Energy Recovery TurboCharger AT-95 Manual
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Energy Recovery TurboCharger AT-95 Manual

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Energy Recovery™ TurboCharger™ (AT & LPT)
Energy Recovery Device
Energy Recovery Inc.
1717 Doolittle Drive, San Leandro, CA 94577
Tel: 1 510 483-7370 / Fax: 1 510 483-7371
www.energyrecovery.com
ERI Document number: 80311-01
Energy Recovery Inc
ERI™ Document Number 80311-01 r6
Page 1 of 54

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  • Page 1 Energy Recovery™ TurboCharger™ (AT & LPT) Energy Recovery Device Energy Recovery Inc. 1717 Doolittle Drive, San Leandro, CA 94577 Tel: 1 510 483-7370 / Fax: 1 510 483-7371 www.energyrecovery.com ERI Document number: 80311-01 Energy Recovery Inc ERI™ Document Number 80311-01 r6...

  • Page 2: Table Of Contents

    4.2 How the ERI TurboCharger Energy Recovery Device Works 4.3 ERI TurboCharger Energy Recovery Devices in SWRO Systems 4.4 ERI TurboCharger Energy Recovery Devices in 2-Stage RO Systems 4.5 ERI TurboCharger Energy Recovery Device Features and Operation 4.6 ERI TurboCharger Bypass Valve Considerations 5.0 Installation...............................12...

  • Page 3: Introduction

    Introduction This manual contains instructions for the installation, operation, and servicing of the Energy Recovery TurboCharger™ energy recovery devices in reverse osmosis systems. This information is provided to ensure the longevity, safe operation, and proper performance of your Turbocharger energy recovery device. Please read this manual thoroughly before installation and operation, and keep it for future reference.
  • Page 4 160lb [73kg] Mechanical lift only LPT-500 200lb [91kg] Mechanical lift only LPT-1000 425lb [193kg] Mechanical lift only LPT-2000 800lb [363kg] Mechanical lift only Table 2.3.1 Estimated Weights of TurboCharger Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 4 of 54...

  • Page 5: Noise

    Please have the model and serial number for your device available for future reference. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 5 of 54...

  • Page 6: Unpacking

    Unpacking 3.1 Inspect Contents Energy Recovery Inc.’s commitment to quality includes the procurement of top quality materials and fabrication to extremely tight tolerances. Assembled ERI™ TurboCharger™ devices are subjected to extensive testing in our wet test facility. Each turbocharger unit is tested for efficiency, boost pressure, and flow rates. Testing records are maintained and each unit is tracked with a serial number.
  • Page 7 Unpacking: Prior to installation, make sure all shipping components are extracted from product. Remove red cap and foam roll from the turbocharger end cap Figure 3.3.2 Red Cap Removal Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 7 of 54...

  • Page 8: Design Considerations

    Figure 4.1 –Pitting/Crevice Corrosion How the ERI TurboCharger Energy Recovery Device Works The ERI TurboCharger device recovers hydraulic energy from the high pressure concentrate (brine) stream in the reverse osmosis (RO) process and transfers that energy to a feed stream. That feed stream may be seawater going into a single stage RO membrane block, or it may be first stage brine stream being boosted in pressure for a second stage membrane block for further recovery of permeate or flux balancing.
  • Page 9 (G). The brine passes through the turbocharger which extracts the pressure energy (G-H). The brine leaves the turbocharger at low pressure for disposal (H). Figure 4.3 – Typical Turbocharger Installation for SWRO TurboCharger Energy Recovery Devices in 2-stage RO Systems Energy Recovery Inc ERI™ Document Number 80311-01 r6...

  • Page 10: Eri Turbocharger Energy Recovery Device Features And Operation

    (H). Figure 4.4 – Typical Turbocharger Installation for 2-stage BWRO ERI™ TurboCharger™ Energy Recovery Device Features and Operation The turbocharger incorporates a number of features designed to insure simple operation, long operating life, proper performance and high availability. The flow of water on the turbine side energizes the turbine impeller.

  • Page 11: Eri Turbocharger Bypass Valve Considerations

    It is important to note that when a bypass is in use, it is highly recommended that the auxiliary valve be FULLY OPEN. This allows the maximum amount of brine to enter the turbine side therefore maximizing the amount of energy recovery. A system installed with the Turbocharger device bypass allows the operator to achieve the desired brine flow.

  • Page 12: Installation

    Provisions should be taken to ensure backpressure can be controlled and measured at site. Stray Currents and Grounding Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 12 of 54...

  • Page 13: Source Water Supply

    Since the TurboCharger is a metallic device, Energy Recovery recommends that it be grounded once it is installed in its final location. Failure to ground the device can result in corrosion, typically at the four piping connections. A threaded bolt is located on the turbine-side support leg which is available for connecting a ground lug.
  • Page 14 Figure 5: Temporary Filter Setup During the Flushing Process 1. Differential pressure gauge 2. Filter  Use a filter with a length 3 times the diameter of the piping.  Conical filters have proven suitable. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 14 of 54...

  • Page 15: Startup And Operation

    10. If the HPP is fully ramped to design speed and the required system pressure has not been achieved to produce the required permeate flow, close the auxiliary valve until the correct flow is achieved. Energy Recovery Inc ERI™ Document Number 80311-01 r6...

  • Page 16: Medium Term (4-14 Days) System Shutdown Sequence

    This can be achieved via removable spool pieces, properly located CLEAN IN and CLEAN OUT connections, or valves. The same bypass used for flushing can also be used for cleaning. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 16 of 54...

  • Page 17: Spare Parts And Toolkits

    2. To remove rotor retaining nut on LPT Socket Wrench/Box Wrench models 125-2000. See table 8.1.2.3 for model specific sizing. 3. To remove end cap nuts (pump side and turbine side) See tables 8.1.1.2, 8.1.1.3, Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 17 of 54...
  • Page 18 Dynamically balanced turbine and pump rotating assembly b. Bearing kit 3. Auxiliary Line Assembly a. Includes Auxiliary Valve b. Includes fittings 4. Thrust Line Assembly a. Includes fittings Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 18 of 54...

  • Page 19: Service

    AT-1100 Compression Hex Head 3/8 X 9/16"-18 UNF SAE STRAIGHT AT-1500 Compression Hex Head 3/8 X 9/16"-18 UNF SAE STRAIGHT AT-2150 Compression Hex Head 3/8" X 1/4"-18 NPT Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 19 of 54...
  • Page 20 1-1/2"-8 UNC 8593 AT-7800 1-5/8"-8 UNC 10382 AT-95 through AT-1500: Pump side end cap can be removed by hand but the use of a hoist may expedite the process. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 20 of 54...
  • Page 21 Step 3 - Remove nuts from turbine side end cap It may be easier to leave two nuts tightened until the rest are removed to prevent the end cap from shifting. See Table 8.1.1.3 for nut sizes. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 21 of 54...
  • Page 22 4499 AT-6000 1-1/4"-8 UNC 4499 AT-7800 1-3/8"-8 UNC 6106 AT-95 through AT-1500: Turbine side end cap can be removed by hand although a hoist may expedite the process. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 22 of 54...
  • Page 23 Step 4 - Removing the rotating assembly (RA) AT-95 through AT-4150: Hold turbine side fastener while the pump side rotor retaining nut is loosened. See table 8.1.1.4 and 8.1.1.5 for sizes. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 23 of 54...
  • Page 24 The use of a breaker bar and a steel pipe is recommended to increase leverage. Energy Recovery Inc ERI™ Document Number 80311-01 r6...
  • Page 25 CARE MUST BE TAKEN during the removal process. The turbine side of the rotor is very heavy and can chip the graphite center bearing. On larger turbochargers, it may require two people to properly remove the rotating assembly. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 25 of 54...
  • Page 26 Step 5 – Volute removal AT-95 thru AT-1500 Remove the turbine side volute by hand. Be sure not to lose the volute pins. Pins sizes can be found in Table 8.1.1.6. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 26 of 54...
  • Page 27 1/2" X 3-1/4" - 1/4"- 20 UNC AT-4150 3/4" X 3-1/2" - 3/8"-16 UNC AT-6000 3/4" X 4.00" - 3/8"-16 UNC AT-7800 3/4" X 5.00" - 3/8"-16 UNC Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 27 of 54...
  • Page 28 Remove second half of the turbine side volute. Again, removing the volute half may take some force as the surface tension of the water will try to hold it in place. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 28 of 54...
  • Page 29 Push the bearing out of the turbine end cap. Note the alignment hole and anti-roll pin when the bearing is removed. The hole and pin must be aligned during reassembly. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 29 of 54...
  • Page 30 Insert the thrust bearing extraction tool into the internal bearing bore and expand it using two (2) 1-1/4” wrenches until it is sung inside the thrust bearing spacer. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 30 of 54...
  • Page 31 You may need a small bar to make the thrust bearing face even while tapping it out. Some force may be required as there is an O-ring on the thrust bearing. Be sure to keep the anti-roll pin from the original thrust bearing. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 31 of 54...
  • Page 32 Start with any bolt and identify it as (1) and location designated as 0°. Bolt (2) will be at 180°; bolt (3) at 270° and bolt (4) at 90°. Using counterclockwise rotation, tighten bolt (5). See examples below and continue rotation until all bolts are tightened. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 32 of 54...

  • Page 33: Lpt Disassembly Procedure

    Compression Hex Head 3/8" X 1/4"-18 NPT LPT-2000 Compression Hex Head 1/2" X 3/8"-18 NPT Remove Turbine Side End Cap retaining ring using a screw driver or similar tool. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 33 of 54...
  • Page 34 Remove turbine side end cap. It may take some force to remove the end cap due to the O-ring. After the end cap is removed, the thrust bearing will now be visible. Remove the thrust bearing retaining ring using a screw driver or similar tool. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 34 of 54...
  • Page 35 Stud and Nut 3/4"-10 UNC X 3-1/2" LPT-2000 Stud and Nut 1.00" - 8 UNC X 4.00" Pry back the pump end cap using a screw driver or similar tool. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 35 of 54...
  • Page 36 LPT-250 Stud and Nyloc Nut 3/8"-16 UNC LPT-500 Stud and Nyloc Nut 1/2"-13 UNC LPT-1000 Stud and Nyloc Nut 5/8-11" UNC LPT-2000 Stud and Nyloc Nut 5/8-11" UNC Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 36 of 54...
  • Page 37 NOTE: If only the thrust bearing is being replaced, you stop at this step and reassembly by following the instructions in reverse order. Remove the turbine impeller and shaft from the turbine side. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 37 of 54...
  • Page 38 Remove the retaining ring from the pump side of the center bearing bore. Gently tap out the center bearing with a rubber mallet or similar tool. LPT disassembly is now complete. To reassemble, please follow these instructions in reverse order. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 38 of 54...
  • Page 39 ENERGY RECOVERY, INC. SAMPLE OPERATING LOG Fax: +1 510 483 7371 Attn: Warranty Administration Department Model of TurboCharger installed ___________________________________ Serial Number ___________________________________________________________ Units (please circle one): psi/gpm bar/m Pump Pump Side Pump Side Turbine Turbine Total Side Inlet Outlet...

  • Page 40: Troubleshooting

    RO plant operator. Conditions not covered in this section may be resolved by contacting Energy Recovery, Inc.’s Service Department. Contact information is provided in the following section.
  • Page 41 1. Unit is cavitating in the turbine Increase backpressure on turbine exhaust. exhaust until noise is eliminated. 2. Damage to RA and/or thrust Inspect entire rotating assembly and bearing all bearings. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 41 of 54...

  • Page 42: Eri Customer/Field Support

    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. 1717 Doolittle Drive San Leandro, CA 94577 USA...

  • Page 43: Appendix A - Halo Disassembly Procedure

    HALO-900 Compression Hex Head 3/8" X 1/4"-18 NPT HALO-1200 Compression Hex Head 3/8" X 1/4"-18 NPT Remove Turbine Side End Cap fasteners. See table 2 for fastener sizes. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 43 of 54...
  • Page 44 Stud and Nut 3/4"-10 UNC Hold turbine side allen head set screw while the pump side rotor retaining nut is loosened. See table 4 and 5 for sizes. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 44 of 54...
  • Page 45 Hex Socket Set Screw 1/2"-13 UNC HALO-1200 Hex Socket Set Screw 1/2"-13 UNC Remove pump side retaining fastener. Table 5 – HALO Pump Side Rotor Retaining Fastener Sizes Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 45 of 54...
  • Page 46 Rotor removal is now complete. Please follow these directions in reverse order for re-installation. It is not necessary to remove the center bearing unless it is damaged. Center bearing removal procedure is below. CENTER BEARING REMOVAL Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 46 of 54...
  • Page 47 Push center bearing out from the turbine side to the pump side. This can require some force to remove. Be careful to not damage the bearing during removal. THRUST BEARING REMOVAL The Thrust bearing is located in the turbine side end cap. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 47 of 54...
  • Page 48 All parts should be thoroughly cleaned prior to re-assembly. Inspect and clean the thrust line of the turbocharger prior to re-assembly. Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 48 of 54...

  • Page 49: Appendix B - Glycerin Sds

    Appendix B – Glycerin SDS Energy Recovery Inc ERI™ Document Number 80311-01 r6 Page 49 of 54...
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