2018 MEMSTAR Pressurized UF O&M Manual - Rev401

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Your Partner in Membrane Solutions

Pressurized Ultrafiltration Modules


Operation and Maintenance Manual

UF- Module Product Line


Revision 4
April 2018
English
Original Instructions

Memstar Pte., Ltd. Memstar USA, Inc.


11 Kian Teck Drive 3655 Pollok Dr.
Singapore 628828 Conroe, TX 77303
+65 67752512 +1 855 MEMSTAR
Memstar.com.sg MemstarUSA.com

©2018 Memstar USA, Inc. All Rights Reserved. Copy by Permission Only. Copyright Strictly Enforced.
All rights reserved. No part of this publication may be reproduced, stored, or transmitted, in any form,
or by any means, mechanical, electronic, photocopying, or otherwise, without the written permission
of Memstar USA, Inc./Memstar Pte. Ltd in whole or in part. No patent liability is assumed with respect to
the use of the information contained herein.

Memstar USA, Inc./Memstar Pte. Ltd strives constantly to improve its high-quality products, the
information contained in this manual is subject to change without notice. For the latest revisions of our
documents please search on our website or directly contact the Memstar Sales and Technical teams.
We have taken every precaution in the preparation of this manual; nevertheless, Memstar USA,
Inc./Memstar Pte. Ltd assumes no responsibility for errors or omissions, and we assume no liability for
damages resulting from the use of the information contained in this publication.
Table of Contents

Preface – About This Manual ........................................................................................


Intended Audience ...........................................................................................................................................
Product application ..........................................................................................................................................
Purpose of This Manual .................................................................................................................................. i
Safety Precautions .......................................................................................................................................... i

1 Overview ................................................................................................................ 2
1.1 Term Abbreviations and Definitions ................................................................ 2
1.2 Key Operating Parameter Definitions ............................................................. 4
Filtrate flow rate ............................................................................................................................................ 4
Filtrate flux ..................................................................................................................................................... 4
Transmembrane Pressure .............................................................................................................................. 4
Normalized permeability ............................................................................................................................... 4
Filtration cycle duration ................................................................................................................................. 4

1.3 Handling and Care of Membrane Modules .................................................. 5


Before Installation.......................................................................................................................................... 5
After Installation ............................................................................................................................................ 5
Storage After Use ........................................................................................................................................... 5

2 UF System Description........................................................................................... 6
3 UF System Commissioning ................................................................................... 9
3.1 Pre-startup Checklist ......................................................................................... 9
3.2 System Integrity Test ........................................................................................ 10
3.3 Installation of Membrane Modules ............................................................... 10
3.3.1 Drain Protective Solution ............................................................................. 10
3.3.2 Installing the Membrane Module on the Skid .......................................... 11
3.4 Startup Cleaning and Module Flush .............................................................. 14
3.5 Initial Flow/Permeability Test .......................................................................... 14
3.6 Integrity Test ...................................................................................................... 14
3.7 Control Sequence Test .................................................................................... 15
3.8 Adjust Operating Setpoints ............................................................................. 15
4 Normal Operations.............................................................................................. 17
4.1.1 Filtration .......................................................................................................... 17
Operating Pressures ..................................................................................................................................... 17

4.1.2 Air Scouring ................................................................................................... 18


4.2 Chemical Cleaning ......................................................................................... 20
4.2.1 Chemical Cleaning Regime Design .......................................................... 20
4.2.2 Method to Verify the Effectiveness of the Cleaning ................................ 21
4.2.3 Cleaning Process Procedures .................................................................... 21

i
4.3 Integrity Testing, Bubble Testing, and Repair ............................................... 24
4.3.1 Integrity Test principle .................................................................................. 24
4.3.2 System Integrity Test Procedure ................................................................. 24
4.3.3 Removal of Membrane Modules ............................................................... 25
4.3.4 Individual Module Integrity Test Procedure.............................................. 25
4.3.4.1 Bubble Test Procedure ............................................................................. 25
For 10” modules........................................................................................................................................... 25
For 6” Modules ............................................................................................................................................ 26

4.3.4.2 Fiber Pinning Procedure ........................................................................... 27


4.3.4.3 Module Leak Test Procedure and Repair .............................................. 27
5 Data Recording ................................................................................................... 28
6 UF system troubleshooting ................................................................................. 29
6.1 General Membrane Module Troubleshooting ............................................. 29
6.2 Common UF System Troubleshooting Basics ............................................... 30

ii
Preface – About This Manual
To get the maximum benefit of your new Memstar UF modules, read this manual thoroughly and refer to it
often. Read this preface to familiarize yourself with the rest of the manual. In this preface you will read about
the following:

• Intended audience for this manual


• Product application
• Purpose of this manual
• Safety precautions
• Support
Every Memstar USA membrane module is shipped with a certificate of inspection. Located on all modules you
will find the model number and the serial number.

This manual applies to the Memstar 6” and 10” diameter pressurized ultrafiltration (UF) module product lines.
For submerged products, please refer to the Memstar Submerged Membrane Modules – Operation and
Maintenance Manual. All warranty claims are dependent upon strict adherence to this manual and shall
follow the warranty claim procedure described in the project specific warranty document.

Intended Audience

Use this manual if you are responsible for installing, setting up, or maintaining Memstar pressurized UF
module(s). There is no need for previous experience with our product.

Product application

The application of the modules covered in this manual are typical water and waste water treatment uses.
These uses include treatment of:

• Surface water (rivers and lakes)


• Seawater
• Groundwater
• Secondary clarified municipal wastewater
• Pretreated industrial wastewater
Please note that performance of the UF membrane modules are unique to each system and subject to the
particular source water quality, temperature, and operating conditions.
Purpose of This Manual

This manual is an installation, operation, and troubleshooting guide for use with Memstar pressurized
ultrafiltration module product line. This manual provides instructions for the following:

• Module installation and removal


• System commissioning
• Operating sequences
• Chemical cleaning
• Integrity testing and repair of the modules
• General troubleshooting
Safety Precautions

Throughout this manual, important statements are set off from the main text with an icon and an associated
signal word: “Danger”, “Warning”, “Caution”, or “Note.” The icon and signal word indicate the severity of the
condition or situation. Be sure to read these statements and take special care to follow the included
instructions.

Symbol Description

Danger means that there is a condition or situation that will cause


DANGER
death or serious injury if you do not follow the instructions given.

Warning means that there is a condition or situation that will cause


WARNING
moderate injury if you do not follow the instructions given.

Caution means that minor injury or product damage could occur


if you do not follow the instructions given. You may also have to
CAUTION
start a procedure over if you do not follow the instructions in a
caution statement

Note means that the text gives additional information,


NOTE
clarification, or helpful hints.

Please familiarize yourself with the appropriate Safety Data Sheets (SDS) for chemicals that will be discussed
throughout this manual and used with the module. These Include, but are not limited to:

• Calcium Chloride (CaCl2)


• Sodium Hypochlorite (NaOCI)
• Sodium Hydroxide (NAOH)
• Hydrochloric Acid (HCI)
• Sulfuric Acid (H2SO4)
• Citric Acid (C6H8O7)

i
1 Overview

1.1 Term Abbreviations and Definitions


Terms Definitions

6” Modules Memstar Module Models with 6” diameter pressure vessel,

starting with UF-06_ _

10” Modules Memstar Module Models with 10” diameter pressure vessel,

starting with UF-10_ _

A physical cleaning method for removing suspended solids fouling from the
Air Scouring
membrane surface

Bubble Point The pressure (at a given temperature) at which the first bubble of gas is formed

Clean Water Filtrate, or tap water

Unfiltered water that has passed through the module on the feed side of the module
Concentrate

Feed The flowrate of water into the membrane

Filtrate Water that has been filtered

Filtration The maximum amount of water that a module is designed to filter


Capacity

Deposits of inorganic or organic substances on the membrane surface, leading to


Fouling
blockage of flow and decrease in permeability

Maintenance Regular chemical cleaning during normal operation


Cleaning
(MC)

Membrane A barrier that is available for the filtration process

NTU Nephelometric Turbidity Unit, a measure of turbidity

P&ID Piping and instrument diagram

Permeability The porosity of the membrane under defined conditions

A group of UF modules mounted on a frame, connected in parallel to a set of


Skid
header pipes

Train A skid or skids operated in unison

A measure of cloudiness or haziness of a fluid; the degree to which


Turbidity a transparent liquid scatters light, usually a measure of the amount
of suspended material in the liquid.

2
UF Ultrafiltration

A single, distinct component comprised of hollow fiber ultrafiltration membranes


UF Module
fixed in a pressure vessel that is ready for connection to a skid

3
1.2 Key Operating Parameter Definitions
Filtrate flow rate

Filtrate flow rate is the rate of the water that passes through the membrane from the feed side to the filtrate
side. It is a function of the pressure, and the quality of the feed water. The filtrate flow rate should be set in
according to Memstar’s recommended membrane flux.

Filtrate flux

Filtrate flux is the volume of filtered water passing through a unit of membrane surface area in a specified
period of time. It is commonly expressed as lmh (Liters of filtered water/m2 of surface area/hr of filtration time),
gfd (gallons of filtered water/ft2 of surface area/day of filtration time), or m/d (m3 of filtered water/m2 of
surface area/day of filtration time). Appropriate flux selection is one of the most important design and
operating considerations. The filtrate flux should be set according to Memstar’s recommendation for your
specific application. The flux may be increased or decreased during operation to account for changes in feed
water quality, temperature or product water demand.

Transmembrane Pressure

Transmembrane Pressure (TMP) is the pressure difference between the feed and filtrate sides of the
membrane. It is commonly measured in units of bar, psi, or kPa. TMP is the driving force for filtration. Most
ultrafiltration systems operate at a constant flow rate during filtration. As filtration occurs, solids deposited on
the membrane surface will create resistance to filtration causing the TMP to increase. Proper design filtrate flux
is necessary to control the rate of TMP increase. Physical and chemical cleaning are required to remove
accumulated fouling and reduce TMP. The maximum allowable TMP is 0.15 MPa (22.1 psi).

Normalized permeability

Normalized permeability, or specific flux, is defined as filtrate flux per applied transmembrane pressure
(differential pressure) corrected to a specified temperature, typically 20 or 25 degrees Celsius. It is commonly
measured in units of lmh/bar or gfd/psi @20 deg C. Normalized permeability is one of the most important
parameters used to measure the performance of the membrane system. In a properly designed and operated
UF system, the normalized permeability will decrease slowly between cleanings and will return to previous
levels after cleaning such that it remains essentially constant over long-term operation.

Filtration cycle duration

The filtration cycle duration is dependent on the quality of the feed water. An appropriate design value should
be selected per Memstar’s recommendation. The actual time should be set by testing at site and adjusted
according to the changes of the feed water quality during the operation. Typical filtration cycle duration is 20-
60 minutes.

4
1.3 Handling and Care of Membrane Modules
CAUTION: To avoid damage to the membrane module, the module should not be subjected to
impact, drops and excessive vibration.

CAUTION: Take caution when opening the shipping container. Do not damage the membrane
with the tools used to open the box.

CAUTION: Two people are recommended to lift the module at all times

Before Installation

Before use, the module should be stored in an area between 5-40˚C (41-104˚F), with good ventilation, no
direct sunlight, and no corrosive substances. Allowing the module to freeze by reaching temperatures below
0˚C (32˚F), may cause serious damage to the membrane. The protective solution in the membrane is
approximately 1.5L of 30% Calcium Chloride (CaCl2) and water. This prevents damage to the membrane,
along with bacterial growth. Do not to not discharge the protective solution until you are ready to install the
module.

After Installation

If the membrane system will be shut down for less than one week, fill the modules with a sodium hypochlorite
solution (50 mg/L).

If the membrane system will be shut down for a prolonged period, flush the sodium hypochlorite solution,
then fill the modules with a sodium bisulfite solution (1.5%) and water. Ensure the modules are completely full of
solution. With air present, sodium bisulfite can form sulfurous acid, which is not compatible with Acrylonitrile
Butadiene Styrene (ABS).

Storage After Use

After initial operation if you store the membrane in another solution, such as a mixture of water and sodium
hypochlorite do not allow the membrane to get below 0˚C (32˚F). Again, the module should be stored in an
area between 5-40˚C (41-104˚F), with good ventilation, no direct sunlight, and no corrosive substances.

5
2 UF System Description
Although Memstar does not typically supply the UF system, it is critical to have properly designed system,
capable of following Memstar’s recommended operating process. Please refer to Memstar’s Pressurized UF
Technical Manual for system design recommendations. To facilitate operation explanation, the following
typical P&IDs are provided.

6
Figure 1: Typical P&ID – ED-Series Modules
7
Figure 2: Typical P&ID - E-Series Modules
8
3 UF System Commissioning
UF system commissioning should not occur until the plant is ready to start normal operations. If not, it is better to
leave the UF modules in their shipping containers, stored according to Section 1.3. Once the plant is ready to
start normal operations, proceed in the following order:

1. Conduct pre-startup checks

2. System Integrity Test

3. Install UF modules on skid(s)

4. Perform start-up cleaning and module flush

5. Initial Flow Test

6. Integrity Test

7. Operating Sequence Test

8. Switch to auto mode

3.1 Pre-startup Checklist


Before loading modules on the skid(s), confirm that the system is ready for commissioning and subsequent
operation.

✓ The piping system is ready and clean

o Flush system piping repeatedly to ensure the pipes are free of debris.

✓ The feed water quality is satisfactory, within design expectations.

✓ All valves are in the closed status and work properly.

o Cycle all valves from the control system

o Check and adjust opening and closing timing, as needed.

▪ The maximum module pressurization/depressurization rate is 0.25 bar (4 psi)/second.

✓ All equipment is in standby status and works properly.

o Cycle all equipment on and off from the control system

o Check and adjust pump and blower ramp-up and ramp-down times, as needed.

▪ The maximum module pressurization/depressurization rate is 0.25 bar (4 psi)/second.

✓ The drain system is ready.

✓ Auto control system is ready.

✓ The electric system is complete.

✓ Pretreatment processes and associated equipment, especially coarse and fine screening, is installed
and working properly.

9
3.2 System Integrity Test
Before installing modules on the skid(s), a system integrity test should be carried out. This is to ensure that
there is no leakage of water or air from the system. After installing the modules, it is more difficult to determine
if a decrease in test pressure is due to a system or module integrity issue.

1. Fill the system piping with water.

2. Once full of water, close valves for the section of the system to be tested.

3. Pressurize with air to 1 bar (15 psi).

4. Once air pressure is stabilized, turn off the air supply. Note the pressure.

5. Check for leaks and decline in the air pressure.

6. Repair any leaks.

7. Repeat until all leaks are fixed and there is effectively no decline in pressure.

3.3 Installation of Membrane Modules

3.3.1 Drain Protective Solution


WARNING: The protective solution, 30% Calcium Chloride (CaCl2), can cause serious eye
irritation. Wear protective gloves, appropriate skin protection, and eye protection when
handling. IF IN EYES: Rinse cautiously with water for several minutes

CAUTION: The protective solution, 30% Calcium Chloride (CaCl2), can corrode metals. Should
the metal pipes or skids come into contact with the protective solution, water should be used to
clean the affected area immediately to prevent corrosion. Protective solution should be
discharged according to your local requirements.

CAUTION: After removing the protective solution, module installation should be completed as
soon as possible to prevent the membrane fibers from drying out. Once the membrane fibers
become dry, the filtration performance of the module may deteriorate or even be totally lost.

CAUTION: Use two people when handling 6” modules. Use a fork lift, or other lifting device,
when handling 10” modules.

Prior to installing the membrane module, the protective solution must be removed. To remove the protective
solution, follow the below steps:

1) Move the module near a drain.


2) Stand the module up vertically with the feed/discharge port facing down. Secure the module with straps to
prevent it from falling over.
3) Remove the sealing caps from the feed/discharge and concentrate ports.
4) For the 6” modules – DN32/1¼” female threaded plastic cap
5) For the 10” modules – DN50/2” rubber caps slid on the grooved end ports
6) Allow the protective solution to pour out of the module for 1-2 minutes.
7) Immediately proceed to install the module on the skid

10
3.3.2 Installing the Membrane Module on the Skid
CAUTION: Before connection, clean the skid piping thoroughly by flushing with water. Ensure
that there are no foreign particles, such as metal or plastic scraps from construction, or sand,
inside the piping.

CAUTION: Use two people when handling 6” modules. Use a fork lift, or other lifting device,
when handling 10” modules.

NOTE: Pay attention to the marks on the ports of the module. The concentrate port must be
connected to the upper end of the skid, and the other end labelled with “feed port” must be
connected to the lower end of the skid. Do not connect the module upside down, this will
cause damage to the module.

CAUTION: Minimize time between draining the protective solution and installing on skid. Once
the membrane fibers become dry, the filtration performance of the module may deteriorate or
even be totally lost.

Module installation should be conducted immediately after draining the protective solution.

1) Ensure all sealing caps are removed.


2) Place the module on the skid with the feed/discharge port side down.
3) Connect each port to the skid piping.
4) Refer to Table 1 for 6” module connection types.
5) Refer to Table 2 for 10” module connection types.
6) A section of transparent pipe is recommended to be installed on the concentrate piping for each module.
This will facilitate identification of compromised modules during integrity testing. For 6” modules, Memstar
offers this fitting, inclusive of the transparent pipe section, two seals, and two union nuts.
7) When connecting to the individual module piping to the header, a grooved end style connection is
recommended.
8) Figure 3 shows an example of individual piping connection to the skid.
9) Installation of all modules on the same skid should be completed in < 8 hours. After installation of all modules
on the same skid, fill the skid with water as soon as possible.

11
Table 1: 6" Module Connection Information
UF-0615E/UF-0615ET UF-0615ED/UF-0615EDT
UF-0620E/UF-0620ET UF-0620ED/UF-0620EDT
A Not Used Feed/Discharge Port –
DN32 / 1 ¼” Female Socket
B Concentrate Port – Concentrate Port –
DN32 / 1 ¼” Female Socket DN32 / 1 ¼” Female Socket
C1 Permeate Port – Permeate Port –
DN32 / 1 ¼” Female Socket DN32 / 1 ¼” Female Socket
C2 Feed/Air Inlet/ Discharge Port – Permeate Port –
DN32 / 1 ¼” Female Socket DN32 / 1 ¼” Female Socket
D N/A Air Inlet Port –
Φ12/9.5 Press Fitting

Table 2: 10" Module Connection Information

UF-1010E/ UF-1010ET
UF-1015E/ UF-1015ET
UF-1020E/ UF-1020ET
A Influent / Discharge Port –
DN50 / 2” Grooved End (Victaulic Style)
B Permeate Port –
DN50 / 2” Grooved End (Victaulic Style)
C Concentrate Port –
DN50 / 2” Grooved End (Victaulic Style)
D Air Inlet Port –
Φ25/19 Female Thread

12
Key:

Transparent Pipe Section

Seal

Union nut - IT Viewing Pipe

Female Pipe Socket

Union nut - Module

Thread to Grooved End Adaptor

Grooved End Style Coupling

Figure 3: Example UF-0620EDT Installation diagram

NOTE: This diagram is an example and does not apply to all module types.

13
3.4 Startup Cleaning and Module Flush
Any remaining protective solution must be flushed before the system is started. If the system is shut down for a
prolonged period, please refer to the module storage information in Section 1.3.

1) Open the filtrate valve and concentrate valve


2) Open the feed valve
3) Start the feed pump slowly to get a low feed pressure, less than 0.1 MPa (14.5 psi)
4) Continue running clean water through the membrane modules until there is no foam in the discharge
water
5) Ensure the filtrate water meets the required quality

3.5 Initial Flow/Permeability Test


To confirm that the module(s) and skid(s) permeability are within expected range, an Initial Flow/Permeability
Test should be conducted, according to the following steps. This process will also allow the flux to stabilize.
Observation of the flow rate and TMP will provide a useful reference point/baseline for long term operations.

NOTE: Control the valve opening and closing speed, such that the pressure increases no faster
than 0.25 bar/second (~4 psi/second).

1) Open top drain valve and feed valve.


2) Start feed pump.
a. When starting filtration, residual air may be present in the membrane modules, and skid. To
prevent any damage to the membrane fibers due to water hammer, keep the feed and
concentrate valves open while filling the membrane modules with feed water until all
accumulated air is vented thoroughly through the concentrate port.
3) With the top drain valve open, slowly open the filtrate valve.
4) Once the filtrate valve is fully open, close the top drain valve.
5) Set the filtrate flow to 30% of the designed capacity.
a. Record the filtrate flow rate, feed pressure, filtrate pressure, concentrate pressure and water
temperature.
6) Increase the filtrate flow rate by 10% approximately every 4 to 6 hours until the designed value is reached.
a. Record the filtrate flow rate, feed pressure, filtrate pressure, concentrate pressure and water
temperature at each step.

3.6 Integrity Test


An integrity test with the modules installed should be conducted prior to starting normal operations. This test will
identify any modules with bad connections or compromised fibers. It is not uncommon to find some modules
with leaks at the connections to the skid or broken fibers. Please follow the procedure explained in Section 4.3.

14
3.7 Control Sequence Test
Prior to starting normal operations, all automatic sequences (Filtration, Air Scour, Maintenance Clean,
Recovery Clean, Integrity Test) need to be tested in auto mode to ensure that the pumps, blowers, and valves
are operating at the correct time. Use the sequence tables in Section 4 to confirm the control sequence is
correct.

3.8 Adjust Operating Setpoints


NOTE: Feed water pressure should be less than 0.3 MPa (43.5 psi) during this adjustment

Prior to switching to automatic operation, setpoints for key operating parameters should be made and
verified. Memstar suggests that the operating parameters in the following table are adjustable.

Table 3 Adjustable Operating Parameter Table

Item Description
1 Feed flow rate
2 Filtrate flow rate
3 Concentrate flow rate
4 Air scouring flow rate
5 Filtrate cycle time
6 Drain time
7 Fill time
8 MC interval
9 MC chemical dosing time
10 MC chemical soaking time
11 MC and RC drain time
12 RC interval
13 RC chemical dosing time
14 RC chemical soaking 1 time
15 RC chemical air scour time
16 RC chemical "top-off" time
17 RC chemical soaking 2 time

The initial set point for these parameters should be according to the system design recommendations
provided by Memstar. Adjustments will likely be made over time depending on the actual feed water quality
and the observed system performance.

Many parameters can only be optimized on site. Use the following procedures to adjust these parameters to
site specific conditions:

1) Concentrate flow rate adjustment – Open the auto concentrate valve and open the manual regulating
valve slowly until the flow rate recommended by Memstar is obtained. Most systems are operated in
dead-end mode, meaning the concentrate flow rate is zero.
2) Air scour flow rate adjustment – Open the auto air scouring valve. Turn on the blower. If using a positive
displacement blower, adjust the blower speed slowly until the flow rate reaches the designed value. If

15
using another type of blower, slowly adjust the manual regulating valve until the flow rate reaches the
designed value
a. Air flow rate per 10” module is 15 m³/h (9 cfm).
b. Air flow rate per 6” module is 5 m³/h (3 cfm).
3) Fill time adjustment - The fill time should be set on site by observing how long it takes for the skid to fill. This is
critical to minimize water wastage and maximize recovery.
4) Drain time adjustment – The drain time should be set on site by observing how long it takes for the skid to
be completely empty. This is critical to ensure foulants have been removed from the skids before refilling.
5) Chemical dosing rate –
a. Turn on the chemical cleaning pump. Measure the water flow rate. Turn off the chemical
cleaning pump.
b. Calculate the required chemical dosing rate to achieve the desired chemical concentration.
c. Set the chemical dosing pump accordingly.
d. Turn on the chemical cleaning pump and the chemical dosing pump.
e. Take a sample of the chemical cleaning solution at the modules. Measure the concentration
(for chlorine cleans) or pH (for caustic and acidic cleans).
f. Adjust the chemical dosing rate up or down to achieve the desired target.
g. Repeat d. through f. until the target is met.
6) RC chemical "top-off" time adjustment – During RC air scour, a portion of the water in the skid is displaced
by air. Prior to RC soak, the skid should be topped off with chemical solution so that the entire length of
membrane fibers will be exposed to chemical. The top-off time should be set by observing the amount of
time it takes for chemical solution to start flowing out of the concentrate valve.

When all the parameters are set under manual mode, the system should be switched to auto mode.

16
4 Normal Operations
After completing the commissioning process above, normal operations should commence immediately. If
there is a break between commissioning and normal operations, follow the instructions in Section 1.3.

Memstar suggests the control system to be capable of being operated in Manual or Auto mode. In each
mode, there are six working conditions. The working conditions are as follows:

• Standby - All the equipment and valves are closed. When power is on, the system will be in stand by
condition.
• Filtration – The system is filtering water.
• Air scour – The filtration process is stopped, and the air scour process is started.
• Maintenance cleaning - The filtration process is stopped, and the maintenance cleaning process is
started.
• Recovery cleaning - The filtration process is stopped, and the recovery cleaning process is started.
• Integrity testing - The filtration process is stopped, and the integrity testing process is started.
When the power is off, the system will be shutdown. All the equipment and valves will be in the stop or closed
state.

4.1.1 Filtration
Most systems using Memstar modules are designed to operate in dead end mode. In dead end mode, all feed
water is converted to filtrate water. During dead end filtration, the feed water valve (AV-01), the filtrate valve
(AV-05), and the feed pump (P-1) are all on. In certain situations, where the solids concentration in the feed
water is high, a small concentrate bleed (5-10% of the feed flow rate) will be utilized to control the solids
accumulations rate in the modules. During filtration, suspended solids are deposited on the membrane
surface. The filtration cycle duration is usually based on a set time interval but may also be set by a meeting a
certain processing volume.

Operating Pressures

1) Feed water pressure: The maximum pressure for the membrane module is 0.3 MPa (43.5 psi).
2) TMP: The maximum TMP is 0.15 MPa (22 psi).

17
4.1.2 Air Scouring
To remove the suspended solids accumulated during filtration, the system should automatically go into the air
scouring process after completion of the set filtration cycle time. During air scour, air is pumped by the blower
(B-1) to the bottom of the membrane modules while the air scour valve (AV-03) and top drain valve (AV-06)
are open. Hollow fibers swing and vibrate in rising air bubbles and the contaminants are stripped away from
membrane surfaces, as a result of the frictional impact from the fiber movements and shearing from localized
eddies formed around rising bubbles. Air scour pressure is equal to the water head above the bottom of the
membrane modules plus some minor losses in the module and piping losses.

NOTE: Make sure the module(s) are full of water throughout the air scour step to gain maximum
cleaning effect.

After reaching the preset air scour time, the skid should be drained by closing the concentrate valve and
opening the drain valve (AV-07). The air scour valve (AV-03) should remain open while the skid is drained. This
will keep solids in suspension and expedite the drain pressure slightly.

NOTE: Make sure the module(s) are completely drained. Failure to do so will result in
accelerated fouling of the membrane modules.

NOTE: The air scouring pressure should be less than 0.05 MPa (7.3 psi)

Once the skid is empty, turn off the air scour valve (AV-03) and the drain valve (AV-07). Open the feed valve
(AV-01) and top drain valve (AV-06). Slowly start the feed pump (AV-01). Once the skid is full of water, and all
air has been evacuated, open the filtrate valve (AV-05) and close the top drain valve (AV-06).

Full details of the air scour sequence can be found in Table 4.

18
Table 4: Control Sequence table – Air Scour
Valve Position Pump Status
Typical Top MC/ Chemical
Drain Filtrate Air for MC/RC Feed Air
Step Feed Filtrate Drain Air Scour Chemical RC Dosing
Step Step Description (AV- to Drain MIT Feed Pump Blower
Duration (AV-01) (AV-05) (AV- (AV-03) Injection Pump Pump (DP-
07) (AV-08) (AV-04) (AV-02) (P-1) (B-1)
(s) 06) (P-2) 1/2/3)
1 Stop Filtration 0 O O X X X X X X X R S S S
Step Transition - Feed
pump speed 10 O O X X X X X X X R→S S S S
adjustment
Step Transition - Valve
positioning and
5 O→X O→X X→O X X→O X X X X S S S→R S
blower speed
adjustment
2 Air Scour 60 X X O X O X X X X S S R S
Step Transition - Valve
5 X X O→X X→O O X X X X S S R S
positioning
3 Air Scour and Drain 60 X X X O O X X X X S S R S
Step Transition -
Blower speed
5 X X X O O X X X X S S R→S S
adjustment and valve
positioning
Step Transition - Feed
pump speed 10 O X O X X X X X X S→R S S S
adjustment
4 Skid Fill 30 O X O X X X X X X R S S S
Step Transition - Valve
5 O X→O O→X X X X X X X R S S S
positioning
5 Resume Filtration 0 O O X X X X X X X R S S S
Total Sequence
190 Notes: O=open valve R=Run pump
duration (s)
Total Sequence
3.2 X=Closed Valve S=Stop Pump
duration (min)

19
4.2 Chemical Cleaning
DANGER: If sodium hypochlorite and acid are mixed, poisonous chlorine gas will be formed.
The skids should be thoroughly rinsed between chemical cleanings so that the chemicals do
not mix.

Air scouring will remove most fouling from the membranes, but not all. Over time, fouling will accumulate.
Chemical cleanings are used to remove fouling that is not removed by air scouring. Chemicals should be
selected based on the type of foulants present. The chemicals used should not damage the membrane
module or create secondary pollution. Memstar utilizes two types of chemical cleaning:

1) Maintenance Clean (MC)- The maintenance clean is a shorter clean designed to maintain the membrane
permeability. In general, a chemical solution is pumped into a drained skid from the feed or filtrate side of
the membranes, usually the filtrate side. After a set soaking time is reached, low pressure air is used to
scour the membrane. After air scouring, the skid is drained and rinsed, before resuming filtration. After
maintenance cleaning, the TMP should be at least partially recovered.
2) Recovery Clean (RC) - The recovery clean is similar to the maintenance clean but uses a higher
concentration of the chemical and longer soak times. The recovery clean is designed to recover the
membrane permeability to the original value. The steps of the RC are very similar to the MC, but with an
extra soaking step. A recovery clean may be triggered by time (every 30-90 days), or when MC fails to
restore membrane permeability and the TMP continues to rise a certain amount about the initial value. For
example, more than 50KPa (7.3 psi) of the initial value.

4.2.1 Chemical Cleaning Regime Design


The chemical cleaning regime (chemicals, frequencies, durations, and concentrations) should be uniquely
selected for each site-specific condition. Contact Memstar for assistance selecting the cleaning regime for
your system. The following table is an indicative guide for various water types with typical quality. Variation
from this table due to site-specific water quality is common.

Oxidant RC Basic RC Acid RC


Oxidant MC Basic MC Acid MC
Frequency Frequency Frequency
Frequency Frequency Frequency
(Days (Days (Days
(# per (# per (# per
between between between
skid/day) skid/day) skid/day)
clean) clean) clean)
Chemical & 200 ppm 3500 ppm 1500 ppm 500 ppm 3500 ppm 5000 ppm
Concentration NaOCl NaOH H2SO4 NaOCl NaOH H2SO4

Ground Water 0.5 0.00 0.14 90 - 90

Seawater 1 0.00 0.14 60 - 60


Surface Water 1 0.33 0.25 60 60 60
Municipal WW -
1 1 0.14 45 45 45
Clarifier Effluent
Industrial WW -
2 1 0.25 30 30 30
Treated Effluent
Table 3 – Chemical Cleaning Parameters
1
Please contact us for the cleaning formulation for special contaminants.

20
4.2.2 Method to Verify the Effectiveness of the Cleaning
Please record the following parameters before and after the cleaning:

1) Feed and filtrate flow rate


2) Feed, concentrate, and filtrate pressure
3) Water temperature
After the cleaning compare the data. If the filtrate flow rate, or TMP could not be recovered it means the
cleaning is not effective, please contact our engineer to find a solution for this issue.

4.2.3 Cleaning Process Procedures


We have outlined the cleaning process for both maintenance clean and recovery clean. On the next couple
pages you can find detailed sequence tables.

The recovery clean procedure should be programmed into the control system. It should be manually initiated
whenever an established number of days have passed (commonly, 30 days), or the TMP reaches 1.5 bar (22
psi). The procedure should be repeated for each chemical. Ensure rinsing is complete before introducing a
new chemical. Typically, sodium hypochlorite is first, followed by sodium hydroxide. Finally, citric, hydrochloric,
or sulfuric acid is used.

21
Table 5: Control Sequence Table - Maintenance Clean

22
Table 6: Control Sequence Table - Recovery Clean

23
4.3 Integrity Testing, Bubble Testing, and Repair
Integrity testing is used to confirm that the system and modules are intact. If membrane fibers are damaged or
broken, or module or skid seals are not made correctly, feed water may pass to the filtrate side of the
membrane and filtrate quality may be affected. This may be indicated by an increase in turbidity. Therefore,
it may be necessary to conduct a n integrity test and repair any damaged membrane fibers or leaking
points.

4.3.1 Integrity Test principle


Pressurized air is applied to one side of the wetted membrane fibers. If the membrane integrity is intact, and
the air pressure is lower than the bubbling point, there will be no observable air flow from the membrane pores.
However, if there are damaged membrane fibers, air flow can be easily observed at pressure far below the
bubbling point. Therefore, the integrity of a membrane module can be tested by observing bubble flow or the
pressure change on one side of the membrane fibers.

4.3.2 System Integrity Test Procedure


Caution: The compressed air used for integrity testing must be oil free. Dirty air will contaminate
the membrane. The maxium air pressure allowed during testing is 100kPa (14.5 psi)

Caution: The testing should be completed in less than 5 minutes. Immediately after testing, the
modules must be filled with water.

The following procedure is used to confirm system integrity and identify any integrity breach in need of repair.

1) Fill up the skid with water to make the membrane modules completely wet.
2) Open the integrity test (IT) valve (AV-04) and the filtrate valve (AV-05). Compressed air applied through
the integrity test valve will drive the water from the feed side of the membrane to the filtrate side. As water
evacuates and air fills the feed side, the pressure will slowly increase until the it reaches a regulated set
point, which should be less than 100KPa (14.5 psi).
3) Allow the pressure to stabilize at the set point, typically ~2 minutes. This will occur once all the water on the
feed side of the membrane has been evacuated.
4) After the pressure has stabilized, close the IT valve. Note the pressure.
5) Hold the pressure for 5 minutes.
6) Typically, if the pressure drop is less than 5KPa (0.7 psi) in 5 minutes, the system integrity is intact. If the
pressure drops rapidly, it indicates that there is a leak in the system.
7) Check the transparent pipe section at the top of each module for leaks. If vigorous bubbles are observed
in the transparent pipe of a module, it should be removed for further testing and repair.

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4.3.3 Removal of Membrane Modules
CAUTION: Use two people when handling 6” modules. Use a fork lift, or other lifting device,
when handling 10” modules.

CAUTION: Once the membrane fibers become dry, the filtration performance of the module
may deteriorate or even be totally lost. When removing the membrane prevent it from become
dry due to air drying.

When necessary, remove the membrane module according to the following instructions:

1) Prior to removal, use the chemical cleaning pump to rinse all the modules on the same skid with about 2
skid volumes of clean water.
2) Stop the operation of the skid.
3) Open the drain valve for the skid and discharge the water from the membrane module through the
feed/discharge port.
4) Disconnect the module at the filtrate port(s), followed by the feed/drain port. Leave the top concentrate
port connected.
5) For 6” modules: Use two people. One person should hold the membrane module steady, while the other
makes disconnection by unscrewing the union nuts.
6) For 10” modules: Use two people. Connect the module to the lifting device. Disconnect by undoing the
grooved end style couplings.
7) Use one person to hold the module steady, while the other makes the final disconnection.
8) Lift the module from the skid and place horizontally on the ground, with the side ports facing up.
9) Cap all the ports of the module immediately using the sealing caps.

4.3.4 Individual Module Integrity Test Procedure


CAUTION: Use two people when handling 6” modules. Use a fork lift, or other lifting device, when
handling 10” modules.

CAUTION: Properly support the module with straps to prevent the module from falling over.

4.3.4.1 Bubble Test Procedure


After removing the suspect module from the skid, perform an integrity test on the module according to one of
the following procedures:

For 10” modules

1) Remove the top end cap.


2) Install integrity test kit, as shown in Figure 4.
i. Fix clamp on filtrate end of module with the eye bolts pointing out from module.
ii. Insert air supply adaptor in the central opening of the module.
iii. Move eye bolts into slots of fixing bar.

25
iv. Tighten wing nuts on eye bolts until the fixing bar cannot move.

NOTE: Do not apply excess force. Excess force may damage the module. The
fixing bar is only intended to prevent movement of the air supply adaptor.

v. Connect compressed air supply line.


1. Compressed air supply line should be regulated to a maximum pressure of 1.3 bar (19 psi)
2. Equip compressed air supply line with air pressure vent valve.

Figure 4: Integrity Test Kit for 10" Modules


3) Place the module in a clear rectangular tank full of water so that it is fully submerged. Fix the module in
place, below the water level. The filtrate end of the module must be accessible and clearly viewable.
4) Apply a small amount of pressure on the membrane 50-100kPa (7.2-14.5 psi), never more than 15 psi
5) If vigorous bubbling is observed on the surface, one or more membrane fiber(s) are damaged and need
to be isolated from operation. Proceed to Section 0.
6) If vigorous bubbling is not observed, proceed to Section 4.3.4.3.

For 6” Modules

1) Fix module on testing stand vertically (the feed water port down)
2) Dismantle the clamp and end cap of the two ends
3 ) Seal the concentrate port and feed water port with sealing cap
4) Connect compressed air to the air inlet
5) Apply a small amount of pressure on the membrane 50-100kPa (7.2-14.5 psi), never more than 15 psi
6) Spray clean water on the end surface of the potting
7) If bubbling (like a fizz) is observed on the surface in a specific location, one or more membrane fiber(s) are
damaged and need to be isolated from operation. Proceed to Section 0.
8) If bubbling (like a fizz) is not observed, proceed to Section 4.3.4.3.

26
4.3.4.2 Fiber Pinning Procedure
1) Once the source of the bubbling has been identified, turn off the pressurized air.
2) Insert a Memstar repair pin into the opening of the damaged fiber and press it in until 2/3 of the pin is inside
the module.
3) Cut the pin.
a. Do not pull the pin out while cutting
4) Press any extruding portion of the pin into the fiber.
5) Follow the bubble test procedure above to make sure the broken fiber is completely sealed.

After the completion of repairing the top filtrate side, the membrane module is turned upside down and is
repaired as per above procedure.

Plastic Needle

Figure 5 Membrane Repair Procedure

4.3.4.3 Module Leak Test Procedure and Repair


1) Install end cap and clamp at discharge/filtrate port end. Also cap the concentrate and feed ports.
2) Place the module horizontally in a water tank large enough to completely submerged it in water
3) Connect an air supply and pressure gauge
4) Apply up to, but never exceeding, 0.1MPa (14psi) of air
5) For the first minute or two air that has been trapped may escape. After that the pressure should hold
steady
6) Observe any air bubbles from the housing, or clamp joints. If a bubble is observed, mark the leaking point
7) If leak is found around a clamp joint, simply replace the old O-rings with new ones. If the housing is the
source of the leak, it can be repaired using epoxy resin. Contact Memstar for recommendation on
selecting an epoxy resin.
8) Repeat Steps 4-7 until no leakage is detected on the module.

Figure 6: Membrane Module Leak Test

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5 Data Recording
It is very important to record the operating data of the system accurately and completely. At minimum, the
following variables should be recorded automatically and stored in an exportable format on the SCADA system
or other data logging equipment.

✓ Feed water pressure (kPa) (psi)

3
✓ Feed water flow rate (m /h) (gpm)

✓ Feed water temperature (°C) (°F)

✓ Filtrate pressure (kPa) (psi)

3
✓ Filtrate flow rate (m /h) (gpm)

✓ Feed water turbidity (NTU)

✓ Product water turbidity (NTU)

Contact Memstar for a data collection spreadsheet.

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6 UF system troubleshooting
6.1 General Membrane Module Troubleshooting
The following are critical to maintain stable operation and produce high quality water over the long term:

1) Properly pre-treated feed water


a. Pretreatment equipment should remain in proper working condition.
Feed water should be within the ranges provided in
b. Table 7. The purpose of controlling these parameters is to minimize the risk of membrane
damage and/or fouling. These ranges apply to all systems using Memstar UF pressurized
modules. Selection of operating parameters depends on the specific project.
2) Appropriate filtrate flux
3) Suitable filtration cycle time
4) Sufficient air scour flow rate
5) Targeted chemical cleaning regime

Feed water quality should be monitored closely. Changes in feed water quality may require adjustment of
operational settings. Careful attention to how the membrane performance is affected by changing feed water
quality is required to make necessary system adjustments.

Table 7 Feed Water Quality Conditions

Parameter Allowed Range Comments

1 – 10 (NIPS)
pH 1—14 allowed during cleaning (TIPS)
1-14 (TIPS)

≤0.5 mm,
Particle Size ≤0.12 mm for seawater feeds, To prevent mechanical damage
no sharp particles allowed

Oil ≤2 mg/L To prevent membrane fouling

Contact the sales team if your operating parameters


Turbidity <300 NTU
exceed the allowed

*This is not an extensive list and does not constitute the only conditions for a valid warranty claim. Refer to
your project specific warranty document for all conditions that apply to your warranty.

29
6.2 Common UF System Troubleshooting Basics

Symptom Possible Causes Solutions

Undergo suitable cleaning; Adjust filtration


flux; Adjust filtration cycle time; Verify
High TMP Fouling of the membrane
automated cleanings are occurring
correctly

Blower fault Check the blower


Low air scouring
flow rate
Valve closed Check the piping and valve

Control system failure Check PID and flow meter


High feed water
pressure
Pressure meter fault Calibrate the pressure meter

Feed pump failure Check feed pump and piping


Low feed water
pressure
Valve failure Check feed valve

No electricity Check power supply

Motor break down VFD failure Check the VFD unit

Check the setting of overload for the


Over load motor. If the value is exceeded,
contact the supplier.
Check the transparent tube on the top
IT failure Membrane leakage of each module, locate the damaged
module and repair it.
Check the compressed air. Check the
No open or close action
solenoid valve.
Valve failure
Check the switch and the 24V power
Switch fault
supply.
Check the water pipe and eliminate the
Air in the meter
High turbidity of air.
product water
Membrane module integrity issue Repair the damaged seal or fiber(s).

Thank you for choosing Memstar Membrane Modules!

For any information that was not covered in this manual, please reach out to your Memstar Sales
representative.

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