OPERATION & MAINTENANCE
OPERATOR DAILY ROUTINE JOBS & CHECKLIST
JOB DESCRIPTION REMARKS
HIGH PRESSURE PUMP(S) AND OTHER
CENTRIFUGAL PUMPS
Check the following :
1. Motor current and voltage Daily
2. Noise
3. Vibration
4. Discharge and suction pressure
Once pr. shift
5. Seal leakage
6. Bearing temperature
7. Lubricant oil level
CHEMICAL DOSING PUMPS
Check for :
1. Noise
2. Vibration Once pr. shift
3. Leakage from pipe connections
CHEMICAL DOSING TANKS AND MIXERS
Check for :
1. Leakage Once pr. shift
2. Noise
3. Vibration When mixer is operated
DEGASSIFIER
Check for :
1. Noise
2. Vibration Once pr. shift
3. Water Flow
(Continue next page)
2
OPERATOR DAILY ROUTINE JOBS & CHECKLIST
JOB DESCRIPTION REMARKS
(Cont'd)
AIR BLOWER
Check for :
1. Noise
2. Vibration
3. Blower temperature Once pr. shift
4. Lubricant oil level
5. Belt wear
AIR COMPRESSOR
Check for :
1. Noise
2. Vibration
3. Lubricant oil level Once pr. shift
4. Drain air receiver
INSPECTION ROUND AT EACH SHIFT
Check for :
1. Leakage pipe points
2. Leaking valves
3. Loose cable connections
4. Fraying, wear or damage to
electrical cables and instrument
leads
3
INSTRUMENT READINGS
JOB DESCRIPTION REMARKS
FLOWS
RAW WATER INLET Every 2nd hour
R.O FEED Twice pr. shift
PERMEATE (= every 4 hours).
BRINE Every 2nd hour
during Plant startup
FILTER PRESSURES
MEDIA FILTER INLET
MEDIA FILTER OUTLET Once pr. shift,
PRESSURE DIFF., MEDIA FILTERS
PRESSURE DIFF., CARTR. FILTERS Twice pr. shift,
(=every 4 hours
PRESSURES, R.O UNITS
HIGH PRESS. PUMP, DISCHARGE Twice pr. shift Verify
R.O OPERATING PRESSURE (= every 4 hours if more
INTERSTAGE PRESSURE Every 2nd hour than
PERMEATE during Plant startup one
BRINE stage
R.O DIFFERENTIAL PRESSURE
OTHER PRESSURE READINGS
RAW WATER PUMPS
FILTER FEED PUMPS
BACKWASH PUMPS Once pr. day
FINAL PRODUCT PUMPS
DEGASSIFIED WATER PUMPS
CLEANING PUMPS
FLUSHING PUMPS
POST-TREATMENT PUMPS
AIR BLOWER
AIR COMPRESSOR (Continue next page)
4
INSTRUMENT READINGS
JOB DESCRIPTION REMARKS
(Cont’d)
TEMPERATURE
FILTERED WATER OUTLET Once pr. shift
(common R.O feed)
R.O FEED Once pr. shift., ref. Attachment A5 and
(for each R.O unit aftercartr. filter) every 2nd hour during Plant startup,
ORP & pH
R.O FEED Twice pr. shift
(= every 4 hours).
Every 2nd hour
during Plant startup
CONDUCTIVITY
R.O FEED Twice pr. shift
PERMEATE (=every 4 hours).
Every 2nd hour
during Plant startup
RUNNING HOURS
RAW WATER PUMPS
FILTER FEED PUMPS
BACKWASH PUMPS
R.O HIGH PRESSURE PUMPS
FINAL PRODUCT PUMPS
DEGASSIFIED WATER PUMPS Weekly
CLEANING PUMPS
FLUSHING PUMPS
POST-TREATMENT PUMPS
AIR BLOWERS
AIR COMPRESSOR
(Continue next page)
5
INSTRUMENT READINGS
JOB DESCRIPTION REMARKS
(Cont'd)
TANK LEVELS
RAW WATER
FINAL PRODUCT Once to twice
BACKWASH pr. shift
REJECT WATER
6
LABORATORY & INSTRUMENT TESTS
JOB DESCRIPTION REMARKS
TURBIDITY
RAW WATER Once pr. shift
SDI
MEDIA FILTER OUTLET Once pr. shift
R.O FEED (after microfilter) Once pr. shift.
Every 2nd hour
during Plant startup
LSI or S&DSI
LAST STAGE BRINE FLOW Monthly
TOTAL IRON Once pr. shift during
Plant startup
MEDIA FILTER OUTLET (If BIRM Filters are reqd. due to
high iron in raw water, regular
regular iron tests are required)
TDS
RAW WATER Once pr. shift
R.O FEED
PERMEATE of each stage Once pr. month
BRINE
EACH PRESSURE VESSEL Once pr. week
FINAL PRODUCT WATER Once pr. shift
pH
FINAL PRODUCT WATER Once pr.
(Continue next page)
7
LABORATORY & INSTRUMENT TESTS
JOB DESCRIPTION REMARKS
FREE RESIDUAL CHLORINE
RAW WATER Once pr. shift
FINAL PRODUCT Once pr. shift
SULPHATE
CARTRIDGE FILTER OUTLET Once pr. shift
ALKALINITY
CARTRIDGE FILTER OUTLET Once pr. shift
CHLORIDE & CONDUCTIVITY
R.O FEED Eight (8) times
PERMEATE of each stage pr. month
BRINE ( Twice a week)
TEMPERATURE
RAW WATER Once pr. shift
TOTAL BACTERIAL COUNT (TBC)
R.O FEED
PERMEATE of each stage Once pr. month
BRINE
COMPLETE WATER ANALYSIS
RAW WATER
R.O FEED Quarterly
PERMEATE (every 3 months)
BRINE
8
R.O PRE-STARTUP CHECK LIST
JOB DESCRIPTION REMARKS
Rotating Equipment
1. Before inspection of rotating parts, power Before starting up this Plant each unit shall be
supply should be shut off at the Control checked in accordance with the procedures as
Panels. Manual isola-tion valves are closed described
2. Confirm that lubricant oil level is normal and
oil is clean. Changing of oil shall be done at
regular intervals in accordance with the
Lubrication Schedule
3. Confirm that the rotating friction element is
correctly greased. Makeup or replacement
of grease is carried out in accordance with
Lubrication Schedule
4. Confirm that the rotating equipment is
correctly coupled with its drive and securely
bolted to the base
5. Make sure that coupling alignment is
accurate
6. Confirm that external cooling/ flushing
water is supplied as required
7. Confirm by hand that the rotating element
is free and check direction of rotation
8. Verify that the isolation valves are
operational
(Continue next page)
9
R.O PRE-STARTUP CHECK LIST
JOB DESCRIPTION REMARKS
(Cont'd)
9. Grease up all points
10. All water pumps must be fully primed and
air vented
11. Action a short test run to ensure that there NEVER START PUMP UNDER DRY
is no abnormal sound or vibration CONDITION
12. For motors coupled to a Gear Unit: start
pump again for a few seconds and stop.
Repeat this three to four times to ensure
lubrication of gear box is complete (for R.O
High Pressure Pumps, confirm that water is
seen dripping from mechanical seal)
R.O Units
1. Open all manual isolation valves on feed,
brine and product (permeate) lines
Pressure Sand / Carbon Filters
1. Open all Filter Inlet/Outlet Valves
2. Close other valves (including drain valve)
3. Check that manholes are closed
4. Check that Pressure Indicators, analysis
element sample valves, Flow Control
Valve(s) etc., all are installed in correct
positions
(Continue next page)
10
R.O PRE-STARTUP CHECK LIST
JOB DESCRIPTION REMARKS
(Cont'd)
Cartridge Filters
1. Open air vent valve until all air is expelled
and close valve
2. Open isolation valves of filter vessel
3. Open drain valve after cartridge filter and
check for SDI
4. Close drain valve when SDI is as required
Degassifier
1. Open inlet and outlet valves
2. Check that power supply to fan motor is
corresponding to the voltage and
frequency as shown on name plate
3. Check that the fan rotates freely in correct
direction
4. Ensure packing media is installed inside
tower
5. Check that the float switches are installed
in correct position and ensure that the float
is moving freely on the chain/rod
6. Check that the bearings are filled with the
correct grade and quantity of grease
(Continue next page)
11
R.O PRE-STARTUP CHECK LIST
JOB DESCRIPTION REMARKS
(Cont'd)
Chemical Dosing Tanks
1. Check that new chemical solutions for all
chemical feed systems have been filled
2. Adjust stroke frequency and/or stroke
length knobs as required
3. Open all manual isolation valves
4. For Sulphuric Acid, make sure that siphon
valves are piped back to tank
5. Check that the tubing and valves are
correctly connected
Water Tanks
1. Check that isolation valves are installed in
correct position
2. Check that the float or level switches are
installed in the correct position (if present)
3. Close all manholes
4. Check that the pressure switches installed
on the tank are at required set point (if
required)
(Continue next page)
12
R.O PRE-STARTUP CHECK LIST
JOB DESCRIPTION REMARKS
(Cont'd)
Membrane Cleaning System
1. Check Cleaning Pump with same
procedure as "Rotating Equip-ment"
2. Check "Cleaning Cartridge Filter" with same
procedure as "Cartridge Filters"
3. Purge all air from the piping line if vent
valves are available
4. Check that level in Cleaning Tank is
enough
5. Open the block valves of piping line
U.V Sterilizer
1. Check that the U.V Sterilizer is properly
grounded
2. Open the inlet valves
3. Check power supply to the unit
4. Check that the U.V lamps are free and
clean from paper warning tags or from any
debris
Pipelines & Valves
1. Vent all air from water pipe lines
2. Open/close the block valves as required
(Continue next page)
13
R.O PRE-STARTUP CHECK LIST
JOB DESCRIPTION REMARKS
(Cont'd)
3. Close air vent and drain valves after
flushing
4. Drain all water from air pipeline
5. Check pipe supports
6. Check pipe and fittings
Electric Equipment & Instruments
1. Check that control and power cabling is Following description shows an outline of check
correct items for electrical equipment and instruments.
Details are given at individual sections of this O &
M Manual
2. Make sure sequence check and interlock
check
3. Check that power supply is available
4. Check that selector switches of electrical
eqipment are in correct position
5. Check the insulation resistance of
transmitter coils
6. Confirm that analyzers are ready for
operation
7. Confirm that all instruments are correctly
indicated and calibrated
8. Make sure that all ORP equipment are
calibrated on site during operation
(Continue next page)
14
R.O PRE-STARTUP CHECK LIST
JOB DESCRIPTION REMARKS
(Cont'd)
Control Panels :
1. Check the voltage and frequency of electric
power supply
2. Check all panel mounted equip-ment and
calibrate
3. Lamp test
4. Interlock and sequence check
15
R.O PLANT STARTUP
JOB DESCRIPTION REMARKS
Preliminary checks
Before starting make sure that : The Plant is assumed to be off line and all selector
switches are set to "Off ".
1. Raw water is available and it meets the If the Plant is in log term storage condition, i.e.
required quality filled with sanitizing fluid then it will be necessary
to initially flush the product to drain by
2. The feed pump systems are opera-tional disconnecting the product discharge piping and
(Filter Feed Pumps and R.O High Pressure connecting a hose
Pumps)
3. The filter(s) have been back-washed and
the valves are set to service position
4. All necessary valves on the raw water line
are open
5. 5 micron (5µ) rated cartridges are correctly
fitted in the housing for pre-treatment
Cartridge Filters
6. All Chemical Dosing Tank contains solution
7. All Chemical Dosing Pumps are primed
8. Strokes and speeds of all Dosing Pumps
are correctly set
Filling of Backwash Tank
In normal operation, the Backwash Tank is being When the R.O Units are not operating, there will
replenished continuously by R.O product water be no water for backwashing the filters apart from
what is stored in the Backwash Tank
(Continue next page)
16
R.O PLANT STARTUP
JOB DESCRIPTION REMARKS
(Cont'd)
Filling of filters
The filters must be filled with water before they are
put in service. Each filter is filled by manually
operating the backwash system and filter valves as
follows :
1. Verify that the Backwash Tank is full of During plant startup it will be necessary to fill the
water tank with water
2. Select the filter to be filled. Open The other filter valves should be closed
Backwash Inlet and Backwash Outlet
Valves for that filter
3. Open the suction valve for the Backwash
Pump to be used for filter filling and keep
discharge valve closed
4. Start the pump by placing its selector
switch in Manual-position. As soon as the
pump starts, manually open the Backwash
Outlet Valve. Limit the flow to
L/s
5. When the filter is full, close the discharge
valve and switch the Backwash Pump to
"Off "
6. Repeat above steps for each filter until all
filters are filled
(Continue next page)
17
R.O PLANT STARTUP
JOB DESCRIPTION REMARKS
(Cont'd)
Startup Procedure
1. Startup preparation (Plant line up) When starting the R.O Unit for the first time, the
following checks should be per-formed to ensure
safety of equipment and personnel and to exclude
possible malfunction :
a. Insulation test should be done using a
megaohm tester when power cables are
disconnected from motors, panel
deenergized. Insula-tion resistance should
not be less than 5 megaohms
b. Dry run test should be performed when
power circuit breaker for motors are "Off "
and control circuit
energized. This test consists of a simulation to
make sure that the process will be controlled
properly
2. Fill media filters (Sand and Carbon Filters)
with water
3. Prepare chemical solutions Fe (SO4)3, H2SO4, NaOCl, CaCl2, NaOH, HCl, Verify
NaCl, etc.
4. Startup of filtration systems (Sand/Carbon
Filters)
5. Startup of Chemical Dosing Pumps
6. Open Cartridge Filters
(Continue next page)
18
R.O PLANT STARTUP
JOB DESCRIPTION REMARKS
(Cont'd)
7. Check pH, Temp., SDI, Cl2, Biological 6.5 < pH < 7.5
matter, F, Ba++, Sr++, Iron... etc. Temp. < 35oC
SDI : as per
guidelines
Cl2 = 0 mg/L If OK: Go to
Biological matter : none Step 8.
Ba++ = 0 mg/L ion If not: Wait
Sr++ = 0 mg/L ion until OK
F = 0 mg/L ion
Total Iron = < mg/L
8. Start R.O High Pressure Pump
9. Start Degassifier Fan
10. Start Degassified Water Pumps
11. Startup Final Product Pumps/ Potable
Water Pumps
12. Startup potable water Post-treat-ment
Chemical Feed Systems
Note : Before operating any pump manually,
check the water level at upstream tank
contains enough water for operation
19
R.O PLANT SHUTDOWN
JOB DESCRIPTION REMARKS
1. Stop R.O High Pressure Pumps Note : Only stop R.O Unit by switching the main
power switch to "Off " in
2. Flush R.O Units using feed water event of an emergency ; never
else
3. Stop Degassifier and Final Product Pumps
Note : When stopping for more than two (2)
4. Stop Raw Water Pumps days, membranes must be prepared for
"long term storage" by filling with
5. Stop all Chemical Dosing Pumps sterilizing solution, see step 8
6. Backwash the filter(s), then stop Air
Blowers
7. Stop filtration system by shutting down If shutdown period is greater than two (2)
Filter Feed Pumps. Close Sand/Carbon days : Go to step 8. If not : Go to step 9
Filters and Cartridge Filters
8. Fill R.O membranes with 1.0 wt % To prevent growth within membranes
Formaldehyde
9. Daily operation of pretreatment system, Replacement with filtered raw water (fresh water)
filters, Cartridge Filters and pumps to
replace the stagnant water inside filter(s)
10. Wait for startup If membranes shall be replaced for storage, Go to
step 11, If not Go to step 9
11. Resanitize membranes with 0.5 wt %
Formaldehyde, 250 mg/L Mg++ from MgCl2
20
FLUSHING OF R.O MEMBRANES
JOB DESCRIPTION REMARKS
Flushing Procedure I The Permeators shall be flushed with flushing
water of TDS less than 5,000 mg/L before and
This procedure should be appliced only when after the following :
flushing sterilization solution, such as when
cleaning a new membrane. There are separate CLEANING
proce-dures for B-9 and B-10 Permeators, as POST-TREATMENT
shown in the Table on next page STERILIZATION
There are four (4) different procedures which may
Flushing Procedure II be applied. The flushing procedure to be applied
depends on whether the Permeator is being
This procedure should be applied in the following Cleaned, Post-treated or Sterilized, and whether
cases : the flush is being performed before or after the
above treatment
* Before Cleaning
* Prior to PT-A and PT-B Post-treatment
* Prior to Sterilization CAUTION: The cleaning flush procedure may be
different than the Post-treatment flush procedure.
Always refer to the following table for the proper
flushing procedure to followed. The Table shows
Flushing Procedure III the pressures, flow rates and treatment times for
each procedure
This procedure should be applied in the following
cases :
In-between successive Cleanings
At the end of Cleaning
At the end of PT-A or PT-B Post-treatment
Flushing Procedure IV
This procedure should be applied only in case of
flushing after Citric Acid cleaning.
21
REGULAR SERVICING & MAINTENANCE JOBS
INTERVAL OR
JOB DESCRIPTION REMARKS
CRITERIA
CARTRIDGE FILTER
1. Change Cartridge 30 Days or
at p>100 kPa
pH MONITOR
1. Calibrate using standard buffer 7 Days
solution
MEMBRANE CLEANING Failure to recognize that some form of 3 Months
failure is taking place and to initiate
cleaning is the most common reason
Permeators are destroyed fouling if
recognized in time, can be stopped and
system performance restored
LUBRICATE BEARINGS ON 3 Months
CENTRIFUGAL PUMP
1. Check guand packing, shift sleeves, 1 Year
Gaskets etc. for any sign of
deterioration
CALIBRATION OF GAUGES 3 Months
AIR COMPRESSOR
1. Clean Air Filter 1 Week
2. Replace Air Filter 1 Year
(Continue next page)
22
REGULAR SERVICING & MAINTENANCE JOBS
INTERVAL OR
JOB DESCRIPTION REMARKS
CRITERIA
(Cont’d)
ELECTRICAL EQUIPMENT
1. Check adjustment and the operation 1 Month
of the protection devices (thermal,
magnetic)
2. Check time delay adjustments 1 Year
3. Tighten the connection 1 Year
23
