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Summary of Contents for Toray NHPA Series
- Page 1 Toray MBR Instruction Instruction Manual Manual “NHPA Series C type” [050-1C, 100-1C, 150-1C, 2C, 3C and 4C] Last updated August 2022 06-G-MB2-NHPAC-220801...
- Page 2 Toray shall not be responsible or liable for any losses or damage incurred due to the use of the information in this document. The information in this document is subject to change without prior notice, and Toray reserves the right to suspend or discontinue the publication of this document.
- Page 3 Toray MBR Contact Information Toray Industries, Inc. — UF & MBR Membrane Products Department (Global Headquarters) Nihonbashi Mitsui Tower, 1-1, Nihonbashi-Muromachi 2 chome, Chuo-ku, Tokyo, 103-8666 Japan Tel: +81-3-3245-4542 Fax: +81-3-3245-4913 Toray Membrane USA, Inc. (TMUS) 13435 Danielson Street, Poway, California 92064 USA...
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Page 4: Table Of Contents
MEMBRANE FILTRATION PROCESS DESIGN FOR “NHPA SERIES” ......15 Standard Time Chart ......................15 Flow Diagram of Membrane Filtration ................. 16 Layout of “NHPA Series” Modules in Membrane Tank ............21 Piping ........................... 24 INSTALLATION OF “NHPA SERIES” ................... 28 Preparatory Procedure ...................... - Page 5 TORAY MBR Lifting Procedure ......................... 55 Storing Products after Use ....................56 Disposing Procedure ......................57 REPLACEMENT PARTS LIST ..................... 58 TROUBLESHOOTING ......................59 WARRANTY POLICY ......................60 XII. REFERENCE ........................61 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.
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Page 6: 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. "NHPA Series" is a new model of NHP-MBR module equipped with thin membrane elements having higher packing density, while reliable performance of Toray PVDF membrane has been kept unchanged. -
Page 7: Outline Of "Nhpa Series
TORAY MBR Outline of “NHPA Series” “NHPA Series” is the membrane module composed of the element block and the aeration block. The element block contains several cassettes, and in the cassette the membrane elements, each of which consists of two flat membrane sheets, are arranged at a constant clearance. - Page 8 TORAY MBR (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 9 TORAY MBR (2) Membrane Structure The flat sheet membrane consists of a PVDF (Polyvinylidene Fluoride) functional layer and a 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 10: For Safe Operation Of "Nhpa Series
TORAY MBR FOR SAFE OPERATION OF “NHPA SERIES” Before using “NHPA 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... -
Page 11: Safety Instruction For Operation And Maintenance
TORAY MBR Take adequate measures, during the installation process, to protect the “NHPA Series” from: sparks emitted from welding equipment, fusion cutting, or grinding. Protect “NHPA Series” from freezing at all the time. Avoid pressurizing the filtrate side of "NHPA Series”. - Page 12 TORAY MBR Make certain the air discharge valve is in the open position to assure any accumulated air is released when first filling the membrane tank with clean water or sludge. After the tank is filled with clean water, close the air discharge valve.
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Page 13: Safety Instruction For 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 replacement parts. Never expose the “NHPA Series” to freezing temperatures at any time. Take measures to keep the membrane elements wet when removing the “NHPA Series”... - Page 14 TORAY MBR 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 pressure less than 10 kPa (100 mbar). Before starting injecting chemical to elements, confirm that the membrane tank liquid level is more than 500 mm above the top of the module.
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Page 15: Specifications And Performance Of "Nhpa Series
TORAY MBR III. SPECIFICATIONS AND PERFORMANCE OF “NHPA SERIES” Specifications of Element TableIII-1 and Fig.III-1 show the specifications and the physical dimensions for the NHPA Series element. Table III-1 Specifications of Element (TSP-50080) Model name TSP-50080 Membrane configuration Flat sheet... - Page 16 TORAY MBR 3. Specifications and Performance of “NHPA Series” Module Figure III-3 shows the cassette arrangement of “NHPA Series” modules shown in this Instruction Manual. Table III-3a shows the specifications of NHPA050-1C, 100-1C and 150-1C cassette and modules. Table III-3b shows the specifications of NHPA-150-2C, -3C, and -4C cassette and modules.
- Page 17 TORAY MBR Table III-3a Specifications of Cassette and Module (NHPA050-1C, 100-1C and 150-1C) Model name ECS035 (Cassette) NHPA050-1C NHPA100-1C NHPA150-1C Number of membrane elements Cassette structure 1 cassette x 1 deck 2 cassettes x 1 deck 3 cassettes x 1 deck...
- Page 18 Air volume as being 0 deg C and 101.325 kPa (1 atm). *5 MBR operation only by Cassette is not assumed. *6 Check tank height and piping condition when using this module for replacement of existing Toray MBR TMR140-100S or NHP210-300S/600D since NHPA is a little taller than existing modules.
- Page 19 30-150 40 - 200 This value is just a reference value and not a guaranteed 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 20: Membrane Filtration Process Design For "Nhpa Series
TORAY MBR MEMBRANE FILTRATION PROCESS DESIGN FOR “NHPA SERIES” This section will address the following for the Toray “NHPA Series”: Standard sequence of operation/time chart, illustrated piping, flow schema, and module(s) layout in the membrane tank. Standard Time Chart Usually intermittent filtration (filtration with relaxation) is recommended. The most common... -
Page 21: Flow Diagram Of Membrane Filtration
TORAY MBR 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. - Page 22 TORAY MBR In order to obtain enough suction pressure for the filtration process, consider friction loss of all pipes and valves. In addition, the filtrate water outlet should be located at least 3 m below the surface of membrane tank water level.
- Page 23 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. Instruction Manual...
- Page 24 When using two pressure gauges, one pressure gauge should be installed on the filtrate water line and the other on the membrane tank, to monitor the trans-membrane pressure. When operating several “NHPA Series” modules simultaneously in one train, it is advised installing one differential pressure measuring instrument for each train.
- Page 25 Filtration d. Air supply unit (such as a blower) This unit supplies air to the air diffusers of "NHPA 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 26: Layout Of "Nhpa Series" Modules In Membrane Tank
TORAY MBR 3. Layout of “NHPA 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 27 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 28 TORAY MBR Tank wall Module Module Module “ ” “ ” “ ” 2 × 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.
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Page 29: Piping
TORAY MBR 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. - Page 30 It is advised that you prepare and attach a “riser pipe” to connect two filtrate manifolds of two element-decks for ease of piping and handling (out of Toray’s scope of supply). Fig.IV-12 shows example of the riser pipe. In case of using a riser pipe, the two element-decks have to be stacked and connected so that filtrate manifolds of both decks come to the same side.
- Page 31 TORAY MBR Air Discharge Valve Chemical Feed Line Chemical Injection Valve Filtrated Water Valve Filtrated Water Outlet Fig.IV-10 Downward Piping from Membrane Tank Chemical Injection Valve Chemical Feed Line Air Discharge Valve Suction Pump Filtrated Water Valve Fig.IV-11 Upward Piping from Membrane Tank...
- Page 32 TORAY MBR Fig.IV-12 Riser Pipe (example) Fig.IV-13 Separate Riser Pipe for Upper/Lower Decks (example) Consider piping materials and regulate the load to the flange connection points at less than 20 kg per flange in order to avoid CAUTION distortion, leakage, or breakage of the air diffuser and filtrate water manifold.
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Page 33: Installation Of "Nhpa Series
TORAY MBR INSTALLATION OF “NHPA SERIES” Preparatory Procedure (1) Take precautions to plan the route for the “NHPA Series” to the membrane tank. The route should include the unloading area for the “NHPA Series” to the final installation site. (2) Make arrangements of the necessary equipment to unload the “NHPA Series” from a truck such as a forklift or pallet jack etc. -
Page 34: Checking Products
Storing Products "NHPA Series" has to be stored indoors under lower than 40 deg C of the temperature. If the “NHPA Series ” cannot be stored indoors due to prevailing construction site conditions, try to minimize the time being out of doors. As soon as possible, move the “NHPA Series” into a protected area to avoid accidental damage. -
Page 35: Installing Products
Review the drawings in the REFERENCE to make certain final tie-ins to the “NHPA Series” are as per the drawings. Refer to the information in the REFERENCE if you intend to install the module without anchoring the module to the floor of the tank (e.g., using guide rails... - Page 36 TORAY MBR consider piping materials and regulate the load to the flange connection points at less than 20 kg per flange, in order to avoid distortion, leakage, or breakage of the plastic air diffuser. If the load exceeds the limit above, put some supports on the piping to reduce the load.
- Page 37 Attach chains or slings to the lifting lugs when lifting element-deck, DANGER element block, or aeration block of “NHPA Series”. Slowly raise the module straight up. Avoid sudden changes in movement to minimize shaking the module. Never allow personnel to stand under the “NHPA Series”...
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Page 38: Start Of Operation
TORAY MBR 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. -
Page 39: 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 "NHPA 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 40: Actual Filtration Operation
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 "NHPA Series” over 10kPa. Instruction Manual 06-G-MB2-NHPAC-220801 35 of 61... -
Page 41: Operation Control
VII. OPERATION CONTROL Standard Operating Conditions Table VII-1 shows standard operating conditions for “NHPA 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 42 TORAY MBR WARNING Do not use the filtrate water for drinking. Analyze the quality of the filtrate water to ensure that the water WARNING quality meets the intended purpose before actual use. Do not use chemicals, toxic agents, oils, or other substances that CAUTION can adversely affect the condition of activated sludge.
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Page 43: Operating Parameters
TORAY MBR Operating Parameters The performance of the “NHPA Series” varies depending on raw water quality and site specific operating conditions. In order to achieve stable “NHPA Series” operation, it is recommended that various operating parameter values be monitored and recorded regularly. - Page 44 TORAY MBR (2) Membrane Scouring Blower: The blower supplying air for membrane scouring should be on continuously. Air flow (and suction pump) should be stopped if the liquid level in the membrane tank falls below the preset low level for a long period or the flow to the membrane tank stops.
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Page 45: Daily Inspection
TORAY MBR Daily Inspection The above Section 2, Chapter VII 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. - Page 46 TORAY MBR (3) Activated Sludge Characteristics The activated sludge of the membrane bioreactor should be self-cohesive and free from odor. 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...
- Page 47 TOC/turbidity, check the operating and biological conditions, and take appropriate actions. (11) Pretreatment System In addition to the operating parameters for the “NHPA 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 48: Maintenance Of "Nhpa 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. Make certain the tube is securely attached to the membrane... -
Page 49: Air Diffuser Cleaning
TORAY MBR Air Diffuser Cleaning A clogged air diffuser cannot evenly distribute air to the membrane elements resulting in, which causes that solids build up on the membrane element surface, or, in extreme cases, the membrane element gets damage. It is recommended that the MBR module(s) be equipped with air diffuser cleaning components/valves that can be automatically controlled from the MBR system PLC. - Page 50 TORAY MBR (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.
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Page 51: Chemical Cleaning Of Element
TORAY MBR 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 52: Handling Of Chemical Agents
TORAY MBR 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 gloves, 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 53 TORAY MBR (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. (g) Do not bring gloves or other contaminated protectors into the rest area.
- Page 54 TORAY MBR Chemical agents used for chemical cleaning can be harmful to one’s health. Wear protective goggles, protective gloves, and other WARNING safety gear when handling chemicals. Make sure to check the details of its material safety data sheet (SDS) beforehand.
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Page 55: Chemical Cleaning Procedure
TORAY MBR 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 56 TORAY MBR 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 57 TORAY MBR (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 58 TORAY MBR (2) Precautions for Element Chemical Cleaning Keep the injecting pressure below 10 kPa (100 mbar). Avoid direct discharge from the chemical pump to the membrane elements. Too high pressure in the membrane element will cause damage to the membrane. Please note that injecting pressure may increase after injecting half of the chemical.
- Page 59 TORAY MBR Immediately stop the chemical cleaning operation if any of the WARNING associated cleaning equipment appears to be malfunctioning. Never mix sodium hypochlorite with oxalic acid or citric acid. Such WARNING mixture generates toxic chlorine gas. Do not inject any chemical into the membrane directly from the chemical pump discharge.
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Page 60: Lifting Procedure
TORAY MBR Lifting Procedure Follow these procedures when lifting the “NHPA 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 61: Storing Products After Use
Storing Products after Use Take the following steps to preserve and store used “NHPA Series” modules. (1) In case of module storage with sludge inside (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 62: Disposing Procedure
TORAY MBR 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. If the membranes are CAUTION allowed to dry out, the permeability of the membranes may be permanently reduced. -
Page 63: Replacement Parts List
TORAY MBR REPLACEMENT PARTS LIST Please contact Toray for the details of the specifications. (1) NHPA050-1C Required Quantity per Module Name Frequency Type No. of replacement parts NHPA050-1C When deterioration Filtrate Tube NHP-TUBE-200 (200pcs set) (50 pcs/unit) detected. When filtrate flow or... -
Page 64: Troubleshooting
TORAY MBR TROUBLESHOOTING Most of the troubles in the operation of “NHPA Series” are related to poor membrane scouring aeration, chemical cleaning delay, and inappropriate pretreatment. The following table lists some performance losses, their causes, and possible countermeasures. Table X-1 Troubleshooting... -
Page 65: Warranty Policy
Toray with the information about operation mode, recording performance data of MBR systems. Please kindly contact Toray if the customer wishes to deviate from any of the procedures or specifications mentioned in this Instruction Manual and request written approval in advance. -
Page 66: Reference
TORAY MBR XII. REFERENCE Following information is provided upon your request: (1) Assembly of Modules (2) Assembly of Guide Rail System (3) Assembly of Hangers. (4) Procedure of Paper filter test. Instruction Manual 06-G-MB2-NHPAC-220801 61 of 61... - Page 67 RO, NF, UF, MBR, and antiscalant products to solve water and process treatment challenges. Contact us today to find out how Toray can help maximize water recovery, achieve high water quality for water reuse, lower energy requirements, and minimize life cycle costs.
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