oxidizing
agent
 Organic polymer, such as coagulant, corrosion inhibitors,
dispersants.
START UP OF
UF SYSTEM
Chemical Storage & Dosing System

 Top up chemical into Chemical Storage Tanks

 Calibrate Dosing Pump according to design dosage
 Determine the dosage of chemical required
 Calculate the dosing rate as following

 For Manual Stroke Pump, adjust pump stroke

manually to achieve the required dosing rate
Chemical Dosage
NaOH for UF CEB Dosage to adjust pH to 9.5 (96 ppm)
NaOCl for UF CEB 20 ppm
H2SO4 for UF CEB Dosage to adjust pH to 2.3 (806 ppm)

Note: Dosage to be confirmed during commissioning

Chemical Storage & Dosing System

 For Auto Stroke Pump, the dosing rate will be

adjusted automatically corresponding to feedback
from dedicated analyzer

Chemical Dosage
FeCl3 for UF Feed Water Dosage to be determined during Jar Test.
Dosing rate adjusted corresponding to
summation of flow detected by FIT-
23003A/B/C
Start-up of UF System

Before Start-up UF Operation, ensure that:

 Sufficient chemical in FeCl3 Storage Tank (2301-L1F),
NaOCl Storage Tank (2301-L7F), NaOH Storage Tank
(2301-L8F) and H2SO4 Storage Tank (2301-L6F)
 Feed Water (Seawater) supply is ready
 UF Wastewater Tank (2301-L4F) and Final Check
Basin are ready to receive wastewater from UF
Backwash or CEB process
 Instrument Air is available
 Ensure all the manual isolation valves and
instrument isolation valves along the flow paths are
opened
 Ensure that Auto Strainer (2301-L1LA/B/C) are
powered up
Start Up Procedures

1. At the HMI, select “AUTO” mode for below equipment:

 All On-Off Valves corresponding to UF system
 UF Backwash Pump (2301-L2J/JA)
 UF Wastewater Pump (2301-L6J/JA)
 FeCl3 Dosing Pump (2301-L1J/JA)
 NaOCl Dosing Pump (2301-L10J/JA)
 NaOH Dosing Pump (2301-L12J/JA)
 H2SO4 Dosing Pump (2301-L9J/JA)

2. Select UF Module to “Service” under “Auto” mode.

3. Filtration shall be proceeded if start permissive met. Check

for any abnormalities. Continue until all operating parameter
reading are stable.

4. Collect a sample of UF Filtrate to check its pH and SDI. (SDI

test kit to be used to check SDI).
SHUT DOWN OF
UF SYSTEM
Shutdown Procedures

1. From the HMI, select “Off” to shutdown UF train from

service

2. At MCC, switch to “Off” mode for all the motor that are
stopped to prevent accidental start during shutdown
maintenance.

3. Check all pressure gauges. If some point is still

pressurized, open the sampling/vent/drain valve along
the line to release pressure.
Shutdown Recommendations

 For Shutdown up to 24 hours

Perform Backwash Top and Backwash Bottom (60s) before
shut down

 For shutdowns for lasting up to 1 week

Daily Perform Filtration for 10 min and then perform CEB
with 20 ppm NaOCl solution with soaking time of 30 min

 For shutdowns for longer than 1 week

Perform CIP.
Flush with 0.75% SBS solution.
Leave the SBS solution in UF modules. Replace every 4 weeks.
TROUBLESHOOTING
OF
UF SYSTEM
Troubleshooting

The most common problems for UF Modules: Membrane

Fouling/Breakage.

Symptoms Possible Causes Solutions

Severe plugging of Perform CIP

membrane
Low feed water
Low Flow of Filtrate
Incorrect flow indication
Valve opening of valve too
small
O-ring seal is damaged
Check Seawater Feed Pump,
Auto Strainer, On-Off valves and
inlet piping
Calibrate flow transmitter, check
UF inlet FCV
Adjust the valve opening
Replace damaged O-ring

Broken housing Locate and repair leaking points

Leaking Operating pressure is too high Identify the cause of high
pressure
Loose connection Tighten the connection
Troubleshooting

Symptoms Possible Causes Solutions

Membrane damage Perform AIT, repair fibre if

High filtrate necessary
turbidity Leakage from seal Confirm point of leak. Repair or
replace as required.

RepairKit 30 Standard.pdf

For Equipment Troubleshooting, shall refer to its

Operation Manual.
SAFETY PRECAUTION
Safety Precaution

IN USING ANY CHEMICALS, FOLLOW ACCEPTED SAFETY

PRACTICES. ALWAYS WEAR EYE PROTECTION AS
MINIMUM, IN CASE OF HANDLING CORROSIVE
CHEMICALS, WEAR FULL FACE COVER AND PROTECTIVE
CLOTHING. REFER TO RELEVANT MATERIAL SAFETY
DATA SHEETS AS SUPPLIED BY CHEMICALS
MANUFACTURERS.

BEFORE DRAINING ANY CHEMICALS FROM STORAGE

TANKS, RUN SERVICE WATER TO THE CHEMICAL DRAIN
POINT. SLOWLY OPEN THE CHEMICAL DRAIN VALVE AND
FLUSH GENEROUSLY WITH SERVICE WATER.
Safety Precaution

ALWAYS WEAR SAFETY HELEMT AND BOOSTS

AT ALL TIME WITHIN PLANT AREA
QUESTIONS ??
QUIZ
 QUIZ QUESTION
1. What is the brand name of UF membrane.

2. What is the material of UF membrane and pore size?

3. There is how many UF train in BAP plant?

4. What is the purpose of Auto Strainer which installed prior to UF

train?

5. What chemical helps to coagulate suspended solids to bigger flocs so

can be easily retained by UF membrane?

6. What is the maximum operating pressure of UF membrane?

7.
8. What is the TMP value which will terminate the UF operation?

9. One filtration cycle including of what activities?

10. What will happen after pre-set no. of filtration cycle is achieved?

11. What are the chemicals will be used for CEB cleaning?

12. When UF CIP cleaning is required?

THANK YOU