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OPERATORS MANUAL

ORION II

Orion II 500-10000 Operators

Page 9 of 95

Manual Part no: DOMAON0100 Issue A

April 2008

3 INTRODUCTION

3.1 GENERAL

Please read these operating and maintenance instructions carefully.

This manual describes the operation and basic maintenance of the ORION range of integrated water
treatment systems, which includes models with nominal outputs ranging from 500 to 10000 litres per
hour.

Ensure that the unit is installed by a Veolia Water engineer and operated in accordance with the
instructions in this manual. If there are any enquiries regarding the installation, operation or
servicing of the ORION unit contact Veolia Water, Service Department.

3.2 SYSTEM OVERVIEW

The ORION unit is a thermally sanitised, integrated packaged system which produces
Pharmaceutical grade water from a potable water feed. It is designed to operate on a continuous
basis and can produce purified water at all times except when performing a thermal sanitisation, or
during cleaning or maintenance.

The ORION platform consists of a number of selectable options that are pre-determined at the sales
stage to meet the customer‟s requirements.

Options available are as follows

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Содержание Orion II 2000

Страница 1: ...OPERATORS MANUAL ORION II Orion II 500 10000 Operators Page 1 of 95 Manual Part no DOMAON0100 Issue A April 2008 ORION II Operators Manual Models 500 10000...

Страница 2: ...2 12 COMMUNICATIONS 13 3 2 13 WINFLEXCC DATA LOGGING 13 3 2 14 STAINLESS STEEL 13 3 2 15 ELECTRICAL CONTROLS 13 3 3 IMPORTANT INFORMATION 14 4 TECHNICAL DATA 15 4 1 NOMINAL FLOWRATES IN SERVICE 15 4...

Страница 3: ...ITOR 27 5 3 3 OPTION 27 PH CONTROLLER 27 5 4 PURIFIED WATER SYSTEM RO SECTION 28 5 4 1 RO FEED TANK TK30 01 28 5 4 2 RO FEED PUMP PU1 28 5 4 3 OPTION 40 SINGLE PASS REVERSE OSMOSIS 29 5 4 4 OPTION 42...

Страница 4: ...ATIOM 66 6 6 1 ALARMS 67 6 7 PROCESS STATUS TEXT 68 6 7 1 GENERAL 68 6 7 2 OPTION 10 SOFTENERS 69 6 7 3 OPTION 11 SOFTENERS TTS 70 6 8 ALARMS 71 6 8 1 FATAL 71 6 8 2 WARNINGS 72 6 8 3 ADDITIONAL OPTIO...

Страница 5: ...0 10000 Operators Page 5 of 95 Manual Part no DOMAON0100 Issue A April 2008 9 3 CALCULATING CEDI CURRENT 92 9 3 1 CURRENT CALCULATION 92 9 4 OPERATING LOG SHEETS 93 9 4 1 DAILY LOG SHEET 93 9 4 2 WEEK...

Страница 6: ...1 45 11 55 55 Fax 33 0 1 45 11 55 00 www veoliawaterst com ORION II Models 500 10000 Conform to the following EC Directives where required The Electromagnetic Compatibility Directive 2004 108 EC incl...

Страница 7: ...hed and the correct rated fuses should be fitted Power should be switched off at a remote isolator before commencing work on the equipment 2 3 EMERGENCY SHUTDOWN In an emergency the unit can be turned...

Страница 8: ...e gas outlet from the separator vented outside the building If a gas separator is not supplied the unit should be installed in a room provided with adequate ventilation see below 2 7 VENTILATION The u...

Страница 9: ...accordance with the instructions in this manual If there are any enquiries regarding the installation operation or servicing of the ORION unit contact Veolia Water Service Department 3 2 SYSTEM OVERVI...

Страница 10: ...articulate matter 11 Standard Softeners Hot Water Sanitisable SOF11 01 SOF11 02 Hot Water Sanitisable Base Exchange Softeners to prevent scaling of the RO membranes Used where the feed water contains...

Страница 11: ...control signal to the Sodium Hydroxide dosing set This reduces the amount of Carbon Dioxide and thereby ionic load in the feed to downstream deionisation equipment 3 2 4 Purified Water System RO Sect...

Страница 12: ...1 Diverter valve to divert water to the product water tank when required and recycle to TK30 01 when not The valve should be fitted as close as possible to the product water tank to minimise product w...

Страница 13: ...nd data logging via password system to provide an audit trail for 21 CFR Pt 11 Compliance 3 2 14 Stainless Steel N A Stainless Steel Pipe The various options can be supplied with Dairy or ASME BPE Pip...

Страница 14: ...n when necessary Corrected flux salt passage and CEDI performance is monitored on a regular basis and any abnormal trends acted upon when necessary If the required product water quality is not being a...

Страница 15: ...System recovery 4 1 1 Single Pass RO only MODEL 500 1000 2000 4000 6000 8000 10000 Feed I h 667 1333 2667 5333 8000 10667 13333 Product l h 500 1000 2000 4000 6000 8000 10000 RO Concentrate to Drain...

Страница 16: ...000 Feed I h 741 1481 2963 5925 8889 11852 14815 Permeate l h 556 1111 2222 4444 6667 8889 11111 RO Concentrate to Drain I h 185 370 741 1481 2222 2963 3704 RO Concentrate Recycle I h 1180 530 860 425...

Страница 17: ...0 4000 6000 8000 10000 Recovery 67 4 2 NOMINAL FLOWRATES PRODUCT WATER IN RECYCLE 4 2 1 Single Pass RO only MODEL 500 1000 2000 4000 6000 8000 10000 Feed I h 60 120 240 480 720 960 1200 Product in Rec...

Страница 18: ...trate Recycled l h 56 111 222 444 667 889 1111 Product in recycle I h 500 1000 2000 4000 6000 8000 10000 Recovery Not Applicable 4 2 4 RO CEDI UF CEDI Concentrate always Recycled when Product in Recyc...

Страница 19: ...00 3000 4 3 2 Twin Pass RO MODEL 500 1000 2000 4000 6000 8000 10000 RO Conc Recycle 45o C P1 I h 1000 1000 1000 2000 2000 3000 3000 RO Conc Recycle 45o C P1 I h 800 800 800 1600 1600 2400 2400 RO Conc...

Страница 20: ...nics colloids and suspended solids SDI 3 Feed water pressure 4 5 bar optimum 6 bar maximum Total hardness 500 ppm as CaCO3 10 ppm as CaCO3 feed to the RO 1 ppm as CaCO3 feed to the CEDI modules Free c...

Страница 21: ...according to Design Qualification Full Load Current also see Design Qualification 4 7 2 Compressed air Instrument grade 6 9bar 1Nm3 h 4 7 3 Degasser Sweep Gas Nm3 h 500 1000 2000 4000 6000 8000 10000...

Страница 22: ...ardness 300mg l 1 Total Hardness 300mg l 2 4 9 SALT SPECIFICATION Property Specification NaCl 99 9 Insoluble matter 100ppm Alkalinity as Na2CO3 150ppm Sulphate as Na2SO4 600ppm Calcium 50ppm Magnesium...

Страница 23: ...any further hardness from the feed water It then requires regeneration by passing a concentrated common salt Sodium Chloride solution through it to displace the hardness ions with Sodium ions before i...

Страница 24: ...that CarboSoft provides an excellent degree of protection from oxidative damage to the RO and CEDI modules should an unexpected quantity of chlorine appear in the feed water RO and CEDI modules on uni...

Страница 25: ...have been exchanged the resin is exhausted and cannot remove any further hardness from the feed water It then requires regeneration by passing a concentrated common salt Sodium Chloride solution throu...

Страница 26: ...ed quantity of chlorine appear in the feed water RO and CEDI modules on units supplied without CarboSoft softeners will not carry warranty against oxidative damage 5 1 6 Cartridge Filtration 5 m cartr...

Страница 27: ...etabisulphite to remove Chlorine from the feed water As the pump is controlled Proportional to Flow it can only be used with option 10 or 11 5 2 2 Option 21 pH Control This option consists of a Dosing...

Страница 28: ...emptied during cleaning and other operating cycles A purified water return connection to allow purified water to be recycled during periods of no usage An opening in the top of the tank normally seale...

Страница 29: ...final RO module passes a pressure sensor PT40 01 and is then split into two streams one is directed to drain and the other recirculated to TK30 01 The flow volumes are measured by FT40 01 and FT40 02...

Страница 30: ...asses through the shell side of the module and oil free filtered air instrument grade is passed down through the centre of the hollow fibres to strip carbon dioxide gas from the water Permeate from th...

Страница 31: ...er consult Veolia Water for assistance 5 5 3 Option 61 Gas Separator An optional gas separator GS61 01 can be fitted in the CEDI concentrate stream to separate the gases produced at the CEDI electrode...

Страница 32: ...rofiltration An optional post treatment Microfilter F72 01 stage can be specified for Orion units where additional bacteria control is required A sanitary sample valve V72 01 on the inlet of the unit...

Страница 33: ...ter deadleg 5 8 3 Option 92 Outlet Three 2 Way Valves VA92 01 VA92 02 VA92 03 are three 2 Way valves to divert water to two product water tanks when required and recycle to TK30 01 when not The valves...

Страница 34: ...sensors reaches 45 C the pump pressure is further reduced to 2 2bar to prevent compaction damage to the RO membranes When the system temperature as recorded by all three sensors exceeds 80 C a hold ti...

Страница 35: ...n which is displayed after every power cycle The System Menu screen is split into a number of sections namely Screens System Cleaning Routines System Configuration Commissioning Diagnostics Command Bu...

Страница 36: ...Items which have 2 digital inputs and 1 digital output e g 3 way outlet valve and optional 2 way valves are animated according to the following table Output Input Open Input Close Description 0 0 1 Gr...

Страница 37: ...presented a valid I Button onto the I Button reader located to the right of the HMI on the outside of the panel Four types of I Buttons are used namely Operator green key ring Supervisor red key ring...

Страница 38: ...ow the system has been configured the Softeners and CDI Stage buttons on the System Menu may have been disabled and hence these screens will not be accessible All graphical screens follow a common lay...

Страница 39: ...be accessed directly by means of the shortcut buttons Softener 1 Softener 2 Pump RO Stage CDI Stage Outlet This is a common feature available on all graphical screens Depending on how the system has b...

Страница 40: ...the system has been configured for a twin pass RO then the Overview screen will show the additional equipment associated with a twin pass RO as seen below The RO stage button has been replaced by sta...

Страница 41: ...Orion II 500 10000 Operators Page 41 of 95 Manual Part no DOMAON0100 Issue A April 2008 Depending on the system configuration the Softeners and CDI stage may be disabled and hence the overview screen...

Страница 42: ...DOMAON0100 Issue A April 2008 6 2 2 SOFTENERS The Softener screen is an overview of the Softener stage as shown below configured with one brine tank The status of each softener is clearly shown above...

Страница 43: ...If being controlled by a pressure then the target flow box is removed and a target pressure box is seen above the pressure bar readout Via the Pump Control Centre panel the pump may be put into manua...

Страница 44: ...f required The Salt Rejection and Corrected Flux values are animated The corrected flux trend may be accessed by means of pressing the graph symbol next to the animated value NOTE the Corrected Flux v...

Страница 45: ...OPERATORS MANUAL ORION II Orion II 500 10000 Operators Page 45 of 95 Manual Part no DOMAON0100 Issue A April 2008 If the system has been setup as a Twin Pass the RO screen will take the following form...

Страница 46: ...o the unit The Voltage and Current applied to the CDI stage can be monitored Also the control on off signal applied to the stacks power card can be enabled disabled via the enable disable buttons Duri...

Страница 47: ...100 Issue A April 2008 For a unit fitted with a UF as seen below the permeate is set higher to take into account the extra loss of the UF recycle after the CDI stage e g for a 2000 unit the Permeate w...

Страница 48: ...en below The Start HWS button allows the operator to manually start a HWS cycle providing the system is not in service The last time a HWS was started manually is recorded together will an incrementin...

Страница 49: ...f the outlet stage Depending on how the system has been configured this will either show 1 x 3 way valve 2 x 2 way valves or 3 x 2 way valves The screen below is an example of when the system is confi...

Страница 50: ...OPERATORS MANUAL ORION II Orion II 500 10000 Operators Page 50 of 95 Manual Part no DOMAON0100 Issue A April 2008 If 2 x 2 ways vales are fitted the outlet screen will take the following form...

Страница 51: ...OPERATORS MANUAL ORION II Orion II 500 10000 Operators Page 51 of 95 Manual Part no DOMAON0100 Issue A April 2008 If 3 x 2 ways vales are fitted the outlet screen will take the following form...

Страница 52: ...rogrammed with 3 cleaning routines namely RO Clean RO Sanitise CDI Clean These cleaning routine are only available if they are enabled from the System Configuration Options screen 6 3 1 RO CLEAN From...

Страница 53: ...ors Page 53 of 95 Manual Part no DOMAON0100 Issue A April 2008 6 3 2 RO SANITISE From this screen the RO Sanitise sequence can be started providing the system status is not in service Follow the Opera...

Страница 54: ...ators Page 54 of 95 Manual Part no DOMAON0100 Issue A April 2008 6 3 3 CDI CLEAN From this screen the CDI Clean sequence can be started providing the system status is not in service Follow the Operato...

Страница 55: ...mely Service HWS CIP Other Analogue Options Users 6 4 1 SERVICE The service screen is where all settings associated with the in service operation are maintained as seen below Depending on the system c...

Страница 56: ...ON II Orion II 500 10000 Operators Page 56 of 95 Manual Part no DOMAON0100 Issue A April 2008 PID VA40 Settings 6 4 2 HWS The HWS screen is where all settings associated with the HWS sequence are main...

Страница 57: ...NUAL ORION II Orion II 500 10000 Operators Page 57 of 95 Manual Part no DOMAON0100 Issue A April 2008 6 4 3 CIP The CIP screen is where all settings associated with the CIP sequences are maintained as...

Страница 58: ...nual Part no DOMAON0100 Issue A April 2008 6 4 4 OTHER The Other screen is where all other setting and maintained as seen below The time data can only be adjusted with Administrator access level Howev...

Страница 59: ...of 95 Manual Part no DOMAON0100 Issue A April 2008 If the printer is set to Connected then an additional printer icon is seen at the top of every screen next to the model size as seen below This allow...

Страница 60: ...ALOGUE The Analogue screen is where all the 20mA setting for each channel are set as seen below These are set setup as parts of the modes size and should not every need to be adjusted The analogue Raw...

Страница 61: ...of 95 Manual Part no DOMAON0100 Issue A April 2008 6 4 6 OPTIONS The Options screen is where the main system configuration is performed as seen below These setting can only be modified with Engineer...

Страница 62: ...Operators Page 62 of 95 Manual Part no DOMAON0100 Issue A April 2008 6 4 7 USERS The Users screen is where users and their associated passwords are maintained as seen below This screen is only provide...

Страница 63: ...eens which are needed but not on a regular basis namely Force IO Control Panel Clean Screen Terminate Application Training Mode Event Log 6 5 1 FORCE I O The Force IO screen allows you to monitor digi...

Страница 64: ...ATION APPLICATION The terminate application button terminates the graphical interface program and returns to the windows desktop Engineer access level is required to perform this function 6 5 5 TRAINI...

Страница 65: ...nual Part no DOMAON0100 Issue A April 2008 6 5 6 EVENT LOG The Event Log is a historical log of system events as seen below This event log is stored in volatile memory so is lost when the power is rem...

Страница 66: ...on the CIP screens While the unit is running the Product Flow and units Recovery are calculated and displayed The product flow is calculated as follows Permeate Flow CDI Concentrate Inlet flow systems...

Страница 67: ...alarms as seen below New alarms just raised have status C for current Operate the Alarm Reset button If the alarm condition has gone away the status will change to D for de activated De activated ala...

Страница 68: ...Service Feeding The Process 9 In Service Divert to Recirculating 10 In Service Shutdown 11 In Service Standby 101 HWS Start 102 HWS Open Tank Inlet 103 HWS Waiting for Low Level 104 HWS Heat Stage 1 W...

Страница 69: ...307 CIP3 Drain Tank 308 CIP3 Refill Tank 309 CIP3 Rinse 310 CIP3 Rinse Complete 311 CIP3 Disconnect Hose etc 312 CIP3 Shutdown 6 7 2 Option 10 Softeners Step Softener 1 Softener 2 0 In Service In Serv...

Страница 70: ...e Draw In Service 6 Brine Draw In Service 7 Move to Fast Rinse In Service 8 Fast Rinse In Service 9 Move to Tank Refill In Service 10 Brine Tank Refill In Service 11 Move to Service In Service 12 In S...

Страница 71: ...igh The feed conductivity is above is fatal setting Fatal Tank Low Level The feed tank has gone low more times than is allowed during a 24 hour period Fatal PU30 01 Pump Not Started The pump has been...

Страница 72: ...tage if the tank temperate goes above a configuration set point this alarm warning is raised and the pump control becomes cyclic Warning CIP Periodic Pump Control Initiated As above Warning Degasser A...

Страница 73: ...The final conductivity reading is above the configurable set point If the unit was feeding the process the feed is diverted to recycle Warning Poor Final Temperature The final temperature reading is a...

Страница 74: ...CS03 Out of Range See above Warning Analogue Input FT1002 Out of Range See above Warning Analogue Input FT4001 Out of Range See above Warning Analogue Input FT4002 Out of Range See above Warning Anal...

Страница 75: ...not come on Warning Softener 1 Service Position Lost While the softeners is in service the service position has been lost Warning Softener 2 Service Position Lost While the softeners is in service th...

Страница 76: ...d Key and above Softeners Stage Advance Supervisor Red Key and above HWS Stage Advance Supervisor Red Key and above Pump Control Supervisor Red Key and above RO Control Supervisor Red Key and above CD...

Страница 77: ...Manual Part no DOMAON0100 Issue A April 2008 If an engineer key is used which has expired the following message will be seen I Buttons can be checked for their type and expired date by means of the I...

Страница 78: ...stalled and commissioned Switch on compressed air supply to the system and regulate to 6 bar using the regulator inside the right hand side control cabinet Switch on feedwater supply to the unit A min...

Страница 79: ...CY SHUTDOWN In an emergency TURN THE UNIT OFF AT THE DOOR INTERLOCK ISOLATOR IMPORTANT IF THE UNIT IS TO BE SHUT DOWN FOR MORE THAN ONE WEEK THEN IT SHOULD BE HOT WATER SANITISED AND ALL THE ISOLATING...

Страница 80: ...ilable electronically from Veolia Water and should be tailored to specific customer requirements The content of the log sheets also depends on what optional equipment if any is included Monitoring the...

Страница 81: ...s Free Cl2 Iron and SDI V12 09 V13 09 Filter Outlet Used to check Hardness Free Cl2 Iron and SDI V45 01 RO Permeate Bacteria sample point and Endotoxin on UF units V70 01 UV Inlet Bacteria sample poin...

Страница 82: ...d 1 Remove Luer cap 2 Open valve and allow full flow out of the valve for 2 minutes 3 Do not touch valve as this can dislodge contaminants from the internal components 4 Open sterile container and pla...

Страница 83: ...following chemicals are recommended for use with ORION systems Solution A Acid Cleaning Solution Properly operated RO systems should not require acid cleaning Precipitation can however occur when the...

Страница 84: ...sures that any temporary transient low flux values are ignored by the system The calculation will automatically be suspended with the last value being displayed when the unit is not in Service The cal...

Страница 85: ...ervisor level security access as these operations will interrupt the supply of product water The procedure is initiated from the RO Clean screen on the HMI All instructions for operation of the CIP se...

Страница 86: ...tivity AIC45 01 should have approached normal service values Check TK30 01 contents to ensure that no visible traces of the cleaning solution remain e g foam coloured water The tank drain valve V30 02...

Страница 87: ...ermine when the unit has been sufficiently rinsed to be put back into production The Acknowledge Action Performed button can be used to step though timed stages Pressure flow rate and temperature limi...

Страница 88: ...f the total input water that is converted to purified water or permeate A recovery of 10 means that only 1 part in ten of the input water is converted to permeate At 50 recovery half of the input wate...

Страница 89: ...ds alkalis and gasses particularly carbon dioxide are poorly rejected A rejection rate of 99 means that that only 1 of the impurities will pass through the membrane A 99 rejection membrane would there...

Страница 90: ...es between the membranes are configured to create liquid flow compartments with inlets and outlets The compartments bound by the anion membrane facing the anode and the cation membrane facing the cath...

Страница 91: ...ions through the cation membranes and captured anions through the anion membranes 4 Cation permeable membranes transport cations such as sodium Na ions out of the diluting compartment but prevent anio...

Страница 92: ...ermine the current setting amps follow these steps I Flow FCE K Where I Current amps Flow Product Flow m3 h FCE Feed Conductivity Equivalent Measured Conductivity S cm CO2 ppm x 2 66 K Constant 0 0924...

Страница 93: ...e A April 2008 9 4 OPERATING LOG SHEETS Examples of a log sheets are shown overleaf however these will vary according to the options chosen The log sheets are available from Veolia Water in soft copy...

Страница 94: ...03 Cartridge Filter Outlet Pressure Bar PI2 PI3 Cartridge Filter Pressure Drop Bar PT30 01 Pump Outlet Pressure Bar PT40 01 RO Concentrate Pressure Bar PI45 01 RO Permeate Pressure Bar PI60 01 CEDI C...

Страница 95: ...ivity S cm Feed Water SDI None V10 11 Softened Water Hardness mg l Softened Water Free Chlorine mg l Softened Water SDI None Softened Water Iron mg l 9 4 3 Microbiology ORION MICROBIOLOGY LOG SHEET Si...

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