Toray 050-1C Instruction Manual Download

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“NHPA Series C type”

[050-1C, 100-1C,

150-1C, 2C, 3C and 4C]

Instruction

Manual

Instruction

Manual

Toray MBR

Last updated August 2022

06-G-MB2-NHPAC-220801

Summary of Contents for 050-1C

Page 1: ... NHPA Series C type 050 1C 100 1C 150 1C 2C 3C and 4C Instruction Manual Instruction Manual Toray MBR Last updated August 2022 06 G MB2 NHPAC 220801 ...

Page 2: ...it transferring this document to any other websites or printed media The material contained in this document may not be used without permission from the copyright holder for any other purpose that exceeds the scope permitted under copyright law 2 Trademarks The TORAY company name used in this document is a trade name and the names of products manufactured by Toray are trademarks or registered trad...

Page 3: ...142 Switzerland Tel 41 61 415 8710 Fax 41 61 415 8720 E mail info tmeu mb mail toray Toray Asia Pte Ltd TAS 111 Somerset Road 14 22 14 27 Singapore 238164 Republic of Singapore Tel 65 6226 0525 Fax 65 6226 0509 Toray BlueStar Membrane Co Ltd TBMC Zone B Tianzhu Airport Industrial Zone Beijing 101318 China Tel 86 10 8048 5216 Fax 86 10 8048 5217 Toray Membrane Middle East LLC TMME PO Box 20279 Damm...

Page 4: ...me Chart 15 2 Flow Diagram of Membrane Filtration 16 3 Layout of NHPA Series Modules in Membrane Tank 21 4 Piping 24 V INSTALLATION OF NHPA SERIES 28 1 Preparatory Procedure 28 2 Unloading Lifting Products 28 3 Checking Products 29 4 Storing Products 29 5 Installing Products 30 VI START OF OPERATION 33 1 Clean Water Operation 33 2 Seeding Sludge Injection 34 3 Actual Filtration Operation 35 VII OP...

Page 5: ...ation which if not avoided will result in serious injury or death This symbol is used to indicate a potentially hazardous situation which if not avoided can result in serious injury or death This symbol is used to indicate a potentially hazardous situation which if not avoided may result in injury or property damage Prohibited This symbol indicates a prohibited action or procedure Instruction This...

Page 6: ... operation 1 Features of MBR The process flow of the conventional activated sludge system CAS and MBR are shown in Fig I 1 and Fig I 2 respectively MBR provides the following advantages 1 Small Footprint Unlike CAS MBR separates sludge within an aeration tank using membranes thus eliminating the space for the sedimentation tank Also with membrane MBR can hold higher concentration of activated slud...

Page 7: ...heets are arranged at a constant clearance Each element is connected via plastic tube to the filtrated water manifold For this C model the aeration block consists of coarse bubble air diffusers to supply scouring air see Fig I 3 This module is used submerged in sludge liquid The following shows the features of NHPA Series Fig I 3 Components and Appearance of NHPA150 1C Nozzle Filtrate water manifo...

Page 8: ...Fig I 5 This mechanism ensures the stable filtration since the membrane does not easily admit of sludge adherence to its surface In addition thin membrane element which consists of two membrane sheets and spacers in between makes it possible to have higher membrane packing density in the module similar to that of a hollow fiber membrane and also the vibration of elements by scouring air improves m...

Page 9: ...Size Numerous small size pores are distributed evenly over the membrane surface with a sharp pore size distribution This structure gives an outstanding high treated water quality and excellent water permeability making the membrane highly resistant to clogging see Fig I 6 and Fig I 7 compared to other membranes The average pore size is 0 08 micrometer 4 Cassette Replacement Membranes can be taken ...

Page 10: ...lower element block at once as one unit when lifting NHPA150 3C or 4C Lift the upper and lower element block separately Make provisions in advance to access the upper portions of the membrane module via a scaffold or ladder when installing NHPA Series module Do not climb on the module structure Never step on the air diffuser and filtrate water manifold Use protective equipment to ensure the safety...

Page 11: ...he air diffuser and filtrate water manifold 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 air diffuser and filtrate water manifold If the load exceeds the limit shown above put some supports on the piping to reduce the load 2 Safety Instruction for Operation and Maintenance Filtr...

Page 12: ...nes longer than necessary to purge the system of entrained air when using clean water in the MBR tank Prolonged clean water operation can clog the membrane pores Keep the membranes wet once they get wet If the membranes are allowed to dry out the permeability of the membranes may be permanently reduced Be sure to pass the seeding sludge through a screen to remove large foreign materials when feedi...

Page 13: ...to maintain sludge viability Once a filtrate tube has been removed or disconnected from either the element nozzle or filtrate manifold it should be replaced with a Toray approved replacement part Old filtrate tubes lose their elasticity and the integrity of the seal can be compromised Never use a pressure washer machine when washing the membrane module and element which can cause fatal delaminatio...

Page 14: ...ing injecting chemical to elements confirm that the membrane tank liquid level is more than 500 mm above the top of the module Store chemicals in a dark cold place free from direct sunlight Use chemical storage tanks constructed of chemically compatible materials to prevent corrosion Never mix sodium hypochlorite with heavy metals or acids The resulting chemical reaction will generate toxic chlori...

Page 15: ...ne area m2 0 7 Dimensions mm Total width 480 Total height 800 Thickness 1 8 Weight kg Dry 0 25 Wet Reference 0 5 Main material Membrane PVDF and PET non woven fiber Nozzle PE Fig III 1 Element Appearance mm 2 Specifications of Filtrate Tube Assembly Table III 2 and Fig III 2 show the specifications and appearance of Tube Assembly Table III 2 Specifications of Filtrate Tube Assembly Material Thermo...

Page 16: ... 150 2C 3C and 4C cassette and modules Note that NHP210 300S and 600D are described in the separate Instruction Manual Contact Toray in case of replacing existing Toray MBR TMR Series or NHP210 Series with NHPA Series Fig III 3 Cassette Arrangement of the NHPA Modules Shown in This Manual EBL050 EBL100 Cassette ECS035 ABL050 C ABL100 C ABL150 C EBL150 EBL150 EBL150 Bolts nuts EBL150 EBL150 EBL150 ...

Page 17: ...lypropylene Connection Manifold ANSI 1 1 2 inch flange using M12 bolts nuts One flange per module Air diffuser ANSI 1 1 4 inch flange Using M12 bolts nuts Two flanges per Aeration block ANSI 1 1 2 inch flange Using M12 bolts nuts Two flanges per Aeration block Operating range 3 Temperature 5 40 deg C pH 2 of liquid 5 10 MLSS Not higher than 18 000 mg L Trans membrane pressure Not higher than 20 kP...

Page 18: ... 2C 2 pcs per module 3C 3 pcs per module 4C 4 pcs per module Air diffuser ANSI 1 1 2 inch flange Using M12 bolts nuts Two flanges per Aeration block Operating range 3 Temperature 5 40 deg C pH 2 of liquid 5 10 MLSS Not higher than 18 000 mg L Trans membrane pressure Not higher than 20 kPa 200 mbar Cleaning chemicals feed pressure Not higher than 10 kPa 100 mbar Cleaning chemicals and chemicals con...

Page 19: ...ids Dried at 103 105 deg C or ISO 11923 3 Measuring method of NTU is complied with Standard Method of Examination of Water and Wastewater 20th Edition 1998 Section 2130 Turbidity or ISO 7027 Table III 5 Flow capacity Reference value Model name NHPA050 1C NHPA100 1C NHPA150 1C Filtration Flow m3 d 4 Sewage 3 25 7 50 10 75 Industrial wastewater 3 17 7 33 10 50 Model name NHPA150 2C NHPA150 3C NHPA15...

Page 20: ...on The air scour should be suspended when the filtration process is stopped except for the following conditions 1 During normal membrane relaxation periods 2 During suspended filtration operation unless aeration is required for mixing or biological demand requirements For the latter the air flow should be reduced to minimum flow rates to prevent membrane damage During low wastewater supply period ...

Page 21: ...having openings of 3 mm or less prior to being introduced into the membrane tank Failure to incorporate the screen device may result in large solids clogging or causing physical damage to the membrane surfaces In order to equalize BOD load and filtration flow capacity it is recommended that a buffer equalization tank be installed to help stabilize operation of the biological treatment and membrane...

Page 22: ...ntrol valve fully closes to effectively stop the filtration process When the liquid level of the membrane tank reaches the designed upper limit the automatic shut off valve on the raw water influent line closes to stop the raw water flow to the membrane tank In the gravity filtration mode air may accumulate in the filtrate water lines To prevent reduction or loss of suction the air in the filtrate...

Page 23: ...evel reaches the designed lower limit the filtration mode should be stopped As with the gravity filtration mode previously discussed should the membrane tank water level reach the designed upper limit the upper limit controller will close the raw water inlet control valve Since the liquid in the tank contains a significant amount of dissolved air some of that dissolved air will accumulate in the f...

Page 24: ...e to control the flow rate of filtrate water It is recommended that each train be fitted with its own discreet filtrate flow rate controller when operating more than one NHPA Series module simultaneously c Trans membrane pressure TMP measurement calculation For trans membrane pressure TMP determination the differential pressure in the filtrate line and water level needs to be measured and calculat...

Page 25: ...is advised installing at a minimum one air flow meter for each train f Suction pump A suction pump is required in the case of pump suction configuration To achieve an accurate designed filtrate flow rate the suction pump should be fitted with a VFD controller The use of a volute pump centrifugal pump or volumetric pump screw pump with self priming functions is recommended g Level sensor Level sens...

Page 26: ... sludge It is very important to arrange the membrane modules with appropriate distances between each module to obtain an effective activated sludge circulation as well as not having excessive space around the modules which allows sludge sedimentation installing sludge agitation if necessary Fig IV 5a and Fig IV 5b illustrate a side view and a top view of the membrane tank containing three membrane...

Page 27: ...odules in an existing aeration tank 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 Fig IV 6 Installation with Stands side view 2 Layout of Modules Installed with Other Aeration Equipment In the case that the membrane modules are to be installed in a tank with other oxygen supplyi...

Page 28: ...ep twice the W1 distance between the modules and other aeration equipment in the case shown in Fig IV 8 Fig IV 8 Membrane Module Layout in Membrane Tank with Other Aeration Equipment top view Tank wall W1 W1 W2 W2 2 W3 W3 Oxygen Supplying Aeration Equipment Module Module Module Tank wall 2 W1 W1 W2 W2 W3 W3 Module Oxygen Supplying Aeration Equipment Module Module ...

Page 29: ...e pipe for easy flange connection without putting stress to the air diffuser Also it is recommended that the air supply flange B be installed above the tank liquid level to lift the module from the tank if necessary To facilitate cleaning of the air diffuser install branch pipes and valves as illustrated in Fig IV 9 It is recommended that these valves be located within 500 mm above the liquid surf...

Page 30: ... chemical injection valve and the air discharge valve should be installed on a pipe tee between the pipe from the filtrate water manifold to the filtrate water control valve These devices are necessary for chemical cleaning and are detailed in sections VIII 3 to VIII 6 It is advised that you prepare and attach a riser pipe to connect two filtrate manifolds of two element decks for ease of piping a...

Page 31: ...d Piping from Membrane Tank Fig IV 11 Upward Piping from Membrane Tank Air Discharge Valve Chemical Feed Line Filtrated Water Valve Chemical Injection Valve Suction Pump Filtrated Water Outlet Filtrated Water Valve Chemical Feed Line Air Discharge Valve Chemical Injection Valve ...

Page 32: ...e water manifold If the load exceeds the limit shown above put some supports on the piping to reduce the load Be sure to confirm that the diameter of filtrate piping is suitable for the assumable maximum flow velocity at each point especially after aggregating filtrate flow from several manifolds such as header pipes 3 Maximum Number of Modules in a Single Header A maximum number of 30 modules per...

Page 33: ... the NHPA Series module One is the element block complete with the prescribed number of membrane elements and the other box an aeration block 2 Do not lift the packages from overhead when unloading the package which contains multiple element blocks or aeration blocks Always lift these packages from underneath using a forklift or pallet jack 3 To avoid damage do not stand or sit on the packages 4 A...

Page 34: ...red 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 Always comply with all recommended storage conditions At all times during transportation and installation of the NHPA ...

Page 35: ... Using clean water in the tank check the operation of major equipment components such as pumps blowers sensors and control systems 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 inste...

Page 36: ...ise the element block by bots and nuts If you apply riser pipe see 2 in the page 24 relevant decks must be connected Put the element block s onto the aeration blocks Joint both using provided bolts if guide rail system is not applied in case of 1C and 2C Use guide rails certainly and do not connect three 3 element decks or more when installing taller module NHPA150 3C and 4C For 3C put one 1 upper...

Page 37: ...es during lifting Use chains or slings with sufficient load rating to lift the weight of the NHPA Series or any of its components When installing NHPA Series module make provisions in advance to access the upper portions of the membrane module via a scaffold or ladder Do not climb on the module structure Never step on the air diffuser and filtrate water manifold Use protective equipment to ensure ...

Page 38: ...al ground water for clean water operation as it may contain much amount of iron manganese calcium and silica which may cause the clogging of the membrane pore 2 Clean Water Operation After feeding clean water to the membrane tank follow the recommended procedures below to start the clean water operation a Start the blower to supply air to the air diffusers Check that the required amount of air is ...

Page 39: ...mbrane pores Do not conduct clean water operation for a long time Clean water operation may cause membrane clogging Keep the membranes wet once they get wet If the membranes are allowed to dry out the permeability of the membranes may be permanently reduced Avoid pressurizing the filtrate side of NHPA Series over 10 kPa 2 Seeding Sludge Injection Do not attempt to produce filtrate from any wastewa...

Page 40: ... approaches 7 000 mg L Gradually increase the flux rate as the condition of the activated sludge improves 2 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 3 Sludge parameters such as MLSS and sludge filterability see 11 in the page 41 should ...

Page 41: ...use silicone based anti foaming agent which may cause choking of membrane pores Recommended Kurita Water Industries Kuriless 653 Schill Seilacher Structol SB2032 The operating conditions may deviate from these standard conditions depending on condition of the sludge raw water quality and or other given operating conditions Table VII 1 Standard Operating Conditions for NHPA Series Parameter Unit Op...

Page 42: ...sludge Avoid abrupt changes in pH temperature trans membrane pressure or any other conditions even if they are within the standard operating conditions Table VII 1 Perform regular inspections of the module Replace worn parts as needed in a timely fashion If anti foaming agents are to be added to the membrane tank use only alcohol based anti foaming products Do not use silicone based anti foaming a...

Page 43: ...ents and sludge properties Every week for water quality analysis 3 Basic Control Philosophy Presented below is the point of the generic MBR control philosophy The actual MBR system control philosophy will be based on the specific site operating conditions 1 Suction Pump The filtrate suction pump should be controlled to operate for intervals of nine 9 minutes on and one 1 minute off The filtrate su...

Page 44: ...he low level the suction pump and membrane scouring air should be stopped If the membrane tank reaches high level the wastewater feed supply should be stopped 4 TMP Two TMP alarms should be incorporated into the MBR control logic A HIGH TMP ALARM should be activated before the TMP increases 5 kPa from the initial TMP value A HIGH HIGH TMP ALARM which stops filtration should be activated when the T...

Page 45: ...ple MBR modules are located in the same tank check that diffused air is being evenly distributed between each MBR module If uneven air distribution is observed conduct an air diffuser cleaning as described in Section 2 Chapter VIII If the scouring air flow rate drops or becomes extremely irregular or if air supply is stopped then immediately stop filtration to prevent membrane clogging 2 Trans Mem...

Page 46: ...e discharge rate In the case where the air supply for biological aeration requirements and the air piping for membrane scouring comes from the same blower do not exceed the recommended range of membrane scouring air flow rate to the diffuser To increase DO concentration of the liquid within the membrane tank adjust the separate biological aeration system 6 pH The recommended pH range is 6 to 8 If ...

Page 47: ...thod is a simple and reliable method to determine the filtration properties of the sludge See the method described in the attached document Toray recommends conducting paper filtration test and measurement of TOC and or turbidity of filtered water routinely In the case an abrupt decrease in filterability is recorded and or increase in TOC turbidity check the operating and biological conditions and...

Page 48: ... filtrate flow or quality cannot be restored Be sure to use Toray approved replacement parts Contact Toray sales department to obtain information on how to order Toray approved replacement parts Make certain the tube is securely attached to the membrane element nozzle when replacing the individual filtrate tubes to the filtrate manifold Do not apply excessive force to the nozzle or membrane elemen...

Page 49: ...e that will remove any accumulated solids clogged in the diffuser holes The efficiency of the air diffuser cleaning will improve by the reverse procedure of the air flow direction indicated above Observe the flow coming out of the discharge nozzles V2 and V4 when performing an air diffuser cleaning cycle In some cases lengthening the duration of the diffuser cleaning cycle can improve the efficien...

Page 50: ... at the inlet point and end point both higher than water level The procedure and standard duration time of each action are as follows Flushing to clean air diffusers 1 to 5 minutes for each flushing event Purge to blow out inside header pipes around 30 seconds for each purge event Filtration must be stopped prior to starting the air diffuser cleaning procedure and restarted one minute after air sc...

Page 51: ...increases can be the result of less than the optimal operating conditions This operating procedure is effective to prolong the life of membranes 4 If the membrane permeability is not recovered by a single chemical cleaning multiple chemical cleaning may be necessary to restore membrane performance 4 Chemical Agents Available for Chemical Cleaning Try and select a cleaner that is most appropriate f...

Page 52: ...ll chemical containers after each use e Thoroughly wash your hands and face and rinse out your mouth after using chemicals f 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 h Forbid unauthorized entry to the place where chemicals are handled i Wear appropriate protectors to avoid inhalation eye...

Page 53: ... strong oxidants and bases b Handle the chemical container with great care Avoid toppling bumping or dragging it c Take care not to spill liquid chemicals and avoid breathing in vapors In the case of dry chemical powders handle in a manner that minimizes the formation of chemical dust d Securely seal all chemical containers after each use e Thoroughly wash your hands and face and rinse out your mo...

Page 54: ...th your skin or clothes immediately wash the contacted area with a large volume of running water If chemicals splash into your eyes immediately flush with large volumes of running water and contact a doctor Store chemicals in a dark cold place free from direct sunlight Use chemical storage tanks constructed of chemically compatible materials to prevent corrosion Never mix sodium hypochlorite with ...

Page 55: ...nd the chemical is being pumped to the elevated cleaning chemical injection tank v Slowly open the chemical injection valve to start injecting the chemical vi After injecting the specified amount of chemicals to the elements stop the chemical feed pump vii Allow the membrane elements to soak for 1 to 3 hours viii After soaking close the chemical injection valve open the filtrate valve and start th...

Page 56: ...cles It is recommended that the filtrate flow be directed back into the raw water tank until no residual cleaning chemical is detected Before directing the filtrate from the raw water tank back to the normal filtrate discharge line test the filtrate pH and chlorine concentration Fig VIII 3 Chemical Cleaning with Chemical Tank Located above Membrane Tank c Chemical cleaning with the chemical feed p...

Page 57: ...rting up the MBR after a chemical cleaning some residual cleaning chemical may be present in the filtrated water for 2 or more filtration cycles It is recommended that the filtrate flow be directed back into the raw water tank until no residual cleaning chemical is detected Before directing the filtrate from the raw water tank back to the normal filtrate discharge line test the filtrate pH and chl...

Page 58: ...ion cycles It is recommended that the filtrate flow be directed back into the raw water tank until no residual cleaning chemical is detected Before directing the filtrate from the raw water tank back to the normal filtrate discharge line test the filtrate pH and chlorine concentration e If a sodium hypochlorite cleaning is immediately followed by acid cleaning or in reverse order make certain that...

Page 59: ...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 To avoid scattering of chemical solution...

Page 60: ...C Also do not lift entire decks at one time The upper lower element block must be lifted one by one to avoid distortion or damage to the element block which may cause severe accident See the instruction below Attach chains or slings to the lifting lugs when lifting element deck element block or aeration block of NHPA Series Slowly raise the module straight up Avoid sudden changes in movement to mi...

Page 61: ...e tank with clean water until the module is completely covered Periodically check the water level and add more water if needed to keep the module covered with water Open air discharge valve before pouring water and keep it open during storage A periodic dosing of the membrane tank storage water to a 50 ppm concentration of sodium hypochlorite will help inhibit the growth of algae microorganism dur...

Page 62: ...ng and transport easier 2 Dispose of the module or module components according to local waste disposal regulations If required disassemble the module and segregate its components accordingly e g combustible incombustible 3 Do not incinerate the membrane unless appropriate facilities are available During the incineration of the membrane materials harmful Hydrogen Fluoride HF gas will be generated I...

Page 63: ... Element Block ECS035 x 3 or EBL150 x 1 4 NHPA150 2C Required Quantity per Module NHPA150 2C Filtrate Tube When deterioration detected NHP TUBE 200 200pcs set 300 pcs unit Cassette or Element Block When filtrate flow or quality cannot be restored after chemical cleaning ECS035 Cassette or EBL150 Element Block ECS035 x 6 or EBL150 x 2 5 NHPA150 3C Required Quantity per Module NHPA150 3C Filtrate Tu...

Page 64: ... the air diffusers to improve air diffusion Conduct chemical cleaning Remove sludge cake by external cleaning Abnormal properties of sludge have worsened its filterability Improve sludge properties Adjust the excess sludge discharge rate Prevent entry of abnormal components such as oils Adjust the BOD load and oxygen supply Adjust the raw water quality add nitrogen phosphorous etc Air is accumulat...

Page 65: ...claim the customer automatically agrees to provide 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 Otherwise the customer has risk of invalidation for any warranty claims tha...

Page 66: ...ction Manual 06 G MB2 NHPAC 220801 61 of 61 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 ...

Page 67: ...ntegrated approach using our 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 TORAY experts in RO NF UF and MBR ...

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