Energy Recovery Pressure Exchanger 65 Series Instruction manual

ENERGY RECOVERY
,
INC.
INSTALLATION, OPERATION, & MAINTENANCE
MANUAL
ERI DOCUMENT NUMBER 80023-01 REVISION 1
ERI™
65 Series Pressure Exchanger™
Energy Recovery Device
for Brackish Water Systems
Energy Recovery, Inc.™
1908 Doolittle Drive, San Leandro, CA 94577 USA
Tel: [phone] / Fax: [phone]
www.energy-recovery.com / [email protected]
© ENERGY RECOVERY, INC., 2006

TABLE OF CONTENTS
1.0 INTRODUCTION 1
2.0 SAFETY 1
3.0 QUALITY & ARRIVAL INSPECTION 2
4.0 DESIGN CONSIDERATIONS 2
4.1 How the PX Energy Recovery Device Works 2
4.2 PX Energy Recovery Devices in BWRO Systems 3
4.3 PX Energy Recovery Device Performance 4
4.4 The PX Booster Pump 5
4.5 Control of Feed Flow, Pressure, and Water Quality 5
4.6 Fresh Water Flushing 6
4.7 Debris and Initial Flushing 6
4.8 High Pressure Remains After Shutdown 6
4.9 Low Pressure Isolation and Over pressurization 6
4.10 Multiple PX Unit Manifold Design 6
5.0 INSTALLATION 7
6.0 OPERATION 8
6.1 System Performance Specifications, Precautions, and Conditions 8
6.2 Start and Stop Procedures 10
6.3 Flow Control and System Balancing 12
7.0 SPARE PARTS AND TOOL KITS 14
8.0 MAINTENANCE 15
8.1 Disassembly Procedure 16
8.2 Assembly Procedure 20
9.0 TROUBLESHOOTING 26
10.0 FIELD COMMISSIONING 29
11.0 REVISION LOG 29
12.0 WARRANTY & LIABILITY 30
13.0 DRAWINGS AND DATA 31

BRACKISH 65-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES
___________________________________________________________
Energy Recovery, Inc. ERI Document Number 80023-01-01
1
NOTE
CAUTION
These flags denote items that, if not strictly observed, can
result in serious injury to personnel.
These flags denote items that, if not strictly observed, can
result in damage or destruction to equipment.
These flags denote highlighted items.
1.0 INTRODUCTION
This manual contains instructions for the installation, operation, and maintenance of the Energy
Recovery, Inc.™™ERI™Brackish 65 Series PX Pressure Exchanger™energy recovery device in
brackish reverse osmosis (BWRO) systems. This information is provided to ensure the long life
and safe operation of your PX™energy recovery device. Please read this manual thoroughly
before installation and operation, and keep it for future reference. This manual is intended for use
by personnel with training and experience in the operation and maintenance of fluid handling
systems.
2.0 SAFETY
The PX Pressure Exchanger energy recovery device is designed to provide safe and reliable
service. However, it is both a pressure vessel and a rotating industrial machine. Operations and
maintenance personnel must exercise prudence and proper safety practices to prevent injury and
to avoid damaging the equipment and surrounding areas. Use of this manual does not relieve
operation and maintenance personnel of the responsibility of applying normal good judgment in
the operation and care of this product and its components. The safety officer at the location
where this equipment is installed must implement a safety program based on a thorough analysis
of local industrial hazards. Proper installation and care of shutdown devices and over-pressure
and over-flow protection equipment must be an essential part of any such program. In general,
all personnel must be guided by all the basic rules of safety associated with high-pressure
equipment and processes. Operation under conditions outside of those stated in Table 6.1 is
unsafe and can result in damage to the Energy Recovery, Inc. (ERI) device.
The flags shown and defined below are used throughout this manual. They should be given
special attention when they appear in the text.
™Energy Recovery, Inc., ERI, PX, Pressure Exchanger, PX Pressure Exchanger and the ERI logo
are trademarks of Energy Recovery, Inc.

BRACKISH 65-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES
___________________________________________________________
Energy Recovery, Inc. ERI Document Number 80023-01-01
2
Energy Recovery, Inc. will not be liable for any project delay, damage or
injury caused by the failure to comply with the procedures in this manual.
This product must never be operated at flow rates, pressures or temperatures
outside of those stated in Table 6.1, or used with liquids not approved by
Energy Recovery, Inc.
NOTE
3.0 QUALITY & ARRIVAL INSPECTION
Energy Recovery, Inc.’s commitment to quality includes the procurement of top quality materials
and fabrication to extremely tight tolerances. At each stage of the manufacturing process, every
part is checked to ensure it meets all dimensional specifications. Assembled ERI devices are
subjected to extensive testing in our wet test facility. Each PX unit is tested for efficiency, noise
levels, operating pressures, and flow rates. Testing records are maintained and each unit is
tracked with a serial number. Each PX unit should be inspected immediately upon arrival at a
customer’s site and any irregularities due to shipment should be reported to the carrier. PX
Pressure Exchanger devices are packed in polystyrene foam with plugs in the fittings to protect
the unit from damage during transport. The PX unit has been run with a dilute biocide solution to
minimize the possibility of biological growth during shipment and storage. The PX unit must
never be exposed to temperatures below 33 degrees Fahrenheit (deg F) [1 deg Centigrade (C)] or
above 113 deg F [45 deg C] during storage or operation.
4.0 DESIGN CONSIDERATIONS
4.1 How the PX Energy Recovery Device Works
The PX Pressure Exchanger energy recovery device facilitates pressure transfer from the high-
pressure brine reject stream to the low-pressure feedwater feed stream. It does this by putting the
streams in direct, momentary contact that takes place in the ducts of a rotor. The rotor is fit into a
ceramic sleeve between two ceramic end covers with precise clearances that, when filled with
high-pressure water, create an almost frictionless hydrodynamic bearing. At any given instant,
half of the rotor ducts are exposed to the high-pressure stream and half to the low-pressure
stream. As the rotor turns, the ducts pass a sealing area that separates high and low pressure.
Thus, the ducts that contain high pressure are separated from the adjacent ducts containing low
pressure by the seal that is formed with the rotor’s ribs and the ceramic end covers.
A schematic representation of the ceramic components of the PX energy recovery device is
provided in Figure 4-1. Feedwater supplied by the feedwater supply pump flows into a rotor duct
on the left side at low pressure. This flow expels brine from the duct on the right side. After the
rotor turns past a sealing area, high-pressure brine flows into the right side of the duct,
compressing and expelling the feedwater. Pressurized feedwater then flows out to the booster
pump. This pressure exchange process is repeated for each duct with every rotation of the rotor,
so that the ducts are continuously filling and discharging. At a nominal speed of 1,200 rpm, 20
revolutions are completed every second.

BRACKISH 65-SERIES PRESSURE EXCHANGER ENERGY RECOVERY DEVICES
___________________________________________________________
Energy Recovery, Inc. ERI Document Number 80023-01-01
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Figure 4-2 illustrates the typical flow path of a PX energy recovery device in a BWRO system.
The reject brine from the BWRO membranes (G) passes through the PX unit, where its pressure
is transferred directly to a portion of the incoming raw feedwater at up to 97% efficiency. This
pressurized feedwater stream (D), which is nearly equal in volume and pressure to the reject
stream, passes through a booster pump (not the main high-pressure pump) to add the small
amount of pressure lost to friction in the PX unit, the membranes, and the associated piping. The
booster pump also serves to drive the flow of the high-pressure stream through the PX unit (G
and D). Fully pressurized feedwater then merges with the main feedwater to the BWRO system
after the main high-pressure pump.
4.2 PX Energy Recovery Devices in BWRO Systems
The PX energy recovery device fundamentally changes the way a BWRO system operates. The
issues presented in this and the following sections should be taken into consideration when
designing a BWRO system. In addition, engineers at Energy Recovery, Inc. are available for
design consultation and review of process and instrument diagrams.
Figure 4-1. Flow Path through PX Unit
Table 4-1. Example Flow Rates and Pressures
High Pressure side
Sealed Area
High-pressure feedwater
going to booster pump
High-
p
ressure brine reject
from RO membranes
Low-pressure
feedwater inlet
Low-pressure brine
reject to drain
Feedwater
Brine
Interface
Rotor Rotation
Low Pressure side
Figure 4-2. Typical Flow Path of a BWRO System with a PX Unit
Inter-stage
Boost Pump
Main High
Pressure Pump
Feedwater Supply
Pump
Fresh Water
Pressure Exchanger
Device or PX Array
F
H
G
I
E
B
A
C
D
J