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Summary of Contents for Toray NHP210 Series
- Page 1 Submerged Membrane Module for MBR TORAY “MEMBRAY” “NHP210 Series” Instruction Manual Toray Industries, Inc. Water Treatment Division 1-1, Nihonbashi-muromachi 2-chome, Chuo-ku, Tokyo 103-8666 Japan Tel +81-3-3245-4542 Fax +81-3-3245-4913 URL www.toraywater.com Published: August 2020 NIRE-170-1-6...
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Page 2: Table Of Contents
MEMBRANE FILTRATION PROCESS DESIGN FOR “NHP210 SERIES” ......12 Standard Time Chart ......................12 Flow Diagram of Membrane Filtration ................. 13 Layout of “NHP210 Series” Modules in Membrane Tank ........... 18 Piping ........................... 21 INSTALLATION OF “NHP210 SERIES” ................24 Preparatory Procedure ...................... - Page 3 Storage Products after Use ....................53 Disposing Procedure ......................54 REPLACEMENT PARTS LIST ..................... 55 TROUBLESHOOTING ......................56 APPENDIX ..........................57 Symbols used in this manual This symbol is used to indicate an imminent hazardous situation DANGER which, if not avoided, will result in serious injury or death. This symbol is used to indicate a potentially hazardous situation WARNING which, if not avoided, can result in serious injury or death.
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Page 4: Introduction
(MBR) that has been developed based on the polymer science and the membrane fabrication technologies accumulated for a long time in Toray Industries, Inc. "NHP210 Series" is a new model of "MEMBRAY" equipped with thin membrane elements having higher packing density, while reliable performance of Toray PVDF membrane has been kept unchanged. -
Page 5: Outline Of "Nhp210 Series
Escherichia coli and Cryptosporidium efficiently. Outline of “NHP210 Series” “NHP210 Series” is the membrane module composed of the element block and the aeration block. The element block contains a number of cassettes and in the cassette membrane elements are stacked at equal clearance, each of which has flat sheet membrane on both sides. - Page 6 (1) Shape of Element The membrane element is a flat sheet type as shown in Fig.I-4. At the normal filtration operation, the sludge accumulated on the membrane surface is cleaned up effectively with upward water stream generated with the scouring air supplied from the air diffusers installed at the bottom side (Fig.I-5).
- Page 7 (2) Membrane Structure The flat sheet membrane consists of PVDF (Polyvinylidene Fluoride) functional layer and the base layer of PET (polyester) non-woven fabric. This structure gives the membrane superior physical strength and high chemical resistance. (3) Membrane Pore Size Numerous small-size pores are distributed evenly over the membrane surface with a sharp pore-size distribution.
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Page 8: For Safe Operation Of "Nhp210 Series
FOR SAFE OPERATION OF “NHP210 SERIES” Before using “NHP210 Series”, please thoroughly read this Instruction Manual and follow the instructions described in this manual, especially the safety precautions shown below. The details of each precaution are described in the relevant chapter Unpacking and Installation When lifting “NHP210 Series”, attach chains or slings to the lifting... -
Page 9: Operation And Maintenance
Install the screen with openings of 3.0 mm or under before the membrane tank. Mesh type screen is recommended. Overflow or CAUTION waste carryover must be avoided at all time. Connect the flanges of air diffuser/manifold to the piping with the tightening torque of 20 N.m, in order to avoid distortion, leakage or CAUTION breakage of the plastic air diffuser/manifold. -
Page 10: Chemical Cleaning Of Element
When it is obvious that a module part is worn and potential for failure is high, promptly replace that part with approved CAUTION replacement parts. Never expose the “NHP210 Series” to freezing temperatures at CAUTION any time. When removing the “NHP210 Series” module from the activated... - Page 11 Immediately stop the chemical cleaning operation if any of the WARNING associated cleaning equipment appears to be malfunctioning. Do not inject any chemical into the membrane directly from the chemical pump discharge. Excessive membrane element internal pressure will damage the element. Be sure to inject chemicals at a WARNING pressure less than 10 kPa (100 mbar).
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Page 12: Specifications And Performance Of "Nhp210 Series
SPECIFICATIONS AND PERFORMANCE OF “NHP210 SERIES” III. Specifications of Element TableIII-1 and Fig.III-1 show the specifications and the physical dimensions for the NHP210 Series element. Table III-1 Specifications of Element (TSP-50080) Model name TSP-50080 Membrane configuration Flat sheet Application Filtration of activated sludge... - Page 13 3. Specifications and Performance of “NHP210 Series” Module Table III-3 shows the specifications of “NHP210 Series” cassette and module. Table III-3 Specifications of Cassette and Module ECS035 NHP210-300S NHP210-600D Model name (Cassette) (Standard module) (Double-decker) Number of membrane elements Cassette structure...
- Page 14 20 - 100 40 - 200 This value is just a reference value and not a guarantee value of Toray. Sustainable operating filtration flow capacity varies among the plant depending on the type of wastewater, total process design and operating condition. In case of industrial wastewater application, it is strongly recommended to conduct a pilot test before membrane tank designing.
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Page 15: Membrane Filtration Process Design For "Nhp210 Series
MEMBRANE FILTRATION PROCESS DESIGN FOR “NHP210 SERIES” This section will address the following for the Toray “NHP210 Series”: Standard sequence of operation/time chart, illustrated piping and flow schematic, and module(s) layout in the membrane tank. Standard Time Chart Usually intermittent filtration (filtration with relaxation) is recommended. The most common... -
Page 16: Flow Diagram Of Membrane Filtration
Flow Diagram of Membrane Filtration Two (2) flow diagrams of the membrane filtration process are shown below. One is for gravity filtration (when site conditions permit) and the other using a suction pump. Also depicted are major ancillary devices required for the membrane filtration process. To reduce the potential for membrane clogging, all activated sludge should pass through a fine mesh screen having openings of 3 mm or less prior to being introduced into the membrane tank. - Page 17 It is recommended that the piping from the filtrate water manifold to the filtrate water outlet should directly penetrate the tank wall, as shown in Fig.IV-2. In addition, if the filtrate water outlet is an open air discharge, it is recommended that a U-shaped “trap” be constructed to seal the filtrate piping with water.
- Page 18 A range of methods can be used to remove air from the filtrate line: vacuum pump, ejector or manual water injection. Contact Toray or refer to the engineering manual for the additional details. NIRE-170-1-6...
- Page 19 VFD controlled suction pump should be installed on the filtrate water line to control the flow rate of filtrate water. When operating more than one “NHP210 Series” module simultaneously it is recommended that each train be fitted with its own discreet filtrate flow rate controller.
- Page 20 Filtration d. Air supply unit (such as a blower) This unit supplies air to the air diffusers of "NHP210 Series" module. The air flow rate supplied to the module should be always within the range of "Scouring Air Flow Rate" indicated in Table III-3.
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Page 21: Layout Of "Nhp210 Series" Modules In Membrane Tank
3. Layout of “NHP210 Series” Modules in Membrane Tank (1) Layout of Modules in Membrane Tank Fig.IV-5a shows how the liquid circulates in the membrane tank. An upward flow of liquid is generated as the air is supplied from the air diffuser located at the bottom of the membrane modules. - Page 22 Contact Toray in the case the existing tank floor is not level If the existing tank floor is not level it is recommended that stands be installed as shown in Fig.IV-6.
- Page 23 Tank wall Module Module Module 2 X W3 Oxygen Supplying Aeration Equipment Fig.IV-7 Membrane Module Layout in Membrane Tank with Other Aeration Equipment (top view) Alternatively keep twice the W1 distance between the modules and other aeration equipment in the case shown in Fig.IV-8. Tank wall 2 ×...
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Page 24: Piping
Piping The procedures of the pipe arrangement for the air diffusers and the filtrate water manifold are described in this section. The connections of the air diffuser and the filtrate water manifold are shown in the module drawings attached to this manual. (1) Pipe Arrangement for the air diffusers The pipe from the air supply device (blower) is connected to the two flanges (A) located on the air diffuser (see Fig.IV-9). - Page 25 VIII-3 to VIII-6. It is advised that you prepare and attach “riser pipe” to connect two filtrate manifolds of one element block for ease of piping and handling (out of Toray’s scope of supply). Fig.IV-12 shows example of the riser pipe.
- Page 26 Chemical injection valve Chemical feed line Air discharge valve Suction pump Filtrated water valve Fig.IV-11 Upward Piping from Membrane Tank Fig.IV-12 Riser Pipe (example) When using polypropylene air diffuser/manifold, consider piping material and regulate the load to the flange connection points less CAUTION than 20 kg per flange, in order to avoid distortion, leakage or breakage of the plastic air diffuser/manifold.
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Page 27: Installation Of "Nhp210 Series
INSTALLATION OF “NHP210 SERIES” Preparatory Procedure (1) Take precautions to plan the route for the “NHP210 Series” to the membrane tank. The route should include the receiving area for the “NHP210 Series” to the final installation site. (2) Make arrangements to have, on site, the necessary equipment to unload the “NHP210 Series”. -
Page 28: Checking Products
“NHP210 Series ” cannot be stored indoors due to prevailing construction site conditions, try to minimize the time out of doors. As soon as possible, move the “NHP210 Series” into a protected area to avoid accidental damage. Always comply with all recommended storage conditions. -
Page 29: Installation Products
(4) Prevent from getting wet. Avoid conditions where condensation may occur on the module or elements. (5) Do not submerge in water until such time the “NHP210 Series” is ready for final installation. (6) Avoid module exposure to direct sunlight. - Page 30 aeration blocks are to be installed, record each block’s serial number and position within the tank. The air diffusers should be installed in a horizontal position to achieve uniform scouring aeration. The maximum allowable deviation from dead level for the air diffusers is 3/1,000 on the top surface of the aeration block in both lateral and vertical directions.
- Page 31 To avoid membrane element damage never place the filtrate connections to the membrane elements under stressful forces. When lifting “NHP210 Series” or its part, attach chains or slings to the module and carefully lift it straight up. Avoid moving the module DANGER from side to side during the lifting procedure.
- Page 32 If the load is higher than the limit above shown, put some supports on the piping to reduce the load. CAUTION Avoid pressurizing the filtrate side of "NHP210 Series” over 10kPa. NIRE-170-1-6...
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Page 33: Start Of Operation
START OF OPERATION Clean Water Operation (1) Check the following items prior to module(s) operation: Check that the air diffusion pipe and the filtrate water pipes are properly connected to the module(s). Check that the element block is securely installed on the aeration block. Remove any protective materials covering the membrane tank. -
Page 34: Seeding Sludge Injection
Start the clean water filtration process. At the initial operation of suction pump, priming (filling the suction piping with water) may be needed for proper pump suction and in that case avoid pressurizing the filtrate side of "NHP210 Series” over 10kPa. Measure and record the trans-membrane pressure and water temperature at designed filtration rates (at normal, maximum and minimum flow rates). -
Page 35: Actual Filtration Operation
2) When the activated sludge requires air for normal metabolic processes. However, under these conditions the amount of air flow directed to the diffuser should be reduced to just the amount required to maintain sludge viability. CAUTION Avoid pressurizing the filtrate side of "NHP210 Series” over 10kPa. NIRE-170-1-6... -
Page 36: Operation Control
VII. OPERATION CONTROL Standard Operating Conditions Table VII-1 shows standard operating conditions for “NHP210 Series". To ensure stable operation, operating parameters such as MLSS, sludge viscosity, DO (dissolved oxygen concentration) and pH should be kept in the range of recommended standard operation conditions listed in Table VII-1 below. - Page 37 Avoid abrupt changes in pH, temperature, trans-membrane CAUTION pressure or any other conditions even if they are within the standard operating conditions (Table VII-1). Perform regular inspections of the module. Replace worn parts, as CAUTION needed, in a timely fashion. CAUTION Protect the modules from freezing.
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Page 38: Operating Parameters
Operating Parameters The performance of the “NHP210 Series” varies depending on raw water quality and site specific operating conditions. In order to achieve stable “NHP210 Series” operation it is recommended that various operating parameter values be monitored and recorded regularly. - Page 39 minute to make certain sufficient sludge mixing has taken place prior to restarting the filtration process. The suction pump should always be off when performing air diffuser cleaning. (2) Membrane scouring blower: The blower supplying air for membrane scouring should be on continuously.
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Page 40: Daily Inspection
Daily Inspection The above section VII 2 lists operating parameters that should be monitored. Daily recording of the values associated with these parameters will be helpful in determining the current condition of the MBR system. Operational data should be analyzed daily to serve as a guide for preventative maintenance. Take action to correct any unfavorable operational trends before more serious conditions develop. - Page 41 The color of healthy activated sludge is typically brown, however this color can differ among plants, depending on wastewater composition, organic load etc. If an unexpected change is observed in sludge characteristics, check current operating conditions such as BOD load, MLSS concentration, DO, pH, temperature and/or wastewater composition, and take appropriate corrective actions.
- Page 42 (11) Pretreatment system In addition to the operating parameters for the “NHP210 Series”, check the status of the pretreatment systems (particularly the screening device) frequently. At regular intervals remove any accumulated trash that may accumulate on the screening device.
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Page 43: Maintenance Of "Nhp210 Series
CAUTION Be sure to use Toray approved replacement parts. Contact Toray sales department to obtain information on how to CAUTION order Toray approved replacement parts. When replacing the individual filtrate tubes to the filtrate manifold,... -
Page 44: Air Diffuser Cleaning
Air Diffuser Cleaning A clogged air diffuser cannot evenly distribute air to the membrane elements resulting in solids build up on the membrane element surface or, in extreme cases, membrane element damage. It is recommended that that the MBR module(s) be fitted with air diffuser cleaning components/valves that can be automatically controlled from the MBR system PLC. - Page 45 (2) Air diffuser cleaning procedure for multiple modules - Practical design For multiple module operation, the flushing procedure described in the previous section can be applied for each module or, a more convenient and simple approach is shown in Fig. VIII-1.
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Page 46: Chemical Cleaning Of Element
3. Chemical Cleaning of Element Continuous filtration of the sludge will eventually result in plugging of the membrane element pores with trapped solids. Clogging of the membrane pores is indicated by a gradual increase in module TMP. A chemical cleaning is recommended when any of the following conditions are observed. -
Page 47: Handling Of Chemical Agents
Handling of Chemical Agents Follow normal safety precautions when handling potentially harmful chemicals. Avoid direct contact with skin. Take precautions when handling chemicals and wear safety goggles, protective cloves and other suitable safety gear to avoid injuries. Prior to handling chemicals, read the chemical SDS information to familiarize yourself with dangers and remedies should a chemical spill or contact accident occur. - Page 48 case of dry chemical powders, handle in a manner that minimizes the formation of chemical dust. (d) Securely seal all chemical containers after each use. (e) Thoroughly wash your hands and face and rinse out your mouth after using chemicals. Do not eat or drink anything in the working place except in a designated place.
- Page 49 (a) Store the container in a dark, cold place. Avoid direct sunlight. Firmly seal to prevent direct contact with air. (b) Use corrosion-resistant containers for storage. Chemical agents used for chemical cleaning can be harmful to one’s health. When handling chemicals, wear protective goggles, WARNING protective gloves and other safety gear.
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Page 50: Chemical Cleaning Procedure
Chemical Cleaning Procedure (1) Element Chemical Cleaning Procedure To begin the cleaning process slowly inject the chemical via the filtrate water nozzle into the elements until the cleaning solution flows through the membranes. Do not apply pressure in excessive of 10 kPa (100 mbar) when injecting the cleaning chemicals. Some recommended cleaning chemical injection methods are shown below. - Page 51 Chemical cleaning with the chemical tank located above the membrane tank (Fig.VIII-3) Confirm that the chemical injection valve is closed. (ii) Using the chemical tank, mix the desired amount of chemical solution. (iii) Discontinue the filtration process and associated module aeration. Next close the filtrate valve.
- Page 52 surface of membrane tank water level. (ii) Using the chemical tank, mix the desired amount of chemical solution. (iii) Stop the filtration process, stop module aeration and finally close the filtrate valve. (iv) Open the chemical feed valve and start the chemical feed pump. Confirm that the outlet of the pressure relief pipe is free of obstructions and that any cleaning solution being discharged is flowing freely back into the chemical tank.
- Page 53 If the flow from the relief pipe is excessive make needed adjustments to the chemical pump discharge flow to reduce relief WARNING pipe discharge flow. Use the safety equipment such as goggles and gloves when inspecting discharge piping and making adjustments.
- Page 54 membrane surface can be destroyed which leads to a foaming issue. This sludge damage will be recovered in the course of time after operation restart and thus not a big trouble. Immediately stop the chemical cleaning operation if any of the WARNING associated cleaning equipment appears to be malfunctioning.
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Page 55: Lifting Procedure
Lifting Procedure Follow these procedures when lifting the “NHP210 Series” modules for maintenance. (1) If guide rail system is not installed in the membrane tank, drain the activated sludge from membrane tank. (2) Disconnect the manifold from the filtrate water line and disjoint the bolts jointing the element block with the aeration block in case bolts/nuts are applied for connecting both blocks. -
Page 56: Storage Products After Use
Storage Products after Use Take the following steps to preserve and store used “NHP210 Series” modules. (1) In case of module storage inside sludge (without sludge drainage), stop filtration and aeration should be stopped or intermittent e.g. five (5) minutes every hour to agitate and supply minimal DO to the sludge. -
Page 57: Disposing Procedure
with a tarp or some other plastic sheet that will protect the module from dust, wind and direct sunlight. Never use a pressure washer machine when washing the CAUTION membrane module element which cause fatal delamination of membrane element edge. Keep the membranes wet once they get wet. -
Page 58: Replacement Parts List
REPLACEMENT PARTS LIST Please contact TORAY for the details of the specifications. (1) NHP210-300S Required Quantity per Module Name Frequency Type No. of replacement parts NHP210-300S When deterioration ECS-Tubeset-050 (50 pcs) Permeate Tube Assembly (150 pcs/unit) detected. ECS-Tubeset-100 (100 pcs) -
Page 59: Troubleshooting
TROUBLESHOOTING Most of the troubles in the operation of “NHP210 Series” are related to poor membrane scouring aeration, delayed chemical cleaning, and pretreatment upsets. The following table lists some performance losses, their causes and possible remedies. Table X-1 Troubleshooting Problem... -
Page 60: Appendix
APPENDIX Following information is provided in the separate-attached document: (1) Assembly of Modules (2) Assembly of Guide Rail System (3) Assembly of Hangers. (4) Procedure of Paper filter test. This Instruction Manual does not intend to guarantee the results of application of the information provided herein or the safety and the compatibility of this product. - Page 66 December 13 , 2011 Rev.3 June 12 , 2020 The paper filtration test measurement procedure 1. Make a filter paper folded (Fig 1).Use filter paper equivalent to No.5C which has a diameter of 185mm (See below tables for reference.) Fig 1. Filter paper folded 2.
- Page 67 Standards of filter paper Used by TORAY JIS P 3801 ASTM E832-81 No.5C ClassG Typical specifications of the filter paper No.5C Mass (g/m Thickness (mm) 0.22 Permeated particle size (μm) Ash (%) 0.01...
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