fedco hpb pressure booster and

Copyright©2010FluidEquipmentDevelopmentCompany‐ page1

Comparisonof

FEDCOHPBPressureBoosterand

ERIPressureExchanger

Preparedby

FluidEquipmentDevelopmentCompanyMarch2009

FluidEquipmentDevelopmentCompany,FEDCO,HPB,MSS,SSD,HP‐HEMI,LP‐HEMI,LPH,PPD,LPS,LPB,ROTOR‐FLO,aretrademarksofFluidEquipmentDevelopmentCompany,LLCEnergyRecovery,Inc.,ERI,PX,PressureExchangerandPXPressureExchangeraretrademarksofEnergyRecovery,Inc.Copyright©FluidEquipmentDevelopmentCompany


TableofContents

WhattoLookforinanEnergyRecoveryDevice

MethodologyofComparison

EquipmentEvaluated

HPBPrinciplesofOperation,Construction,Installation,OperationandOverhaul

HP‐HEMI

FeedPressureControl

PXPrinciplesofOperation,RotorBlowThrough,RotorFailure,MultipleUnitReliability

PXAuxiliaryEquipmentandMulti‐TrainOperation

OperatingRange

Safety‐EquipmentandPersonnel

PXEffectonHPPumpPerformance

EconomicsAnalysis,SpecificEnergyConsumption,LifeCycleCostandCapitalCosts

Toughness–AbilitytoDealwithUnexpectedConditions

WarrantyLengthandExceptions

SummaryofComparison

FEDCOTrainingandContactInformation

3

4

5

6

11

12

13

19

21

22

23

24

26

27

29

30


WhattoLookforinaEnergyRecoveryDevice(ERD)

LifeCycleCost–minimizesthecostpermeateoverthelifeoftheplant;

LowCapitalCost–equallyimportanttoLifeCycleCost,theequipmentmustbeaffordabletoencouragecustomerstousedesalinationasasolutiontowaterscarcityandsystembuilderstowinproposalswithcompetitivebids;

Reliability–provideyearsofcontinuousservicewithzeromaintenance;

Safety–inherentlysafeforpersonnelandequipment;

Easeofoperationandmaintenance–Forasystemtoworkforyears,itmustbeeasytooperateandmaintainedregardlessoftheleveloftrainingorexperience;

LongTermSupport–supplierfinancialstrengthandindependence.


MethodologyofComparison

TheFEDCOHPBturbochargermanufacturedbyFluidEquipmentDevelopmentCompany(FEDCO)iscomparedwiththePressureExchanger(PX)manufacturedbyEnergyRecovery,Inc.(ERI).

Alldatausedinthiscomparisonwereobtainedfromthefollowingsources:1.  PublisheddatafromFluidEquipmentDevelopmentCompany(FEDCO);2.  PublisheddatafromEnergyRecovery,Inc.(ERI)•  Primarily“Installation,Operation&MaintenanceManuals”for“65SeriesPressureExchanger™”(ERI

Docnumber80019‐01‐02)referredtoas“PXManual”inthisdocument3.  Reasonableengineeringestimates

Allcalculationsanddataarefullytransparent.DetailsareavailablefromFEDCOuponrequest.

Ifthereareanyerrorsinthedataoranalysis,pleasecontactusimmediatelyandwewillcorrectaccordingly.

Anynewinformationregardingthedatainthispresentationwillbegreatlyappreciated.


EquipmentEvaluated

ERIPX‐220Nominalratings:•  Feedflow=50m3/hr(220gpm)

(PXunitsrequiresubstantialadditionalequipmenttoachievefunctionalitywhichwillbeincludedintheevaluation)

FEDCOHydraulicPressureBooster(HPB)Nominalratings:•  Feedflow=10to2800m3/hr(44–12,300gpm)

FEDCOHP‐HEMINominalratings:•  Feedflow=300to2800m3/hr


HPB‐PrincipleofOperation

FEDCOHydraulicPressureBooster(HPB)

TheHPBproducesupto50%ofthemembranepressurerequirement,thereby,reducingtheenergyinputandsizeoftheHPfeedpump,motorandmotorstarter/VFD.Typicalinstallationandoperationareindicatedbelow.

P=2barQ=120m3/h

P=66bar

P=38barP=64barQ=78m3/h

P=0.5bar(maybeatvirtuallyanydesiredvalue)

Feed

Permeate

Q=42m3/h

MSSFeedPump(oranyothertypeof

HPpump)

HPBenergyrecoverydevice

•  Worksjustlikeanautomotiveturbocharger•  Automaticallyboostsfeedpressure•  Fullypoweredbybrinepressure•  Absolutelynootherequipmentrequired

P T

P&IDSymbolforTurbochargers

Brine(turbine)

Feed(pump)

KeyConcepts


HPB–InternalConstruction

Turbinenozzle

Turbineimpeller

Rotorshaft

Pumpimpeller

Brinecontrolvalve

FEED

BRINE

Bearing

Membrane

•  Onemovingpart•  Noshaftseal–zeroleakagetoatmosphere•  Waterlubricatedbearings•  Integralbrinecontrolvalve•  All‐duplexorSuperDuplexConstruction•  Quietandsmoothoperation•  MostcompactsizeofallERDs

Features


HPB‐Installation

•  nohighpressureboosterpumps•  nospecialinstrumentation•  noisolationvalves•  brinedisposalatanypressure

Integralbrinecontrolvalve

Lowpressurebrinetodisposal

Highpressurebrinefrommembrane

Highpressurefeedtomembrane

Feet

Victaulic™pipejoints

Mediumpressurefeedfromfeedpump

HPB‐40

HPB‐1000

TheHPBcanbeinstalledinanyorientation‐sideways,vertical,etc.Connectthe4pipesandtheinstallationiscomplete.

Features


HPBOperation

Toincreasebrinepressure:

Todecreasebrinepressure:• Openthevalve

• Closethevalve

•  Easytrainingofoperatingstaffs,replacementstaffintuitivelylearnsoperation•  OperatorerrorcannotdamagetheHPBorfeedpump•  Simplicitydemandedbymilitaryusers,off‐shoreoperators,hotelsandresorts•  Reducescomplexityinlargesystemstherebyreducingsystemcontrolcosts.

manualorautomaticvalveactuator

Features

•  Startthelowpressurefeedpump,ventairfromsystem•  Starthighpressurefeedpump•  Walkaway–systemisrunning

Operation


HPB–Overhaul

OverhaulRequirements•  15‐60minutes•  Noskilledlabor•  Nospecialtools•  Nomeasurements•  Sameprocedureforevery

HPBmodel


HydraulicEnergyManagementIntegration(HEMI)

TheHP‐HEMIisanHPBwithamotorattachedtothelowpressure(brineoutlet)endoftherotor.Themotorhelpsadjusttherotorspeedtoprovidethedesiredfeedpressure.TheHEMImotoristypically10‐15%ofsizeofHPfeedpumpmotorandusesastandard(lowvoltage)VFD.TheHEMI:•  Regulatesfeedflowandpressurefordesiredmembraneperformance;•  EliminatesneedforVFDorcontrolvalveontheHPfeedpump;•  Regulatesbrineflowandpressureasrequiredfordesiredmembraneperformance;•  CanprovidetotalfeedandbrineregulationviaPLCcontrol(providedbyFEDCO).

HP‐HEMI‐1000HP‐HEMImodelscoverflowrangesfrom300to2000+m3/hr

Brineauxnozzleactuator

100hpHEMImotor

PLCcontrollerwithGUIinterface


FeedPressureControl

TheHP‐HEMIcanproducetheexactamountoffeedboostneededtomeetmembranerequirements.TheHPpumprunsatconstantspeedandwithoutathrottlevalvetoregulatefeedpressure.TheHEMImodulatesfeedandbrinepressureexactlyasneededtoachievedesiredmembranepressurefromaconstantpressurefeedsupply.

ThePXsystem,incomparison,hasabsolutelynoabilitytoregulatefeedpressure.Therefore,costlyandenergywastingfeedthrottlevalvesorVariableFrequencyDrivesontheHPpumparerequired.ThatisonereasonwhytheHEMIcandeliveralowerenergyconsumptionthanthePXsysteminrealisticfieldoperation.

Thechart(below)presentsatypicalannualpressurevariation.TheHEMIsmoothlyadjustsitsoperationtodelivertherequiredmembranepressurewithoutanythrottling.NotethattheHPpumpoperatesatfixedpressurethuseliminatingtheneedforafeedcontrolvalveorvariablefrequencydrive.

FeedpressuretoHPpump

80

60

40

20

Pressure(b

ar)

Jan Feb Mrch Aprl May June July Aug Sept Oct Nov Dec

DischargepressurefromHPpump

DischargepressurefromHEMI(membranepressure)

HPPumpDP(constant)

HEMIDP(variable)

HEMIPerformancewithVariableMembranePressure


PXPrincipleofOperation

Qf=feedflowQb=brineflowQp=permeateflow

1–“P&IDDIAGRAM–TypicalInstallation”,PXManual

HighinletpressureboosterpumpwithVFD.BoostspressureandusedtocontrolPXrotorrotation.

Membrane

FM1

FM2

HPflowmeter

HPfeedpump

Isolationvalve(3)

Controlvalve.Providesbackpressuretopreventcavitationandcontrolfill/purgerateofrotorpassages.

Asimplifiedsystemdiagram[1]–specialflushingpiping,safetyinterlocks,PXsampleports,etc.omittedforclarity.Indicatedflowsareapproximate.

Residualpressurereliefvalve

Qp

Qb

Qp

Qb

QfQf

PXunits(1to20+)


PX‐PrincipleofOperation

Agivenrotorchannelisalternatelyfilledwithlowpressurefeedandthenpurgedwithhighpressurebrinewiththefillpurgecyclecontrolledbytherateofrotorrotation,brinedischargecontrolvalveandHPboostpump.

Rotorrotationratemustbecloselymatchedtothefill/purgerate.However,therotorspeedandfill/purgecyclerateoperateindependentlytherebyrequiringadjustmentoftheHPboosterpumpandbrinecontrolvalvetomaintainacceptableoperation.

Changesinfeedwaterconditionsorpretreatmentpressuremayrequireongoingadjustmentstomaintainthephaserelationshipbetweenrotorrotationandfill/purgecycletimes.

Rotorbearing

Endseal

CYCLESTART

LPbrineDischarge–flowratecontrolledbybrinecontrolvalve,pretreatmentpressureandbrinedisposalpressure

HPbrinefill

LPfeedfill

HPfeeddischarge–flowratecontrolledbyHPboosterpump

CYCLEEND

Rotor

Rotorchannel

LPfeedfillport

HPfeeddischargeport

LPbrinedischargeport

HPbrinefillport

SealareaRotorbearing


PX–RotorBlowThrough

Unbalanceoperationmeansthattherotorspeediswrongforchannelfillratesresultinginthebrine/feedinterfacemovingoutsidetherotorchannelresultingin“blowthrough[1]”.Brineblowthroughcanreachveryhighlevelstherebypossibleforcingasystemshutdown.Attheveryleast,feedpressurewillriseandpermeatequalitywilldeteriorateduetoexcessivefeedTDS.

Lubricationflow(feedleakingintothebrinestream(1‐2%whenunitsarenew)

Brine/feedinterface–theinterfacelocationoscillatesfromoneendofthechanneltotheotherendseveralhundredtimesperminute.Atnormaloperation,4‐5%ofbrinemixeswithfeedandentersthemembrane

Rotorrotationisdrivenbyimpingementofflowonendofrotor

“UNBALANCED”OPERATION–RotorBlowThrough

LPfeedenteringLPbrine“Blowthrough”

HPbrineenteringHPfeed“Blowthrough”

“BALANCED”OPERATION

BlowThrough

[1]‐page15,PXManual


StuckPXRotorFailure

Therearetwotypesofrotorfailure.Onefailureinvolvesdestructionoftherotorand/orbearingsurfaces.Thisdiscussionwillfocusonastalledorstuckrotor.

AstuckrotorcreatesabrineflowintoHPfeedstreamapproximatelyequaltonormalunitrating.Forexample,astalledPX‐220mayinjectfrom45to55m3/hrofbrineintothefeedstream[1].Thisisthemostextremeformof“blowthrough”.

Factorsthatcanstalltherotorinclude:•  bio‐fouling[2]•  debrisinthefeedorbrinestreams[3]•  precipitatessuchasvarioussalts[4]•  Severalanti‐scalantsandvariouswatertreatmentchemical[5]•  damagedrotor,bearingorendplatescausedby:

• airbubbles[6]• operationoutsidethespecifiedflowrange[7]• pressurespikesdamagingtherotorand/orbearingsurfaces[8]• cavitation[9]

Brinepassestomembrane

Feedpassestobrinedrain

Potentialstickingarea

•  Systemisshutdown;•  PXarrayisolatedanddrained;•  Failedunitphysicallyremovedtoworkarea;•  Disassembled,cleanedandre‐assembled(49+steps).Pleaserefertopage10tocomparewiththeinternalinspectionoftheHPB.

Un‐stickingthePXrotor•  TorqueexertedbyfeedorbrineimpingingonthePXrotorislow;•  ThePXbearingsurfacesareverylarge(i.e.Theentirerotor);•  Thecombinationoflowtorque,largebearingsurfacesandsmallclearancescreatesensitivitytobio‐foulingandotherfoulants.Incontrast,theHPBhashightorqueandsmallbearingsurfacesmakingrotorstickingvirtuallyimpossible.

WhythePXrotorsticksandtheHPBdoesnot

1‐privatecommunicationswithPXusers2‐page13,PXManual3‐page27,PXManual

4–Privatecommunications5‐page12,PXManual6‐page8,PXManual

7‐page11,PXmanual8‐page8,PXManual9‐page11,PXManual


PotentialPXRotorDestruction

Cavitation

“Failuretodoso[maintainingflowlimits]canresultindamageordestructiontothePXunitand/orotherequipment.”[1]

Operatingbeyondflowlimits

”…[sufficientbackpressurerequiredto]preventdestructivecavitation”[2]

AirBubbles“LargebubblescandamagethePXdevice”[3]

Pressurespikes

“Pressure/flowspikesrequireparticularconsiderationinsystemswithmultipleSWROtrainsastrainsgoon‐andoff‐line.Anautomaticflowcontrolsystemistypicallynotresponsiveenoughtoprovideconstantflowduringsuddenpressurechanges.Emergencyshutdownsequencesshouldincludeshuttingdowntheseawatersupplypump(s)toavoidoverflow.”[4]

ThePXrotorisdescribedasbeingverytoughbasedonitsceramicconstruction.However,thefactorsthatcandestroytherotorcanoccurinvirtuallyanyseawaterROsystem.

ThecostofrepairingaPXunitwithworn‐outordestroyedrotorisapparentlyquiteclosetothecostofanentirelynewunit[5].Incontrast,ifanHPBrotorneedsreplacement(forexampleduetomassiveingestionofdebris),thecostofanewrotorandbearingsetisabout40%ofthenewunitcost.Moreover,therotorcanoftenberefurbishedtoan“asnew”conditionbyFEDCOforafractionofthecostofanoverhaulkit.

1‐page11,PXmanual2‐page11,PXManual3‐page8,PXManual

4‐page8,PXmanual5‐PrivatecommunicationswithPXusers


MultiplePXUnitsandSystemReliability

TheabovestatementmeansthatasinglefailedPXunitinanarrayof1‐4unitscanforcesystemshutdown.Here’swhy:•  afailedunitallowsbrineflowintothefeedequaltoor

exceedingtheratedcapacity;•  forexample,aPX‐220mayallow50m3/hrofbrine

contaminationofthefeedstream[1];•  Highlevelsofbrinecontaminationgreatlydegradessystem

performancetothepointofpreventingsystemoperation;•  Thereforepotentialforsystemfailureisincreasedby400%

comparedtoasingleunitofsimilarreliabilityinaPXsystemwithfour(4)units.

“…withaconservativedesign,aplantwithmultiplePX'sindesignsoffiveormorecantypicallyoperateindefinitelywithoneormorePX'sremovedfromservice…”‐fromERIpublishedstatements

Failureofanyunitmayrequiresystem

shutdown.

1 2 3 4 5 6 7 8 9 10

1.0

0.8

0.6

0.4

0.2

MTB

F

NumberofPXunits/train

MeanTimeBetweenFailures(MTBF)istheaveragetimebetweenfailuresofagivenitem.TwooperatingunitswiththesameMTBFwillexperienceafailureinoneoftheunitsat50%ofthesingleunitMTBF[2].Extendingthisconcepttoasystemthatallows1failureper5operatingunitsresultsintheadjacentchart.HeretheMTBFappliestoROsystemfailurerelativetotheMTBFofasinglePXdevice.

Thus,multiplePXunitscreateashortersystemMTBF.

1‐privatecommunicationswithvariousPXusers2‐“ReliabilityandMTBFOverview”byScottSpeaks,VicorReliabilityEngineering

SinglePXunitMTBF(referencevalue)

MTBFofsystemequippedwithmultiplePXunitsrelativetosingleunitMTBF


PXAuxiliaryEquipment

A–Residualpressureremainsonthefeedsideofthesystemaftershutdown.Thisvalverelievespressuretoreducepotentialforaccidentsduringsystemmaintenance

B–Aflowmeterratedformembranepressureisneededtohelpachieve“flowbalance”ofthePXunits

C–ThispumpregulatesPXfeedrateandmustbeadjustedincombinationwithvalveFtoachieve“flowbalance”.Mustberatedformembranepressureoperation.

D–EachPXunitgeneratessoundlevelsupto92dB.Anarrayof10unitsmayemitatotaldBof102dBmakingacousticalenclosureshighlydesirableifnotmandatory.

E–Toreducepipestrain,aspoolpieceisrequiredforeachPXconnectionwith2Victaulic™jointsperspoolpiece.APXarrayof20unitsrequire80spoolpiecesand160Victaulic™joints.

F–Regulatesbrineflowtohelpachieve“flowbalance”

G–Neededtohelpachieve“flowbalance”

H–Isolatesunitsfromcleaningchemicals

I–Usedtodetectexcessivebrinemixingindicatingafailedunit

J–Four(4)manifolds

Notshown:•  specialflushingpipesandvalves•  safetyinterlocks•  cleaningbypasslines•  specialpressurecontrolvalvesandemergencyshutdownformulti‐trainoperation.

FM1

FM2

HPfeedpump

Isolationvalve(3)(H)

Controlvalve(F)

HighinletpressureboosterpumpwithVFD(C)

HPflowmeter(B)

Acousticalenclosure(D)

Sampletap(4)(I)

LPflowmeter(G)

Residualpressurereliefvalve(A)

Spoolpiece(E)

Manifold(J)


PXMulti‐TrainOperation

Membrane

Membrane

Membrane

A

B

C

AroutinepumptripontheHPpumporLPfeedpumpsupplywillcauseamomentarychangeinfeedsupplypressure.TheconsequencescanresultinseveredamagetothePXERD[1].

Forexample,atripofPumpB(diagramatright)cancausePXunitsintrainsAandCtosufferdestructionfromamomentarypressure/flowspike.

Specialfastactingcontrolvalves,emergencyshutdownsandotherspecialmeansareneededtoreducethepotentialfordestructionofthePXunits[2].

Or,thePXtrainscanbesuppliedbyaseparatepretreatedwatersupplysystemwithseparatefeedpumpsandsupplypiping[3].Substantialaddedcostsandcomplexitiesareincurred.

PXequipmentpackage

HPpump

LPpump

Pressurepulsation

HPBandHEMIunitsareimmunefromeffectsofflowsurgesandpressurespikes

Potentialrotordamage

Potentialrotordamage

1–page8,PXManual2–page8,PXManual3–page8,PXManual


OperatingRange

PXflowlimits

TypicalmembraneresponsetochangesinfeedTDS

HPBoperatingenvelop

ForPX,theLPbrinepressuremustbeatleast1barlessthanLPfeedpressuretoallowpurgigofbrinefromthePXrotorchannels.

Thislinkagebetweenfeedpretreatmentpressureandbrinedischargepressurecomplicatestheneedtodischargebrineathigherpressures.

HPBhasnorestrictionofLPbrinepressurerelativetofeedpressure.

•  HPBhydrauliccharacteristicsmatchmembraneperformance.

•  HPBisnotsubjecttoseveredamageordestructionifflowreacheshydrauliclimits.

PXpressurerequirements


Safety

ThePXhasavarietyofstringentoperatingrequirementsthat,ifnotcloselyadhered,canresultinseriousequipmentdamageandpossibleinjurytopersonnel.Examplesinclude:1.  VerystrictflowlimitsotherwisePXunitsmaybedestroyed[1];2.  Retainingringcanfailwith“catastrophic”resultsifexposedtomoisture[2];3.  Highpressureremaininsystemaftershutdownexposingmaintenancepersonneltorisk[3];

ThePXrequiresadditionalequipmentwhichinvolve:1.  BoosterpumpandVFDwithassociatedelectricalcomponents,wiring,conduits,etceachwiththeirownhazards

andsafetyrequirements;2.  Additionallockout–tagoutsafetyprocedures;3.  Highlytrainedmaintenancepersonnelrequiredformotor,VFD,PLCcontrolsandinterlocks,highaccuracyflow

meterssamplingoffeedandbrineateachPXunit,etc.;4.  HundredsofadditionalVictaulic™highpressurepipejointsinlargePXarrays;5.  StoppageofPXrotorduringsystemoperationisequivalenttoasuddenblockageofthebrineflow.Feed

pressuremayriseabruptly.Ifsafetyequipmentfailstorespond,seriousdamagecanoccurthroughthesystem;6.  Noiselevelsthatcangreatlyexceed90dB.90dBisconsideredharmfultounprotectedoperatingstaff[4].

1–p.8,PXManual2–p.11,PXManual

3–p.9,PXManual4–OccupationalSafetyandHealthAdministration(OSHA)–Regulation1910.5(a)


PXEffectonHPPumpEfficiencyEfficiency(%

)

10

101 100 1000 10000

20

30

40

50

60

70

80

90

100

Flow(m3/h)

Illustratedintheadjacentfigure,efficienciesofwell‐designcentrifugalHPpumpsincreasefromabout57%tonearly90%overflowrangestypicalofROsystems.

ThePXreducesHPpumpflowtothatofthepermeateflowthusreducingpumpefficiencyrelativetoapumphandlingtheentirefeedflow.

Forexample,assumeanSWROsystemproduces450m3/hrat45%recovery.WiththePX,theHPpumphandles450m3/hrbutwithanHPBorHEMIthefeedpumphandles1,000m3/hr.TheexpectedHPpumpefficienciesare80.7%and84.2%respectively–over4%reductioninHPpumpefficiencyforthePX.

Thus,thePXreducesfeedpumpefficiencyforagiventraincapacity.

TypicalHPPumpEfficiencyversusFlowRate

WithHPBorHEMI

WithPX


EconomicAnalysisSEC(kw‐hr/m

3 )

1.00

5.00

6.00

7.00

8.00

2.00

3.00

4.00

10 100 1000 10000

NoERD

HPB

PX

HEMI

Qfeed(m3/hr)

SpecificEnergyConsumption

Recovery=45%Psuc=2barPm=60‐70barPr=58‐68barPex=1barFeedthrottlepressurecontrolHPPefficiencyfromchartonpage21

Period=15yearsPower=$0.09kw‐hrInterest=7%Inflation=3%Fieldrate=950USD/day(maintenance)Cost=1.50USD(lostrevenueduringdowntime)AllpumpefficienciesarecalculatedwithoutregardtotypeofERD.

Overhaul:PX‐5yearsHPB&HEMI‐6years

MajorAssumptions

Conclusions•  HPBSECwithin3‐12%ofPX•  HEMIbeatsthePXSECinallcases•  HPBandHEMImatchesorbeatsthePXinLifeCycleCost

TheHPBandHEMIprovidealowerLCCandlowercostpermeate

0

LifeCycleCost(USD

)(millions)

500 1000 2000

NoERD

PX

HPB

HEMI

Qfeed(m3/hr)1500 2500

5

10

15

20

25

30

35

LifeCycleCost


BidCompetitiveness

0

CapExandInstall(USD

)(millions)

500 1000 2000

NoERD

PX

HPB

HEMI

Qfeed(m3/hr)1500 2500

0.2

0.6

0.8

1.0

1.4

1.6

1.8 CapitalandInstallationCosts

1.2

0.4

Thischartillustratesthecapitalandinstallationcostsforthefollowingequipment:•  ERD•  highpressurepump•  controlvalve,•  contactor•  associateddesignandprocurementcosts.

TheHPBandtheHEMIpackageshavemuchlowertotalcostthanwiththePXpackageresultinginasubstantialreductionofthetotalSWROsystem.

WiththeHPBandHEMI,theOEMcanofferlowerbidpriceswithgreatermargins.


Toughness‐AbilitytoHandletheUnexpected

70C/60C

20micron

Nopotentialdamage

Norestrictions

Nopotentialdamage

NopotentialforERDdamagefromoperatingerror

Zero

TurnoffHPpump,LPpump

TurnofHPpump,LPpump

Nodamagetounit

Nodamage

Noproblems

Temperature(Storage/operating)

Particlesize

Bio‐fouling

Anti‐scalantsandwatertreatmentchemicals

Pressurespikes

Mis‐operation

Brineintrusionintofeed

Startup

Shutdown

Membranecleaning

Flowvariation

Airbubblesinfeedorbrine

HPB PX45C/45C[1]

5micron[2]

Cancauseunitfailure–warrantyrequiresextensiveprecautions[3]

Totalprohibitiononseveraltypes,verystrictusagerequirementsonothers.Nowatertreatmentchemicalsofanykind[4].

Extensivesystemmodifications,fastactingvalves,emergencyshutdownsprescribed[5[.

ComplexoperatingrequirementincreasespotentialforoperatorerrorresultinginpossibledestructionofERDandothersystemcomponents

“Normal”leakageis5+%ofbrineflowandcanbemuchhigherifflowsare“unbalanced”[6[

Followmulti‐pageprocedures,verifysafetyinterlocksareinplace,perform“flowbalance”toprevent“blowthrough”[7].

Followingshutdownsequence,systemremainsdangerouslypressurizedforaperiodoftime[8].

PXunitsmustbephysicallyremovedfromsystemorisolationvalesemployed[9].

Rotorcanbedestroyedbyslightvariationsinflowratebeyondspecifiedlimits[10].

Voidswarranty,candestroytheunit[11]

Factor

1–p.4,PXManual2–p.11,PXManual3–p.13,PXManual

4–p.11,PXManual5–p.8,PXManual6–p.2“ERITechnicalBulletin:IsobaricDeviceBrine/SeawaterMixingEffect”

7–p.15,PXManual8–p.9,PXManual9–p.14,PXManual

10–p.7,PXManual11–p.8,PXManual


WarrantyLength

WiththeHPB,thereisoneandonlyonewarranty.

WiththePX,manysuppliersofcriticalequipmentareinvolvedeachwiththeirownwarranty,length,termsandexceptions.Warrantymanagementandadministrationcanbecomemajordifficulties.

FEDCO‐Three(3)yearsfromshipment

PLC,sensors,actuators?

PX‐Two(2)yearsfromshipment[1]

HPboosterpump–18months?

HP&LPflowmeters?

Control,isolation&samplevalves?

MotorandVFD?

MultiplewarrantiesfrommultipliersuppliersforthePXsystem

1–p.29,PXManual


WarrantyExceptions

Everydisclaimerandexceptioninawarrantymayrepresentmultiplefailuresinthefieldforwhichthesupplierhandnoanswerandnosolution.

Aqualitywarrantyhasaminimumofexceptions,warningsanddisclaimers.ThePXwarrantyreflectsavarietyofoperatingissuesforwhichERIhasaddressedthroughwarrantyexceptions–i.e.thePXdesignrestrictionsarenowtheresponsibilityofthecustomer.

Incomparison,theFEDCOwarranty:• keepdebrisfromtheunit• maintainbrinedisposalpressure• avoidexcessivepipestrain.


SummaryofComparison

LifeCycleCost–provideslowestcostofpermeate

Capitalcost–lowestengineering,procurementandpurchasecost

Brinefeedmixing–nocontaminationoffeedwithbrine

Reliability–fewestcomponents,simplestconstruction

Easeofoperation–requiresleastamountoftraining,lesspotentialforoperatorerror

Noise–whichERDisinherentlyquieter

Safety–LeastamountofHPequipment,piping,joints,noelectricalcomponents

Maintenance–noauxiliaries,easierandlowercostoverhauls

OperatingRange–broadestoperatingrange,immunetomis‐operation

Toughness–abilitytohandletheunexpected

ReliabilityandWarranty–longestandmostgenerouswarranty

FEDCOHPB

ERIPXSystem


Tel:+734.241.3935Fax:+734.241.5173

sales@fedco‐usa.comwww.fedco‐usa.com

FEDCOTraining

800TernesDriveMonroe,MI48162USA

WiththemostcomprehensiveproducelinesfromanyROequipmentsupplier,FEDCOoffersthemostcomprehensivetrainingonallaspectsof:

•  HPBandHP‐HEMI•  MSSfeedpumps•  SSDfeedpumps•  LP(lowpressure)ERDsandpumps•  ROsystemcontrolformaximumenergyefficiency

Classsizesrangefrom2to10.ContactFEDCOtodayfordetails.

ComprehensivetrainingonSelection,InstallationCommissioningandMaintenanceofallFEDCOProducts

fedco hpb pressure booster and

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