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Energy Recovery Pressure Exchanger 65 Series Installation, Operation & Maintenance Manual

For brackish water systems
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ENERGY RECOVERY, INC.
INSTALLATION, OPERATION, & MAINTENANCE
MANUAL
ERI DOCUMENT NUMBER 80023-01 REVISION 1
ERI™
65 Series Pressure Exchanger™
Energy Recovery Device
for Brackish Water Systems
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., 2006

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Summary of Contents for Energy Recovery Pressure Exchanger 65 Series

  • Page 1 65 Series Pressure Exchanger™ Energy Recovery Device for Brackish Water Systems 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., 2006...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION SAFETY QUALITY & ARRIVAL INSPECTION DESIGN CONSIDERATIONS How the PX Energy Recovery Device Works PX Energy Recovery Devices in BWRO Systems PX Energy Recovery Device Performance The PX Booster Pump Control of Feed Flow, Pressure, and Water Quality...

  • Page 3: Introduction

    (BWRO) 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. This manual is intended for use by personnel with training and experience in the operation and maintenance of fluid handling systems.

  • Page 4: Quality & Arrival Inspection

    A schematic representation of the ceramic components of the PX energy recovery device is provided in Figure 4-1. Feedwater supplied by the feedwater supply pump flows into a rotor duct on the left side at low pressure.

  • Page 5: Px Energy Recovery Devices In Bwro Systems

    Brine Interface Figure 4-2 illustrates the typical flow path of a PX energy recovery device in a BWRO system. The reject brine from the BWRO membranes (G) passes through the PX unit, where its pressure is transferred directly to a portion of the incoming raw feedwater at up to 97% efficiency. This...

  • Page 6: Px Energy Recovery Device Performance

    Example flow rates and pressures for a BWRO system with one PX-220B are listed in Table 4.1 below, with reference to Figure 4-2. In a BWRO system with an ERI energy recovery device installed, the main high-pressure (HP) pump is sized to equal the BWRO permeate flow plus a small amount of bearing lubrication flow, not the full BWRO feed flow.

  • Page 7: The Px Booster Pump

    PX units to help stabilize flow. Where feasible, Energy Recovery, Inc. recommends incorporation of a high-flow alarm on the feedwater supply set at 95% of PX unit capacity and an automatic high flow shutdown at a maximum of 100% of capacity.

  • Page 8: Fresh Water Flushing

    Debris and Initial Flushing Prior to 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 recommends installation of basket strainers at both inlets to the PX device or PX device array.

  • Page 9: Installation

    BRACKISH 65-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES ___________________________________________________________ PX unit array can be achieved by using large manifold pipe diameters eliminate manifold constrictions.. In a sufficiently large manifold, the pressure drop along the manifold is much less than the pressure drop through a PX unit such that the manifolds serve as constant-pressure reservoirs, regardless of flow orientation.

  • Page 10: Operation

    • HP OUT is the high-pressure feedwater outlet. • LP IN is the low-pressure feedwater inlet. • LP OUT is the low-pressure reject/brine outlet. The external fittings on the PX energy recovery device are made with plastic, glass-reinforced ® plastic or AL-6XN or equivalent stainless steel.
  • Page 11 BRACKISH 65-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) 400 psig 28 bar Maximum feedwater inlet pressure (LP IN) 150 psig 10 bar...

  • Page 12: Start And Stop Procedures

    BRACKISH 65-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES ___________________________________________________________ • Entrained or trapped air or other gasses must be purged from the BWRO system before pressurization. Large bubbles in a pressurized system can result in damage to piping and equipment, including the PX unit.
  • Page 13 BRACKISH 65-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES ___________________________________________________________ 7. After the PX unit and booster pump have run for five to ten minutes and all air and gas has been purged from the system, start the main high-pressure pump. The BWRO system pressure will increase to the point where the permeate flow will equal the flow from the main high-pressure pump.

  • Page 14: Flow Control And System Balancing

    BRACKISH 65-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES ___________________________________________________________ Failing to flush the PX unit with fresh water may result in excessive biological growth that may foul the PX unit and inhibit rotation upon CAUTION start-up. The high-pressure and low-pressure sides of the PX unit must be flushed individually.
  • 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 should be set to equal flow rates to within 5.0% for optimum BWRO operation.

  • Page 16: Spare Parts And Tool Kits

    BWRO plant design. 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, ERI recommends use of the following: •...

  • Page 17: Maintenance

    There are no shafts, couplings, seals, or lubrication systems to maintain or monitor. A sample operating-log has been provided at the end of Section and must be submitted by fax or e-mail to Energy Recovery, Inc. upon NOTE completion of startup and balancing routines. Data should be recorded daily and maintained during the life of the warranty to support any claims.

  • Page 18: Disassembly Procedure

    ___________________________________________________________ Disassembly Procedure The following procedure is for disassembling a 65 Series PX energy recovery device to inspect the ceramic components. The internal ceramic components can be reached through the brine end of the vessel, therefore only the brine access cover needs to be removed. Refer to Section 7.0 for a listing of spare parts and tool kits useful for disassembly and reassembly of a PX unit.
  • Page 19 BRACKISH 65-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES ___________________________________________________________ Figure 8.2 – Remove 5/16-inch socket cap screws and remove the securing ring 10. Tap down on the port bearing plate to loosen the lock ring segments as shown in Figure 8.3.
  • Page 20 BRACKISH 65-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES ___________________________________________________________ Figure 8.4 – Extract port bearing plate subassembly 12. Remove the thrust ring. Remove the LP nipple. See Figure 8.5. Figure 8.5 - Rotor subassembly inside vessel LP Nipple Thrust Ring Tension...
  • Page 21 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. f. Contact Energy Recovery, Inc. if problems are encountered. Energy Recovery, Inc. ERI Document Number 80023-01-01...

  • Page 22: Assembly Procedure

    BRACKISH 65-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES ___________________________________________________________ Assembly Procedure This assembly procedure assumes that the PX unit has been disassembled per the previous section. All parts should be carefully cleaned with soap and water prior to assembly to ensure that no dirt or debris contaminates the PX device.
  • Page 23 BRACKISH 65-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES ___________________________________________________________ Introduction of non-water soluble films such as grease, oil, wax, CAUTION petroleum jelly, etc. may cause the PX unit’s rotor to seize. Alignment pins must not bind or be shaved during installation.
  • Page 24 BRACKISH 65-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES ___________________________________________________________ 11. Thread the second pair of hex nuts (stop nuts) onto the tension rod. Torque each stop nut to 40 ft-lb (56 N-m) against the first nut. 12. Verify that the rotor can spin freely.
  • Page 25 BRACKISH 65-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES ___________________________________________________________ Figure 8.15 – Insert port bearing plate subassembly Look into LP port to ensure port lines up with the LP nipple and the LP hole in endcover Quad Ring 23. Mount the quad ring onto the port bearing plate subassembly. Lubricate the quad ring.
  • Page 26 BRACKISH 65-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES ___________________________________________________________ 26. Insert the fiberglass securing ring. Bolt down the securing ring with three 5/16-inch socket- head cap screws. When handling and installing a PX unit, care should be taken to avoid dropping the unit or putting undue strain on the port fittings CAUTION to avoid internal damage.
  • Page 27 BRACKISH 65-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 28: Troubleshooting

    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 29 BRACKISH 65-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES ___________________________________________________________ SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION 4. PX unit or ceramic cartridge Verify that the PX unit has been installed upside down installed with the end marked “HP IN” oriented toward the brine inlet.
  • Page 30 BRACKISH 65-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES ___________________________________________________________ SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION 2. A jammed or stalled rotor See Symptom D. short circuits high-pressure reject water with high- pressure feed water. No exchange occurs; no audible rotation. 3. Malfunctioning and/or stalled Check booster pump’s rotation,...

  • Page 31: Field Commissioning

    ___________________________________________________________ 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 BWRO system manufacturer’s location. Although not required, ERI offers commissioning as an additional service for those customers who may find it beneficial..

  • Page 32: Warranty & Liability

    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 33: Drawings And Data

    BRACKISH 65-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES ___________________________________________________________ 13.0 DRAWINGS AND DATA Energy Recovery, Inc. ERI Document Number 80023-01-01...
  • Page 34 ON O-RING SURFACES 32 RMS THE INFORMATION CONTAINED IN THIS DRAWING ENG APPR. 07/01/2003 PRODUCT BRACKISH IS THE SOLE PROPERTY OF ENERGY RECOVERY DIMENSIONING AND TOLERANCING PER ANSI INC. ANY REPRODUCTION IN PART OR AS A SIZE DWG. NO. Y14.5M (LATEST)
  • Page 35 THE INFORMATION CONTAINED IN THIS DRAWING ENG APPR. 07/01/2003 .97±.06 PRODUCT BRACKISH IS THE SOLE PROPERTY OF ENERGY RECOVERY DIMENSIONING AND TOLERANCING PER ANSI INC. ANY REPRODUCTION IN PART OR AS A SIZE DWG. NO. Y14.5M (LATEST) WHOLE WITHOUT THE WRITTEN PERMISSION OF...
  • Page 36 LABEL, "MADE IN U.S.A." THE INFORMATION CONTAINED IN THIS DRAWING PRODUCT ENG APPR. 07/01/2003 BRACKISH IS THE SOLE PROPERTY OF ENERGY RECOVERY 30051-01 LABEL, "PATENT" INC. ANY REPRODUCTION IN PART OR AS A SIZE DWG. NO. WHOLE WITHOUT THE WRITTEN PERMISSION OF...

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