o and m water midde east-abb-senthil ro dss-ver1
TRANSCRIPT
-
7/30/2019 O and M Water Midde East-ABB-Senthil RO DSS-Ver1
1/14
DSS for SWRO Plant O&MTechnical experience and lessonslearned from O&M of a membrane basedwater plant
Dr. Senthilmurugan, Technology Manager ABB Water Industry Segment Initiative, 17 April - 2012
-
7/30/2019 O and M Water Midde East-ABB-Senthil RO DSS-Ver1
2/14
O&M of SWRO plant
ABB profile in water Market
Challenges in O&M of SWRO plant
Importance of DSS for O&M of SWRO plant
Asset management of SWRO plant
Membranes, Pumps, ERDs, Pretreatment filters etc.
Advance operation of SWRO plant
Energy optimization (operation of RO / NF/UF/MFmembranes, Pumps, ERDs, filters etc. )
Maintenance schedule optimization (membranes,pumps)
ABBs solution for O&M of SWRO plant
Optimax Membrane Performance
DSS for O&M of SWRO plant
Content of talk
Month DD, Year | Sl ide 2 ABB Group
ABB profile in waterMarket
Challenges
Importance of DSS
Asset Management
Advance operation
ABB solution
Summary
ERD - Energy recovery deviceSWRO- Sea Water Reverse Osmosis
-
7/30/2019 O and M Water Midde East-ABB-Senthil RO DSS-Ver1
3/14
ABB in Water cycle
ABB profile in water
Market
Challenges
Importance of DSS Asset Management
Advance operation
ABB solution
Summary
Where do we operate in Water market and applications?
Month DD, Year | Sl ide 3 ABB Group
Overall Water
Cycle
Basics Pumping
Stations
Desalination
Water Treatment
Waste water
treatment
Water Network
Wastewater
Network
Irrigation Water Industry water
Sum up
Raw water
Pumping station
Desalination plants
IRRIGATION WATER
Pumping stationsIrrigation Network
INDUSTRY WATERIndustrial Pumping stationsIndustrial Water TreatmentIndustrial Wastewater Treatment
Waste Water
NetworkWater Network
Waste Water
Treatment Plants
WaterTreatment Plants
Water Discharge & Monitoring
Water Abstraction &
Monitoring
-
7/30/2019 O and M Water Midde East-ABB-Senthil RO DSS-Ver1
4/14
A proper selection and operation of pretreatment process
will prevent or minimize bio fouling,scaling and membrane plugging in reverseosmosis units
Optimal operation and accurate control offlow and pressure to pretreatment system
leads to energy minimization inpretreatment and RO section
leads to life extension for RO andpretreatment filters
also leads to minimal performancedegradation of membrane due to fouling
Typical maintenance activities of
pretreatment units to sustain plant productionlevel such as
Flushing of membrane (order of days)
Chemical cleaning of membrane (order ofmonths)
Partial replacement / full replacement ofmembrane elements (order of years)
ABB profile in waterMarket
Challenges
Importance of DSS
Asset Management
Advance operation
ABB solution
Summary
SWRO desalination plant O&M activitiesChallenges in Operation of SWRO plant
Month DD, Year | S lide 4 ABB Group
Conventional pretreatment
Membrane based pretreatment
MF UF NF
Sea water Treated water
to desalting unit
-
7/30/2019 O and M Water Midde East-ABB-Senthil RO DSS-Ver1
5/14
High pressure is applied at membrane feed
side
to overcome the osmotic pressure of thesolute
to cause transport of the solvent from feedside to permeate side (product water)
Particles accumulate near the membrane
surface (concentration polarization)
concentration increases over time
membrane performance decreases
Membrane fouling rate due to concentration
polarization is influenced by multiple factors,
e.g. changes in process conditions
(temperature, feed flow concentration,)
Root cause analysis for changing foulingrate is difficult
Actions to overcome fouling include cleaning
(backwashing, chemical cleaning),
membrane exchange, change of pump
setpoints to keep productivity level
ABB profile in waterMarket
Challenges
Importance of DSS
Asset Management
Advance operation
ABB solution
Summary
SWRO desalination plant O&M activitiesChallenges in in Operation of SWRO plant
Month DD, Year | Sl ide 5 ABB Group
Time
Membraneperformance
Differentialpressure
Permeateflux
-
7/30/2019 O and M Water Midde East-ABB-Senthil RO DSS-Ver1
6/14
SWRO desalination plant O&M activities
Major process units of SWRO plant
RO, UF / MF membranes of pretreatment units, Pumps, ERD
Due to fouling the membrane under goes for regular maintenancesactives such as
Flushing of membrane (order of days)
Cleaning of membrane (order of months)
Partial replacement / full replacement of membrane elements(order of years)
Due to regular wear and tear of pumps, ERD, the efficiency of pumpsvaries ~ 5%, the maintenance activities are
Maintenance for mechanical components Challenge: how to schedule of maintenance activates of membrane
systems
To optimize water production cost
To minimize carbon footprint per m3 of water production
ABB profile in waterMarket
Challenges
Importance of DSS
Asset Management
Advance operation
ABB solution
Summary
Challenges in Maintenance of SWRO plant
Month DD, Year | Sl ide 6 ABB Group
MF - Micro FiltrationUF Ultra Filtration
-
7/30/2019 O and M Water Midde East-ABB-Senthil RO DSS-Ver1
7/14
Decision support system (DSS) for SWRO plant
Membrane fouling monitoring and its impact on membranechemical cleaning schedules, and optimization of RO process(Gauder et al., 2010) is important
Lu et al., (2006) determined optimal membrane maintenanceschedules without considering the membrane life cycle intooptimization problem fromulation
ABBs DSS for SWRO calculates the optimal membranemaintenance schedules
By minimizing water production cost over membrane lifetime
Also helps in minimizing the specific energy consumption
(SEC) of the plant by optimally distributing the productionload among RO trains.
The proposed DSS consists of several functionalities, namely,scheduler, load distributor, membrane management systemand simulator.
ABB profile in waterMarket
Challenges
Importance of DSS
Asset Management
Advance operation
ABB solution
Summary
Importance of scheduling membrane maintenance activities
Month DD, Year | Sl ide 7 ABB Group
-
7/30/2019 O and M Water Midde East-ABB-Senthil RO DSS-Ver1
8/14
Estimation of optimal membranemaintenance schedules
Reduces unplanned plant outages due tonon-optimal schedules.
Minimizes the overall water production costduring membrane life cycle and considersconstraints on
product quality - in order to maintainacceptable salt level in the product water,
product water demand - in order toachieve the plant production target, andalso
concentration polarization factor - toimprove membrane life time, duringoptimization.
The trend of water permeability parameter
with respect to membrane chemicalcleaning and replacement schedules (referFig)
The water permeability increases as andwhen the membrane gets cleaned orreplaced.
The optimal schedule is always better thanfixed schedule in terms of production cost
ABB profile in waterMarket
Challenges
Importance of DSS
Asset
Management
Advance operation
ABB solution
Summary
Decision support system (DSS) for SWROScheduler
Month DD, Year | S lide 8 ABB Group
-
7/30/2019 O and M Water Midde East-ABB-Senthil RO DSS-Ver1
9/14
Provides the membrane operational and maintenancehistory for analysis like
Any violations (process or maintenance) happened inpast operation
Provides proof for membrane warranty from operationperspectives
It can extracts events like cleaning and chemical andwater usage back flushing and chemical cleaning
It also facil itates operator to represent process violationsby means of rules.
It will provide % hrs of plant is operated above thresholdvalue recommended by supplier and OEM
Compares the OEM and optimal schedules
Decision support system (DSS) for SWROMembrane Management System (MMS)
Month DD, Year | Sl ide 9 ABB Group
ABB profile in waterMarket
Challenges
Importance of DSS
Asset
Management
Advance operation
ABB solution
Summary
Operation
C Cleaning
R Replacement
OEM Schedules Optimal
Schedules
C 20/08/2010 10/08/2010
C&R 16/04/2011 25/05/2011
C 2/10/2011 30/9/2011
C&R 10/10/2015 1/12/2015
-
7/30/2019 O and M Water Midde East-ABB-Senthil RO DSS-Ver1
10/14
In RO plant, several RO trains will berunning in parallel
Each train will have differentmembrane fouling status
Trains that are more fouled requiremore energy to produce samequantity of product water
Optimal production load distributionamong RO trains is required tominimize overall SEC of a ROsection
ABB profile in waterMarket
Challenges
Importance of DSS
Asset Management
Advance operation
ABB solution
Summary
Decision support system (DSS) for SWROLoad distributor
Month DD, Year | Sl ide 10 ABB Group
-
7/30/2019 O and M Water Midde East-ABB-Senthil RO DSS-Ver1
11/14
The simulator helps the operator to validatedifferent scenarios which otherwise cannot betested in the real plant.
It helps the operator in analyzing the effect ofoperational and maintenance parameters(such as feed flow, feed pressure and numberof membrane cleanings) on the productioncost.
Simulator allows to compare differentmembrane maintenance schedules in terms ofcost ($/m3 of product water produced).
ABB profile in waterMarket
Challenges
Importance of DSS
Asset Management
Advance operation
ABB solution
Summary
Decision support system (DSS) for SWROSimulator
Month DD, Year | Sl ide 11 ABB Group
-
7/30/2019 O and M Water Midde East-ABB-Senthil RO DSS-Ver1
12/14
ABBs solution for SWRO plant
Optimax Membrane Performance
Monitor membrane fouling and optimize membraneoperation including pumps and Membranes
Overcomes known drawbacks of other approaches(ASTM and thumb rule)
Provides advanced operation of membrane systems Consists of two modules:
Module 1: Online Membrane Performance Monitoring
Module 2: Online Membrane Process Optimization
Applicable for membrane systems based on ReverseOsmosis (RO) and Nano-Filtration (NF) treatmenttechnology
Model-based membrane monitoring solution for individualmembrane trains
For more details: http://www.abb.com/water
ABB profile in waterMarket
Challenges
Importance of DSS
Asset Management
Advance operation
ABB solution
Summary
Advance Operation and Maintenance
Month DD, Year | Sl ide 12 ABB Group
-
7/30/2019 O and M Water Midde East-ABB-Senthil RO DSS-Ver1
13/14
Scheduler
Provides optimal schedule formembrane maintenance activities
When the membrane are to becleaned and replaced
How much % of membranes are tobe replaced
Load distributor
Provides optimal production load
distribution between RO trains
Optimal production load
distribution minimizes overall
specific energy consumption
Membrane Management System
Provides operational andmaintenance history
Displays process violations viaalarms
Conditions for processviolations can be provided bymeans of rules
Simulator
Facilitates to validate what - ifscenarios
How energy consumptionchanges with processvariables
How production cost changeswith membrane maintenanceactivities
ABB profile in waterMarket
Challenges
Importance of DSS
Asset Management
Advance operation
ABB solution
Summary
SummaryDSS for SWRO Plant O&M
Month DD, Year | Sl ide 13 ABB Group
-
7/30/2019 O and M Water Midde East-ABB-Senthil RO DSS-Ver1
14/14