TABLE OF CONTENTS SYSTEM DESCRIPTION SPECIFICATIONS 1.1.1 PERFORMANCE CHARACTERISTICS 1.1.2 PHYSICAL CHARACTERISTICS 1.1.3 UTILITY REQUIREMENTS 1.1.4 ENVIRONMENTAL REQUIREMENTS EQUIPMENT REQUIRED FOR OPERATION 1.2.1 CONSUMABLES 1.2.2 TEST EQUIPMENT PREPARATION FOR USE, INSTALLATION AND INITIAL ADJUSTMENT UNPACKING AND HANDLING LOCATION GENERAL THEORY OF OPERATION REVERSE OSMOSIS THEORY APPLICATION OF REVERSE OSMOSIS PRODUCT WATER QUALITY STANDARDS...
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OPERATION START-UP PROCEDURE SHUTDOWN PROCEDURES 4.2.1 SHUTDOWN PROCEDURE (SHORT TERM) 4.2.2 SHUTDOWN PROCEDURE (EXTENDED) FRESH WATER FLUSH PROCEDURE MAINTENANCE INSTRUCTIONS GENERAL RAW WATER STRAINER INSPECTION FILTER ELEMENT CLEANING OR REPLACEMENT DRIVE BELT INSPECTION AND REPLACEMENT RO MEMBRANE CLEANING 5.5.1 CLEANING CHEMICALS 5.5.2 WHEN TO CLEAN RO ELEMENT PRESERVATION...
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LIST OF FIGURES Figure 2.0 - Recommended Installation (Below Water Line) ..........5 Figure 2.1 - Proper Installation (Above Water Line) ............6 Figure 3.0 - Simple (Reverse) Osmotic System ............... 9 Figure 3.1 - Simplified Schematic of an RO System............10 Figure 5.0 - Maintenance Task Chart ................
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The following are the types of flags used in this technical manual. They designate safety related items and important operational instructions and should be given special attention when they appear in the text: Text formatted in this manner concerns an operating procedure or practice WARNING that, if not strictly observed, can result in injury to personnel or loss of life.
SYSTEM DESCRIPTION The Village Marine Tec. (VMT) Seawater Desalinator is a single-pass purification system that uses reverse osmosis (RO) as its method of seawater desalination. This unit produces potable (drinking) quality water with salt concentrations of < 500 ppm by removing approximately 99% of the dissolved salt in seawater.
PREPARATION FOR USE, INSTALLATION AND INITIAL ADJUSTMENT UNPACKING AND HANDLING Remove unit from shipping crate and inspect for shipping damage. CAUTION Do not allow unit or any components to be exposed to freezing temperatures. If it is anticipated that the unit may be exposed to freezing temperature, please contact VMT in advance for technical assistance.
If it is not possible to mount the watermaker below the water line, the boost pump can lift to a maximum height of 15 feet (5 feet for 50 Hz units) above the water line with the boost pump removed from the frame and installed below the RO frame near the through hull.
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Inlet and discharge interconnecting lines should be constructed of a NON- FERROUS material. Examples of some suitable materials are PVC, copper-nickel, 316 stainless steel pipe or a reinforced non-collapsing hose. Ferrous piping produces rust that will irreversibly foul the membrane and void the RO unit warranty. NOTE Avoid connecting the inlet piping to any water line that services any other piece of equipment.
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Strictly observe all applicable electrical codes and regulations governing the installation and wiring of electrical equipment. Typical codes specify the type and size of conduit, wire diameter and class of wire insulation depending upon the amperage and environment. The power supply should always be of a greater service rating than the requirements of the RO unit.
GENERAL THEORY OF OPERATION REVERSE OSMOSIS THEORY Reverse osmosis, like many other practical scientific methods, has been developed from processes first observed in nature. Osmosis is a naturally occurring phenomenon in which a semi-permeable membrane separates a pure and a concentrated solution (a semi-permeable membrane is defined as one that preferentially passes a particular substance).
APPLICATION OF REVERSE OSMOSIS Seawater contains many kinds of solids dissolved in solution. The most prevalent is common table salt (sodium chloride). Other minerals that may be present in solution are substances that usually contain various compounds of calcium and sulfate. The sum of all of the solids dissolved in a particular sample of water is referred to as Total Dissolved Solids or TDS.
It should be noted that no system is capable of removing all of the dissolved solids from seawater. The system is actually designed to reject approximately 99% of the TDS or, in other words, to allow 1% of the 35,000 ppm TDS in the seawater to pass into the product water.
Permeate With constant..And increasing..Capacity Salinity and Pressure Temperature Increases Increases Temperature and Pressure Salinity Increases Decreases Temperature and Salinity Pressure Decreases Increases Table 3.1 - Factors Affecting Permeate Quality NOTE If feedwater salt concentration decreases, the product water flow rate should not be allowed to increase more than 20% above rated flow.
Example: Raw water temp: 15°C TCF: 1.47 Actual product flow: 113.5 (gph) Calculation: 113.5 x 1.47 = 167 (gph) Temperature Corrected flow: 167 (gph) (167 gph is the normal flow for a PW4000) °C Factor °C Factor °F Factor °F Factor 3.64 0.97...
OPERATIONAL DESCRIPTION 3.5.1 FILTRATION SYSTEM Seawater supplied to the intake of the Village Marine RO desalination unit will initially flow through the raw water strainer, ST1, which removes large particulate matter. Once through the strainer, the raw water is supplied to the low pressure boost pump, P1, which raises the pressure of the water in order to provide enough positive feed pressure to flow through the filtration system and into the suction of the high pressure pump.
then flows directly into the membrane array. The membrane array is an arrangement of fiberglass pressure vessels each containing a RO membrane element. The pressurized feedwater flows along the membrane elements where reverse osmosis takes place (see Section 3.1). The feedwater flow is divided into two streams - the high purity product stream (referred to as the permeate) and the increasingly concentrated reject stream (referred to as the brine or reject).
WATER QUALITY MONITOR The Water Quality Monitor (MON) monitors and displays permeate salinity, temperature and accumulated unit operating hours. It also provides operational mode control of the system product valve. 3.6.1 PUSHBUTTONS Temperature – allows the operator to display permeate temperature (as opposed to the normal permeate salinity display).
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Reject Water Flow Indicates the amount of reject water discharged Meter from the RO unit. Product Water Flow Indicates the amount of permeate produced by Meter the RO unit. Water Quality Monitor See Section 3.6 for detailed description. LP Pump Magnetic Provides ON/OFF control of LP pump.
HP Regulating Valve Maintains and controls system back pressure. Allows operator to bypass the HP Regulating HP Bypass Valve Valve during start-up, shutdown and cleaning. Used to re-circulate the brine during cleaning Cleaning Valve and preservation procedures. Based on its salinity, directs permeate to either Product Diversion Valve the potable water tank(s) or to drain.
OPERATION START-UP PROCEDURE NOTE The HP Pump should rotate in the counter-clockwise direction (when facing the protruding end of the shaft). Check the HP pump oil level by observing sight gauge located on the pump. On initial start up, check the drive belt tension by removing the belt guard. See Section 5.4 for detailed procedure.
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CAUTION Failure to open the High Pressure Bypass Valve (which is required to bleed any entrapped air) can result in hydraulic shock to the system. Verify electrical power is supplied to the RO unit. CAUTION The low pressure (LP) boost pump should not be started if the feed system pressure as read on the inlet side of the Pre-filter Pressure gauge is more than 40 psi.
WARNING Pressure, as indicated on the inlet side of the RO Membrane Array gauge, should never exceed 1000 psi. NOTE The system pressure required to produce equivalent amounts of permeate is lower for fresh water sources (approximately 200 psi) and brackish water sources (approximately 400 psi) than for seawater applications.
If required, secure the LP boost pump by pressing the red LP PUMP STOP button located on the front panel. Secure the feedwater system by closing a feedwater valve upstream of the water maker or by turning the Flush Valve, V10, to the midway position. If the anticipated shutdown period will be 24 hours or more, flush the system as per Section 4.3 - Flushing Procedure.
Once you have observed fresh water flow through Reject Flow meter, run the system for an additional 2 to 4 minutes. For greater flushing flow, start the HP pump as well. Secure the pumps. Return the Flush Valve, V10, to midway position, isolating the watermaker.
RAW WATER STRAINER INSPECTION Isolate the raw water supply and open the strainer housing. Remove the screen from the strainer bowl. Remove any debris from screen and inspect the screen closely for damage. Replace as required. Check the sealing gasket or o-ring is in good condition, and keeping the seal in place install the screen and reclose the strainer housing hand tight.
The filter element may be cleaned by flushing it with water to remove foreign matter from the filter pleats. If the filter element appears oil-fouled or is damaged in any way, discard it and install a new element. Reinstall the filter element. Be sure to install the filter element with the end marked "TOP"...
Check the drive belt tension. Adjust the base plate as required to obtain proper belt tension. Be sure to properly align the pump and motor pulleys using a straight edge (at a minimum). After the belt has been sufficiently tightened and aligned, secure the HP pump by tightening the pump mounting nuts.
The use of chemicals or cleaning methods other than those outlined below will void the RO unit warranty. Non-ionic surfactants for membrane cleaning or other chemicals not approved in writing by VMT will void the RO unit warranty. 5.5.2 WHEN TO CLEAN During normal operations, mineral scale and biological matter will foul the RO membranes.
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complete the dedicated cleaning filter can be cleaned and set aside until the next membrane cleaning is required. Pour the chemical solution into the empty 20 micron filter housing and the 5 micron housing (drain water first as necessary) and reinstall the filter housing lids. Start the LP boost pump.
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Place the Cleaning Valve, V5, in the Cleaning Flow position. Remove the lid from the 20 micron filter tank, pour the cleaning solution into the tank (drain water first as necessary) and replace the lid. Start the LP boost pump. Start the HP pump.
RO ELEMENT PRESERVATION / PICKLING During periods when the RO unit is to be shut down for an extended period of time, it is necessary to circulate a preservative solution through the membranes to prevent the growth of biological organisms. Use the following procedure to preserve the RO elements: Secure the raw water supply to RO unit (external to the unit).
RESTARTING UNIT AFTER PRESERVATION Restart unit using the procedure contained in Section 4.1 - Start-up Procedure. Use the MODE button on the Water Quality Monitor to light the DUMP lamp for the first 15 minutes of production to make sure all preservative is flushed clear prior to filling the fresh water tanks.
PRESSURE VESSEL AND MEMBRANES PRESSURE VESSEL DISASSEMBLY NOTE It is not necessary to remove a pressure vessel from the RO unit for disassembly. Disconnect all plumbing connections from the pressure vessel to be disassembled. Remove the bolts holding each end plug in place with an Allen wrench. Place a mark on each end plug removed and its corresponding collar.
Figure 6.1 - Brine Seal Orientation Note which end of the pressure vessel the brine seal is visible from. This is the feed end of the pressure vessel. When reinstalling the RO membrane, the brine seal must be located at the feed end of the pressure vessel. Note the feed flow direction marked by a sticker on the outside of the pressure vessel, or trace the flow direction from the high pressure pump to confirm the high pressure flow direction.
PRESSURE VESSEL ASSEMBLY Clean all parts thoroughly. Inspect the o-rings on all fittings. Replace any parts that are damaged. NOTE Do not apply Teflon tape or other sealant to straight thread fittings such as those used on HP hose assemblies and their adapters. Install the product water and end plug o-rings onto the end plugs.
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resistance is felt. Continue to apply moderate pressure until the product water tube seats in the end plug. Install the remaining end plug making sure to align the end plug holes with the mounting holes on the pressure vessel while paying particular attention to the reference mark (see Section 6.3.1, Step 2).
PRESERVATION FOR STORAGE When the Village Marine Tec RO unit is to be shut down for an extended period of time, it is necessary take steps to prevent the growth of biological organisms and to prevent the water in the RO unit from freezing. Either continue to flush the unit with fresh water each week, or circulate a preservative solution (see section 5.6).
INTRODUCTION Aqua Pro Pumps “Titan Series” High Pressure Pumps are the product of our years of experience in the water treatment industry, and have been specifically designed and engineered for corrosive and high-pressure applications. Your new Aqua Pro Pump is made with dependable and proven technology to meet your highest demands. SPECIFICATIONS Specifications subject to change without notice.
5P50 Titan Series High Pressure Titanium Positive Displacement Pump INITIAL START-UP INFORMATION WARNING This is a positive displacement pump. A properly designed pressure relief safety valve must be installed in the discharge piping. Failure to install such a relief mechanism could result in personal injury or damage to the pump or system. Aqua Pro Pumps does not assume any liability or responsibility for the operation of a customer’s high-pressure system.
CAUTION DO NOT RUN PUMP WITH FROZEN FLUID. DO NOT RUN PUMP DRY. STORAGE For extended storage or between uses in cold climates, drain all pumped fluids from pump and flush with antifreeze solution to prevent freezing and damage to the pump.
5P50 Titan Series High Pressure Titanium Positive Displacement Pump PREVENTIVE MAINTENANCE SCHEDULE The Required Maintenance Schedule specifies how often you should have your pump inspected and serviced. It is essential that your pump be serviced as scheduled to retain its high level of safety, dependability, and performance. Not performing these tasks could result in catastrophic failure.
MAINTENANCE RECORD Keep record of all maintenance activities to ensure maintenance is performed. Note trends and increase maintenance as necessary. RECOMMEND ACTUAL HOURS ACTIONS / NOTES SIGNATURE DATE SERVICE HOURS 1050 1550 Valve Inspection, Oil 2050 2550 Valve Inspection, Oil 3050 3550 4050...
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5P50 Titan Series High Pressure Titanium Positive Displacement Pump TROUBLESHOOTING Use the troubleshooting table below. If problems persist, contact your dealer. PROBLEM PROBABLE CAUSE SOLUTION Low Pressure Belt Slippage Make sure the correct belt is used. If the correct belt is used and the belt is slipping, then tighten.
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PROBLEM PROBABLE CAUSE SOLUTION Oil leaking from crankshaft Worn crankshaft oil seal Replace damaged oil seals. area Bad bearing Replace bearing. Cut or worn o-ring on bearing Replace o-ring on bearing cap. Water in crankcase Humid air condensing into water Change oil every three months or 500 hours inside the crankcase Excessive play in the end of...
5P50 Titan Series High Pressure Titanium Positive Displacement Pump SERVICE CAUTION Ensure pump is disconnected from the motor or any driving devices. Service the pump in a clean, dirt-free environment. Pump rebuild kits are available for valve or seal overhauls. Contact your dealer for ordering information. INTRODUCTION All tasks should be performed in a clean environment, free from dust and debris.
VALVE INSPECTION AND SERVICE Valves may be serviced while the manifold assembly is attached to the crankcase assembly. In most cases, service can be completed while the pump is in place within the watermaker system. Remove ten valve plugs (44) from the manifold using a 1 ½“ socket wrench. Remove the valves (41) and springs (42) from each valve port.
5P50 Titan Series High Pressure Titanium Positive Displacement Pump SEAL REPLACEMENT If condition based seal service is required (Seal Kit PN 70-3080), use the following instructions outlined in the OIL SEAL REPLACEMENT section. To determine the need of condition based service, look for signs of oil or water drip under the pump.
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NOTE Examine the ceramic plungers (27), Fig. 6, for cracks, heavy scoring, or unusual wear. Slide ceramic plungers (27) onto plunger rod, and insert the new plunger retainer washer (31) into the plunger. Clean the plunger retaining nuts (32), Fig. 5. With the aid of a pick remove the plunger retainer back-up ring (29) and the plunger retainer o-ring (30).
5P50 Titan Series High Pressure Titanium Positive Displacement Pump BEARING CAP O-RING/SEAL REPLACEMENT You will need these tools and parts to do the following: 1/4" Allen Wrench Pick Seal, Oil, Crankshaft (16): PN. 70-0701 O-Ring, Bearing Cap (15): PN. 70-0703 ...
NOTE A light coating of silicon grease (PN. 21-1122) should be used on all new o-rings and seals. Use of any other type of grease may result in o-ring or seal failure. Install the new sight glass o-ring (20) and the crankcase cover o-ring (18) provided with the rebuild kit. NOTE A light coating of Anti-Seize Lubricant (PN.
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5P50 Titan Series High Pressure Titanium Positive Displacement Pump (NOTICE: Unscrew one connecting rod cap at a time. Keep the bolts in the same hold it came out of. Store the connecting rod caps like the picture below in order from 1-5. Fig. 8) Fig.
Fig. 9 Removal of the Crankshaft bearing Slide out the Connecting Rods (10) and the Plunger Rod Assembly (8). Check for abnormal wear or scoring. ***Note: Remember where each connecting rod came out of the crankcase. Keep them in the same order. The connecting Rods and Caps are numbered for this reason.
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5P50 Titan Series High Pressure Titanium Positive Displacement Pump Apply a light coat of anti-seize to the 4 Socket Head Cap Screws (17). Install the pulley side Bearing Side Pate (14) using the 4 Socket Head Cap Screws (17) with a ¼” Allen wrench Insert Plunger oil Seal (6) into crankcase.
SERVICING THE MANIFOLD The following are the procedures for servicing the manifold assembly using the 5P50 Manifold Rebuild Kit (PN. 70-3075). The manifold assembly must be detached from the crankcase to do the following service. Fig. 12: Manifold Assembly ADAPTER O-RING REPLACEMENT You will need these tools and parts to do the following: ...
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5P50 Titan Series High Pressure Titanium Positive Displacement Pump NOTE Valves may be serviced while the manifold assembly is attached to the crankcase assembly. If manifold assembly has been removed from the crankcase assembly, place the assembly on a clean work surface. Remove all of the valve plug assemblies from the manifold assembly using a 1 1/2”...
MANIFOLD SEAL SERVICING NOTE Pump manifold assembly must be detached from the crankcase assembly to service the seals. You will need these tools and parts to do the following: Snap Ring Pliers Tool, Seal Insertion: PN. 91-7228 Flat screw driver ...
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5P50 Titan Series High Pressure Titanium Positive Displacement Pump Fig. 15: Weep Ring Extraction With a flat screwdriver remove the high-pressure seals (36). Manually remove the high-pressure seal spacer (35). Insert the high-pressure seal spacer (35) into the bore. NOTE A light coating of silicon grease (PN.
ATTACHING THE MANIFOLD TO THE CRANKCASE You will need these tools and parts to do the following: 15/16” Socket/ Socket Wrench or Combination Wrench Dead Blow Hammer Manifold Nut (53): PN. 70-1305 Ceramic Lubricant: PN. 85-0087 ...
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® Aqua Pro Sea Water RO Membranes Contact Information: Key Feature: Parker Hannifin Corporation Racor Division/Village Marine Tec. 2000 W. 135th St. Aqua Pro ® thin film composite By selecting the highest grade of Gardena, CA 90249 membranes deliver high salt...
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The housings fit VMT pleated cartridge elements of 100 square feet area. Available in 0.5, 1, 5, 20, and 100 micron ratings. Contact Information: Parker Hannifin Corporation Racor Division/Village Marine Tec. 2000 W. 135th St. Gardena, CA 90249 phone: 310 516-9911...
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13”/33 cm *Filter Housing Vessel is designed in accordance with ASME section x pressure vessel code. To maintain peak performance always use genuine Parker Racor Village Marine replacement parts. We reserve the right to change our specifications or standards without notice.
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Cartridge Kits are designed specifically the RO watermaker industry and for small RO Systems. The Cartridges Parker Hannifin Corporation are superior to wound or polyspun allow for easy and effective membrane Racor Division/Village Marine Tec.