Table of Contents
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Table of Contents
Troubleshooting
Related Manuals for Energy Recovery Pressure Exchanger PX Q400
Summary of Contents for Energy Recovery Pressure Exchanger PX Q400
- Page 1 PX® Pressure Exchanger®, PX Q400 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL Energy Recovery Inc. 1717 Doolittle Drive, San Leandro, CA 94577 Tel: 1 510 483-7370 www.energyrecovery.com Energy Recovery DOCUMENT NUMBER 80882-01-00 © Energy Recovery, Inc., 2022...
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Page 2: Table Of Contents
PX Q400 Energy Recovery Device TABLE OF CONTENTS INTRODUCTION ......................... 3 ABOUT THIS MANUAL ..................3 DEVICE BASICS ....................3 PX DEVICE IN RO SYSTEMS ................... 4 CIRCULATION PUMP WITH PX DEVICES ............... 4 PX OPERATIONAL LIMITS ..................4 SAFETY ..........................5 HIGH PRESSURE REMAINS AFTER SHUTDOWN ............ - Page 3 PX DISASSEMBLY ..................... 18 ASSEMBLY PROCEDURE ..................24 CARTRIDGE ASSEMBLY ................... 24 TROUBLESHOOTING ......................30 PRELIMINARY PROCEDURES ................30 INSTRUMENTATION .................... 30 TROUBLESHOOTING GUIDE ................31 LEARNING MORE AND CONTACTING ENERGY RECOVERY..........33 REVISION LOG ........................33 Energy Recovery Document Number 80882-01-00...
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Page 4: Introduction
PX® Pressure Exchanger® (PX) energy recovery device. This manual is intended for use by personnel with training and experience in the installation and operation of fluid handling systems. For additional information regarding using the PX device in RO systems, refer to Energy Recovery’s website:... -
Page 5: Px Device In Ro Systems
PX Operational Limits Successful operation of the PX Q400 energy recovery device requires observation of some basic operating conditions and precautions. The PX unit must be installed and operated in accordance with this manual and good industrial practice to ensure safe operation and a long service life. -
Page 6: Safety
Storage, operating, and feedwater temperature range 33-120 °F 1-49 °C pH range 1-12 (short term at limits) Further information about PX or other Energy Recovery products or service can be found by contacting Energy Recovery at: Energy Recovery Inc. 1717 Doolittle Drive, San Leandro, CA 94577 Tel: 1 510 483-7370 www.energyrecovery.com... -
Page 7: High Pressure Remains After Shutdown
Always make sure the RO system is fully depressurized before disconnecting any piping or equipment. Low-Pressure Isolation and Over-Pressurization If the low-pressure side of the PX energy recovery device is isolated before DANGER the high-pressure side is depressurized, the PX unit or the low-pressure piping may be damaged by over-pressurization. -
Page 8: Hydrostatic Testing
PX Q400 Energy Recovery Device Hydrostatic testing The PX shall not be subjected to hydrostatic testing outside of ERI’s test DANGER facility. If hydrostatic testing of the plant piping and machinery is needed, please remove the PX before doing so. Failure to do so may cause damage to the device and/or injury. -
Page 9: Horizontal Lifting Procedure
PX Q400 Energy Recovery Device Horizontal Lifting Procedure 1) Space two (2) Flat-Eye Web Sling along the outer diameter of the PX as shown in Figure 3-1. Ensure slings are equally spaced with respect to the center-plane of the PX. -
Page 10: Vertical Lifting Procedure
PX Q400 Energy Recovery Device Vertical Lifting Procedure 1) Wrap the PX using the single Sling “Choker” method shown in Figure 3-3. 2) Place Sling below top side-port shown in Figure 3-4. Carefully lift and place unit as required. Figure 3-3: Single Choker method... -
Page 11: Operation
The following procedures are general guidelines for the startup and shutdown of PX unit systems. Procedure details will vary by plant design. Contact Energy Recovery if your process design significantly differs from that shown in Figure 1-1. Always ensure that the operating limits listed in Section 1.5 are followed. -
Page 12: Short Term Shutdown Sequence
PX Q400 Energy Recovery Device 2. Start the feedwater supply pump. The feed flow through the PX unit(s) may or may not cause the rotor to begin to rotate. Rotation will produce a humming sound that is audible at close proximity to the PX unit(s). -
Page 13: Long Term Shutdown Sequence
PX Q400 Energy Recovery Device Long Term Shutdown Sequence If the process is to be shut down for long term (the time frame depends on the characteristics of the RO system and feedwater), the RO system including the PX units must be thoroughly flushed with fresh water to remove any salt, and precautions should be taken to inhibit biological growth. -
Page 14: High- And Low-Pressure Flow Rates
PX Q400 Energy Recovery Device by debris, overflow, or insufficient discharge pressure, excess lubrication flow may occur. Monitoring lubrication flow is a good way to check the integrity of an operating PX unit. Lubrication flow can be monitored using any of the following three methods: •... -
Page 15: Flushing
PX Q400 Energy Recovery Device outlet flow will result in lower quality permeate, increased feed pressure, and higher energy consumption. For more information refer to Energy Recovery document 80088-01 Mixing Technical Bulletin or contact Energy Recovery customer service. 4.5. Flushing There are two types of flush: Feedwater Flush and Fresh Water or Permeate Flush. -
Page 16: Purge Air
Table 5-1. These tools, with the exception of the hoist and torque wrench, are included in the PX Q400 tool kit (Energy Recovery Part Number 20469-01). In addition, the PX Q400 unit can be mounted on a stand or on blocks to facilitate service, or the LP connection port can be unthreaded in order to support the unit on the housing. -
Page 17: Disassembly Procedure
NUT, LIFTING EYE, 1/2"-13, 316 Replacement seals and alignment pins are included in Energy Recovery’s standard spare parts kits (Energy Recovery Part Number 20467-01). One spare parts kit should be used each time a PX unit is opened for service. -
Page 18: Disassembly Procedure For The Px Device On The Rack Or Piping
PX Q400 Energy Recovery Device Disassembly Procedure for the PX Device on the Rack or Piping 1. Depressurize all high-pressure and low-pressure piping to and from the PX unit. 2. Close all valves to and from the PX unit/rack or drain system. -
Page 19: Px Disassembly
PX Q400 Energy Recovery Device PX Disassembly 1. Unscrew and remove the bottom LP port Figure 5-3. Otherwise, use blocks or a stand to support the unit by the bottom end of the fiberglass housing shown in Figure 5-4. Do not support the unit or apply stress to the low-pressure port. - Page 20 Bearing Plate Figure 5-5: Disassembly of PX Segmented and Securing Rings 3. Extract Head Assembly from the housing using an Energy Recovery Head Puller tool 20471-01 shown in Figure 5-6. Assisted lifting can be achieved using the All-thread and Lifting Eye 5/8-11” as shown in Figure 5-7. Take care not to apply stress to the LP port if it is still in place.
- Page 21 PX Q400 Energy Recovery Device 4. Remove the Interconnect using Interconnect removal tool 10608-01. See Figure 5-8. a. Tip: If more access is needed, proceed with removing the cartridge before removing the Interconnect. See Section 5.2.2 step 5 for cartridge removal.
- Page 22 PX Q400 Energy Recovery Device Lifting tool • Lifting Eye 10506-01 • All thread 10606-01 • Coupling Nut 30092-01 Estimated Cartridge Weight: 50 lbs (22.8 kgs) Figure 5-9: PX Cartridge lifting tool assembly. Can be installed with or without Interconnects assembled.
- Page 23 PX Q400 Energy Recovery Device 7. Support PX Cartridge and allow room for Tension Rod and wrench. Refer to Figure 5-11 for PX Cartridge construction and Figure 5-12 for reference support dimensions. a. Note: Concentrate and Feedwater orientation is dependent on orientation of PX during disassembly.
- Page 24 The sleeve should slide on easily. If the rotor and sleeve become bound, use hot water on the sleeve to loosen it from the rotor. vi. Contact Energy Recovery, Inc. if problems are encountered. Figure 5-13: Disassembly of Spacer and Endcover...
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Page 25: Assembly Procedure
PX Q400 Energy Recovery Device Assembly Procedure This assembly procedure assumes that the PX Q400 unit has been disassembled per the previous section. All parts should be carefully cleaned with clear water prior to assembly to ensure that no dirt or debris contaminates the PX device. All parts should be thoroughly inspected for damage and/or debris prior to reassembly. - Page 26 PX Q400 Energy Recovery Device 5. Place Endcover and Tension-rod onto support block as shown in Figure 5-19. a. Tip: Placing a block under the Tension-rod will prevent it from falling down. (3) Dowel Pin (2) Interconnect Spacer (2) Dowel Pin...
- Page 27 PX Q400 Energy Recovery Device Hex Nut Metal Washer Fiberglass Washer Figure 5-21: Top Endcover and Cartridge hardware Figure 5-20: Rotor-Sleeve assembly 9. Carefully inspect the contact lines between the sleeve and the Endcovers to be sure there are no gaps, see Figure 5-22. If a gap is present, disassemble and clean to ensure no debris is in the cartridge.
- Page 28 PX Q400 Energy Recovery Device 10. Torque Sequence. Refer to Figure 5-23. a. Tighten the nut closest to the cartridge assembly and torque to 15 ft-lb (20 N-m). b. Thread the second nut onto the tension rod. This nut will act as a lock nut. Torque to 40 ft-lb (56 N-m) while holding the adjacent nut.
- Page 29 PX Q400 Energy Recovery Device 13. Lubricate the Cartridge O-rings, the four (4) LP Interconnect counter-bore and the inside of the housing. a. Tip: Inspect O-ring on Cartridge to ensure no tears, rips, or any other defects. Replace O-rings if required.
- Page 30 PX Q400 Energy Recovery Device 23. If LP Port was removed, install following the procedure below. See Figure 5-26 for reference. a. Apply food grade anti-seize to LP port thread. b. Lubricate O-ring. i. Tip: Inspect O-ring for to ensure no tears, rips, or any other defects are present.
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Page 31: Troubleshooting
The following list of instrumentation is useful in monitoring and diagnosing the operation of PX devices. • Energy Recovery requires that one flowmeter be installed in the PX unit(s) HP flow circuit and one in the LP flow path. • Energy Recovery requires a pressure instrument be installed between the low-pressure outlet and any control valve to monitor device backpressure. -
Page 32: Troubleshooting Guide
PX Q400 Energy Recovery Device Troubleshooting Guide SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION 1. Operating PX unit(s) above rated Immediately reduce flow rates. flow rates To increase system capacity, add PX unit(s) in parallel to existing units. 2. Operating PX unit(s) below Increase feedwater supply pressure. - Page 33 PX Q400 Energy Recovery Device 5. Stuck rotor See Symptom D. C. High salinity in 1. Unbalanced system Check flow rates. See Section 4. high-pressure 2. A stalled rotor See Symptom D. feedwater stream 1. Foreign debris or biological growth Conduct a fresh water flush.
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Page 34: Learning More And Contacting Energy Recovery
Energy Recovery at +1-510-483-7370. Refer to Technical documents for PX device component names and the bill of materials for the PX unit assembly. Refer to Products section in Energy Recovery website for recommended spare parts and tool kits.
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