Veolia Orion II 500 User manual

OPERATORS MANUAL
ORION II
Orion II 500-10000 Operators
Page 1 of 95
Manual Part no: DOMAON0100 Issue A
April 2008
ORION II
Operators Manual
Models 500 –10000

OPERATORS MANUAL
ORION II
Orion II 500-10000 Operators
Page 2 of 95
Manual Part no: DOMAON0100 Issue A
April 2008
TABLE OF CONTENTS
1DECLARATION OF CONFORMITY..............................................................................................................6
2HEALTH AND SAFETY RECOMMENDATIONS..........................................................................................7
2.1 CHEMICALS ...........................................................................................................................................7
2.2 ELECTRICITY.........................................................................................................................................7
2.3 EMERGENCY SHUTDOWN...................................................................................................................7
2.4 AIR AND WATER PRESSURE...............................................................................................................7
2.5 HOT WATER AND HOT SURFACES.....................................................................................................7
2.6 ELECTRODE GASSES ..........................................................................................................................8
2.7 VENTILATION.........................................................................................................................................8
3INTRODUCTION............................................................................................................................................9
3.1 GENERAL...............................................................................................................................................9
3.2 SYSTEM OVERVIEW.............................................................................................................................9
3.2.1 PRE-TREATMENT SYSTEMS...............................................................................................................10
3.2.2 PRE-TREATMENT DOSING.................................................................................................................11
3.2.3 PRE-TREATMENT MONITORING..........................................................................................................11
3.2.4 PURIFIED WATER SYSTEM RO SECTION............................................................................................11
3.2.5 PURIFIED WATER SYSTEM DEIONISING SECTION ...............................................................................11
3.2.6 PURIFIED WATER SYSTEM POLISHING SECTION.................................................................................12
3.2.7 TOC MONITOR ................................................................................................................................12
3.2.8 OUTLET VALVES...............................................................................................................................12
3.2.9 OPERATING MODE ...........................................................................................................................12
3.2.10 CLEANING........................................................................................................................................13
3.2.11 CONTROL PANEL..............................................................................................................................13
3.2.12 COMMUNICATIONS............................................................................................................................13
3.2.13 WINFLEXCC DATA LOGGING............................................................................................................13
3.2.14 STAINLESS STEEL ............................................................................................................................13
3.2.15 ELECTRICAL CONTROLS ...................................................................................................................13
3.3 IMPORTANT INFORMATION...............................................................................................................14
4TECHNICAL DATA......................................................................................................................................15
4.1 NOMINAL FLOWRATES IN SERVICE.................................................................................................15
4.1.1 SINGLE PASS RO ONLY....................................................................................................................15
4.1.2 TWIN PASS RO ONLY .......................................................................................................................15
4.1.3 RO +CEDI (CEDI CONCENTRATE RECYCLED).................................................................................16
4.1.4 RO +CEDI (CEDI CONCENTRATE TO DRAIN)...................................................................................16
4.1.5 RO +CEDI +UF (CEDI CONCENTRATE RECYCLED) ........................................................................16
4.1.6 RO +CEDI +UF (CEDI CONCENTRATE TO DRAIN) ..........................................................................17
4.2 NOMINAL FLOWRATES PRODUCT WATER IN RECYCLE...............................................................17
4.2.1 SINGLE PASS RO ONLY....................................................................................................................17
4.2.2 TWIN PASS RO ONLY .......................................................................................................................17
4.2.3 RO +CEDI (CEDI CONCENTRATE ALWAYS RECYCLED WHEN PRODUCT IN RECYCLE)........................18
4.2.4 RO +CEDI +UF (CEDI CONCENTRATE ALWAYS RECYCLED WHEN PRODUCT IN RECYCLE)................18
4.3 FLOWRATES (HOT WATER SANITISATION).....................................................................................19
4.3.1 SINGLE PASS RO.............................................................................................................................19
4.3.2 TWIN PASS RO................................................................................................................................19
4.4 DIMENSIONS .......................................................................................................................................19
4.4.1 MAIN SKID MM..................................................................................................................................19
4.4.2 8000 &10000 SOFTENERS MM ........................................................................................................20
4.5 FEEDWATER REQUIREMENTS..........................................................................................................20
4.6MAXIMUM FLOWS L/H ........................................................................................................................20
4.7 SERVICES............................................................................................................................................21
4.7.1 ELECTRICAL.....................................................................................................................................21
4.7.2 COMPRESSED AIR ............................................................................................................................21

OPERATORS MANUAL
ORION II
Orion II 500-10000 Operators
Page 3 of 95
Manual Part no: DOMAON0100 Issue A
April 2008
4.7.3 DEGASSER SWEEP GAS NM3/H.........................................................................................................21
4.7.4 VENTILATION....................................................................................................................................21
4.7.5 ELECTRODE GASSES........................................................................................................................21
4.8 BRINE TANKS ......................................................................................................................................22
4.9 SALT SPECIFICATION.........................................................................................................................22
5PROCESS DESCRIPTION ..........................................................................................................................23
5.1 PRE-TREATMENT SYSTEMS .............................................................................................................23
5.1.1 OPTION 10 NON HOT WATER SANITISABLE SOFTENERS AND FILTERS ................................................23
5.1.2 CARTRIDGE FILTRATION ...................................................................................................................24
5.1.3 INTERCONNECTING PIPEWORK..........................................................................................................24
5.1.4 COOLING WATER LINE......................................................................................................................24
5.1.5 OPTION 11 HOT WATER SANITISABLE SOFTENERS AND FILTERS ........................................................25
5.1.6 CARTRIDGE FILTRATION ...................................................................................................................26
5.1.7 RECIRCULATION LOOP......................................................................................................................26
5.1.8 OPTION 12 UPVC INLET,NO FILTERS ...............................................................................................27
5.1.9 OPTION 13 STAINLESS STEEL INLET,WITH FILTERS...........................................................................27
5.1.10 OPTION 14 STAINLESS STEEL INLET,NO FILTERS..............................................................................27
5.2 DOSING SYSTEMS..............................................................................................................................27
5.2.1 OPTION 20 SODIUM METABISULPHITE DOSING...................................................................................27
5.2.2 OPTION 21 PHCONTROL..................................................................................................................27
5.3 INLET MONITORS................................................................................................................................27
5.3.1 OPTION 25 HARDNESS MONITOR......................................................................................................27
5.3.2 OPTION 26 CHLORINE MONITOR .......................................................................................................27
5.3.3 OPTION 27 PHCONTROLLER............................................................................................................27
5.4 PURIFIED WATER SYSTEM RO SECTION........................................................................................28
5.4.1 RO FEED TANK TK30-01.................................................................................................................28
5.4.2 RO FEED PUMP PU1.......................................................................................................................28
5.4.3 OPTION 40 SINGLE PASS REVERSE OSMOSIS....................................................................................29
5.4.4 OPTION 42 TWIN PASS REVERSE OSMOSIS.......................................................................................30
5.5 PURIFIED WATER SYSTEM DEIONISATION SECTION ...................................................................30
5.5.1 OPTION 50 DEGASSING....................................................................................................................30
5.5.2 OPTION 60 CONTINUOUS ELECTRICAL DEIONISATION (CEDI).............................................................30
5.5.3 OPTION 61 GAS SEPARATOR............................................................................................................31
5.6 PURIFIED WATER SYSTEM POLISHING SECTION..........................................................................31
5.6.1 OPTION 70 UV.................................................................................................................................31
5.6.2 OPTION 71 ULTRAFILTRATION...........................................................................................................32
5.6.3 OPTION 72 MICROFILTRATION...........................................................................................................32
5.7 PRODUCT WATER OUTLET...............................................................................................................32
5.7.1 OPTION 80 OUTLET CONDUCTIVITY MEASUREMENT...........................................................................32
5.7.2 OPTION 81,82 &83 TOCMONITORS................................................................................................32
5.8 OUTLET VALVES.................................................................................................................................33
5.8.1 OPTION 90 OUTLET 3-WAY VALVE....................................................................................................33
5.8.2 OPTION 91 OUTLET TWO 2-WAY VALVES..........................................................................................33
5.8.3 OPTION 92 OUTLET THREE 2-WAY VALVES.......................................................................................33
5.8.4 PRODUCT WATER RETURN LINE .......................................................................................................33
5.9 CLEANING IN PLACE (CIP) SYSTEM.................................................................................................33
5.10 HOT WATER SANITISATION (HWS)...............................................................................................34
6CONTROL SYSTEM....................................................................................................................................35
6.1 OPERATOR INTERFACE.....................................................................................................................35
6.1.1 OVERVIEW....................................................................................................................................35
6.1.2 DEVICE COLOURS.......................................................................................................................35
6.1.3 NUMERIC DATA COLOURS.........................................................................................................37
6.1.4 ACCESS ........................................................................................................................................37
6.2 SCREENS.............................................................................................................................................38
6.2.1 OVERVIEW....................................................................................................................................39
6.2.2 SOFTENERS.................................................................................................................................42
6.2.3 PUMP.............................................................................................................................................43

OPERATORS MANUAL
ORION II
Orion II 500-10000 Operators
Page 4 of 95
Manual Part no: DOMAON0100 Issue A
April 2008
6.2.4 RO STAGE.....................................................................................................................................44
6.2.5 CDI STAGE....................................................................................................................................46
6.2.6 HWS...............................................................................................................................................48
6.2.7 OUTLET.........................................................................................................................................49
6.3 SYSTEM CLEANING ROUTINES ........................................................................................................52
6.3.1 RO CLEAN.....................................................................................................................................52
6.3.2 RO SANITISE ................................................................................................................................53
6.3.3 CDI CLEAN....................................................................................................................................54
6.4 SYSTEM CONFIGURATION................................................................................................................55
6.4.1 SERVICE .......................................................................................................................................55
6.4.2 HWS...............................................................................................................................................56
6.4.3 CIP.................................................................................................................................................57
6.4.4 OTHER ..........................................................................................................................................58
6.4.5 ANALOGUE...................................................................................................................................60
6.4.6 OPTIONS.......................................................................................................................................61
6.4.7 USERS...........................................................................................................................................62
6.5 COMMISSIONING / DIAGNOSTICS ....................................................................................................63
6.5.1 FORCE IO.....................................................................................................................................63
6.5.2 CONTROL PANEL.........................................................................................................................64
6.5.3 CLEAN SCREEN...........................................................................................................................64
6.5.4 TERMINATION APPLICATION .....................................................................................................64
6.5.5 TRAINING MODE..........................................................................................................................64
6.5.6 EVENT LOG...................................................................................................................................65
6.6 COMMAND BUTTONS AND STATUS INFORMATIOM ......................................................................66
6.6.1 ALARMS ........................................................................................................................................67
6.7 PROCESS STATUS TEXT...................................................................................................................68
6.7.1 GENERAL.........................................................................................................................................68
6.7.2 OPTION 10 SOFTENERS....................................................................................................................69
6.7.3 OPTION 11 SOFTENERS (TTS)..........................................................................................................70
6.8 ALARMS................................................................................................................................................71
6.8.1 FATAL..............................................................................................................................................71
6.8.2 WARNINGS.......................................................................................................................................72
6.8.3 ADDITIONAL OPTION 11 (TTS) ALARMS.............................................................................................75
6.9 ACCESS LEVELS.................................................................................................................................76
7PLANT OPERATION...................................................................................................................................78
7.1 OPERATING MODES...........................................................................................................................78
7.2 STARTUP AND SHUTDOWN...............................................................................................................78
7.3 PLANT MONITORING ..........................................................................................................................79
7.3.1 SAMPLE POINTS ...............................................................................................................................81
7.3.2 BACTERIA SAMPLING PROCEDURE.....................................................................................................81
7.3.3 SAMPLING METHOD ..........................................................................................................................82
8RO MEMBRANE CLEANING......................................................................................................................83
8.1 GENERAL.............................................................................................................................................83
8.2 CORRECTED FLUX (CF) CALCULATION...........................................................................................84
8.3 RO CLEANING PROCEDURE .............................................................................................................85
8.3.1 SAFETY NOTES.................................................................................................................................85
8.3.2 CLEANING INSTRUCTIONS.................................................................................................................85
9APPENDIX...................................................................................................................................................88
9.1 REVERSE OSMOSIS...........................................................................................................................88
9.1.1 GENERAL.........................................................................................................................................88
9.1.2 WATER RECOVERY ..........................................................................................................................88
9.1.3 MEMBRANE REJECTION....................................................................................................................88
9.2 CEDI......................................................................................................................................................90
9.2.1 WHAT IS CONTINUOUS ELECTRODEIONISATION..................................................................................90
9.2.2 TECHNOLOGY DESCRIPTION .............................................................................................................90
9.2.3 HOW THE CEDI SYSTEM WORKS.......................................................................................................91

OPERATORS MANUAL
ORION II
Orion II 500-10000 Operators
Page 5 of 95
Manual Part no: DOMAON0100 Issue A
April 2008
9.3 CALCULATING CEDI CURRENT.........................................................................................................92
9.3.1 CURRENT CALCULATION ...................................................................................................................92
9.4 OPERATING LOG SHEETS.................................................................................................................93
9.4.1 DAILY LOG SHEET............................................................................................................................93
9.4.2 WEEKLY LOG SHEET........................................................................................................................95
9.4.3 MICROBIOLOGY................................................................................................................................95

OPERATORS MANUAL
ORION II
Orion II 500-10000 Operators
Page 6 of 95
Manual Part no: DOMAON0100 Issue A
April 2008
1 DECLARATION OF CONFORMITY
DECLARATION OF CONFORMITY
Veolia Water
Solutions and Technologies
L'Aquarène
1, Place Montgolfier
94417 Saint-Maurice cedex
France
Tel : [phone]
Fax : [phone]
www.veoliawaterst.com
ORION II
Models
500 - 10000
Conform to the following EC Directives where required:
The Electromagnetic Compatibility Directive 2004/108/EC
(including any additions or amendments thereafter)
and
The Low voltage Directive (Electrical Safety) 2006/95/EC
(including any additions or amendments thereafter)
and
The Machinery Directive 98/37/EC
(including any additions or amendments thereafter)
P T Jordain.
Technical Manager
April 2008

OPERATORS MANUAL
ORION II
Orion II 500-10000 Operators
Page 7 of 95
Manual Part no: DOMAON0100 Issue A
April 2008
2 HEALTH AND SAFETY RECOMMENDATIONS
Use caution when working on Veolia Water equipment. The following items are likely to present
possible hazards - chemicals, ion exchange resins, electricity, air pressure, water pressure, hot
water and hot surfaces. Please ensure personnel are familiar with these hazards and that adequate
precautions are maintained.
2.1 CHEMICALS
Chemicals used on Orion systems during normal use are –
Salt which is added to the Brine Tank(s) for regenerating the softeners
Elgalite RU3 which is an organic acid cleaner for the Reverse Osmosis membranes
Elgalite LF12 which is an alkaline detergent also used to clean the Reverse Osmosis membranes
Refer to safety data sheets supplied with the above products and follow the safety instructions during
use.
2.2 ELECTRICITY
The unit must be properly earthed and the correct rated fuses should be fitted. Power should be
switched off at a remote isolator before commencing work on the equipment.
2.3 EMERGENCY SHUTDOWN
In an emergency the unit can be turned off at the door isolator, since the Shutdown command on the
HMI touch panel requires a pass key and takes time to activate.
2.4 AIR AND WATER PRESSURE
Veolia Water equipment operates at pressure and, where possible, this should be reduced before
commencing work. Normal protection from freezing should be taken, as ice inside pressure vessels
and pipework can cause rupture. Compressed air can be dangerous and care should taken with its
use.
2.5 HOT WATER AND HOT SURFACES
Whilst the ORION unit operates at ambient temperatures during normal operation, components from
the soft water break tank onwards (generally the stainless steel part of the unit) are periodically
elevated to 85oC to sanitise the system. When the unit is at elevated temperature a warning beacon
flashes to highlight this danger and care should be taken to prevent the risk of burning by touching
hot stainless steel surfaces, or scalding by opening valves etc.

OPERATORS MANUAL
ORION II
Orion II 500-10000 Operators
Page 8 of 95
Manual Part no: DOMAON0100 Issue A
April 2008
2.6 ELECTRODE GASSES
The CEDI unit produces small amounts of gas containing hydrogen which is flammable and should
be vented to a point outside the building. The gas can be removed from the unit in a gas separator
and the gas outlet from the separator vented outside the building.
If a gas separator is not supplied the unit should be installed in a room provided with adequate
ventilation, see below.
2.7 VENTILATION
The unit should be operated in a properly ventilated room to prevent overheating and to remove any
traces of hydrogen not removed by the gas separator. As a general guideline the air in the room
should be changed four times per hour.
IF IN DOUBT FURTHER INFORMATION ON SAFETY CAN BE OBTAINED FROM YOUR LOCAL
VEOLIA WATER SERVICE DEPARTMENT

OPERATORS MANUAL
ORION II
Orion II 500-10000 Operators
Page 9 of 95
Manual Part no: DOMAON0100 Issue A
April 2008
3 INTRODUCTION
3.1 GENERAL
Please read these operating and maintenance instructions carefully.
This manual describes the operation and basic maintenance of the ORION range of integrated water
treatment systems, which includes models with nominal outputs ranging from 500 to 10000 litres per
hour.
Ensure that the unit is installed by a Veolia Water engineer and operated in accordance with the
instructions in this manual. If there are any enquiries regarding the installation, operation or
servicing of the ORION unit contact Veolia Water, Service Department.
3.2 SYSTEM OVERVIEW
The ORION unit is a thermally sanitised, integrated packaged system which produces
Pharmaceutical grade water from a potable water feed. It is designed to operate on a continuous
basis and can produce purified water at all times except when performing a thermal sanitisation, or
during cleaning or maintenance.
The ORION platform consists of a number of selectable options that are pre-determined at the sales
stage to meet the customer‟s requirements.
Options available are as follows –

OPERATORS MANUAL
ORION II
Orion II 500-10000 Operators
Page 10 of 95
Manual Part no: DOMAON0100 Issue A
April 2008
3.2.1 Pre-treatment Systems
Option
10
Standard Softeners
Non Hot Water Sanitisable
SOF10-01, SOF10-02
Base Exchange Softeners to prevent scaling of the RO
membranes. Used where the feed water contains less
than 0.02 mg/l of free chlorine.
CarboSoft Softeners
Non Hot Water Sanitisable
SOF10-01, SOF10-02
Combined Base Exchange Softeners and Activated
Carbon units, prevents scaling of the RO membranes
and removes up to 0.25mg/l of free chlorine from the
feed water.
On Orion 8000 & 10000 the softeners are mounted off the main skid.
Cartridge Filtration
FI10-01
5micron Depth Filters removes particulate matter.
11
Standard Softeners
Hot Water Sanitisable
SOF11-01, SOF11-02
Hot Water Sanitisable Base Exchange Softeners to
prevent scaling of the RO membranes.
Used where the feed water contains less than 0.02 mg/l
of free chlorine.
CarboSoft Softeners
Hot Water Sanitisable
SOF11-01, SOF11-02
Hot Water Sanitisable Combined Base Exchange
Softeners and Activated Carbon units, prevents scaling
of the RO membranes and removes up to 0.25mg/l of
free chlorine from the feed water.
On Orion 8000 & 10000 the softeners are mounted off the main skid.
Cartridge Filtration
FI10-01
5micron Depth Filters removes particulate matter.
12
Cartridge Filtration
FI12-01
PVC Inlet system, no softeners.
5micron Depth Filters removes particulate matter.
13
Cartridge Filtration
FI12-01
Stainless Steel Inlet system, no softeners.
5micron Depth Filters removes particulate matter.
14
PVC Inlet system, no softeners or Filters.

OPERATORS MANUAL
ORION II
Orion II 500-10000 Operators
Page 11 of 95
Manual Part no: DOMAON0100 Issue A
April 2008
3.2.2 Pre-treatment Dosing
Option
20
Proportional to Flow
PU20-01 & TK20-01
Dosing set for dosing Sodium Metabisulphite to remove
Chlorine from the feed water.
21
Proportional to pH
PU21-01 & TK21-01
Dosing set for dosing Sodium Hydroxide to raise the pH of
the feed water. This reduces the amount of Carbon Dioxide
and thereby ionic load in the feed to downstream
deionisation equipment.
3.2.3 Pre-treatment Monitoring
Option
25
Hardness Monitor
AE25-01
Feed water hardness monitor.
26
Chlorine Monitor
AE26-01
Feed water chlorine monitor.
27
pH Controller
AE27-01
Measures the pH of the feed water and supplies a control
signal to the Sodium Hydroxide dosing set. This reduces
the amount of Carbon Dioxide and thereby ionic load in the
feed to downstream deionisation equipment.
3.2.4 Purified Water System RO Section
Option
30
Break Tank
TK30-01
Soft Water Break Tank also used for Recirculation of
Purified Water and Cleaning in Place (CIP).
40
Single Pass Reverse
Osmosis
RO40
Removes up to 99% of the impurities from the feed water.
42
Twin Pass Reverse
Osmosis
RO42
Provides a higher degree of purification used on high
salinity feed water, feed water containing high
concentrations of silica or where greater process security is
desired.
3.2.5 Purified Water System Deionising Section
Option
50
Membrane Degasser
DG50
Used where the feed water contains high levels of carbon
dioxide to enhance the operation of CEDI Module.
60
CEDI Module
CD60
Continuous Electrical Deionisation unit removes remainder
of the dissolved ionic impurities.

OPERATORS MANUAL
ORION II
Orion II 500-10000 Operators
Page 12 of 95
Manual Part no: DOMAON0100 Issue A
April 2008
3.2.6 Purified Water System Polishing Section
70
Ultra Violet Irradiation*
UV70
This can be fitted to the outlet of the CEDI to enhance
bacteria control.
71
Ultrafiltration*
UF71
This can be fitted to the outlet of the CEDI to remove
endotoxins and bacteria from the product water.
72
Microfiltration*
MF72
This can be fitted to the outlet of the CEDI to enhance
bacteria control.
* NB only one of the above three options may be chosen
3.2.7 TOC Monitor
81
TOC Monitor
AE81-01
Anatel TOC 600 to monitor the product water TOC.
82
TOC Monitor
AE82-01
Sievers 500RL to monitor the product water TOC.
83
TOC Monitor
AE83-01
Thornton 5000TOC to monitor the product water TOC.
3.2.8 Outlet Valves
90
Outlet 3-Way Valve
VA90-01
Diverter valve to divert water to the product water tank when
required and recycle to TK30-01 when not. The valve
should be fitted as close as possible to the product water
tank to minimise product water deadleg.
91
Outlet Two 2-Way
Valves
VA91-01 & VA91-02
Two 2-Way valves to divert water to the product water tank
when required and recycle to TK30-01 when not. The
valves should be fitted as close as possible to the product
water tank to minimise product water deadleg.
92
Outlet Three 2-Way
Valves
VA92-01, VA92-02 &
VA92-03
Three 2-Way valves to divert water to two product water
tanks when required and recycle to TK30-01 when not. The
valves should be fitted as close as possible to the product
water tanks to minimise product water deadleg.
3.2.9 Operating Mode
100
Continuous Operation
Unit runs continuously and recycles product water when
Product Water Tank is full.
101
Start / Stop
Unit starts and stops when tank empties and fills. There is,
however, an intermittent recycle of water to prevent long
periods of stagnation.

OPERATORS MANUAL
ORION II
Orion II 500-10000 Operators
Page 13 of 95
Manual Part no: DOMAON0100 Issue A
April 2008
3.2.10 Cleaning
110
Manual CIP
111
Semi-Automatic CIP
3.2.11 Control Panel
120
Painted Carbon Steel Enclosure IP55
121
Semi-Automatic CIP
3.2.12 Communications
130
Ethernet card for communication with Main Computer System.
3.2.13 WinFlexCC Data Logging
141
Access security and data logging via password system to provide an audit trail
for 21 CFR Pt 11 Compliance.
3.2.14 Stainless Steel
N/A
Stainless Steel Pipe
The various options can be supplied with
Dairy or ASME BPE Pipe. NB HWS
Softeners, RO, CEDI & UF concentrate is
only available in Dairy pipe.
3.2.15 Electrical Controls
Instrumentation
Set of Conductivity, Flow, Level, Pressure and Temperature
sensors for process monitoring and control.
Control Panel
An integrated control panel containing a combined LED Touch
Panel and Display (also called a Human Machine Interface or HMI),
Programmable Logic Controller (PLC)

OPERATORS MANUAL
ORION II
Orion II 500-10000 Operators
Page 14 of 95
Manual Part no: DOMAON0100 Issue A
April 2008
3.3 IMPORTANT INFORMATION
Please ensure that the following are regularly checked and action taken as required:
The pre-treatment softeners, filters, etc. are working reliably.
Brine Tank Salt levels are maintained.
Free chlorine in the feed to the RO system and CEDI is less than 0.02mg/l.
Performance log sheets are regularly maintained and any abnormal trends acted upon when
necessary.
Corrected flux, salt passage and CEDI performance is monitored on a regular basis and any
abnormal trends acted upon when necessary.
If the required product water quality is not being achieved and at the same time the current set
point is not being achieved then the DC voltage setting may need to be changed on the CEDI
Transformer, consult Veolia Water for assistance.
In addition, water analyses of the feed water should be routinely checked (for example, hardness, silt
density index, iron, etc.) so that wide fluctuations of composition and temperature can be quickly
identified. If such fluctuations occur contact your local Veolia Water Service Department for advice.

OPERATORS MANUAL
ORION II
Orion II 500-10000 Operators
Page 15 of 95
Manual Part no: DOMAON0100 Issue A
April 2008
4 TECHNICAL DATA
4.1 NOMINAL FLOWRATES IN SERVICE
Nominal flows are based on operation at 15C, 500mg/l TDS, 20mg/l CO2 and SDI <3
Actual flow rates are site specific and will be defined in the Design Qualification for the plant,
but in general will depend on –
Operating temperature
Feed water analysis
Size of unit
Required product water specification
System recovery
4.1.1 Single Pass RO only
MODEL
500
1000
2000
4000
6000
8000
10000
Feed
I/h
667
1333
2667
5333
8000
10667
13333
Product
l/h
500
1000
2000
4000
6000
8000
10000
RO Concentrate to Drain
I/h
167
333
667
1333
2000
2667
3333
RO Concentrate Recycle
I/h
1180
530
860
4250
3520
4000
5260
Recovery
%
75
4.1.2 Twin Pass RO only
MODEL
500
1000
2000
4000
6000
8000
10000
Feed
I/h
990
1780
3210
6350
8940
11920
14530
Product
l/h
500
1000
2000
4000
6000
8000
10000
RO Concentrate to Drain
I/h
490
780
1210
2350
2940
3920
4530
Pass 1 RO Conc Recycle
I/h
900
900
200
4600
4800
1800
1200
Pass 2 RO Conc Recycle
I/h
890
1170
1270
4700
4700
6270
6350
Recovery
%
50 –70

OPERATORS MANUAL
ORION II
Orion II 500-10000 Operators
Page 16 of 95
Manual Part no: DOMAON0100 Issue A
April 2008
4.1.3 RO + CEDI (CEDI Concentrate Recycled)
MODEL
500
1000
2000
4000
6000
8000
10000
Feed
I/h
685
1370
2741
5481
8222
10963
13704
Permeate
l/h
556
1111
2222
4444
6667
8889
11111
RO Concentrate to Drain
I/h
185
370
741
1481
2222
2963
3704
RO Concentrate Recycle
I/h
1180
530
860
4250
3520
4000
5260
CEDI Concentrate Recycled
l/h
56
111
222
444
667
889
1111
Product
I/h
500
1000
2000
4000
6000
8000
10000
Recovery
%
73
4.1.4 RO + CEDI (CEDI Concentrate to Drain)
MODEL
500
1000
2000
4000
6000
8000
10000
Feed
I/h
741
1481
2963
5925
8889
11852
14815
Permeate
l/h
556
1111
2222
4444
6667
8889
11111
RO Concentrate to Drain
I/h
185
370
741
1481
2222
2963
3704
RO Concentrate Recycle
I/h
1180
530
860
4250
3520
4000
5260
CEDI Concentrate to Drain
l/h
56
111
222
444
667
889
1111
Product
I/h
500
1000
2000
4000
6000
8000
10000
Recovery
%
67
4.1.5 RO + CEDI + UF (CEDI Concentrate Recycled)
MODEL
500
1000
2000
4000
6000
8000
10000
Feed
I/h
685
1370
2741
5481
8222
10963
13704
Permeate
l/h
585
1169
2338
4676
7013
9351
11689
RO Concentrate to Drain
I/h
185
370
741
1481
2222
2963
3704
RO Concentrate Recycle
I/h
1180
530
860
4250
3520
4000
5260
CEDI Concentrate Recycled
l/h
58
117
234
468
701
935
1169
UF Concentrate Recycled
l/h
26
52
104
210
312
420
526
Product
I/h
500
1000
2000
4000
6000
8000
10000
Recovery
%
73

OPERATORS MANUAL
ORION II
Orion II 500-10000 Operators
Page 17 of 95
Manual Part no: DOMAON0100 Issue A
April 2008
4.1.6 RO + CEDI + UF (CEDI Concentrate to Drain)
MODEL
500
1000
2000
4000
6000
8000
10000
Feed
I/h
743
1487
2975
5949
8923
11898
14873
Permeate
l/h
585
1169
2338
4676
7013
9351
11689
RO Concentrate to Drain
I/h
185
370
741
1481
2222
2963
3704
RO Concentrate Recycle
I/h
1180
530
860
4250
3520
4000
5260
CEDI Concentrate to Drain
l/h
58
117
234
468
701
935
1169
UF Concentrate Recycled
l/h
26
52
104
210
312
420
526
Product
I/h
500
1000
2000
4000
6000
8000
10000
Recovery
%
67
4.2 NOMINAL FLOWRATES PRODUCT WATER IN RECYCLE
4.2.1 Single Pass RO only
MODEL
500
1000
2000
4000
6000
8000
10000
Feed
I/h
60
120
240
480
720
960
1200
Product in Recycle
l/h
500
1000
2000
4000
6000
8000
10000
RO Concentrate to Drain
I/h
60
120
240
480
720
960
1200
RO Concentrate Recycle
I/h
1287
743
1287
5103
4800
5700
7390
Recovery
%
Not Applicable
4.2.2 Twin Pass RO only
MODEL
500
1000
2000
4000
6000
8000
10000
Feed
I/h
60
120
240
480
720
960
1200
Product in Recycle
l/h
500
1000
2000
4000
6000
8000
10000
RO Concentrate to Drain
I/h
60
120
240
480
720
960
1200
Pass 1 RO Conc Recycle
I/h
1330
1560
1170
6470
7020
4760
4530
Pass 2 RO Conc Recycle
I/h
890
1170
1270
4700
4700
6270
6350
Recovery
%
Not Applicable

OPERATORS MANUAL
ORION II
Orion II 500-10000 Operators
Page 18 of 95
Manual Part no: DOMAON0100 Issue A
April 2008
4.2.3 RO + CEDI (CEDI Concentrate always Recycled when Product in Recycle)
MODEL
500
1000
2000
4000
6000
8000
10000
Feed
I/h
60
120
240
480
720
960
1200
Permeate
l/h
556
1111
2222
4444
6667
8889
11111
RO Concentrate to Drain
I/h
60
120
240
480
720
960
1200
RO Concentrate Recycle
I/h
1287
743
1287
5103
4800
5700
7390
CEDI Concentrate Recycled
l/h
56
111
222
444
667
889
1111
Product in recycle
I/h
500
1000
2000
4000
6000
8000
10000
Recovery
%
Not Applicable
4.2.4 RO + CEDI + UF (CEDI Concentrate always Recycled when Product in Recycle)
MODEL
500
1000
2000
4000
6000
8000
10000
Feed
I/h
60
120
240
480
720
960
1200
Permeate
l/h
585
1169
2338
4676
7013
9351
11689
RO Concentrate to Drain
I/h
60
120
240
480
720
960
1200
RO Concentrate Recycle
I/h
1287
743
1287
5103
4800
5700
7390
CEDI Concentrate Recycled
l/h
58
117
234
468
701
935
1169
UF Concentrate Recycled
l/h
26
52
104
210
312
420
526
Product in recycle
I/h
500
1000
2000
4000
6000
8000
10000
Recovery
%
Not Applicable

OPERATORS MANUAL
ORION II
Orion II 500-10000 Operators
Page 19 of 95
Manual Part no: DOMAON0100 Issue A
April 2008
4.3 FLOWRATES (HOT WATER SANITISATION)
NB these are nominal flows and may vary in practice.
4.3.1 Single Pass RO
MODEL
500
1000
2000
4000
6000
8000
10000
RO Conc Recycle <45oC
I/h
1000
1000
1000
2000
2000
3000
3000
RO Conc Recycle >45oC
I/h
800
800
800
1600
1600
2400
2400
Conc Drain during cooling
l/h
475
525
675
1400
1650
3000
3000
4.3.2 Twin Pass RO
MODEL
500
1000
2000
4000
6000
8000
10000
RO Conc Recycle <45oC P1
I/h
1000
1000
1000
2000
2000
3000
3000
RO Conc Recycle >45oC P1
I/h
800
800
800
1600
1600
2400
2400
RO Conc Recycle <45oC P2
I/h
80
80
100
200
200
400
400
RO Conc Recycle >45oC P2
I/h
60
60
80
150
150
300
300
Conc Drain during cooling
l/h
475
525
675
1400
1650
3000
3000
4.4 DIMENSIONS
4.4.1 Main Skid mm
500 –2000
Single Pass RO
2000
TPRO
4000
6000
8000*
10000*
Length
3000
3450
3650
4000
4750
Width
1500
1750
2000
Height
2100
2190
2400
2450
Shipping
Height
2100
*NB On 8000 & 10000 Models the softeners are supplied as a separate assembly, see below.

OPERATORS MANUAL
ORION II
Orion II 500-10000 Operators
Page 20 of 95
Manual Part no: DOMAON0100 Issue A
April 2008
4.4.2 8000 & 10000 Softeners mm
Option 10 Non HWS Softeners
Option 11 HWS Softeners
8000
10000
8000
10000
Length
1965
1900
Width
1445
1200
Height
2670
2175
Shipping
Vessels shipped horizontally
4.5 FEEDWATER REQUIREMENTS
General
Potable water free from organics, colloids and suspended solids
(SDI <3)
Feed water pressure
4 –5 bar (optimum) 6 bar maximum
Total hardness
<500 ppm as CaCO3
< 10 ppm as CaCO3(feed to the RO)
< 1 ppm as CaCO3(feed to the CEDI modules)
Free chlorine
< 0.25 ppm (Standard units with CarboSoft softeners)
< 0.02 ppm (non CarboSoft softeners)
Temperature
10 - 30C
4.6 MAXIMUM FLOWS L/H
500
1000
2000
4000
6000
8000
10000
Feed without Softeners
1.9
2.8
4.9
9.8
13.9
18.5
23.2
Drain without Softeners
1.9
2.8
4.9
9.8
13.9
17
22
Feed with Softeners
3.2
4.2
6.6
13.3
18.8
25.1
32.6
Drain with Softeners
2.9
3.5
5
12
15.0
17
22