Testing and Commissioning Procedure for Integrapac™ Ultrafiltration IP-77XP Modules This

Technical manual provides information for commissioning a system using Integrapac™

Ultrafiltration IP-77XP modules. This applies to both conventional Integrapac Ultrafiltration IP-
77XP Module as well as Integrapac™ Ultrafiltration IP-77XP skids.

TABLE OF CONTENTS

1. INTRODUCTION ................................................................................................................................ 2
2. PRE-COMMISSIONING ACTIVITIES ............................................................................................. 2
3. PHASE 1 - FLUSHING AND TESTING THE SYSTEM ............................................................... 4
3.1. Cleaning and Disinfection...................................................................................................... 4
3.2. Testing the automation of the rack ..................................................................................... 5
4. PHASE 2 – INSTALLATION AND TESTING WITH MODULES ............................................... 6
4.1. Analysis of the feed water ..................................................................................................... 6
4.2. Receipt and Installation of Modules.................................................................................... 6
4.3. Membrane Integrity Testing (MIT) ........................................................................................ 6
4.4. Preserving the modules and/or system ............................................................................. 6
4.4.1. Clean Water Flux Profile Test ....................................................................................... 7
5. PRECAUTIONS ................................................................................................................................. 7

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1. INTRODUCTION

The goal of this document is to outline the general procedures for testing and commissioning
Integrapac™ Ultrafiltration IP-77XP Module and skids. The document should provide
sufficient information to aid in the planning and sequencing of the testing and commissioning
process. For specific projects, an independent check must be carried out as to its suitability.
It specifies the various implementation procedures including installing, cleaning, and testing
the system. A typical P&ID of an Integrapac™ Ultrafiltration IP-77XP Module and Skids
system can be provided upon request as a guideline for system configuration and for
determining the recommended amount of equipment and instruments needed for a fully
automated Integrapac™ Ultrafiltration IP-77XP Module and Skid system. The details of
construction, equipment manufacturers, model numbers, and site specific drawings are to be
provided by the System Supplier.
The procedures discussed within this document are to be read in conjunction with the System
Supplier commissioning procedures. Construction completion activities must be verified as
complete before commissioning can start. Commissioning is carried out by functionally testing
each main process component of the Integrapac™ Ultrafiltration IP-77XP Module and Skid
plant offline. This document is design to be included in the overall testing and commissioning
plan for the plant.

2. PRE-COMMISSIONING ACTIVITIES

Immediately following the construction activities, the following items must be check prior to
commissioning:

 Tanks: Construction (i.e. installing connections, tapping, installing tank vents, or any
other related activity) should be completed to all tanks involved in the membrane
system including, but not limited to:
o Feed Tank
o Filtrate Tank
o CIP (Clean in Place) Tank
o CEB (Chemically Enhance Backwash) Tank
A visual inspection for internal cleanliness must be made to all the tanks listed above.

 Power and Electrical Components: Test all pumps, electrical connections, inputs and
outputs of each instrument, level switches, and motor rotation to ensure proper
installation and functionality. This check must be done prior to introducing water into
the system.
 Other Equipment and Instrumentation: Pressure transmitters, flow meters, pumps,
valves, and all measuring devices must be installed. Some systems may require a
ventilation or air conditioning system to keep instrumentation cool.

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 o With the skids full of water, check timing of valves to both open and close for
all automatic valves. Valves should be optimized to prevent water hammer
and pressure spikes, and to avoid loss of production time while valves open
and close. Each valve should be checked to ensure that they are properly
fastened.
o All instrumentation used for analysis must be calibrated and ranges set.
Instrumentation and equipment test sheets should be completed and validated
by a representative of the System Supplier.
o All flow control valves should be throttled a minimum of 3 times to ensure
reproducibility of the flow set point.
 Sequences of each operating mode (Filtration, Air Scour, Drain, Top Backwash,
Bottom Backwash ,Forward Flush and, Membrane Integrity Test) must be checked
before commissioning and introducing water.
 Alarms modes need to be verified.
 All pipework, couplings, fittings, and other connections must be both visually checked
and leak tested to ensure there are no loose components or leakages.
 All Chemically, CEB (Chemically Enhance Backwash), CIP (Clean in Place), and other
dosing systems should be ready for use, as applicable to the specific system design.
 All piping such as the feed, filtrate, air scour, air integrity, CEB and CIP must be
checked and compared to the P&ID of the system / plant.
 The air scour compressor should be ready for use.
o A pressure regulator should be installed to prevent the air supplied for scouring
from exceeding 1.5 bar (~22 psi).
o A safety release valve should be installed to prevent the air being supplied to
the module from ever exceeding 5 bar.
 The compressed air system should be ready for use.
o A minimum pressure of 6 bar (87 psi) is recommended for valve actuation;
however, this pressure should be confirmed with the selected valve
manufacturers requirements.
o The compressed air supply should be checked.
o Hydranautics recommends the receiver be equipped with a low and high
pressure detector. When the pressure in the air receiver is less than 6 bar (87
psi), the compressor should be started automatically until the pressure reaches
8 bar (145 psi). Care should be taken to avoid exceeding 10 bar (145 psi).
o Ensure that the air is oil free.
o The air pressure relief valve for the air integrity line must be calibrated at 1.4
bar (20 psi).
o The pressure regulator for the air integrity line needs to be adjusted to be 1.4
bar (20 psi) max.
o To avoid overpressurizing the module, a safety release valve should be
installed to prevent the air pressure from ever exceeding 5 bar.
All construction should be completed prior to delivering and installing the modules to prevent
foreign matter (i.e. debris, dust, shavings, etc.) from entering the modules. If there is a pre-

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 treatment system prior to the Integrapac™ Ultrafiltration IP-77X Modules and Skid system, it
must be commissioned and optimized before the membrane system is commissioned in order
to ensure that the expected feed water quality is provided to the modules.

3. PHASE 1 - FLUSHING AND TESTING THE SYSTEM

It is important to clear all lines of any particulates that may enter into the module and cause
fiber damage. To do so, flush all the piping system without connecting into the Integrapac™
Ultrafiltration IP-77X Modules and Skid system. And open feed/concentrate/filtrate/drain
headers valve. Flushing the system prior to installation of the modules is critical for several
reasons:

 To clear tanks and lines of debris and particulates that can get trapped into the module
and cause fiber damage.
 To check the performance of the pumps before start up.
 To check seals of valves, flanges, and various other connections and components.
 To check the automation and sequences of the different modes of operation without
the risk of damaging the membranes as a result of programming error or mechanical
failure of equipment.
 To disinfect the system with the addition of a Chemically to the feed, if needed.

3.1. Cleaning and Disinfection

Ensure that the tanks are empty by cleaning the inside thoroughly and removing any large
items. Make sure to rinse and fill the feed tanks with clean water (i.e. potable or city water).
This will then be used to flush the pipes and common headers. Rinse/flush the system for
approximately 30 minutes at a feed piping velocity of 2.5 – 3.0 m/s (8.2 – 9.8 ft/s) to remove
any debris trapped in the Integrapac™ Ultrafiltration IP-77XP Module and Skid system.
For disinfection, a 10 ppm chlorine solution rinse can be performed (minimum contact time of
six hours, but 24 hours is recommended). This disinfection is intended to eliminate any
bacteria that may have formed after installation of the racks. It is best for this solution to be
prepared in both the feed tank and filtrate/RC tank. It is recommended to initially flush the
system from the feed side using the feed tank and then again from the filtrate side with the
filtrate/Back wash tank. The solution will need to travel through all the piping, connections,
and headers within the system. Once the soaking

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3.2. Testing the automation of the skid

Testing the automation with Integrapac™ Ultrafiltration IP-77X Modules and Skid system
verifies that correct valves and pumps begin when called upon by the operator or program. It
is important to also check pump speeds, air flow rates, dosing pump rates, etc. at this time.
The opening and closing of valves will need to be physically verified for every sequence.
Before beginning any tests, timers and setpoints need to be set in the PLC. They are specific
to the tests done with the dummy modules. Please contact Hydranautics to determine these
values where necessary. The following sequences should be tested:

 Filtration
o Feed pump settings
o Valve positions
o Flow and flow transmitter values
o Pressure and pressure transmitter values

 Filtration with concentrate (if applicable)

 Air scour
o Compressor settings
o Feed pump settings
o Valve positions
o Flow and flow transmitter values
o Pressure and pressure transmitter values
 Maintenance clean with Normal Backwash
o Cleaning/Backwash pump settings
o Valve positions
 Recovery clean with CEB( Chemically Enhance Backwash)
o Dosing pumps injection settings
o Cleaning/Backwash pump settings
o Valve positions
 Recovery clean with CIP(Clean In Place)
o Cleaning/CIP pump settings
o Valve positions
 Membrane Integrity Test
o Valves positions
o Pressure and pressure transmitter values

NOTE: It is important to ensure that valves are opened prior to starting any pump and
pumps are stopped prior to closing any valves. Also, pressurization rates during any
sequence should be slowly ramped up and down at a rate of no more than 0.25 bar/sec
(3.6 psi/sec).

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 Once the sequences above have been checked and optimized, the sequencing cycles
should be tested. Check the recommended number of filtration and air scour cycles prior
to conducting a Normal Maintenance Cleaning are correct. Any failure should be noted
and addressed immediately.

The following readings should be noted when testing the feed pump: pressure at the
discharge of the feed pump by reading the pressure transmitter value and flow rate given
by the filtrate flow transmitter.

4. PHASE 2 – INSTALLATION AND TESTING WITH MODULES

4.1. Analysis of the feed water

Preliminary samples will be taken to check the following parameters to see if they are in line
with the expected values: temperature, turbidity, total suspended solids, COD, BOD, TOC,
iron, manganese, aluminum, hardness, alkalinity, and PH.
4.2. Receipt and Installation of Modules

To control bacterial growth and prevent damage caused by fibers drying out, the DuPont
Ultrafiltration IntegraPac™ modules are wetted and stored in a non-hazardous standard
storage solution containing pH buffered food-grade 1% wt. sodium metabisulfite (SMBS). At
the end of the manufacturing process, storage solution is automatically injected into the
modules and all inlet and outlet ports are sealed using plastic discs, couplings, and threaded
plugs. The modules are sealed in a plastic bag prior to boxing. Skid components (underframe,
air scour piping, filtrate piping) are shipped in a separate boxes or crates. As part of the quality
assurance program, all IntegraPac™ modules are tested for integrity and performance (“wet
tested”) at the factory, prior to packaging and shipment.
After completion of system testing, install modules according to NSF/ANSI 61 and 419
certified drinking water modules require specific conditioning procedures prior to producing
potable water.

4.3. Membrane Integrity Testing (MIT)

After installing the modules, perform a MIT according to DOW recommended procedure.
4.4. Preserving the modules and/or system
If necessary, skids and/or modules may be stored by following DOW recommended
procedure.

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 4.4.1. Clean Water Flux Profile Test
Test:
1. Supply clean tap water to the Integrapac™ Ultrafiltration IP-77XPand HYDRAcube system.
This can be done by filling a feed tank or making the the proper connections for lines/piping.
2. For new or “long-term” stored membranes, flush the modules with the clean water to remove
the preservatives. The modules should be flushed at a flux rate of 60 LMH (35 GFD) for 30
min to drain. For systems that cannot supply the recommended flux rate above, longer
flushings may be required. The modules will need be flushed for 10 mins from feed to
concentrate, 10 mins from feed to filtrate + concentrate, and the last 10 mins from feed to
filtrate.
3. Once the modules have been flushed, it is time to begin the clean water flux profile test.
Each skid should be individually tested. Run filtration cycles with the clean water at 25%, 50%,
75%, and 100% of the design flow rate. Record the feed pressure, filtrate pressure, trans-
membrane pressure (TMP), filtrate flow, and water temperature during each filtration cycle. It
is recommended to take at least four readings at various flow rates, but more can be
conducted if desired.
NOTE: The filtrate may also be sent at this time to the Filtrate tank to check the water
quality.
4. After completion of the clean water flux profile test, data logging, normalization, and
performance analysis should be performed according to DOW recommended standards and
to be recorded.

5. PRECAUTIONS

In addition to other precautions given in the “notes” throughout the document, please
consider the following as well when operating an Integrapac™ Ultrafiltration IP-77XP skid
system:
1. Do not use silicone grease for lubrication in areas where it may remain internally within
the pipework, as the grease can irreversibly foul the membranes.
2. The maximum applied pressure rating for an Integrapac Ultrafiltration™ IP-77XP module
is 6 bar (87 psig) at 25°C (77°F).
3. The maximum transmembrane pressure (TMP) is 2.1 bar (30.5 psig).
4. The maximum instantaneous feed turbidity is 300 NTU.
5. The maximum instantaneous chlorine exposure is 5000 ppm.
6. The operating pH range is 4 – 10, while the cleaning pH range is 1 – 12

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 7. The maximum temperature rating of a Integrapac™ Ultrafiltration IP-77XPmodule is 40°C
(104°F). To avoid thermal shock, temperature increases should be limited to a rate of
change of 1°C per minute.
8. Emulsified oil and grease should be < 2 ppm in the feed, free oil and grease must be <
0.1 ppm.
9. Avoid handling and rotating the feed end adapter whenever possible.
10.A ≤120 µm screen filter is required directly ahead of the Integrapa™c Ultrafiltration IP-
77XP module(s) regardless of pretreatment for seawater applications; a ≤500 µm screen
filter is required directly upstream of the modules for other applications.

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