Energy Recovery 8500 Series Installation, Operation & Maintenance Manual

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ENERGY RECOVERY, INC.
INSTALLATION, OPERATION, & MAINTENANCE
MANUAL
Series 8500-2400 PX Booster Pumps
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., 2001-2005
Energy Recovery, Inc.
ERI Document Number 80020-01-2

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Summary of Contents for Energy Recovery 8500 Series

  • Page 1 Series 8500-2400 PX Booster Pumps 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., 2001-2005 Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 2: Table Of Contents

    NSTALL THE ECHANICAL 7.4 D ISASSEMBLY OF 7.5 A SSEMBLY OF 7.6 M OTOR EARING ERVICE 8.0 TROUBLE SHOOTING 9.0 ERI FIELD COMMISSIONING 10.0 WARRANTY AND LIABILITY 11.0 REVISION LOG 12.0 DRAWINGS AND DATA Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 3: Introduction

    1.0 INTRODUCTION This manual contains instructions for the installation, operation, and maintenance of the Energy Recovery, Inc.™ (ERI™) PX Booster Pumps for energy recovery in Sea Water Reverse Osmosis (SWRO) systems in conjunction with ERI’s Pressure Exchanger™ (PX™) technology. The PX Booster Pump boosts the pressure in the high pressure portion of an SWRO system to make up the small pressure losses that occur through the SWRO membranes, the PX units and the associated piping.
  • Page 4: Principle Of Operation

    Operation under conditions outside of those stated in Table 6-1 can result in damage to the PX Booster Pump and will void the warranty. Energy Recovery Inc. will not be liable for any project delay, damage or injury caused by the failure to comply with the procedures in this NOTE manual.
  • Page 5 Booster Pump Outlet/ Seawater 1000 / 69 SWRO Feed Stream 1000 / 69 PX HP Inlet/ Reject 971 / 67 PX LP Outlet/ Reject 15 / 1.0 SWRO Product Water 5 / 0.3 Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 6: Installation

    SWRO system equipped with PX technology, the main pump will provide 41% of the energy, the booster will provide 2% and the PX unit(s) will provide the remaining 57%. Since the PX energy recovery device uses no external power, the total power savings is 57% compared to a system with no energy recovery.
  • Page 7: Operation

    Failure to observe these conditions and precautions can result in violation of the warranty, damage to the equipment, and/or harm to personnel. Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 8: Precautions And

    Pumps are listed in Table 6-1. PX Booster Pumps are not designed to operate outside of these ranges. 6.1.4 Physical Characteristics See Section 13.0 for weights and dimensions. Connections dimensions and requirements are provided in Table 6-2. Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 9: Utilityr

    PX device. 1. Verify system is de-energized and un-pressurized. 2. Check tightness of all lines and fittings. 3. Supply feed water to the SWRO system and the PX unit’s low-pressure inlet. Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 10: Maintenance And Startup

    A sample operating-log has been provided in Section 8.0 of this manual and must be submitted by fax or e-mail to Energy Recovery, Inc. in San Leandro, California upon completion of the startup and flow balancing routines. Submittal of this form with the initial startup data within 24 hours of startup is a condition of obtaining PX Booster Pump warranty coverage.
  • Page 11: Lubricate Booster Pump

    ERI offers a tool kit (ERI Part Number 20003-01) for PX Booster Pump maintenance operations. Alternately, a list of tools and materials recommended for maintenance of the mechanical seal are provided in Table 7-3. Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 12: Remove The Old

    There is an access slot for these screws at the side of the bell housing. See Figure 7-3. 6. Remove the four bolts that hold the inlet housing to the bell housing with a 9/16” wrench as shown in Figure 7-4. Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 13 9. The mechanical seal includes the primary seal and the stationary or mating plate as shown in Figure 7-6. Extract the stationary plate from the seal plate by pushing through the seal plate with a rod as shown in Figure 7-7. Remove stationary plate from the seal plate. Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 14 10. Clean the coupling and the shaft keys to remove any salt deposits or debris. Keep the shafts and coupling clean and free of dirt, rust and foreign CAUTION matter. Use plenty of anti-seize upon reassembly to ensure easy disassembly the next time. Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 15: Install The New

    Make sure that the drainage hole is oriented so that it will be on the bottom of the bell housing when the PX Booster Pump is reinstalled. Torque the bolts to 40 foot-pounds (ft-lbs) / 58 N-m. Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 16 Insert the new stationary seal into the seal plate. Be sure to line up the groove in the bottom of the stationary ring with the anti-rotation pin as shown in Figure 7- 15. The stationary seal must seat flat and level in the seal plate. Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 17 8. Align the shaft key with the slot in the coupling and install the pump onto the bell housing as shown in Figure 7-17. Figure 7-17 – Install Pump into Bell Housing Align shaft Finger tight key with slot in coupling Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 18 Figure 7-21. Reassemble pump according to the steps above. Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 19 15. With the pump and motor shafts in contact, tighten the eight (8) coupling screw as shown in Figure 7-23. NOTE: THE PUMP AND MOTOR SHAFT MUST BE IN CONTACT. Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 20 Coupling Screw 8 ft-lb / 8 ft-lb / 8 ft-lb / 8 ft-lb / 12 ft-lb / 12 ft-lb / Torque 11 N-m 11 N-m 11 N-m 11 N-m 16 N-m 16 N-m Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 21: Disassembly Of Wet End

    FEW SECONDS. Damage will occur in seconds if the pump runs with insufficient feed flow. 7.4 Disassembly of Wet End The following procedure should be used when rebuilding the wet end of PX Booster Pumps. 1. Verify that the system is de-energized and un-pressurized. Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 22: Assembly Of Wet End

    Figure 7-29 below. 3. Install the bell housing as shown in Figure 7-29. Be sure the drainage hole is oriented downward toward the floor. Torque bolts to 40 ft-lbs (58 N-m). Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 23 Figure 7-32. If seal is not correctly compressed, remove the pump and install a fender washer into the shaft coupling or a shim spacer onto the shaft as shown in Figure 7-33. Reassemble pump according to the steps above. Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 24 PX Booster Pump models, the gap between the impeller and the wear ring cannot be directly viewed. In this case, measure the distance between any two features on the diffuser plate and the impeller as shown in Figure 7-36. Record the measurement. Then raise the Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 25 Figure 7-36 - Adjust the Gap Between the Impeller and Diffuser Plate Using Spacers 1/16” (1.6mm) Figure 7-37 - Set the Gap Using Measurements at the Edge of the Parts for 2400-Series Pumps Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 26 Diffuser plate Diffuser bowl Spacer washer (optional) Bearing journal Thrust washer Impeller Figure 7-39 - Complete Stage Assembly for 2400-Series Pumps Diffuser Bowl Bowl Sleeve Spacer Washer(s) (optional) Bearing journal Thrust washer Impeller Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 27 0 ft-lbs) of torque to the outlet nozzle with a pipe wrench as shown in Figure 7-44 below. Insufficient torque will result in the bowls breaking free, spinning and pump failure. Figure 7-42 - Install Shell and Outlet Nozzle Figure 7-43 – Tighten Shell Figure 7-44 – Tighten Outlet Nozzle Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 28: Motor Bearing Service

    The following procedure describes removal and replacement of motor bearings. Consult the current motor manual on the motor vendor’s website for additional guidance or information: Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 29 10. Remove the bearing lubrication covers (x2). See Figure 7-45. Figure 7-45 – Remove Bearing Lubrication Covers 11. Remove the front bell from the motor body. See Figure 7-46. Figure 7-46 – Remove Front Bell Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 30 14. Use a bearing puller to remove the thrust bearing from the front of the shaft and the back bearing from the back of the shaft. See Figure 7-49. Figure 7-49 – Pull Bearing with Bearing Puller Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 31 27. Grease the bearings with a grease gun through the grease fittings. Use a high-quality bearing grease such as Shell Dolium R or Chevron SR1 2. 28. Reassemble the pump according the procedures provided above. Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 32: Trouble Shooting

    The best troubleshooting tool is the knowledge of the plant gained through experience. Any condition not covered in this section may be resolved by contacting Energy Recovery, Inc.’s Service Department.
  • Page 33 Test capacitor per previous accelerate. instructions. Faulty stationary switch. Inspect switch contacts and connections. Verify that switch reeds have some spring in them. Bad bearings. Noisy or rough feeling bearings should be replaced. Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 34 Damaged or blocked stage Check and replace stage assemblies. assemblies as required. G. Motor stalled Power failure or trip. Verify proper power and voltage connections. Check motor overload mechanisms. I.e. Fuses and /or circuit breakers. Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 35 I. Excessive noise Excessive flow rate. Lower flow rate or apply backpressure to pump. Insufficient feed water. Check feed pressure and inspect wet end assembly. Motor bearing failure. Check motor bearings and/or replace motor. Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 36 SERIES 8500-2400 PX BOOSTER PUMPS ENERGY RECOVERY, INC. SAMPLE OPERATING LOG NOTE: Daily data must be collected and maintained to support any warranty claims. Initial data must be submitted within 24 hours of startup. Fax: +1 510 483 7371 Attn: Warranty Administration Department...
  • Page 37: Eri Field Commissioning

    Should a problem develop with any ERI product, our Technical Services group is prepared to handle customers’ concerns whether the location is domestic or overseas. Service rates are available upon request. Energy Recovery, Inc. 1908 Doolittle Drive San Leandro, CA 94577 USA Tel: +1 510 483 7370 Fax: +1 510 483 7371 Email: sales@energy-recovery.com Web: www.energy-recovery.com...
  • Page 38: Warranty And Liability

    SERIES 8500-2400 PX BOOSTER PUMPS 10.0 WARRANTY AND LIABILITY Customers who wish to return goods to Energy Recovery, Inc. (ERI) for repair, warranty evaluation and/or credit should contact ERI’s Customer Service Center at (510)483-7370 between the hours of 08:00 and 17:00 Pacific Standard Time on work days.
  • Page 39: Revision Log

    1-24-05 bearing service, added warranty 12.0 DRAWINGS AND DATA PX Booster Pump Assembly Drawings, Overall Dimensions and Labeling Diagrams, Shipping Configuration Drawings PX Booster Pump Characteristic (Pump) Curves ERI PX Booster Pump Brochure Energy Recovery, Inc. ERI Document Number 80020-01-2...
  • Page 40 2. USE REQUIRED QTY OF SPACER WASHERS TO ACHIEVE SPACING 51000-01 HOUSING, BELL, BOOSTER PUMP ALUM OUTLINED IN THE OPERATIONS AND MAINTANCE MANUAL. 3. ENERGY RECOVERY INC., RESERVES THE RIGHT TO MAKE CHANGES 51008-01 PLATE, SEAL AL6XN AT ANY TIME WITHOUT NOTICE.
  • Page 41 1. MOTORS ARE CUSTOMIZED TO EMPLOY A SPECIAL THRUST BEARING. CONTACT ENERGY RECOVERY INC. FOR REPLACEMENT OR REPAIR. 2. MOTOR = 5 H.P. 184T FRAME 3. ENERGY RECOVERY INC. RESERVES TO RIGHT TO MAKE SPECIFICATION OR DIMENSION CHANGES WITHOUT NOTICE. 4. LABEL LOCATIONS ARE APPROX AS SHOWN.
  • Page 42 THE INFORMATION CONTAINED IN THIS DRAWING PRODUCT ENG APPR. 05/28/2003 BOOSTER, HP-8503 SHIPPING WEIGHT: 280 LBS / 127 Kgs IS THE SOLE PROPERTY OF ENERGY RECOVERY INC. ANY REPRODUCTION IN PART OR AS A 1" SIZE DWG. NO. WHOLE WITHOUT THE WRITTEN PERMISSION OF DRAWING STATUS ENERGY RECOVERY INC.
  • Page 43 MOTOR 7.5 H.P., 213T, BOLT ON C-FLANGE OUTLINED IN THE OPERATIONS AND MAINTANCE MANUAL. 51000-01 HOUSING, BELL, BOOSTER PUMP ALUM 3. ENERGY RECOVERY INC., RESERVES THE RIGHT TO MAKE CHANGES AL6XN 51008-01 PLATE, SEAL AT ANY TIME WITHOUT NOTICE. 51005-01...
  • Page 44 1. MOTORS ARE CUSTOMIZED TO EMPLOY A SPECIAL THRUST BEARING. CONTACT ENERGY RECOVERY INC. FOR REPLACEMENT OR REPAIR. 2. MOTOR = 7.5 H.P. 213T FRAME 3. ENERGY RECOVERY INC. RESERVES TO RIGHT TO MAKE SPECIFICATION OR DIMENSION CHANGES WITHOUT NOTICE. 4. LABEL LOCATIONS ARE APPROX AS SHOWN.
  • Page 45 2" THE INFORMATION CONTAINED IN THIS DRAWING PRODUCT ENG APPR. 05/28/2003 BOOSTER, HP-8504 IS THE SOLE PROPERTY OF ENERGY RECOVERY INC. ANY REPRODUCTION IN PART OR AS A 1" SIZE DWG. NO. SHIPPING WEIGHT: 300 LBS / 136 Kgs WHOLE WITHOUT THE WRITTEN PERMISSION OF DRAWING STATUS ENERGY RECOVERY INC.
  • Page 46 51000-01 HOUSING, BELL, BOOSTER PUMP ALUM OUTLINED IN THE OPERATIONS AND MAINTANCE MANUAL. 51008-01 PLATE, SEAL AL6XN 3. ENERGY RECOVERY INC., RESERVES THE RIGHT TO MAKE CHANGES INLET, BOOSTER PUMP AL6XN AT ANY TIME WITHOUT NOTICE. 51005-01 AL6XN 51011-03 SHELL, BOOSTER PUMP...
  • Page 47 1. MOTORS ARE CUSTOMIZED TO EMPLOY A SPECIAL THRUST BEARING. CONTACT ENERGY RECOVERY INC. FOR REPLACEMENT OR REPAIR. 2. MOTOR = 10 H.P. 215TC FRAME 3. ENERGY RECOVERY INC. RESERVES TO RIGHT TO MAKE SPECIFICATION OR DIMENSION CHANGES WITHOUT NOTICE. 4. LABEL LOCATIONS ARE APPROX AS SHOWN.
  • Page 48 2" THE INFORMATION CONTAINED IN THIS DRAWING PRODUCT ENG APPR. 05/28/2003 BOOSTER, HP-1253 IS THE SOLE PROPERTY OF ENERGY RECOVERY SHIPPING WEIGHT: 300 LBS / 136 Kgs INC. ANY REPRODUCTION IN PART OR AS A 1" SIZE DWG. NO. WHOLE WITHOUT THE WRITTEN PERMISSION OF DRAWING STATUS ENERGY RECOVERY INC.
  • Page 49 2. USE REQUIRED QTY OF SPACER WASHERS TO ACHIEVE SPACING OUTLINED IN THE OPERATIONS AND MAINTANCE MANUAL. 51000-01 HOUSING, BELL, BOOSTER PUMP ALUM 3. ENERGY RECOVERY INC., RESERVES THE RIGHT TO MAKE CHANGES 51008-01 PLATE, SEAL AL6XN AT ANY TIME WITHOUT NOTICE.
  • Page 50 2. MOTOR: -01 = 15 H.P. 254TC FRAME -02 = 15 H.P. 254T WITH BOLT ON C-FLANGE 3. ENERGY RECOVERY INC. RESERVES TO RIGHT TO MAKE SPECIFICATION OR DIMENSION CHANGES WITHOUT NOTICE. 4. LABEL LOCATIONS ARE APPROX AS SHOWN. 11.5±1.0 13.8±1.0...
  • Page 51 2" THE INFORMATION CONTAINED IN THIS DRAWING PRODUCT ENG APPR. 05/28/2003 BOOSTER, HP-1254 IS THE SOLE PROPERTY OF ENERGY RECOVERY INC. ANY REPRODUCTION IN PART OR AS A 1" SIZE DWG. NO. SHIPPING WEIGHT: 380 LBS / 172.5 Kgs WHOLE WITHOUT THE WRITTEN PERMISSION OF DRAWING STATUS ENERGY RECOVERY INC.
  • Page 52 51000-01 HOUSING, BELL, BOOSTER PUMP ALUM OUTLINED IN THE OPERATIONS AND MAINTANCE MANUAL. 51008-01 PLATE, SEAL AL6XN 3. ENERGY RECOVERY INC., RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE. AL6XN 51005-01 INLET, BOOSTER PUMP 316 SS 51041-01 3/16"...
  • Page 53 2. MOTOR: -01 = 15 H.P. 254TC FRAME -02 = 15 H.P. 254T WITH BOLT ON C-FLANGE KIT 3. ENERGY RECOVERY INC. RESERVES TO RIGHT TO MAKE SPECIFICATION OR DIMENSION CHANGES WITHOUT NOTICE. 4. LABEL LOCATIONS ARE APPROX AS SHOWN.
  • Page 54 2" THE INFORMATION CONTAINED IN THIS DRAWING PRODUCT ENG APPR. 05/28/2003 BOOSTER, HP-2402 IS THE SOLE PROPERTY OF ENERGY RECOVERY INC. ANY REPRODUCTION IN PART OR AS A 1" SIZE DWG. NO. WHOLE WITHOUT THE WRITTEN PERMISSION OF SHIPPING WEIGHT:380 LBS / 172.3 Kgs DRAWING STATUS ENERGY RECOVERY INC.
  • Page 55 2. USE REQUIRED QTY OF SPACER WASHERS TO ACHIEVE SPACING 51040-01 MOTOR 20 H.P., 256TC OUTLINED IN THE OPERATIONS AND MAINTANCE MANUAL. 51000-01 HOUSING, BELL, BOOSTER PUMP ALUM 3. ENERGY RECOVERY INC., RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE. 51008-01 PLATE, SEAL AL6XN AL6XN 51005-01...
  • Page 56 CONTACT ENERGY RECOVERY INC. FOR REPLACEMENT OR REPAIR. 2. MOTOR: -01 = 20 H.P. 256TC FRAME -02 = 10 H.P. 256T WITH BOLT ON C-FLANGE KIT 3. ENERGY RECOVERY INC. RESERVES TO RIGHT TO MAKE SPECIFICATION OR DIMENSION CHANGES WITHOUT NOTICE. +2.0 11.6 4.
  • Page 57 2" THE INFORMATION CONTAINED IN THIS DRAWING PRODUCT ENG APPR. 05/28/2003 BOOSTER, HP-2403 IS THE SOLE PROPERTY OF ENERGY RECOVERY INC. ANY REPRODUCTION IN PART OR AS A SHIPPING WEIGHT: 430 LBS / 195 Kgs 1" SIZE DWG. NO. WHOLE WITHOUT THE WRITTEN PERMISSION OF DRAWING STATUS ENERGY RECOVERY INC.
  • Page 58 1908 Doolittle Dr. ENERGY RECOVERY, INC. REV BY CKD REVISION DATE San Leandro, CA HP 8503 Issued for Distribution 11/23/04 94577, USA 000 RLS JPM PX BOOSTER PUMP Phone: 510-483-7370 SHEET Fax: 510-483-7371 DESCRIPTION 1 of 1 DOCUMENT NUMBER PUMP CURVES...
  • Page 59 1908 Doolittle Dr. ENERGY RECOVERY, INC. REV BY CKD REVISION DATE San Leandro, CA HP 8504 Issued for Distribution 11/23/04 94577, USA 000 RLS JPM PX BOOSTER PUMP Phone: 510-483-7370 SHEET Fax: 510-483-7371 DESCRIPTION 1 of 1 DOCUMENT NUMBER PUMP CURVES...
  • Page 60 1908 Doolittle Dr. ENERGY RECOVERY, INC. REV BY CKD REVISION DATE San Leandro, CA HP 1253 Issued for Distribution 11/23/04 94577, USA 000 RLS JPM PX BOOSTER PUMP Phone: 510-483-7370 SHEET Fax: 510-483-7371 DESCRIPTION 1 of 1 DOCUMENT NUMBER PUMP CURVES...
  • Page 61 1908 Doolittle Dr. ENERGY RECOVERY, INC. REV BY CKD REVISION DATE San Leandro, CA HP 1254 Issued for Distribution 11/23/04 94577, USA 000 RLS JPM PX BOOSTER PUMP Phone: 510-483-7370 SHEET Fax: 510-483-7371 DESCRIPTION 1 of 1 DOCUMENT NUMBER PUMP CURVES...
  • Page 62 1908 Doolittle Dr. ENERGY RECOVERY, INC. REV BY CKD REVISION DATE San Leandro, CA HP 2402 Issued for Distribution 11/23/04 94577, USA 000 RLS JPM PX BOOSTER PUMP Phone: 510-483-7370 SHEET Fax: 510-483-7371 DESCRIPTION 1 of 1 DOCUMENT NUMBER PUMP CURVES...
  • Page 63 1908 Doolittle Dr. ENERGY RECOVERY, INC. REV BY CKD REVISION DATE San Leandro, CA HP 2403 Issued for Distribution 11/23/04 94577, USA 000 RLS JPM PX BOOSTER PUMP Phone: 510-483-7370 SHEET Fax: 510-483-7371 DESCRIPTION 1 of 1 DOCUMENT NUMBER PUMP CURVES...
  • Page 64 HP-8500 HP-2400 through PX BOOSTER PUMPS The PX BOOSTER Pump is a high performance pump designed to provide a small pressure boost within a high-pressure, corrosive seawater environment. 30 - 300 GPM / 6.8 - 68 m Seawater reverse osmosis (SWRO) units using PX Pressure Exchanger technology employ a high-pressure circulation loop.The ERI PX BOOSTER...
  • Page 65 HP-8500 HP-2400 HP-8500 HP-2400 through through Specifications Typical Flow Range Full Load Dimensions Shipping Amps inches Model (m3/hr) 460 vac H x W x L Weight HP-8503 50-70 (11.4-15.9) 10 x 12 x 39 130 lbs. HP-8504 70-100 (15.9-22.7) 11 x 12 x 43 160 lbs.

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