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Energy Recovery Pressure Exchanger 4S Series Installation, Operation & Maintenance Manual

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ENERGY RECOVERY, INC
.
INSTALLATION, OPERATION, & MAINTENANCE
MANUAL
ERI DOCUMENT NUMBER 80022-01 REVISION 4
ERI™
4S Series Pressure Exchanger™
Energy Recovery Device
Energy Recovery, Inc.
1908 Doolittle Drive, San Leandro, CA 94577 USA
Tel: +1 510 483 7370 / Fax: +1 510 483 7371
/
www.energy-recovery.com
sales@energy-recovery.com
© Energy Recovery, Inc., 2004-6
Energy Recovery, Inc.
1
ERI Document Number 80022-01-04

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  • Page 1 4S Series Pressure Exchanger™ Energy Recovery Device Energy Recovery, Inc. 1908 Doolittle Drive, San Leandro, CA 94577 USA Tel: +1 510 483 7370 / Fax: +1 510 483 7371 www.energy-recovery.com sales@energy-recovery.com © Energy Recovery, Inc., 2004-6 Energy Recovery, Inc. ERI Document Number 80022-01-04...

  • Page 2: Table Of Contents

    4S-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES INSTALLATION, OPERATION, & MAINTENANCE MANUAL ERI 4S SERIES PRESSURE EXCHANGER TABLE OF CONTENTS 1.0 INTRODUCTION 2.0 SAFETY 3.0 QUALITY & ARRIVAL INSPECTION 4.0 DESIGN CONSIDERATIONS 4.1 H PX E OW THE NERGY ECOVERY EVICE ORKS 4.2 PX E...

  • Page 3: Introduction

    (SWRO) systems. This information is provided to ensure the long life and safe operation of your PX™ energy recovery device. Please read this manual thoroughly before installation and operation and keep it for future reference. The instructions in this manual are intended for personnel with general training and experience in the operation and maintenance of fluid handling systems.

  • Page 4: Quality & Arrival Inspection

    Figure 4-2 illustrates the typical flow path of a PX energy recovery device in an SWRO system. The reject brine from the SWRO membranes (G) passes through the PX unit, where its pressure Energy Recovery, Inc.
  • Page 5 Example flow rates and pressures for an SWRO system with one PX-90S are listed in Table 4-1 below with reference to Figure 4-2. In an SWRO system with an ERI energy recovery device Energy Recovery, Inc.
  • Page 6 97% efficiency. One advantage of operating at lower recoveries with PX energy recovery devices is that a lower operating pressure is required to produce a given amount of permeate. Since the main high-pressure-pump flow rate always equals the permeate flow rate plus the hydrodynamic bearing lubrication flow rate, low energy consumption at low recovery rates is possible with ERI technology.

  • Page 7: The Px B

    4.3 PX Energy Recovery Device Performance PX Pressure Exchanger device performance data for a range of possible flow and pressure conditions is provided on Energy Recovery, Inc.’s website. The following data are given in the form of performance curves: • High- and low-pressure pressure drop as a function of flow rate •...

  • Page 8: Debris And

    HP pump. During initial start up, all piping associated with the PX energy recovery device should be thoroughly flushed to assure that no debris enters and/or damages the PX unit. Energy Recovery, Inc. recommends installation of basket strainers at both inlets to the PX device or PX device array.
  • Page 9 4.9 Low Pressure Isolation and Over Pressurization If the low-pressure flow stream of the PX energy recovery device is isolated before the high- pressure side is depressurized, there is a risk that the PX unit or the low-pressure piping could be damaged by over-pressurization.

  • Page 10: Installation

    4S-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES 5.0 INSTALLATION The 4S-series PX energy recovery device can be installed in horizontal, vertical or any other orientation. The PX-45S, -70S and -90S have four connections labeled HP IN, HP OUT, LP IN, and LP OUT. The PX-140S has dual HP OUT and LP IN connections and single HP IN and LP OUT connections.
  • Page 11 4S-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES Table 6-1. System Performance Limits Parameter Specification English Units SI Units Maximum high pressure (HP IN or HP OUT) 1,200 psig 82.7 bar Maximum feedwater inlet pressure (LP IN) 300 psig 20.7 bar Minimum feedwater inlet pressure (LP IN) 27 psig 1.9 bar...

  • Page 12: Start And

    4S-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES • Allowable flow ranges for individual PX units are listed in Table 6-1. PX units are not designed to operate outside of these ranges. • Seawater feed to PX units must be filtered to 5 microns or less and should be subjected to the same pretreatment as seawater being fed to the SWRO membranes.

  • Page 13: Membrane

    4S-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES 6. Adjust the brine flow to balance the high- and low-pressure flows to the PX unit. 7. After the PX unit and booster pump have run for 5 to 10 minutes and all air and gas has been purged from the system, start the main high-pressure pump.
  • Page 14 4S-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES The PX unit must be flushed with fresh water for extended shutdowns to avoid excessive biological growth that may foul the PX device and inhibit CAUTION rotation upon start-up. The high pressure and low pressure sides of the PX unit should be flushed separately.
  • Page 15 PX unit. 6.3.3 Balancing the PX Energy Recovery Device To achieve balanced flow through the PX energy recovery device, use flow meters installed in the low- and high-pressure lines. The high- and low-pressure brine flows should be set equal to within 5.0% for optimum SWRO operation.

  • Page 16: Spare Parts And Tool Kits

    7.0 SPARE PARTS AND TOOL KITS The PX Pressure Exchanger energy recovery device needs no scheduled periodic maintenance. However, in the event that the PX unit is disassembled, Energy Recovery, Inc. recommends use of the following: ALL 4S-Series PXs: 4S Tool Kit – Energy Recovery, Inc. Part Number 20023-01 PX-45S, -70S, -90S: 4S Single Rotor Spares Kit –...
  • Page 17 4S-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES disassembly of a PX unit. Depending upon the reason for the maintenance work, complete assembly or disassembly may not be required. Refer to Section for PX device component 13.0 names and the bill of materials for the PX unit assembly. Refer to Section for recommended spare parts and tool kits.
  • Page 18 Tap down to loosen access cover if necessary. 6. Remove access cover by one of the following methods: a. If using Energy Recovery, Inc. 4S Series Tool Kit, bolt the slide hammer onto the access cover. Pull access cover.
  • Page 19 4S-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES Figure 8.4 – Mark vessel to recall alignment Figure 8.5 – Thread lifting eye into standoff Standoff LP nipple countersink Place a mark in line with LP countersink Figure 8.6 – Stand ceramic cartridge on blocks...
  • Page 20 4S-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES Contact Energy Recovery, Inc. immediately if ceramic is damaged or broken or if problems are encountered. Do not attempt to reassemble a PX unit with damaged or broken parts. 16. Remove the low pressure nipples.
  • Page 21 4S-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES 3. Insert dowel pins into the 3 holes in the end of the sleeve. Make sure the dowel pins insert fully without binding and without being shaved. If the pins bind, remove and clear pins and holes of any debris.
  • Page 22 4S-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES 8. Center the rod on the assembly. 9. Install the washers and hex nuts as shown in Figure 8.11. 10. Install the hex nuts. Tighten and torque the hex nuts onto ceramic rotor subassembly to 10 ft- lb (14 N-m) as shown in Figure 8.12...
  • Page 23 4S-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES Figure 8.14 – Orient center manifold with vessel Figure 8.15 – Screw side ports into center manifold Inspect and lubricate O-rings 15. Generously lubricate the inside of the vessel with glycerin. 16. Insert the ceramic cartridge into the vessel as shown in Figure 8.16. Make sure that the brine LP nipple (shown in Figure 8.13) is aligned with the countersink in the vessel.
  • Page 24 4S-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES 17. NOTE: The top and bottom ceramic cartridges in a PX-140S differ. The bottom cartridge is a mirrored version of the top cartridge. Therefore, the top cartridge must be returned to the top of the vessel and the bottom cartridge to the bottom of the vessel.
  • Page 25 4S-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES 24. Bolt down the lock ring with six (6) socket-head cap screws. 25. Inspect and lubricate the O-ring on the LP port. Install the LP port into the access cover. When handling and installing a PX device, care should be taken to avoid...
  • Page 26 4S-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES ENERGY RECOVERY, INC. SAMPLE OPERATING LOG NOTE: Daily data must be collected and maintained to support any warranty claims. Fax: +1 510 483 7371 Attn: Warranty Administration Department Total number of Pressure Exchangers in parallel...

  • Page 27: Trouble Shooting

    This section is designed to guide the operator in identifying and correcting most of the problems that could occur in the PX Pressure Exchanger energy recovery device. The instructions provided below are intended for use by personnel with general training and experience in the operation and maintenance of fluid handling systems.
  • Page 28 4S-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES B. Excessive high 1. Main high-pressure pump is Verify that main HP pump flow pressure in SWRO operating at too high a flow rate does not exceed the system. rate. membrane array production capacity for a given temperature, salinity and fouling factor.
  • Page 29 4S-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES F. Low reject flow. 1. Excessive pressure losses Contact SWRO supplier. through SWRO system. 2. Malfunctioning and/or stalled Check booster pump operation, booster pump. flows, and pressures. Energy Recovery, Inc. ERI Document Number 80022-01-04...

  • Page 30: Field Commissioning

    4S-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES 10.0 FIELD COMMISSIONING The Technical Services staff of Energy Recovery, Inc. offers commissioning service for all ERI products during field installation and/or at a SWRO system manufacturer’s location. Although commissioning is not a requirement, some customers might feel more comfortable with the offered service.

  • Page 31: Limited Primary Product Warranty

    4S-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES 12.0 LIMITED PRIMARY PRODUCT WARRANTY Energy Recovery, Inc. (ERI) warrants that its Pressure Exchanger (PX) device(s) will not fail or malfunction as a result of defects in materials, workmanship, or design for a period of twenty-four (24) months from date of shipment.
  • Page 32 4S-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES 5. Entrained or trapped air or other gasses must be purged from the SWRO system before pressurization. Large bubbles in a pressurized system can result in damage to piping and equipment including the PX unit.

  • Page 33: Drawings And Data

    13.0 DRAWINGS AND DATA PRESSURE EXCHANGER ASSEMBLY DRAWINGS PROCESS AND INSTRUMENT DIAGRAMS Energy Recovery, Inc. ERI Document Number 80022-01-04...

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